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ZG - Replace Heat Exchanger
1- Install the combustion air inducer gasket, provided in
this kit, and the previously removed combustion air
blower.
2- Set replacement heat exchanger in unit, rotate frame
front pieces in place and secure heat exchanger with
screws.
Note - Use an awl to line up screw holes. Install screws on
the back side of the assembly before the front side.
Tighten screws only after all screws are in place; this
allows a small amount of movement to assist starting all
screws.
3- Replace the burner box and secure in place with
screws.
Note - To make installation easier, start the screw on the
back, lower side of frame. Cut a slit in the back, lower
screw hole on the burner box. Set the burner box in place,
push down to force the slit over the partially-engaged
screw and tighten screw.
4- Replace gas manifold.
5- Reinstall vent connector.
6- Remove the two screws and patch plate covering the
primary limit opening and discard. Reinstall primary
limit.
7- Connect wiring to primary limit, ignitor and flame
sensor, gas valve, flame roll-out switch and
combustion air inducer.
8- Connect combustion air prove switch plastic tubing to
pressure port on heat exchanger vestibule.
9- Install heat exchanger support bracket and align hole
in panel with end of bracket. Fit panel in place and
secure bracket to the panel with retained speed nut.
10- Replace other panels and refer to unit installation
instructions to start unit.
11- Start unit blower according to unit installation
instructions. Check for air leaks out of the gas heat
exchanger compartment. Use high temperature RTV
or the mastic seals to seal any air leaking out of the
gas heat compartment.
12- Start unit in heating mode according to unit
installation instructions. Check for proper operation
of gas heat using lighting sequence provided in the
unit installation instructions or lighting instruction
label provided on unit.
13- On initial start-up, a slight amount of smoke may
enter the building due to the residual manufacturing
process lubrication on the surface of the heat
exchanger. In down flow applications, remove the
horizontal supply air panel to dilute the smoke. In
horizontal airflow applications, inform building
occupants there may be a slight amount of smoke
entering the building on initial start up.
14- Dispose of packing materials and replaced heat
exchanger properly.
COMBUSTION AIR BLOWER ASSEMBLY - ZG
COMBUSTION
AIR INDUCER
COLLECTOR
COVER
BURNER
GAS VALVE
Page 6
PLASTIC
PRESSURE
TUBING
PORT
VENT
CONNECTOR
COMBUSTION
AIR PROVE
SWITCH
PRIMARY LIMIT
LOCATION
FIGURE 10
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