Bryant 355MAV User Manual

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service and

355MAV

maintenance procedures

DELUXE 4-WAY MULTIPOISE VARIABLE-CAPACITY DIRECT-VENT CONDENSING GAS FURNACE

A93040

NOTE: Read the entire instruction manual before starting the installation.

This symbol → indicates a change since the last issue.

WARNING: ELECTRICAL SHOCK, FIRE, OR EXPLOSION HAZARD

Failure to follow safety warnings exactly could result in dangerous operation, serious injury, death, or property damage. Improper servicing could result in dangerous operation, serious injury, death, or property damage.

- Before servicing, disconnect all electrical power to furnace.

- When servicing controls, label all wires prior to disconnecting. Reconnect wires correctly.

- Verify proper operation after servicing.

Series I

Cancels: SP05-57 SP05-64

9-04

WARNING: FIRE OR EXPLOSION HAZARD

Failure to follow this warning could cause corrosion of heat exchanger, fire, personal injury, or death. 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, kerosene, cigarette lighter fluid, dry cleaning fluids, or other volatile fluids.

3. Paint thinners and other painting compounds, paper bags, or other paper products.

TABLE OF CONTENTS

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

GENERAL......................................................................................2

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS........2

CARE AND MAINTENANCE.....................................................3

Cleaning and/or Replacing Air Filter.......................................3

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

Cleaning Burners ......................................................................5

Cleaning Heat Exchangers........................................................5

Flushing Collector Box and Drainage

System.......................................................................................6

Servicing Hot Surface Igniter...................................................8

Electrical Controls and Wiring.................................................8

Checking Heat Tape Operation

(If Applicable)...........................................................................9

Winterizing................................................................................9

WIRING DIAGRAM...................................................................10

TROUBLESHOOTING ...............................................................10

WARNING: ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in possible damage to this equipment, serious personal injury, or death. The ability to properly perform maintenance on this equipment requires certain expertise, mechanical skills, tools, and equipment. If you do not possess these, do not attempt to perform any maintenance on this equipment other than those procedures recommended in the User’s Manual.

—1—

SAFETY CONSIDERATIONS

Recognize safety information. This is the safety-alert symbol When you see this symbol on the unit 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 may 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.

Installing and servicing heating equipment can be hazardous due to gas and electrical components. Only trained and qualified service agency personnel should install, repair, or service heating equipment.

These instructions are written as if the furnace is installed in an

GENERAL

upflow application. An upflow furnace application is where the blower is located below the combustion and controls section of the furnace, and conditioned air is discharged upward. Since this furnace can be installed in any of the 4 positions shown in Fig. 2, you must revise your orientation to component location accordingly.

AIRFLOW

UPFLOW

A98308

Fig. 1—Multipoise Furnace in Upflow Orientation

EFFICIENCY RATING CERTIFIED

ISO 9001:2000

CERTIFIED

REGISTERED

Untrained personnel can perform basic maintenance functions described in User’s Information Manual 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, on tags, and on labels attached to or shipped with the unit and other safety precautions that may apply.

CAUTION: CUT HAZARD

Failure to follow this caution may result in personal injury. Be careful of sharp metal edges, etc. Use care and wear protective clothing, gloves, and safety glasses when removing parts.

Follow all safety codes including the National Fuel Gas Code (NFGC) NFPA 54-2002/ANSI Z223.1-2002 in the USA, CSA B149.1-00 National Standard of Canada, Natural Gas and Propane Installation Codes (NSCNGPIC) in Canada, and the Installation Standards, Warm Air Heating and Air Conditioning Systems (NFPA 90B) ANSI/NFPA 90B. Wear safety glasses and work gloves. Have a fire extinguisher available during start-up and adjustment procedures and service calls.

HORIZONTAL

RIGHT

AIRFLOW

HORIZONTAL

LEFT

DOWNFLOW

AIRFLOW

Fig. 2—Multipoise Orientation

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

→

CAUTION: UNIT DAMAGE HAZARD

Failure to follow this caution may damage furnace

components.

Electrostatic discharge can affect electronic components.

Take precautions during furnace installation and servic-

ing 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.

AIRFLOW

A93041

—2—

WASHABLE FILTER

FILTER SUPPORT

FILTER RETAINER

WASHABLE FILTER OR DISPOSABLE MEDIA FILTER IN FILTER CABINET

Fig. 3—Bottom Filter Arrangement

A00232

WASHABLE

FILTER

IN FURNACE

WASHABLE FILTER OR DISPOSABLE MEDIA FILTER IN FILTER CABINET

Fig. 4—Filter Installed for Side Inlet

FILTER RETAINER

A00233

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 furnace failure, it is essential that maintenance be performed annually. Consult your local dealer for maintenance and maintenance contract availability.

WARNING: ELECTRICAL SHOCK HAZARD

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

The minimum maintenance that should be performed on this equipment is as follows:

1. Check and clean or replace air filter each month as needed.

2. Check blower motor and wheel for cleanliness annually.

3. Check electrical connections for tightness and controls for proper operation each heating season. Service as necessary.

4. Check for proper condensate drainage. Clean as necessary.

5. Check for blockages in combustion-air and vent pipes annually.

6. Check burners for cleanliness annually.

I. CLEANING AND/OR REPLACING AIR FILTER

The air filter arrangement may vary depending on the application or orientation.

WARNING: FIRE, CARBON MONOXIDE AND POISONING HAZARD

Failure to follow this warning could result in fire, personal injury, or death. Never operate unit without a filter or with the blower access panel removed. Dust and lint on internal parts in furnace can cause a loss of efficiency.

NOTE: If the filter has an airflow direction arrow, the arrow must point toward the blower.

To clean or replace filters, proceed as follows: If filter is installed in filter cabinet adjacent to furnace:

1. Turn off electrical supply to furnace.

2. Remove filter cabinet door.

3. Slide filter out of cabinet.

4. 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.

5. If equipped with factory specified disposable media filter, replace only with a factory specified media filter of the same size.

6. Slide filter into cabinet.

7. Replace filter cabinet door.

8. Turn on electrical supply to furnace.

If filter is installed in furnace blower compartment:

1. Turn off electrical supply to furnace.

2. Remove main furnace door and blower access panel.

3. Release filter retainer wire. (See Fig. 3 or 4.)

NOTE: Filters shown in Fig. 3 and 4 can be in furnace blower compartment or in filter cabinet, but not in both.

4. Slide filter out of furnace.

5. Furnaces are equipped with permanent, washable filter(s). Clean filter by spraying cold tap water through filter in opposite direction of airflow.

6. Rinse filter and let dry. Oiling or coating filter is not recommended.

7. Slide filter into furnace.

8. Recapture filter retaining wire.

9. Replace blower access panel and main furnace door.

II. BLOWER MOTOR AND WHEEL MAINTENANCE

To ensure 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.

—3—

PLUG

CAP

COLLECTOR BOX

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX

TUBE (PINK)

COLLECTOR BOX

TUBE (GREEN)

INDUCER HOUSING

(MOLDED) DRAIN

TUBE (BEHIND

COLLECTOR BOX

DRAIN TUBE)

COLLECTOR BOX

DRAIN TUBE (BLUE)

FIELD-INSTALLED

FACTORY-SUPPLIED

DRAIN TUBE

COUPLING (LEFT

DRAIN OPTION)

FIELD-INSTALLED

FACTORY-SUPPLIED

DRAIN TUBE

FIELD-INSTALLED

FACTORY-SUPPLIED

⁄2-IN. CPVC STREET

ELBOWS (2) FOR

LEFT DRAIN OPTION

FIELD-INSTALLED

FACTORY-SUPPLIED

COUPLING (RIGHT

CONDENSATE TRAP

DRAIN TUBE

DRAIN OPTION)

A01030

Fig. 5—Factory-Shipped Upflow Tube

Configuration

(Shown with Blower Access Panel Removed)

The following items should be performed by a qualified service technician.

Clean blower motor and wheel as follows:

1. Turn off electrical supply to furnace.

2. Remove main furnace door and blower access panel.

3. Disconnect wires. All factory wires can be left connected, but field thermostat

connections may need to be disconnected depending on their length and routing.

