Assessments - 4, GPA: 4.3
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Clean old sealant from parts. 18. Loosen hose clamp and remove 7/8-in. drain tube from trap. 19. Hold bucket under 7/8-in. drain tube. 20. Using garden hose, flush each cell of the condensing heat exchanger with water. Use care not to spray water onto interior surfaces of control compartment. Dry all surfaces. Be careful not to remove sealant around cell openings in cell panel. 21. Using field-provided small wire brush, steel spring cable, reversible electric drill, and vacuum cleaner, clean primary heat exchanger cells. Do not use wire brush or other sharp object to clean condensing heat exchanger. Failure of the condensing heat exchanger will occur—flush with water only. a. Assemble wire brush and steel spring cable. (1.) Use 4 ft of 1/4-in. diameter high-grade steel spring cable (commonly known as drain cleaning or Roto-Rooter cable). (2.) Use 1/4-in. diameter wire brush (commonly known as 25-caliber rifle cleaning brush). NOTE: The materials required in items (1.) and (2.) can be purchased at local hardware stores. (3.) Insert twisted wire end of brush into end of spring cable, and crimp tight with crimping tool or strike with ball-peen hammer. Tightness is very important. (4.) Remove metal screw fitting from wire brush to allow insertion into cable. b. Clean each primary heat exchanger cell. (1.) Attach variable-speed, reversible drill to end of spring cable (end opposite brush). (2.) Insert brush end of cable into upper opening of cell and slowly rotate with drill. Do not force cable. Gradually insert at least 3 ft of cable into 2 upper passes of cell. (See Fig. 7.) Fig. 7—Cleaning Primary Heat Exchanger Cell (3.) Work cable in and out of cell 3 or 4 times to obtain sufficient cleaning. Do not pull cable with great force. Reverse drill and gradually work cable out. (4.) Insert brush end of cable in lower opening of cell, and proceed to clean 2 lower passes of cell in same manner as 2 upper passes. 4 (5.) Repeat procedures (above) until each furnace cell has been cleaned. (6.) Using vacuum cleaner, remove residue from each cell. (7.) Using vacuum cleaner with soft brush attachment, clean burner assembly. Step 4—Reassemble Furnace (After Cleaning Heat Exchangers) 1. Install choke plate (when used). Be sure choke plate bottom conforms to top flange of condensing heat exchanger. 2. Reinstall coupling box(es): a. Apply sealant releasing agent (Pam) to cell panel where coupling box flange matches. (See Fig. 8.) b. Apply a generous bead 3/16-in. dia) of G.E. RTV 122,162, or Dow-Coming RTV 738 sealant (NO substitute is permissible) to flange of coupling box. Your distributor should have G.E. RTV 122, 162, or Dow-Coming RTV 738 sealants in stock. c. Being careful not to smear sealant, position coupling box so that slot in insulation is on left side and install coupling box. APPLY RELEASE AGENT TO AREA INDICATED BY SHADING COUPLING BOX (INSIDE VIEW) Fig. 8—Inside View of Coupling Box A87318 NOTE: Downflow furnace only—position primary (lower) coupling box so that tallest end is on right side. 3. Reinstall inducer assembly. a. Upflow furnace only —Be sure small round gasket(s) is in place between blower shelf and inducer housing. b. Apply sealant releasing agent (Pam) to collector box. (See Fig. 9.) c. Apply 1/8-in. diameter bead of G.E. RTV 122, 162, or Dow-Corning RTV 738 sealant to back of inducer housing. Apply sealant around inlet air opening. (The sealant should be about 1/4 in. from the edge of the inlet air opening.) d. Install inducer assembly on collector box and support bracket to coupling box. e. Connect inducer motor plug-in connector to wiring har-ness.Reconnect wires to pressure switch using furnace wiring diagram. (See Fig. 17.) f. Reconnect pressure tubes to pressure switch. (See Fig. 13 or 14.) 4. Connect small drain tube from top of trap to fitting on bottom of inducer housing. (See Fig. 13 or 14.) A86100 Fig. 9—Backside of Inducer Assembly Housing Fig. 10—Burner Enclosure AB7301 BURNER FUME 5. Connect 7/8-in. drain tube to trap and collector box, and tighten hose clamps. (See Fig. 13 or 14.) 6. Reinstall vent pipe and drain tube. a. Upflow furnace only: (1.) Reconnect vent pipe. Be sure clamps are tight. (2.) Connect drain tube from collector box to inducer outlet box. b. Downflow furnace only: (1.) Reconnect vent pipe. Be sure clamps are tight.. (2.) Reinstall vent pipe enclosure. (3.) Connect drain tube from collector box to inducer outlet elbow. 7. Upflow furnace only—reinstall main control box. a. Reinstall main control box on blower shelf. 5 13/32"- Ex IF B' 3Q 11/32" 1 IGNITOR ASSEMBLY \ / \ %' IGNITOR ASSEMBLY A91064 Fig. 12—Position of Ignitor to Burner •¥b od PRESSURE TUBING HEAT EXCHANGER DIFFERENTIAL PRESSURE SWITCH % OD PRESSURE TUBING VZ OD DRAIN TUBING (TUBE PASSES THROUGH BLOWER SHELF) 'DRAIN TRAP A91113 Fig. 13—Upflow Furnace Pressure and Drain Tubing Diagram b. Reconnect edge connector at main c...
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