International comfort products 1186071 User manual

443 06 5102 01 10/22/15
Specifications subject to change without notice.
Installation Instructions
COLLECTOR BOX REPLACMENT KIT
FOR CONDENSING GAS FURNACES
for use with 35−in. (889mm)
High Efficiency Gas Furnace
1186071, 1186072
1186073, 1186074
NOTE: Read the entire instruction manual before starting the
installation.
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
. 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 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 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 electrical
supply to the furnace. Check accessories and cooling unit for
additional electrical supplies that must be shut off during
furnace servicing. Lock out and tag switch with a suitable
warning label. Verify proper operation after servicing.
!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, safety glasses and
gloves when handling parts, and servicing furnaces.
INTRODUCTION
This instruction covers the Collector Box replacement on
35−inch (889 mm) high, high efficiency condensing gas
furnaces with hot surface ignition. The Collector Box should be
replaced when the Collector Box is cracked or warped.
There are four different Collector Box assemblies to service all
Single stage, Two−stage, Variable Speed and Modulating
furnaces. Each Collector Box assembly is matched to the
cabinet width of the furnace.
DESCRIPTION AND USAGE
The collector box kit contains a collector box and the necessary
gaskets and screws to replace a collector box. Table 1 lists the
kit contents.
Table 2 list the furnace input to the appropriate collector box kit.

2443 06 5102 01
Specifications subject to change without notice.
Table 1 Kit Contents
QUANTITY DESCRIPTION
1 Collector Box Assembly
2Condensate Trap Gasket
4Collector Box Drain Plug
1Collector Box Gasket
1Inducer Housing Inlet Gasket
2Inducer Housing Drain Gaskets
8Screws with Washers
Table 2 Kit Numbers
UNIT SIZE
INPUT BTUH KIT NUMBER CASING WIDTH
in(mm)
26,000
1186071 14−3/16 (360)
40,000
60,000
40,000
1186072 17−1/2 (445)
60,000
80,000
60,600
1186073 21 (533)
80,000
100,000
120,000 1186074 24−1/2 (622)
140,000
INSTALLATION
Unit Shut Down
!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 electrical
supply to the furnace. Check accessories and cooling unit for
additional electrical supplies that must be shut off during
furnace servicing. Lock out and tag switch with a suitable
warning label. Verify proper operation after servicing.
1. Set room thermostat to lowest setting or “OFF.”
2. Disconnect power at external disconnect, fuse or circuit
breaker.
3. Turn off gas at external shut−off or gas meter.
4. Remove outer doors and set aside.
5. Turn electric switch on gas valve to OFF.
Vent Pipe Removal
NOTE: The vent pipe may be connected to the furnace at the
rubber vent pipe support. Before cutting the vent pipe, loosen
the clamps around the vent pipe coupling and move the vent
pipe away from the furnace. Support the vent pipe as close to
the furnace as possible to prevent damage to the vent system.
NOTE: If the vent pipe passes through the vent pipe coupling
into the vent elbow on the inducer, it may be necessary to cut
the vent pipe external to the casing, then re−cement the vent
pipe with a field−supplied coupling.
1. Support the vent pipe as close to the furnace as possible
to prevent damage to the vent system.
2. Cut vent pipe with a hacksaw and move the remaining
vent pipe out of the way. Secure the vent pipe if
necessary.
3. Loosen both clamps at the vent pipe support attached to
furnace casing.
4. Loosen clamp for the vent pipe at vent elbow on the
inducer assembly.
5. Remove remaining vent pipe through the top of the
furnace casing and set aside.
Remove J−Box and Main Harness
!CAUTION
UNIT OPERATION HAZARD
Failure to follow this caution may result in unit damage or
improper operation.
Label all wires prior to disconnection when servicing controls.
!PRUDENCE
D’EQUIPEMENT D’OPERATION
Toute erreur de câblage peut être une source de danger et
de panne.
Lors des opérations d’entretien des commandes, étiqueter
tous les fils avant de les déconnecter.
NOTE: Depending on the location of the J−Box and cover, it
may not be necessary to remove the J−Box cover or bracket to
remove the Collector Box. If the J−Box cover and bracket
interfere with the removal of the Collector Box, remove the
J−Box as shown below:
1. Remove the blower door.
2. Remove the screw that secures the J−Box cover to the
J−Box bracket and set the cover aside.
