Carrier NPLPCONV013C00 Small Packaged Products Accessory Propane Gas Conversion Kit Instruction Manual

Carrier NPLPCONV013C00 Small Packaged Products Accessory Propane Gas Conversion Kit Instruction Manual

NOTE : Read the entire instruction manual before starting the installation.

This kit is used on:
Two-Stage Models: PGR5 (Two-Stage conversion starts on page 7).
Single-Stage Models: PDD3, PDS3, PGD3, PDD4, PDS4, PGD4, PGD5, PGN4, PGN5, PGS3, PGS4, PGS5, WPG34, and WPG44.
(Single-Stage conversion starts on page 2).
This kit must not be used on PGD4****2, PGS4****2,
PGR5 ****2 and WPG4****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.

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.

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.

NPLPCONV013C00: Installation Instructions

Fig. 1 – Low NOx Baffle Location

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 PDD3, PDS3, PGD3, PDD4, PDS4, PGD4, PGD5, PGN4, PGN5, PGS3, PGS4, PGS5, WPG34, and WPG44. This kit must not be used on PGD4****2, PGS4****2, PGR5 ****2 and WPG4****U models. These models are for Natural Gas Only.

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 NPLPCONV014C00.

SINGLE-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.

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 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.
    Table 1 – Single-Stage Kit Contents
    
    *.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
    
    Fig. 3 – Single-Stage Igniter, Flame Sensor; Orifice/Main Burner Relationship
    
    Fig. 4 – Single-Stage Gas Valve
    Fig. 5 – Single-Stage Orifice Installation

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).

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

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

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

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. ).

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

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

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 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.

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 1177092) to visible side of gas valve.
35. Attach conversion label (P/N 50CY502881) above unit rating plate on exterior of unit.
36. Attach completed conversion responsibility label (see Fig. 15, P/N 50CY502881) 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.

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.

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

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

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

TWO-STAGE KIT INTRODUCTION

These instructions cover the installation of a propane gas conversion kit on models: PGR5.
This kit must not be used on PGD4****2, PGS4****2, PGR5 ****2 and WPG4****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 NPLPCONV014C00.

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.

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

Fig. 7 – Fan Partition Bracket Removal

Fig. 8 – Two-Stage Burner Bracket

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.
    
    Fig. 9 – Two-Stage Igniter, Flame Sensor, Orifice/Main Burner Relationship**** Table 5 – Burner Insert Usage (40 and 60 kBtuh Units Only)
    

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. 10 – Burner Assembly
    
    Fig. 11 – Two-Stage Gas Valve

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.
    
    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 1177092) to visible side of gas valve.

36. Attach conversion label (P/N 117709) above unit rating plate on exterior of unit.

37. Attach completed conversion responsibility label (see Fig. 15, P/N 50CY502881) inside control access panel.
    Fig. 12 – Orifice and Burner Insert Installation

Fig. 13 – Pressure Switch Wiring

Table 6 – Two-Stage Sequence of Operations

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

Fig. 14 – Monoport Burner

IMPORTANT : Restart unit and leak check all gas connections including the main service connection, gas valve, gas spuds, and manifold pipe plug.

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.

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.)

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

© 2023 Carrier. All rights reserved.
A Proud Member of the Carrier Family

Catalog No: IIK-NPLPCONV-01
Replaces: 46206211402

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

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