4. Position control box, transformer, and door switch assembly to right side of furnace casing.

5. If condensate trap is located in left- or right-hand side of furnace casing, proceed to item 6. Otherwise remove trap and tubing as described below (See Fig. 5.):

a. Disconnect field drain connection from condensate trap. b. Disconnect drain and relief port tubes from condensate

trap.

c. Remove condensate trap from blower shelf.

6. Remove screws securing blower assembly to blower shelf and slide blower assembly out of furnace. Detach ground wire and disconnect blower motor harness plugs from blower motor.

NOTE: Blower wheel is fragile. Use care.

7. Clean blower wheel and motor by using a vacuum with soft brush attachment. Be careful not to disturb balance weights (clips) on blower wheel vanes. Do not bend wheel or blades as balance will be affected.

8. 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 and blower housing so each arm is positioned at the same hole 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. f. Remove blower wheel from housing. g. Clean wheel per instructions on degreaser cleaner. Do

not get degreaser in motor.

9. Reassemble motor and blower wheel by reversing items 8b through 8f. Ensure wheel is positioned for proper rotation. Be sure to attach ground wire and reconnect blower harness plugs to blower motor.

10. Reinstall blower assembly in furnace.

11. Reinstall condensate trap and tubing if previously removed. a. Reinstall condensate trap in hole in blower shelf.

b. Connect condensate trap drain tubes. See Fig. 5 or tubing

diagram on main furnace door for proper tube location. (1.) Connect 1 tube (blue or blue and white striped)

from collector box.

(2.) Connect 1 tube (violet or unmarked) from inducer

housing.

(3.) Connect 1 tube (relief port, green or pink) from

collector box.

c. Connect field drain to condensate trap.

NOTE: Ensure tubes are not kinked or pinched, as this will affect operation.

12. Reinstall control box, transformer, and door switch assembly on blower shelf.

13. Reconnect wires. a. Refer to furnace wiring diagram and connect thermosta

leads if previously disconnected. (See Fig. 17.)

WARNING: ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death. Blower access panel 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.

14. Turn on electrical supply. Manually close blower access panel 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 G and R to Y/Y2 on furnace control thermostat terminals. (See Fig. 12.)

15. If furnace is operating properly, release blower access panel door switch, replace blower access panel, and replace main furnace door.

—4—

III. CLEANING BURNERS

The following items should be performed by a qualified service technician. If the burners develop an accumulation of light dirt or dust, they may be cleaned by using the following procedure:

1. Turn off gas and electrical supplies to furnace.

2. Remove main furnace door.

3. Remove burner box cover.

4. Using backup wrench, disconnect gas supply pipe from furnace gas valve.

→

CAUTION: ELECTRICAL SHOCK AND UNIT DAMAGE HAZARD

Failure to follow this caution may result in minor personal injury or furnace component damage. Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

5. Remove wires from gas valve. Note location for reassembly.

6. Remove burner box pressure tube from gas valve regulator fitting.

7. Remove screws that secure manifold to burner box. (See Fig. 6.)

NOTE: Do not remove burner box from cell panel.

8. Remove manifold, orifices, and gas valve as 1 assembly.

9. Remove screws attaching burner assembly in burner box.

10. Remove burner assembly from burner box.

NOTE: All burners are attached to burner bracket and can be removed as 1 assembly.

11. Clean burners with soft brush and vacuum.

12. Reinstall manifold, orifice, and gas valve assembly in burner box. Ensure manifold seal grommet is installed properly and burners fit over orifices.

13. Reconnect wires to gas valve. Refer to furnace wiring diagram for proper wire location.

CELL

PANEL

MANIFOLD MOUNTING SCREWS

14. Reinstall burner box pressure tube to gas valve regulator fitting.

15. Reinstall gas supply pipe to furnace gas control valve using backup wrench on gas valve to prevent rotation and improper orientation.

NOTE: Use propane gas resistant pipe dope to prevent gas leaks. DO NOT use Teflon tape.

WARNING: FIRE, EXPLOSION, UNIT DAMAGE HAZARD

Failure to follow this warning could result in property damage, personal injury, or death. Gas valve switch MUST be facing forward or tilted slightly.

16. Replace burner box cover.

17. Turn on gas and electrical supplies to furnace.

18. Check for gas leaks.

WARNING: FIRE OR EXPLOSION HAZARD

Failure to follow the safety warnings exactly could result in serious injury, death or property damage. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury or loss of life.

19. Replace main furnace door.

IV. CLEANING HEAT EXCHANGERS

The following items should be performed by a qualified service technician.

A. Primary Heat Exchangers

If the heat exchangers get an accumulation of light dirt or dust on the inside, they may be cleaned by the following procedure:

NOTE: If the heat exchangers get a heavy accumulation of soot and carbon, both the primary and secondary heat exchangers 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, improper vent termination, incorrect size or damaged manifold orifice(s), improper gas, or a restricted heat exchanger (primary or secondary). Action must be taken to correct the problem.

1. Turn off gas and electrical supplies to furnace.

2. Remove main furnace door.

MANIFOLD

GAS VALVE REGULATOR FITTING

GAS CONTROL VALVE

Fig. 6—Burner Box Assembly

GASKET

A02312

—5—

→

CAUTION: ELECTRICAL SHOCK AND UNIT DAMAGE HAZARD

3. Disconnect wires or connectors to flame rollout switch, gas valve, igniter, and flame sensor.

4. Disconnect combustion-air intake pipe from intake housing.

5. Remove the pressure switch tube from intake housing.

6. Remove screws attaching intake housing to burner box, and rotate intake housing away from burner box for removal.

7. Using backup wrench, disconnect gas supply pipe from furnace gas control valve.

8. Disconnect pressure tubing from gas valve.

9. Remove 2 screws attaching top filler panel and rotate upwards to gain access to screws attaching burner box to cell panel.

10. Remove screws attaching burner box to cell panel. (See Fig.

6.)

NOTE: Burner box cover, manifold, gas valve, and burner assembly should be removed as 1 assembly.

11. Clean heat exchanger openings with a vacuum and a soft brush. (See Fig. 7.)

NOTE: After cleaning, inspect the heat exchangers to ensure they are free of all foreign objects that may restrict flow of combustion products.

PRIMARY HX INLET OPENINGS

RTV

PAM

A93087

Fig. 8—Combustion-Air Intake Housing Gasket Repair

15. Turn on gas and electrical supplies to furnace.

16. Check furnace operation through 2 complete heat operating cycles. Look through sight glass in burner enclosure to check burners. Burner flames should be clear blue, almost transparent. (See Fig. 10.)

17. Check for gas leaks.

WARNING: FIRE OR EXPLOSION HAZARD

Fig. 7—Cleaning Inlet Openings of Primary Heat

Exchangers

12. Reverse items 4 through 10 for reassembly.

→

CAUTION: UNIT MAY NOT OPERATE

Failure to attach this ground wire to an adequate casing ground may cause the furnace control to lock out. The ground wire from the gas valve MUST be attached to the burner box attachment screw.

NOTE: Be sure burner box gasket is installed between burner box and cell panel. (See Fig. 6.) If gasket is damaged, replace it.

NOTE: Inspect combustion-air intake housing. If foamed gasket was removed, check for any damage. If gasket is damaged in any way, it must be repaired. To repair, remove damaged gasket section, apply sealant 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) to burner box and apply a small bead of G.E. RTV 162, G.E. RTV 6702, or Dow-Corning RTV 738 sealant to edge of combustion-air intake housing. (See Fig. 8.)

13. Refer to furnace wiring diagram and reconnect wires to flame rollout switch, gas valve, igniter, and flame sensor.

14. Reconnect pressure switch tubes to gas valve and intake housing. Refer to tube routing label on main furnace door for proper tube location. (See Fig. 9.) Be sure tubes are not kinked.

A96305

18. Replace main furnace door.

B. Secondary Heat Exchangers NOTE: The condensing side (inside) of the secondary heat

exchangers CANNOT be serviced or inspected. A small number of bottom outlet openings can be inspected by removing the inducer assembly. See Flushing Collector Box and Drainage System section for details on removing inducer assembly.

