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manual abstract
If the unit does not have a reset box on the back, call IMI Cornelius Service at 800-238-3600. NOTE: Open the Cornelius web site search for 629088480INS, and print the instructions off in color. Parts List Item Description Qty 1 Retro-Kit Enclosure Box (with wiring inside) 1 2 Hole Template 1 3 Short Thread-Cutting Screws (if needed) 6 4 Set of wire ties 1 5 Screws, 1 spare 3 6 Wiring Diagram – 620920907 1 7 7/8” Bushing (if needed) 1 8 Hex Nut 1 9 Harness, In-Rush Protection 2 10 Label, Hot Gas Error (not shown) 1 11 Brass Screws and S.S. Lock-washers (not shown) 4 Retro-Kit Enclosure Box Bushing Hex Nut Screws Tool List Wire Diagram Hole Template Set of Wire Ties Short Thread Cutting Screws In-Rush Protection Harnesses Multi-Use Screwdriver Wire Stripper/Crimper 1/4” Nut Driver Needle Nose Pliers Multi-meter Set of Mixed Terminals (red male and female AMP fastons, fully insulated) Release Date: June 30, 2005 Revision: C © 2005, IMI Cornelius Inc. - 1 -Publication Number: 629088480INS Thermostat Reset Upgrade Kit Installation Instructions Installation Instructions 1. Pull Pinnacle away from wall. DISCONNECT POWER FROM THE UNIT. Remove lower back panel. 2. Remove the 4 screws holding contactor box cover (bottom rear of unit). The box will now pivot on hinges. Also remove the 4 screws holding the original safety circuit box on the back of the lower frame. Contactor Box Original Safety Box 3. Remove leads LD1 and LD2 from Place TX1-LD1 and TX1-LD2 back on transformers. transformer 1, located in contactor box. Use same location from placement. These are the piggybacked connections. Remove the labeled terminals from the piggybacks and replace in their original positions. Remove piggybacked wires and leads from transformer. Publication Number: 629088480INS - 2 - © 2005, IMI Cornelius Inc. Thermostat Reset Upgrade Kit Installation Instructions 4. Remove thermostat wires from their connections. Feed the wires out of the contactor box. Discard the black jumper wire. 5. Feed the white wires that originate from the safety circuit box out of the contactor box. Disconnect white contactor wire from thermostat wire. Disconnect black jumper from thermostat wire and discard. Remove the two white wires and black thermostat wires from contactor box. 6. Pull out safety circuit box and remove the ground screw. Disconnect the main power and contactor harness leads for the contactor. 7. Feed the white wires out through the hole and remove the box. NOTE: Note the mounting hole locations on Box with mounting holes on Box with mounting holes on the original box. If the mounting holes are on top and bottom. Drill new. sides. Use existing. the side of the box, proceed to step 14. If the mounting locations are on the top and bottom, remove all wires and bushing and proceed to the next step to drill new mounting holes. © 2005, IMI Cornelius Inc. - 3 -Publication Number: 629088480INS Thermostat Reset Upgrade Kit Installation Instructions 8. Place hole template at lower left of back of frame. The dot sticker should be at the lower left of template. Line up edge of hole template to edge of frame, as shown, and clamp in place. Template Dot sticker in lower left. Clamp in place. Start Holes 9. Start 4 smaller holes with the drill using the 1/8” bit through template and into frame. DO NOT DRILL THE ENTIRE HOLE, ONLY START HOLE TO MARK LOCATION! If preferred, use a center punch to mark hole locations. 10. Unclamp the template and place just inside frame, as shown. The template MUST BE between the frame and hoses to prevent hose puncture. Be sure that large hole in template is in position well above the holes being drilled 11. Drill the two small holes near the left side. Move the template, as shown, when finished drilling making sure it is between the frame and hoses, with the large template hole away from the right side holes. Drill the 2 smaller holes on the right. Place template, as shown, between frame and hoses. Place template in this position when drilling large hole. 12. File down any burrs on all 4 holes, carefully clean up all metal shavings. 13. Place Snap Bushing in the 7/8” hole. Feed the main power and contactor harnesses through the hole. Publication Number: 629088480INS - 4 - © 2005, IMI Cornelius Inc. Thermostat Reset Upgrade Kit Installation Instructions Snap bushing inserted. Harness from contactor box. Main power lead harness. 14. Remove contactor from box and connect main power and contactor harnesses, as shown. IMPORTANT – Main power MUST be on same side as flag terminals already attached to contactor (see photo). Remount contactor in box. 15. Feed the remaining 4 wires (2 red, 2 orange) through hole. Contactor harness here. Main power harness here. Remount contactor in the box by locating this screw than turn the contactor to locate the other screw. Feed these wires through the hole. © 2005, IMI Cornelius Inc. - 5 -Publication Number: 629088480INS Thermostat Reset Upgrade Kit Installa...