Carrier CPLPCONV013C00 Gas Conversion Kit Owner's Manual

Owner's Manual for Carrier models including: CPLPCONV013C00 Gas Conversion Kit, CPLPCONV013C00, Gas Conversion Kit, Conversion Kit, Kit

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Installation Instructions WARNING ...

Installation Instructions WARNING ! WARNING ! WARNING !

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CPLPCONV013C00: Installation Instructions
CPLPCONV013C00 Small Packaged Products Accessory Propane Gas Conversion Kit Standard Altitude Only 0-2000 FT (0-610 m) 40,000-130,000 Btu/hr

Installation Instructions

NOTE: Read the entire instruction manual before starting the installation.
This kit is used on:
Two-Stage (2 - 5 Tons) Models: 48DU, 48DT, 48VG (208/230 VAC models), 48VR, 48XL, 48XT, 577B, 577D, 577E (208/230 VAC models), 677B, 677D and 677E. (Two-Stage conversion starts on page 7.)
Single-Stage (1-1/2 - 5 Tons) Models: 48ES, ("1") series or later (Examples: 48ES-060130311, 48ES-060130511, 48ES-060130611), 48ES-A, 48ESNA, 48EZ "1" series or later (Examples: 48EZ-060130311, 48EZ-060130511, 48EZ-060130611), 48EZ-A, 48EZNA, 48VG (460 VAC models), 48VL, 48VT, 574D "B" series or later (Examples: 574DNW060130NB, 574DPW060130NB, 574DEW060130NB), 574D*WA, 577C, 577E (460 VAC models), 674D "B" series or later (Examples: 674DNW060130NB, 674DPW060130NB, 674DEW060130NB), 674D*WA, 677C, all PY3G except "B" series (Example: PY3GNA060115AB) and PY4G. (Single-Stage conversion starts on page 2.)
This kit must not be used on 48VGU, 48VLU, 577*********U, PY4G*******U models. These models are for Natural Gas Only.
Safety Considerations
Installation and servicing of this equipment can be hazardous due to mechanical and electrical components. Only trained and qualified personnel should install, repair, or service this equipment.
Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters. All other operations must be performed
by trained service personnel. When working on this equipment, observe precautions in the literature, on tags, and on labels attached to or shipped
with the unit and other safety precautions that may apply.
Follow all safety codes. Wear safety glasses, protective clothing, and work gloves. Use quenching cloth for brazing operations. Have fire extinguisher available. Read these instructions thoroughly and follow all
warnings or cautions included in literature and attached to the unit.
Consult local building codes, the current editions of the National Electrical Code (NEC) NFPA 70 and NFPA 90B-Installation Warm Air Heating and A/C Systems (Residential). In Canada refer to the current editions of the Canadian Electrical Code CSA C22.1.
Recognize safety information. This is the safety-alert symbol . When you see this symbol on the unit and in instructions or manuals, be alert to
the potential for personal injury. Understand these signal words: DANGER, WARNING, and CAUTION. These words are used with the
safety-alert symbol. DANGER identifies the most serious hazards which
will result in severe personal injury or death. WARNING signifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices which may result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.

