T&C TCWS.54NG03.C User manual

181208-12 5056.4252103 TCWS.54NG03.C
TCWS.54NG03.C
BLACK DIAMOND
BURNER KIT
INSTRUCTIONS
PART# TCWS.54NG03.C
For TCWS Series C
These instructions are supplementary to the Installation
and Operating Instructions supplied with the replace
and should be kept together. Refer to the Installation
and Operating Instructions for proper gas supply, safety
requirements and operating instructions.
IMPORTANT:
THESE INSTRUCTIONS ARE TO REMAIN
WITH THE HOMEOWNER

TCWS.54NG03.C 181208-12
If converting to propane see conversion
instructions on page #6 before proceeding.
Install panels according to the TCWS.54CE
Installation and Operating manual prior to
burner installation. (Page 23)
1 Attach fuel ex line and pilot assembly to bulkhead
ttings. Ensure the main ex line travels around
the mounting leg towards the front of the rebox
as shown. (Fig. #1)
2. Connect spark electrode wire (ORANGE) to the
rear electrical bulk head tting. Connect the ame
sensor wire to the front electrical bulk head tting.
(Fig. #1)
ORANGE WIRE
Contents of Package
Black Diamond Burner Installation
1 BURNER TRAY
Fig #1
2 5 LB GLASS MEDIA
2 BURNER ASSEMBLIES
1 PILOT ASSEMBLY
1 1/2 SS FLEX LINE
1 HARDWARE PACK
2 MANIFOLD ASSEMBLIES
2 PORCELAIN TRIM
2

TCWS.54NG03.C181208-12
3. Attach both manifold brackets to the
bottom of the rebox using four screws.
(Fig. #2)
4. Connect gas lines to both orifice
assemblies on the mounting brackets.
(Fig. #3)
CAUTION:
Ensure that all connections are gas
tight.
5. Bend side tabs on burner tray inwards
about 20°. (Fig. #4)
6. Tilt the burner tray into the unit and place
on top of the legs. Attach pilot to burner
tray. (Fig. #5)
Fig #2
Fig #3
Fig #4
Fig #5
3

TCWS.54NG03.C 181208-12
7. Secure the burner tray to legs using
eight screws (Fig. #6)
NOTE: use a light to aid aligning the
holes in the tray with the leg.
NOTE: check air shutter for correct
fuel setting before proceeding
further.Both burner shutters are to be
set the same, fully closed for natural
gas. 13/64 (0.2)” open for LP.
8. Install the right burner by tipping
into location trough and slipping the
venturi tube over the orice. Test
for connection by lightly prying at
the end of the burner with a screw
driver.Repeat with left burner.(Fig.
#7)
CAUTION: The burners should be
tightly butted up against each other
at the center to ensure correct
operation.
9. Place glass media into the burner
tray and brush smooth so that a
very light layer covers the burners.
(Fig. #8)
NOTE: Too much glass media will
cause sooting and improper ame
pattern.
10. Place rear porcelain trim, wide
edge, against the back panel and
press down over the pre-bent tabs
on the burner tray. (Fig. #9)
Fig #6
Fig #9
Fig #8
Fig #7
4

TCWS.54NG03.C181208-12
11. Place the front porcelain trim so
that it rests on the front shelf of
the rebox and is snug against the
rebox frame.
Ensure that the wide edge of the
trim is against the rebox frame.
(Fig. #10 & 11)
WIDE EDGE TO FRONT OF
FIREPLACE WITH FRONT
TRIM, TO THE REAR OF THE
FIREBOX FOR REAR TRIM.
Fig #10
Fig #11
5

TCWS.54NG03.C 181208-12
WARNING
This conversion kit
shall be installed by a
qualied service agency
in accordance with the
manufacturer's instructions
and all applicable codes
and requirements of
the authority having
jurisdiction.
If the information in these
instructions is not followed
exactly, a re, explosion
or production of carbon
monoxide may result
causing property damage,
personal injury or loss of
life.
The qualied 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 specied in the
manufacturer's instructions
supplied with the kit.
If the unit is to be used on propane convert as follows using the components
supplied with this burner:
CAUTION
The gas supply and electrical power shall be shut off before proceeding with
the conversion.
Note:
Factory supplied components must be used to ensure correct input.
After conversion conrm proper manifold pressure.
1. If installed remove the glass media from
the burners.
2. If installed remove the burner from the
burner tray by gently lift up the left side
of the burner and disengage the burner
tube from the orice. (Fig. #14)
3. Using a 1/2” wrench, undo the
natural gas burner orice,
(marked #32). Apply a small amount
of pipe joint compound to the threads
of the propane burner orice
(marked 1.8mm) to ensure a good
seal, before screwing it into the tting.
Loosen the primary air shutter screw,
open shutter to give a gap of 13/64”
(0.2”) and re-tighten.Repeat on other
burner. (Fig. #15a)
4. With a 7/16” wrench loosen the pilot
head on the pilot assembly. (Fig. #16)
Propane Conversion
Fig #15
Fig #16
Fig #14
Fig #15a
6

