Instruction manual
TableI - Two-Stage Kit Contents
ITEM
Installation Instructions
Propane Gas Orifice #50*
Propane Gas Orifice #51 *
Propane Gas Orifice #52*
Propane Gas Orifice #56"
Propane Gas Orifice #54*
Propane Gas Orifice #56*
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 6/4 in. (19 mm)
Wire Harness
Propane Conversion Label (Rating Plate)
Propane Conversion Label (Installer Responsibility)
Propane Conversion Warning Label (Gas Valve)
Burner Insert
• Referto Table 4to determine the correct orifice to use.
PART NO. QUANTITY
ItKCPLPCONV- 11 1
LH32RF070 3
LH32RF067 3
LH32RF065 3
LH32RF060 3
LH62RF055 3
LH62RF047 3
EF39ZW026 2
HKO2LBO08 1
CAO5RAO01 2
CA01 CA010 1
CA01CAO01 2
48DU400080 1
48VL500206 1
48VL500207 1
48DU500076 1
48GS5004651 6
Firing Tube
NOx Baffle
ELECTRICALSHOCK HAZARD
Fig. 1 - Low NOx Baffle Location
A01051
Failure to follow this warning could result in personal
iniury or death.
Before installing or servicing system, always turn off main
power to system. There may be more than one disconnect
switch. Tag disconnect switch with suitable warning label.
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 4 for proper manifold pressure settings for high
stage and low stage.
TWO-STAGE KIT INTRODUCTION
These instructions cover the installation of a propane gas
conversion kit on models 48DT, 48DU, 48XL, 48XT, 577B,
577D, 677B and 677D that are equipped with a White Rodgers
2-stage combination automatic gas valve regulator.
DESCRIPTION AND USAGE
This Two-Stage kit is applicable to units with heating inputs from
40,000 to 130,000 Btu/hr installed at high altitudes from 2001 ft
(610m) to 6000 ft (1829 m). It cannot be used for standard altitude
installation. Standard altitude conversion (0-2001 ft) (0-610 m)
must use kit CPLPCONV013A00.
TWO-STAGE KIT INSTALLATION
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.
1. Turn off gas supply first, then power to unit.
2. Remove the front 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.
5. Disconnect the gray, blue, brown and green/yellow wires
from the gas valve and remove 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 screw securing the brown wire from the burner
assembly. 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.
12. For 2-Stage 40,000 Btu/hr and 60,000 Btu/hr models only!
Remove the burners from the rack, save the screws. Remove
the snap ring from the end of each burner. 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. 2 for correct orientation).