Payne PG8J Installation Instructions Manual page 48

9/32˝
Fig. 51 --- Igniter Position- -Side View
Fig. 52 --- Igniter Position- -Top View
Fig. 53 --- Cleaning Heat Exchanger Cell
6. Remove screws that fasten the collector box assembly to
the cell panel. Be careful not to damage the collector box.
Inducer assembly and elbow need not be removed from
collector box.
7. Disconnect gas line from gas manifold.
8. Remove the 5 screws that attach the burner assembly to
the cell panel. The gas valve and individual burners need
not be removed from support assembly.
NOTE: Be very careful when removing burner assembly to
avoid breaking igniter. See Fig. 51 and 52 for correct igniter
location.
9. Using field- -provided 25- -caliber rifle cleaning brush,
36- -in. long, 1/4 in. diameter steel spring cable, a variable
speed, reversible electric drill, and 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
NOTE: The materials needed in item 9 can usually be purchased
5/16˝
at local hardware stores.
A05025
1-7/8"
10. Remove old sealant from cell panel and collector box
flange.
11. Spray releasing agent on the heat exchanger cell panel
A05026
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 con-
nection diagram on wiring label, if wires were not marked
for reconnection locations.):
A01050
a. Draft safeguard switch.
b. Inducer motor.
c. Pressure switch(es).
d. Limit over- -temperature switch.
e. Gas valve.
g. Flame- -sensing electrode.
h. Flame rollout switches.
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¡ã
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.
48
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 Fig. 60.)
(3.) Work cable in and out of cell 3 or 4 times to ob-
tain 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.
f. Hot surface igniter.
i. Install NOx baffles (if removed).