V. FLUSHING COLLECTOR BOX AND DRAINAGE SYSTEM

1. Turn off gas and electrical supplies to furnace.

2. Remove main furnace door.

3. Disconnect inducer motor and pressure switch wires or connectors.

4. Disconnect pressure switch tubes.

5. Disconnect vent pipe from inducer housing outlet by loosening coupling clamp on inducer outlet.

6. Disconnect drain tube from inducer housing. (See Fig. 8.)

7. Remove inducer housing assembly by removing 4 bolts attaching assembly to cell panel.

8. Flush inside of collector box with water until discharge from condensate trap is clean and runs freely.

NOTE: Ensure the drain tube disconnected from the inducer housing is higher than the collector box opening or water will flow out tube.

9. Inspect inside area of collector box for any pieces of foreign materials and remove if present.

—6—

CAUTION: UNIT DAMAGE HAZARD

DO NOT use wire brush or other sharp object to inspect or dislodge materials in secondary heat exchangers as failure of the secondary heat exchanger may occur. Flush with water only.

10. Reassemble inducer assembly by reversing items 5-7. Tighten vent coupling clamp screw(s) to 15 in.-lb of torque.

NOTE: If seal between the inducer housing and the collector box is damaged in any way, it must be repaired. To repair, apply sealant releasing agent such as PAM cooking spray or equivalent (must not contain corn or canola oil, aromatic or halogenated hydrocarbons which can cause an inadequate seal to occur) to inducer housing. (See Fig. 11.) Apply a small bead of G.E. RTV 162, G.E. RTV 6702, or Dow-Corning RTV 738 sealant to groove in collector box.

11. Refer to furnace wiring diagram and reconnect wires to inducer motor and pressure switches or connectors.

12. Reconnect pressure tubes to pressure switches. See diagram on main furnace door for proper location of tubes. Be sure tubes are not kinked. (See Fig. 9.)

13. Turn on gas and electrical supplies to furnace.

14. Check furnace operation through 2 complete heat operating cycles. Check area below inducer housing, vent pipe, and condensate trap to ensure no condensate leaks occur. If leaks are found, correct the problem.

15. Check for gas leaks.

Furnace is shipped from factory in upflow configuration. Pressure tube and drain tube routing MUST match the diagrams below.

Condensate Trap; Factory Installed

in Blower Shelf

(Blower access panel removed)

COLLECTOR BOX TUBE

COLLECTOR BO X TUBE (GREE N)

INDUCER HOUSING (MOLDED) DRAIN TUBE

(BEHIND COLLECTOR BOX DRAIN TUBE)

COLLECTOR BOX DRAIN TUBE

FACTORY-SUPPLIED DR AIN TUBE

COUPLING (LEFT DRAIN OPTION)

Condensate Trap on

COLLECTOR BO X TUBE (GREEN)

BURNER EN C LO SURE PRESSU R E

REFERENCE TUBE ASSEMBLY

INDUCER HOUSING DRAIN TUBE (VIOLET)

(PINK )

(BLUE)

FIELD-INSTALLED

FIELD-INSTALLED FACTORY-

SUPPLIED DRAIN TUBE

LEFT Side

CAP

COLLECTOR BOX DRAIN TUBE

(BLUE & WHITE STRIPED)

COLLECTOR BOX

EXTENSION TUBE

CONDENSATE TRAP

Tube location when used in UPFLOW application

BURNER EN C L OSURE PRESSU R E

Tube location when used in DOWN FLOW application

PLUG

TUBE ROUTING

REFERENCE TUBE ASSEMBLY

CAP

PLUG

COLLECTOR BOX

DRAIN TUBE

(BLUE & W HITE STRIPED)

CONDENSATE TRAP

FIELD-INSTALLED

FACTORY-SUPPLIED DRAIN

TUBE COUPLING (RIGHT

DRAIN OPTION)

FIELD-INSTALLED FACTORY-SUPPLIED 1/2-IN. CPVC STREET

ELBOWS (2) FOR LEFT

DRAIN OPTION

COLLECTOR BOX DRAIN TUBE

(BLUE )

COLLECTOR BO X EXTENSION TUBE

COLLECTOR BOX TU BE

(PINK)

COLLECTOR BO X TUBE

(PINK)

COLLECTOR BOX TU BE

(GREEN)

COLLECTOR BOX DRAIN TUBE

(BLUE )

CONDENSA TE TR AP

INDUCER HOUSING

DRAIN TUBE

(VIOLET)

COLLECTOR BOX TUBE

(GREEN)

BURNER EN CLOSURE

PRESSURE REFERENCE

TUBE ASSEMBLY

COLLECTOR BOX DRAIN TUBE

(BLUE & WHITE STRIPED)

INDUCER HOUSING

DRAIN TUBE

(VIOLET)

DRAIN TUBE

COUPLING

DRAIN TUBES ROUTED IN

FRONT OF GAS VALVE

Tube location when used on

HORIZONT AL - LEFT ap plication

COLLECTOR BO X DR AIN TUBE

PLUG

CAP

BURNER

ENCLOSURE

PRESSURE

REFERENCE TUBE

ASSEMBLY

COLLECTOR BOX

EXTENSION TUBE

CONDENSATE TRAP

COLLECTOR BOX EXTENSION DRAIN TUBE

COLLECTOR BO X TUBE (PINK) RELOCATE T UBE BE TW EE N BLOWER SHELF AND

INDUCER HOUSING FOR 0 40,06 0 , AND 080 HEATING INP UT FURNACES

NOTE:

1. All tubing must be connected securely and routed to avoid kinks and traps.

2. Pressure tubing must always slope away from pressure switch to collector box connection as shown.

3. HORIZONTAL-LEFT installations require the collector box pressure tube to be relocated between the inducer housing and the blower shelf to prevent a trap.Refer to the Installation Instructions for further details.

DRAIN TUBE

COUPLING

(BLUE & WHITE STRIPED)

COLLECTOR

BOX TUBE

(GREEN)

INDUCER HOUSING

DRAIN TUBE

(VIOLET)

COLLECTOR BOX

DRAIN TUBE (BLUE)

COLLECTOR BOX DRAIN TUBE (BLUE)

PLUG

CAP

COLLECTOR BO X TUBE (GREE N)

COLLECTOR BOX DRAIN TUBE

(BLUE AND W HITE STRIPED)

Condensate Trap on LEFT

Side Optional

BURNER ENCLOSURE PRESSURE

REFERENCE TUBE ASSEMBLY CAP

PLUG

COLLECTOR BOX

DRAIN TUBE

(BLUE & WHITE STRIPED)

Condensate Trap on

CAP

COLLECTOR BOX DRAIN TUBE

(BLUE )

COLLECTOR BOX TUBE

PLUG

COLLECTOR BOX EXTENSION TUBE

CONDENSATE TRAP

COLLECTOR BOX EXTENSION

GAS VALVE

Tube location when used on

HORIZONTAL - RIGHT application

COLLECTOR BOX TUBE (PIN K)

INDUCER HOUSING DRAIN TUBE (VIOLET)

AUXILIARY "J" BOX RELOCATED HERE

COLLECTOR BO X EXTENSION TUBE

CONDENSATE TRAP

325400-201 REV. C (LIT - BOTTOM)

RIGHT Side

(PINK)

DRAIN TUBE

TUBE ASSEMBLY

BURNER

ENCLOSURE

PRESSURE

REFERENCE

Fig. 9—Furnace Pressure and Drain Tubing Diagram

—7—

A00351

BURNER FLAME

MANIFOLD

Fig. 10—Burner Flame

BURNER

PAM

RTV

A89020

WARNING: FIRE OR EXPLOSION HAZARD

16. Replace main furnace door.

VI. SERVICING HOT SURFACE IGNITER

The igniter does NOT require annual inspection. Check igniter resistance before removal.

1. Turn off gas and electrical supplies to furnace.

2. Remove main furnace door.

3. Disconnect igniter wire connection.

4. Check igniter resistance. a. Using an ohm meter, check resistance across both igniter

leads in connector. b. Cold reading should be between 45 ohms and 90 ohms. c. If ohm reading is higher than 110 ohms, igniter is

cracked and must be replaced.

5. Remove igniter assembly.

Fig. 11—Gasket on Collector Box

→

CAUTION: UNIT DAMAGE HAZARD

Failure to follow this caution may result in premature failure of the igniter. The igniter is fragile. DO NOT allow it to hit the side of the burner box opening while removing or replacing it.

b. Inspect igniter for a white area indicating a crack may be

present. If found, replace igniter.

