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Replacement Aluminized Primary Heat Exchanger: Installation Instructions
Unit Checkout
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.
6. Set thermostat to "OFF".
7. Turn on power at external disconnect, fuse or circuit breaker.
8. Turn on gas at external shut-off or gas meter.
9. Check for gas leaks with a commercially available soap solution
made specifically for the detection of leaks.
10. Manually close blower door switch.
WARNING
!
ELECTRICAL OPERATION HAZARD
Failure to follow this warning could result in personal injury or death.
Blower door opens 115-v power to furnace control. No component
operation can occur unless switch is closed. Exercise caution to avoid
electrical shock from exposed electrical components when manually
closing this switch for service purposes.
11. Initiate component test through circuit board by referring to
"Component Test" on status code label on blower access door for
complete test sequence information.
12. If any status codes are flashed, refer to status code label on unit
blower door.
13. Turn thermostat fan switch to "ON", "Continuous" or jumper R to
G terminals at furnace control board.
14. Check for air leakage around cell panel. It may be necessary to
remove heat exchanger assembly and top gasket between cell panel
and furnace casing top plate. Re-install and re-check for blower air
leaks.
15. Remove jumper(s) or set thermostat fan to "Auto" or "OFF".
16. Release blower door switch.
17. Install blower access door.
18. Set thermostat to call for heat.
19. Allow unit to initiate a complete call for heat cycle.
20. Check for air leakage around collector box. A whistling noise may
indicate air leak in collector box seal.
NOTE: If there is a severe air leak in the collector box seal, pressure
switch may not close or will re-open, resulting in no ignition or erratic
burner operation.
NOTE: Heat Exchanger failure may have been caused by one or more of
the following conditions. As part of the system check-out, verify that the
following conditions are not affecting the operation of the furnace:
• Short Cycling-Defective thermostat: Incorrect thermostat anticipator
setting, dirty filter or over-sized furnace.
• Under firing/low Btu input: Set manifold pressure and verify firing
rate as shown on rating plate by clocking the gas meter.
• Over-firing/high Btu input: Set manifold pressure and verify firing
rate as shown on rating plate by clocking the gas meter.
• Low temperature rise: Set unit for correct temperature rise range as
shown on unit rating plate.
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
• Contaminated combustion air: Remove contaminates or provide
ample fresh air for combustion.
• Excessive amounts of outside ventilation air: Return air temperature
cannot be below 60 degrees F for extended periods of time.
• Incorrect venting or termination: Recirculation of products of
combustion into the combustion air pipe can damage the furnace.
Verify proper venting and vent termination per installation
instructions. For additional information, and a complete sequence of
furnace operation, refer to furnace Installation, Start-Up and
Operating Instructions.
21. After System Check-out is complete, set thermostat below room
temperature.
22. Verify that burner shuts down and blower completes selected off
delay time.
23. Verify furnace operates properly and set thermostat to desired room
temperature.
24. Re-install outer door.
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