18
440 04 6001 00
Specifications subject to change without notice.
NOTE
: If manifold does not fit flush against the burner, do
not force the manifold on the burner assembly. The burners
are not fully seated forward in the burner assembly. Remove
the manifold and check burner positioning in the burner
assembly assembly before re-installing the manifold.
6. Attach the green/yellow wire and ground terminal to
one of the manifold mounting screws.
7. Install the remaining manifold mounting screws.
8. Check the igniter alignment. See Figure 8, Figure 9
and Figure 14.
9. Attach the wires to the roll-out switches.
10. Align the burner assembly with the openings in the
primary cell inlet panel and attach the burner
assembly to the cell panel.
11. Connect the wire for the flame sensor.
12. Connect the wire for the Hot Surface Igniter.
NOTE
: Use propane-resistant pipe dope to prevent leaks.
Do not use Teflon tape.
13. Install the gas pipe to the gas valve.
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.
!
WARNING
14. Check for gas leaks with a commercially available
soap solution made specifically for the detection of
leaks.
15. Turn gas on at electric switch on gas valve and at
external shut-off or meter
16. Turn power on at external disconnect, fuse or circuit
breaker.
17. Run the furnace through two complete heating cycles
to check for proper operation
18. Install control door when complete.
Servicing Hot Surface Igniter
The igniter does
NOT
require annual inspection. Check
igniter resistance before removal. Refer to Figure 8,
1. Turn off gas and electrical supplies to furnace.
2. Remove control door.
3. Disconnect igniter wire connection.
4. Check igniter resistance. Igniter resistance is affected
by temperature. Only check resistance when the
igniter is at room temperature.
a. Using an ohm meter, check resistance across both
igniter leads in connector.
b. Cold reading should be between 40 ohms and 70
ohms.
5. Remove igniter assembly.
a. Using a 1/4
−
in. driver, remove the two screws
securing the igniter mounting bracket to the burner
assembly (See Figure 14 .)
b. Carefully withdraw the igniter and bracket assembly
through the front of the burner assembly without
striking the igniter on surrounding parts.
c. Inspect igniter for signs of damage or failure.
d. If replacement is required, remove the screw that
secures the igniter on igniter bracket and remove the
igniter.
6. To replace igniter and bracket assembly, reverse
items 5a through 5d.
7. Reconnect igniter harness to the igniter, dressing the
igniter wires to ensure there is no tension on the
igniter itself. (See Figure 14.)
8. Turn on gas and electrical supplies to furnace.
9. Verify igniter operation by initiating control board self
−
test feature or by cycling thermostat.
10. Replace control door.
Flushing Collector Box and Drainage System
ELECTRICAL SHOCK AND FIRE HAZARD
Failure to follow this warning could result in personal
injury, death, and/or property damage.
Turn off the gas and electrical supplies to the furnace
and install lockout tag before performing any
maintenance or service. Follow the operating
instructions on the label attached to the furnace.
!
WARNING
1. Turn off gas and electrical supplies to furnace.
2. Remove control door.
3. Disconnect pressure switch tube from pressure
switch port.
NOTE
: Ensure the pressure switch tube disconnected from
the pressure switch is higher than the collector box opening
or water will flow out of tube.
4. Remove the collector box plug from the top port on
the upper corner of the collector box. (See Figure 10)
5. Attach a funnel with a flexible tube to port on the
collector box.
6. Flush inside of collector box with water until discharge
water from condensate trap is clean and runs freely.
7. Repeat steps 4 thru 6 with middle plug on upper
corner of collector box.
8. Remove the pressure switch tube from the collector
box.
NOTE
: Do
NOT
blow into tube with tube connected to the
pressure switch.
9. Clean pressure switch port on collect box with a small
wire. Shake any water out of pressure switch tube.
10. Reconnect tube to pressure switch and pressure
switch port.
11. Remove the relief tube from the port on the collector
box and the trap.
12. Clean the relief port on collect box and the trap with a
small wire. Shake any water out of the tube.
13. Reconnect relief tube to trap and collector box ports.
Cleaning Condensate Drain and Trap
NOTE
: If the condensate trap is removed, a new gasket
between the trap and collector box is required. Verify a
condensate trap gasket is included in the service kit or
obtain one from your local distributor.
1. Disconnect power at external disconnect, fuse or
circuit breaker.
2. Turn off gas at external shut-off or gas meter.
3. Remove control door and set aside.
4. Turn electric switch on gas valve to OFF.
5. Disconnect external drain from condensate drain
elbow or drain extension pipe inside the furnace and
set aside.