NOTE: A small crack cannot be seen on a new igniter. After a period of operation, a white area will be visible around the crack.

c. If replacement is required, replace igniter on igniter

bracket external to furnace to avoid damage as the silicon portion is very brittle and will easily crack or shatter.

d. To remove igniter from igniter bracket, remove screw

holding igniter ceramic block to bracket and pull ceramic block out of bracket.

6. To replace igniter/igniter assembly, reverse items 5a through 5d.

7. Reconnect igniter wire connection.

8. Turn on gas and electrical supplies to furnace.

9. Verify igniter operation by initiating control board self-test feature or by cycling thermostat.

10. Replace main furnace door.

VII. ELECTRICAL CONTROLS AND WIRING

A93081

→

CAUTION: BURN HAZARD

Failure to follow this caution may result in minor personal injury. Allow igniter to cool before removal. Normal operating temperatures exceed 2000°F.

a. Do not remove igniter from bracket while assembly is in

furnace. Using a 1/4 in. nutdriver, remove screw securing bracket and ignitor assembly to bottom of burner box. The screw in the bracket is always located toward outside of burner box. The screw may be hidden by inlet box or inlet pipe, but can be removed without removing either. After removing screw, slide igniter and bracket toward outside of burner box and pull straight out.

—8—

→

WARNING: ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death. There may be more than 1 electrical supply to the unit. Check accessories and cooling unit for additional electrical supplies.

The electrical ground and polarity for 115-v wiring must be maintained properly. Refer to Fig. 12 for field wiring information and to Fig. 16 for unit wiring information. NOTE: If the polarity is not correct, the STATUS LED on the furnace control will flash rapidly and prevent the furnace from operating. The control system also requires an earth ground for proper operation of the furnace control and flame sensor.

BLK

WHT

GND

115-VOLT FIELD-

SUPPLIED

FUSED

DISCONNECT

BLK

WHT

JUNCTION BOX

FIVE

WIRE

THREE-WIRE

HEATING-

ONLY

CONTROL

BOX

FURNACE

COM

W/W1

Y/Y2

R G

24-VOLT

TERMINAL

BLOCK

NOTE 2

WCY RG

NOTE 1

NOTES: 1.

Connect Y/Y2-terminal as shown for proper operation. Some thermostats require a "C" terminal connection as shown.

2. If any of the original wire, as supplied, must be replaced, use

3. same type or equivalent wire.

Fig. 12—Field Wiring

FIELD 24-VOLT WIRING FIELD 115-, 208/230-, 460-VOLT WIRING FACTORY 24-VOLT WIRING FACTORY 115-VOLT WIRING

1-STAGE THERMOSTAT TERMINALS

CONDENSING

UNIT

FIELD-SUPPLIED

FUSED DISCONNECT

GND

208/230- OR 460-VOLT THREE PHASE

208/230VOLT SINGLE PHASE

A95236

The 24-v circuit contains an automotive-type, 3-amp fuse located on the furnace control. (See Fig. 13.) Any direct shorts of the 24-v wiring during installation, service, or maintenance will cause this fuse to blow. If fuse replacement is required, use ONLY a fuse of identical size. The furnace control LED will flash status code 24 when fuse needs to be replaced.

With power to the unit disconnected, check all electrical connections for tightness. Tighten all screws on electrical connections. If any smoky or burned connections are found, disassemble the connection, clean all parts, strip wire, and reassemble properly and securely.

Reconnect electrical supply to unit and observe unit through 1 complete operating cycle and check for proper operation.

VIII. CHECKING HEAT TAPE OPERATION (IF APPLICABLE)

In applications where the ambient temperature around the furnace is 32°F or lower, freeze protection measures are required. If this application is where heat tape has been applied, check to ensure it will operate when low temperatures are present.

NOTE: Heat tape, when used, should be wrapped around the condensate drain trap and drain line. There is no need to use heat tape within the furnace casing. Most heat tapes are temperature activated, and it is not practical to verify the actual heating of the tape. Check the following:

1. Check for signs of physical damage to heat tape such as nicks, cuts, abrasions, gnawing by animals, etc.

2. Check for discolored heat tape insulation. If any damage or discolored insulation is evident, replace heat tape.

3. Check that heat tape power supply circuit is on.

→

CAUTION: UNIT AND PROPERTY DAMAGE HAZARD

Failure to follow this caution may result in furnace component failures or water property damage. If this furnace is to be operated in an unconditioned space where the ambient temperatures may be 32°F or lower, freeze protection measures must be taken. See CONDENSATE DRAIN PROTECTION section of Installation, Start-up, and Operating Instructions. (See Fig. 14.)

IX. WINTERIZING

→

CAUTION: UNIT DAMAGE HAZARD

Failure to follow this caution may result in furnace component damage. Freezing condensate left in the furnace will damage the furnace.

If the furnace will be off for an extended period of time in a structure where the temperature will drop to 32°F or below, winterize as follows:

1. Turn off electrical supply to furnace.

2. Remove main furnace door.

3. Disconnect upper inducer housing drain connection cap from inducer housing. (See Fig. 15.)

4. Connect field-supplied 1/2-in. I.D. inducer housing tube to upper inducer housing drain connection.

5. Insert funnel in tube and pour one quart of antifreeze, propylene glycol (RV, swimming pool antifreeze, or equivalent) into funnel/tube until it is visible at point where condensate enters open drain. (See Fig. 16.)

—9—

MODEL PLUG

(

CONNECTOR

SW1 SETUP

SWITCHES AND

BLOWER OFF-

DELAY

AIR CONDITIONING

(A/C) AIRFLOW

SETUP SWITCHES

24-V THERMOSTAT

TERMINALS

STATUS AND COMM

LED LIGHTS

COMMUNICATION

CONNECTOR

CONTINUOUS FAN

(CF) AIRFLOW

SETUP SWITCHES

FUTURE

APPLICATIONS

HUMIDIFIER

TERMINAL (24-VAC

0.5 AMP MAX.

ACRDJ – AIR

CONDITIONING

RELAY DISABLE

JUMPER

FLASH

UPGRADE

CONNECTOR

(FACTORY

ONLY)

3-AMP FUSE

TRANSFORMER 24-VAC

CONNECTIONS

115-VAC (L2) NEUTRAL

CONNECTIONS

PL1 – LOW VOLTAGE MAIN

HARNESS CONNECTOR

Fig. 13—Variable Capacity Furnace Control

CAUTION: UNIT DAMAGE HAZARD

Failure of plastic components may occur. Do not use ethylene glycol (Prestone II antifreeze/coolant or equivalent automotive type).

6. Replace drain connection cap and clamp to inducer housing.

7. Replace main furnace door.

8. Propylene glycol need not be removed before restarting furnace.

WIRING DIAGRAM

See Fig. 12, 13, and 18 for Wiring Diagram

EAC-1 TERMINAL

115-VAC 1.0 AMP MAX.)

115-VAC (L1) LINE

VOLTAGE CONNECTIONS

32°F MINIMUM INSTALLED AMBIENT OR FREEZE PROTECTION REQUIRED

PL3 – ECM BLOWER

HARNESS

CONNECTOR

PL2 – HOT SURFACE IGNITER & INDUCER

MOTOR CONNECTOR

A02278

TROUBLESHOOTING

Use the troubleshooting guide, the status code LED on the furnace control and the component test to isolate furnace operation problems.

A more detailed troubleshooting guide is available from your distributor.

For an explanation of status codes, refer to service label located on

Fig. 14—Freeze Protection

A93058

back of main furnace door. (See Fig. 17.)

—10—

The furnace control stores all status codes for a period of 72 hours, regardless of 115-v or 24-v power interruption.

NOTE: Removing blower access panel opens blower access panel door switch and terminates 115-v power to furnace control. Before removing blower access panel or turning off 115-v power, look into blower access panel sight glass for current LED status.

1. To retrieve status code, proceed with the following:

NOTE: NO thermostat signal may be present at furnace control and all blower time delay periods must be completed.

a. Leave 115-v power to furnace turned on. b. Remove main furnace door. c. Look into blower access panel sight glass for current

LED status code. d. Remove blower access panel. e. Turn setup switch SW1-1 to ON position. (See Fig. 13 or

18 for location.) f. Manually close blower access panel door switch. Use a

piece of tape to hold switch closed.

