Bryant 393AAV User's Manual
Contents
1. ADJUSTMENT SWITCH sien i yer Tol e 24V THERMOSTAT ISI TERMINALS _ IBIR S Y S w TESTTWIN Sf Cow HUMIDIFIER TERMINAL SL av 24 VAC 0 5 AMP MAX E gt LSI hum 5 LED OPERATION amp STATUS LIGHT O HARNESS CONNECTOR UO OW SEC 1 QO I a OOO LA 24V TRANSFORMER SEC 2 3 AMP FUSE Ni ene COOL HEAT oe BLOWER SPEED i SELECTION TERMINALS o l a il SPARE 2 te I I d EAC 1 BLACK 115 VAC L1 4 POWER SUPPLY EAC ELECTRONIC AIR CLEANER TERMINALS 115 VAC 1 0 AMP MAX EAC 2 WHITE 115 VAC L2 NEUTRAL CONNECTION HOT SURFACE IGNITER CONNECTOR INDUCER MOTOR CONNECTOR A99258 Fig 6 Furnace Control The 24 v circuit contains an automotive type 3 amp fuse located on the control See Fig 6 Any 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 3 amp fuse The control LED will display status code 24 when fuse needs to be replaced 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 power to the unit and observe unit throug2. Present Blue Red Medium Low Low Common L2 COM CAUTION Heating air speed selection MUST be ad A justed to provide proper temperature rise as specified on the rating plate Failure to adjust the heating speed may shorten heat exchanger life 13 Turn on electrical supply Manually close blower access 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 W and then R to Y on furnace control thermostat terminals WARNING Blower access 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 warn ing could result in electrical shock personal injury or death NOTE If thermostat terminals are jumpered before blower ac cess door switch is closed blower will run for 90 sec before beginning a heating or cooling cycle 14 If furnace is operating properly REMOVE TAPE TO RELEASE BLOWER ACCESS DOOR SWITCH replace blower access door lil CLEANING HEAT EXCHANGER The following steps should be performed by a qualified service technician NOTE If the heat exchangers get a heavy accumulation of soot and carbon they 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
3. 24VAC HSI HOT SURFACE IGNITOR 115 VAC FIELD WIRING 115VAC HSIR HOT SURFACE IGNITOR RELAY SPST N O FIELD WIRING 24VAC HUM 24VAC HUMIDIFIER CONNECTION 5 AMP MAX IDM INDUCED DRAFT MOTOR zo CONDUCTOR ON PCB IDR INDUCED DRAFT RELAY SPST N O M FIELD WIRING TERMINAL ILK BLOWER ACCESS PANEL INTERLOCK SWITCH SPST N O FIELD GROUND JB JUNCTION BOX LED LIGHT EMITTING DIODE FOR STATUS CODES EQUIPMENT GROUND LGPS LOW GAS PRESSURE SWITCH SPST N O FIELD SPLICE LS LIMIT SWITCH AUTO RESET SPST N C 34 PLUG RECEPTACLE OL AUTO RESET INTERNAL MOTOR OVERLOAD TEMP SW Fig 7 Unit Wiring Diagram TO 115VAC FIELD DISCONNECT ILKI TESTIWN FUI NOTE 6 it PF 1 SEC2 Ss FRS2 NOTE 12 gt HUM z o x el WHEN USED I 4 1 NOTE 1 e os R 5 NOTE 13 NOTE 13 EF L w ie WHEN USED l NOTES CONOAR N gt ey 4 Gas valve leads are interchangeable on single stage valves SCHEMATIC DIAGRAM Li L2 NATURAL GAS amp PROPANE 7H EQUIPMENT GROUND L1 TD 2l NOT USED WHEN USED GV Y NOTE 5 G p FSE 6 a aea If any of the original equipment wire is replaced use wire rated for 105 C Inducer IDM and blower BLWM moto
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5. oeuunj 10 ysomjonp 0 Buoys spea e soway Bulpnjou Buum a6eyor mo u HOUS 10 X09949 N3dO SI 3SNA ADVLIOA MO1 yams ainssaid eAoajeq Bujiqni ainsseid palonijsqo 10 payoeuuogsiq 40 49949 N3dO LON TIIM HOLIMS a3unssatud J9 U9O onuoo BANDBJOq yea 10 piou os aajen seb uado y9ns 10 Y99049 paea si ynez mun unu IIA 130Npu pezi61eue ap sem NLA seb JIUA p su s sem owe TYN IS SNIAOHd 3IWV14 TVWHON8V SJM aAleA Seb 0 LOYS 10 IMSIN 04 U09 uo Kelas aayen seb p so o yong JO Y90949 K141 0 s lnultu S Pem pue Jemod yo uny LNOAD071 ONILVAH SVD ve ON 88S say Ul 18s 1 olne IM JONJUOD s dwaye ul wey A01d pue sef lluBi 0 pales wa skS LNOMDO7 NOILIN I E ON 88S s yenuewW sanba yms ynoj jO1 wej4 siu Jaye inooo Ilim 1 s 1 olnvy s lnului uey 1J B5uo uado sem yAMS uT LAOA907 H LIMS 107104 AWV14 HO LINIT pasoj M Y ye y 104 eo e Bulinp paydniaqul SI Jamod aoeuUIN u uA 98S 06 104 UNL IA JOMO G uoyesado unon APZ HO ASLI dN YAMOd Y314dV NO H3AAO 18 waysAs yoayo 0 J9 9 Buljooo 10 Bulyeay e uBnoiuul1 wajshs uny paydnejul SI Avg 10 AGLL Jemod JaAQUayYM JO SIY 8p Jaye paseia ale syney INVA SNOIAAYd ON SERVICE TRAINING Packaged Service Training programs are an excellent way to increase your knowledge of the equipment discussed in this manual including e Uni
