Collector Box
Replacement Kit
Cancels: New
IIK 330A-40-5
6-98
Installation Instructions
Part No. 310215-751 through 310215-797
NOTE: Read the entire instruction manual before starting the
installation.
SAFETY CONSIDERATIONS
Installing and servicing heating equipment can be hazardous due to
gas and electrical components. Only trained personnel should
install or service heating equipment.
Untrained personnel can perform basic maintenance functions
such as cleaning coils, or cleaning and replacing filters. All other
operations should be performed by trained service personnel.
When working on heating equipment, observe precautions in the
literature, on tags, and on labels attached to the unit.
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.
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 a hazard which
could result in personal injury or death. CAUTION is used to
identify unsafe practices which would 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.
This kit contains the following items:
Collector box
Gasket
Screw (shallow head Phillips)
Installation Instructions
1
2
4
1
INSTALLATION
NOTE: A releasing agent such as PAM cooking spray or equivalent (must not contain corn or canola oil, aromatic or halogenated
hydrocarbons or inadequate seal may occur) 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.
Step 1—Remove the Collector box
1. Turn off electric supplies to unit and thermostat. More than 1
disconnect may be required to disconnect power to unit.
2. Remove blower and control access doors.
3. Turn off gas at external supply shutoff or turn gas control knob
to off. On models with an electric switch gas control, set
switch to off.
4. Disconnect and remove vent connector (flue extension on
downflow/horizontal models) from inducer housing outlet.
Follow all safety codes. Wear safety glasses and work gloves.
Have a fire extinguisher available.
INTRODUCTION
This instruction covers the collector box installation on all hot
surface ignitor units. The collector box should be replaced anytime
there is damage to the pressure switch pressure tap, when corrosion
has created visible surface damage to the box, or anytime
functionality of the collector box has been compromised.
There are currently 5 different primary sizes of collector boxes,
each having about 6 different sizes of flue restriction. Total there
are about 30 different combinations of collector boxes.
NOTE: It is very important that you verify that the collector box
you are installing be the same size as you are removing. Always
verify the flue restrictor HOLE SIZE before installing a collector
box.
DESCRIPTION AND USAGE
The collector box replacement kit can be utilized to restore units
having collector boxes that require repair.
Vent connector may be hot to the touch. Failure to follow this
warning could result in personal injury.
NOTE: It may be necessary to completely remove the flue
extension cover from downflow/horizontal furnaces.
5. Unplug inducer motor wires, draft safeguard switch wiring,
and pressures switch wiring.
6. Remove screws from top corners of furnace casing (upflow
furnaces only).
7. Disconnect pressure switch tube from collector box.
8. Remove 3 screws securing inducer assembly (motor, wheel,
and mount) to inducer housing and remove inducer motor
assembly.
Failure to support the inducer assembly during removal may
damage the inducer wheel.
9. Remove pressure switch from inducer housing. It is not
necessary to disconnect electrical leads from pressure switch.
10. On upflow furnaces, remove 2 screws securing inducer
housing through top of furnace casing. On downflow furnaces,
inducer housing mounting screws are installed through blower
support shelf.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 4
PC 101
Catalog No. 535-703
Printed in U.S.A.
Form 58D-14SI
Pg 1
6-98
Replaces: New
Tab 6a 8a
11. Remove 4 screws securing collector box and inducer housing
assembly together.
5. Spin black plastic cooling fan on inducer motor to be certain
there is no interference inside of inducer housing. If interference occurs, wheel must be readjusted.
NOTE: Units produced starting in January 1998 do not use the 4
screws inside of inducer housing, instead they use a Tog-L-Loc
process to connect inducer housing to collector box. This process
consist of a mechanical staking operation that bonds assemblies
together. To separate 2 assemblies, drill out 8 stakes using 1/4 drill
bit. (See Fig. 1.)
6. Secure relief box to top plate (upflow furnaces) or to blower
shelf (downflow/horizontal furnaces).
7. Reinstall pressure switch, vent connector, and draft safeguard
switch.
NOTE: On downflow furnaces, seal flue extension to inducer
outlet with high temperature RTV.