WARNING: UNIT MAY NOT OPERATE

Failure to follow this warning could result in electrical shock, personal injury, or death. Blower access panel door switch opens 115-v power to furnace control. No component operation can occur unless switch is closed. Caution must be taken when manually closing this switch for service purposes.

A99118

Fig. 15—Inducer Housing Drain Tube

A99119

Fig. 16—Funnel in Drain and Antifreeze Running

Through Trap

g. The AMBER LED will flash the status codes in the order

of occurence. Record status codes until status code 11 flashes (1 short and 1 long).

h. After status code # flashes, the status codes will repeat

until setup switch SW1-1 is turned off.

i. Remove tape to release blower access panel door switch

and replace blower access panel.

j. Operate furnace through 1 heat cycle to test for proper

operation and check LED status.

k. If furnace is operating properly and LEDs indicate

proper operation, replace main furnace door.

2. Status codes are erased after 72 hours or they can be manually erased by performing the following procedure:

a. Leave 115-v power to furnace turned on. b. Remove main furnace door. c. Look into blower access panel sight glass for current

LED status code. d. Remove blower access panel. e. Turn setup switch SW1-1 to ON position. (See Fig. 13 or

18 for location.) f. Jumper thermostat terminals R, W/W1, and Y/Y2 on

furnace control.

g. Manually close blower access panel door switch. Use a

piece of tape to hold switch closed.

h. After status code 11 flashes for at least 2 times, remove

R, W/W1, and Y/Y2 jumpers. i. Turn setup switch SW1-1 to OFF position. j. Remove tape to release blower access panel door switch

and replace blower access panel.

k. Operate furnace through 1 heat cycle to check for proper

operation and check LED status. l. If furnace is operating properly and LEDs indicate proper

operation, replace main furnace door.

—11—

3. The control can also assist in troubleshooting by performing a Component Test. The Component Test will functionally operate all furnace components, except the gas valve.

NOTE: The component test feature will not operate if the furnace control is receiving any thermostat signals or until all time delays have expired.

a. To initiate Component Test proceed with the following:

(1.) Leave 115-v power to furnace turned on. (2.) Remove main furnace door. (3.) Remove blower access panel. (4.) Turn setup switch SW1-6 to ON position. (5.) Manually close blower access panel door switch.

Use a piece of tape to hold switch closed.

WARNING: UNIT MAY NOT OPERATE

Failure to follow this warning could result in electrical shock, personal injury, or death. Blower access panel door switch opens 115-v power to control center. No component operation can occur unless switch is closed. Caution must be taken when manually closing this switch for service purposes.

b. When items (1) through (5) above have been completed,

the following will occur:

(1.) Inducer motor operates at medium speed through

step (3), then turns off.

(2.) After waiting for 15 seconds, hot surface igniter is

energized for 15 sec, then de-energized.

(3.) Main blower motor operates at midrange airflow for

15 seconds, then turns off.

(4.) After component operation test is completed, 1 or

more fault codes (11, 25, 41, or 42) will flash. See service label on back of main furnace door or Fig. 15 for explanation of codes.

NOTE: To repeat component test, turn setup switch SW1-6 to OFF and then back to ON.

c. After component test, perform the following:

(1.) Remove tape to release blower access panel door

switch and turn setup switch SW1-6 to OFF posi-

tion. (2.) Replace blower access panel. (3.) Operate furnace through 1 heat cycle to check for

proper operation and check LED status. (4.) If furnace is operating properly and LEDs indicate

proper operation, replace main furnace door.

—12—

SERVICE

If status code recall is needed disconnect the "R" thermostat lead, reset power, and put setup switch "SW1-1" in the ON position. To clear the status code history put setup switch "SW1-1" in the ON position and jumper thermostat terminals "R", "W/W1", and "Y/Y2" simultaneously until status code #11 is flashed.

LED CODE

CONTINUOUS OFF CONTINUOUS ON RAPID FLASHING -

EACH OF THE FOLLOWING STA TUS CODES IS A TWO DIGIT NUMBER WITH THE FIRST DIGIT DETERMINED BY THE NUMBER OF SHORT FLASHES AND THE SECOND DIGIT BY THE NUM BER OF LONG FLASHES.

11 NO PREVIO U S CODE - Stored status codes are erased automatically after 72 hours or as

specified abov e.

12 BLO WER ON AFTER POWER UP- (115 VAC or 24 VAC) - Blower runs for 90 seconds, if unit is

powered up during a call for he at (R-W/W1 closed ) or (R-W/W1 opens) during the blower on-delay period.

13 LIMIT CIRCUIT LOCKOUT - Loc kout occ u rs if the limit, o r flame rollout s witch is ope n lo n g er than

3 minutes or 10 successive limit trips occurred during high-heat. Control will auto reset after

3 hours. Refer to status code #33. 14 IGNITION LOCKOUT - Control will a u t o- reset after 3 hours . Ref e r to status co de #34. 15 BLOWER MOTOR LOCKOUT- Indicates the blower failed to reach 250 RPM or the blower failed

to communicate within 30 seconds after being turned ON in two successive h eating cycles .

Control will auto reset after 3 hours. Refer to status code #41. 21 GAS HEATING LOCKOUT- Control will NOT auto reset. Check for:

- Mis-wired gas valve. - Defectiv e control (va lve rela y )

22 ABNORMAL FLAME-PROVING SIGNAL - Flame is proved while gas valve is de-en e rgiz ed .

Inducer will run until fault is cleared. Check for:

- Leaky gas valve. - Stuck-open gas valve.

23 PRESSURE SWITCH DID NOT OPEN- Check for:

- Obstructed pressure tubing. - Pressure switch stuck closed.

24 SECONDARY VOLTAGE FUSE IS OPEN - Check for:

- Short circuit in secondary voltage (24 VAC) wiring.

25 MODEL SELECTION OR SETUP ERROR- Either indicates the model plug (PL4) is missing or incorrect

or setup switch "SW1-1" or "SW1-6" is positioned improperly. If code flashes only 4 times on

power-up control is defaulting to model selec tion stored in memory. Check the following:

- Thermo st at ca l l wit h "SW1-1" ON. - Thermo st at ca l l wit h "SW1-6" ON.

- "SW1-1 " and "SW1-6" both ON together. - Two differe nt furnace models twinned.

- Wiring diagram for m o d el plug nu mb e r an d resistanc e va lues if code flas he s co ntin u ou sly.

31 HIGH-HEAT PRESSU RE SW ITCH O R RELA Y D ID N OT CLOSE OR REOPENED - Indicates the high-heat

pressure switch input failed to clos e on a call for high-heat, or opened during high-heat.

Control relay may be de fec tive or gas valve is mis-wired. Refer to status code #32. 32 LOW-HEAT PRESSURE SWITCH DID NOT CLOSE OR REOPENED - Indicates the low-heat pressure

switch input failed to close on a call for low-heat, or opened during low-heat. If opens during

blower on-delay period, blower will come on for the selected blower off-delay. If opens within

5 minutes after ignition the next heating cycle will be restricted to high-heat. Check for:

- Proper v ent sizing. -Plugged condensate drain.

- Low inlet gas pressure (i f LG P S u sed). - Excessive wind .

- Restricted combustion air su pply. - Improper pre ssure switch wiring .

- Water in vent piping, possible sagging pipe. - Disconnected or obstructed pressure tubing.

- Failed or "Out-of-Calibration" pressure switch es.

33 LIMIT CIRCUIT FAULT - Indicates the limit, or flame rollout is open or the furnace is operating in

high-heat only mode du e to 2 succ e ssive low heat limit trips. Blower will run for 4 minutes or

until open switch remakes whic hever is longer. If open longer than 3 minutes, code changes

to lockout #13. If open less than 3 minutes status code #33 c ontinues to flash until blower shuts

off. Flame rollout s w itch require s man u al reset. Check for:

- Improper or misaligned limit and/or limit shield. - Defective switch or connections.

- Improper low-heat gas input adjustment. - Loose blower wheel.

- Stuck high-heat solenoid in gas valve - Proper rear air baffle.

