Instruction Manual
Table Of Contents
- Installation Instructions
- SAFETY CONSIDERATION
- INTRODUCTION
- DESCRIPTION AND USAGE
- INSTALLATION
- Unit Shut Down
- Vent Pipe Removal
- 1. Support the vent pipe as close to the furnace as possible to prevent damage to the vent system.
- 2. Cut vent pipe with a hacksaw and move the remaining vent pipe out of the way. Secure the vent pipe if necessary.
- 3. Loosen both clamps at the vent pipe support attached to furnace casing.
- 4. Loosen clamp for the vent pipe at vent elbow on the inducer assembly. See Fig. 1.
- 5. Remove remaining vent pipe through the furnace casing and set aside.
- 1. Support the vent pipe as close to the furnace as possible to prevent damage to the vent system.
- Manifold Removal / Burner Box Removal
- 1. Disconnect the gas pipe from gas valve and remove pipe from the furnace casing.
- 2. Disconnect the connector harness from gas valve (Modulating only) or remove individual wires from terminals on gas valve (All other models).
- 3. Disconnect the wires from gas valve, flame sensor and hot surface igniter.
- 4. Remove wires from both roll-out switches.
- 5. Support the manifold and remove the 4 screws that secure the manifold assembly to the burner box and set aside. Note the location of the green and yellow ground wire for reassembly later.
- 6. Support the burner box assembly and remove the screws that attach the burner box to the heat exchanger cell panel.
- 7. Set the burner box assembly aside.
- 1. Disconnect the gas pipe from gas valve and remove pipe from the furnace casing.
- Pressure Switch Removal
- 1. Remove the front pressure switch tube from the port on the collector box. See Fig. 1.
- 2. Disconnect the pressure switch harness (modulating only) from the main wiring harness or remove the individual wires from the front pressure switch (non-modulating). Not the location of the wires for reassembly.
- 3. Remove the screws that attach the pressure switch assembly to the inducer.
- 4. Remove the back pressure switch tube that connects to the inducer assembly.
- 5. Remove the wires from the back pressure switch. Note the location of the wires for reassembly. (Non-modulating).
- 6. If the relief tube for the condensate trap is routed across the inducer assembly, remove the tube from the port on the collector box and from the stand-offs on the inducer and move the tube aside.
- 7. Set the pressure switches aside.
- 1. Remove the front pressure switch tube from the port on the collector box. See Fig. 1.
- Inducer Assembly Removal
- 1. Remove the door bracket from the front edge of the blower shelf.
- 2. Remove the wires that connect the main wiring harness to the inducer motor harness.
- 3. Remove the condensate trap relief tube from the port on the collector box and the stand-offs on the inducer housing.
- 4. Remove the screws from the tabs on inducer assembly that secures the inducer to the collector box. Note: there is one mounting tab directly under the vent elbow.
- 5. Remove the inducer assembly and set aside.
- 6. To avoid double gasketing and leakage, check to make sure the drain gaskets for the inducer and the inducer inlet gasket are not still attached to the inducer housing.
- 7. Remove any adhered gaskets from the front of the collector box. Verify old gaskets are reusable or obtain new gaskets from the distributor. Apply gaskets to the rear of the inducer housing and set aside for reassembly later.
- 1. Remove the door bracket from the front edge of the blower shelf.
- Condensate Drain and Trap Removal
- 1. Disconnect external drain from condensate drain elbow or drain extension pipe inside the furnace and set aside.
- 2. Disconnect the condensate trap relief hose from collector box port and the molded retainer clips on the inducer housing.
- 3. Remove the screw that secures the condensate trap to the collector box, remove the trap and set aside.
- 4. Rinse condensate trap in warm water until trap is clean.
- 5. Clean relief port on Condensate Trap with a thin wire or paper clip, rinse with warm water and set aside.
- 6. Flush condensate lines with warm water.
- 7. Shake trap dry.
- 1. Disconnect external drain from condensate drain elbow or drain extension pipe inside the furnace and set aside.
- Remove J-Box and Main Harness
- 1. Remove the screw that secures the J-Box cover to the J-Box bracket. See Fig. 3.
- 2. Disconnect the field wiring from the factory wiring and remove the ground wire from the green ground screw on the J-Box bracket.
- 3. Remove factory wiring from the J-Box.
- 4. Disconnect the factory wires from the main limit switch.
