Bryant 330JAV, 331JAV User Manual
service and
330JAV
maintenance procedures
PLUS 80 2-STAGE GAS-FIRED
INDUCED-COMBUSTION FURNACES
NOTE: Read the entire instruction manual before starting the
installation.
This symbol → indicates a change since the last issue.
TABLE OF CONTENTS
SAFETY CONSIDERATIONS.....................................................1
INTRODUCTION..........................................................................2
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
PROCEDURE ................................................................................2
CARE AND MAINTENANCE.....................................................2
Cleaning and/or Replacing Air Filter.......................................2
Blower Motor and Wheel.........................................................3
Cleaning Heat Exchanger.........................................................4
Electrical Controls and Wiring.................................................6
WIRING DIAGRAMS...................................................................7
TROUBLESHOOTING .................................................................7
EFFICIENCY
RATING
CERTIFIED
331JAV
Series D
Cancels: SP04-65 SP04-73
11-01
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REGISTERED QUALITY SYSTEM
Fig. 1—Model 330JAV Horizontal
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, tags, and
labels attached to or shipped with the unit and other safety
precautions that may apply.
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A95137
A94086
Fig. 2—Model 331JAV Downflow
A94085
Fig. 3—Model 330JAV Upflow
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. In Canada, refer to the current
edition of the National Standard of Canada CAN/CGA-B149.1and .2-M00 Natural Gas and Propane Gas Installation Codes
(NSCNGPIC) and Amendment No. 1. Wear safety glasses and
work gloves. Have fire extinguisher available during start-up and
adjustment procedures and service calls.
—1—
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 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 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. A FAILURE TO FOL-
LOW THIS WARNING COULD RESULT IN POS-
SIBLE DAMAGE TO THIS EQUIPMENT, SERIOUS
PERSONAL INJURY, OR DEATH.
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 equipment failure, it is essential that periodic maintenance be performed
on this equipment. Consult your local dealer as to proper frequency
of maintenance and availability of a maintenance contract.
WARNING: Never store anything on, near, or in contact
with furnace, such as:
1. Spray or aerosol cans, rags, brooms, dust mops,
vacuum cleaners, or other cleaning tools.
2. Soap powders, bleaches, waxes or other cleaning
compounds, plastic or plastic containers, gasoline,
kerosene, 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.
INTRODUCTION
These procedures are for size 60,000 through 120,000 Btuh units.
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
PROCEDURE
CAUTION: Electrostatic discharge can affect electronic
components. Take precautions during furnace installation
and servicing to protect the furnace electronic control.
Precautions will prevent electrostatic discharges from
personnel and hand tools which are held during the
procedure. These precautions will help to avoid exposing
the control to electrostatic discharge by putting the
furnace, the control, and the person at the same electrostatic 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 ungrounded objects, etc.).
4. If you touch ungrounded objects (recharge your body with
static electricity), firmly touch furnace again before touching control or wires.
5. Use this procedure for installed and uninstalled (ungrounded) furnaces.
6. Before removing a new control from its container, discharge 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.
WARNING: Turn off gas and electrical supplies to unit
before performing any maintenance or service on it.
Follow 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, personal 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 the 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
filter access 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. Downflow—filters installed in return-air duct. (see Fig. 4.)
a. Turn off electrical supply before removing blower access
door.
b. Remove blower access door.
c. Reach up behind top plate, tilt filters toward center of
return-air plenum, remove filters. Replace filters if torn
or damaged..
d. Furnaces are equipped with permanent, washable filters.
e. Clean filters by spraying tap water through filter from
opposite direction of airflow.
—2—
INSTALLATION
POSITION
OF FILTERS
RETURN-AIR
PLENUM
AIRFLOW
MOUNTING
SCREWS
RELIEF
BOX
GAS
VALVE
CONTROL
FLUE
COLLAR
BLOCKED
VENT
SAFEGUARD
PRESSURE
SWITCH
FLUE
COLLECTOR
BOX
ACCESS DOOR
A88486
Fig. 4—Downflow Filter Arrangement
f. Rinse and let dry. Oiling or coating of filters is not
recommended or required.
g. Reinstall filters.
h. Replace blower access door and turn on electrical supply
to furnace.
