service and maintenance procedures
Contents
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3. labels attached to or shipped with the unit and other safety precautions that may apply APPROVED Follow all safety codes In the United States follow all safety S codes including the National Fuel Gas Code NFPA No 54 1996 ANSI Z223 1 1996 In Canada refer to the current edition of the National Standard of Canada CAN CGA B149 1 and 2 M95 Natural Gas and Propane Gas Installation Codes Wear safety glasses and work gloves Have fire extinguisher available during r start up and adjustment procedures and service calls Recognize safety information This is the safety alert symbol When you see this symbol on the furnace and in instructions or manuals be alert to the potential for personal injury Understand the signal words DANGER WARNING and CAU TION These words are used with the safety alert symbol DAN GER identifies the most serious hazards which will result in severe personal injury or death WARNING signifies a hazard which could result in personal injury or death CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage Fig 2 Model 331AAV Downflow A94086 CERTIFICATION OF MANUFACTURING SITE A94085 Fig 3 Model 330AAV Upflow WARNING The ability to properly perform mainte nance on this equipment requires certain expertise me chanical skills tools and equipment If
4. INVA 1888 13538 OLNY dW31H3AO HOLIMS LIWN 2577 A SELON d e IMS ON 1890 3ATVA SVO ADIN 1845 13938 IYNNYN dI3183AO HOLIMS LINT 1977 5991 p e ma 5 ON39331 aasn He d es 21 IMM P o IWM oad j eooooo0 Qo090 891 8 ILON an 3 n wag ma oaan n Wd AVIS 99 ssa udine SH 310N EE 9 ONINNIML 1931 Haan ANNO 1V3H HOIH a NIML IH vad 208 ICI c ISV zs 6 Woo ANTSG HO 3NO TS Cam u S D v ILON sA ISN NIHM om 2 sud pile md 38 O 2 zd 823 zsud IN t ae eee td JOuINOO 99 VIN FOVNEN m m 23592 9 Si ILON 3918 2 wn S SdH OvNvZ im cm 038 081 dum lt Tr im 035 SEL 2935 1995 Ay 06 Ir E 089 OvASIL 1H9IIMS 330 H3MOT8 I zw 6 4 3 9 ILON E br zi a3sn N3HM 0 3v3 YISH m I al Blz NAHM HOLIMS g 2 5 stv 193NNOOSIa 03515 amp m aasn N3HM 5 1584 C dQ3uvas 1000H E Wal Y 55 4 r 39745 uma n ug 1V3H SVO IH U571H M Ssa e s 8 lV3HSVO O P 1N3 dino3 SdH AUD EE TES T STON 2584 51 aNvdOHd SVD TWHALWN WVH9VIG OLLVWSHOS HOLIMS LOANNOOSIG 071315 OVASLL OL WVY9VId NOLLO3NNOO Service should be performed only by qualified person
5. PRIOR TO DISCHARGING YOUR BODY S ELECTROSTATIC CHARGE TO GROUND 2 Firmly touch a clean unpainted metal surface of the furnace chassis which is close to the control Tools held in a person s hand during grounding will be satisfactorily discharged 3 After touching the chassis you may proceed to service the control or connecting wires as long as you do nothing that recharges your body with static electricity for example DO NOT move or shuffle your feet DO NOT touch un grounded objects etc 4 If you touch ungrounded objects recharge your body with static electricity firmly touch furnace again before touch ing control or wires 5 Use this procedure for installed and uninstalled un grounded furnaces 6 Before removing a new control from its container dis charge your body s electrostatic charge to ground to protect the control from damage If the control is to be installed in a furnace follow items 1 through 5 before bringing the control or yourself into contact with the furnace Put all used AND new controls into containers before touching ungrounded objects 7 An ESD service kit available from commercial sources may also be used to prevent ESD damage CARE AND MAINTENANCE For continuing high performance and to minimize possible equip ment failure it is essential that periodic maintenance be performed on this equipment Consult your local dealer as to proper frequency of maintenance and availabilit
