Carrier 1184802, Installation Instructions Manual

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Replacement Aluminized Primary Heat Exchanger: Installation Instructions
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
5
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.
BEGIN RE-ASSEMBLY
Install Heat Exchanger Primary Cell Panel
1. Align the primary cell panel with the primary inlet plate of heat
exchanger assembly.
2. Avoid damaging the cell panel insulation during alignment.
3. Insert 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, see Fig. 6 .
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 heat
exchanger outlet panel, see Fig. 6 .
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. 6 .
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. 6 and Fig. 5 .
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. 6 .
5. Install the screws for the Finger Baffles and the remaining screws
for the top edge of the Coupling Box Cover.
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 over the tab on the primary cell
panel, see Fig. 5 .
NOTE: The front edge of the sidewall baffle has a slot that engages a tab
on the primary cell panel.
2. Insert the screws that attach the sidewall baffle to the primary cell
panel.
3. Align the rear edge of the baffle with the screw holes in the
coupling box cover.
A11414
Fig. 5 – Coupling Box/Sidewall Baffle Removal / Installation - Rear
View
4. Insert the screws that attach the sidewall baffles to the coupling
box.
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.
NOTE: Be sure cell panel insulation is folded over the top flange of the
primary cell inlet panel so that when the heat exchanger is fully installed,
the insulation seals between the top plate and the top flange of the cell
panel.
NOTE: Be sure the cell panel insulation is visible on both sides of the
heat exchanger cell panel so that when the heat exchanger is fully
installed, the insulation seals between the cell panel and the mounting
brackets. If any insulation is not visible, pull the heat exchanger forward,
adjust the insulation and reinstall so that the cell panel is properly sealed
to the top plate and to the mounting brackets.
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.
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.
NOTE: There is a slot on each side of the front panel of the condensing
heat exchanger. The collector box has alignment tabs on the back that fit
into the slots on the condensing heat exchanger panel.