34 IGNITION PROVING FAULT - Control will try three more times before a lockout #14 occurs. If

flame signal is lost during blower on-delay period, blower will come on for the selected blowe r

off-delay. Check for: - Gas valve de f e c t iv e o r t urned "OFF".

- Defe ctive Hot Surface Igniter - Manual valve shut-off.

- Low inlet gas pressure - Flam e sensor must not be grounded.

- Inadequate flame carryover or rough ignition. - Control ground continuity

- Green/Yellow wire MUST be connected to furnace sheet metal.

- Proper flame sense micro amps (.5 micro amps DC min., 4.0 - 6.0 nominal).

- Oxide buildup on flame sensor (clean with fin e steel wo ol.)

41 BLOWER MOTOR F AUL T - Indicates the blower failed to reach 250 RPM or the blower failed to

commun i c a te within the prescribed time limits. Thi rty se c onds after be ing turned ON or te n

seconds during steady-state operation. 42 INDUCER MOTOR F AUL T - Indicates the inducer has not started within 20 seconds after a call for

heat, the inducer motor RPM is outside its valid range of operation, or the inducer RPM signal

was lost for 5 seconds during operation. Check for:

- Proper v ent sizing. - Restricted combustion air supply.

- Failed induc er motor. - Improper motor wiring.

43 LOW-HEAT PRESSURE SWITCH OP EN W HILE HIGH-HEAT PRESSURE SWITCH IS CLOSED- Check for:

- Plugged condensate drain. - Low inlet gas pressure (if LGPS used).

- Water in vent piping, possibly sagging pipe. - Improper pressure switch wiring.

- Stuck open low-heat pressure switch. - Disconnected or obstructed pressure tubing.

45 CONTROL CIRCUITRY LOCKOUT - Auto-reset after 1 hour lockout due to:

- Flame sense circuit falure. - Gas valve relay stuck op en .

- Software chec k error.

Reset power to clear loc kout. Replace control if status cod e re p ea ts .

Check for 115 VAC at L1 and L2, and 24 VAC at SEC-1 and SEC-2. Control has 24 VAC power. Line voltage (115 VAC) polarity is reversed.

STATUS

COMPONENT TEST

To initiate the component test sequence, shut "OFF" the room thermostat or disconnect th e "R" thermostat lead. Reset power and then put setup switch "SW 1-6" in the ON position to start the com ponent test sequence. Once initiated the furnace control will turn th e inducer ON. The inducer motor will r u n for th e entire test. The hot surface igniter and blower motor will be turned ON f o r 15 se conds each. When the blower is turned OFF the inducer will be turned OFF. When the component test is completed one or more of the following codes will flash.

CODE DESCRIPTION

Indicates the inducer and blower motor tested OK. Visual check of hot surface igniter required.

11 25 SETUP ERROR 41 BLOWER MOTOR FAULT 42 INDUCER MOTOR FAULT -

control. To repeat component test tu rn setup switch "SW1-6" OFF and then back ON . After component test is completed put setup sw itch "SW1-6" in the O FF position and reconnect the "R" thermostat lead.

- Same as code 25 above. Indicates blower motor failed test. Check blower, wiring, and furnace control. Indicates inducer motor failed test. Check inducer, wiring and furnace

328072-101 REV. A

Fig. 17—Service Label

—13—

A02279

SCHEMATIC DIAGRAM

TO 115V A C FIELD-DISCONNECT SWITCH

FRS

CONNECTION DIAGRAM

EQUIPMENT

ILK

BLU

SW1-7,8

BLOWER OFF DELAY

HSI

PL10

PL2

GROUND

FUSED OR CIRCUIT

RED RED

NOTE #8

RED

LPS

RED

HPS

BRN

SEC

120

78 78

SELECTION

OFF OFF OFF

HSIR

ORN

327971-101 REV. A

PL12

ILK

RED GRN YEL BLU

180

5.1

012

100

BLWM

PL12

IND

NOTE #7

PL10

WHT

PL2

220

5.1

120 013

115VAC

EAC-2

PL14

EAC-1

EAC

BLWM

BLK

1 2 3

OFF

1 2 3

OFF 1 2 3

OFF

PL1

1 2 3

OFF

1 2 3

OFF

1 2 3

OFF

1 2 3

PL8

OFF

1 2 3

OFF

SIZE

A/C OR CF AIRFLOW SELECTION CHART BASED ON 350 CFM/TON

MODEL

SW4

OAT

PRINTED CIRCIUT BOARD

040,060,

TRAN

SEC1

PL14

PL13

122512251225

1050

875

700

525

DEF.

3.5T080

PL9

SEC2

24VAC

PL1-8

HUMR

HUM

GRN/YEL

PL12

WHT

NEUTRAL - L2

COMM

ACRDJ

HUM

AB CD

LPS

PL1-2

PL1-12

HPSR

ACR

COMMR

PRINTED CIRCIUT BOARD

TRAN

BLU

WHT

NOTE #11

EAC-2

SEC-1

LEDS

SW1

PL4

FU1

NOTE #6

PL1-6

FRS LS

YEL

1 2 3 4 5

RED

GRN

YEL BLU

IND

BLK

NOTE #7 PL12

BLK

EAC-1

210017501400

1750

1225

1050

875

875 1050 1225 1400

700

DEF.

1. Default A/C airflow when A/C switches are in OFF position

2. Default cont. fan airflow when CF switches are in OFF position

120

5T080,100

PL7

SEC-2

FUSE 3-AMP

NOTE #8

ACRDJ

W/W1

W/W1DHUM G om

W2 Y/Y2 RY1

RED

STAT US

LGPS

PL1-4

DHUM

WHT

CODE

24V

HPS

PL1-3

PL1-10

(WHEN USED)

CPU

Y/Y2

JUNCTION

IND Inductor (Note #7)

LED Light Emitting Diode for Status Codes

LGPS Low Gas Pressure Switch, SPST (N.O.)

A/C Air Conditioning (Adjust abl e Airflow -CFM)

ACR Air Conditioning Relay, SPST (N.O.)

ACRDJ Air Conditioning Relay Defeat Jumper

LEGEN

TERMINAL

LPS Low-Heat Pressure Switch, SPST (N.O.)

BLWM Blower Motor (ECM)

FSE

PL1-5

A02291

PL1-1

NOTE #3

GVR

PCB

NOTE #5

COM

CONTROL TERMINAL

FACTORY POWER

WIRING (115VAC)

2. Use only copper wire between the d isconnect switch and the furnace junction box (JB).

3. This wire must be connected to furnac e shee t m e tal for control to prove flam e .

4. Symbols are electrical representation only.

1. If any of the original equipment wire is replaced use wire rated for 105°C.

NOTES:

FACTORY CONTROL

WIRING (24VAC)

FIELD CONTROL

WIRING (24VAC)

CONDUCTOR ON

90 seconds or 5 seconds when dehumidify call is active.

auto-reset after three hours.

5. Solid lines inside PCB are printed circuit board conductors and are not included in legend.

6. Replace only with a 3 am p fuse.

7. Inductor is used with 3/4 hp and 1 hp ECM Blower motors.

8. Factory connected when (LGPS) not used.

9. Blower off-delay, gas heating selections are (90, 120, 150, 180) seconds, cooling or heat pump

CONTROL

FIELD WIRING

SCREW TERMINAL

electronic control circuits.

10. Ignition lockout will o c c u r after four cons ecutive u nsucce s sful trials for ignit io n . C ontrol w ill

11. Any of the 5 wires shown within the NEUTRAL L2 box can be connected to any terminal within the box.

12. Blower motor (BLWM) and Inducer m otor (IDM) are locked-rotor overload protected by redundant

EQUIPMENT

GROUND

PLUG RECEPTACLE

Fig. 18−Wiring Diagram

SPST (N.O.)

LS Limit Switch, Auto-Reset, SPST (N.C.)

PCB Printed Circuit Board

PL1 12-Circuit Connector

PL2 4-Circuit HSI & IDM Co n nec tor

PL3 4-Circuit ECM BLWM Conne c t o r

PL4 4-Circuit Model Plu g Connector

PL7 4-Circuit Communication Connector

PL9 2-Circuit OAT Connector

PL10 2-Circuit HSI Connector

PL11 IDM Connector (12-Ci rcuit)

PL12 1-Circuit Inductor Splice Connector

PL13 16-Circuit ECM Blower Ctrl. Connector

PL14 5-Circuit ECM Blower Powe r Connector

SW1-1 Manual Switch, Status Code Recall, SPST (N.O.)