6. h Wiring connectors leading to control 6 Remove 8 screws that secure flue collector box to center panel Be careful not to damage sealant 7 Remove complete inducer assembly from furnace exposing flue openings 8 Using field provided small wire brush steel spring cable reversible electric drill and vacuum cleaner clean cells as follows a Assemble wire brush and steel spring cable 1 Use 48 in of 1 4 in diameter high grade steel spring cable commonly known as drain clean out or Roto Rooter cable 2 Use 1 4 in diameter wire brush commonly known as 25 caliber rifle cleaning brush NOTE The materials needed in items 1 and 2 can usually be purchased at local hardware stores 3 Insert twisted wire end of brush into end of spring cable and crimp tight with crimping tool or strike with ball peen hammer TIGHTNESS IS VERY IMPORTANT 4 Remove metal screw fitting from wire brush to allow insertion into cable b Clean each heat exchanger cell 1 Attach variable speed reversible drill to end of spring cable end opposite brush 2 Remove cell outlet plates IMPORTANT Replace screws in center panel before cleaning 3 Insert brush end of cable into upper opening of cell and slowly rotate with drill DO NOT force cable Gradually insert at least 36 in of cable into 2 upper passes of cell See Fig 8 A91252 Fig 8 Cleaning Heat Excha
7. Cleanable Cleanable 1 16 X 25 X1 1 20 X25 X 1 Cleanable 2 16X25X1 1 24 X 25 X1 Cleanable Factory provided with furnace Filters may be field modified as required by cutting and folding frame as indicated on filter AIRFLOW INSTALLATION OF FILTERS A94307 Fig 4 Horizontal Filter Arrangement m AIRFLOW X POSITION RETURN AIR PLENUM B deeem 7 y y px EE ELI EL yl yr z EE ACCESS DOOR SS SS a A88486 Fig 5 Downflow Filter Arrangement WARNING Never operate unit without a filter or with filter access door removed A failure to follow this warning could result in fire personal injury or death Horizontal and Downflow Each furnace requires 2 filters which are installed in the return air duct See Fig 4 and 5 To remove filters for cleaning or replacement proceed as follows a Turn off electrical supply before removing blower access door Remove blower access door Reach up behind top plate tilt filters toward center of return air plenum remove filters and clean as needed Replace if torn Furnaces are equipped with permanent washable filters ngos e Clean filters by spraying tap water through filter from opposite direction of airflow f Rinse and let dry Oiling or coating of filters is not recommended or require
8. LO C IDE e PHASE DISCONNECT BOX Gee 1 tle le t SWITCH CONTROL Ff M WHEN REQUIRED BOX 4 ES PON 24 VOLT TERMINAL BLOCK NOTES 1 Connect Y terminal as shown for proper operation FURNACE 2 Some thermostats require a C terminal connection as shown 3 If any of the original wire as supplied must be replaced use same type or equivalent wire Ne te ce A97443 Fig 10 Heating and Cooling Application Wiring Diagram FIELD 24 VOLT WIRING FIELD 115 208 230 460 VOLT WIRING FACTORY 24 VOLT WIRING FACTORY 115 VOLT WIRING 2 STAGE THERMOSTAT TERMINALS PEN 1 amp 5 6 8 5 0 O FIELD SUPPLIED FUSED DISCONNECT Lire ET 208 230 OR HEA ONLY et NE M60 VOLT THREE 4g BLK ge pert M eee WHT d q Sen e 1 4r NE 1 208 230 GND O Md te 115 VOLT FUSED JUNCTION N 1 t e levi e i L e L PHASE DISCONNECT BOX R4 rac 1 e lov an SWITCH CONTROL eos ie 2 SPEED WHEN REQUIRED CONDENSING 24 VOLT UNIT TERMINAL BLOCK NOTES 1 Connect Y terminal as shown for proper operation FURNACE 2 Some thermostats require a C terminal connection as shown 3 If any of
9. V ON 1589 AV13H HOLIMS SHNSS3Yd 1V3H HOIH 555 10H1NOO O N 1SdS HOLIMS SYNSS3Yd 1V3H HOIH SdH o 39V1S z JAWA SVO D gt T G3TIVLSNI 07314 ISNA znd NOILONN e GATIVISNI AHOLOVJ 3dAL INLOWOLNY diy ISNA ind lt RQ 2 3000 SNLYLS OSIY 300810313 HOSN3S 353 C 2 o 55118 ONINNIML IS2 NIME 0 1588 13534 dW31H3AO HOLIMS LNOTION 504 07 1585 19539 TWANVN dW3LY3AO HOLIMS LNOTION 584 NOWINOO NOLLO3NNOO H3NV310 HIVOINOHLO3 H 2 0 5 095 CSE IG ONINNIAL ft dINV 1 OWA SH NOLLOSNNOO OINOHLO3 H lt VANYN 1545 CON HOLIMS GH NO34VS 1 ssa MAIN SSHOLIMS ONLLL3S 330 93M0 18 v MS AMLINOUIO ONY HOSSSOOHdOHOIN fido a 1549 HOLIMS XTINO LVH MO1 ZMS SOLD VO Ho reh lt 2 e LH a 15 HOLOWH3MOT8 Fanon 4 HO153NNOO Wal LInouio e eld HOLIOVdVO LIIdS LN3NVINH3d 03345 9 10 HOLOW H3MO 8 WME ZM YOLOANNOD LINDHIO 6 1085 AVISH 39NVHO 03395 HOLOIN H3MO 8 H10 1H8 pe LINOYIO 21 Vd 1095 AvT3H 3ONVHO 03395 HOLOW HO1 1H8 UAIJIGINNH Z