- 5. Remove the screw that secures the door switch to the blower shelf and the blower shelf door bracket. Remove the screws from the blower shelf door bracket, and set the bracket aside.
- 6. Remove main harness from the slot in the blower shelf.
- 1. Remove the screw that secures the J-Box cover to the J-Box bracket. See Fig. 3.
- Collector Box Removal
- Heat Exchanger Assembly Removal
- Remove Coupling Box
- 1. Remove the screws that secure the finger baffle from the Coupling Box Cover. See Fig. 5.
- 2. Remove the screws that secure the Coupling Box Cover to the rear of the Heat Exchanger Assembly.
- 3. Starting at the upper beveled edge of the coupling box, use a putty knife or gasket scraper to get between the coupling box cover and the Primary Cell Outlet panel to break the silicone seal between the parts.
- 4. Pry upwards with the putty knife as you move around the Coupling Box cover.
- 5. Once the Coupling Box cover is sufficiently loosened, remove the coupling box cover from the rear of the Heat Exchanger Assembly. See Fig. 6.
- 6. Remove the screws that secure the Sidewall Baffles to the Primary Cell Panel and set aside.
- 1. Remove the screws that secure the finger baffle from the Coupling Box Cover. See Fig. 5.
- Separate Primary and Condensing Heat Exchangers
- 1. Remove the screws that attach the condensing heat exchanger assembly to the primary cell outlet panel and remove the screws that attach the condensing heat exchanger outlet panel to the primary inlet panel.
- 2. Gently use a putty knife or gasket scraper to get between the primary cell inlet panel and condensing heat exchanger if it is needed to break the seal between the parts.
- 3. Repeat the procedure at the primary cell outlet panel and containment plate attached to the inlet of the secondary heat exchanger.
- 1. Remove the screws that attach the condensing heat exchanger assembly to the primary cell outlet panel and remove the screws that attach the condensing heat exchanger outlet panel to the primary inlet panel.
- Remove Primary and Condensing Heat Exchanger
- 1. Remove screws that attach the sidewall baffles to the heat exchanger cell panel. See Fig. 8.
- 2. Avoid damaging the cell panel insulation by pulling the sidewall baffle outward from the rear of coupling box, then pull the baffle backward to slide the baffle off of the locater tab on the cell panel.
- 3. Repeat the procedure for the opposite side baffle.
- 4. Remove the screws around each burner inlet opening that attaches the heat exchanger cell panel to the primary inlet plate of the primary heat exchanger assembly.
- 5. If not removed already, remove the screws that attach the primary cell panel to the front of condensing heat exchanger section.
- 6. Separate the Primary Heat Exchanger from the Condensing Heat Exchanger.
- 7. Remove the primary cell panel from the primary cell inlet plate and set aside.
- 1. Remove screws that attach the sidewall baffles to the heat exchanger cell panel. See Fig. 8.
- BEGIN RE-ASSEMBLY
- Install Heat Exchanger Primary Cell Panel
- Attaching Primary and Condensing Heat Exchangers
- 1. Align the bottom edge primary cell outlet panel with the top edge of the condensing heat exchanger assembly, and align the top edge of the condensing heat exchanger outlet panel with the bottom edge of the primary cell inlet panel.
- 2. The orange foam gasket must be between the primary cell outlet panel and the containment plate that is attached to the condensing heat exchanger. The white fiber gasket or equivalent must be between the primary cell inlet panel and the condensing ...
- 3. Insert all the screws, except the outboard screws in the primary outlet panel, to secure the primary heat exchanger panels to the condensing heat exchanger panels (front and back). See Fig. 5.
- 1. Align the bottom edge primary cell outlet panel with the top edge of the condensing heat exchanger assembly, and align the top edge of the condensing heat exchanger outlet panel with the bottom edge of the primary cell inlet panel.
- Install Coupling Box Cover/Finger Baffles
- 1. Apply a 1/4” bead of low adhesion silicone (white) to the coupling box cover in the pattern shown in Fig. 9.
- 2. Align the Coupling Box Cover over the rear of the Heat Exchanger Assembly. See Fig. 5 and Fig. 6.
- 3. Install the screws that secure the bottom edge and sides of the Coupling Box to the Heat Exchanger Assembly.
- 4. Align the Finger Baffles along the top edge of the Coupling Box Cover. See Fig. 5.
- 5. Install the screws for the Finger Baffles and the remaining screws for the top edge of the Coupling Box Cover.
