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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.
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.
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.
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.
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, rout 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.
Burner Box/Manifold Installation
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
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.
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 rollout 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).
NOTE: Use only propane- -resistant pipe dope. Do not use Teflon
tape.
9. Insert the gas pipe through the grommet in the casing. Ap-
ply a thin layer of pipe dope to the threads of the pipe and
thread the pipe by into the gas valve.
NOTE: Use a back- -up wrench on the gas valve to prevent the
valve from rotating on the manifold or damaging the mounting to
the burner box.
10. With a back- -up wrench on the inlet boss of the gas valve,
finish tightening the gas pipe to the gas valve.
11. Turn gas on at electric switch on gas valve.
12. Turn power on at external disconnect, fuse or circuit break-
er.
6
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