3. Disconnect the field wiring from the factory wiring and
remove the ground wire from the green ground screw on
the J−Box bracket.
4. Remove factory wiring from the J−Box.
5. Disconnect the factory wires from the main limit switch.
6. Remove the screw that secures the door switch to the
blower shelf.
7. Remove main harness from the slot in the blower shelf.
Condensate Drain and Trap Removal
NOTE: If the condensate trap is removed, a new gasket
between the trap and collector box is required. Verify a
condensate trap gasket is included in the service kit or obtain
one from your local distributor.
1. Disconnect external drain from condensate drain elbow
or drain extension pipe inside the furnace and set aside
2. Disconnect the condensate trap relief hose from collector
box port and the molded retainer clips on the inducer
housing.
NOTE: If condensate has a heat pad attached to the trap,
trace the wires for the pad back to the connection point and
disconnect the wires for the heat pad.
3. Remove the screw that secures the condensate trap to
the collector box, remove the trap and set aside.
4. Remove the trap gasket from the collector box if it did not
come off when the trap was removed.
5. Discard the old trap gasket.
6. Rinse condensate trap in warm water until trap is clean.
7. Flush condensate lines with warm water.

443 06 5102 01 3
Specifications subject to change without notice.
8. Shake trap dry.
Pressure Switch Removal
!CAUTION
UNIT OPERATION HAZARD
Failure to follow this caution may result in unit damage or
improper operation.
Label all wires prior to disconnection when servicing controls.
!PRUDENCE
D’EQUIPEMENT D’OPERATION
Toute erreur de câblage peut être une source de danger et
de panne.
Lors des opérations d’entretien des commandes, étiqueter
tous les fils avant de les déconnecter.
NOTE: There are two types of pressure switches. The
modulating pressure switch assembly has three pressure
switches. Two are side−by−side with the third switch mounted
to the back of one of the switches.
All other single and two−stage furnaces have two pressure
switches mounted back−to−back.
PSC inducer pressure switches have a tube on the back
pressure switch that connects to the port on the inducer
assembly.
Modulating pressure switches do not have a port on the rear
pressure switch
1. Remove the front pressure switch tube from the port on
the collector box. (See Figure 1)
2. Modulating −Disconnect the pressure switch harness
from the main wiring harness
Non−Modulating −remove the individual wires from the
front pressure switch.
Note the location of the wires for reassembly.
3. Remove the screws that attach the pressure switch
assembly to the inducer.
4. Remove the back pressure switch tube that connects to
the inducer assembly. (PSC only)
5. Remove the wires from the back pressure switch (PSC
Only). Note the location of the wires for reassembly.
6. Set the pressure switches aside.
7. If the relief tube for the condensate trap is routed across
the inducer assembly, remove the tube from the port on
the collector box and from the stand−offs on the inducer
and move the tube aside.
Inducer Assembly Removal
1. Remove the door bracket from the front edge of the
blower shelf.
2. Remove the wires that connect the main wiring harness
to the inducer motor harness.
3. Remove the condensate trap relief tube from the port on
the collector box and the stand−offs on the inducer
housing.
4. Remove the screws from the tabs on inducer assembly
that secures the inducer to the collector box. Note there
is one mounting tab directly under the vent elbow.
5. Remove the inducer assembly and set aside.
6. To avoid double gasketing and leakage, check to make
sure the drain gaskets for the inducer and the inducer
outlet gasket are not still attached to the collector box.
7. Remove the vent elbow from the inducer assembly and
set aside.
Figure 1 Inducer Assembly Motor Image
Inducer Mounting Screw
Pressure Switch
Inducer Mounting Screw
Remove Vent Elbow
Vent Elbow Clamp
Remove Tube(s) from
Standoffs
Inducer Mounting Screw
Inducer Mounting Screw
Pressure Switch
Mounting Screw
Motor image, component location may vary. A11361

4443 06 5102 01
Specifications subject to change without notice.
Collector Box Removal
1. Remove the screws that secure the collector box to the
heat exchanger cell panel and set aside.
2. Remove collector box gasket and discard.
Collector Box Installation
1. Verify old collector box gasket has been removed from
heat exchanger.
2. Remove adhesive backing from collector box gasket and
align gasket on the collector box.
3. Attach the gasket to the collector box.
4. Remove the adhesive backing from the condensate trap
gasket.