- 1. Apply a 1/4” bead of low adhesion silicone (white) to the coupling box cover in the pattern shown in Fig. 9.
- Install Sidewall Baffles
- 1. Avoid damaging the cell panel insulation by inserting the sidewall baffle inward from the rear of coupling box to the indexing tab on the primary cell panel then align the baffle with the coupling box cover. Insert the slot on the sidewall baffle ...
- Fig. 5 – Heat Exchanger Removal / Installation
- Fig. 6 – Coupling Box/Sidewall Baffle Removal / Installation - Rear View
- Heat Exchanger Assembly Installation
- 1. Lift the heat exchanger assembly and set the rear of the assembly on the blower deck.
- 2. Slide the heat exchanger onto the support rails in the furnace casing.
- 3. Raise the rear of the heat exchanger and set the bottom of the sidewall baffles on top of the support rails in the blower deck.
- 4. Slide the heat exchanger assembly into the casing, making sure the bottom edge of the sidewall baffle slides into the engagement tab on the support rails.
- 5. Continue to slide the heat exchanger assembly backward into the casing until the primary cell panel is flush with the mounting brackets on the side of the casing.
- 6. Align the primary cell panel with the mounting brackets.
- 7. Insert the screws that attach the primary cell panel to mounting brackets on the casing.
- 8. Align the filler plate to the bottom edge of the condensing heat exchanger assembly.
- 9. Secure the filler plate to the condensing heat exchanger and casing.
- 1. Lift the heat exchanger assembly and set the rear of the assembly on the blower deck.
- Collector Box Installation
- 1. Verify old collector box gasket is reusable or obtain a new gasket from the distributor (preferred).
- 2. Obtain new condensate trap gasket from distributor and install.
- 3. Align the tabs on the collector box to the slots on the condensing heat exchanger panel.
- 4. With the collector box fully seated against the condensing heat exchanger cell panel, install the screws through the collector box.
- 5. Tighten the screws in an alternating pattern around the collector box. Do not over-tighten.
- 1. Verify old collector box gasket is reusable or obtain a new gasket from the distributor (preferred).
- Install J-Box and Main Harness
- 1. Insert grommet for main harness in the slot in the blower shelf.
- 2. Align the door switch to the blower shelf.
- 3. Align and install door bracket to the front edge of the blower shelf and secure the door switch during upper door bracket installation.
- 4. Connect the field wiring from the factory wiring and attach the ground wire to the green ground screw on the J-Box bracket.
- 5. Attach the J-Box cover to the J-Box bracket.
- 6. Install the screw to secure the J-Box cover to the bracket.
- 7. Connect the factory wires to the main limit switch.
- 1. Insert grommet for main harness in the slot in the blower shelf.
- Install the Condensate Trap and Drain
- 1. Align the trap with the drain outlet on the collector box.
- 2. Secure the trap to the collector box with the screw.
- 3. Connect the condensate trap relief tube from collector box port and insert the tube into the molded retainer clips on the inducer housing.
- 4. Insert the condensate drain elbow through the casing until it is properly seated. Or, connect the drain elbow to the drain extension pipe and route the pipe behind the inducer.
- 5. Connect the drain elbow to the condensate trap.
- 6. Connect the inducer leads from the main wiring harness to the inducer motor harness.
- 1. Align the trap with the drain outlet on the collector box.
- Inducer Assembly Installation
- 1. Verify the inducer assembly has gaskets on the drain stubs and at the inducer inlet.
- 2. Verify the choke plate is installed on the inlet opening of the inducer.
- 3. Align the tabs on inducer assembly to the brass inserts on the collector box.
- 4. Insert the mounting screws through the tabs to secure the inducer to the collector box. Remember there is a mounting tab located under the vent elbow.
- 5. Insert the mounting screws by hand through the tabs to secure the inducer to the collector box. There is a mounting tab located under the vent elbow.
- 6. Tighten the screws in an alternating pattern by hand. Do not use a screw gun or over-tighten the mounting screws.
- 7. Connect the inducer leads from the main wiring harness to the inducer motor harness.
- 8. Route condensate trap relief tube through standoffs on inducer housing and connect to the port on the collector box.
- Fig. 7 – Collector Box Gasket Condensate Trap
- 1. Verify the inducer assembly has gaskets on the drain stubs and at the inducer inlet.
