Bryant A93040 User's Manual
Contents
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4. F or lower freeze protection measures must be taken Insert funnel in drain tube and pour antifreeze propylene glycol RV swimming pool antifreeze or equivalent into furnace until it is visible at point where condensate enters open drain See Fig 14 Reconnect drain tube to inducer housing Replace main furnace door CAUTION Do not use ethylene glycol Prestone II antifreeze coolant or equivalent automotive type Failure of plastic components will occur A94208 Fig 13 Inducer Housing Drain Tube NIBA prouajos yeay Yon S jusuwisnipe indu seb yeay plays ywi Jo pue ywi 10 40 Y90949 sdiu WWI yeay SAISSIDINS OM 0 ANP JUO si yun y Jo uedo si 10 yojims Pu 94 SOPU LINW4HOLIMS LINT SOUOIIMS 4 JO palle yojims ainssaud Jo yms aunsseld adid Ajqissod Buidid Juan ayesuapuod 140 0949 suado Jo eo 134e QO 0 S IBJ 10 Je S Yms SINSSSIA SAJEIPU LINYA HOLIMS JUNSSIHA MOT sayolims SINSSAIA HONEIAIIEI J0 INO JO palle yams aunssaud Jo
5. Fig 11 Field Wiring The 24 v circuit contains an automotive type 3 amp fuse located on the control center See Fig 12 Any direct shorts of the 24 v wiring during installation service or maintenance will cause this fuse to blow If fuse replacement is required use ONLY a fuse of identical size With power to the unit disconnected check all electrical connec tions for tightness Tighten all screws on electrical connections If any smoky or burned connections are found disassemble the connection clean all parts strip wire and reassemble properly and securely Reconnect electrical supply to unit and observe unit through 1 complete operating cycle Electrical controls are difficult to check without proper instrumentation if there are any discrepancies in the operating cycle contact your dealer and request service Vill TROUBLESHOOTING For an explanation of fault codes refer to service label located on back of main furnace door or Fig 15 The control center stores all fault codes for a period of 5 good or proper operating cycles regardless of 115 or 24 v power interruption NOTE Removing blower access panel opens blower access panel door switch and terminates 115 v power to control center Look into blower access panel sight glass for current LED status 1 To retrieve fault code proceed with the following NOTE NO thermostat signal may be present at control center and all blower time delay off periods must be co
6. POEUN SAJBA SED 10 2995 sIN990 y 1N0Y00 sawi 93144 04909 LINYA ONIAOUd bb er cv bY ve A98305 gt Fig 16 Wiring Diagram SERVICE TRAINING Packaged Service Training programs are an excellent way to increase your knowledge of the equipment discussed in this manual including e 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 15 1998 Bryant Heating amp Cooling Systems 7310 W Morris St Indianapolis IN 46231 16 Printed in U S A sp0539 Catalog No 5335 505
7. on heating equipment observe precautions in the literature on tags and on labels attached to or shipped with the unit and other safety precautions that may apply Follow all safety codes including NFPA 54 ANSI Z223 1 1996 National Fuel Gas Code and ANSI NFPA 90B Installation Stan dards Warm Air Heating and Air Conditioning Systems In Canada refer to the current edition of the National Standard of Canada CAN CGA B 149 Wear safety glasses and work gloves Have a fire extinguisher available during start up and adjustment procedures and service calls EFFICIENCY RATING CERTIFIED ama APPROVED R As an ENERGY STARSM Partner Bryant Heating amp Cooling Systems has deter mined that this product meets the ENERGY STAR guide lines for energy efficiency Recognize safety information This is the safety alert symbol A 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 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 hazards 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 NOTE is used to highlight suggestions which will result in
8. 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 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 GENERAL These instructions are written as if the furnace is installed in