SW1-2 Manual Switch, Low-Heat Only, SPST (N.O.)

SW1-3 Manual Switch, Low-Heat Rise Adj. SPST (N.O.)

SW1-4 Manual Switch, Comfort/Efficiency Adjustment,

SW1-5 Manual Switch, Cooling CFM/Ton, SPST (N.O. )

SW1-6 Manual Switch, Component Test, SPST (N.O.)

SW1-7,8 Manual Switches, Blower Off-Delay, SPST(N.O.)

SW4-1 Manual Switch, Twinning Main (OFF) / Sec. (ON)

SW4-2&3 FOR FUTURE USE

TRAN Transformer, 115VAC / 24VAC

(115VAC 1.0 Amp Max.)

Factory Installed

CF Continuous Fan (Adjustable Airflow -CFM)

COMMR Communication Relay, SPDT

CPU Microprocessor / Circuitry

DHUM DHUM Connection (24VAC )

EAC-1 Elec tronic Air Cleaner Connection

EAC-2 Electronic Air Cleaner Connection (Common)

FRS Flame Rollout Switch, Man. Reset, SPST(N.C.)

FSE Flame-Proving Sensor Electrode

FUSE F use, 3 Amp, Autom otive Blade T ype,

GV Gas Valve

GVR Gas Val v e Rel ay, DPST (N.O.)

HPS High-Heat Pressure Switch, SPST (N.O.)

HPSR High-Heat Pressure Switch Relay, SPST (N.C.)

HSI Hot Surface Igniter (115VAC)

HSIR Hot Surface Igniter Relay, SPST (N.O.)

HUM 24VAC Humidifier Connection (0.5 Amp Max.)

HUMR Humidifier Relay , SPST (N.O.)

IDM Inducer Draft Motor, 2-Speed, Shaded Pole

IDR Induce r Motor Relay, SPST (N.O.)

IHI/LOR Inducer Motor Speed Change Relay, SPDT

ILK Blower Door Interlock Switch, SPST (N.O.)

IDM

PL11

IHI/LOR

PL13

PL1-11

PL1-7

PCB

PL1-9

CPU

IDR

NOTE #5

GND

NEUTRAL

NOTE #2

SWITCH (WH E N RE Q’D)

BREAKER DISCONNECT

(WHEN USED)LGPS

GRY

GRN/YEL

SEC

150

FU2

IDM

YEL

ORN

GRN/YEL

FSE

WHT

YEL

GRN/YEL

BRN

NOTE #3

SEC

180

SEC

7 8

OFF

123 4

PL3

WHT BLK

HSI

BRN

WHT

MODEL

PL4 - MODEL PLUG CHART

MODEL

BLK

HSI

WHT

PL3

120

150

2 - 3

5.1

1 - 4

PIN RESISTANCE K

008

009

010

011

PLUG

HK70EZ

040

060

SIZE

5T-080

3.5T080

—14—

A02350a

Close door switch.

Is door switch closed?

YES

NO NO

YES YES

Is there 115V going to switch? Is circuit breaker closed?

Check for continuity in wire from circuit

Replace door switch.

breaker to furnace.

Close circuit breaker and go back to

START.

Check room thermostat or

interconnecting cable.

Is 24V present at W/W1, W2, Y1, Y/Y2 or

G thermostat terminals on the furnace

control?

YES

Disconnect all the thermostat wires from

the furnace control.

Does the problem repeat when using a

YES

jumper wire?

The thermostat is not compatible with the

furnace control. Either install a ballast

resistor, connect the Com24V thermostat

terminal to the thermostat, or replace the

thermostat.

YES

Replace transformer.

Does the control respond to W/W1, W2,

Y1, Y/Y2, and G (24V) thermostat

signals?

Run system through a low-heat, high-

heat, or cooling cycle to check operation.

Status codes are erased after 72 hours

or can be manually erased by putting

setup switch SW1-1 in the ON position

and jumpering R, W/W1, and Y/Y2

simultaneously until status code #11 is

flashed.

Replace furnace control.

NOYES

Troubleshooting Guide – Variable Speed

START

Is there 115V at L1 and L2?

NO NO NO

Is AMBER LED status light on?

YES

Is there 24V at SEC-1 and SEC-2?

Replace furnace control.

Check for correct line voltage polarity. If

units are twinned, check for proper low-

voltage (24V) transformer phasing.

YES

Is AMBER LED status light blinking

rapidly without a pause?

To recall previous status codes disconnect the R

thermostat connection, reset power, and put setup

switch SW1-1 in the ON position. The AMBER LED

Is AMBER LED status light blinking

ON/OFF slowly with a combination of

short and long flashes?

will flash the status codes in the order of occurrence.

Record status codes until status code #11 flashes (1

short and 1 long flash). After status code #11

flashes the status codes will repeat. Status codes

are erased after 72 hours or can be manually erased

by putting setup switch SW1-1 in the ON position

and jumpering R, W/W1, and Y/Y2 simultaneously

until status code #11 is flashed. When done put

setup switch SW1-1 in the OFF position.

Was there a previous status code other

than #11?

YES

Determine status code. The status code

is a 2 digit number with the first digit

determined by the number of short

flashes and the second digit by the

number of long flashes?

Go to section below for the status code

that was flashed.

—15—

A02350b

LOCKOUT Auto-reset

after 1 hour lockout due

to:

45 CONTROL CIRCUITRY

WHILE HIGH-HEAT PRESSURE

SWITCH IS CLOSED - Check for:

- Low-heat pressure switch stuck open.

43 LOW-HEAT PRESSURE SWITCH OPEN

- Flame circuit failure.

- Disconnected or obstructed pressure

open.

- Gas valve relay stuck

tubing.

- Improper pressure switch wiring.

- Software check error.

Reset power to clear

- Low inlet gas pressure (if LGPS used).

- Plugged condensate drain.

lockout. Replace control

if code repeats.

pipe.

- Water in vent piping, possible sagging

Replace furnace control.

Unplug igniter harness from control and

repeat component test by turning setup

Check for continuity in the

harness and igniter. Replace

defective component.

YES

switch SW1-6 OFF and then back ON.

Check for 115V between pin 3 and

NEUTRAL-L2 on the control. Was 115V

present for the 15 second period?

Reconnect the R thermostat lead and set

Check connections. If OK,

thermostat to call for heat. Connect

replace control.

voltmeter across gas valve connections.

Does gas valve receive 24V?

Check that all gas valves are

turned on. Replace valve.

YES

or rough ignition.

bracket.

Check for:

- Inadequateflame carryover

- Low inlet gas pressure.

- Proper firing rate.

YES

Does gas valve open and allow gas to

flow?

Do the main burners ignite?

- Air leakage around igniter

YES

Allow blower tocome on and

YES

repeat test to check for

Do the main burners stay on?

intermittent operation.

Check connections and retry.

Repeat call for heat and check flame

If current is near typical value

sensor current during trial for ignition

(4.0-6.0 nominal) and burners

will not stay on, repeat check

period. Is the DC microamps below 0.5?

in high-heat. If burners will

still not stay on replace

control. If burners operate in

high-heat then switch to low-

heat, check manifold

Clean flame sensor with fine steel wool

and recheck current. Nominal current is

pressure. If OK, check

burner carryover and flame

sensor location.

4.0 to 6.0 microamps.

YES

Is current near typical value? Replace electrode.

Will main burners ignite and stay on? Replace furnace control.

YES

Fixed.

NOT CLOSE OR REOPENED – If opens

during blower on-delay period, blower will

32 LOW-HEAT PRESSURE SWITCH DID

erased after 72 hours or can be manually

erased by putting setup switch SW1-1 in

11 NO PREVIOUS CODE – Status codes are

- Low inlet gas pressure (if LGPS used).

- Restricted combustion air supply.

12 BLOWER ON AFTER POWER UP –

- Disconnected or obstructed pressure

(115V OR 24V) – Normal operation.

tubing.

Blower runs for 90 seconds, if unit is

- Proper vent sizing.

come on for the selected blower off-delay.

