Bryant 333BAV User Manual

service and

333BAV

maintenance procedures

UPFLOW/HORIZONTAL, VARIABLE-SPEED, 2-STAGE, INDUCED-COMBUSTION FURNACES

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 60,000 through 120,000 Btuh units. Index Page

SAFETY CONSIDERATIONS.....................................................1

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

PROCEDURE...........................................................................2

CARE AND MAINTENANCE..................................................2-5

Air Filter Arrangement..........................................................2-3

Blower Motor and Wheel.........................................................3

Cleaning Heat Exchanger......................................................3-5

Electrical Controls and Wiring.................................................5

Troubleshooting ........................................................................5

Application Wiring Diagrams ..................................................6

Unit Wiring Diagram................................................................7

Service Label ............................................................................8

Troubleshooting Guide .............................................................9

333JAV

Series B

Cancels: SP04-43 SP04-50

10-97

A95137

Fig. 1—Model 333BAV or 333JAV 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.

Follow all safety codes. In the United States, follow all safety

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codes including the National Fuel Gas Code NFPA No. 541996/ANSI Z223.1-1996. In Canada, refer to the current edition of the National Standard of Canada CAN/CGA-B149.1- and .2-M95 Natural Gas and Propane Gas Installation Codes. 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, and CAUTION. 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.

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CANADIAN GAS ASSOCIATION

APPROVED

A94085

CERTIFICATION OF MANUFACTURING SITE

WARNING: The ability to properly perform maintenance on this equipment requires certain expertise, mechanical skills, tools, and equipment. If you do not possess these items, do not attempt to perform any maintenance on this equipment other than those procedures recommended in the User’s Manual. A FAILURE TO FOLLOW THIS WARNING COULD RESULT IN POSSIBLE DAMAGE TO THIS EQUIPMENT, SERIOUS PERSONAL INJURY, OR DEATH.

Fig. 2—Model 333BAV or

333JAV Upflow

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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 and motor. 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, the motor, and the person at the same electrostatic potential.

WARNING: Turn off the gas and electrical supplies to the unit before performing any maintenance or service on it. Follow the operating instructions on the label attached to the furnace. A failure to follow this warning could result in personal injury.

CAUTION: As with any mechanical equipment, personal injury can result from sharp metal edges, etc.; therefore, be careful when removing parts.

1. Disconnect all power to the furnace. DO NOT TOUCH

THE CONTROLS OR ANY WIRE CONNECTED TO THE CONTROLS 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 controls. Tools held in a person’s hand during grounding will be satisfactorily discharged.

3. After touching the chassis you may proceed to service the controls, motor, 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 or motor from its container, discharge your body’s electrostatic charge to ground to protect the control or motor from damage. If the control or motor is to be installed in a furnace, follow items 1 through 5 before bringing the control, or motor, or yourself into contact with the furnace. Put all used AND new controls and motors into containers before touching ungrounded objects.

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: If motor is removed from blower assembly, the motor MUST be reinstalled so arrow on end of the motor is pointing in the direction of airflow through the furnace. The belly band MUST be the specified distance from the motor end shield surface at the shaft end. (See Fig. 3.)

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 the proper frequency of maintenance and the availability of a maintenance contract.

WARNING: Never store anything on, near, or in contact with the furnace, such as: 1. Spray or aerosol cans, rags, brooms, dust mops, vacuum cleaners, or other cleaning

tools.

2. Soap powders, bleaches, waxes or other cleaning compounds, plastic or plastic containers, gasoline, 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.

A95268

DIMENSIONS (IN.)

FURNACE SIZE D

036060 1 048080 1-1/2 060100 3 060120 3

Fig. 3—Motor Belly Band Location

A. Air Filter Arrangement

The air filter arrangement may vary depending on the application. Refer to Table 1 for filter size information.

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.

1. Upflow and horizontal. Each furnace requires 1 or 2 filters which are installed in the blower compartment. (See Fig. 4.) To remove filters for cleaning or replacement, proceed as follows:

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TABLE 1—UPFLOW/HORIZONTAL FILTER SIZE INFOR-

MATION (IN.)

FURNACE

CASING WIDTH

14-3/16 (1) 16 X 25 X 1* (1) 14 X 25 X 1 Cleanable

21 (1) 16 X 25 X 1 (1) 20 X 25 X 1* Cleanable

24-1/2 (2) 16 X 25 X 1* (1) 24 X 25 X 1 Cleanable

* Factory-provided with the furnace. † Filters may be field modified as required by cutting and folding the frame as indicated on the filter.

FILTER SIZE†

Side Return Bottom Return

FILTER

TYPE

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. 4.) For side return, clips may be used on either or both sides of the furnace.

MOUNTING

SCREWS

DRAFT SAFEGUARD SWITCH

Clean as follows:

1. Remove blower access door.

2. Disconnect blower electrical leads from motor. Squeeze latches to remove connectors from motor. Disconnect green ground wire from screw. Note location of wires for reassembly.