6. 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 WARNING Turn off the gas and electrical supplies to the unit before performing any maintenance or service A Follow the operating instructions on label attached to furnace 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 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 sonal injury can result from sharp metal edges etc therefore be careful when removing parts I CLEANING AND OR REPLACING AIR FILTER The air filter arrangement may vary depending on application NOTE If the filter has an airflow direction arrow the arrow must point toward the blower WARNING Never operate unit without a filter or with A filter access
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8. Service and 393AAV Maintenance Procedures Series B amp C GAS FIRED INDUCED COMBUSTION FURNACE Cancels SP04 58 SP04 61 10 00 NOTE Read the entire instruction manual before starting the installation TABLE OF CONTENTS SAFETY CONSIDERATIONS oi sesi sass seisescsnsedisaveasonconsasaeiotsenscs tenses 1 INTRODUCTION eraa ceteris ist ssnaccttsiaadastuseseeagtses cles 2 ELECTROSTATIC DISCHARGE ESD PRECAUTIONS PRO CEDURE Sa ama aaa y E quas as A m Ma e asas 2 CARE AND MAINTENANCE 2 Cleaning and or Replacing Air Filter aaa 2 Blower Motor and Wheel 0sii esisasasasasnvsseecienien 3 Cleaning Heat EXCHANGED u cesses casazeuseseccpectccs ccetcpnesseoess ay 4 Electrical Controls and Wiring ceceseeseeeeeceeeeeeeeteeeereenees 5 WIRING DIAGRAMS e503 sssstevsessactad cassia daneatasateneeenelen cess 9 Troubleshooting siseses sasie esaia ansas in 9 SAFETY CONSIDERATIONS A94085 Installing and servicing heating equipment can be hazardous due to Fig 1 Model 393AAV Upflow Furnace gas and electrical components Only trained and qualified person nel should install repair or service heating equipment EFFICIENCY ik aes CERTIPIED Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters All other operations must ama be performed by trained service personnel When working on heating equ
9. TE 14 NOTE 13 m I I m 135SEC te 5 Em l NOTE 15 I m 180 SEC 5G RED Ea I I 225 SEC i _ k WHEN USED NOTE 11 Gv Dea ee ees ae ee S s 6 gg WHT FSE FL 987 GVR ooo RED FRS1 FRS2 GRNYEL GRN YEL TY NOTE 5 SEC 1 ss HI LO wm BLU BLK RELAY 24 VAC 3A FU1 BLOWER IDR BLWRI FUSED DISCONNECT SWITCH WHEN REQD OTE 4 l 4 eu BLK FU2 rc WHT 1 NEUTRAL l I GND l I LEGEND ALS AUXILIARY LIMIT SWITCH OVERTEMP MANUAL RESET SPST N C BLWR BLOWER MOTOR RELAY SPST N O PCB PRINTED CIRCUIT BOARD BLWM BLOWER MOTOR PL1 9 CIRCUIT CONNECTOR BVSS BLOCKED VENT SHUTOFF SWITCH SPST N C PL2 2 CIRCUIT PCB CONNECTOR CPU MICROPROCESSOR AND CIRCUITRY fee FETCH Conn DSS DRAFT SAFEGUARD SWITCH PL5 2 CIRCUIT HSI PCB CONNECTOR EAC 1 ELECTRONIC AIR CLEANER CONNECTION 115 VAC 1 5 AMP MAX PRS PRESSURE SWITCH SPST N O EAC 2 ELECTRONIC AIR CLEANER CONNECTION COMMON TEST TWIN COMPONENT TEST amp TWIN TERMINAL F FUSIBLE LINK TRAN TRANSFORMER 115VAC 24VAC FRS FLAME ROLLOUT SW MANUAL RESET SPST N C FSE FLAME PROVING ELECTRODE JUNCTION FUI FUSE 3 AMP AUTOMOTIVE BLADE TYPE FACTORY INSTALLED UNMARKED TERMINAL FU2 FUSE OR CIRCUIT BREAKER CURRENT INTERRUPT DEVICE Pascual FIELD INSTALLED amp SUPPLIED PCE GV GAS VALVE REDUNDANT OPERATORS FACTORY WIRING 115VAC GVR GAS VALVE RELAY DPST N O HILO BLOWER MOTOR SPEED CHANGE RELAY SPDT FACTORY WIRING
10. an 2 lower passes of cell in same manner as 2 upper passes NOTE 2 FIELD 24 V WIRING FIELD 115 208 230 460 V WIRING FACTORY 24 V WIRING FACTORY 115 V WIRING THERMOSTAT FIVE WIRE TERMINALS FIELD SUPPLIED THREE WIRE TE I DISCONNECT HEATING ONLY Cus c i D gt o 208 230 OR BLOWER DOOR SWITCH N I e e1 460 V el Tel e THREE I I l I PHASE x it 1 2 S S C 4 J I 9 N I I e e e os aes I _ alaa ND INGLE GND R GH RSE lee a A lpr O 0 PHASE 115 V FIELD AUXILIARY O jee fo SUPPLIED _ J BOX L 4 E GND DISCONNECT aa NOTE T al CONDENSING Or re ee UNIT 24 V TWO TERMINAL WIRE BLOCK FURNACE NOTES 1 Connect Y terminal in furnace as shown for proper blower operation 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 A98521 Fig 5 Heating and Cooling Application Wiring Diagram 5 Repeat foregoing procedures until each cell in furnace has been cleaned 6 Using vacuum cleaner remove residue from each cell 7 Using vacuum cleaner with soft brush attachment clean burner assembly 8 Reinstall cell inlet plates and burner assembly Care must
