320720---751 thru ---761
Primary Cell Inlet Panel Kit
Installation Instructions
NOTE: Read the entire instruction manual before starting the
installation.
!
CAUTION
SAFETY CONSIDERATIONS
CUT HAZARD
Improper
installation,
adjustment,
alteration,
service,
Failure to follow this caution may result in personal injury.
maintenance, or use can cause explosion, fire, electrical shock, or
other conditions which may cause death, personal injury, or
property damage. Consult a qualified installer, service agency, or
your distributor or branch for information or assistance. The
qualified installer or agency must use factory--authorized kits or
accessories when modifying this product. Refer to the individual
instructions packaged with the kits or accessories when installing.
Sheet metal parts may have sharp edges or burrs. Use care
and wear appropriate protective clothing, safety glasses and
gloves when handling parts and servicing furnaces.
Follow all safety codes. Wear safety glasses, protective clothing,
and work gloves. Have a fire extinguisher available. Read these
instructions thoroughly and follow all warnings or cautions
include in literature and attached to the unit. Consult local
building codes, the current editions of the National Fuel Gas
Code (NFGC) NFPA 54/ANSI Z223.1 and the National
Electrical Code (NEC) NFPA 70.
!
CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in improper and
dangerous operation.
Label all wires prior to disconnection when servicing
controls.
In Canada, refer to the current editions of the National Standards
of Canada CAN/CSA--B149.1 and .2 Natural Gas and Propane
Installation Codes, and Canadian Electrical Code CSA C22.1
INTRODUCTION
Recognize safety information. This is the safety--alert symbol
When you see this symbol on the unit and in instructions or
manuals, be alert to the potential for personal injury.
.
This instruction covers installation of the Primary Cell Inlet Panel
Kit Part No. 320720--751, --753, --754, --755, --756, --757, --758,
--760 and --761 in 40--in. (1016 mm) tall, condensing gas
furnaces. See Table 1 for kit usage.
Understand the signal words DANGER, WARNING, and
CAUTION. These words are used with the safety--alert symbol.
DANGER identifies the most serious hazards which will result in
severe personal injury or death. WARNING signifies hazards
which could result in personal injury or death. CAUTION is
used to identify unsafe practices which may result in minor
personal injury or product and property damage. NOTE is used
to highlight suggestions which will result in enhanced
installation, reliability, or operation.
NOTE: A releasing agent such as PAM cooking spray or
equivalent (must not contain corn or canola oil, halogenated
hydrocarbons nor aromatic contents to prevent inadequate seal)
and RTV sealant (G.E. 162, G.E. 6702, or Dow--Corning 738)
are needed before starting installation. DO NOT substitute any
other type of RTV sealant. G.E. 162 (P771--9003) is available
through RCD in 3--oz tubes.
DESCRIPTION AND USAGE
Use this Primary Cell Inlet Panel Kit when replacement of a
factory--installed primary cell inlet panel is required.
!
WARNING
FIRE, EXPLOSION AND ELECTRICAL SHOCK
HAZARD
This Primary Cell Inlet Panel Kit contains the following items:
Failure to follow this warning could result in personal
injury, death and/or property damage.
Primary Cell Inlet Panel
Burner Box Gasket
Cell Mounting Screw No. 8D X 3/8--in.(10 mm) 25 max
Installation Instructions
1
1
Before installing or servicing system, always turn off main
electrical and gas supplies to unit and tag with appropriate
lockout. There may be more than one disconnect switch.
1
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PRIMARY HEAT
EXCHANGER
(BEHIND CELL
INLET PANEL)
BURNER
COMBUSTION-AIR
INTAKE
ENCLOSURE
CONNECTION
BURNER
GAS VALVE
GAS VALVE
ENCLOSURE
COMBUSTION-
AIR INTAKE
CONNECTION
AUXILIARY
JUNCTION BOX
PRIMARY HEAT
EXCHANGER
(BEHIND CELL
INLET PANEL)
CAP AND
CLAMP
(UNUSED
DRAIN
CONN.)
