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
→
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.
ama
CANADIAN GAS ASSOCIATION
APPROVED
R
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
—1—
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.)
D
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:
—2—
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
7.
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:
—3—
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.
13
32
BURNER
"
Fig. 6—Position of Ignitor to Burner
11
CELL
PANEL
HOT
SURFACE
IGNITOR
ASSEMBLY
C
IGNITOR
L
7
8
"
C
BURNER
L
IGNITOR
ASSEMBLY
32
"
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.
—4—
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