! WARNING
FIRE, EXPLOSION, CARBON MONOXIDE POISONING, PROPERTY DAMAGE HAZARD Failure to follow this warning could result in personal injury, death or property damage. This conversion kit shall be installed by a qualified service agency in accordance with the manufacturer's instructions and all applicable codes and requirements of the authority having jurisdiction. The qualified service agency is responsible for the proper installation of this kit. The installation is not proper and complete until the operation of the converted furnace is checked as specified in the manufacturer's instructions supplied in the kit.
! WARNING
FFEU, EXPLOSION, EMPOISONNEMENT PAR CARBON DE MONOXYDE, RISQUE DE DOMMAGE À LA PROPRIÉTÉ La négligeance de suivre l'avis suivant, peut causer des blessures personnelles, la mort ou du dommage à la propriété. Cette trousse de conversion doit être installée par un Entrepreneur qualifié, selon les instructions du fabricant et doit se conformer à toutes les exigences et tout les codes pertinents de l'autorité compétente. L'Entrepreneur qualifié est responsable, et doit s'assurer de bien suivre les instructions dans cet avis. L'installation sera considèrèè conforme et rencontrant les spécifications et instructions du fabriquant qui sont inclus dans la trousse, seulement aprés vérification de l'opération de la fournaise convertie.
! WARNING
UNIT OPERATION HAZARD Failure to follow this caution may result in damage to unit components. Before converting a unit to propane gas, remove the burner assembly and inspect the heat exchanger tubes. If there are V-shaped NOx baffles installed in the firing tubes, (see Fig. 1). THEY MUST BE REMOVED PRIOR TO CONVERTING THIS UNIT TO PROPANE GAS.

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 1

CPLPCONV013C00: Installation Instructions

Fig. 1 Low NOx Baffle Location

A221566

! WARNING
EXPLOSION, PERSONAL INJURY HAZARD Failure to follow this warning could result in personal injury or death. This unit is designed to operate at a minimum 10.0 IN.W.C. of manifold pressure on high stage with propane gas. Refer to Table 8 for proper manifold pressure settings for high stage and low stage.

SINGLE-STAGE KIT INTRODUCTION
These instructions cover the installation of a propane gas conversion kit on models 48ES "1" series or later (Examples: 48ES-060130311, 48ES-060130511, 48ES-060130611), 48ES-A, 48ESNA, 48EZ "1" series or later (Examples: 48EZ-060130311, 48EZ-060130511, 48EZ-060130611), 48EZ-A, 48EZNA, 48VG (460 VAC models), 48VL, 48VT, 574D "B" series or later (Examples: 574DNW060130NB, 574DPW060130NB, 574DEW060130NB), 574D*WA, 674D "B" series or later (Examples: 674DNW060130NB, 674DPW060130NB, 674DEW060130NB), 674D*WA, 577C, 577E (460 VAC models), 677C, all PY3G except "B" series (Example: PY3GNA060115AB) and PY4G.
This kit must not be used on 48VGU, 48VLU, 577*********U, PY4G*******U models. These models are for Natural Gas Only.

1. Turn off gas supply first, then power to unit.
2. Remove the control access panel from unit.
3. Disconnect the gas pipe from the gas valve.
4. Remove the screw attaching the gas manifold to the basepan, and partially slide out the entire burner rack assembly from unit. Save screw. The fan partition mounting bracket may be removed for easier access to the burner assembly. The bracket may be removed for easier access to the burner assembly. The bracket may be removed by removing 2 screws (located on the left side of the control compartment on the fan partition panel) and sliding the bracket forward, bottom first. See Fig. .)
5. Disconnect the gray and brown wires from the gas valve and remove blue wires from the rollout switch.
NOTE: To locate rollout switch, see Fig. 2.
6. Disconnect orange sparker cable from the sparker.
7. Disconnect yellow flame sensor wire from the flame sensor.
8. Remove the screw securing the brown wire from the burner assembly. Ground screw is attached to the fan partition panel. Save screw.
9. Completely slide out the entire burner rack assembly from unit.
10. Inspect the inlet of the heat exchanger tubes for presence of V-shaped NOx baffles (see Fig. 1). If baffles are present, they must be removed prior to converting unit for propane gas. Using needle-nose pliers, remove NOx baffles, squeeze sides of the baffle, if necessary, to remove from the heat exchanger tubes.
IMPORTANT: If it is expected that this unit will be converted back to natural gas at a later time, these baffles should be retained for reuse. Otherwise the baffles may be discarded.
11. Using a 5/16 in. nut driver, remove the four screws securing the manifold/gas valve assembly to the burner assembly. Save these screws.