11. ards THIS WARNING COULD RESULT IN POSSIBLE which could result in personal injury or death CAUTION is used DAMAGE TO THIS EQUIPMENT SERIOUS PER to identify unsafe practices which would result in minor personal SONAL INJURY OR DEATH injury or product and property damage NOTE is used to highlight suggestions which will result in enhanced installation reliability or operation CAUTION Label all wires prior to disconnection when A servicing controls Wiring errors can cause improper and dangerous operation INTRODUCTION These instructions are written for the Gas Fired Induced Combus tion Furnace 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 AN 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 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
12. be exercised to center burners in cell openings 10 Clean flame sensor with fine steel wool 11 Remove old sealant from center panel and collector box flange and apply new sealant to collector box flange and reinstall on center panel making sure all 8 screws are secure NOTE A releasing agent such as PAM cooking spray or equiva lent must not contain corn or canola oil aromatic or halogenated hydrocarbons or inadequate seal may occur and RTV sealant G E 162 6702 or Dow Corning 738 are needed before starting installation DO NOT substitute any other type of RTV sealant G E 162 P771 9003 is available through RCD in 3 oz tubes 12 Reinstall relief box and inducer assembly NOTE If inducer assembly gasket is damaged use RTV sealant to seal inducer assembly to collector box NOTE A releasing agent such as PAM cooking spray or equiva lent must not contain corn or canola oil aromatic or halogenated hydrocarbons or inadequate seal may occur and RTV sealant G E 162 6702 or Dow Corning 738 are needed before starting installation DO NOT substitute any other type of RTV sealant G E 162 P771 9003 is available through RCD in 3 oz tubes 13 Reconnect wires to the following components a Blocked vent safeguard switch b Inducer motor c Pressure switch d Limit overtemperature switch es e Gas valve 5 f Hot surface ignitor g Flame sensing electrode h Flame rollout switch es if applicabl
13. corrected such as improper adjustment of manifold pressure insufficient or poor quality combustion air incorrect size or damaged manifold orifice s improper gas or a restricted heat exchanger Action must be taken to correct the problem If it becomes necessary to clean the heat exchanger because of dust or corrosion proceed as follows 1 Turn gas and electrical power to furnace to OFF 2 Remove control access door 3 Disconnect vent connector from furnace flue collar 4 Remove 2 screws that secure relief box See Fig 2 5 Disconnect wires to the following components Mark wires to aid in reconnection of a Blocked vent safeguard switch Inducer motor Pressure switch e Limit overtemperature switch es Gas valve Hot surface ignitor Flame sensing electrode p gt oa mo Flame rollout switch es if applicable 6 Remove complete inducer assembly and relief box from furnace 7 Remove 8 screws that secure flue collector box to center panel Be careful not to damage collector box 8 Remove burner assembly and cell inlet plates IMPORTANT Replace screws in center panel before cleaning NOTE Be very careful when removing burner assembly to avoid breaking ignitor See Fig 3 for correct ignitor location 9 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 cab