9. A93040 NOTE Read the entire instruction manual before performing any service or maintenance This symbol gt indicates a change since the last issue Index Page SAFETY 1 2 ELECTROSTATIC DISCHARGE ESD PRECAUTIONS 2 GENERA Luo essen CARE AND MAINTENANCE Cleaning and or Replacing Air 1 Blower Motor and Wheel Cleaning B rmeis ea ee Cleaning Heat Exchangers s0sesesesesenenenenenenaneneananananenen Primary Heat Exchangers Secondary Heat Exchangers Flushing Collector Box and Drainage System Servicing Hot Surface Ignitor neeseseesenenenesnennnenennn Electrical Controls and Wiring nesenesennesenneneeneneenennenn Troubleshooting eeesnennnnn Checking Heat Tape Operation If Applicable WiAnteri costosos a SERVICE LABEL Essens WIRING DIAGRAM unnuesensesesnenensennenennenenenonenensenenennenenan SAFETY CONSIDERATIONS Installing and servicing heating equipment can be hazardous due to gas and electrical components Only trained and qualified person nel should install repair or service heating equipment 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
10. OLET COLLECTOR BOX COLLECTOR BOX EXTENSION TUBE PLUG COLLECTOR BOX TUBE PINK Tube location when used on HORIZONTAL LEFT application AUXILIARY J BOX RELOCATED HERE COLLECTOR BOX DRAIN TUBE BLUE amp WHITE STRIPED PLUG COLLECTOR BOX EXTENSION TUBE COLLECTOR BOX TUBE GREEN INDUCER COLLECTOR BOX EXTENSION DRAIN TUBE COUPLING COLLECTOR BOX TUBE PINK RELOCATE TUBE HOUSING DRAIN TUBE VIOLET DRAIN TUBE BLUE BETWEEN BLOWER SHELF AND INDUCER HOUSING FOR NOTE 040 060 AND 080 HEATING INPUT FURNACES DRAIN TUBE COUPLING RIGHT DRAIN OPTION DRAIN TUBE BLUE COLLECTOR BOX LEVEL 0 1 2 MAX 1 UPFLOW OR DOWNFLOW COLLECTOR BOX TUBE PINK COLLECTOR BOX TUBE GREEN COLLECTOR BOX DRAIN TUBE BLUE CONDENSATE gt TRAP INDUCER HOUSING DRAIN TUBE VIOLET INSTALLATION LEVEL 0 1 2 MAX FRONT VA HORIZONTAL Condensate Trap on LEFT Side Optional COLLECTOR BOX DRAIN TUBE BLUE amp WHITE STRIPED COLLECTOR BOX TUBE GREEN COLLECTOR BOX DRAIN TUBE BLUE STRIPE INDUCE HOUSING D TUBE VIOLI DRAIN Ti COUPLING DRAIN TUBES ROUTED IN OF GAS VALVE CAP COLLECTOR BOX DRAIN TUBE BLUE COLLECTOR BOX TUBE PINK PLUG COLLECTOR BOX EXTENSION TUBE THY CONDENSATE COLLECTOR B
11. OPERATION IF APPLICABLE In applications where the ambient temperature around the furnace is 32 F or lower freeze protection measures are required If this application is where heat tape has been applied check to ensure it will operate when low temperatures are present NOTE Heat tape when used should be wrapped around the condensate drain trap and drain line There is no need to use heat tape within the furnace casing Most heat tapes are temperature activated and it is not practical to verify the actual heating of the tape Check the following 1 Check for signs of physical damage to heat tape such as nicks cuts abrasions gnawing by animals etc 2 Check for discolored heat tape insulation If any damage or discolored insulation is evident replace heat tape 3 Check that heat tape power supply circuit is on X WINTERIZING A CAUTION Freezing condensate left in the furnace will damage the equipment If the furnace will be off for an extended period of time in a structure where the temperature will drop to 32 F or below winterize as follows 1 Turn off electrical supply to furnace 2 Remove main furnace door 3 Disconnect drain tube from inducer housing See Fig 13 10 32 F MINIMUM INSTALLED AMBIENT OR FREEZE PROTECTION REQUIRED vi ATM A93058 CAUTION If this furnace is installed in an uncondi tioned space where the ambient temperatures may be 32
12. OX EXTENSION DRAIN TUBE Tube location when used on HORIZONTAL RIGHT application COLLECTOR BOX DRAIN TUBE BLUE COLLECTOR BOX TUBE PINK COLLECTOR BOX TUBE GREEN COLLECTOR BOX DRAIN TUBE BLUE AND WHITE STRIPED COLLECTOR BOX EXTENSION TUBE CONDENSATE TRAP INDUCER HOUSING DRAIN TUBE VIOLET 1 All tubing must be connected securely and routed to avoid kinks and traps 2 Pressure tubing must always slope away from pressure switch to collector box connection as shown 3 HORIZONTAL LEFT installations require the collector box pressure tube to be relocated between the inducer housing and the blower shelf to prevent a trap Refer to the Installation Instructions for further details EE Fig 8 Furnace Pressure and Drain Tubing Diagram 322094 101 REV B A94212 12 13 14 15 16 A89020 Fig 9 Burner Flame Reconnect pressure tubes to pressure switches See diagram on main furnace door for proper location of tubes Be sure tubes are not kinked See Fig 8 Turn on gas and electrical supplies to furnace Check furnace operation through 2 complete heat operating cycles Check area below inducer housing vent pipe and condensate trap to ensure no condensate leaks occur If leaks are found correct the problem Check for gas leaks WARNING Never use matches candles flame or other sources of ignition to check for gas leakage Use a soap and water s