- Pressure Switch Installation
- 1. Connect the wires to the back pressure switch.
- 2. Connect the tube for the back pressure switch to the inducer assembly.
- 3. Connect the tube for the front pressure switch to the port on the collector box.
- 4. Attach the pressure switch assembly to the inducer.
- 5. Connect the pressure switch harness (modulating only) to the main wiring harness or attach the individual wires to the pressure switch (non-modulating).
- 6. If necessary, route the pressure switch tubing for the front pressure switch through the stand-off on the inducer assembly.
- 7. If necessary, route the condensate trap relief tubing through the stand-off on the inducer assembly. Reconnect tubing to the ports on the condensate trap and collector box.
- 1. Connect the wires to the back pressure switch.
- Burner Box/Manifold Installation
- 1. Support the burner box assembly and install the screws that attach the burner box to the heat exchanger cell panel.
- 2. Align the orifices in the manifold assembly with the support rings on the end of the burner.
- 3. Insert the orifices in the support rings of the burners. Manifold mounting tabs should fit flush against the burner box
- 4. Attach the green/yellow wire and ground terminal to one of the manifold mounting screws.
- 5. Install the remaining manifold mounting screws.
- 6. Connect the wires to both roll-out switches.
- 7. Connect the wires to the flame sensor and hot surface igniter.
- 8. Connect the connector harness from gas valve (Modulating only) or attach the individual wires to the terminals on gas valve (All other models).
- 9. Insert the gas pipe through the grommet in the casing. Apply a thin layer of pipe dope to the threads of the pipe and thread the pipe by into the gas valve.
- 10. With a back-up wrench on the inlet boss of the gas valve, finish tightening the gas pipe to the gas valve.
- 11. Turn gas on at electric switch on gas valve.
- 12. Turn power on at external disconnect, fuse or circuit breaker.
- 1. Support the burner box assembly and install the screws that attach the burner box to the heat exchanger cell panel.
- Vent Pipe Installation
- 1. Insert the vent pipe through the intended vent opening of the furnace casing and insert into the outlet of the inducer vent elbow.
- 2. Tighten the clamp for the vent pipe at vent elbow on the inducer assembly.
- 3. Align the remaining vent pipe system to the vent pipe in the furnace casing.
- 4. Solvent cement the pipes as required for the type of material used.
- 5. Tighten both clamps at the vent pipe support attached to furnace casing.
- 1. Insert the vent pipe through the intended vent opening of the furnace casing and insert into the outlet of the inducer vent elbow.
- Unit Checkout
- 6. Set thermostat to “OFF”.
- 7. Turn on power at external disconnect, fuse or circuit breaker.
- 8. Turn on gas at external shut-off or gas meter.
- 9. Check for gas leaks with a commercially available soap solution made specifically for the detection of leaks.
- 10. Manually close blower door switch
- 11. Initiate component test through circuit board by referring to “Component Test” on status code label on blower access door for complete test sequence information.
- 12. If any status codes are flashed, refer to status code label on unit blower door.
- 13. Turn thermostat fan switch to “ON”, “Continuous” or jumper R to G terminals at furnace control board.
- 14. Check for air leakage around cell panel. It may be necessary to remove heat exchanger assembly and top gasket between cell panel and furnace casing top plate. Re-install and re-check for blower air leaks.
- 15. Remove jumper(s) or set thermostat fan to “Auto” or “OFF”.
- 16. Release blower door switch.
- 17. Install blower access door.
- 18. Set thermostat to call for heat.
- 19. Allow unit to initiate a complete call for heat cycle.
- 20. Check for air leakage around collector box. A whistling noise may indicate air leak in collector box seal.
- 21. After System Check-out is complete, set thermostat below room temperature.
- 22. Verify that burner shuts down and blower completes selected off delay time.
- 23. Verify furnace operates properly and set thermostat to desired room temperature.
- 24. Re-install outer door.
- Fig. 8 – Heat Exchanger Panel Assembly
- Fig. 9 – Collector Box Sealant Application
REPLACEMENT ALUMINIZED PRIMARY HEAT EXCHANGER: Installation Instructions
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
6
5. Connect the drain elbow to the condensate trap.
NOTE: If condensate has a heat pad attached to the trap, trace the wires
for the pad back to the connection point and connect the wires for the
heat pad.
6. Connect the inducer leads from the main wiring harness to the
inducer motor harness.
