Installation Instructions LPK-OH - LEGACY/PHOENIX NG to LP Gas Conversion Kit Models: LEGACY42-IFT PHOENIX42-IFT WARNING: This conversion kit shall be installed by a qualified service agency in accordance with the manufacturer s instructions and all applicable code and requirements of the authority having jurisdiction. If the information in these instructions is not followed exactly, a fire, explosion or production of carbon monoxide may result causing property damage, personal injury or loss of life. 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 appliance is checked as specified in the manufacturer s instructions supplied with the kit. CAUTION! Risk of Cuts, Abrasions or Flying Debris. Wear protective gloves and safety glasses during installation. Sheet metal edges are sharp. Note: An arrow ( ) found in the text signifies change in content. 1 Components LPK-OH Description Dexen Valve Regulator Replacement Kit. Includes gas regulator, conversion label and instructions Main Burner Orifice (LP) Pilot orifice (.014 for LP) Installation instructions Installer conversion label Table 1.1 Note: The LPK-OH kit is for a one time conversion only. Discard unused parts. Note: For gas models not listed, refer to the model s installation instructions for proper conversion kit or contact your Hearth & Home Technologies dealer. For the dealer nearest you, please visit www.heatilator.com. 1
2 Orifice Sizes for Conversions A. Conversion - Orifices LPK-OH (CONVERT TO LP) Threaded Orifice Size Model Table 2.1.098 LEGACY42-IFT PHOENIX42-IFT 3 Preparation Required Tools 7/16 in. Open End Wrench (2) 3/4 in. Open End Wrench Safety Glasses Manometer #20 Tamper Proof Torx Small Cabinet Screwdriver Non-corrosive Leak-Check Solution A. Turn off the Gas and Electrical Power To turn off the gas, locate the manual shutoff valve in the control area in the bottom of the appliance. Turn the manual shutoff valve so it is perpendicular to the gas line (Figure 3.1). Shut off all electrical power to the appliance by turning off the appropriate circuit breaker or removing the fuse in the electrical panel. B. Access the Control Area Note: Care must be taken when working on appliance to avoid damage to logs, burner and hearth pieces. Remove the logs and grate, set aside. Remove (3) Front Hearth Refractory pieces. See Figure 3.2. OFF Front Hearth Refractory Grate Assembly Figure 3.1 Manual Shutoff Valve Figure 3.2 2
Remove (2) Side Hearth Refractory pieces. See Figure 3.3. Side Hearth Refractories Disconnect incoming flexible gas line from gas valve. Remove orange and green wires from the valve. Slide Burner Assembly towards the front of the appliance and stand upright. Make certain Burner Assembly is stable and will not fall over. Caution: Use care not to damage Burner Top or Refractory when standing Burner Assembly upright. When Burner Assembly is standing upright, access to components for conversion is possible. See Figure 3.6. Orifice Figure 3.3 Remove left and right Side Hearth Refractory Brackets, (3) screws each. See Figure 3.4. Valve Pilot Figure 3.6 Go to Section 4 - Converting the Appliance. Hearth Refractory Bracket Figure 3.4 Remove (4) screws, (2) per side, securing Burner Assembly to the base of the appliance. See Figure 3.5. Figure 3.5 3
4 Converting the Appliance The LEGACY42-IFT/PHOENIX42-IFT come equipped with a Dexen PIP valve.(figure 4.1) use only the Dexen Valve Regulator Replacement Kit or Replacement Valve. Follow the regulator replacement instructions that came with the regulator replacement kit. After completion of the regulator replacement instructions, return to these instructions. Note: Save the label that came with the Dexen conversion kit for later placement. Note: Remove all components blocking your access and set aside. Figure 4.1 Dexen Intermittent Pilot Valve 4
5 Replace the Pilot and Burner Orifice WARNING Fire Risk Orifices must be replaced Failure to replace the orifices could result in overheating the gas appliance and possibly damaging your appliance and your home. Note: Appearance of pilot may vary. PILOT ORIFICE PILOT HOOD A. Replace Pilot Orifice Loosen the nut at the base of the pilot hood with a 7/16 in. wrench. See Figures 5.1 & 5.2. Turn the nut until it comes free of the pilot. Discard the pilot orifice and replace it with the new LP pilot orifice. Handle carefully. Do not drop. Tighten the nut with a 7/16 in. wrench. Tighten until snug. (Used in assembly with 2-sided hood). PILOT TUBE ASSEMBLY CHECK FOR LEAKS Figure 5.2 Pilot Figure 5.1 Pilot Location 5