13. an upflow application An upflow furnace application is where the blower is located below the combustion and controls section of the furnace and conditioned air is discharged upward Since this furnace can be installed in any of the 4 positions shown in Fig 2 you must revise your orientation to component location accord ingly CARE AND MAINTENANCE For continuing high performance and to minimize possible equip ment failure it is essential that maintenance be performed annually on this equipment Consult your local dealer for maintenance and maintenance contract availability AIRFLOW gt UPFLOW HORIZONTAL HORIZONTAL RIGHT DOWNFLOW AIRFLOW AIRFLOW AIRFLOW A93041 Fig 2 Multipoise Orientations WARNING Turn off the gas and electrical supplies to the unit before performing any maintenance or service AA Follow the operating instructions on the label attached to the furnace Failure to follow this warning could result in personal injury or death The minimum maintenance that should be performed on this equipment is as follows 1 Check and clean or replace air filter each month as required 2 Check blower motor and wheel for cleanliness annually 3 Check electrical connections for tightness and controls for proper operation each heating season Service as necessary A Check for proper condensate drainage Clean as necessary 5 Check for blockages in combustion air and vent pipes annuall
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16. enhanced installation reliability or operation WARNING The ability to properly perform mainte nance on this equipment requires certain expertise me chanical skills tools and equipment If 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 FAILURE TO FOLLOW THIS WARNING COULD RESULT IN POSSIBLE DAMAGE TO THIS EQUIPMENT SERIOUS PER SONAL INJURY OR DEATH WARNING Never store anything on near or in contact with the 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 kerosene cigarette lighter fluid dry cleaning fluids or other volatile fluids Paint thinners and other painting compounds paper bags or other paper products Failure to follow this warning can cause corrosion of the heat exchanger fire personal injury or death ELECTROSTATIC DISCHARGE ESD PRECAUTIONS 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 A personnel and hand tools which are held during the procedure These precautions will help to avoid exposing the control to electrostatic discharge by putting
17. er wheel remove wheel from the blower housing and wash it with an appropriate degreaser To remove wheel pat aa WASHABLE FILTER Se FILTER RETAINER A93045 Fig 4 Filter Installed for Side Inlet a Mark blower wheel location on shaft before disassembly to ensure proper reassembly b Loosen setscrew holding blower wheel on motor shaft NOTE Mark blower mounting arms and blower housing so each arm is positioned at the same hole location during reassembly c Mark blower wheel orientation and cutoff plate location to ensure proper reassembly d Remove screws securing cutoff plate and remove cutoff plate from housing e Remove bolts holding motor mounts to blower housing and slide motor and mounts out of housing f Remove blower wheel from housing g Clean wheel per instructions on degreaser cleaner 9 Reassemble motor and blower wheel by reversing items 8b through 8f Ensure wheel is positioned for proper rotation 10 Reinstall blower assembly in furnace 11 Reinstall condensate trap and tubing if previously removed a Reinstall condensate trap in hole in blower shelf b Connect condensate trap drain tubes See Fig 8 or tubing diagram on main furnace door for proper tube location 1 Connect 1 tube blue or blue and white striped from collector box 2 Connect 1 tube violet or unmarked from inducer housing 3 Connect 1 tube relief port green or pink from collector b