14. cuit breaker to furnace Replace transformer Check for correct line voltage polarity If units are twinned check for proper low voltage 24v transformer phasing Check for previous fault by momentarily shorting the TEST erminal and the C terminal until he LED goes out LED will flash he status code of any previous ault or the code No 11 1 short and 1 long flash if no previous ault After the control repeats the code 3 times the control will go hrough a brief component test sequence The inducer will start and run for the entire component est The HSI blower motor heat speed and blower motor cool speed will run for 10 15 sec each Was there a previous fault code other than No 11 YES Check room thermostat or interconnecting cable Does control respond to W Y or G 24 vac thermostat signals YES Is 24 vac present at W Y or G terminals on the control Replace control if it does not respond to 24 vac signal at W Y or G screw terminals Run system through a heating or cooling cycle to check operation Status codes are erased after 48 hrs or whenever power 115v or 24v is interrupted A99123a Ec L66V SHA uo Aejs pue lu6Bi 1 uinq ureu IIM 191u 5 01 U09 BoeR deYy SHA pono l aoe day anjen jeoidA seau lu uuno s sdweoJo W 0 9 0 O p Ajjeulwou s jueuND Juano yoayoes pue sadedpues BUI YIM JOSUaS SWE ULAJI JUD 01 U09 og d 4 uo
15. door removed A failure to follow this warning could result in fire personal injury or death To clean or replace filters proceed as follows 1 Filters installed in media cabinet adjacent to furnace see Fig 2 AIR FLOW A99294 Fig 2 Model 393AAV Upflow Furnace a Turn off electrical supply to furnace b Remove filter cabinet door c Slide filter out of cabinet d If equipped with permanent washable filter clean filter by spraying cold tap water through filter in opposite direction of airflow Rinse filter and let dry Oiling or coating of the filter is not recommended e If equipped with factory specified disposable media filter replace only with media filter having the same part number and size f Slide filter into cabinet g Replace filter cabinet door h Turn on electrical supply to furnace 2 Filters installed in side s and or bottom of blower compart ment See Fig 2 a Disconnect electrical power before removing access doors b Remove blower and control access doors c Release filter retainer from clip at front of furnace casing See Fig 2 For side return clips may be used on either or both sides of the furnace d Slide filter s out e Furnaces are equipped with permanent washable filters Clean filters with tap water Spray water through filter in opposite direction of airflow f Rinse and let dry Oiling or coating of filter is NOT recommended or required g Rein
16. e 14 Reinstall vent connector to furnace flue collar After fully assembling vent connector to furnace flue collar securely fasten vent connector to flue collar with 2 field supplied corrosion resistant sheet metal screws located 180 degrees apart and midway up the collar 15 16 17 Turn electrical power and gas to ON Set thermostat and check furnace for proper operation Verify blower airflow and speed changes between heating and cooling 18 Check for gas leaks 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 19 Replace control access door IV ELECTRICAL CONTROLS AND WIRING CAUTION There may be more than 1 electrical supply A to the unit Check accessories and cooling the unit for additional electrical supplies The electrical ground and polarity for 115 v wiring must be maintained properly Refer to Fig 5 for field wiring information and to Fig 7 for furnace wiring information NOTE If the polarity is not correct the STATUS LED on the control will flash rapidly and prevent the furnace from heating The control system also requires an earth ground for proper operation of the control and flame sensing electrode BLOWER OFF DELAY
17. 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 the proper frequency of maintenance and availability of a maintenance contract 2 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
18. h 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 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 the 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 For an explanation of status codes refer to service label located on blower access door Fig 8 or the troubleshooting guide The control stores 1 status code the last status code to occur for a period of 48 hr or until the 115 or 24 v power is interrupted NOTE Look into blower access door sight glass for current LED status BEFORE removing the blower access door Removing blower access door will open blower access door switch and terminate 115 v power to control and status code will be erased 1 To retrieve status code proceed with the following NOTE NO thermostat signal shall be present at control and all blower off delays must be completed a Leave 115 v power to furnace turned on b Look into blower access door sight glass for current LED status NOTE Leave blower access panel installed to maintain power to control to view curren