2. Upflow/Horizontal–filters installed in media cabinet adjacent to furnace (See Fig. 5.)
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.
3. Upflow/Horizontal–filter(s) installed in side(s) and/or bottom of blower compartment (See Fig. 5.)
a. Turn off electrical supply before removing blower and
control access doors.
b. Release filter retainer from clip at front of furnace
casing. (See Fig. 5.) For side return, clips may be used
on either or both sides of the furnace.
c. Slide filter out.
d. Clean filters by spraying tap water through filter from
opposite direction of airflow.
FILTER
RETAINER
WASHABLE
FILTER
FURNACE
A00293
WASHABLE
FILTER OR
DISPOSIBLE
MEDIA FILTER
IN FILTER
CABINET
HUMHUM
C
24V
OM
GRYW
Fig. 5—Model 330JAV Upflow
e. Rinse and let dry. Oiling or coating of filter is not
recommended or required.
f. Place filter in furnace.
g. Replace blower and control access doors and turn on
electrical supply to furnace.
II. BLOWER MOTOR AND WHEEL
The following items should be performed by a qualified service
technician:
For long life, economy, and high efficiency, clean accumulated 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 blower access door.
3. Downflow only:
a. Disconnect vent connector from furnace flue collar. (See
Fig. 6.)
b. Remove internal vent pipe enclosure cover.
c. Disconnect and remove short piece of vent pipe from
within furnace.
d. Disconnect and remove vent pipe enclosure. Push bot-
tom side backward to release tabs.
NOTE: Vent pipe is SCREWED and RTV sealed to relief box.
4. Disconnect blower leads from furnace control. Note wire
color and location for reassembly. Also, disconnect auxiliary limit switch leads (downflow only, if present).
All other factory wires can be left connected, but field
thermostat connections may need to be disconnected depending on their length and routing.
5. Remove 2 screws securing control and transformer support
to furnace.
6. Hang control and transformer support to front of furnace
casing.
—3—
FLUE
COLLAR
NOTE: Refer to Table 1 for motor speed lead relocation if leads
were not identified before disconnection.
VENT PIPE
AUXILIARY
LIMIT
SWITCH
MOUNTING
SCREWS
RELIEF
BOX
ENCLOSURE
CONTROL
DRAFT
SAFEGUARD
SWITCH
PRESSURE
SWITCHES
MANUAL
RESET
LIMIT
SWITCHES
A99092
Fig. 6—Model 331JAV Downflow
7. Remove screws holding blower assembly to blower deck
and slide blower assembly out of furnace.
8. 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.
9. If greasy residue is present on blower wheel, remove wheel
from the blower housing and wash it with an appropriate
degreaser. To remove wheel:
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 mounts to blower housing
and slide motor and mounts out of housing. Disconnect
capacitor and ground wire attached to blower housing
before removing motor.
f. Remove blower wheel from housing.
10. Reassemble motor and blower by reversing items 9a
through 9f. Be sure to reattach ground wire.
11. Reinstall blower assembly in furnace.
12. Reinstall control box and support assembly in furnace.
13. Reconnect blower leads to furnace control and auxiliary
limit switch leads (downflow only).
Refer to furnace wiring diagram, and connect thermostat
leads if previously disconnected. (See Fig. 11.)
TABLE 1—SPEED SELECTOR
COLOR SPEED
Black High Cool
Yellow (When Present) Medium High Spare
Blue Medium Low Heat
Red Low Spare
White Common C
Orange (When Present) Medium Spare
FACTORY-
ATTACHED
TO
OM
CAUTION: Heating speed selection MUST be adjusted
to provide proper temperature rise as specified on the
rating plate. Failure to adjust the heating speed may
shorten heat exchanger life.
14. Reinstall internal vent pipe and enclosure on downflow
furnaces only by reversing items 3a through 3c.
NOTE: A 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) 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.
15. 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.
16. 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 furnace control. 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 electrical shock, personal injury, or
death.
NOTE: If thermostat terminals are jumpered before blower access door switch is closed, blower will run for 90 sec before
beginning a heating or cooling cycle.
17. If furnace is operating properly, remove tape to release
blower access door switch, replace blower access door.
III. 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
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 heat exchanger because of light
dust or corrosion proceed as follows:
—4—
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