DESCRIPTION AND USAGE
This single-stage kit is applicable to units with heating inputs from 40,000 to 130,000 Btu/hr installed at standard altitudes from 0 ft to 2000 ft. (0 to 610 m). They cannot be used for high altitude installation. High altitude conversion (2001-6000 ft) (610-1829 m) must use kit CPLPCONV014C00.
SINGLE-STAGE KIT INSTALLATION
! WARNING
FIRE, EXPLOSION, ELECTRICAL HAZARD Failure to follow this warning could result in personal injury, death or property damage. Gas supply MUST be shut off before disconnecting electrical power and proceeding with conversion.

! WARNING
ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death. Before installing or servicing system, always turn off main power to system and install lockout tag. There may be more than one disconnect switch. Lock out and tag switch with suitable warning label.

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 2

CPLPCONV013C00: Installation Instructions

Table 1 Single-Stage Kit Contents

ITEM
Installation Instructions Propane Gas Orifice #49* Propane Gas Orifice #51* Propane Gas Orifice #53* Propane Gas Orifice #55* Regulator Spring (92-0659)
Pressure Switch 90° Elbow, 1/8 in. NPT Nipple, 1/8 in. NPT x 2 in. (51 mm) Close Pipe Nipple, 1/8 in. NPT x 3/4 in. (19 mm)
Wire Harness Propane Conversion Label (Rating Plate) Propane Conversion Label (Installer Responsibility) Propane Conversion Warning Label (Gas Valve)
Burner Insert

PART NO.
IIK-CPLPCONV-25
LH32RF073
LH32RF067
LH32RF060
LH32RF052
EF39ZW023 HK02LB008 CA05RA001 CA01CA010 CA01CA001 48DU400080 48VL500383 48VL500384 48DU500076 50CY502897

QUANTITY 1 3
3
3
3 1 1 2 1 2 1 1 1 1 3

*. Refer to Table 8 to determine the correct orifice to use.
12. For certain 40,000 Btu/hr and all 3 cell 60,000 Btu/hr units only (refer to Table 5). Remove the burners from the rack, and save the screws. Remove the snap ring from the end of each burner (see Fig. 12). Refer to Table 5 for correct burner insert for specific model. Install burner insert in the end of each burner with the flat sides of the quare vertical and horizontal. Replace the snap ring to retain the burner insert (see Fig. 12 for snap ring orientation) for each burner. Replace the burners in the rack using the saved screws, making sure closed crossovers of burners are at each end.
13. Remove the natural gas orifices from the manifold using a 9/16 in. wrench and install the correct propane gas orifices in the manifold (See Table 8 to select correct orifice size based on rated input. See Fig. 3 and Fig. 5 for orifice installation).
14. Replace the manifold/gas valve assembly into the burner assembly using the four screws saved from Step 11.
15. Remove the plug on the inlet end of the gas valve using a 3/16 in. hex wrench.
16. Install the 1/8 in. NPT x 3/4 in. (19 mm) close pipe nipple where the plug was removed (see Fig. 6). Use pipe thread dope (field-supplied, must be certified for use with propane gas) for all joints, making sure not to get any excess in the pipe or valve. Next, install a 1/8 in. elbow, a 1/8 in. NPT x 3/4 in. (19 mm) close pipe nipple, 1/8 in. elbow, 1/8 in. x NPT 2 in. (51 mm) nipple, and a low gas pressure switch as shown in Fig. 6.
17. Remove regulator cover screw from the gas regulator (see Fig. 4). Save regulator cover screw.
18. Using a screwdriver, remove the plastic regulator adjust screw from the gas regulator (see Fig. 4). Save plastic regulator adjust screw.
19. Remove regulator spring (silver) from the gas regulator (see Fig. 4. Discard regulator spring.
20. Install propane gas regulator spring (white) shipped with this kit. (See Fig. 4).
21. Install plastic adjust screw into the gas regulator, turn clockwise 13.5 turns (see Fig. 4).
22. Verify igniter, flame sensor, orifice/main burner relationship prior to completing conversion. (See Fig. 3.) Partially slide burner rack assembly into unit.

