OUTER DOOR (BASE) SERVICE KIT

SAFETY CONSIDERATIONS

Improper installation, adjustment, alteration, service, 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.

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 included 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.

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.

Recognize safety information. This is the safety-alert symbol [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 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.

⚠️ WARNING: FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury, death and/or property damage. The ability to properly perform maintenance on this equipment requires certain knowledge, mechanical skills, tools, and equipment. If you do not possess these, do not attempt to perform any maintenance on this equipment other than those procedures recommended in the Home Owner's Information Manual.

⚠️ WARNING: FIRE, EXPLOSION, ELECTRICAL SHOCK AND CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury, death and/or property damage. Improper installation, adjustment, alteration, service, maintenance, or use can cause carbon monoxide poisoning, explosion, fire, electrical shock, other conditions, which could result in personal injury or death. Consult your distributor or branch for information or assistance. The qualified installer or agency must use only factory-authorized kits or accessories when servicing this product.

⚠️ WARNING: ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal injury or death, or property damage. Before installing, modifying, or servicing system, main electrical disconnect switch must be in the OFF position and install a lockout tag. There may be more than one disconnect switch. Lock out and tag switch with a suitable warning label. Verify proper operation after servicing.

Introduction

This instruction covers the outer door installation on 35 in. (889 mm) tall condensing gas furnaces. The door should be replaced when it is missing or severely damaged. Minor damage or scrapes may be repaired and the finish repaired with touch-up paint.

Description and Usage

The door replacement kit can be utilized to restore units having missing door or doors severely damaged beyond repair. This kit contains the following items: Outer Door assembly with latches and model specific Instruction Booklets matched to different types of furnaces. The Instruction Booklets are matched to specific model families as shown in Table 1. Match the QUICK REFERENCE NUMBER and affix new booklet to the new door assembly.

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to lowest setting or "OFF".
2. Turn off all electric power to the appliance if service is to be performed.
3. Remove control access panel.
4. Push gas control switch to "OFF".
5. Replace control access panel.

Installation

CAUTION: CUT HAZARD

Failure to follow this caution may result in personal injury. Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing and gloves when handling parts.

1. Remove all packing materials from Outer Door.
2. Remove the Instruction Booklets.
3. Orient door to the correct installation position.
4. Brand logo may be repositioned to the correct position.
5. To reposition logo:
   1. Depress plastic retaining pins on reverse side of logo.
   2. Push logo out of mounting holes in outer door.
   3. Rotate logo to correct position and align logo retaining pins with holes in outer door.
   4. Snap logo into place by pushing on front of logo in the area where the retaining pins are located.

Install the Correct Instruction Booklet

The Instruction Booklets have a quick reference number in a black circle on the lower right corner of the safety information panel. A portion of the label is shown below in Fig. 1. The full label is shown in Fig. 3.

To locate the correct Instruction Booklet:

1. Verify the furnace model number from the unit rating plate on the inside of the blower door.
2. Locate the quick reference number next to the furnace model in Table 1.
3. Locate the correct Instruction Booklet.
4. Remove the adhesive backing from Instruction Booklet.
5. Center the Instruction Booklet on the inside of the new door assembly (see Fig. 2).
6. Press the booklet firmly in place.
7. Install both furnace doors.
8. Check for proper engagement of the blower door switch by running the furnace through one heating cycle.

NOTE: Extra labels may be kept for future use or discarded.

Instruction Booklets

Safety Information Panel

FOR YOUR SAFETY READ BEFORE OPERATING

WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

A. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.

B. BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.
• Do not touch any electric switch; do not use any phone in your building.
• Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.
• If you cannot reach your gas supplier, call the fire department.

C. Use only your hand to turn the gas control switch. Never use tools. If the switch will not turn by hand, don't try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

D. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

OPERATING INSTRUCTIONS

1. STOP! Read the safety information above on this label.
2. Set the thermostat to lowest setting or "OFF".
3. Turn off all electric power to the appliance.
4. This appliance is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.
5. Remove control access panel.
6. Push gas control switch to "OFF". (Match gas control on furnace to one of the pictures shown)
7. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you then smell gas, STOP! Follow "B" in the safety information above on this label. If you don't smell gas, go to next step.
8. Push gas control switch to "ON". (Match gas control on furnace to one of the pictures shown)
9. Replace control access panel.
10. Turn on all electric power to the appliance.
11. Set thermostat to desired setting.
12. If the appliance will not operate, follow the instructions "To Turn Off Gas To Appliance" and call your service technician or gas supplier.

NOTE: The diagrams for gas control switches are not included in this transcription.

LOCATION OF QUICK REFERENCE NUMBER

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to lowest setting or "OFF".
2. Turn off all electric power to the appliance if service is to be performed.
3. Remove control access panel.
4. Push gas control switch to "OFF".
5. Replace control access panel.

NOTICE: Removal of these instructions will void compliance of this furnace with ANSI Z21.47. (French: AVIS: Le retrait de ces instructions annulera la conformité de cette fournaise à la norme ANSI Z21.47.)