Bryant A93040 User Manual

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A93040

NOTE: Read the entire instruction manual before performing any service or maintenance.

This symbol → indicates a change since the last issue. Index Page

SAFETY CONSIDERATIONS..................................................1-2

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

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

CARE AND MAINTENANCE................................................2-11

Cleaning and/or Replacing Air Filter ...................................2-3

Blower Motor and Wheel Maintenance................................3-4

Cleaning Burners ......................................................................4

Cleaning Heat Exchangers....................................................4-5

Primary Heat Exchangers ................................................4-5

Secondary Heat Exchangers................................................5

Flushing Collector Box and Drainage System.....................5-7

Servicing Hot Surface Ignitor ..................................................7

Electrical Controls and Wiring .............................................7-8

Troubleshooting.....................................................................8-9

Checking Heat Tape Operation (If Applicable) ....................10

Winterizing ........................................................................10-11

SERVICE LABEL..................................................................12-13

WIRING DIAGRAM...................................................................14

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, on tags, and on labels attached to or shipped with the unit and other safety precautions that may apply.

Follow all safety codes, including NFPA 54/ANSI Z223.1-1996, National Fuel Gas Code and ANSI/NFPA 90B, Installation Standards, Warm Air Heating and Air Conditioning Systems. In Canada, refer to the current edition of the National Standard of Canada CAN/CGA-B-149. Wear safety glasses and work gloves. Have a fire extinguisher available during start-up and adjustment procedures and service calls.

CANADIAN GAS ASSOCIATION

APPROVED

As an ENERGY STAR Partner, Bryant Heating & Cooling Systems has determined that this product meets the ENERGY STAR guidelines for energy efficiency.

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, 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.

WARNING: 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. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN POSSIBLE DAMAGE TO THIS EQUIPMENT, SERIOUS PERSONAL INJURY, OR DEATH.

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, kerosene, cigarette lighter fluid, dry cleaning fluids, or other volatile fluids.

3. Paint thinners and other painting compounds, paper

bags, or other paper products. Failure to follow this warning can cause corrosion of the heat exchanger, fire, personal injury, or death.

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

CAUTION: Electrostatic discharge can affect electronic

components. Take precautions during furnace installation and servicing to protect the furnace electronic control. Precautions will prevent electrostatic discharges from personnel and hand tools which are held during the procedure. These precautions will help to avoid exposing the control to electrostatic discharge by putting the furnace, the control, and the person at the same electrostatic potential.

AIRFLOW

UPFLOW

AIRFLOW

HORIZONTAL

LEFT

DOWNFLOW

AIRFLOW

HORIZONTAL

Fig. 2—Multipoise Orientations

WARNING: 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. Failure to follow this warning could result in personal injury or death.

RIGHT

AIRFLOW

A93041

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.

7. An ESD service kit (available from commercial sources) may also be used to prevent ESD damage.

GENERAL

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

CARE AND MAINTENANCE

For continuing high performance and to minimize possible equipment failure, it is essential that maintenance be performed annually on this equipment. Consult your local dealer for maintenance and maintenance contract availability.

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

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

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.

CAUTION: Personal injury could result from sharp metal edges, etc. Use care when removing parts.

I. CLEANING AND/OR REPLACING AIR FILTER

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

CAUTION: Never operate unit without a filter or with the blower access panel removed. Failure to follow this warning could result in a fire or personal injury.

To clean or replace the filters, proceed as follows:

1. Turn off electrical supply to furnace.

2. Remove main furnace door and blower access panel.

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

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 of filter is not recommended.

7. Slide filter into furnace.

—2—

WASHABLE FILTER

WASHABLE

FILTER

FILTER RETAINER

FILTER SUPPORT

FILTER RETAINER

A93046

Fig. 3—Bottom Filter Arrangement

8. Recapture filter retainer wire.

9. Replace blower access panel and main furnace door.

10. Turn on electrical supply to furnace.

NOTE: If the filter has cross-mesh binding, the binding must face the blower. If the filter has an air direction arrow, the arrow must point toward the blower.

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.

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. a. Disconnect motor wiring harness plug on blower hous-

ing. b. Disconnect auxiliary limit switch leads at switch. c. Disconnect field thermostat connections 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.

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.

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:

A93045

Fig. 4—Filter Installed for Side Inlet

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.

9. Reassemble motor and blower wheel by reversing items 8b through 8f. Ensure wheel is positioned for proper rotation.

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. 8 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 motor and

auxiliary limit switch leads. (See Fig. 16.)

b. Connect thermostat leads if previously disconnected.

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 on control center thermostat terminals. (See Fig. 11.)

—3—

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

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

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 gas valve.

CAUTION: 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. 5.)

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

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

15. Reinstall gas supply pipe to gas 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: Gas valve knob or switch MUST be facing forward or tilted upward. Failure to follow this warning could result in property damage, personal injury, or death.

16. Replace burner box cover.

17. Turn on gas and electrical supplies to furnace.

18. Check for gas leaks.

WARNING: Never use matches, candles, flame, or other sources of ignition to check for gas leakage. Use a soap-and-water solution. Failure to follow this warning could result in a fire, personal injury, or death.

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.

A96304

Fig. 5—Burner Box Assembly

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.

CAUTION: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and hazardous operation.

3. Disconnect wires or connectors to rollout switch, gas valve, ignitor, 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 gas 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.

5.)

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. 6.)

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

12. Reverse items 4 through 10 for reassembly.

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

NOTE: Be sure burner box gasket is installed between burner box and cell panel. 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

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