Fig. 2 Single-Stage Burner Bracket

A07874

Fig. 3 Single-Stage Igniter, Flame Sensor; Orifice/Main BurnA0e7r890 Relationship
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 3

CPLPCONV013C00: Installation Instructions

Fig. 4 Single-Stage Gas Valve

A07808

Fig. 5 Single-Stage Orifice Installation

A14635

23. Disconnect the orange wire from the combustion air pressure switch and connect it to the orange wire on the low gas pressure switch (LGPS) equipped with a 1/4 in. male quick-connect terminal. The low gas pressure switch should have one unconnected orange wire remaining. Connect this wire to the vacant terminal on the combustion air pressure switch (see Fig. 13).

27. Slide burner rack assembly into base pan. Align burner rack with screws on sheet metal partition and slide assembly back tight to the partition. Replace the screw attaching the burner rack to the base pan removed in step 4. If the fan partition mounting bracket was removed, slide bracket back into place and fasten with 2 screws (see Fig. ).

24. Reconnect the blue wires removed in Step 5 to the rollout switch and reinstall the rollout switch.

28. Reconnect the brown wire from the burner assembly to the fan partition panel, using the ground screw saved from step 8.

25. Reconnect orange sparker cable to sparker and reconnect the yellow flame sensor wire to the flame sensor.

29. Remove the 1/8 in. pipe plug on the gas manifold and connect a pressure manometer (see Fig. 10).

26. Reconnect the gray and brown wires removed in Step 5 to the gas valve.

30. Reconnect electrical power and gas supply to the unit. For propane applications, the gas pressure must not be less than 11.0 IN. W.C. or

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 4

CPLPCONV013C00: Installation Instructions
greater than 13 IN. W.C. at the unit connection. A 1/8-in. NPT plugged tapping, accessible for test gauge connection, must be installed immediately upstream of the gas supply connection to the gas valve and downstream of manual equipment shutoff valve.
The newly installed low gas pressure switch is a safety device used to guard against adverse burner operating characteristics that can result from low gas supply pressure. Switch opens at not less than 6.5 IN. W.C. and closes at not greater than 10.2 IN. W.C.
This switch also prevents operation when the propane tank level is low which can result in gas with a high concentration of impurities, additives, and residues that have settled to the bottom of the tank. Operation under these conditions can cause harm to the heat exchanger system.
This normally open switch closes when gas is supplied to gas valve under normal operating pressure. The closed switch completes control circuit. Should an interruption or reduction in gas supply occur, the gas pressure at switch drops below low gas pressure switch setting, and switch opens. Any interruption in control circuit (in which low gas pressure switch is wired) quickly closes gas valve and stops gas flow to burners.
! WARNING
FIRE AND EXPLOSION HAZARD Failure to follow this warning could result in personal injury and/or property damage. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury or loss of life.
IMPORTANT: Restart unit and leak check all gas connections including the main service connection, gas valve, gas spuds, and manifold pipe plug. All leaks must be repaired before firing unit.

31. Fire unit and verify proper ignition and proper sequence of operation (Table 2). See Table 8 for proper manifold pressure setting for your unit. Adjust the gas valve setting by turning the plastic adjustment screws clockwise to increase pressure and counter-clockwise to decrease pressure. Refer to Table 3 for required rated heating input rates. Replace regulator cover screws when finished (see Fig. 4).
32. With control access panel removed, observe unit heating operation. Watch burner flames to see if they are blue in appearance, and that the flames are approximately the same for each burner (see Fig. 14).
33. Turn off unit, remove pressure manometer and replace the 1/8 in. pipe fitting on the gas manifold (see Fig. 10).
34. Attach warning label (P/N 48DU500076) to visible side of gas valve.
35. Attach conversion label (P/N 48VL500383) above unit rating plate on exterior of unit.
36. Attach completed conversion responsibility label (see Fig. 15, P/N 48VL500384) inside control access panel.
IMPORTANT: Restart unit and leak check all gas connections including the main service connection, gas valve, gas spuds, and manifold pipe plug.
! WARNING
FIRE AND EXPLOSION HAZARD Failure to follow this warning could result in personal injury and/or property damage. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury or loss of life.
37. After all leaks are eliminated, replace control access panel.

