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22. Replace blower access door and secure with 2 screws (downflow furnace only). CLEANING HEAT EXCHANGER The following steps should be performed by a qualified service technician: NOTE: Deposits of soot and carbon indicate the existence of a problem which needs to be corrected. Take action to correct the problem. If it becomes necessary to clean the heat exchanger because of carbon deposits, soot, etc., proceed as follows: 1. Turn off gas and power to furnace. 2. Remove 2 screws from blower access door (downflow furnace only). Remove control and blower access doors. 3. Remove vent pipe enclosure (downflow furnace only) and disconnect vent pipe from relief box. 4. Remove 2 screws that secure relief box. (See Fig. 4 or 5.) 5. Disconnect wires to the following components: a. Draft safeguard switch b. Inducer motor c. Pressure switch d. Limit overtemperature switch e. Gas valve f. Edge connector leading to control box 6. Remove 8 screws that secure flue collector box to center panel. Be careful not to damage sealant. 7. Remove complete inducer assembly from furnace, exposing flue openings. 8. Clean cells as follows using field-provided small wire brush, steel spring cable, reversible electric drill, and vacuum cleaner. a. Assemble wire brush and steel spring cable. (1.) Use 48 in. of 1/4-in. diameter high-grade steel spring cable (commonly known as drain clean-out or Roto- Rooter cable). (2.) Use 1/4-in. diameter wire brush (commonly known as 25-caliber rifle cleaning brush). NOTE: The items needed in steps (1.) and (2.) can usually be purchased at local hardware stores. (3.) Insert twisted wire end of brush into end of steel 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 heat exchanger cell. (1.) Attach variable-speed, reversible drill to end of steel 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 36 in. of cable into 2 upper passes of cell. (See Fig. 6.) A91252 Fig. 6—Cleaning 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.) Remove burner assembly and cell inlet plates. (5.) Replace screws in center panel and cells before cleaning. 4 PILOT HEAD V–NOTCH FALLS 1/8. DIRECTLY BELOW FRONT EDGE OF BURNER CARRYOVER. A91249 Fig. 7—Position of Pilot to Burner (6.) 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. (7.) Repeat foregoing procedures until each cell in furnace has been cleaned. (8.) Remove residue from each cell using vacuum cleaner. (9.) Clean burner assembly using vacuum cleaner with soft brush attachment. (10.) Reinstall cell inlet plates and burner assembly. Care must be exercised to center the burners in the cell openings. 9. After cleaning flue openings, check sealant on flue collector to ensure that it has not been damaged. If new sealant is needed, contact your dealer or distributor. 10. Clean and replace flue collector assembly, making sure all 8 screws are secure. 11. Reinstall 2 screws in relief box. 12. Reconnect wires to the following components: a. Draft safeguard switch b. Inducer motor c. Pressure switch d. Limit overtemperature switch e. Gas valve f. Edge connector leading to control box 13. Reconnect vent pipe to relief box. Replace vent pipe enclosure (downflow furnace only). 14. Replace blower access door only and secure with 2 screws (downflow furnace only). 15. Turn on electrical power and gas. 16. Set thermostat and check furnace for proper operation. Never use a match or other open flame to check for gas leaks. Use a soap-and-water solution. A failure to follow this warning could result in fire, personal injury, or death. 17. Check for gas leaks. 18. Replace control access door. ELECTRICAL CONTROLS AND WIRING NOTE: There may be more than 1 electrical supply to unit. The electrical ground for 115-v wiring must be maintained properly. Refer to Fig. 8 for field wiring information and to Fig. 9 for unit wiring information. With power disconnected to unit, check all electrical connections for tightness. Tighten all screws on electrical connections. If any smoky or burned connections are noticed, disassemble the connection, clean all parts and stripped wire, and reassemble properly and securely. Electrical controls are difficult to check without proper instrumentation; therefore, reconnect electrical power to unit and observe unit through 1 complete operating cycle. The 24-v circuit contains an automotive-type, 3-amp fuse located on the main control board. Any direct shorts during installation, service, or maintenance could cause this fuse to blow. If fuse replacement is required, use ONLY a 3-amp fuse o...

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