19. iate degreaser To remove wheel ae 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 motor and blower housing so motor and each arm is positioned at the same 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 and motor mounts to blower housing and slide motor and mounts out of housing Disconnect capacitor and ground wire attached to blower housing before removing motor Motor mount belly band need not be removed unless motor is to be replaced f Remove blower wheel from housing CAUTION The blower wheel should not be dropped or bend as balance will be affected 9 Reassemble motor and blower by reversing items 9a through 9f Be sure to reattach ground wire 10 Reinstall blower assembly in furnace 11 Reinstall control and transformer support assembly in furnace 12 Reconnect blower leads to furnace control Refer to furnace wiring diagram See Fig 7 and connect thermostat leads if previously disconnected NOTE Refer to Table 1 for motor speed lead relocation if leads were not identified before disconnection TABLE 1 SPEED SELECTOR FACTORY ATTACHED TO Black Yellow When High Medium High
20. ipment observe precautions in the literature tags and labels attached to or shipped with the unit and other safety precautions that may apply Follow all safety codes In the United States follow all safety codes including the National Fuel Gas Code NFGC NFPA No 54 1999 ANSI Z223 1 1999 and the Installation Standards Warm Air Heating and Air Conditioning Systems NFPA 90B ANSI NFPA 90B In Canada refer to the current edition of the REGISTERED QUALITY SYSTEM National Standard of Canada CAN CGA B149 1 and 2 M95 Natural Gas and Propane Gas Installation Codes NSCNGPIC Wear safety glasses and work gloves Have fire extinguisher available during start up and adjustment procedures and service calls Recognize safety information This is the safety alert symbol AN When you see this symbol on the furnace and in instructions or WARNING The ability to properly perform mainte manuals be alert to the potential for personal injury nance on this equipment requires certain expertise me hanical skills tool d i t If d t Understand these signal words DANGER WARNING and PG S A ee SP a ee possess these do not attempt to perform any maintenance CAUTION These words are used with the safety alert symbol i Afon this equipment other than those procedures recom DANGER identifies the most serious hazards which will result in mended in the User s Manual FAILURE TO FOLLOW severe personal injury or death WARNING signifies haz
21. le 1 Use 48 in of 1 4 in diameter high grade steel spring cable commonly known as drain clean out or Roto Rootert 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 13 39 11 30 BURNER I CELL ee PANEL NO HOT SURFACE IGNITOR ASSEMBLY IN i IGNITOR 7 3 NT BURNER IGNITOR ASSEMBLY A93347 Fig 3 Position of Ignitor to Burner 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 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 4 A91252 Fig 4 Cleaning Heat Exchanger Cell 3 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 4 Insert brush end of cable in lower opening of cell and proceed to cle
22. ned refer to twinning kit instructions 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 11 NO PREVIOUS CODE Stored status codes are erased when power 115VAC or 24VAC to control is interrupted or 48 hours after each fault is cleared 12 BLOWER ON AFTER POWER UP 115VAC or 24 VAC Blower runs for 90 seconds if unit is powered up during a call for heat R W closed 13 LIMIT OR FLAME ROLL OUT SWITCH LOCKOUT Control will auto reset after three hours Reset switch or replace fuse link Refer to 33 14 IGNITION LOCKOUT Control will auto reset after three hours Refer to 34 21 GAS HEATING LOCKOUT Control will NOT auto reset Check for Mis wired gas valve Defective control Valve relay 22 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 23 PRESSURE SWITCH DID NOT OPEN Check for Obstructed pressure tubing Pressure switch stuck closed 24 SECONDARY VOLTAGE FUSE IS OPEN Check for Short circuit in secondary voltage 24VAC wiring 31 PRESSURE DRAFT SAFEGUARD AUX LIMIT SWITCH when used OR BLOCKED VENT SWITCH when used DID NOT CLOSE OR REOPENED DOWNFLOW ONLY If open longer than five minutes inducer shuts off for 15 minutes before retry Check for Proper ven