Table 2 Single-Stage Sequence of Operations
For Units With a Separate Blower Fan Control Board
Trial-for-Ignition Sequence: The ignition sequence is to immediately energize the inducer motor on a call for heat.Within approximately 5 sec of the call for heat, the gas valve will open and the igniter will spark. Seven sec will be allowed to prove flame sense on the far burner. Flame-Proving: Once flame is proven, the control will wait an additional 45 sec to energize the indoor blower motor. On removal of the call for heat, the gas valve will immediately shut down, the inducer motor will run for an additional 5 sec, and the indoor blower will run for an additional 45 sec (minimum).
For Units With an Integrated Ignition/Blower Fan Control
Trial-for-Ignition Sequence: The ignition sequence is to turn on the inducer motor for 5 second pre-purge after a call for heat is established. The gas valve will then open and the igniter will spark. Seven seconds will be allowed to prove flame to sense on the far burner. Flame-Proving: Once flame is proven, the control will wait an additional 30 sec to energize the indoor blower motor. On removal of the call for heat, the gas valve will immediately shut down, the inducer motor will run for an additional 5 sec, and the indoor blower will run for an additional 90 sec (minimum).

Table 3 Single-Stage Rated Heating Input, Propane Gas (0-2000 ft (0-610 m) Altitude)

NAMEPLATE INPUT (BTU/HR) 40,000 60,000 90,000 115,000 127,000 130,000

RATED HEATING INPUT PROPANE (BTU/HR) 38,000 53,000 79,000 103,000 116,000 116,000

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 5

CPLPCONV013C00: Installation Instructions

Fig. 6 Installing Elbows, Nipples, and Pressure Switch on Single-Stage Units

A09017

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 6

CPLPCONV013C00: Installation Instructions

TWO-STAGE KIT INTRODUCTION
These instructions cover the installation of a propane gas conversion kit on models 48DT, 48DU, 48VG (208/230 VAC models), 48VR, 48XL, 48XT, 577B, 577D, 577E (208/230 VAC models), 677B, 677D and 677E that are equipped with a White Rodgers 2-stage combination automatic gas valve regulator. This kit must not be used on 48VGU, 48VLU, 577*********U, PY4G*******U models. These models are for Natural Gas Only.
DESCRIPTION AND USAGE
This Two-Stage kit is applicable to units with heating inputs from 40,000 to 130,000 Btu/hr installed at standard altitudes from 0 ft to 2000 ft (0 to 610 m). It cannot be used for high altitude installation. High altitude conversion (2001-6000 ft) (610-1829 m) must use kit CPLPCONV014C00.
TWO-STAGE KIT INSTALLATION
! WARNING
FIRE, EXPLOSION, ELECTRICAL HAZARD Failure to follow this warning could result in personal injury, death or property damage. Gas supply MUST be shut off before disconnecting electrical power and proceeding with conversion.
! WARNING
ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death. Before installing or servicing system, always turn off main power to system and install lockout tag. There may be more than one disconnect switch. Lock out and tag switch with suitable warning label.

