800SA/801SA: Installation, Start–Up, Operating and Service and Maintenance Instructions
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
34
A05025
Fig. 48 – Igniter Position-Side View
NOTE:
The materials needed in item 9 can usually be purchased
at local
hardware stores.
9. Using a field-provided 25-caliber rifle cleaning brush; a 36-in. (914
mm) long, 1/4” (6 mm) diameter steel spring cable; and a variable
speed, reversible electric drill; and a vacuum cleaner, clean cells as
follows:
a. Remove metal screw fitting from wire brush to allow insertion
into cable.
b. Insert the twisted wire end of brush into end of spring cable, and
crimp tight with crimping tool or crimp by striking with
ball-peen hammer. TIGHTNESS IS VERY IMPORTANT.
(1.) Attach variable-speed, reversible drill to the end of
spring
cable (end opposite brush).
(2.) Insert brush end of cable into the outlet opening of cell
and
slowly rotate with drill. DO NOT force cable.
Gradually
insert cable into upper pass of cell (see
).
A91252
Fig. 49 – Cleaning Heat Exchanger Cell
(3.) Work cable in and out of cell 3 or 4 times to obtain
sufficient cleaning. DO NOT pull cable with great
force.
Reverse drill and gradually work cable out.
(4.) Insert brush end of cable in burner inlet opening of
cell, and
proceed to clean 2 lower passes of cell in
same manner as
upper pass.
(5.) Repeat foregoing procedures until each cell in furnace
has
been cleaned.
(6.) Using vacuum cleaner, remove residue from each cell.
(7.) Using vacuum cleaner with soft brush attachment,
clean
burner assembly.
(8.) Clean flame sensor with fine steel wool.
(9.) Install NOx baffles (if removed).
(10.)Reinstall burner assembly. Center burners in cell
openings.
10. Remove old sealant from cell panel and collector box flange.
11. Spray releasing agent on the heat exchanger cell panel where
collector box assembly contacts cell panel.
NOTE:
A releasing agent such as cooking spray or equivalent
(must not
contain corn or canola oil, aromatic or halogenated
hydrocarbons or
inadequate seal may occur) and RTV sealant
(G.E. 162, 6702, or
Dow-Corning 738) are needed before starting installation. DO NOT
substitute any other type of RTV sealant. G.E. 162 (P771-9003) is
available through RCD in 3-oz. tubes.
12. Apply new sealant to flange of collector box and attach to cell panel
using existing screws, making sure all screws are secure.
13. Reconnect wires to the following components. (Use connection
diagram on wiring label, if wires were not marked for reconnection
locations.):
a. Draft safeguard switch.
b. Inducer motor.
c. Pressure switch(es).
d. Limit over-temperature switch.
e. Gas valve.
f. Hot surface igniter.
g. Flame-sensing electrode.
h. Flame rollout switches.
i. Install NOx baffles (if removed).
14. Reinstall internal vent pipe, if applicable.
15. Reinstall vent connector on furnace vent elbow. Securely fasten
vent connector to vent elbow with 2 field-supplied,
corrosion-resistant, sheet metal screws located 180° apart.
16. Replace blower access door only, if it was removed.
17. Set thermostat above room temperature and check furnace for
proper operation.
18. Verify blower airflow and speed changes between heating and
cooling.
19. Check for gas leaks.
20. Replace outer access door.
SEQUENCE OF OPERATION
NOTE:
Furnace control must be grounded for proper operation or
control will lock out. Control is grounded through green/yellow wire
routed to gas valve and manifold bracket screw.
Using the schematic diagram, follow the sequence of operation through
the different modes. Read and follow the wiring diagram very carefully.
NOTE:
If a power interruption occurs during a call for heat (W), the
control will start a 90-sec blower-only ON period two seconds after
power is restored, if the thermostat is still calling for gas heating. The
amber LED light will flash code 12 during the 90-sec period, after which
the LED will be ON continuous, as long as no faults are detected. After
the 90-sec period, the furnace will respond to the thermostat normally.
The blower door must be installed for power to be conducted through the
blower door interlock switch ILK to the furnace control CPU,
transformer TRAN, inducer motor IDM, blower motor BLWM,
hot-surface igniter HSI, and gas valve GV.
9/32”
7.1mm
5/16”
7.9mm
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.