18. he Clean Up Procedure a Leave 115 v power to furnace turned on Remove main furnace door Look into blower access panel sight glass for current LED status Remove blower access panel Turn setup switch SW 1 to ON position See Fig 12 or 16 for location Jumper thermostat terminals R W and Y on control center EAC ELECTRONIC AIR CLEANER TERMINALS 115 VAC 1 AMP MAX HOT SURFACE IGNITOR CONNECTOR O Ba ooooo0oo000000 1 MAIN BLOWER CONTROL WIRE CONNECTOR 00000 ES IA ES FAN CF SETUP SWITCHES TRANSFORMER 24 V CONNECTORS 115 V CONNECTORS 11 ooo i T PRESSURE SWITCH a CONNECTOR gt HUM HUMIDIFIER o TERMINAL AK 24 VAC 0 5 AMP MAX 12 Lo24 V THERMOSTAT TERMINALS Sz Ba DEHUMIDIFY ENABLE DE g WHEN PROVIDED E AS 14 J DEHUMIDIFIER DEHUM F417 CONNECTOR Samp FUSE STATUS AND DIAGNOSTIC LED LIGHTS AIR CONDITIONING 1 CI A C SETUP SWITCH SETUP SWITCHES SW AND BLOWER OFF DELAY SETUP SWITCHES Lee aaa CONNECTOR MODEL PLUG A98296 gt Fig 12 Variable Capacity Contro
19. ilure to follow this warning could result in personal injury or death b When items 1 through 5 above have been completed the following will occur 1 The control center goes through a brief self test This self test takes approximately 2 sec to complete After door switch is closed red microprocessor LED briefly comes on Then green LED comes on for 1 sec followed by 1 sec where both the green and yellow LEDs are on During this time the control is checking itself 2 Inducer motor operates for 20 sec at low speed operates for 20 sec at high speed then turns off 3 Hot surface ignitor is energized for 15 sec then de energized 4 Main blower motor operates for 20 sec at low speed operates at high speed for 20 sec then turns off 5 After component operation test is completed 1 or more fault codes 11 22 41 or 42 will flash See service label on back of main furnace door or Fig 15 for explanation of codes NOTE To repeat component test turn setup switch SW 6 to OFF and then back to ON 9 After component test perform the following 1 Release blower access panel door switch and turn setup switch SW 6 to OFF position 2 Replace blower access panel 3 Operate furnace through 1 heat cycle to check for proper operation and check LED status 4 If furnace is operating properly and LEDs indicate proper operation replace main furnace door IX CHECKING HEAT TAPE
20. itor After a period of operation a white area will be visible around the crack c If replacement is required replace ignitor on ignitor bracket external to furnace to avoid damage as the silicon portion is very brittle and will easily crack or shatter d To remove ignitor from ignitor bracket remove screw holding ignitor ceramic block to bracket and pull ce ramic block out of bracket 6 To replace ignitor ignitor assembly reverse items 5a through 5d 7 Reconnect ignitor wire connection Turn on gas and electrical supplies to furnace 9 Verify ignitor operation by initiating control board self test feature or by cycling thermostat 10 Replace main furnace door Vil ELECTRICAL CONTROLS AND WIRING CAUTION There may be more than 1 electrical supply to the unit Check accessories and cooling unit for additional electrical supplies The electrical ground and polarity for 115 v wiring must be maintained properly Refer to Fig 11 for field wiring information and to Fig 16 for unit wiring information NOTE If the polarity is not correct the STATUS LED on the control center will flash rapidly and prevent the furnace from operating The control system also requires an earth ground for proper operation of the control center and flame sensing H ae A98325 gt
21. l Center g Manually close blower access panel door switch Use a piece of tape to hold switch closed WARNING Blower access panel door switch opens 115 v power to control center No component operation can occur Caution must be taken when manually closing this switch for service purposes Failure to follow this warning could result in personal injury or death h After fault code 11 flashes for at least 2 times remove R W and Y jumpers i Turn setup switch SW 1 to OFF position j Release blower access panel door switch and replace blower access panel k Operate furnace through 1 heat cycle to check for proper operation and check LED status 1 If furnace is operating properly and LEDs indicate proper operation replace main furnace door The control can also assist in troubleshooting by performing a Component Test The Component Test will functionally operate all furnace components except the gas valve a To initiate Component Test proceed with the following 1 Leave 115 v power to furnace turned on 2 Remove main furnace door 3 Remove blower access panel 4 Turn setup switch SW 6 to ON position 5 Manually close blower access panel door switch Use a piece of tape to hold switch closed WARNING Blower access panel door switch opens 115 v power to control center No component operation A occur Caution must be taken when manually closing this switch for service purposes Fa