INDUCER
MOTOR
AUXILIARY
JUNCTION BOX
VENT OUTLET
CONDENSING
HEAT
EXCHANGER
(BEHIND CELL
INLET PANEL)
CAP AND
CLAMP
VENT OUTLET
INDUCER MOTOR
WIRE
(UNUSED
DRAIN
CONNECTOR
CONNECTION)
VENT
OUTLET
PRESSURE
SWITCHES
CONDENSING
HEAT
EXCHANGER
(BEHIND CELL
INLET PANEL)
VENT OUTLET
PRESSURE
SWITCHES
INDUCER MOTOR
CONTROL
CENTER
CONTROL
CENTER
CONDENSATE
TRAP
BLOWER
INDUCER
HOUSING
DRAIN TUBE
ACCESS PANEL
SAFETY
BLOWER
ACCESS
PANEL
SAFETY
INTERLOCK
SWITCH
MOTOR AND
BLOWER
ASSEMBLY
INTERLOCK
SWITCH
CONDENSATE
TRAP
AIR FILTER AND
RETAINER
AIR FILTER
AND RETAINER
MOTOR AND
BLOWER ASSEMBLY
A01026
A93407
Fig. 1 -- Two--Stage, Two--Speed and Fixed--Capacity
Model(s) in Upflow Orientation
Fig. 2 -- Variable--Speed Model in Upflow Orientation
NOTE: Visually check location of main limit and shield to
ensure shield is not touching primary cells. If shield is touching,
short cycling of limit will occur.
Remove Inducer Assembly
1. If not previously disconnected, disconnect inducer motor
wire connector at quick--connect.
2. If not previously disconnected, disconnect pressure switch
wires.
3. Remove collector box pressure switch tube from pressure
switch.
4. Remove four screws attaching inducer housing to cell pan-
el.
8. Reinstall condensing heat exchanger assembly to primary
cell inlet panel.
Reinstall Inducer Assembly
1. Inspect connector box gasket where inducer housing will
mate.
NOTE: If gasket is damaged in any way, it must be repaired. To
repair, apply a small bead of G.E. RTV 162, G.E. 6702, or
Dow--Corning RTV 738 to damaged gasket area. Apply sealant
releasing agent such as PAM cooking spray or equivalent (must
not contain corn nor canola oil, halogenated hydrocarbons or
aromatic content to prevent inadequate sealing) to inducer
housing mating surface.
NOTE: Inducer housing, inducer motor, and pressure switch(es)
should be removed as 1 assembly.
Install Primary Cell Inlet Panel
1. Remove four screws attaching condensing heat exchanger
assembly to primary cell inlet panel.
2. Remove screws attaching primary cells to primary cell in-
let panel.
2. Attach inducer assembly to cell panel by aligning four
screws through inducer housing spacers. Tighten screws to
secure.
3. Remove main limit and shield from primary cell inlet pan-
el. Note orientation of shield and direction of main limit
for reassembly.
3. Attach collector box pressure switch tube to pressure
switch. See tubing diagram of furnace for proper location
attachment.
4. Remove primary cell inlet panel by lifting panel off con-
densing heat exchanger collector box.
4. If control was removed from furnace with whole cell panel
assembly, reconnect inducer motor wire connector at
quick--connect.
5. Slide new inlet cell panel over condensing heat exchanger
collector box.
5. If control was removed from furnace with whole cell panel
assembly, reconnect pressure switch wires. Refer to wiring
diagram on furnace for proper attachment.
6. Attach primary cell inlet panel to primary cells by doing
the following:
a. Center primary cell inlet panel over primary cell open-
ings.
Reinstall Burner Enclosure Assembly
1. Position burner enclosure gasket between the burner box
and inlet cell panel and secure burner box on inlet cell
panel using screws removed earlier.
b. Use an awl to align holes and start ALL screws
(provided in kit) in primary cells.
c. After all screws are started, check position of fiberglass
gasket and tighten screws in cells.
2. Connect pressure tube to gas valve.
3. Inspect gasket, then install intake housing on burner en-
closure.
7. Install main limit and shield in primary cell inlet panel.
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COLD SPOT
BAFFLE
COUPLING
BOX
PRIMARY
CELL
PRIMARY CELL
INLET PANEL
MAIN LIMIT
SHIELD
T-TABS
MAIN LIMIT
BURNER
ENCLOSURE
GASKET
BLOWER
SHELF
CONDENSING
HEAT EXCHANGER
CELL REAR PANEL
CONDENSING
HEAT EXCHANGER
ASSEMBLY
PRIMARY CELL
OUTLET PANEL
PRESSURE
SWITCH
NOTE: ACTUAL COMPONENT LOCATION MAY VARY
DEPENDING ON MODEL & SERIES.