10. V A A94169 Fig 13 Service Label 9 NOTES TROUBLESHOOTING Refer to information label on blower compartment door GUIDE A WARNING for procedure for use of LED status codes and problem solving suggestions LED indicator is viewed through window on blower ELECTRICAL SHOCK HAZARD compartment door If 115 vac power is energized or interrupted during a call for heat the indoor blower will run for 90 sec before a gas heating cycle begins Code 12 E n After replacing any component verify correct operating I LED is flashing rapidly check line voltage polarity PERFORM THIS PROCEDURE sequence If Code 24 is displayed check for blown fuse ONLY QUALIFIED AND TRAINED SERVICE PERSONNEL SHOULD If LED is OFF check line voltage and 24 v transformer START n e If Code 45 is displayed replace control CU 24v should be present across R Yes and C If not check for Turn thermostat OFF r 39 Is indoor blower on __ 1 Open flame rollout switch On furnace control note current No FRS Code 33 settings for setup switches 1 SW 1 le 2 Open limit switch LS and 2 SW 2 then set SW 1 to OFF 24v should be present across C and W If not check for Code 33 SW 2 to ON 1 Open thermostat 3 Check all low voltage wiring 2 Open 24 v fuse FU1 Code 24 connections 3 Faile
11. ame sensor microamps 4 0 nominal 0 5 minimum for control to recognize flame Y Indoor blower motor starts on No 115v should be present at the blower motor If so check capacitor No heating speed after 45 sec gt gt If capacitor is OK replace blower motor If 115v are not present se 45 is warm up period the blower motor check all 115 v wiring to motor payed Yes e f not check for 1 Satisfied thermostat N 2 Open inlet gas pressure switch when used Furnace runs until call for 3 Open pressure switch LPS Code 32 heat ends 4 Open draft safeguard switch DSS Code 32 5 Open auxilliary limit ALS downflow horizontal only Code 32 No Replace control only if Code 45 is ai Yes 6 Open 24 v fuse FU1 Code 24 displayed or if all checks are OK 7 Open limit switch LS Code 13 or 33 Turn thermostat to OFF gas valve No 8 Open flame rollout switch FRS Code 13 or 33 shuts off burners 5 sec inducer 9 Check 115 v line voltage LED off post purge ae S Check for sources of electrical noise interference electronic air Yes cleaners nearby TV or radio antennas No dre tata Aner 3 If inducer and burners continue to operate check for 24v at the i 10 ed gas valve If 24v are present verify that the thermostat is open No Replace control only if Code 45 is across R and W If no voltage is present turn the gas valve displayed or if all checks ar
12. ck for Short circuit in secondary voltage 24V wiring HIGH HEAT PRESSURE SWITCH OR RELAY DID NOT CLOSE OR REOPENED Check for Control relay may be defective Refer to 32 LOW HEAT PRESSURE DRAFT SAFEGUARD OR AUX LIMIT DOWNFLOW ONLY SWITCH DID NOT CLOSE OR REOPENED Check for Proper vent sizing and condensate pitch with side wall vent Low inducer voltage 115v Blower motor and capacitor Defective inducer motor Defective pressure switch Excessive wind Restricted vent Inadequate combustion air supply Disconnected or obstructed pressure tubing LIMIT OR FLAME ROLL OUT FRS SWITCH IS OPEN FRS switch requires manual reset Check for Inadequate combustion air supply FRS switch only Dirty filter or restricted duct system Loose blower wheel Defective switch or connections Blower motor or capacitor failure IGNITION PROVING FAULT Control will retry three times before lockout 14 Check for Oxide buildup on flame proving sensor clean with fine sandpaper Proper flame proving microamps 0 5 minimum Proper control ground continuity Flame proving sensor must be ungrounded Smooth flame carryover and ignition Manual valve s OFF LOW HEAT PRESSURE DRAFT SAFEGUARD OR AUXILIARY LIMIT SWITCH OPEN WHILE HIGH HEAT PRESSURE SWITCH IS CLOSED Check for Disconnected or obstructed pressure tubing Defective pressure switch stuck open Refer to 32 and 33 REPLACE CONTROL 320893 101 RE