1. Turn off gas supply first, then power to unit.
2. Remove the control access panel from unit.
3. Disconnect the gas pipe from the gas valve.
4. Remove the screw attaching the gas manifold to the basepan, and partially slide out the entire burner rack assembly from unit. Save screw. The fan partition mounting bracket may be removed for easier access to the burner assembly. The bracket may be removed by removing 2 screws (located on the left side of the control compartment on the fan partition panel) and sliding the bracket forward, bottom first. See Fig. 7.
5. Disconnect the gray, blue, brown and green/yellow wires from the gas valve and remove blue or violet wires from the rollout switch.
NOTE: To locate rollout switch, see Fig. 8.
6. Disconnect orange sparker cable from the sparker.
7. Disconnect white flame sensor wire from the flame sensor.
8. Remove the ground screw securing the brown wire from the burner assembly. Ground screw is attached to the fan partition. Save screw.
9. Completely slide out the entire burner rack assembly from unit.
10. Inspect the inlet of the heat exchanger tubes for presence of V-shaped NOx baffles (see Fig. 1). If baffles are present, they must be removed prior to converting unit for propane gas. Using needle-nose pliers, remove NOx baffles, squeeze sides of the baffle, if necessary, to remove from the heat exchanger tubes.
IMPORTANT: If it is expected that this unit will be converted back to natural gas at a later time, these baffles should be retained for reuse. Otherwise the baffles may be discarded.
11. Using a 5/16 in. nut driver, remove the four screws securing the manifold/gas valve assembly to the burner assembly. Save these screws.

Table 4 Two-Stage Kit Contents

PART NO.
IIK-CPLPCONV-25 LH32RF073 LH32RF067 LH32RF060 LH32RF052 EF39ZW023 HK02LB008 CA05RA001 CA01CA010 CA01CA001 48DU400080 48VL500383 48VL500384 48DU500076 48GS500465 50CY502897

QUANTITY 1 3 3 3 3 2 1 2 1 2 1 1 1 1 3 3

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 7

CPLPCONV013C00: Installation Instructions

Fig. 7 Fan Partition Bracket Removal

A09320

(2006 - 2010 Models)

C00150
Fig. 8 Two-Stage Burner Bracket

(2010 - Current Models)

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 8

A07874

CPLPCONV013C00: Installation Instructions
12. For 2-stage 40,000 Btu/hr and 60,000 Btu/hr only! Remove the burners from the rack, save the screws (see Fig. 12). Remove the snap ring from the end of each burner. Refer to Table 5 for correct burner insert for specific model. Install burner insert in the end of each burner with the flat sides of the square vertical and horizontal. Replace the snap ring to retain burner insert (see Fig. 12 for correct orientation). Replace the burners in the rack using the saved screws, making sure closed crossovers of burners are at each end.
13. Remove the natural gas orifices from the manifold using a 9/16 in. wrench and install the correct propane gas orifices in the manifold (See Table 8 to select correct orifice size based on rated input. See Fig. 9 and Fig. 12 for orifice installation).
14. Replace the manifold/gas valve assembly into the burner assembly using the four screws saved from step 11.
15. Remove the plug on the inlet end of the gas valve using a 3/16 in. hex wrench.

Table 5 Burner Insert Usage (40 and 60 kBtuh Units Only)

Model
48VG(--,N)B,E,K 48VL(--,N)(B,C,D,E,F,K)*****3 48VR(--,N)(B,C,E,K) 48VT(--,N)(B,C,E,K)*****3 577CNW(B,C,D,E,F,K) 577ENW(B,E,K) 677CNW(B,C,E,K) 677ENW(B,C,E,K) PY4GN 48DU 48DT 48VG(--,N)A 48VR(--,N)A 48XL 48XT 577B 577D 577ENWA 677B 677D 677ENWA

Applicable Heating Input Sizes (kBtu/hr) 40, 60 40, 60 40, 60 40, 60 40, 60 40, 60 40, 60 40, 60 40, 60 40, 60 40, 60 40, 60 40, 60 40, 60 40, 60 40, 60 40, 60 40, 60 40, 60 40, 60 40, 60

