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Thermostat Reset Upgrade Kit Installation Instructions

© 2005, IMI Cornelius Inc.

- 1 -

Publication Number: 629088480INS

INSTALLATION INSTRUCTIONS

FCB Pinnacle 2 Flavor Emerson Units

 T

HERMOSTAT

 R

ESET

 U

PGRADE

 K

IT

 P/N 629088480

IMPORTANT:  This procedure is intended for use by a Qualified Service Technician.

IMPORTANT:  This kit is intended to be a direct replacement of the existing safety circuit. 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 www.cornelius.com, search for 629088480INS, and print the 
instructions off in color.

Parts List

Tool 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

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)

Short Thread 
Cutting Screws

Set of Wire Ties

Hole Template

Retro-Kit

Enclosure Box

In-Rush Protection 
Harnesses

Screws

Bushing

Hex Nut

Wire Diagram

Release Date: June 30, 2005

 www.cornelius.com

Revision: C

Summary of Contents for 629088480

Page 1: ...the instructions off in color Parts List Tool 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...

Page 2: ...t 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 3 Remove leads LD1 and LD2 from transformer 1 located in contactor box These are the piggybacked connections Remove the labeled terminals from the piggybacks and replace in their original positions Contactor Box Original Safety Box Place TX1 LD1 and TX1 LD2 back on tra...

Page 3: ...eads for the contactor 7 Feed the white wires out through the hole and remove the box NOTE Note the mounting hole locations on the original box If the mounting holes are on 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 Disconnect white contactor wire from thermostat wi...

Page 4: ... 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 ...

Page 5: ... 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 Snap bushing inserted Harness from contactor box Main power lead harness 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 wire...

Page 6: ...ure that you connect the two red wires to one thermostat and the orange wires to the other thermostat Zip tie the bundles together 18 Change out the screws in the back of the thermostat with the supplied brass and stainless steel lockwashers NOTE Only remove one screw at a time Do not remove both screws at the same time or the thermostat can fall and be damaged 19 Using hand tools remove one screw...

Page 7: ...er as shown 22 Repeat procedure for second screw 23 Repeat steps 18 20 for all barrels If the existing screws do not come out or they break during this change call IMI Cornelius Service at 800 238 3600 24 After screw replacements insure thermostat is flush against brass retaining nut by grasping the body of the thermostat with your finger and gently trying to wiggle it No movement should be detect...

Page 8: ...inal on the contactor in the safety circuit enclosure D Verify that incoming power L1 and L2 are on the side of the contactor with the existing wires E Verify that the unit power leads T1 and T2 are on the side of the contactor without the existing wires 27 After verifying that the unit is wired correctly connect power to unit and verify If the unit does not power up and the red LED is illuminated...

Page 9: ...ame and drive 4 short thread cutting screws included in kit through safety circuit box into frame 30 Swing Contactor Box closed and place cover over box Drive the 4 screws that were removed to hold cover and box in place on unit 31 Replace lower back panel of unit Move unit back into place for operation Open the front control box to add the in rush protection harnesses In Rush Protection Harness ...

Page 10: ...P4 terminal that you pulled from the board 35 Position the In Rush Protection Harness into the control box so that it does not contact the control box or door when closed Zip tie to the main harness as needed 36 Repeat steps 25 28 on each inverter board on the unit 1 board per barrel 37 Close front control box 38 Attach new wiring diagram directly over the existing one Place Hot Gas Error Warning ...

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