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WARNING
LABEL ALL WIRES PRIOR TO DISCON-
NECTION WHEN SERVICING CON-
TROLS. WIRING ERRORS CAN CAUSE
IMPROPER AND DANGEROUS OPERA-
TION RESULTING IN FIRE, ELECTRI-
CAL SHOCK, PROPERTY DAMAGE,
PERSONAL INJURY OR DEATH.
WARNING
HOLES IN THE EXHAUST TRANSITION
OR HEAT EXCHANGER CAN CAUSE
TOXIC FUMES TO ENTER THE HOME.
THE EXHAUST TRANSITION OR HEAT
EXCHANGER MUST BE REPLACED IF
THEY HAVE HOLES OR CRACKS IN
THEM. FAILURE TO DO SO CAN
CAUSE CARBON MONOXIDE POISON-
ING RESULTING IN PERSONAL INJURY
OR DEATH.
WARNING
DISCONNECT MAIN ELECTRICAL
POWER TO THE UNIT BEFORE
ATTEMPTING MAINTENANCE.
FAILURE TO DO SO MAY RESULT IN
ELECTRICAL SHOCK OR SEVERE
PERSONAL INJURY OR DEATH.
38
3. Close doors and windows. This reduces the heating and cooling load on the sys-
tem.
4. Avoid excessive use of exhaust fans.
5. Do not permit the heat generated by television, lamps or radios to influence the
thermostat operation.
6. Except for the mounting platform, keep all combustible articles three feet from the
unit and exhaust system.
7. IMPORTANT: Replace all blower doors and compartment cover after servicing the
unit. Do not operate the unit without all panels and doors securely in place.
8. Do not allow snow or other debris to accumulate in the vicinity of the appliance.
FURNACE SECTION MAINTENANCE
The unit's furnace should operate for many years without excessive scale build-up in
flue passageways; however, it is recommended that a qualified installer, service
agency, or the gas supplier annually inspect the flue passageways, the exhaust system
and the burners for continued safe operation, paying particular attention to deterioration
from corrosion or other sources.
If during inspection the flue passageways and exhaust system are determined to
require cleaning, the following procedures should be followed (by a qualified installer,
service agency, or gas supplier):
1. Turn off the electrical power to the unit and set the thermostat to the lowest
temperature.
2. Shut off the gas supply to the unit either at the meter or at manual valve in
the supply piping.
3. Remove the furnace controls access panel and the control box cover.
4. Disconnect the gas supply piping from the gas valve.
5. Disconnect the wiring to the induced draft blower motors, gas valve, flame sensor,
and flame roll-out control, and ignitor cable. Mark all wires disconnected for
proper reconnection.
6. Remove the screws (4) connecting the burner tray to the heat exchanger mounting
panel.
7. Remove the burner tray and the manifold assembly from the unit.
8. Remove the screws (10) connecting the four induced draft blowers to the collector
box and screws (12) connecting the inducer mounting plate to the heat exchanger
center panel. Remove the induced draft blowers and the collector box from the
unit.
9. Remove the turbulators from inside the heat exchangers by inserting the blade of a
screwdriver under the locking tabs. Pop the tabs out of the expanded grooves of
the heat exchanger. Slide the turbulators out of the heat exchangers.
10. Direct a water hose into the outlet of the heat exchanger top. Flush the inside of
each heat exchanger tube with water. Blow out each tube with air to remove exces-
sive moisture.
11. Reassemble (steps 1 through 9 in reverse order). Be careful not to strip out the
screw holes used to mount the collector box and inducer blower. Replace
inducer blower gasket and collector box gasket with factory replacements if
damaged.
The manufacturer recommends that a qualified installer, service agency or the gas sup-
plier visually inspect the burner flames for the desired flame appearance at the begin-
ning of the heating season and approximately midway in heating season.
The manufacturer also recommends that a qualified installer, service agency or the gas
supplier clean the flame sensor with steel wool at the beginning of the heating season.
LUBRICATION
IMPORTANT: DO NOT attempt to lubricate the bearings on the blower motor or the
induced draft blower motor. Addition of lubricants can reduce the motor life and void
the warranty.
The blower motor and induced draft blower motor are prelubricated by the manufac-
turer and do not require further attention.
A qualified installer, service agency or the gas supplier must periodically clean the
motors to prevent the possibility of overheating due to an accumulation of dust and
dirt on the windings or on the motor exterior. And, as suggested elsewhere in these
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Troubleshooting