23. omponent test sequence shut OFF the room thermostat or disconnect the R thermostat lead Briefly short the TEST terminal to the Com 24V terminal Status LED will flash code and then turn ON the inducer motor The inducer motor will run for the entire component test The hot surface ignitor blower motor heat speed and blower motor cool speed will be turned ON for 10 15 seconds each Gas Valve and Humidifier will not be turned on olol R G 320615 102 REV K LIT Fig 8 Service Label R A99233 4 If furnace is operating properly and LED indicates proper e Component Test will function as described in item 2 operation replace control access door above 5 Component Test can also be initiated by performing the f Check LED status following g If LED status indicates proper operation RELEASE a Remove control access door BLOWER ACCESS DOOR SWITCH replace blower b Remove blower access door access door and replace control access door c Manually close blower access door switch WARNING Blower access door switch opens 115 v WIRING DIAGRAMS power to control No component operation can occur I 7 f Caution must be taken when manually closing this switch Refer to Fig 5 6 and 7 for wiring diagrams for service purposes Failure to follow this warning could result in personal injury or death TROUBLESHOOTING Refer to service label See Fig 8 The Trouble
24. rs contain internal auto reset thermal overload switches OL Blower motor speed selections are for average conditions see installation instructions for details on opimum speed selection se only copper wire between the disconnect switch and the furnace junction box JB This wire must be connected to furnace sheetmetal for control to detect flame Penlaca only with a 3 amp fuse w lead not on all motors Blower on delay gas heating 45 seconds cooling or heat pump 2 seconds Blower off delay gas heating 90 135 180 or 225 seconds cooling or heat pump 90 seconds 135 seconds only on some models Ignition lockout will occur after four consecutive unsuccessful trials for ignition Control will auto reset after three hours When used auxiliary limit switch ALS is on some downflow models only When used FL is on upflow models only Some models may have spade quick connect terminals Factory connected when LGPS is not used Factory connected when BVSS is not used BVSS used when Chimney Adapter Accessory Kit is installed 322869 101 REV H A00304 SERVICE If status code recall is needed do not remove power or blower door Briefly remove and then reconnect one main limit wire to display stored status code LED CODE STATUS CONTINUOUS OFF Check for 115VAC at L1 and L2 and 24VAC at SEC 1 and s CONTINUOUS ON Control has 24VAC power RAPID FLASHING Line voltage 115VAC polarity reversed If twin
25. shooting Guide can d BRIEFLY short jumper TEST 3 16 in quick connect be a useful tool in isolating furnace operation problems Beginning terminal on control adjacent to LED status light and with the word Start answer each question and follow the Com 24V terminal on furnace control thermostat termi appropriate arrow to the next item nal block See Fig 6 The Guide will help you identify the problem or failed component NOTE If TEST to Com 24V terminals are jumpered longer than After replacing any component verify correct operation sequence 2 sec LED will flash rapidly and test request will be ignored 9 o START YES Is red LED status light blinking ON OFF slowly with a combination of short and long flashes Determine status code The status code is a 2 digit number with the first digit determined by the number of short flashes and the second digit by the number of long flashes Is red LED status light on Is red LED status light blinking rapidly without a pause Go to section with status code determined Troubleshooting Guide NO NO Is there 115v at L1 and L2 Is door switch closed YES Is there 115v going to switch Close door switch and go to start Is there 24v at SEC 1 and SEC 2 Is circuit breaker closed Replace control center Replace door switch Close circuit breaker and go back to start Check for continuity in wire from cir
