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BEGIN RE- -ASSEMBLY
Install Heat Exchanger Primary Cell Panel
1. Align the primary cell panel with the primary inlet plate of
heat exchanger assembly.
2. Avoid damaging the cell panel insulation during alignment.
3. Insert the screws around each burner inlet opening that at-
taches the heat exchanger cell panel to the primary inlet
plate of the primary heat exchanger assembly.
Attaching Primary and Condensing Heat
Exchangers
1. Align the bottom edge primary cell outlet panel with the top
edge of the condensing heat exchanger assembly, and align
the top edge of the condensing heat exchanger outlet panel
with the bottom edge of the primary cell inlet panel.
2. The orange foam gasket must be between the primary cell
outlet panel and the containment plate that is attached to the
condensing heat exchanger. The white fiber gasket or equi-
valent must be between the primary cell inlet panel and the
condensing heat exchanger outlet panel.
3. Insert all the screws, except the outboard screws in the
primary outlet panel, to secure the primary heat exchanger
panels to the condensing heat exchanger panels (front and
back). See Fig. 5.
4. Remove the screws used to temporarily hold the Contain-
ment Plate in place.
Install Coupling Box Cover/Finger Baffles
1. Apply a 1/4" bead of low adhesion silicone (white) to the
coupling box cover in the pattern shown in Fig. 9.
2. Align the Coupling Box Cover over the rear of the Heat Ex-
changer Assembly. See Fig. 5 and Fig. 6.
3. Install the screws that secure the bottom edge and sides of
the Coupling Box to the Heat Exchanger Assembly.
4. Align the Finger Baffles along the top edge of the Coupling
Box Cover. See Fig. 5.
5. Install the screws for the Finger Baffles and the remaining
screws for the top edge of the Coupling Box Cover.
Install Sidewall Baffles
1. Avoid damaging the cell panel insulation by inserting the
sidewall baffle inward from the rear of coupling box to the
indexing tab on the primary cell panel then align the baffle
with the coupling box cover.
Insert the slot on the sidewall baffle over the tab on the
primary cell panel. See Fig. 6.
NOTE: The front edge of the sidewall baffle has a slot that
engages a tab on the primary cell panel.
Fig. 6 - - Sidewall Baffle Removal / Installation - - Rear View
2. Insert the screws that attach the sidewall baffle to the
primary cell panel.
3. Align the rear edge of the baffle with the screw holes in the
coupling box cover.
4. Insert the screws that attach the sidewall baffles to the coup-
ling box.
Heat Exchanger Assembly Installation
1. Lift the heat exchanger assembly and set the rear of the as-
sembly on the blower deck.
2. Slide the heat exchanger onto the support rails in the fur-
nace casing.
3. Raise the rear of the heat exchanger and set the bottom of
the sidewall baffles on top of the support rails in the blower
deck.
4. Slide the heat exchanger assembly into the casing, making
sure the bottom edge of the sidewall baffle slides into the
engagement tab on the support rails.
NOTE: Be sure cell panel insulation is folded over the top flange
of the primary cell inlet panel so that when the heat exchanger is
fully installed, the insulation seals between the top plate and the top
flange of the cell panel.
NOTE: Be sure the cell panel insulation is visible on both sides of
the heat exchanger cell panel so that when the heat exchanger is
fully installed, the insulation seals between the cell panel and the
mounting brackets. If any insulation is not visible, pull the heat
exchanger forward, adjust the insulation and reinstall so that the
cell panel is properly sealed to the top plate and to the mounting
brackets.
5. Continue to slide the heat exchanger assembly backward in-
to the casing until the primary cell panel is flush with the
mounting brackets on the side of the casing.
6. Align the primary cell panel with the mounting brackets.
7. Insert the screws that attach the primary cell panel to mount-
ing brackets on the casing.
8. Align the filler plate to the bottom edge of the condensing
heat exchanger assembly.
9. Secure the filler plate to the condensing heat exchanger and
casing.
Collector Box Installation
1. Verify old collector box gasket has been removed from heat
exchanger. See Fig 7.
2. Remove adhesive backing from collector box gasket and
align gasket on the collector box.
3. Attach the gasket to the collector box.
4. Remove the adhesive backing from the condensate trap gas-
ket.
5. Attach the gasket over the drain outlets on the collector box.
6. Repeat the procedure for the drain outlet.
NOTE: There is a slot on each side of the front panel of the
condensing heat exchanger. The collector box has alignment tabs
on the back that fit into the slots on the condensing heat exchanger
panel.
7. Align the tabs on the collector box to the slots on the
condensing heat exchanger panel.
8. With the collector box fully seated against the condensing
heat exchanger cell panel, install the screws through the
collector box.
9. Tighten the screws in an alternating pattern around the
collector box. Do not over- -tighten.
A11414
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