830CA: 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
5. Disconnect Flame Sensor wire from Flame Sensor.
6. Remove the flame sensor from the burner assembly.
7. (Optional) Remove the Hot Surface Igniter (HSI) and bracket from
the burner assembly.
8. Check igniter resistance. Nominal resistance is 40 to 70 ohms at
room temperature and is stable over the life of the igniter.
9. Clean the flame sensor with fine steel wool (0000 grade). Do not
use sand paper or emery cloth.
To reinstall igniter and flame sensor:
1. Install the Hot Surface Igniter (HSI) and bracket with gasket in
burner assembly.
2. Install flame sensor in burner assembly.
3. When installing the HSI and flame sensor,
¼
” screws that are the
same size of those removed must be used. Do not use longer
screws.
NOTE:
If insulation assembly is damaged, do not attempt to repair,
must be replaced with insulation kit.
NOTE:
Proper use of Personal Protective Equipment (PPE) must be
followed, including safety glasses, gloves, and dust mask when
removing and reinstalling the heat exchanger insulation assembly.
4. Connect the wire for the flame sensor.
5. Connect the wire for the Hot Surface Igniter.
6. Turn gas on at electric switch on gas valve and at external shut-off
or meter
7. Turn power on at external disconnect, fuse or circuit breaker.
8. Run the furnace through two complete heating cycles to check for
proper operation
9. Install control door when complete.
CLEANING HEAT EXCHANGER
The following steps should be performed by a qualified service agency:
NOTE:
If the heat exchangers get a heavy accumulation of soot and
carbon, they should be replaced rather than trying to clean them
thoroughly. A heavy build-up of soot and carbon indicates that a
problem exists which needs to be corrected, such as improper adjustment
of gas valve outlet pressure, insufficient or poor quality combustion air,
incorrect size or damaged orifice(s), improper gas, or a restricted heat
exchanger. Action must be taken to correct the problem.
If it becomes necessary to clean the heat exchangers because of dust or
corrosion, proceed as follows:
1. Turn OFF gas and electrical power to furnace.
2. Remove outer access door.
3. Disconnect vent connector from furnace vent elbow.
4. Disconnect wires to the following components. Mark wires to aid in
reconnection of (be careful when disconnecting wires from
switches because damage may occur):
a. Inducer motor
b. Transducer
c. Limit over-temperature switch
d. Gas valve
e. Hot surface igniter
f. Flame-sensing electrode
g. Burner thermal switch
h. DSS Draft Safeguard
5. Remove screws that fasten the inducer cover assembly to the cell
panel. Be careful not to damage the collector box. Inducer assembly
and elbow need not be removed from collector box.
6. Disconnect gas supply line from gas valve.
7. Remove screws that attach the burner assembly to the cell panel.
The gas valve and burners tube need not be removed from burner
box.
NOTE:
Be very careful when removing burner assembly to avoid
breaking igniter.
8. Remove insulation assembly from burner tube inlets.
NOTE:
Proper use of Personal Protective Equipment (PPE) must be
followed, including safety glasses, gloves, and dust mask when
removing and reinstalling the heat exchanger insulation assembly.
9. Using field-provided large caliber rifle cleaning brush, 36-in. (914
mm) long steel spring cable, a variable speed, reversible electric
drill, and vacuum cleaner, clean cells as follows:
NOTE:
The materials needed in item NO TAG can usually be purchased
at local hardware stores.
Remove metal screw fitting from wire brush to allow insertion into
cable.
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.
A180230
Fig. 43 – Igniter Position
(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
(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 two 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.
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.
IGNITOR
POSITION