5. Attach the gasket over the drain outlets on the collector
box.
6. Repeat the procedure for the drain outlet.
NOTE: There is a slot on each side of the front panel of the
condensing heat exchanger. The collector box has alignment
tabs on the back that fit into the slots on the condensing heat
exchanger panel.
7. Align the tabs on the collector box to the slots
condensing heat exchanger.
8. With the collector box fully seated against the
condensing heat exchanger cell panel, install the screws
through the collector box.
!CAUTION
UNIT OPERATION HAZARD
Failure to follow this caution may result in unit damage or
improper operation.
Over torquing the screws may result in a cracked collector
box.
9. Tighten the screws with a non−powered screwdriver to
12 lb.−in. in an alternating pattern around the collector
box. Do not over−tighten.
Figure 2 Collector Box
A12500
Adhesive to face
Collector Box Assy.
Plug, Drain (4)
Gasket (2)
Collector Box (Base)
Adhesive on this side
Gasket, Collector Box
Collector Box Assy. (Cover with Inserts)
5
Re-attach the collector box using the screws
with washer included in the kit. Tighten the screws
with a non-powered screwdriver to 12 lb-in. in an
alternating pattern around the collector box.
Do not over-tighten.
6
3
4
1
2
Replace Inducer Assembly Gaskets
1. Remove the old gasket from around the inlet to the
inducer assembly
2. Remove the two gaskets around the drain stubs of the
inducer assembly. Verify that the surfaces around the
drain stubs are clean and smooth.
3. Remove the adhesive backing from a inducer housing
drain gasket and attach the gasket over the drain stub of
the inducer assembly
4. Repeat the procedure for the other drain stub
5. Insert the inducer inlet gasket in the groove around the
inlet of the inducer assembly
6. Verify the gasket is fully seated in the groove.
Inducer Assembly Installation
1. Verify any remaining gaskets on the collector box are
removed and discarded.
2. Verify the inducer assembly has gaskets on the drain
stubs and at the inducer inlet.
3. Verify the Inlet Choke Plate (when used) is installed on
the inlet opening of the inducer.
4. Align the tabs on inducer assembly to the brass inserts
on the collector box.
5. Insert the mounting screws by hand through the tabs to
secure the inducer to the collector box. Remember there
is a mounting tab located under the vent elbow.
6. Tighten the screws in an alternating pattern by hand. Do
not use a screw gun or over−tighten the mounting
screws.

443 06 5102 01 5
Specifications subject to change without notice.
7. Connect the inducer leads from the main wiring harness
to the inducer motor harness.
8. Attach the vent elbow to the inducer outlet. Torque the
vent elbow clamp 15 lb.−in.
Install J−Box and Main Harness
NOTE: If the J−Box cover and bracket were removed as part
of the collector box replacement, install the J−Box and bracket
as shown below:
1. Insert grommet for main harness in the slot in the blower
shelf.
2. Align the door switch to the blower shelf.
3. Install the screw to secure the door switch.
4. Install the door bracket to the front edge of the blower
shelf.
5. Connect the field wiring from the factory wiring and
attach the ground wire to the green ground screw on the
J−Box bracket.
6. Attach the J−Box cover to the J−Box bracket
7. Install the screw to secure the J−Box cover to the
bracket.
8. Connect the factory wires to the main limit switch.
Pressure Switch Installation
NOTE: There are two types of pressure switches. The
modulating pressure switch assembly has three pressure
switches. Two are side−by−side with the third switch mounted
to the back of one of the switches.
All other furnaces have two pressure switches mounted
back−to−back.
The tube for the front pressure switch connects the switch to
the port on the collector box. The tube for the switch mounted
on the back connects the switch to the port on the inducer
assembly.
1. Connect the wires to the back pressure switch.
2. Connect the tube for the back pressure switch to the
inducer assembly. (PSC only)
3. Connect the tube for the front pressure switch to the port
on the collector box.
4. Attach the pressure switch assembly to the inducer.
5. Modulating −connect the pressure switch harness to
the main wiring harness
Non−Modulating −attach the individual wires to the
pressure switch.
Install the Condensate Trap and Drain
NOTE: If the condensate trap is removed, a new gasket
between the trap and collector box is required. Verify the
condensate trap gasket was replaced as outlined in “Collector
Box Installation”
1. Align the trap with the drain outlet on the collector box.
2. Secure the trap to the collector box with the screw.
3. Connect the condensate trap relief tube from collector
box port and insert the tube into the molded retainer clips
on the inducer housing.