22. l supplies to furnace 18 Check for gas leaks WARNING Never use matches candles flame or other sources of ignition to check for gas leakage Use a soap and water solution Failure to follow this warning could result in a fire personal injury or death 19 Replace main furnace door IV CLEANING HEAT EXCHANGERS The following items should be performed by a qualified service technician A Primary Heat Exchangers If the heat exchangers get an accumulation of light dirt or dust on the inside they may be cleaned by the following procedure NOTE If the heat exchangers get a heavy accumulation of soot and carbon both the primary and secondary heat exchangers should be replaced rather than trying to clean them thoroughly due to their intricate design A build up of soot and carbon indicates that a problem exists which needs to be corrected such as improper adjustment of manifold pressure insufficient or poor quality combustion air improper vent termination incorrect size or damaged manifold orifice s improper gas or a restricted heat exchanger primary or secondary Action must be taken to correct the problem 1 Turn off gas and electrical supplies to furnace 2 Remove main furnace door CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and hazardous operation 3 Disconnect wires or connectors to rollout switch gas valve ignitor and flame senso
23. mpleted a Leave 115 v power to furnace turned on b Remove main furnace door c Look into blower access panel sight glass for current LED status d Remove blower access panel e Turn setup switch SW 1 to ON position See Fig 12 or 16 for location f Manually close blower access panel door switch Use a piece of tape to hold switch closed WARNING Blower access panel door switch opens 115 v power to control center No component operation can occur Caution must be taken when manually closing this switch for service purposes Failure to follow this warning could result in personal injury or death LEDs display last fault code to occur first followed by any other fault that has occurred in the last 5 good or proper cycles The remaining faults displayed will be in numerical order starting from the lowest number first Only 1 of each fault code will be displayed regardless of how many times the fault has occurred Fault code display will continue and repeat as described above or until setup switch SW 1 is turned off Release blower access panel door switch and replace blower access panel Operate furnace through 1 heat cycle to test for proper operation and check LED status k If furnace is operating properly and LEDs indicate proper operation replace main furnace door 2 Fault code display can be removed from control s display mode by performing the following This is also called t
24. olution Failure to follow this warning could result in a fire personal injury or death Replace main furnace door VI SERVICING HOT SURFACE IGNITOR The ignitor does NOT require annual inspection Check ignitor resistance before removal 1 Turn off gas and electrical supplies to furnace 2 Remove main furnace door 3 Disconnect ignitor wire connection 4 Check ignitor resistance a Using an ohm meter check resistance across both ignitor leads in connector b Cold reading should be between 45 ohms and 90 ohms c If ohm reading is higher than 110 ohms ignitor is cracked and must be replaced 5 Remove ignitor assembly A CAUTION Allow ignitor to cool before removal Nor mal operation temperatures exceed 2000 F a Do not remove ignitor from bracket while assembly is in furnace Using a 1 4 in nutdriver remove screw secur ing bracket and ignitor assembly to bottom of burner box The screw in the bracket is always located toward outside of burner box The screw may be hidden by inlet box or inlet pipe but can be removed without removing either After removing screw slide ignitor and bracket toward outside of burner box and pull straight out CAUTION The ignitor is fragile DO NOT allow it to hit the side of the burner box opening while removing or replacing it b Inspect ignitor for a white area indicating a crack may be present If found replace ignitor NOTE A small crack cannot be seen on a new ign