Inducer Assembly Installation
1. Verify the inducer assembly has gaskets on the drain stubs and at
the inducer inlet.
2. Verify the choke plate is installed on the inlet opening of the
inducer.
3. Align the tabs on inducer assembly to the brass inserts on the
collector box.
4. Insert the mounting screws through the tabs to secure the inducer to
the collector box. Remember there is a mounting tab located under
the vent elbow.
5. Insert the mounting screws by hand through the tabs to secure the
inducer to the collector box. There is a mounting tab located under
the vent elbow.
6. Tighten the screws in an alternating pattern by hand. Do not use a
screw gun or over-tighten the mounting screws.
7. Connect the inducer leads from the main wiring harness to the
inducer motor harness.
8. Route condensate trap relief tube through standoffs on inducer
housing and connect to the port on the collector box.
A11442
Fig. 7 – Collector Box Gasket Condensate Trap
Pressure Switch Installation
NOTE: There are two types of pressure switches. The modulating
pressure switch assembly has three pressure switches.
Two are side-by-side with the third switch mounted to the back of one of
the switches.
All other furnaces have two pressure switches mounted back-to-back.
The tube for the front pressure switch connects the switch to the port on
the collector box. The tube for the switch mounted on the back connects
the switch to the port on the inducer assembly.
1. Connect the wires to the back pressure switch.
2. Connect the tube for the back pressure switch to the inducer
assembly.
3. Connect the tube for the front pressure switch to the port on the
collector box.
4. Attach the pressure switch assembly to the inducer.
5. Connect the pressure switch harness (modulating only) to the main
wiring harness or attach the individual wires to the pressure switch
(non-modulating).
6. If necessary, route the pressure switch tubing for the front pressure
switch through the stand-off on the inducer assembly.
7. If necessary, route the condensate trap relief tubing through the
stand-off on the inducer assembly. Reconnect tubing to the ports on
the condensate trap and collector box.
Burner Box/Manifold Installation
1. Support the burner box assembly and install the screws that attach
the burner box to the heat exchanger cell panel.
2. Align the orifices in the manifold assembly with the support rings
on the end of the burner.
3. Insert the orifices in the support rings of the burners. Manifold
mounting tabs should fit flush against the burner box
NOTE: If manifold does not fit flush against the burner box, the burners
are not fully seated forward. Remove the manifold and check burner
positioning in the burner box assembly.
4. Attach the green/yellow wire and ground terminal to one of the
manifold mounting screws.
5. Install the remaining manifold mounting screws.
6. Connect the wires to both roll-out switches.
7. Connect the wires to the flame sensor and hot surface igniter.
8. Connect the connector harness from gas valve (Modulating only) or
attach the individual wires to the terminals on gas valve (All other
models).
NOTE: Use only propane-resistant pipe dope. Do not use Teflon tape.
9. Insert the gas pipe through the grommet in the casing. Apply a thin
layer of pipe dope to the threads of the pipe and thread the pipe by
into the gas valve.
NOTE: Use a back-up wrench on the gas valve to prevent the valve
from rotating on the manifold or damaging the mounting to the burner
box.
10. With a back-up wrench on the inlet boss of the gas valve, finish
tightening the gas pipe to the gas valve.
11. Turn gas on at electric switch on gas valve.
12. Turn power on at external disconnect, fuse or circuit breaker.
Vent Pipe Installation
1. Insert the vent pipe through the intended vent opening of the
furnace casing and insert into the outlet of the inducer vent elbow.
2. Tighten the clamp for the vent pipe at vent elbow on the inducer
assembly.
3. Align the remaining vent pipe system to the vent pipe in the furnace
casing.
4. Solvent cement the pipes as required for the type of material used.
5. Tighten both clamps at the vent pipe support attached to furnace
casing.
Unit Checkout
6. Set thermostat to “OFF”.
7. Turn on power at external disconnect, fuse or circuit breaker.
8. Turn on gas at external shut-off or gas meter.
9. Check for gas leaks with a commercially available soap solution
made specifically for the detection of leaks.
10. Manually close blower door switch
REMOVE OLD GASKET
APPLY NEW GASKET TO COLLEC-
TOR BOX BEFORE RE-INSTALLING
CONDENSATE TRAP
CONDENSATE TRAP
WARNING
!
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal injury, death
and/or property damage.
Never purge a gas line into a combustion chamber. 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.