BURNER
ENCLOSURE
INDUCER
MOTOR
AND GAS VAVLE
A05128
Fig. 3 -- Expanded View of Heat System Components in Upflow Orientation
NOTE: If gasket is damaged in any way, it must be repaired. To
repair, apply a small bead of G.E. RTV 162, G.E. 6702, or
Dow--Corning RTV 738 to damaged gasket area. Apply sealant
releasing agent such as PAM cooking spray or equivalent (must
not contain corn nor canola oil, halogenated hydrocarbons or
aromatic content to prevent inadequate sealing) to burner
enclosure mating surface.
NOTE: When reinstalling condensing heat exchanger assembly,
the lower flange of the condensing heat exchanger cell rear panel
must engage on the T--tabs in rear blower shelf. (See Fig. 3.)
3. Install three screws to each side of inlet cell panel and into
cell panel supports.
4. If previously removed, reinstall control center in casing
flange.
4. Connect pressure tube to intake housing.
Reinstall Whole Cell Panel Assembly
5. If control center is located in burner compartment or fur-
nace, reinstall blower motor leads, transformer wires, door
switch wires, and auxiliary limit switch wires (if present)
through blower shelf and grommet.
!
CAUTION
6. If control is located in blower compartment of furnace,
pull wires to flame sensor, hot surface igniter, overtemper-
ature switch, gas valve, pressure switch(es), inducer motor,
limit switch, and J--box through blower shelf.
PERSONAL INJURY HAZARD
Failure to follow this caution may result in personal injury.
Whole cell panel assembly is heavy. Get help to lift and
install.
7. Install J--box.
8. Reattach wires to control center or components. See wir-
ing diagram on furnace for proper attachment.
1. Install whole cell panel assembly with heat exchanger,
burner box, inducer assembly, J--box (if applicable), and
control center (if applicable) through front of furnace.
9. Reinstall condensate trap where previously installed fur-
nace casing or blower shelf.
10. Reconnect condensate trap drain tubes. See tubing dia-
gram on furnace for proper tube location.
!
WARNING
11. Connect field drain to condensate trap.
NOTE: Ensure tubes are not kinked or pinched, as this will
affect operation.
FIRE AND UNIT OPERATION HAZARD
Failure to follow this warning could result in personal
injury, death and / or property damage.
12. Connect vent pipe by inserting pipe into coupling, elasto-
meric (rubber) coupling, and then fully into inducer hous-
ing outlet.
13. Connect combustion--air intake pipe to intake housing and
install screw to secure. Do not use RTV unless previously
used.
DO NOT cut or tear foil face insulation. If cuts or tears
occur, repair insulation with foil tape.
2. Secure whole cell panel assembly to blower shelf by in-
stalling two screws through blower housing (four screws
on 120 and 140 sizes) and two screws next to blower
housing.
14. Install top filler panel.
15. Install gas supply pipe to gas valve using backup wrench.
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NOTE: Use propane gas--resistant pipe dope to prevent gas leaks
DO NOT use Teflon tape.
!
WARNING
EXPLOSION AND FIRE HAZARD
Failure to follow this warning could result in personal
injury, death and/or property damage.
For upflow or downflow applications, gas valve knob
or switch must be facing forward or tipped to the UP
position.
16. Connect field power supply to J--box.
17. Install blower access panel.
18. Turn on gas and electrical supplies to furnace.
19. Check for gas leaks.
!
WARNING
EXPLOSION AND FIRE HAZARD
Failure to follow this warning could result in personal
injury, death, and/or property damage.
Never test for gas leaks with an open flame. Use a
commercially available soap solution made specifically for
the detection of leaks to check all connections.
20. Check furnace operation through two cycles.
21. Check for condensate leaks.
22. Replace furnace door.
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Printed in U.S.A.
Edition Date: 09/10
Copyright 2010 CAC / BDP S 7310 W. Morris St. S Indianapolis, IN 46231
Catalog No: IIK320720---005
Replaces: IIK320720--004
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
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