25. ox c Connect field drain to condensate trap NOTE Ensure tubes are not kinked or pinched as this will affect operation 12 Reinstall control box transformer and door switch assem bly on blower shelf 13 Reconnect wires a Refer to furnace wiring diagram and connect motor and auxiliary limit switch leads See Fig 16 b Connect thermostat leads if previously disconnected 14 Turn on electrical supply Manually close blower access panel door switch Use a piece of tape to hold switch closed Check for proper rotation and speed changes between heating and cooling by jumpering R to G and R to Y on control center thermostat terminals See Fig 11 WARNING Blower access panel door switch opens 115 v power to control center No component operation can occur Caution must be taken when manually closing this switch for service purposes Failure to follow this warning could result in personal injury or death 15 If furnace is operating properly release blower access panel door switch replace blower access panel and replace main furnace door CLEANING BURNERS The following items should be performed by a qualified service technician If the burners develop an accumulation of light dirt or dust they may be cleaned by using the following procedure 1 Turn off gas and electrical supplies to furnace 2 Remove main furnace door 3 Remove burner box cover 4 Using backup wrench disconnect gas supply pipe from ga
26. r 4 Disconnect combustion air intake pipe from intake housing 5 Remove the pressure switch tube from intake housing 6 Remove screws attaching intake housing to burner box and rotate intake housing away from burner box for removal 7 Using backup wrench disconnect gas supply pipe from gas valve 8 Disconnect pressure tubing from gas valve 9 Remove 2 screws attaching top filler panel and rotate upwards to gain access to screws attaching burner box to cell panel 10 Remove screws attaching burner box to cell panel See Fig 5 NOTE Burner box cover manifold gas valve and burner assembly should be removed as 1 assembly 11 Clean heat exchanger openings with a vacuum and a soft brush See Fig 6 NOTE After cleaning inspect the heat exchangers to ensure they are free of all foreign objects that may restrict flow of combustion products 12 Reverse items 4 through 10 for reassembly WARNING The ground wire from the gas valve MUST be attached to the burner box attachment screw Failure to attach this ground wire to an adequate casing ground will cause the furnace control to lock out NOTE Be sure burner box gasket is installed between burner box and cell panel If gasket is damaged replace it NOTE Inspect combustion air intake housing If foamed gasket was removed check for any damage If gasket is damaged in any way it must be repaired To repair remove damaged gasket section apply sealant
27. releasing agent such as PAM cooking spray or equivalent must not contain corn or canola oil aromatic or halogenated hydrocarbons or inadequate seal may occur to burner This appliance requires a special venting system Refer to the installation instructions for parts list and method of installation Furnace must be installed level or pitched forward within 1 2 inch of level for proper drainage Failure will result in equipment or property damage See Installation Manual for IMPORTANT unit support details on horizontal applications Furnace is shipped from factory in upflow configuration Pressure tube and drain tube routing MUST match the diagrams below Condensate Trap Factory Installed in Blower Shelf Blower access panel removed COLLECTOR BOX TUBE PINK COLLECTOR BOX TUBE GREEN INDUCER HOUSING MOLDED DRAIN TUBE BEHIND LLECTOR BOX DRAIN TUBE COLLECTOR BOX DRAIN TUBE BLUE FIELD INSTALLED FACTORY SUPPLIED UBE COUPLING DRAIN OPTION ELD INSTALLED FACTORY SUPPLIED DRAIN TUBE PLUG COLLECTOR BOX DRAIN TUBE BLUE amp WHITE STRIPED CONDENSATE TRAP FIELD INSTALLED FACTORY SUPPLIED FIELD INSTALLED FACTORY SUPPLIED 1 2 IN CPVC STREET ELBOWS 2 FOR LEFT DRAIN OPTION COLLECTOR BOX TUBE GREEN COLLECTOR BOX DRAIN TUBE BLUE amp WHITE STRIPED COLLECTOR BOX EXTENSION TUBE CONDENSATE TI INDUCER HOUSING DRAIN TUBE VI