13. d g Reinstall filters h Replace blower access door and turn on electrical supply to furnace 2 Upflow Each furnace requires 1 or 2 filters which are installed in the blower compartment See Fig 6 To remove filters for cleaning or replacement proceed as follows a Turn off electrical supply before removing blower and control access doors b Release filter retainer from clip at front of furnace casing See Fig 6 For side return clips may be used on either or both sides of the furnace MOUNTING SCREWS DRAFT y SAFEGUARD A sy SAL RELIEF BOX Eam B PRESSURE Ed SWITCHES LIMIT SWITCH MANUAL RESET LIMIT SWITCH CONTROL a T g FILTER BE RETAINER In A WASHABLE FILTER 93393 Fig 6 Model 330AAV Upflow c Slide filter out d Clean filters by spraying tap water through filter from opposite direction of airflow e Rinse and let dry Oiling or coating of filter is not recommended or required f Place filter in furnace g Replace blower and control access doors and turn on electrical supply to furnace B Blower Motor and Wheel For long life economy and high efficiency clean accumulated dirt and grease from blower wheel and motor annually The following steps should be performed by a qualified service t
14. d transformer N o Cycle 115 v power e If Code 23 is displayed the pressure switch es is stuck closed 3 off for 3 sec then on Replace switch and or check pressure tube for blockage No Replace control if all checks are OK System malfunction Code 21 No 115v should be present at the inducer motor If so replace inducer Continuous LED gt motor If not check 115 v wiring Yes If Code 32 is displayed check for Set thermostat to call for heat 1 Open gas inlet pressure switch when used Set FAN switch to AUTO 2 Open pressure switch LPS and or tube Code 32 3 Open draft safeguard switch DSS Code 32 Y M rei ALS downflow horizontal only Code 32 Replace control only if Code 45 is 7 No Check all low voltage wiring connections displayed or if all checks are OK Draft inducer motor starts gt 115v should be present at the ignitor If so replace the ignitor if not check 115 vac wiring to ignitor Yes r3 No LPS DSS or ALS open while HPS if closed high gas heat only Is Code 22 displayed gt Code 43 Yes i r Control will attempt to light burners 4 times approximately 1 minute Flame present when not normal Y between attempts Code 34 Vo
15. e OK Yes control knob or switch to the OFF position Replace gas valve Heating sequence of operation complete Remove blower door 24v should be present across R and C If not check for move setup switch 1 SW 1 to ON 1 Open limit switch LS Code 13 or 33 position and repeat process to check 2 Open flame rollout switch FRS Code 13 or 33 No Replace control only if Code 45 is high fire operation When finished displayed or if all checks are OK return SW 1 and SW 2 to original 24v should not be present across R and G If so turn thermostat desired settings FAN switch to AUTO A93386 10 SERVICE TRAINING Packaged Service Training programs are an excellent way to increase your knowledge of the equipment discussed in this manual including Unit Familiarization Maintenance Installation Overview Operating Sequence A large selection of product theory and skills programs is available using popular video based formats and materials All include video and or slides plus companion book Classroom Service Training plus hands on the products in our labs can mean increased confidence that really pays dividends in faster troubleshooting fewer callbacks Course descriptions and schedules are in our catalog CALL FOR FREE CATALOG 1 800 962 9212 Packaged Service Training Classroom Service Training A94328 1997 Bryant Heating amp Cooling Systems 7310 W Morris St Indianapol
