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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.
4. Bend the straight end of the turbulator strip over 90 degrees
to hold the turbulator in the secondary heat exchanger tube.
Install Containment Plate
NOTE: Both the containment plate and secondary heat exchanger
panel surfaces must be clean and dry. All loose or residual sealant
must be removed from the mating surfaces.
NOTE: Do not use a releasing agent on the Containment Plate or
Heat Exchanger Assembly.
1. Apply a 3/16" wide bead of high adhesion (grey) silicone,
Novaguard 400- -303 RTV, or equivalent as noted on page 1,
around the Containment Plate as shown in Fig. 7. Note the
orientation of the plate in Fig. 7
2. Align the containment plate as shown in Fig. 7.
3. Temporarily hold the containment plate in place by in-
stalling one screw through the hole on each side of the con-
tainment plate.
NOTE: After the primary heat exchanger assembly is attached to
the secondary heat exchanger, these screws will be removed to
allow the coupling box cover to be installed.
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 temporarily at-
tached to the condensing heat exchanger. The white fiber
gasket or equivalent 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. 7.
2. Align the Coupling Box Cover over the rear of the Heat Ex-
changer Assembly. See Fig. 5 and Fig. 4.
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.
6. Align the sidewall baffles to the heat exchanger cell panel.
See Fig. 4 and Fig. 6.
NOTE: The front edge of the sidewall baffle has a slot that
engages a tab on the primary cell panel.
7. 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.
8. Secure the Sidewall Baffles with the screws.
Install Sidewall Baffles
1. Insert the slot on the sidewall baffle over the tab on the
primary cell panel. See Fig. 6.
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.
5
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