3. Remove control.

4. Remove screws holding blower assembly to blower deck and slide blower assembly out of furnace.

5. Mark blower wheel, motor, and motor support in relation to blower housing before disassembly to ensure proper reassembly.

6. Loosen setscrew(s) holding blower wheel on motor shaft.

7. Remove bolts holding motor and motor mount to blower housing and slide motor and mount out of housing. Motor mount belly band need not be removed unless motor is to be replaced.

RELIEF

BOX MAIN

LIMIT

SWITCH

MANUAL

RESET

LIMIT

SWITCHES

AIRFLOW

SELECTOR

CONTROL

PRESSURE SWITCHES

WASHABLE FILTER

FILTER RETAINER

A95270

Fig. 4—Upflow/Horizontal Component Identification

c. Slide filter out. d. Clean filters by spraying tap water through filter from

opposite direction of airflow.

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.

B. Blower Motor and Wheel

For long life, economy, and high efficiency, clean accumulated dirt and grease from the blower wheel and motor annually.

The following steps should be performed by a qualified service technician:

The motors have prelubricated sealed bearings and require no lubrication.

Remember to disconnect the electrical supply before removing access doors.

CAUTION: The blower wheel should not be dropped or bent as balance will be affected.

8. Remove blower wheel from housing. a. Mark cutoff plate location to ensure proper reassembly.

b. Remove screws holding cutoff plate and remove cutoff

plate from housing.

c. Lift blower wheel from housing through opening.

9. Clean blower wheel and motor using a vacuum with soft brush attachment. Do not remove or disturb balance weights (clips) on blower wheel blades.

10. Reinstall blower wheel by reversing items 8 a through c. Be sure wheel is positioned for proper rotation.

11. Reassemble motor and blower by reversing items 4 through

CAUTION: Be sure the motor is properly positioned in the blower housing. The motor arrow must point in the direction of airflow through the furnace after the blower assembly has been reinstalled in the furnace.

12. Reinstall blower assembly in furnace.

13. Reinstall control. If motor has ground wire, be sure it is connected as before.

14. Connect blower electrical leads to motor. Please note that connections are polarized for assembly. DO NOT FORCE.

15. If power choke is attached to blower housing, ensure it is connected in series with black power lead to motor.

C. Cleaning Heat Exchanger

The following steps should be performed by a qualified service technician:

NOTE: Deposits of soot and carbon indicate the existence of a problem which needs to be corrected. Take action to correct the problem.

If it becomes necessary to clean the heat exchanger because of carbon deposits, soot, etc., proceed as follows:

1. Turn gas and power to furnace to OFF.

2. Remove control and blower access doors.

3. Disconnect wires to the following components. Mark wires to aid in reconnection of:

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a. Draft safeguard switch. b. Inducer motor. c. Pressure switch(es). d. Limit overtemperature switch(es). e. Gas valve. f. Hot surface ignitor. g. Flame-sensing electrode. h. Wiring connectors leading to control.

4. Remove 2 screws that secure relief box. (See Fig. 4.)

5. Remove 8 screws that secure flue collector box to center panel. Be careful not to damage sealant.

6. Remove complete inducer assembly from furnace, exposing flue openings.

7. 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 cable.

(1.) Use 48 in. of 1/4-in. diameter high-grade steel

spring cable (commonly known as drain clean-out or Roto-Rooter 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.

(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.) Remove cell outlet plates. IMPORTANT: Replace

screws in center panel to secure heat exchanger cells before cleaning.

(3.) 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. 5.)

A91252

Fig. 5—Cleaning Heat Exchanger Cell

(4.) 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.

(5.) Remove burner assembly and cell inlet plates.

NOTE: Be very careful when removing the burner assembly to avoid breaking the ignitor. See Fig. 6 for the correct ignitor location.

BURNER

Fig. 6—Position of Ignitor to Burner

CELL PANEL

HOT SURFACE IGNITOR ASSEMBLY

IGNITOR

BURNER

IGNITOR ASSEMBLY

A93347

(6.) IMPORTANT: Replace screws in center panel to

secure heat exchanger cells before cleaning.

(7.) Insert brush end of cable in lower opening of cell,

and proceed to clean 2 lower passes of cell in same manner as 2 upper passes.

(8.) Repeat foregoing procedures until each cell in

furnace has been cleaned.

(9.) Using vacuum cleaner, remove residue from each

cell.

(10.) Using vacuum cleaner with soft brush attachment,

clean burner assembly.

(11.) Reinstall cell outlet plates and screws FIRST;

then, reinstall cell inlet plates and burner assembly. Care must be exercised to center the burners in the cell openings.

8. After cleaning flue openings, clean flue collector. Check sealant on flue collector to ensure that it has not been damaged. If new sealant is needed, contact your dealer or distributor.

9. Replace flue collector assembly, making sure all 8 screws are secure.

10. Reinstall relief box.

11. Reconnect wires to the following components: a. Draft safeguard switch.

b. Inducer motor. c. Pressure switches. d. Limit overtemperature switch(es). e. Gas valve. f. Hot surface ignitor.

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