12. Remove screws securing collector box to front of cell panel.
13. Use putty knife or automotive-type gasket scraper and carefully pry up on collector box assembly where it meets cell
panel. Work knife or scraper along collector box to break
silicone seal. Continue to pry around collector box until
collector box can be removed.
8. Connect pressure switch tubing to collector box fitting.
9. Using wiring diagram located on blower access door, reconnect:
a. Pressure switch
14. Clean any remaining silicone residue from cell panel.
b. Draft safeguard switch
Step 2—Installation of Collector Box
c. Inducer motor plug
NOTE: A releasing agent such as PAM cooking spray or equivalent (must not contain corn or canola oil, aromatic or halogenated
hydrocarbons or inadequate seal may occur) 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.
10. Secure vent pipe to relief box with screws.
11. Replace blower access door.
12. Turn on gas at gas control (knob or switch) gas supply shutoff
and line voltage electrical supply.
13. Replace control access door.
14. Check furnace through 1 complete heating cycle for proper
operation.
1. Spray face surface of cell panel with a releasing agent.
2. Apply 1/8-in. to 3/16-in. bead of high temperature silicone to
back outside edge of collector box.
NOTE: Blower will run for 90 sec if thermostat is turned up
above room temperature when 120-v power is restored. A fault
code 12 will flash after 90 sec. To clear the fault code, turn off
power, turn thermostat off or down below room setting. Turn
power back on. Set thermostat to desired temperature.
3. Using alignment tabs on bottom corners of collector box,
realign collector box assembly against cell panel and install all
screws.
Step 3—Installation of Inducer Housing and Motor
Step 4—System Check-Out
1. Align inducer housing so outlet is facing up. Place new gasket
provided in kit, between collector box and inducer housing
inlet. Set inducer tabs into slots provided in collector box.
1. Initiate component test through circuit board.
2. If any faults are flashed, refer to fault code label on unit
blower door.
2. Use 1/8-in. drill bit and drill 4 mounting holes in collector box
(see Fig. 1) for hole location.
3. Set thermostat above room temperature.
3. Use 4 shallow head Phillips screws provided in kit to mount
inducer box to collector box.
4. Allow unit to initiate a complete call for heat cycle.
5. Check for air leakage around collector box. A whistling noise
may indicate air leak in collector box seal.
NOTE: A new inducer assembly gasket is provided in the
collector box kit.
NOTE: If there is an air leak in the collector box seal, pressure
switch may not make.
4. Including new gasket, install inducer motor assembly in
inducer housing and fasten with 3 original mounting screws.
Make certain inducer motor ground wire is reinstalled in
original location.
For additional information and a complete sequence of operation,
refer to furnace Installation, Start-Up and Operating Instructions.
NOTE: The 3 original mounting screws are shorter in length than
other screws. Use of longer screws will result in interference
between screws and inducer wheel.
2
DRILL OUT TOG-L-LOC
WITH 1/4-IN. DIA
DRILL BIT TYP
COLLECTOR BOX
GASKET
REMOVE INDUCER
DRILL 4 HOLES WITH
DRILL BIT TO
MOUNT INDUCER
HOUSING TYP
1/8-IN. DIA
INDUCER HOUSING TABS
A98309
Fig. 1—Inducer Housing and Collector Box Assembly
3
SERVICE TRAINING
Packaged Service Training programs are an excellent way to increase your
knowledge of the equipment discussed in this manual, including:
• Unit Familiarization
• Maintenance
• Installation Overview
• Operating Sequence
A large selection of product, theory, and skills programs is available, using popular
video-based formats and materials. All include video and/or slides, plus companion
book.
Classroom Service Training plus "hands-on" the products in our labs can mean
increased confidence that really pays dividends in faster troubleshooting, fewer
callbacks. Course descriptions and schedules are in our catalog.
CALL FOR FREE CATALOG 1-800-962-9212
[ ] Packaged Service Training
[ ] Classroom Service Training
A94328
Copyright 1998 Carrier Corporation
330a405
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 4
PC 101
Catalog No. 535-703
Printed in U.S.A.
Form 58D-14SI
Pg 4
6-98
Replaces: New
Tab 6a 8a