16. echnician Some motors have prelubricated sealed bearings and require no lubrication These motors can be identified by the absence of oil ports on each end of the motor For those motors with oil ports lubricate as follows Lubricate motor every 5 years if motor is used on intermittent operation thermostat FAN switch in AUTO position or every 2 years if motor is in continuous operation thermostat FAN switch in ON position Remember to disconnect the electrical supply before removing access doors Clean and lubricate as follows 1 Remove blower access door 2 Disconnect vent pipe on downflow horizontal furnace only a Remove vent pipe enclosure b Disconnect vent pipe and remove short piece of pipe from furnace VENT PIPE AUXILIARY ENCLOSURE LIMIT SWITCH CONTROL MOUNTING SCREWS DRAFT SAFEGUARD SWITCH PRESSURE SWITCHES RELIEF BOX MANUAL RESET LIMIT SWITCHES A93394 Fig 7 Model 331AAV Downflow c Disconnect wires from auxiliary limit on blower housing if present 3 Disconnect blower electrical leads from control See Fig 6 and 7 Note location of wires for reassembly 4 Remove control 5 Remove screws holding blower assembly to blower deck and slide blower assembly out of furnace 6 Loosen a screw in strap holding motor capacitor to blower housing and slide capacitor o
17. in control Any 24 v electrical shorts during installation service or maintenance could cause this fuse to blow If fuse replacement is required use ONLY a 3 amp fuse The control will display code 24 when fuse needs replacement The control in this furnace is equipped with an LED status light to aid in installation servicing and troubleshooting It can be viewed through the sight glass or window on blower access door The control indicates status with the LED on continuously rapid flashing or a code composed of 2 digits The first digit is the number of short flashes the second is the number of longs flashes Refer to service label on blower compartment door for code explanations and useful troubleshooting suggestions See Fig 13 It is important to note that power to furnace must not be interrupted and furnace blower door must not be removed until the LED status code es is recorded When power to control is interrupted status memory is erased The control will store up to 5 previous codes but will not store non current code longer than 48 hr To retrieve previous codes if present no thermostat inputs to control must be present and all aut time delays must expire Remove 1 of the red main limit wires 1 to 4 sec until the LED light goes out then reconnect it See Fig 6 and 7 Do not leave red wire disconnected for longer periods of time as control will assume an overtemperature condition exists and will respond with ind
18. is IN 46231 12 Printed in U S A 5 0448 Catalog 5333 002
19. items 5 through 9 If motor has ground wire be sure it is connected as before CAUTION Be sure motor is properly positioned in blower housing The motor oil ports must be at a minimum of 45 above the horizontal centerline of motor after blower assembly has been reinstalled in furnace 15 Reinstall blower assembly in furnace 16 Reinstall control See step c 13 for reassembly of vent pipe and flue enclosure for downflow horizontal furnaces 17 Connect blower electrical leads to control Please note that connections are polarized for assembly DO NOT FORCE C Cleaning Heat Exchanger The following steps should be performed by a qualified service technician NOTE Deposits of soot and carbon indicate the existence of a problem which needs to be corrected Take action to correct the problem If it becomes necessary to clean heat exchanger because of carbon deposits soot etc proceed as follows 1 Turn gas and power to furnace to OFF 2 Remove control and blower access doors 3 Remove vent pipe enclosure on downflow horizontal fur nace only and disconnect vent pipe from relief box 4 Remove 2 screws that secure relief box See Fig 6 or 7 5 Disconnect wires to the following components Mark wires to aid in reconnection of a Draft safeguard switch b Inducer motor c Pressure switch es d Limit overtemperature switch es e Gas valve f Hot surface ignitor g Flame sensing electrode
