508187-01
Issue 2116
Page 37 of 51
Cleaning the Heat Exchanger and Burners
NOTE:
Use papers or protective covering in front of the
furnace during cleaning.
1.
Turn off both electrical and gas power supplies to
furnace.
2. Remove flue pipe and top cap (some applications top
cap can remain) from the unit.
3.
Label the wires from gas valve, rollout switches,
primary limit switch and make-up box then disconnect
them.
4.
Remove the screws that secure the combustion air
inducer/pressure switch assembly to the collector box.
Carefully remove the combustion air inducer to avoid
damaging blower gasket. If gasket is damaged, it must
be replaced to prevent leakage.
5.
Remove the collector box located behind the
combustion air inducer. Be careful with the collector
box gasket. If the gasket is damaged, it must be
replaced to prevent leakage.
6.
Disconnect gas supply piping. Remove the screw
securing the burner box cover and remove cover.
Remove the four screws securing the burner manifold
assembly to the vestibule panel and remove the
assembly from the unit.
7.
Remove screws securing burner box and remove
burner box.
8.
NOx units only - Remove screw securing NOX insert.
Remove NOx insert. See Figure 20.
9. Remove screws from both sides, top and bottom of
vestibule panel.
10.
Remove heat exchanger. It may be necessary to
spread cabinet side to allow more room. If so, remove
five screws from the left side or right side of cabinet.
11.
Backwash using steam. Begin from the burner opening
on each clam. Steam must not exceed 275°F.
12. To clean burners, run a vacuum cleaner with a soft
brush attachment over the face of burners. Visually
inspect inside the burners and crossovers for any
blockage caused by foreign matter. Remove any
blockage. Figure 19 shows burner detail.
13.
To clean the combustion air inducer visually inspect
and using a wire brush clean where necessary. Use
compressed air to clean off debris and any rust.
14.
Reinstall heat exchanger in vestibule. (Replace the
five screws in the cabinet from step 10 if removed).
15.
NOx units only - Replace NOx inserts.
16.
Reinstall collector box and combustion air assembly.
Reinstall all screws to the collector box and combustion
air inducer. Failure to replace all screws may cause
leaks. Inspect gaskets for any damage and replace if
necessary.
17.
Reinstall burner box, manifold assembly and burner
box cover.
18.
Reconnect all wires.
19. Reconnect top cap and vent pipe to combustion air
inducer outlet.
20. Reconnect gas supply piping.
21. Turn on power and gas supply to unit.
22. Set thermostat and check for proper operation.
23. Check all piping connections, factory and field, for gas
leaks. Use a leak detecting solution or other preferred
means.
Some soaps used for leak detection are corrosive to
certain metals. Carefully rinse piping thoroughly after
leak test has been completed. Do not use matches,
candles, flame or other sources of ignition to check for
gas leaks.
CAUTION
24. If a leak is detected, shut gas and electricity off and
repair leak.
25. Repeat steps 24 and 26 until no leaks are detected.
26. Replace access panel.
Figure 20. NOx Inserts
NOx Insert
