REZNOR
Revision: OPT-FAN-CTRL (09-22) 209185-A
Supersedes: CP-Thermocore-1-FC (12-15) PN209185R6
REPLACEMENT KIT (PN 209184) INSTALLATION
FOR DISCONTINUED FAN CONTROL
ALL DUCT FURNACES AND PACKAGED SYSTEMS WITH THERMOCORE® 1 HEAT EXCHANGER
DANGER
This replacement kit is to be installed by a qualified service agency in accordance with these instructions and in compliance with all codes and requirements of authorities having jurisdiction. Improper installation, adjustment, alteration, service, and/or maintenance can cause property damage, injury, or death. The qualified agency performing this work assumes responsibility for this installation.
The fan control used on heaters with a Thermocore® 1 heat exchanger has been discontinued by the manufacturer. This kit is designed to replace the fan control and applies to all products using a Thermodisc #29T12-32517 fan control (PN 10357).
Refer to the installation manual provided with the unit for important safety information.
Ensure that all components listed in Table 1 are available before beginning installation.
| Component | Description | PN (Quantity) |
|---|---|---|
| Time delay wired relay assembly | SPST, includes relay PN 209164 (#12S20-305131) | 209186 (1) |
| Bracket | Mounting, relay | 209167 (1) |
| Screw | #10 x 3/8 | 96246 (1) |
| Fan control | 125/90°F (#60T82-314585) | 209166 (1) |
| Fan control shield | Assembly | 209169 (1) |
| Wire connector | Twist-on, orange | 16354 (2) |
INSTALLATION
- Turn OFF gas and disconnect electric power.
- Remove control access panel, open electrical box cover (if provided), and locate existing fan control (see Figure 1).
- Disconnect four wires from fan control. Save blue and red wires that connect to terminals 1 and 3 and discard brown and black wires that connect to terminals A and B.
The image shows an older fan control unit mounted in an electrical box, with wires connected. A limit control is also visible. The obsolete fan control has terminals labeled A, B, 1, and 3.
NOTE: Depending on model and unit size, the junction box may or may not have a heat shield.
4. If unit is equipped with junction box heat shield (see Figure 2), disconnect limit control (see Figure 1) wires. Remove and discard heat shield and reconnect limit control wires.
The image shows a metal heat shield designed for a junction box, likely to protect components from heat.
5. Remove and save two screws that secure existing fan control (see Figure 1). Remove and discard control.
6. Install replacement fan control (see Figure 3):
- Position replacement fan control in same location and slide fan control shield through hole in panel and insert sensor side of fan control into shield.
- Secure replacement fan control and fan control shield using two existing screws.
- Connect blue and red wires to replacement fan control.
The image displays the new replacement fan control unit and its associated shield. The fan control is shown with terminals for wire connections, and the shield is positioned to protect it.
7. Install time delay relay (see Figure 4):
- Directly above fan control, remove and save two screws that secure patch plate to panel. Discard patch plate.
- Position relay mounting bracket in same location. Orient bracket so that large tab is at top and small tab is at bottom and align mounting holes.
- Secure relay mounting bracket using two existing screws.
- Secure time delay relay to mounting bracket using screw from kit.
The image shows the relay mounting bracket and the time delay relay component, illustrating how they are assembled and positioned for installation.
8. Connect time delay relay wires in accordance with wiring diagram shown in Figure 5.
This section contains two detailed wiring diagrams. The first diagram illustrates the wiring for a line voltage circuit, showing connections for a disconnect switch, replacement fan control, limit control, time delay relay, fan motor/blower relay, and gas valve. The second diagram shows the wiring for a 24V control circuit with similar components. Notes clarify wire connections and component installations, including specific terminal connections for the fan control and relay.
9. Close electrical box cover (if provided) and install control access panel.
10. Turn ON electric and gas and check unit for proper operation.
DO NOT DESTROY. PLEASE READ CAREFULLY. KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.
Specifications and illustrations subject to change without notice or incurring obligations.
Latest version of this manual is available at www.reznorhvac.com.
©2022 Nortek Global HVAC LLC, O'Fallon, MO. All rights reserved.
Revision: OPT-FAN-CTRL (09-22) 209185-A