B. Replace Burner Orifice(s) Note: Test fittings for leaks with the pilot lit and the burner off. Burner Orifices - Novus NDV & NBV Using (2) 3/4 in. wrenches, disconnect flexible gas line from threaded orifice. See Figure 5.3. Using 3/4 in. wrench remove NG orifice from burner neck and discard orifice. See Figure 5.3. Replace the existing orifice with the appropriate propane orifice and tighten. Remove the NG air shutter. When converting from NG to propane, the air shutter must be removed. See Figure 5.4. Reconnect the flexible gas line to the new propane threaded orifice and tighten. All connections must be tightened and checked for leaks with a commercially available, non-corrosive leak check solution. Be sure to rinse off the solution when done leak testing. Natural Gas Figure 5.4 Air Shutter (Before & After) Propane Burner Neck Flexible Gas LIne Orifice Figure 5.3 Burner Orifice 6
6 Adjust the Air Shutter The LEGACY IFT/PHOENIX42-IFT require the air shutter be removed when the appliance is converted to burn propane. No futher air shutter adjustments need to be made. 7
7. A. Leak Test Checking Your Conversion WARNING Fire Risk Explosion Risk All connections must be checked and leaks must eliminated. Incomplete gas line connections could cause a gas leak. Turn on the gas and electricity. Gas Leak Test All connections must be tightened and checked for leaks with a commercially available, non-corrosive leak check solution. Be sure to rinse off the solution when done leak testing. If the solution indicates there is a leak, tighten and seal the connection and then retest. Leak Test Dexen Intermittent Pilot Ignition Models Turn on the appliance and test for leaks at the valve and the burner orifice using the method above. Inlet Gas Pressure Verify the inlet gas supply pressure by connecting a manometer to the inlet side of the valve. If the inlet gas pressure is incorrect, do not adjust without specific approval and instruction from the gas supplier. Changing inlet pressure may effect other appliances in the residence. Manifold Gas Pressure To measure the manifold pressure, loosen the manifold pressure tap with a small flathead screwdriver, and connect a manometer to the 1/8 in. manifold pressure tap on the side of the valve. See Figure 7.1. Ignite the appliance and ensure the pressure is between 3.2-3.7 in. for NG and 9.5-10.5 in. for LP water column. Shut off Appliance Remove the manometer and tighten the manifold pressure tap. 1. Loosen the Tap marked "OUT" with a small Screwdriver. B. Checking the Pressure Dexen Valve WARNING Fire Risk! Explosion Risk! Asphyxiation Risk! Manometer 2. Attach manometer hose. 3. Light main burner and check pressure. High pressure will damage valve. Low pressure could cause explosion. Check all fittings and connections with a noncorrosive commercially available leak-check solution. DO NOT use open flame. Figure 7.1 Intermittent Pilot Manometer Adjustment 8
8 All labels must be filled out and/or installed by the individual completing the conversion. This must be finished or the conversion is not complete. See Figures 8.1-8.3. Fill out the installer conversion label (Figure 8.1). After filling out the label, clean an area near the existing rating label and attach. Attach the valve manufacturer conversion labels as indicated in Figures 8.2 and 8.3 Locate the lighting instruction card and attach the red LP or blue NG label (included with this conversion kit) over the existing blue or red label. LPK-OH Attaching Labels Place conversion label here Figure 8.2 Dexen Conversion Label Placement THIS PLATE MUST BE AFFIXED AS CLOSE AS POSSIBLE TO THE EXISTING RATING PLATE. THE FOLLOWING MUST BE COMPLETED BY THE INDIVIDUAL CONVERTING THISAPPLIANCE: THIS APPLIANCE HAS BEEN CONVERTED TO FUEL, ORIFICE, MANIFOLD PRESSURE, AND INPUT, ON (date), WITH KIT # LPK-OH BY (name &address of organization making this conversion) WHOACCEPTS THE RESPONSIBILITY FOR THE CORRECTNESS OF THIS CONVERSION. Figure 8.1 Conversion Label 4095-906A THIS CONTROL HAS BEEN CONVERTED TO LP Figure 8.3 Dexen Conversion Label THIS CONTROL HAS BEEN CONVERTED TO NG 9