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

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.

CERTIFIED

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.

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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.

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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

24V

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.

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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

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:

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