If opens within 5 minutes after ignition the

next heating cycle will be restricted to

high-heat. Check for:

the ON position and jumpering R, W/W1,

and Y/Y2 simultaneously until status code

#11 is flashed. Run system through a low-

heat, high-heat, or cooling cycle to check

system.

- Defective or miswired pressure switches

- Excessive wind.

powered up during a call for heat (R-

W/W1 closed) or when (R-W/W1 opens)

- Pluggedcondensatedrain.

- Water in vent piping, possible sagging

during the blower on-delay period.

pipe.

occurs if the limit or flame rollout switch is

13 LIMIT CIRCUIT LOCKOUT – Lockout

limit or flame rollout switch is open or the

furnace is operating in high-heat only

33 LIMIT CIRCUIT FAULT – Indicates the

open longer than 3 minutes or 10

successive limit trips occurred during high-

heat. Control will auto-reset after 3 hours.

mode due to 2 successive low-heat limit

trips. Blower will run for 4 min. or until

open switch remakes whichever is longer.

See code 33.

If open longer than 3 min., code changes

to lockout #13. If open less than 3 min.

status code #33 continues to flash until

ignite gas and prove flame in 4 attempts.

14 IGNITION LOCKOUT – System failed to

blower shuts off. Flame rollout switch

Control will auto-reset after 3 hours. See

- Loose blower wheel.

- Defective switch or connections.

15 BLOWER MOTOR LOCKOUT – Indicates

shield.

- Improper low-heat gas input adjustment.

- Improper or misaligned limit and/or limit

- Stuck high-heat solenoid in gas valve.

the blower failed to reach 250 RPM or the

blower failed to communicate within 30

seconds after being turned ON in two

successive heating cycles. Control will

auto-reset after 3 hours. See code 41.

21 GAS HEATING LOCKOUT – Turn off

not sensed during the trial for ignition

34 IGNITION PROVING FAILURE – If flame is

power and wait 5 minutes to retry. Check

for:

period, the control will repeat the ignition

- Stuck closed gas valve relay on control.

sequence 3 more times before lockout #14

- Miswire or short to gas valve wire.

occurs. If flame signal is lost during the

blower on-delay period, blower will come on

for the selected blower off-delay. Check

the following items first before proceeding

Flame is proved while gas valve is de-

energized. Inducer will run until fault is

22 ABNORMAL FLAME-PROVING SIGNAL

- Proper rear air baffle.

requires manual reset. Check for:

status code 34.

to furnace sheet metal.

- Manual shut-off valve.

- Gas valve turned off.

to the next step.

- Green/Yellow wire MUST be connected

- Flame sensor must not be grounded.

To determine whetherthe problem is in the

gas valve, igniter, or flame sensor the

system can be operated in component test

mode. To check the igniter remove the R

thermostat connection from the control,

reset power, and put setup switch SW1-6 in

the ON position to start the component test.

Does the igniter glow orange/white by the

end of the 15 second warm-up period?

wiring including thermostat leads.

Disconnect thermostat leads to isolate

short circuit.

cleared. Check for:

- Stuck open or leakygas valve.

Check for:

- Obstructed pressure tube.

23 PRESSURE SWITCH DID NOT OPEN –

- Pressure switch stuck closed.

Check for:

24 SECONDARY VOLTAGE FUSE IS OPEN

- Short circuit in secondary voltage (24V)

—16—

A02350c

You have an open wire or bad

terminal on either the BLACK or

Turn power back on. Is there 115VAC at

PL14-5 and PL14-4?

YES

WHITE power leads between

the furnace control and the

blower motor. If you have a

power choke disconnect it and

check continuity.

YES

Is there 12-VDC at PL13-7 RED (+) and

PL13-1 GREEN (-)?

YES

wer

You have an open wire or bad

terminal on either the RED or

GREEN wire between the

furnace control and the blower

motor.

YES

Is there 12-VDC at PL3-1 RED (+) and

PL3-2 GREEN (-)?

Is there 5-VDC at PL3-3

Replace the furnace control.

Is there 5-VDC at PL13-16 YELLOW (+)

YES

YELLOW (+) and PL3-2

GREEN (-)?

YES

The voltage just measured should be

and PL13-1 GREEN (-)?

You have an open wire or bad

terminal on the YELLOW wire

between the furnace control and

very stable and should not fluctuate more

than .02-VDC. If the voltage fluctuates

more than this get a different voltmeter

the blower motor.

before proceeding.

Turn power off, reconnect PL13 and

PL14 to the blower motor, then turn

power back on. Connect a DC voltmeter

across PL3-3 YELLOW (+) and PL3-2

GREEN (-). Does the voltage fluctuate

more than it did in the previous step?

Turn power off, disconnect PL13 and

PL14 from the blower motor, then turn

power back on. Connect a DC voltmeter

across PL13-16 BLUE (+) and PL13-1

GREEN (-). The voltage should be near

0-VDC but it will fluctuate briefly several

times a second. If you have an analog

voltmeter the needle will briefly go high

several times a second. If you have a

digital voltmeter with a bar graph it will

show a large change in magnitude on the

bar graph several times a second. If you

have a standard digital voltmeter it will

show a brief fluctuation in voltage and the

magnitude may vary depending on the

voltmeter used.

YES

after being turned ON or ten seconds

during steady-state operation. Turn po

off and check the following items first

defaulting to the model selection stored in

memory. If status code 25 flashes

continuously it could indicate any of the

before proceeding to the next step.

following:

- Rubbing blower wheel.

- Model plug PL4 is missing and there is

blower failed to reach 250 RPM or the

blower failed to communicate within the

prescribed time limits. Thirty seconds

41 BLOWER MOTOR FAULT – Indicates the

SETUP ERROR – If status code 25 only

flashes 4 times on power-up the control is

missing its model plug PL4 and is

25 INVALID MODEL SELECTION OR

- Loose blower wheel.

- Wiring from furnace control to blower

no valid model stored in permanent

memory. This will happen if you forget

motor.

Remove the R thermostat connection from

to install the model plug PL4 on a

service replacement control.

the furnace control, disconnect both

connectors from the blower motor PL13

and PL14. Does the blower wheel turn

freely?

Replace the blower control module attached to

- Thermostat call with SW1-1 ON.

- Thermostat call with SW1-6 ON.

- SW1-1 and SW1-6both ON.

- Two different furnace models twinned.

RELAY DID NOT CLOSE OR

31 HIGH-HEAT PRESSURE SWITCH OR

the blower motor. Follow the instructions with

the blower control module to make sure the

entire blower motor does not need to be

replaced.

You have an open wire or bad terminal on the

BLUE wire between the furnace control and the

- Control relay may be defective.

- Gas valve is miswired.

- See status code 32.

REOPENED - Check for:

inducer motor has not started within 20

seconds after a call for heat, the inducer

42 INDUCER MOTOR FAULT – Indicates the

blower motor.

Replace the furnace control.

- Proper vent sizing.

- Failed inducer motor.

- Restricted combustion air supply.

motor RPM is outside its valid range of

operation, or the inducer RPM signal was

lost for 5 seconds during operation.

- Improper motor wiring.

Check for:

Connect a DC voltmeter across PL3-4 BLUE

(+) and PL3-2 GREEN (-). Does the voltage

fluctuate as described two steps back?

YES

Does the voltage fluctuate as described in the

previous step?

YES

Replace the blower control module attached to

the blower motor. Follow the instructions with

the blower control module to make sure the

entire blower motor does not need to be

replaced.

—17—

SER VICE TRAINING

Packaged Service Training programs are an excellent way to increase your knowledge of the equipment discussed in this manual, including:

• Unit Familiarization • Maintenance

• Installation Overview • Operating Sequence A large selection of product, theory, and skills programs is available, using popular video-based formats and materials. All include video and/or slides, plus companion book.

Classroom Service Training plus "hands-on" the products in our labs can mean increased confidence that really pays dividends in faster troubleshooting, fewer callbacks. Course descriptions and schedules are in our catalog.

CALL FOR FREE CATALOG 1-800-644-5544

[ ] Packaged Service Training [ ] Classroom Service Training

A94328

—18—

—19—

—20—

Printed in U.S.A. SP0564 Catalog No. 5335-523

Bryant 355MAV User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual