Bryant 383kav Furnace

service and maintenance proceduresGAS-FIRED INDUCED-COMBUSTION FURNACES Cancels: SP04-59 373LAV 383KAV Series G SP04-62 10-00 NOTE: Read the entire instruction manual before performing any service or maintenance. This symbol → indicates a change since the last issue. These procedures are for size 44,000 through 154,000 Btuh input units. Index Page SAFETY CONSIDERATIONS..................................................1-2 ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS PROCEDURE ...........................................................................2 CARE AND MAINTENANCE................................................2-13 Air Filter Arrangement..........................................................2-3 Blower Motor and Wheel......................................................3-4 Cleaning Heat Exchanger......................................................5-6 Electrical Controls and Wiring .............................................6-7 Troubleshooting ...................................................................7-13 Unit Wiring Diagram................................................................9 Service Label ..........................................................................10 Troubleshooting Guide ......................................................12-13 SAFETY CONSIDERATIONS Installing and servicing heating equipment can be hazardous due to gas and electrical components. Only trained and qualified personnel 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 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. In the United States, follow all safety codes including the National Fuel Gas Code (NFGC) NFPA 54-1999/ANSI Z223.1-1999 NFPA 90B. In Canada, refer to the CAN/CGA-B149.1- and .2-M95 National Standard of Canada, Natural Gas and Propane 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 . 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, CAUTION, and NOTE. These words are used with the safety-alert symbol. DANGER 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. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation. A94087 Fig. 1—Model 373LAV Horizontal ama CERTIFIED A94086 Fig. 2—Model 373LAV Downflow REGISTERED QUALITY SYSTEM A94085 Fig. 3—Model 383KAV Upflow —1— Put all used AND new controls into containers before touching ungrounded objects. 3. TABLE 1—FILTER SIZE INFORMATION FOR DOWNFLOW/HORIZONTAL FURNACES (IN. dry cleaning fluids. unpainted. plastic or plastic containers. such as: 1. † Filters may be field modified as required by cutting to desired size. DO NOT TOUCH THE CONTROL OR ANY WIRE CONNECTED TO THE CONTROL PRIOR TO DISCHARGING YOUR BODY’S ELECTROSTATIC CHARGE TO GROUND. or death. Spray or aerosol cans. . cigarette lighter fluid. Check blower motor and wheel for cleanliness each heating and cooling season. or in contact with the furnace. or other paper products. The minimum maintenance that should be performed on this equipment is as follows: 1. CAUTION: As with any mechanical equipment. rags. 4. or death. WARNING: Never store anything on. Wiring errors can cause improper and dangerous operation. Firmly touch a clean. do not attempt to perform any maintenance on this equipment other than those procedures recommended in the User’s Manual. CARE AND MAINTENANCE For continuing high performance and to minimize possible equipment failure. therefore. etc.. Follow the operating instructions on label attached to furnace. paper bags. An ESD service kit (available from commercial sources) may also be used to prevent ESD damage. firmly touch furnace again before touching control or wires. CAUTION: Label all wires prior to disconnection when servicing controls. Service as necessary. gasoline.WARNING: The ability to properly perform maintenance on this equipment requires certain expertise. 2. 3. 7. DO NOT touch ungrounded objects. etc. OR DEATH.) FURNACE CASING WIDTH 14-3/16 17-1/2 21 24-1/2 FILTER QUANTITY AND SIZE (2) 16 X 20 X 1 (2) 16 X 20 X 1 (2) 16 X 20 X 1 (2) 16 X 20 X 1 FILTER TYPE Cleanable Cleanable Cleanable Cleanable TABLE 2—FILTER SIZE INFORMATION FOR UPFLOW FURNACES (IN. bleaches. 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. the control. near. Refer to Table 1 or 2 for filter size information. 5. or other volatile fluids. dust mops. and the person at the same electrostatic potential. personal injury. Replace if torn. 3. Consult your local dealer as to the proper frequency of maintenance and the availability of a maintenance contract. 2. A failure to follow this warning could result in corrosion of the heat exchanger. ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS PROCEDURE CAUTION: Electrostatic discharge can affect electronic components. Air Filter Arrangement The air filter arrangement may vary depending on the application. personal injury can result from sharp metal edges. 1. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN POSSIBLE DAMAGE TO THIS EQUIPMENT. follow items 1 through 5 before bringing the control or yourself into contact with the furnace. Before removing a new control from its container. DO NOT move or shuffle your feet. If you do not possess these. A failure to follow this warning could result in fire. 2. Soap powders. discharge your body’s electrostatic charge to ground to protect the control from damage. kerosene. These precautions will help to avoid exposing the control to electrostatic discharge by putting the furnace. fire. mechanical skills. Paint thinners and other painting compounds. Clean and lubricate as necessary.). Disconnect all power to the furnace. Check electrical connections for tightness and controls for proper operation each heating season. be careful when removing parts. 6. Check and clean air filter each month or more frequently if required.) FURNACE CASING WIDTH 14-3/16 17-1/2 21 24-1/2 FILTER QUANTITY AND SIZE† Side Return Bottom Return (1) 16 X 25 X 1* (1) 14 X 25 X 1 (1) 16 X 25 X 1* (1) 16 X 25 X 1 (1) 16 X 25 X 1 (1) 20 X 25 X 1* (2) 16 X 25 X 1 (1) 24 X 25 X 1* FILTER TYPE Cleanable Cleanable Cleanable Cleanable * Factory-provided with the furnace. A failure to follow this warning could result in personal injury. SERIOUS PERSONAL INJURY. If the control is to be installed in a furnace. tools. and equipment. WARNING: Turn off the gas and electrical supplies to the unit before performing any maintenance or service. Use this procedure for installed and uninstalled (ungrounded) furnaces. Take precautions during furnace installation and servicing to protect the furnace electronic control. waxes or other cleaning compounds. WARNING: Never operate unit without a filter or with filter access door removed. —2— A. personal injury. Tools held in a person’s hand during grounding will be satisfactorily discharged. or other cleaning tools. metal surface of the furnace chassis which is close to the control. it is essential that periodic maintenance be performed on this equipment. Precautions will prevent electrostatic discharges from personnel and hand tools which are held during the procedure. If you touch ungrounded objects (recharge your body with static electricity). brooms. vacuum cleaners. . Replace blower access door... 2. d. Downflow only. 6.. These motors can be identified by the absence of oil ports on each end of the motor.. 5—Downflow Filter Arrangement 1. and high efficiency. ... Reinstall filter(s). 8. Downflow/Horizontal Each furnace requires 2 filters which are installed in the return-air duct.. . Remove blower and control access doors. . 3.. 4. .. Clean blower wheel and motor using a vacuum with soft brush attachment.. . Replace blower and control access doors. Also.. tilt filters toward center of return-air plenum.. Oiling or coating of filters is not recommended or required.. b. . Furnaces are equipped with permanent.g. e. Disconnect and remove short piece of vent pipe from within furnace. —3— . economy.) b.. Remove screw from front of door and remove blower access door. NOTE: Vent pipe is SCREWED and RTV sealed to relief box.. Clean blower motor and wheel as follows: 1. Do not remove or disturb balance weights (clips) on blower wheel blades... Spray water through filter in opposite direction of airflow. Upflow Each furnace requires 1 or 2 filters which are installed in the blower compartment. . b.. A88486 . a.. 7. 7. e. (See Fig. 6. h. proceed as follows: a. . . Rinse and let dry. Blower Motor and Wheel The following steps should be performed by a qualified service technician.. .. g.) To remove filters for cleaning or replacement. and clean as needed. Remove 2 screws from blower access door (downflow/horizontal furnace only) and remove blower access door. Clean filters with tap water. All other factory wires can be left connected. f. Reinstall filters.. Oiling or coating of filter is not recommended or required.. . Restore electrical power to furnace. The blower wheel should not be dropped or bent as balance will be affected.. Reach up behind top plate. . .. (See Fig. Furnaces are equipped with permanent. A94307 . Remove internal vent pipe enclosure cover. Disconnect and remove vent pipe enclosure. AIRFLOW d. . c. (See Fig. remove filters. washable filters. Slide filter(s) out. d... Rinse and let dry.. The inducer and blower motors are pre-lubricated and require no additional lubrication. Spray water through filter in opposite direction of airflow. . Replace if torn... c. Clean filters with tap water. 5. Release filter retainer from clip at front of furnace casing. (See Fig. Remove screws holding blower assembly to blower deck and slide blower assembly out of furnace. f... Hang control and transformer support to front of furnace casing. Push bottom side backward to release tabs. 6. h... Remove 2 screws securing control and transformer support to furnace. 4—Horizontal Filter Arrangement INSTALLATION POSITION OF FILTERS RETURN-AIR PLENUM ACCESS DOOR Fig.. . . disconnect auxiliary limit switch leads (downflow only. To ensure long life... c. 4 and 5. . . AIRFLOW Fig.. clips may be used on either or both sides of the furnace. Disconnect vent connector from furnace flue collar. B. Disconnect electrical power before removing access doors. Disconnect blower leads from furnace control. Disconnect electrical power before removing blower access door. clean accumulated dirt and grease from blower wheel and motor annually.) For side return. Turn off electrical supply to furnace.) To remove filters for cleaning or replacement.. 2... washable filters. Note wire color and location for reassembly.. i. Restore electrical power to furnace. but field thermostat connections may need to be disconnected depending on their length and routing. proceed as follows: a. if present). Remove blower wheel from housing. 7—Model 373LAV Downflow TABLE 3—SPEED SELECTOR COLOR Black Yellow (When present) Blue Red White SPEED High Medium-High Medium-Low Low Common FACTORYATTACHED TO Cool Spare Heat Spare L2/COM CAUTION: Heating air speed selection MUST be adjusted to provide proper air temperature rise as specified on the rating plate. Remove bolts holding motor and motor mounts to blower housing and slide motor and mounts out of housing. 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. Reinstall control and transformer support assembly in furnace. Remove screws securing cutoff plate and remove cutoff plate from housing. 15. Mark blower wheel orientation and cutoff plate location to ensure proper reassembly. Disconnect capacitor and ground wire attached to blower housing before removing motor. Use a piece of tape to hold switch closed. . or Dow-Corning 738) are needed before starting installation. 14. and connect thermostat leads if previously disconnected. Reconnect blower leads to furnace control and auxiliary limit switch leads (downflow only).E. remove wheel from the blower housing and wash it with an appropriate degreaser. sheet metal screws located 180° apart and midway up the collar. d. 162. b. 12. Motor mount belly band need not be removed unless motor is to be replaced. 6702. 10. 162 (P771-9003) is available through RCD in 3-oz. motor. e.) NOTE: Refer to Table 3 for motor speed lead relocation if leads were not identified before disconnection. Loosen setscrew holding blower wheel on motor shaft. To remove wheel: a. Reassemble motor and blower by reversing items 9a through 9f. 6—Model 383KAV Upflow 9. c. tubes. securely fasten vent connector to flue collar with 2 field-supplied. Turn on electrical supply. Downflow furnaces only: Reinstall internal vent pipe and enclosure by reversing items 3a through 3d. If a greasy residue is present on blower wheel. 13. Reinstall blower assembly in furnace.E. Mark blower wheel location on shaft before disassembly to ensure proper reassembly. 16.FLUE COLLAR MOUNTING SCREWS RELIEF BOX GAS VALVE CONTROL RELIEF BOX FILTER RETAINER WASHABLE FILTER GAS VALVE HUM FLUE COLLAR VENT PIPE ENCLOSURE AUXILIARY LIMIT SWITCH (WHEN USED) MOUNTING SCREWS CONTROL HUM COM W 24V BLOCKED VENT SAFEGUARD PRESSURE SWITCH FLUE COLLECTOR BOX Y R G BLOCKED VENT SAFEGUARD PRESSURE SWITCH MANUAL RESET LIMIT SWITCHES →Fig. G. Be sure to reattach ground wire. CAUTION: The blower wheel should not be dropped or bent as balance will be affected. Manually close blower access door switch. Reinstall vent connector to furnace flue collar. DO NOT substitute any other type of RTV sealant. corrosion-resistant. (see Fig. 12. After fully assembling vent connector to furnace flue collar. f. —4— COM W Y R G 24V A00261 A99285 Fig. Failure to adjust the heating speed may shorten heat exchanger life. NOTE: A releasing agent such as PAM cooking spray or equivalent (must not contain corn or canola oil. 11. Refer to furnace wiring diagram. NOTE: Mark blower mounting arms. aromatic or halogenated hydrocarbons or inadequate seal may occur) and RTV sealant (G. and blower housing so motor and each arm is positioned at the same location during reassembly. . 4. 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. (4. (2. blower will run for 90 sec before beginning a heating or cooling cycle. Disconnect vent connector from furnace flue collar. and vacuum cleaner. Push bottom side backward to release tabs. Gas valve. and proceed to clean 2 lower passes of cell in same manner as 2 upper passes. b.) Attach variable-speed. If furnace is operating properly. Flame-sensing electrode. (3. reversible drill to end of spring cable (end opposite brush). 7. or a restricted heat exchanger. IMPORTANT: Replace screws in center panel and cells before cleaning. A build-up of soot and carbon indicates that a problem exists which needs to be corrected. Hot surface igniter. 8. or damaged manifold orifice(s). personal injury. incorrect size.) Use 1/4-in. 17. REMOVE TAPE TO RELEASE BLOWER ACCESS DOOR SWITCH.) Using vacuum cleaner.) (3. 9.) Using vacuum cleaner with soft brush attachment. steel spring cable. Flame rollout switch(es). Disconnect wires to the following components. (7. Remove vent pipe enclosure by removing screw in upper back. c. 8—Position of Igniter to Burner 10. of cable into 2 upper passes of cell. h. No component operation can occur. Remove complete inducer assembly and relief box from furnace.) Use 48 in. —5— HOT SURFACE IGNITER ASSEMBLY C L 7 8" C L IGNITER BURNER IGNITER ASSEMBLY A99286 Fig. TIGHTNESS IS VERY IMPORTANT.) Insert brush end of cable into upper opening of cell and slowly rotate with drill. Disconnect and remove short piece of vent pipe from within furnace.WARNING: Blower access door switch opens 115-v power to furnace control. NOTE: The materials needed in (1. replace blower access door. Assemble wire brush and steel spring cable. diameter high-grade steel spring cable (commonly known as drain clean-out or Roto-Rooter® cable). Inducer motor. b. remove residue from each cell. g. (6. 8 for correct igniter location.) can usually be purchased at local hardware stores. (2. Remove 8 screws that secure flue collector box to center panel. they should be replaced rather than trying to clean them thoroughly due to their intricate design. Clean each heat exchanger cell. a. (See Fig. proceed as follows: 1. 6 or 7. clean cells as follows: a. Turn gas and electrical power to furnace OFF. 2.) Remove metal screw fitting from wire brush to allow insertion into cable. Pressure switch. Remove 2 screws that secure relief box. or death. Gradually insert at least 36 in. Remove internal vent pipe enclosure cover. and crimp tight with crimping tool or strike with ball-peen hammer.) and (2. Failure to follow this warning could result in electrical shock. of 1/4-in. f. e. 3. improper gas. See Fig. Action must be taken to correct the problem.) Insert brush end of cable in lower opening of cell. c. Remove burner assembly and cell inlet plates. 5.) Insert twisted wire end of brush into end of spring cable.) Work cable in and out of cell 3 or 4 times to obtain sufficient cleaning. (1. NOTE: Be careful when removing burner assembly to avoid breaking igniter. DO NOT force cable. if applicable. NOTE: Vent pipe is SCREWED and RTV sealed to relief box.) 6. Remove control and blower access doors. such as improper adjustment of manifold pressure. DO NOT pull cable with great force. reversible electric drill. (5. (1. (4. Disconnect internal vent pipe and enclosure on downflow furnaces only. Mark wires to aid in reconnection of: a.) Repeat foregoing procedures until each cell in furnace has been cleaned. 9. Using field-provided small wire brush. Be careful not to damage collector box. insufficient or poor quality combustion air. clean burner assembly. d. C. Reverse drill and gradually work cable out. (See Fig. Caution must be taken when manually closing this switch for service purposes. diameter wire brush (commonly known as 25-caliber rifle cleaning brush). If it becomes necessary to clean the heat exchanger because of dust or corrosion. Limit overtemperature switch(es). Blocked vent safeguard switch. 13 32" 11 32" BURNER CELL PANEL NOTE: If thermostat terminals are jumpered before blower access door switch is closed. b. 18. c. Refer to Fig.E. and status code will be erased. 11. NOTE: A releasing agent such as PAM cooking spray or equivalent (must not contain corn or canola oil. A91252 Fig. 1. making sure all 8 screws are secure. Check accessories and cooling unit for additional electrical supplies.19. Clean flame sensor with fine steelwool.E. or maintenance will cause this fuse to blow. Reinstall relief box and inducer assembly. use ONLY 3-amp fuses. disassemble the connection. 10 for field wiring information and to Fig. h. 20. WARNING: Never use a match or other open flame to check for gas leaks. sheet metal screws located 180° apart and midway up the collar. Set thermostat and check furnace for proper operation. tubes. 11. or a code composed of 2 digits. corrosion-resistant. Gas valve. Reconnect wires to the following components. Reconnect electrical power to the unit and observe unit through 1 complete operating cycle. replace control access door first. 6702. and reassemble properly and securely. or death. A failure to follow this warning could result in fire. Check for gas leaks. 9—Cleaning Heat Exchanger Cell (8. and all blower-OFF delays must be completed. If fuse replacement is required. The control system also requires an earth ground for proper operation of the control and flame sensing. Reinstall internal vent pipe and enclosure on downflow furnaces only by reversing items 4a through 4c. securely fasten vent connector to flue collar with 2 field-supplied. f. or Dow-Corning 738) are needed before starting installation. Limit overtemperature switch(es). 3-amp fuse located on the control. G. It can be viewed through the sight glass or window on blower access door. The control in this furnace is equipped with an LED status light to aid in installation.E. b. g.) Any shorts of the 24-v wiring during installation. If any smoky or burned connections are found. 13. On downflow/horizontal furnaces. Leave 115-v power to furnace turned on. G. a. service. Electrical controls are difficult to check without proper instrumentation. Hot surface igniter. NOTE: A releasing agent such as PAM cooking spray or equivalent (must not contain corn or canola oil. personal injury. the second is the number of long flashes. aromatic or halogenated hydrocarbons or inadequate seal may occur) and RTV sealant (G. 162 (P771-9003) is available through RCD in 3-oz. tubes. b. DO NOT substitute any other type of RTV sealant. 13. 12. DO NOT substitute any other type of RTV sealant. The electrical ground and polarity for 115-v wiring must be properly maintained. DO NOT substitute any other type of RTV sealant. 162 (P771-9003) is available through RCD in 3-oz. Electrical Controls and Wiring CAUTION: There may be more than 1 electrical supply to the unit. Pressure switch. The control indicates status with the LED on continuously. Blocked vent safeguard switch. strip wire. 6702. 162 (P771-9003) is available through RCD in 3-oz. remove blower access door. Look into blower access door sight glass for current LED status. Turn electrical power and gas to ON. e. proceed with the following: NOTE: NO thermostat signal may be present at control center. NOTE: If inducer assembly gasket is damaged. 6702. 23. Remove old sealant from center panel and collector box flange and apply new sealant to collector box flange and reinstall on center panel. servicing. Removing blower access door will open blower access door switch and terminate 115-v power to control.E. refer to service label located on blower access door or Fig. a. 21. 22. 12 for furnace wiring information. NOTE: If the polarity is not correct. 162. To retrieve status code. tubes. or Dow-Corning 738) are needed before starting installation. NOTE: Leave blower access panel installed to maintain power to control to view current LED status. (The first digit is the number of short flashes.) Reinstall cell inlet plates and burner assembly.E. Verify blower airflow and speed changes between heating and cooling. 162. The control stores 1 status code (the last status to occur) for a period of 48 hrs or until the 115. and the troubleshooting guide. . (See Fig. check all electrical connections for tightness.or 24-v power is interrupted. NOTE: A releasing agent such as PAM cooking spray or equivalent (must not contain corn or canola oil. —6— D. NOTE: Look into blower access door sight glass for current LED status. use RTV sealant to seal inducer assembly to collector box.E. Replace blower access door only. Use a soap-and-water solution. aromatic or halogenated hydrocarbons or inadequate seal may occur) and RTV sealant (G. 17. G. then replace blower access door and secure with screws in front of door. or Dow-Corning 738) are needed before starting installation. 15. Replace control access door on upflow furnace. The control LED will display status code 24 when fuse needs to be replaced. contact your dealer and request service. if there are any discrepancies in the operating cycle. With power to the unit disconnected. Reinstall vent connector on furnace flue collar. Flame rollout switch(es). if applicable. The 24-v circuit contains an automotive-type. Care must be exercised to center burners in cell openings.) For an explanation of status codes. the STATUS LED on the control center will flash rapidly and prevent the furnace from heating. 162. clean all parts. and troubleshooting. After fully assembling vent connector to furnace flue collar. aromatic or halogenated hydrocarbons or inadequate seal may occur) and RTV sealant (G. rapid flashing. 14. Tighten all screws on electrical connections. 16. d. Flame-sensing electrode. Inducer motor. Connect Y-terminal in furnace as shown for proper blower operation. 10—Heating and Cooling Application Wiring Diagram c. and COM-24V terminal on furnace thermostat connection block. If furnace is operating properly and LED indicates proper operation. Hot surface igniter is energized for 15 sec. No component operation can occur. RELEASE BLOWER ACCESS DOOR SWITCH. must be replaced. This procedure is also referred to as "Component Test. verify correct operation sequence. and replace control access door. d. E. (See Fig. then reconnect it. WARNING: Blower access door switch opens 115-v power to control. If any of the original wire. 3/16-in. 2.OR 460-V THREE PHASE GND GND 115-V FIELDSUPPLIED DISCONNECT AUXILIARY J-BOX C O N T R O L R G C Y GND 208/230-V SINGLE PHASE NOTE 1 CONDENSING UNIT TWO WIRE NOTES: 1.) NOTE: If TEST to COM-24V terminals are jumpered longer than 2 sec. Main blower operates at cooling speed for 10 sec. Manually close blower access door switch. (See Fig. b. Beginning with the word "Start. replace control access door. then turns off. 24-V TERMINAL BLOCK FURNACE A98521 Fig. BRIEFLY short (jumper) TEST. Remove blower access door. BRIEFLY remove either wire from the main limit switch until LED goes out. then turns off. and test request will be ignored. Component Test can also be initiated by performing the following: a. When above items have been completed. quick-connect terminal on control (adjacent to LED diagnostic light). g. and retrieval request is ignored. as supplied. f. c. 208/230-. Component Test will function as described in item 2 above. NOTE: If wire to main limit is disconnected longer than 4 sec. the following will occur: a. Some thermostats require a "C" terminal connection as shown. Items a through e above will assist in furnace troubleshooting since all components are functionally operated except the gas valve. use same type or equivalent wire. 2.FIELD 24-V WIRING FIELD 115-. Caution must be taken when manually closing this switch for service purposes. e. 460-V WIRING FACTORY 24-V WIRING FACTORY 115-V WIRING NOTE 2 FIVE WIRE THREE-WIRE HEATING-ONLY BLOWER DOOR SWITCH BLK WHT BLK WHT W W C R G Y THERMOSTAT TERMINALS FIELD-SUPPLIED DISCONNECT 208/230. Troubleshooting Refer to the service label. 5. If LED status indicates proper operation. LED will flash rapidly." 3. 13. then deenergized. Operate furnace through 1 heat cycle to test for proper operation and check LED status. main blower starts. replace blower access door. Failure to follow this warning could result in personal injury or death. Check LED status. The guide will help to identify the problem or failed component. After replacing any component. Remove control access door. Main blower operates at heating speed for 10 sec. d. Inducer motor stops. f. 4. 3. LED flashes a status code 4 times." answer each question and follow the appropriate arrow to the next item. d. Inducer motor starts and continues to run the entire component test. Remove control access door. c. This guide can be a useful tool in isolating furnace operation problems. Record this status code for further troubleshooting.) Pages 10 and 11 contain a troubleshooting guide. b. e. —7— . 11. 11—Furnace Control —8— .HUM 24V TEST/TWIN COM W Y R G 24-V THERMOSTAT TERMINALS HUMIDIFIER TERMINAL (24-VAC 0.0 AMP MAX) 115-VAC (L1) POWER SUPPLY HOT SURFACE IGNITOR CONNECTOR EAC-2 115-VAC (L2) NEUTRAL CONNECTION INDUCER MOTOR CONNECTOR A99255 Fig.5 AMP MAX) LED OPERATION & DIAGNOSTIC LIGHT HARNESS CONNECTOR SEC-1 3-AMP FUSE COOL HEAT 24-V TRANSFORMER SEC-2 SPARE-1 BLOWER SPEED SELECTION TERMINALS SPARE-2 EAC-1 EAC-ELECTRONIC AIR CLEANER TERMINALS (115-VAC 1. -MANUAL RESET. BVSS used when Chimney Adapter Accessory Kit is installed. SPST-(N. MAX. 15.5 AMP. SPST -(N.) COMPONENT TEST & TWIN TERMINAL TRANSFORMER-115VAC/24VAC JUNCTION UNMARKED TERMINAL PCB TERMINAL FACTORY WIRING (115VAC) FACTORY WIRING (24VAC) FIELD WIRING (115VAC) FIELD WIRING (24VAC) CONDUCTOR ON PCB FIELD WIRING TERMINAL FIELD GROUND EQUIPMENT GROUND FIELD SPLICE PLUG RECEPTACLE G 5 FSE COM 6 NOT USED 9 NOT USED NOTES: 1. Factory connected when LGPS is not used. SPST-(N.O. Inducer (IDM) and blower (BLWM) motors contain internal auto-reset thermal overload switches (OL).) BLOWER MOTOR BLOCKED VENT SHUTOFF SWITCH. AUTOMOTIVE BLADE TYPE.C. Gas valve leads are interchangeable on single stage valves. SPST(N. auxiliary limit switch (ALS) is on some downflow models only.C. SPST -(N. 13.) LIMIT SWITCH. 14. SPST -(N. see installation instructions for details on optimum speed selection. gas heating 45 seconds. Blower-on delay. 322869-101 REV. PCB PL1 PL2 PL3 PL5 PRS TEST/TWIN TRAN PRINTED CIRCUIT BOARD 9-CIRCUIT CONNECTOR 2-CIRCUIT PCB CONNECTOR 3-CIRCUIT IDM CONNECTOR 2-CIRCUIT HSI/PCB CONNECTOR PRESSURE SWITCH. SW.O.C. 9.5 AMP PL2 PL3 NOTE #12 HUM R W BRN LS FL NOTE #13 4 PL1 NOTE #13 PRS LGPS (WHEN USED) (WHEN USED) NOTE #14 BVSS WHT BLK BLK BLK —9— PL5 1 2 WHT IDM BLK ILK JB FUSED DISCONNECT SWITCH (WHEN REQ’D) NOTE #4 BLK L1 FU2 NEUTRAL Y HSIR IDR BLWR HI/LO GVR DSS 3 CPU NOTE #14 NOTE #15 GVR-1 2 8 ALS (WHEN USED) GV NOTE #5 HSI GRN/YEL WHT GND LEGEND ALS BLWR BLWM BVSS CAP CPU DSS EAC-1 EAC-2 FL FRS FSE FU1 FU2 GV GVR HI/LO HSI HSIR HUM IDM IDR ILK JB LED LGPS LS OL AUXILIARY LIMIT SWITCH.O. (135 seconds only on some models) 10. cooling or heat pump 2 seconds. Replace only with a 3 amp fuse. AUTO RESET. 3. 6. DPST -(N.O.O. 3 AMP . 12. If any of the original equipment wire is replaced use wire rated for 105°C. 2. Yellow lead not on all motors.5 AMP MAX. This wire must be connected to furnace sheetmetal for control to detect flame. 5.O.) ELECTRONIC AIR CLEANER CONNECTION (COMMON) FUSIBLE LINK FLAME ROLLOUT SW. 180 or 225 seconds.C. Control will auto-reset after three hours.PCB NOTE #9 (NOT ON ALL MODELS) BLOWER OFF DELAY SELECTION CHART SW2 BLOWER OFF DELAY SW1 G R Y W COM HUM DSS ORN (WHEN USED) NOTE #14 BVSS ORN ORN (WHEN USED) NOTE #11 ALS ORN ORN TO 115VAC FIELD DISCONNECT PRS (WHEN USED) LGPS ILK YEL SPARE-2 HEAT L1 HI/LO SPARE-1 COOL COM EAC-1 HSIR EAC-2 1 1 2 NOTE #7 L1 L2 SCHEMATIC DIAGRAM (NATURAL GAS & PROPANE) LO MED LO MED HI HI OL CAP COM BLWM L2 NOTE #4 EQUIPMENT GROUND 90 SEC 135 SEC 180 SEC 225 SEC GVR TEST/TWIN NOTE #14 LED BLU RED LS NOTE #13 BLWR START NOTE #15 (WHEN USED) NOTE #11 GV FL FRS2 GRN/YEL BLK TRAN WHT WHT (COM) GRN/YEL NOTE #5 PL1 3 2 1 6 5 4 9 8 7 WHT RED FSE FRS1 HSI IDM PL2 IDR PR1 TRAN 24VAC TEST/TWIN 2 PL5 HI/LO RELAY SEC-1 SEC-2 BLU RED 115VAC PR2 1 3 PL3 2 NOT USED HSIR IDR BLWR 24 VAC-3A FU1 FUSE BLOWER SPEED COOL SPARE-1 SELECT L2 HEAT SPARE-2 EAC-1 EAC-2 BLK (HI) BRN OL YEL (MED HI) NOTE #7 BLU (MED LO) RED (LO) WHT (COM) WHT BLK BLWM START GRN/YEL FU1 NOTE #6 SEC-1 GVR-2 CAP SEC-2 7 1 FRS1 (WHEN USED) NOTE #11 FRS2 120 VAC L1 PR1 1 2 1 2 3 WHT PR2 COM 1. SPDT HOT SURFACE IGNITOR (115 VAC) HOT SURFACE IGNITOR RELAY . SPST-(N. SPST-(N. When used. SPST -(N. 12—Furnace Wiring Diagram .(N. -MANUAL RESET. Blower motor speed selections are for average conditions.) BLOWER ACCESS PANEL INTERLOCK SWITCH. Some models may have spade quick connect terminals. When used. cooling or heat pump 90 seconds. 4. 7.) CAPACITOR MICROPROCESSOR AND CIRCUITRY DRAFT SAFEGUARD SWITCH ELECTRONIC AIR CLEANER CONNECTION (115 VAC 1. Ignition-lockout will occur after four consecutive unsuccessful trials-for-ignition. OVERTEMP . Blower-off delay.) AUTO-RESET INTERNAL MOTOR OVERLOAD TEMP.) BLOWER MOTOR RELAY . Factory connected when BVSS is not used. FACTORY INSTALLED FUSE OR CIRCUIT BREAKER CURRENT INTERRUPT DEVICE (FIELD INSTALLED & SUPPLIED) GAS VALVE-REDUNDANT OPERATORS GAS VALVE RELAY . gas heating 90. SPST .) FLAME PROVING ELECTRODE FUSE. H A00304 →Fig.) INDUCED DRAFT MOTOR INDUCED DRAFT RELAY .) 24VAC HUMIDIFIER CONNECTION (. 8. 135. FL is on upflow models only. Use only copper wire between the disconnect switch and the furnace junction box (JB). 11.O.) BLOWER MOTOR SPEED CHANGE RELAY .) JUNCTION BOX LIGHT-EMITTING DIODE FOR STATUS CODES LOW GAS PRESSURE SWITCH. H A96263 Fig. refer to twinning kit instructions.Defective inducer motor or start capacitor. COMPONENT TEST To initiate the component test sequence. . If it opens after trial for ignition period.Vent restriction or high winds. Check for: .Low inducer voltage. OR BLOCKED VENT SHUTOFF (when used) SWITCH DID NOT CLOSE OR REOPENED . or sag.Short circuit in secondary voltage (24V) wiring. Briefly short the TEST terminal to the ’Com 24V’ terminal. .or fuse link.5 microamps D. 13—Service Label —10— . 33 LIMIT OR FLAME ROLL-OUT SWITCH IS OPEN . DRAFT SAFEGUARD.Stored status codes are erased when power (115V or 24V) to control is interrupted or 48 hours after each fault is cleared. Inducer will run until fault is cleared. 14 IGNITION LOCKOUT .Blower runs for 90 seconds. The hot surface ignitor. . 21 GAS HEATING LOCKOUT .Inadequate Combustion air supply Flame Roll-out Switch or fuse link. blower motor-heat speed.code changes to #13.SERVICE LED CODE CONTINUOUS OFF CONTINUOUS ON RAPID FLASHING - STATUS Check for 115VAC at L1 and L2.Flame is proved while gas valve is de-energized. if unit is powered up during a call for heat (R-W closed).Loose blower wheel. Refer to #34.Manual shut-off valve.Disconnected or obstructed . inducer shuts off for 15 minutes before retry.Control will NOT auto reset.Stuck-open gas valve or leaky gas valve. Status LED will flash code and then turn ON the inducer motor. The inducer motor will run for the entire component test. If twinned. blower will come on for 90 second recycle delay. Check for: . Line voltage (115V) polarity reversed.Inadequate flame carryover or rough ignition. For flame roll-out switch or fuse link.Defective blower motor or start capacitor. 31 PRESSURE. Manual reset or replace.Control will try three more times before a lockout #14 occurs. 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. . minimum). refer to #33. . 34 IGNITION PROVING FAILURE . 22 ABNORMAL FLAME-PROVING SIGNAL .Open Flame Roll-out switch.C. If flame signal lost after trial for ignition period.Defective pressure switch (stuck closed).Green wire MUST be connected to furnace sheet metal. 6 5 4 3 9 8 7 STATUS TEST 2 1 HUM Com 24V W Y R G 320615-102 REV. 11 NO PREVIOUS CODE . 13 LIMIT OR FLAME ROLL-OUT SWITCH LOCKOUT . .shut OFF the room thermostat or disconnect the "R" thermostat lead. .Proper flame sense microamps (. . blower will come on for 90 second recycle delay.Defective switch or connections. and blower motor-cool speed will be turned ON for 10-15 seconds each.Gas valve turned off. 12 BLOWER ON AFTER POWER UP (115V or 24V) .Stuck gas valve relay on control or miswire to gas valve circuit.Dirty filter or restricted duct system.Auto reset after three hours. Check for: . Check for: . Check for: .Proper vent sizing and condensate pitch . . AUXILIARY-LIMIT (when used).Defective pressure switch or connections. .If open longer than five minutes. pressure tubing.Inadequate Combustion air supply. .Oxide buildup on flame sensor (clean with fine sandpaper). 24 SECONDARY VOLTAGE FUSE IS OPEN Check for: .Obstructed pressure tubing.Low inlet gas pressure. and 24VAC at SEC-1 and SEC-2. .Control will auto-reset after three hours. . .If open longer than three minutes. . Control has 24V power. 23 PRESSURE SWITCH DID NOT OPEN Check for: . . —11— . check for proper low-voltage (24v) transformer phasing. 11? YES Determine status code. Check room thermostat or interconnecting cable. Replace transformer. The HSI. blower motor heat speed. Status codes are erased after 48 hrs or whenever power (115v or 24v) is interrupted. Is red LED status light blinking rapidly without a pause? YES NO Check for correct line voltage polarity. After the control repeats the code 3 times. Replace control center. Is red LED status light on? NO NO YES Is there 24v at SEC-1 and SEC-2? NO YES NO Is there 115v going to switch? YES NO Is circuit breaker closed? NO YES YES Replace door switch. LED will flash the status code of any previous fault or the code No. 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. Y. or G screw terminals. The inducer will start and run for the entire component test. .START Is there 115v at L1 and L2? Is door switch closed? Close door switch and go to start. NO NO Does control respond to W. YES Close circuit breaker and go back to start. Y. or G 24-vac thermostat signals? NO YES Is 24 vac present at W. YES Go to section with status code determined. 11 (1 short and 1 long flash) if no previous fault. and blower motor cool speed will run for 10-15 sec each. or G terminals on the control? YES Replace control if it does not respond to 24-vac signal at W. Y. Check for previous fault by momentarily shorting the TEST terminal and the C terminal until the LED goes out. Is red LED status light blinking ON/OFF slowly with a combination of short and long flashes? NO —12— Was there a previous fault code other than No. Check for continuity in wire from circuit breaker to furnace. the control will go through a brief component test sequence. If units are twinned. Run system through a heating or cooling cycle to check operation. • Motor start capacitor. Connect voltmeter across gas valve connections. 23 PRESSURE SWITCH WILL NOT OPEN .Normal operation. Replace control center. • Manual shut-off valve. Check for: • Stuck closed gas valve relay on control. YES Does gas valve open and allow gas to flow? NO Check that all gas valves are turned on. • Green wire must be connected NO to furnace sheet metal. If it opens after trial for ignition period. R-W closed. • Inadequate combustion air supply (flame rollout switch only). • Gas valve turned off. • Low line voltage (115v). • Defective pressure switch. Clean flame sensor with fine sandpaper and recheck current. inducer shuts off for 15 minutes before retry. Unplug ignitor harness from control center and inititate another component test sequence. Replace valve. NO YES Check connections and retry. replace control center.System failed to ignite gas and prove flame in 4 attempts.0 to 6. • Low inlet gas pressure. • Miswire or short to gas valve wire. blower will come on for 90-sec recycle delay. See No. Does the ignitor glow orange/white hot by the end of the 17-sec warm-up period? YES Fixed. • Open flame rollout switch. A99123 YES .Flame was sensed while gas valve was de-energized. • Defective limit switch or connections. • Defective pressure switch or connections. the system can be operated in the component test mode to check the ignitor. 13. 12 BLOWER ON AFTER POWER UP (115V OR 24V) . 22 ABNORMAL FLAME PROVING SIGNAL . Check for: • Stuck open gas valve solenoid or leak. • Inadequate combustion air. the control will repeat the ignition sequence 3 more times before going into lockout. YES Allow blower to come on and repeat test to check for intermittent operation. Reconnect the R thermostat lead and set thermostat to call for heat. Disconnect thermostat leads to isolate short circuit. Control will auto-reset in 3 hrs. See No. Was 115v present for the 17-sec period? NO Replace control center. First. • Dirty filter.Check for: • Disconnected or obstructed pressure tubing. 34 YES Do main burners ignite? —13— NO YES Do main burners stay on? 33 LIMIT OR FLAME ROLLOUT SWITCH IS OPEN . • Vent restrictions or high winds. Does gas valve receive 24v? 13 LIMIT OR FLAME ROLLOUT SWITCH LOCKOUT Limit switch was open longer than 3 minutes. code changes to No. Replace defective component. 24 LOW-VOLTAGE FUSE IS OPEN . 34 IGNITION PROVING FAILURE If flame is not sensed during the trial for ignition period. • Low inlet gas pressure. Flame rollout switch requires manual reset. • Motor start capacitor. If flame signal is lost after trial for ignition period. NO Check for: • Inadequate flame carryover on rough ignition. • Defective inducer motor. Current is nominally 4.If limit switch is open longer than 3 minutes. Auto-reset will occur after 3 hrs.5? 21 GAS HEATING LOCKOUT Turn off power and wait 5 minutes to retry. or flame sensor.If open longer than 5 minutes. If current is near typical value and control will not stay on.Faults are erased after 48 hrs or whenever power (115v or 24v) is interrupted. 14. Is current near typical value? NO YES NO Will main burner ignite and stay on? Replace electrode. • Loose blower wheel. Check for 115v between pins 1 and 2 on the control center. • Defective control center. Blower will run for 90 sec when furnace power is interrupted during a call for heat. 31 PRESSURE SWITCH WILL NOT CLOSE OR REOPEN .11 NO PREVIOUS FAULT . Repeat call for heat and check flame sensor current during trial for ignition period. 33 NO Check connections. Run system through a heating or cooling cycle to check system. replace control center. To determine whether the problem is in the gas valve.Check for: • Short in low-voltage wiring including thermostat leads shorting to ductwork or furnace cabinet. Check for: • Proper vent sizing or pitch or sag. If OK. Is the DC microamps below 0. manual reset. remove the R thermostat connection from the control center and initiate the component test sequence. blower will come on for 90 sec recycle delay. YES Check for continuity in the harness and ignitor. 14 IGNITION LOCKOUT . Inducer will run until fault is cleared. No.0 microamps. Check for: • Blower motor failure. Check for the following items first before proceding to the next step. ignitor. —14— . —15— . Course descriptions and schedules are in our catalog. Indianapolis. Classroom Service Training plus "hands-on" the products in our labs can mean increased confidence that really pays dividends in faster troubleshooting. including: • Unit Familiarization • Maintenance • Installation Overview • Operating Sequence A large selection of product. fewer callbacks.SERVICE TRAINING Packaged Service Training programs are an excellent way to increase your knowledge of the equipment discussed in this manual. IN 46231 —16— Printed in U. using popular video-based formats and materials. Morris St. CALL FOR FREE CATALOG 1-800-962-9212 [ ] Packaged Service Training [ ] Classroom Service Training A94328 © 2000 Bryant Heating & Cooling Systems 7310 W. theory. plus companion book.A. All include video and/or slides. sp0462 Catalog No. and skills programs is available.S. 5337-310 .