Burner Insert P/N
50CY502897
48GS500465

16. Install the 1/8 in. NPT x 3/4 in. (19 mm) close pipe nipple where the plug was removed (see Fig. 16). Use pipe thread dope (field-supplied, must be certified for use with propane gas) for all joints, making sure not to get any excess in the pipe or valve. Next, install a 1/8 in. elbow, a 1/8 in. NPT x 3/4 in. (19 mm) close pipe nipple, 1/8 in. elbow, 1/8 in. x NPT 2 in. (51 mm) nipple, and a low gas pressure switch as shown in Fig. 16.
17. Remove regulator cover screws for both high and low stage gas regulators (see Fig. 11). Save regulator cover screws.
18. Using a screwdriver, remove plastic adjust screws from both high and low stage gas regulators (see Fig. 11). Save plastic adjust screws.
19. Remove regulator springs (silver) from both high and low stage gas regulators (see Fig. 11). Discard regulator springs.
20. Install propane gas regulator springs (white) shipped with this kit. One into the low stage gas regulator and one into the high stage gas regulator (see Fig. 11).
21. Install plastic adjust screw into the high stage gas regulator. turn clockwise 13.5 turns (see Fig. 11).

Fig. 9 Two-Stage Igniter, Flame Sensor, Orifice/Main BurnAe0r7889 Relationship

Fig. 10 Burner Assembly
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 9

C99019

CPLPCONV013C00: Installation Instructions

Fig. 11 Two-Stage Gas Valve

A07804

22. Install plastic adjust screw into the low stage gas regulator. turn clockwise 9.5 turns (see Fig. 11).

23. Verify igniter, flame sensor, orifice/main burner relationship prior to completing conversion. (See Fig. 9.) Partially slide burner rack assembly into unit.

24. Disconnect the orange wire from the combustion air pressure switch and connect it to the orange wire on the low gas pressure switch (LGPS) equipped with a 1/4 in. male quick-connect terminal. The low gas pressure switch should have one unconnected orange wire remaining. Connect this wire to the vacant terminal on the combustion air pressure switch (see Fig. 13).

25. Reconnect the blue or violet wires removed in item 5 to the rollout switch and reinstall the rollout switch.

26. Reconnect orange sparker cable to sparker and reconnect the white flame sensor wire to the flame sensor.

27. Reconnect the remaining wires removed in Step 5 to the gas valve. Connect the gray wires to (HI). Connect the blue wires to (M). Connect the brown and green/yellow wires to (C).

28. Slide burner rack assembly into base pan. Align burner rack with screws on sheet metal partition and slide assembly back tight to the partition. Replace the screw attaching the burner rack to the base pan removed in step 4. If the Fan partition mounting bracket was removed, slide bracket back into placed and fasten with 2 screws. (See Fig. .)

29. Reconnect the brown wire from the burner assembly to the fan partition panel, using the ground screw saved from Step 8.

30. Remove the 1/8 in. pipe plug on the gas manifold and connect a pressure manometer (see Fig. 10).

31. Reconnect electrical power and gas supply to the unit. For propane applications, the gas pressure must not be less than 11.0 IN. W.C. or greater than 13 IN. W.C. at the unit connection. A 1/8-in. NPT plugged tapping, accessible for test gauge connection, must be installed immediately upstream of the gas supply connection to the gas valve and downstream of manual equipment shutoff valve.

The newly installed low gas pressure switch is a safety device used to guard against adverse burner operating characteristics that can result from low gas supply pressure. Switch opens at not less than 6.5 IN. W.C. and closes at not greater than 10.2 IN. W.C.

This switch also prevents operation when the propane tank level is low which can result in gas with a high concentration of impurities, additives, and residues that have settled to the bottom of the tank. Operation under these conditions can cause harm to the heat exchanger system.

This normally open switch closes when gas is supplied to gas valve under normal operating pressure. The closed switch completes control

