Carrier 48DU Instruction Manual Page 1

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Installation Instructions
This kit is used on:
Two-Stage (2 - 5 Tons) Models: 48DU, 48DT, 48XL, 48XT,
577B, 577D, 677B, and 677D. (Two-Stage conversion starts on
Page 2.)
Single-Stage (1-1/2 - 5 Tons) Models: 48ES, 48EZ, 48VL,
48VT, 574D, 577C, 674D, 677C, and PY3G. (Single-Stage
conversion starts on Page 9.)
NOTE: Read the entire instruction manual before starting the
installation.
SAFETY CONSIDERATIONS
Improper installation, adjustment, alteration, service maintenance,
or use can cause explosion, fire, electrical shock, or other
conditions which may cause death, personal iniury, or property
damage. Consult a qualified installer, service agency, or your
distributor or branch for information or assistance. The qualified
installer or agency must use factory-authorized kits or accessories
when modifying this product. Refer to the individual instructions
packaged with the kits or accessories when installing.
Follow all safety codes. Wear safety glasses, protective clothing,
and work gloves. Have a 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 Fuel Gas Code
(NFGC) NFPA 54/ANSI Z223.1, and the National Electrical Code
(NEC) NFPA 70.
In Canada refer to the current editions of the National Standards of
Canada CAN/CSA-BI49.1 and .2 Natural Gas and Propane
Installation codes, and Canadian Electrical Code CSA C22.1
Recognize safety information. This is the safety-alert symbol z_X
When you see this symbol on the unit and in instructions or manu-
als, 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 per-
sonal injury or death. CAUTION is used to identify unsafe practic-
es which may result in minor personal injury or product and prop-
erty 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
iniury, 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.
FEU, EXPLOSION, EMPOISONNEMENT PAR
CARBON DE MONOXYDE, RISQUE DE
DOMMAGE A LA PROPRII_TI_
La n_gligeance de suivre l'avis suivant, peut causer des
blessures personnelles, la mort ou du dommage fi la
proprietY.
Cette trousse de conversion doit _tre install_e par un
Entrepreneur qualifi_, selon les instructions du fabricant et
doff se conformer fi routes les exigences et tout les codes
pertinents de l'autorit_ comp_tente. L'Entrepreneur qualifi_
est responsable, et doff s'assurer de bien suivre les
instructions dans cet avis. L'installation sera consid_r_
conforme et rencontrant les specifications et instructions du
fabriquant qui sont inclus dans la trousse, seulement apr_s
v_rification de l'op_ration de la fournaise convertie.
[]NIT 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.
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Summary of Contents

Page 1 - Installation Instructions

Installation InstructionsThis kit is used on:Two-Stage (2 - 5 Tons) Models: 48DU, 48DT, 48XL, 48XT,577B, 577D, 677B, and 677D. (Two-Stage conversion s

Page 2 - TWO-STAGE KIT INSTALLATION

This normally open switch closes when gas is supplied to gas valveunder normal operating pressure. The dosed switch completescontrol circuit. Should a

Page 3 - _., ...ST,C... STSC_W

Table 6 - Single-Stage Sequence of OperationsTrial-for-Ignition Sequence: The ignition sequence is to immediately energize the inducer motor on a call

Page 4 - Fig. 5 - Monoport Burner

BURNERFLAME(Blueinappearance)BURNERMANIFOLDFig. 14 - Monoport BurnerJ :////A07805Single-Stage 90,000 BTUH to130,000 BTUH UnitsSingle-Stage 40,000 BTUH

Page 5

Rollout SwitchFig. 16 - Single-Stage Burner BracketBurner BracketA0787413

Page 6 - TWO-STAGE 40,000 BTUH UNITS

LOW GAS PRESSURE SWITCH\1/8 NPTx 2 NIPPLESINGLE-STAGE GAS VALVEELBOW1/8 NPTx 3/4 CLOSE PiPE NIPPLE1/8 NPTx 3/4 CLOSE PIPE NIPPLEFig. 17 - Installing E

Page 7 - (JOUR - MOIS - ANNEE)

TableI - Two-Stage Kit ContentsITEMInstallation InstructionsPropane Gas Orifice #50*Propane Gas Orifice #51 *Propane Gas Orifice #52*Propane Gas Orifi

Page 8

Replacetheburnersintherackusingthesavedscrews,makingsureclosedcrossoversofburnersareateachend.13.Removethenaturalgasorificesfromthemanifoldusinga9/16i

Page 9 - SINGLE-STAGE KIT INSTALLATION

Table 2 - Two-Stage Sequence of OperationsInducer Pre-Purge Period: When the inducer motor comes up on high speed, the pressure switch closes, and the

Page 10

IMPORTANT: Restart unit and leak check all gas connectionsincluding the main service connection, gas valve, gas spuds, andmanifold pipe plug.FIRE AND

Page 11 - Manifold

FLAMESENSORBURNER (3)MANIFOLDORIFICE (3)TWO-STAGE90,000 BTUHTO 130,000 BTUH UNITSFLAMESENSORORIFICE (3)BURNER INSERT (3)_ SPARKER"__- - GASVALVE.

Page 12 - MANIFOLD

Table 4 - Propane Gas Orifice Sizes and Manifold Pressures (IN. W.C.)PROPANE CONVERSION KiT RATING PLATE CARRIER CORP.TH S APPL ANCE HAS BEEN CONVERTE

Page 13 - Burner Bracket

TWO -STAGE GAS VALVE1/8 NPTx 3/4 CLOSE PIPE NIPPLE1/8 NPTx 3/4 CLOSE PIPE NIPPLE1/8 ELBOW1/8 ELBOW1/8 NPTx2 NIPPLELOW GAS PRESSURE SWITCHFig. 9 - Inst

Page 14 - Catalog No: IIKCPLPCONV-11

SINGLE-STAGE KIT INTRODUCTIONThese instructions cover the installation of a propane gasconversion kit on models 48ES, 48EZ, 48VL, 48VT, 574D, 577C,674

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