28. s valve CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation 5 Remove wires from gas valve Note location for reassem bly 6 Remove burner box pressure tube from gas valve regulator fitting 7 Remove screws that secure manifold to burner box See Fig 5 EX Ta A96304 Fig 5 Burner Box Assembly 8 Remove manifold orifices and gas valve as 1 assembly 9 Remove screws attaching burner assembly in burner box 10 Remove burner assembly from burner box NOTE All burners are attached to burner bracket and can be removed as 1 assembly 11 Clean burners with soft brush and vacuum 12 Reinstall manifold orifice and gas valve assembly in burner box Ensure manifold seal grommet is installed properly and burners fit over orifices 13 Reconnect wires to gas valve Refer to furnace wiring diagram for proper wire location 14 Reinstall burner box pressure tube to gas valve regulator fitting 15 Reinstall gas supply pipe to gas valve using backup wrench on gas valve to prevent rotation and improper orientation NOTE Use propane gas resistant pipe dope to prevent gas leaks DO NOT use Teflon tape WARNING Gas valve knob or switch MUST be facing forward or tilted upward Failure to follow this warning could result in property damage personal injury or death 16 Replace burner box cover 17 Turn on gas and electrica
29. y 6 Check burners for cleanliness annually A CAUTION Personal injury could result from sharp metal edges etc Use care when removing parts I CLEANING AND OR REPLACING AIR FILTER The air filter arrangement may vary depending on the application or orientation CAUTION Never operate unit without a filter or with A the blower access panel removed Failure to follow this warning could result in a fire or personal injury To clean or replace the filters proceed as follows 1 Turn off electrical supply to furnace 2 Remove main furnace door and blower access panel 3 Release filter retainer wire See Fig 3 and 4 4 Slide filter out of furnace 5 Furnaces are equipped with permanent washable filter s Clean filter by spraying cold tap water through filter in opposite direction of airflow 6 Rinse filter and let dry Oiling or coating of filter is not recommended 7 Slide filter into furnace WASHABLE del 8 9 10 FILTER RETAINER FILTER SUPPORT A93046 Fig 3 Bottom Filter Arrangement Recapture filter retainer wire Replace blower access panel and main furnace door Turn on electrical supply to furnace NOTE If the filter has cross mesh binding the binding must face the blower If the filter has an air direction arrow the arrow must point toward the blower BLOWER MOTOR AND WHEEL MAINTENANCE To ensure long life economy and high efficienc
30. y clean accumu lated dirt and grease from blower wheel and motor annually The inducer and blower motors are pre lubricated and require no additional lubrication These motors can be identified by the absence of oil ports on each end of the motor The following items should be performed by a qualified service technician Clean blower motor and wheel as follows 1 2 Turn off electrical supply to furnace Remove main furnace door and blower access panel Disconnect wires a Disconnect motor wiring harness plug on blower hous ing b Disconnect auxiliary limit switch leads at switch c Disconnect field thermostat connections depending on their length and routing Position control box transformer and door switch assembly to right side of furnace casing If condensate trap is located in left or right hand side of furnace casing proceed to item 6 otherwise remove trap and tubing as described below a Disconnect field drain connection from condensate trap b Disconnect drain and relief port tubes from condensate trap c Remove condensate trap from blower shelf Remove screws securing blower assembly to blower shelf and slide blower assembly out of furnace Clean blower wheel and motor by using a vacuum with soft brush attachment Be careful not to disturb balance weights clips on blower wheel vanes Do not bend wheel or blades as balance will be affected If greasy residue is present on blow
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