circuit. Should an interruption or reduction in gas supply occur, the gas pressure at switch drops below low gas pressure switch setting, and switch opens. Any interruption in control circuit (in which low gas pressure switch is wired) quickly closes gas valve and stops gas flow to burners.
! WARNING
FIRE AND EXPLOSION HAZARD Failure to follow this warning could result in personal injury and/or property damage. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury or loss of life.
IMPORTANT: Restart unit and leak check all gas connections including the main service connection, gas valve, gas spuds, and manifold pipe plug. All leaks must be repaired before firing unit.
32. Fire unit and verify proper ignition and proper sequence of operation (Table 6). See Table 8 for proper low stage and high stage manifold pressure settings for your unit. Adjust the gas valve setting for high and low stages by turning the plastic adjustment screws clockwise to increase pressure and counter-clockwise to decrease pressure for the respective stages. Refer to Table 7 for required rated heating input rates. Replace regulator cover screws when finished (see Fig. 11).
33. With control access panel removed, observe unit heating operation in both low stage operation and high stage operation. Watch burner flames to see if they are blue in appearance, and that the flames are approximately the same for each burner (see Fig. 14).
34. Turn off unit, remove pressure manometer and replace the 1/8 in. pipe fitting on the gas manifold (see Fig. 10).
35. Attach warning label (P/N 48DU500076) to visible side of gas valve.
36. Attach conversion label (P/N 48VL500383) above unit rating plate on exterior of unit.
37. Attach completed conversion responsibility label (see Fig. 15, P/N 48VL500384) inside control access panel.

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 10

CPLPCONV013C00: Installation Instructions

A14641

Fig. 12 Orifice and Burner Insert Installation
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 11

A150780

CPLPCONV013C00: Installation Instructions

Fig. 13 Pressure Switch Wiring

A14614

Table 6 Two-Stage Sequence of Operations
Inducer Pre-Purge Period: When the inducer motor comes up on high speed, the pressure switch closes, and the ignition control on the furnace board begins a 15 sec pre-purge period. If the pressure switch fails to remain closed, the inducer will remain running. After the pressure switch recloses, the Infinity ignition control will begin a 15 sec pre-purge period. Trial-for-Ignition Sequence: The spark igniter will spark for 3 sec, the main gas valve relay contact closes to energize the gas valve on low stage. After 5 sec, the igniter is de-energized and a 2-sec flame-proving period begins. NOTE: The unit always lights on high speed inducer and low stage gas valve operation. Flame-Proving: When the burner flame is proved at the flame-proving sensor, the furnace control determines what heating stage to run based on feedback from the thermostat. If the thermostat is asking for low stage gas heat, the ignition control will change the inducer speed to low speed and keep the gas valve energized on low stage. If the thermostat is asking for high stage gas heat, the ignition control will maintain running the inducer on high speed and energize the gas valve's high stage relay to increase gas flow.

Table 7 Two-Stage Rated Heating Input, Propane Gas (0-2000 ft (0-610 m) Altitude)

NAMEPLATE INPUT (BTU/HR)
40,000 60,000 90,000 115,000 127,000 130,000

RATED HEATING INPUT PROPANE (BTU/HR)

High Stage

Low Stage

38,000

26,000

57,000

39,000

79,000

58,500

103,000

75,000

116,000

84,500

116,000

84,500

BURNER FLAME

BURNER

MANIFOLD

Fig. 14 Monoport Burner
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 12

C99021

CPLPCONV013C00: Installation Instructions
IMPORTANT: Restart unit and leak check all gas connections including the main service connection, gas valve, gas spuds, and manifold pipe plug.
! WARNING
FIRE AND EXPLOSION HAZARD Failure to follow this warning could result in personal injury and/or property damage. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury or loss of life.

38. After all leaks are eliminated, replace control access panel.
! WARNING
EXPLOSION, PERSONAL INJURY HAZARD Failure to follow this warning could result in personal injury or death. This unit is designed to operature at a minimum 10.0 IN. W.C. of manifold pressure with propane gas. Refer to Table 8 for proper manifold pressure settings.

Fig. 15 Conversion Responsibility Label Table 8 Propane Gas Orifice Sizes and Manifold Pressures (IN. W.C.)

A14633

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. 13

A14634

CPLPCONV013C00: Installation Instructions

Fig. 16 Installing, Elbows, Nipples, and Pressure Switch on Two-Stage Units

A09016

Edition Date: 09/23

Catalog No: IIK-CPLPCONV-25 Replaces: IIK-CPLPCONV-23

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

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