Core Blower Replacement Procedure - 5100 Series

Item # 1041730R includes both kits listed below.

Replacement Motor Kit (1040403R) Includes:

• Motor Assembly

• Capacitor

• Capacitor Boot

• Label Fan Motor Direction

Replacement Wheel Kit (1020003R) includes:

• Blower Wheel 9 1/8" X 4 1/4"

De-energize System

De-energize the system and remove the electrical panel cover to gain access to the electrical compartment.

Remove Transformer

Remove the two (2) screws from the 75VA transformer (Figure 1) and set aside.

Disconnect Wires

Cut tie wraps securing the black and white wires to core blower and disconnect.

Remove Capacitor

Remove the capacitor (Figure 1) from the electrical panel center insert and disconnect the brown wires. Set the capacitor to the side.

Remove Processor Board

Remove screw and unhinge the processor control board (Figure 1) to gain access to the low voltage panel (Figure 2).

Remove Low Voltage Panel

Remove the low voltage panel (Figure 2) by taking out the four (4) screws and set aside.

Remove Wire Raceway

Remove the wire raceway (Figure 2) by taking out the three (3) screws and set aside.

Remove Center Panel

Remove the six (6) screws on the electrical panel center insert (Figure 2) and remove the panel.

Remove Core Blower Assembly

Remove the screws securing the core blower assembly (Figure 3). Remove the motor assembly by turning to the side. Make sure the element wires do not get damaged in the process.

Loosen Set Screw

Using a 5/32" Hex wrench, loosen the two (2) set screws on the blower wheel.

Remove Wheel

Remove the blower wheel from motor shaft.

Install Wheel

Slide the new blower wheel onto the motor shaft ensuring the set screws are aligned with the two (2) flat faces of the shaft. Leave 1/4" gap (Figure 4) between the wheel and mounting plate. Tighten set screws to 120 in/lbs.

Spin Test

Spin the wheel by hand to ensure the wheel is not touching the blower plate.

Insert Assembly

Insert new core blower assembly, rotating it so that the flat edge of the core blower plate (Figure 5) is towards the top. The blower motor wiring should be off the lower right side of the motor. Secure in place using previously removed hardware.

Note

Secure Raceway

Secure the wire raceway.

Install Center Panel

Reinstall the electrical panel center insert back inside the system being careful of all wiring.

Attach Rotation Label

Adhere the Fan Motor Direction label on the panel center insert (Figure 3). Verify reversing connection is correctly selected for the motor install.

Mount Capacitor

Mount the capacitor and attach the ground (green) wire to the electrical panel center insert with the mounting screw.

Position Rubber Boot

Slide the rubber capacitor boot onto the brown wires.

Attach Wires to Capacitor

Attach the brown wires to the capacitor and secure the boot over the capacitor terminals. Verify the capacitor is correct for the blower motor installed.

Connect White Wire

Connect the blue wire from the system to the white wire on the blower.

Connect Black Wire

Connect the black/yellow wire from system to the black wire on blower.

Install Low Voltage Panel

Secure the low voltage panel into place, hinge the processor control board back in position, and secure.

Secure Transformer

Secure the 75VA transformer in the base of the electrical panel. Verify the transformer jumper ring terminal is secured with the left transformer screw.

Secure Motor Wiring

Route and secure the core blower wiring in a manner that prevents damage once the system is energized.

Check Motor Rotation

Energize the system and verify motor direction.

Reinstall Cover

Reinstall electrical panel cover.