20. ltage is present at the gas valve for 7 Replace gas valve sec during each ignition trial System will lockout after 4 attempts e Is the gas valve control knob or switch in the OPEN or ON position 24v should be present across the gas valve terminals C and M P and HI for high fire test during the 7 sec ignition trial If 15 sec inducer pre purge not check all low voltage wiring connections to valve Yes If 24v are present and main gas does not flow N 1 Supply pressure gt 13 6 in we rn Replace control only if Code 45 is Ignitor warms up and glows No 2 Replace gas valve displayed or if all checks are OK orange yellow 17 sec warm up e Check ignitor position Yes Check burner carryover gap Main b Check gas supply pressure 4 5 in we minimum 1 gt ain burners ignite Check manifold pressure 1 3 to 1 7 in wc for low fire 3 2 to Y Nas 3 8 in wc for high fire Check for proper orifice size Is Code 31 high gas heat only 32 33 or 34 displayed Check code information label to diagnose Y No Check polarity of 115 v power at J box and control Twinned Replace control if Code 45 is dis Main burners stay on I furnace polarities must match rapid flashing LED No played or if all checks are OK e Check d tinutity f J box t trol Clean flame sensor if microamps Y Yes ground continutity from J box to control aro below orinal Check fl
21. nger Cell 4 Work cable in and out of cell 3 or 4 times to obtain sufficient cleaning DO NOT pull cable with great force Reverse drill and gradually work cable out 5 Remove burner assembly and cell inlet plates NOTE Be very careful when removing burner assembly to avoid breaking ignitor See Fig 9 for correct ignitor location 6 IMPORTANT Replace screws in center panel and cells before cleaning 7 Insert brush end of cable in lower opening of cell and proceed to clean 2 lower passes of cell in same manner as 2 upper passes 555 p 11 30 13 39 um v CELL 8 PANEL Du HOT 10 11 12 13 14 15 16 17 SURFACE IGNITOR ASSEMBLY S om 1 IGNITOR dE 7fg z BURNER i NN IGNITOR ASSEMBLY c 93347 Fig 9 Position of Ignitor to Burner 8 Repeat foregoing procedures until each cell in furnace has been cleaned 9 Using vacuum cleaner remove residue from each cell 10 Using vacuum cleaner with soft brush attachment clean burner assembly 11 Reinstall cell outlet plates and screws FIRST then reinstall cell inlet plates and burner assem bly Care must be exercised to center burners in cell openings After cleaning flue openings check sealant on flue collector
22. oor blower operation This places control in status recall mode and displays first code stored in memory Record code and repeat the disconnect and reconnect of red wire recording each code until code 11 is displayed indicating no additional faults After last code is displayed or after 2 minutes in the code recall mode the control will return to normal standby mode Use any recorded fault codes service label and troubleshooting diagram on following pages to diagnose and correct any problem condition E Troubleshooting Refer to service label See Fig 13 Page 10 contains a trouble shooting guide This guide can be a useful tool in isolating furnace operation problems Beginning with the word Start answer each question and follow the appropriate arrow to the next item The guide will help to identify the problem or failed component After replacing any component verify correct operation sequence 80SZ6V V ASU 101 65 eui Jou y JeueN uoee 61 peeds j009 YBIH pue jeay sed YBIH peedg yea H sed Mo7 JeMo q 614 lt NO ISH peeds ufip peads mo7 eut WN
23. s SERVICE If status code recall is needed do not remove power or blower door LED CODE STATUS CONTINUOUS OFF Check for 115V at L1 and L2 and 24V at SEC1 and SEC2 CONTINUOUS ON Control has 24V power RAPID FLASHING Line voltage polarity reversed If twinned 24V power to one furnace may be out of phase with power to other furnace EACH OF THE FOLLOWING STATUS CODES IS A TWO DIGIT NUMBER WITH THE FIRST DIGIT DETERMINED BY THE NUMBER OF SHORT FLASHES AND THE SECOND DIGIT BY THE NUMBER OF LONG FLASHES NO PREVIOUS CODE Stored status codes are erased when power 115V or 24V to control is interrupted or 48 hours after each fault is cleared BLOWER ON AFTER POWER UP Blower runs for 90 seconds if unit is powered up during a call for heat R W W1 closed Note 2 sec ON delay LIMIT OR FLAME ROLL OUT FRS SWITCH LOCKOUT Auto reset after three hours FRS switch requires manual reset Check for Refer to 33 IGNITION LOCKOUT Control will auto reset after three hours Refer to 34 GAS HEATING LOCKOUT Control will NOT auto reset Check for Mis wired gas valve Defective control valve relay ABNORMAL FLAME PROVING SIGNAL Flame is proved while gas valve is de energized Inducer will run until fault is cleared Check for Leaky gas valve Stuck open gas valve LOW OR HIGH HEAT PRESSURE SWITCH DID NOT OPEN Check for Obstructed pressure tubing Defective pressure switch stuck closed SECONDARY VOLTAGE FUSE IS OPEN Che
