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NOTE: If condensate has a heat pad attached to the trap, trace the
wires for the pad back to the connection point and disconnect the
wires for the heat pad.
3. Remove the screw that secures the condensate trap to the
collector box, remove the trap and set aside.
4. Rinse condensate trap in warm water until trap is clean.
5. Clean relief port on Condensate Trap with a thin wire or
paper clip, rinse with warm water and set aside.
6. Flush condensate lines with warm water.
7. Shake trap dry.
Remove J- -box and Main Harness
1. Remove the screw that secures the J- -box cover to the J- -box
bracket. See Fig. 2.
2. Disconnect the field wiring from the factory wiring and re-
move the ground wire from the green ground screw on the
J- -box bracket.
3. Remove factory wiring from the J- -box.
4. Disconnect the factory wires from the main limit switch.
5. Remove the screw that secures the door switch to the
blower shelf and the blower shelf door bracket. Remove
the screws from the blower shelf door bracket, and set the
bracket aside.
6. Remove main harness from the slot in the blower shelf.
Collector Box Removal
1. Remove the screws that secure the collector box to the heat
exchanger cell panel and set aside.
2. Remove collector box gasket and discard.
3. Flush out the Collector Box with warm water including the
tube ports. Clean tube ports on Collector Box with a thin
wire or paper clip, rinse with warm water and set aside.
Heat Exchanger Assembly Removal
CAUTION
!
CUT HAZARD
Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or burrs. Use care and
wear appropriate protective clothing and gloves when
handling parts and servicing furnaces.
1. Remove the screws that attach the filler plate to the bottom
edge of the condensing heat exchanger assembly and cas-
ing.
2. Remove screws that secure the heat exchanger assembly to
the furnace casing. Do not remove the screws around the
burner inlets that attaches the primary inlet panel to the inlet
plate of the primary heat exchanger.
3. Pull assembly out of casing until the back edge of the heat
exchanger is resting on the front edge of the blower shelf.
4. Lift the heat exchanger assembly out of the casing and set
aside.
Remove Coupling Box
1. Remove the screws that secure the finger baffle from the
Coupling Box Cover. See Fig. 5.
2. Remove the screws that secure the Coupling Box Cover to
the rear of the Heat Exchanger Assembly.
3. Starting at the upper beveled edge of the coupling box, use
a putty knife or gasket scraper to get between the coupling
box cover and the Primary Cell Outlet panel to break the
silicone seal between the parts.
4. Pry upwards with the putty knife as you move around the
Coupling Box cover.
5. Once the Coupling Box cover is sufficiently loosened, re-
move the coupling box cover from the rear of the Heat Ex-
changer Assembly. See Fig. 4.
Separate Primary and Condensing Heat Ex-
changers
1. Remove the screws that attach the condensing heat ex-
changer assembly to the primary cell outlet panel and re-
move the screws that attach the condensing heat exchanger
outlet panel to the primary inlet panel.
2. Gently use a putty knife or gasket scraper to get between the
primary cell inlet panel and condensing heat exchanger if it
is needed to break the seal between the parts.
3. Repeat the procedure at the primary cell outlet panel and
containment plate attached to the inlet of the secondary heat
exchanger.
Remove Primary and Condensing Heat Exchanger
NOTE:
The primary heat exchanger assembly is factory- -
assembled at primary cell attachment plate and the primary rear cell
outlet panel. The individual heat exchanger cells cannot be
removed in the field and are replaced as one assembly.
1. Remove screws that attach the sidewall baffles to the heat
exchanger 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. See Fig. 6.
2. Avoid damaging the cell panel insulation by pulling the
sidewall baffle outward from the rear of coupling box, then
pull the baffle backward to slide the baffle off of the locator
tab on the cell panel.
3. Repeat the procedure for the opposite side baffle.
4. Separate the Primary Heat Exchanger from the Condensing
Heat Exchanger.
5. Discard failed Condensing Heat Exchanger assembly.
Turbulator Removal
NOTE: The turbulators are factory- -installed in a replacement
condensing heat exchanger. It is not necessary to remove them to
replace a condensing Heat Exchanger Assembly. If it is necessary
to remove the turbulators, perform the following steps:
1. Bend the end of turbulator strip that holds it inside the sec-
ondary heat exchanger tube straight.
NOTE: Use caution when removing the turbulator strips. Do not
bend, twist kink or flatten the turbulator strip. A damaged
turbulator strip must be replaced with the identical type of
turbulator strip used with the furnace. Do not use a turbulator strip
from a different model family of furnaces. Efficiency, reliability or
unit operation may be affected.
2. Pull the turbulator strip outward from the tube.
3. Repeat the step for each turbulator.
4. Wipe each turbulator off with a clean, soft cloth.
BEGIN RE- -ASSEMBLY
Turbulator Installation
NOTE: The turbulators are factory- -installed in a replacement
condensing heat exchanger. If the turbulators were removed for
cleaning, re- -install the turbulators as follows:
1. Make sure that one end to the turbulator strip is bent 90 de-
grees.
NOTE: Use caution when installing the turbulator strips. Do not
bend, twist kink or flatten the turbulator strip. A damaged
turbulator strip must be replaced with the identical type of
turbulator strip used with the furnace. Do not use a turbulator strip
from a different model family of furnaces. Efficiency, reliability or
unit operation may be affected.
2. Push the straight end of turbulator strip forward into the sec-
ondary heat exchanger tube until the angled end is against
the edge of the tube.
3. Repeat the step for each turbulator.
3
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