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Install J- -box and Main Harness
1. Insert grommet for main harness in the slot in the blower
shelf.
2. Align the door switch to the blower shelf.
3. Align and install door bracket to the front edge of the
blower shelf and secure the door switch during upper door
bracket installation.
4. Connect the field wiring from the factory wiring and attach
the ground wire to the green ground screw on the J- -box
bracket.
5. Attach the J- -box cover to the J- -box bracket.
6. Install the screw to secure the J- -box cover to the bracket.
7. Connect the factory wires to the main limit switch.
Install the Condensate Trap and Drain
NOTE: If the condensate trap is removed, a new gasket between
the trap and collector box is required. Verify a condensate trap
gasket is included in the service kit or obtain one from your local
distributor.
1. Align the trap with the drain outlet on the collector box.
2. Secure the trap to the collector box with the screw.
3. Connect the condensate trap relief tube from collector box
port and insert the tube into the molded retainer clips on the
inducer housing.
4. Insert the condensate drain elbow through the casing until it
is properly seated. Or, connect the drain elbow to the drain
extension pipe and route the pipe behind the inducer.
5. Connect the drain elbow to the condensate trap.
NOTE: If condensate has a heat pad attached to the trap, trace the
wires for the pad back to the connection point and connect the
wires for the heat pad.
Inducer Assembly Installation
1. Verify any remaining gaskets on the collector box are re-
moved and discarded.
2. Verify the inducer assembly has gaskets on the drain stubs
and at the inducer inlet.
3. Verify the choke plate is installed on the inlet opening of the
inducer.
4. Align the tabs on inducer assembly to the brass inserts on
the collector box.
5. Insert the mounting screws through the tabs to secure the
inducer to the collector box. Remember there is a mounting
tab located under the vent elbow.
6. Connect the inducer leads from the main wiring harness to
the inducer motor harness.
Fig. 7 - - Collector Box Gasket Condensate Trap
Pressure Switch Installation
NOTE: There are two types of pressure switches. The modulating
pressure switch assembly has three pressure switches.
Two are side-by-side with the third switch mounted to the back of
one of the switches.
All other furnaces have two pressure switches mounted
back- -to- -back.
The tube for the front pressure switch connects the switch to the
port on the collector box. The tube for the switch mounted on the
back connects the switch to the port on the inducer assembly.
Burner Box/Manifold Installation
NOTE: If manifold does not fit flush against the burner box, the
burners are not fully seated forward. Remove the manifold and
check burner positioning in the burner box assembly.
7
CONDENSATE TRAP
APPLY NEW GASKET TO COLLEC-
TOR BOX BEFORE RE-INSTALLING
CONDENSATE TRAP
REMOVE OLD GASKET
1. Connect the wires to the back pressure switch.
2. Connect the tube for the back pressure switch to the inducer
assembly.
3. Connect the tube for the front pressure switch to the port on
the collector box.
4. Attach the pressure switch assembly to the inducer.
5. Connect the pressure switch harness (modulating only) to
the main wiring harness or attach the individual wires to the
pressure switch (non- -modulating).
6. If necessary, route the pressure switch tubing for the front
pressure switch through the stand- -off on the inducer as-
sembly.
7. If necessary, route the condensate trap relief tubing through
the stand- -off on the inducer assembly. Reconnect tubing to
the ports on the condensate trap and collector box.
1. Support the burner box assembly and install the screws that
attach the burner box to the heat exchanger cell panel.
2. Align the orifices in the manifold assembly with the support
rings on the end of the burner.
3. Insert the orifices in the support rings of the burners. Mani-
fold mounting tabs should fit flush against the burner box
4. Attach the green/yellow wire and ground terminal to one of
the manifold mounting screws.
5. Install the remaining manifold mounting screws.
6. Connect the wires to both roll- -out switches.
7. Connect the wires to the flame sensor and hot surface ig-
niter.
8. Connect the connector harness from gas valve (Modulating
only) or attach the individual wires to the terminals on gas
valve (All other models).
A11442
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