24. service and 330AAV maintenance procedures 331AAV 2 SPEED 2 STAGE Series B INDUCED COMBUSTION GAS FIRED FURNACE Cancels SP04 28 SP04 48 9 97 NOTE Read the entire instruction manual before performing any service or maintenance This symbol indicates a change since the last issue Index Page SAFETY CONSIDERATIONS seen 1 2 ELECTROSTATIC DISCHARGE ESD PRECAUTIONS PROCEDURE etae CREDERE 2 CARE AND MAINTENANCE 2 7 Air Filter Arrangement sse 2 3 Blower Motor and Wheel esee 3 4 Cleaning Heat Exchanger eee 4 6 Electrical Controls and Wiring sees 6 7 Fig 1 Model 331AAV Horizontal Troubleshooting eese 7 10 A94087 Unit Wiring Diagram nne 8 Seryice L abel isse RR PROPERE ERAS 9 Troubleshooting Guide esee 10 SAFETY CONSIDERATIONS Installing and servicing heating equipment can be hazardous due to EFFICIENCY ma RATING gas and electrical components Only trained and qualified person CERTIFIED nel should install repair or service heating equipment ama Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters All other operations must be performed by trained service personnel When working on heating equipment observe precautions in the literature tags and
25. the original wire as supplied must be replaced use same type or equivalent wire A97444 Fig 11 Heating and Cooling Application Wiring Diagram for 2 Stage Thermostats and or 2 Speed Condensing Units Check for gas leaks Replace control door WARNING Never use a match or other open flame to check for gas leaks Use a soap and water solution A failure to follow this warning could result in fire personal injury or death D Electrical Controls and Wiring NOTE There may be more than 1 electrical supply to unit Gr The electrical ground and polarity for 115 v wiring must be maintained properly Refer to Fig 10 and 11 for field wiring information and to Fig 12 for unit wiring information If the polarity is NOT correct the furnace control will display code 02 on the status LED and prevent heat operation The control system also requires an earth ground for proper operation of the microproces sor With power disconnected to unit check all electrical connections for tightness Tighten all screws on electrical connections If any smoky or burned connections are noticed disassemble the connec tion clean all parts and stripped wire and reassemble properly and securely Electrical controls are difficult to check without proper instrumentation therefore reconnect electrical power to unit and observe unit through 1 complete operating cycle The 24 v circuit contains an automotive type 3 amp fuse located on the ma
26. to ensure that it has not been damaged If new sealant is needed contact your dealer or distributor Clean and replace flue collector assembly making sure all 8 screws are secure Reinstall relief box Reconnect wires to the following components a Draft safeguard switch b Inducer motor Pressure switches a Limit overtemperature switch es Gas valve Hot surface ignitor Flame sensing electrode mh Wiring connectors leading to control Reconnect vent pipe to relief box When applicable replace vent pipe enclosure Replace blower door only Turn power and gas to ON Set thermostat and check furnace for proper operation Verify blower airflow and speed changes between heating and cooling 18 19 FIELD 24 VOLT WIRING FIELD 115 208 230 460 VOLT WIRING FACTORY 24 VOLT WIRING FACTORY 115 VOLT WIRING 1 STAGE THERMOSTAT TERMINALS FIVE M O OOO FIELD SUPPLIED WIRE FUSED DISCONNECT TWO WIRE EN __ Sas HEATING B 9 208 230 OR ONLY e i460 VOLT 5 DUM eT pot tk V H 2 nae WB e ______ war _______ TUE al e RT XU n l e e 7 208 230 d X ale VOLT GND ot Mee L 4 431 4 4e1 e SINGLE 115 VOLT FUSED JUNCTION m E
