PG96MSA: Installation, Start-up, Operating and Service and Maintenance Instructions
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
65
A11403
Fig. 66 – Burner Assembly
To reinstall burner assembly:
1. Install the Hot Surface Igniter (HSI) and bracket in burner
assembly.
2. Install flame sensor on burner.
3. Align the edges of the one-piece burner with the slots in the burner
assembly and slide the burners forward until they are fully seated in
the burner assembly.
4. Align the orifices in the manifold assembly with the support rings
on the end of the burner.
5. Insert the orifices in the support rings of the burners.
NOTE: If manifold does not fit flush against the burner, do not force the
manifold on the burner assembly. The burners are not fully seated
forward in the burner assembly. Remove the manifold and check burner
positioning in the burner assembly before re-installing the manifold.
6. Attach the green/yellow wire and ground terminal to one of the
manifold mounting screws.
7. Install the remaining manifold mounting screws.
8. Check the igniter alignment. See Fig. 66, Fig. 67, and Fig. 68.
9. Attach the wires to the roll-out switches.
10. Align the burner assembly with the openings in the primary cell
inlet panel and attach the burner assembly to the cell panel.
11. Connect the wire for the flame sensor.
12. Connect the wire for the Hot Surface Igniter.
NOTE: Use propane-resistant pipe dope to prevent leaks. Do not use
PTFE thread-seal tape.
13. Install the gas pipe to the gas valve.
14. Check for gas leaks with a commercially available soap solution
made specifically for the detection of leaks.
15. Turn gas on at electric switch on gas valve and at external shut-off
or meter
16. Turn power on at external disconnect, fuse or circuit breaker.
17. Run the furnace through two complete heating cycles to check for
proper operation
18. Install control door when complete.
A11405
Fig. 67 – Igniter Position - Top View
L12F041
Fig. 68 – Igniter Position - Side View
Servicing Hot Surface Igniter
The igniter does NOT require annual inspection. Check igniter
resistance before removal. Refer to Fig. 66, Fig. 67, and Fig. 68.
1. Turn off gas and electrical supplies to furnace.
2. Remove control door.
3. Disconnect igniter wire connection.
4. Check igniter resistance. Igniter resistance is affected by
temperature. Only check resistance when the igniter is at room
temperature.
a. Using an ohm meter, check resistance across both igniter leads in
connector.
b. Cold reading should be between 40 ohms and 70 ohms.
5. Remove igniter assembly.
a. Using a 1/4-in. driver, remove the two screws securing the igniter
mounting bracket to the burner assembly See Fig. 66.
b. Carefully withdraw the igniter and bracket assembly through the
front of the burner assembly without striking the igniter on
surrounding parts.
c. Inspect igniter for signs of damage or failure.
d. If replacement is required, remove the screw that secures the
igniter on igniter bracket and remove the igniter.
6. To replace igniter and bracket assembly, reverse items 5a through
5d.
7. Reconnect igniter harness to the igniter, dressing the igniter wires to
ensure there is no tension on the igniter itself. See Fig. 66.
8. Turn on gas and electrical supplies to furnace.
9. Verify igniter operation by initiating control board self-test feature
or by cycling thermostat.
10. Replace control door.
Flushing Collector Box and Drainage System
1. Turn off gas and electrical supplies to furnace.
WARNING
!
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal injury, death,
and/or property damage.
Never purge a gas line into a combustion chamber. 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. A
fire or explosion may result causing property damage, personal injury
or loss of life.
FLAME SENSOR
(BELOW BURNER)
FLAME ROLLOUT
SWITCH
BRACKET, IGNITER
IGNITER
BURNER SUPT. ASSY
BURNER ASSY
WARNING
!
ELECTRICAL SHOCK AND FIRE HAZARD
Failure to follow this warning could result in personal injury, death,
and/or property damage.
Turn off the gas and electrical supplies to the furnace and install lockout
tag before performing any maintenance or service. Follow the operating
instructions on the label attached to the furnace.
2-1/2-in.
(64.4)
1-1/4-in.
(31.8)
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