Fig #18
TCWS.54NG03.C181208-12
5. Slide the pilot adjustment band over and
ensure that the hole in the orice band
is showing.
Fig. #17a shows NG position
Fig. #17b shows LP position).
6. Remove the access panel, 10 screws,
and set aside.
7. Lift the control box shield and rest
on the edge of the screw above the
access hole (Fig. #18)
CONTROL BOX SHIELD
8. Remove the minimum rate screw
located in the valve. (Fig. #19)
The minimum rate screw is sealed with
an O-ring. Use a thin bladed
screwdriver to back the screw out past
the limit of the threading. At this point
a groove on the screw body will be
visible just above the valve body. Insert
a thin tool (knife blade or ne
screwdriver blade) into the groove and
gently pry the screw up. It helps to
rotate the screw while lifting on it.
9. Replace the minimum rate screw with the
one provided in the propane conversion
kit supplied with this replace. Ensure
that the screw is fully seated. (Fig.
#20)
Fig #17a
Fig #19
Fig #20
NG POSITION LP POSITION
Fig #17b
7

Fig #24
TCWS.54NG03.C 181208-12
10. Pull off the rubber cap from the top of
the pressure regulator.
(Fig. #21)
11. Press down on the center post and rotate
90°. The center post should stay down.
(Fig. #22). Replace the rubber cap.
12. Fill in the date and the name of the
person who performed the conversion in
the white area on the conversion label.
Peel off the protective backing and apply
the conversion label directly over the
gas specications on the rating label.
13. Re-locate the control box shield and
re-attach the access panel to the side
of the rebox with the screws
previously removed. (Fig. #23 & 24)
14. If the burner was removed in previous
steps replace in reverse order or return
to installation process on Pg. 2.
WARNING: Both the
control box shield and
the access panel must
be reinstalled after
conversion/ installation
or servicing has been
completed.Failure to do
so will cause overheat
ing andpremature failure
of the control system.
CONTROL SHIELD SHOWN IN
PROPER CLOSED POSITION
Fig #21
Fig #22
Fig #23
NG LP
8

TCWS.54NG03.C181208-12
1. Remove the plug from the pressure test
port using a 3/16” hex key. The plug is
located between the right side lintel and
rebox side.
(Fig. #25)
2. Thread the extension test tting into the
open port.
(Fig. #26)
3. Attach a pressure gauge onto the
tting.
4. When testing is complete shut off the
gas, remove the tting and replace the
plug. Thread sealant will be required to
ensure a gas tight connection.
Note:To test the gas pressure, turn off the gas supply before removing the plug from
the supply pressure test port or manifold pressure test port.
Verify gas pressures with the replace lit and on the highest setting.
SUPPLY
PRESSURE
MANIFOLD
PRESSURE
Fig #27
Correct gas pressure requirement:
Supply Pressure Natural Gas Propane
Min. Pressure 5.0" WC 12.5" WC
(For purpose of input adjustment)
Max. Pressure 13.9" WC 13.9" WC
Manifold Pressure
Maximum 3.8" WC 11" WC
Minimum 2.1" WC 5.5" WC
Gas Pressure Check
Fig #25
Fig #26
9

TCWS.54NG03.C 181208-12
The air shutter on the burner tube controls the primary combustion air. It is set to the closed
position at the factory for natural gas fuel.For LP see Pg.6.Some adjustment may be necessary
to obtain desired ame and to eliminate carbon deposits. Evaluate ame appearance after
the replace has reached operating temperature. See Fig. #26 for proper ame pattern.
Open primary air if the window glass and rebox have carbon accumulation and/or the
ames are long, dark and stringy. The shutter may also be opened to lessen the ame
height.
NOTE:
Proper air shutter setting is required.
The ame should be just orange and “lazy”. It should NEVER be set to create sooting
on internal parts and window glass. Allow the replace to run for 30 minutes before
evaluating ame appearance.
Burner Flame Adjustment
Fig #26
10

NOT SHOWN
*
*
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3
6
5
4
TCWS.54NG03.C181208-12
ITEM.......DESCRIPTION......................................................... PART NO.
#1..........BLACK DIAMOND BURNER ........... TCWS.54NG03.C
#2..........GLASS MEDIA (2 required).................... TCRP.501201
#3..........MAIN SUPPLY TUBE...................................... 5019.223
#4..........PILOT ASSEMBLY...............................TCRP.5005025C
ITEM.......DESCRIPTION......................................................... PART NO.
#5..........ORIFICE, NATURAL GAS (#32)..................5021.332.A
#6..........PROPANE CONVERSION KIT.......... TC36.LPCSTE01
(WHEN ORDERING, INCLUDE PART NUMBER WITH DESCRIPTION)
Replacement Parts
1
KIT CONTENTS:
11
4
115
11
3
4
11

Technical support: 1-877-715-2664
Web site: www.townandcountryreplaces.net
2975 Allenby Rd., Duncan, BC V9L 6V8
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