Replacement Aluminized Primary Heat Exchanger: Installation Instructions
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
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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 to 21 lb-in.. Do not over-tighten.
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.
Install the Condensate Trap and Drain
NOTE:
If the condensate trap is removed, a new gasket between the trap
and collector box is required. Obtain one from your local distributor.
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.
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.
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.