4. Insert the condensate drain elbow through the casing
until it is properly seated. Or, connect the drain elbow to
the drain extension pipe and route the pipe behind the
inducer.
5. Connect the drain elbow to the condensate trap.
NOTE: If condensate has a heat pad attached to the trap,
trace the wires for the pad back to the connection point and
connect the wires for the heat pad.
Vent Pipe Installation
1. Orient the vent elbow in the required location. Torque the
vent elbow clamp 15 lb−in.
2. Insert the vent pipe through the furnace casing and into
the outlet of the inducer vent elbow.
3. Tighten the clamp for the vent pipe at vent elbow on the
inducer assembly 15 lb−in.
4. Align the remaining vent pipe system to the vent pipe in
the furnace casing.
5. If the pipe was cut, solvent cement the pipes as required
for the type of material used.
6. Tighten both clamps at the vent pipe support attached to
furnace casing 15 lb-in.
Unit Checkout
!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.
!WARNING
RISQUE D’EXPLOSION ET D’INCENDIE
Le non−respect des avertissements de sécurité pourrait
d’entraîner des blessures graves, la mort ou des dommages
matériels.
Ne jamais utiliser une flamme nue por vérifier la présence
des fuites de gaz. Pour la vérification de tous les joints,
utiliser plutôt une solution savonneuse commerciale
fabriquée spécifiquement pur la détection des fuites de gaz.
Un incendie ou une explosion peut entraîner des dommages
matériels, des blessures ou la mort.
1. Set thermostat to “OFF”.
2. Turn on power at external disconnect, fuse or circuit
breaker.
3. Turn on gas at external shut−off or gas meter.
4. Check for gas leaks with a commercially available soap
solution made specifically for the detection of leaks to
check all connections.
5. Manually close blower door switch.
6. Initiate component test through circuit board by referring
to “Component Test” on status code label on blower
access door for complete test sequence information.
7. If any status codes are flashed, refer to status code label
on unit blower door.
8. Turn thermostat fan switch to “ON”, “Continuous” or
jumper R to G terminals at furnace control board.
9. Check for air leakage around cell panel. It may be
necessary to remove heat exchanger assembly and top
gasket between cell panel and furnace casing top plate.
Re−install and re−check for blower air leaks.
10. Remove jumper(s) or set thermostat fan to “Auto” or
“OFF.”
11. Release blower door switch.
12. Install blower access door.

6443 06 5102 01
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13. Set thermostat to call for heat.
14. Allow unit to initiate a complete call for heat cycle.
15. Check for air leakage around collector box. A whistling
noise may indicate air leak in collector box seal.
16. Allow the call for heat to continue until water drains out
the condensate drain. Check for water leaks around the
collector box and inducer assembly.
NOTE: If there is a severe air leak in the collector box seal,
pressure switch may not close or will re−open, resulting in no
ignition or erratic burner operation.
NOTE: As part of the system check−out, verify that the
following conditions are not affecting the operation of the
furnace:
SShort Cycling−Defective thermostat: Incorrect
thermostat anticipator setting, dirty filter or over−sized
furnace.
SUnder firing/low BTU input: Set manifold pressure and
verify firing rate as shown on rating plate by clocking
the gas meter.
SOverfiring/high BTU input: Set manifold pressure and
verify firing rate as shown on rating plate by clocking
the gas meter.
SLow temperature rise: Set unit for correct temperature
rise range as shown on unit rating plate.
SContaminated combustion air: Remove contaminates
or provide ample fresh air for combustion.
SExcessive amounts of outside ventilation air: Return
air temperature cannot be below 60 degrees F for
extended periods of time.
SIncorrect venting or termination: Recirculation of
products of combustion into the combustion air pipe
can damage the furnace. Verify proper venting and
vent termination per installation instructions. For
additional information, and a complete sequence of
furnace operation, refer to furnace Installation,
Start−Up and Operating Instructions.
17. After System Check−out is complete, set thermostat
below room temperature.
18. Verify that burner shuts down and blower completes
selected off delay time.
19. Verify furnace operates properly and set thermostat to
desired room temperature.
20. Re−install outer doors.
Copyright 2015 International Comfort Products
Lewisburg, Tennessee 37091 USA