27. ut from under strap 7 Mark blower wheel motor and motor support in relation to blower housing before disassembly to ensure proper reas sembly 8 Loosen setscrew s holding blower wheel on motor shaft 9 Remove bolts holding motor and motor mount to blower housing and slide motor and mount out of housing Discon nect ground wire attached to blower housing before remov ing motor 10 Lubricate motor when oil ports are provided a Remove dust caps or plugs from oil ports located at each end of motor b Use a good grade of SAE 20 nondetergent motor oil and put 1 teaspoon 5 cc 3 16 oz or 16 to 25 drops in each oil port Do not over oil c Allow time for total quantity of oil to be absorbed into each bearing d After oiling motor be sure to wipe excess oil from motor housing e Replace dust cap or plugs on oil ports 11 Remove blower wheel from housing a Mark cutoff location to ensure proper reassembly b Remove screws holding cutoff plate and remove cutoff plate from housing c Lift blower wheel from housing through opening 12 Clean blower wheel and motor using a vacuum with soft brush attachment Do not remove or disturb balance weights clips on blower wheel blades The blower wheel should not be dropped or bent as balance will be affected 13 Reinstall blower wheel by reversing items 11 a through c Be sure wheel is positioned for proper rotation 14 Reassemble motor and blower by reversing
28. y of a maintenance contract WARNING Turn off gas and electrical supplies to unit before performing any maintenance or service on it A Follow operating instructions on label attached to fur nace A failure to follow this warning could result in personal injury The minimum maintenance that should be performed on this equipment is as follows 1 Check and clean air filter each month or more frequently if required Replace if torn 2 Check blower motor and wheel for cleanliness each heating and cooling season Clean and lubricate as necessary 3 Check electrical connections for tightness and controls for proper operation each heating season Service as necessary CAUTION As with any mechanical equipment per A sonal injury can result from sharp metal edges etc therefore be careful when removing parts A Air Filter Arrangement The air filter arrangement may vary depending on application Refer to Table 1 or 2 for filter size information TABLE 1 DOWNFLOW HORIZONTAL FILTER SIZE INFORMATION IN FILTER SIZE 2 14 X 20 X 1 2 14 X 20 X 1 2 16 X 20 X 1 2 16 X 20 X 1 FURNACE CASING WIDTH FILTER TYPE Cleanable Cleanable Cleanable Cleanable TABLE 2 UPFLOW FILTER SIZE INFORMATION IN FURNACE FILTER SIZE FILTER CASING WIDTH Side Return Bottom Return TYPE 14 3 16 1 16 X25 X t 1 16 X25 X t 1 14 X25 X 1 1 16 X 25 X1
29. you do not possess these do not attempt to perform any maintenance on this equipment other than those procedures recom mended in the User s Manual A FAILURE TO FOL LOW THIS WARNING COULD RESULT IN POS SIBLE DAMAGE TO THIS EQUIPMENT SERIOUS PERSONAL INJURY OR DEATH WARNING Never store anything on near or in contact with furnace such as 1 Spray or aerosol cans rags brooms dust mops vacuum cleaners or other cleaning tools 2 Soap powders bleaches waxes or other cleaning compounds plastic or plastic containers gasoline kero sene cigarette lighter fluid dry cleaning fluids or other volatile fluids 3 Paint thinners and other painting compounds paper bags or other paper products A failure to follow this warning could result in corrosion of the heat exchanger fire personal injury or death ELECTROSTATIC DISCHARGE ESD PRECAUTIONS PROCEDURE CAUTION Electrostatic discharge can affect electronic components Take precautions during furnace installation and servicing to protect the furnace electronic control Precautions will prevent electrostatic discharges from personnel and hand tools which are held during the procedure These precautions will help to avoid exposing the control to electrostatic discharge by putting the furnace the control and the person at the same electro static potential 1 Disconnect all power to the furnace DO NOT TOUCH THE CONTROL OR ANY WIRE CONNECTED TO THE CONTROL
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