Bryant 333JAV, Series C Service And Maintenance Procedures Manual
Service and
333BAV
Maintenance Procedures
UPFLOW/HORIZONTAL
VARIABLE-SPEED, 2–STAGE
INDUCED-COMBUSTION FURNACE
NOTE: Read the entire instruction manual before starting the
installation.
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.................................................5
Wiring Diagrams............................................................................6
Troubleshooting..............................................................................6
333JAV
Series C&D
Cancels: SP04-57 SP04-64
10-00
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.
In the United States, follow all safety codes including the National
Fuel Gas Code (NFGC) NFPA No. 54-1996/ANSI Z223.1-1999.
In Canada, refer to the current edition of the National Standard of
Canada CAN/CGA-B149.1- and .2-M99 Natural Gas and Propane
Gas 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 these 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 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.
A94085
Fig. 2—Model 333BAV or 333JAV Upflow
EFFICIENCY
RATING
CERTIFIED
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9
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REGISTERED QUALITY SYSTEM
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—1—
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 items, do not attempt to perform any
maintenance on this equipment other than those proce-
dures recommended in the User’s Manual. A FAILURE
TO FOLLOW THIS WARNING COULD RESULT IN
POSSIBLE DAMAGE TO THIS EQUIPMENT, SERI-
OUS PERSONAL INJURY, OR DEATH.
INTRODUCTION
These instructions are written for the Upflow/Horizontal, VariableSpeed, 2–Stage, Induced-Combustion Furnace.
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.
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 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
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, motor, or yourself into
contact with the furnace. Put all used AND new controls
into containers before touching ungrounded objects.
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 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.
WARNING: Turn off the gas and electrical supplies to
the unit before performing any maintenance or service on
it. Follow 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.
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.)
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. Filters installed in media cabinet adjacent to furnace (see
Fig. 4):
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.
—2—
D
DIMENSIONS (IN.)
FURNACE SIZE D
036060 1
048080 1–1/2
060100 3
060120 3
Fig. 3—Motor Belly Band Location
FLUE
COLLAR
MOUNTING
SCREWS
RELIEF
BOX
GAS
VALVE
CONTROL
HUM
C
24V
OM
GRYW
WASHABLE
FILTER OR
DISPOSIBLE
MEDIA FILTER
IN FILTER
CABINET
Fig. 4—Upflow/Horizontal Component Identification
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.
2. Filter(s) installed in side(s) and/or bottom of blower compartment (See Fig. 4):
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.
c. Slide filter out.
BLOCKED
VENT
SAFEGUARD
PRESSURE
SWITCH
FLUE
COLLECTOR
BOX
FILTER
RETAINER
WASHABLE
FILTER
FURNACE
A95268
A00293
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. Fasten filter retainer in front slot.
h. Replace blower and control access doors and turn on
electrical supply to furnace.
II. BLOWER MOTOR AND WHEEL
For long life, economy, and high efficiency, clean accumulated dirt
and grease from blower wheel and motor annually.
The following items 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.
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.
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 8a through 8c.
Be sure wheel is positions for proper rotation.
11. Reassemble motor and blower by reversing items 6 and 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. Be sure motor ground wire is connected
as before.
—3—
14. Reinstall vent connector on 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.
15. Connect blower electrical leads to motor. Please note that
connections are polarized for assembly. DO NOT FORCE.
16. If power choke is attached to blower housing, ensure it is
connected in series with black power lead to motor.
17. Replace blower and control access doors and turn on
electrical power to furnace.
18. Check for proper blower operation in heating and cooling.
III. 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 electrical 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:
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 complete inducer assembly from flue collector
box, exposing flue openings.
6. Remove 8 screws that secure flue collector box to center
panel. Be careful not to damage sealant.
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-Rootert 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.)
(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.
A91252
Fig. 5—Cleaning Heat Exchanger Cell
11
CELL
PANEL
HOT
SURFACE
IGNITOR
ASSEMBLY
C
IGNITOR
L
7
"
8
C
BURNER
L
IGNITOR
ASSEMBLY
32"
A93347
BURNER
13
32"
Fig. 6—Position of Ignitor to Burner
NOTE: Be very careful when removing the burner assembly to
avoid breaking the ignitor. See Fig. 6 for the correct ignitor
location.
(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.
—4—
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