26. stall filter s h Replace blower and control access doors i Restore electrical power to furnace ll BLOWER MOTOR AND WHEEL The following items should be performed by a qualified service technician To ensure long life economy and high efficiency 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 Clean blower motor and wheel as follows 1 Turn off electrical supply to furnace 2 Remove control and blower access door 3 Disconnect blower leads from furnace control Notice wire color and location for reassembly All other factory wires can be left connected but field thermostat connections may need to be disconnected de pending on their length and routing 4 Remove 2 screws securing control and transformer support to furnace 5 Hang control and transformer support to side of furnace casing 6 Remove screws holding blower assembly to blower deck and slide blower assembly out of furnace 7 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 8 If a greasy residue is present on blower wheel remove wheel from the blower housing and wash it with an appropr
27. t Familiarization e Maintenance e Installation Overview e 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 2000 Bryant Heating amp Cooling Systems 7310 W Morris St Indianapolis IN 46231 Printed in U S A sp04 61 Catalog No 5339 307
28. t LED status c Remove control access door d BRIEFLY remove either wire from the main limit switch until LED goes out then reconnect it NOTE If wire to main limit is disconnected longer than 4 sec main blower starts and retrieval request is ignored 2 When above items have been completed the following will occur a LED flashes a status code 4 times Record this status code for further troubleshooting b Inducer motor starts and continues to run the entire component test c Hot surface ignitor is energized for 15 sec then de energized d Main blower operates at heating speed for 10 sec then turns off e Main blower operates at cooling speed for 10 sec then turns off f Inducer motor stops Items a through e above will assist in furnace troubleshooting since all components are functionally operated except the gas valve This procedure is also referred to as Component Test 3 Operate furnace through 1 heat cycle to test for proper operation and check LED status 6 i u ii i ismsamissi WHEN USED WHEN USED sw2 G 7 NOTE 14 NOTE 11 WHEN USED p C B BLOWER R DSS BVSS ALS PRS LGPS NOTE 9 OF y NOT ONALL MODELS _ sm fw ORN f RN ORN ta BLOWER OFF DELAY Com SELECTION CHART YEL I I 90 SEC TEST TWIN wm NO
29. t sizing Low inducer voltage 115VAC Defective inducer motor Defective Blower motor or capacitor Restricted vent Defective pressure switch Excessive wind Inadequate combustion air supply Disconnected or obstructed pressure tubing If it opens after trial for ignition period blower will come on for 90 second recycle delay LIMIT OR FLAME ROLL OUT SWITCH IS OPEN If open longer than three minutes code changes to 13 Flame roll out switch requires manual reset Check for Defective blower motor or capacitor Dirty filter or restricted duct system Loose blower wheel Defective switch or connections Inadequate combustion air supply Flame Roll out Switch or fuse link open Open Flame Roll out Switch or fuse link Manual reset or replace IGNITION PROVING FAILURE Control will try three more times before lockout 14 occurs If flame signal lost after trial for ignition period blower will come on for 90 second recycle delay Check for Oxide buildup on flame sensor clean with fine steel wool Proper flame sense microamps 5 microamps D C min 4 0 6 0 nominal Gas valve defective or gas valve turned off Defective Hot Surface Ignitor Manual valve shut off Low inlet gas pressure Control ground continuity Green wire MUST be connected to furnace sheet metal Inadequate flame carryover or rough ignition Flame sensor must be ungrounded COMPONENT TEST To initiate the c
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