Bryant Deluxe 340AAV Service And Maintenance Instructions
340AAV
Deluxe 4--Way
Multipoise Fixed--Capacity
Condensing Gas Furnace
Service and Maintenance Instructions
For Sizes 040--120, Series B
NOTE: Read the entire instruction manual before starting the
installation.
TABLE OF CONTENTS
PAGE
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 4..................
Cleaning Burners 6...................................
Cleaning Heat Exchangers 7............................
Primary Heat Exchangers 7............................
Secondary Heat Exchangers 7..........................
Flushing Collector Box and Drainage System 8.............
Servicing Hot Surface Igniter 10.........................
Electrical Controls and Wiring 11........................
Checking Heat Tape Operation (If Applicable) 11...........
Winterizing 13......................................
WIRING DIAGRAM 13................................
TROUBLESHOOTING 13..............................
Status Codes 13.....................................
Component Tests 14..................................
!
WARNING
ELECTRICAL SHOCK, FIRE, OR EXPLOSION
HAZARD
Failure to follow safety warnings exactly could result in
dangerous operation, personal 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.
SAFETY CONSIDERATIONS
Recognize safety information. This is the safety--alert symbol .
When you see this symbol on the furnace and in instructions or
manuals, be alert to the potential for personal injury.
Understand the signal words DANGER, WARNING, and
CAUTION. These words are used with the safety--alert symbol.
DANGER identifies the most serious hazards which will result in
severe personal injury or death. WARNING signifies a hazard
which could result in personal injury or death. CAUTION is used
to identify unsafe practices which 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.
!
WARNING
ELECTRICAL SHOCK, FIRE, OR EXPLOSION
HAZARD
Failure to follow this warning could result in possible
damage to this equipment, 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.
!
WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could property damage,
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.
1
!
CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in damage to
furnace.
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and dangerous
operation.
GENERAL
This furnace can be installed as a direct vent (2--pipe) or non--direct
vent (1--pipe) condensing gas furnace. 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
340AAV
installed in any of the 4 positions shown in Fig. 2, you may need to
revise your orientation to component location accordingly.
AIRFLOW
UPFLOW
A05086
Fig. 1 -- Furnace in Upflow Orientation
ama
ISO 9001:2000
CERTIFIED
REGISTERED
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. 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.
Follow all safety codes including the National Fuel Gas Code
(NFGC) NFPA 54--2006/ANSI Z223.1--2006 in the USA, CSA
B149.1--05 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.
AIRFLOW
HORIZONTAL
LEFT
Fig. 2 -- Multipoise Orientation
DOWNFLOW
AIRFLOW
HORIZONTAL
RIGHT
AIRFLOW
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 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.
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
A93041
2
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)
mayalsobeusedtopreventESDdamage.
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
FILTER
SUPPORT
Fig. 3 -- Bottom Filter Arrangement
FILTER
FILTER
RETAINER
FILTER
FILTER
RETAINER
A08586
340AAV
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.
!
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.
Step 1 — Cleaning and/or Replacing Air Filter
The air filter arrangement may vary depending on the application
or orientation. See Table 1 or 2 for filter size and type.
A08587
Fig. 4 -- Filter Installed for Side Inlet
!
WARNING
FIRE, CARBON MONOXIDE POISONING
HAZARD
Failure to follow this warning could result in personal injury,
death or property damage.
Never operate unit without a filter or with the blower access
panel removed. Operating a unit without a filter or with the
blower access door removed could cause damage to the
furnace blower motor. Dust and lint on internal parts of
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:
3
Table 1 – Furnace Air Filter Table
FURNACE CASING WIDTH
IN (MM)
17--- 1/2 (445)
21 (533 )
24--- 1/2 (610)
(1) 16 x 25 x 3/4
(406 x 635 x 19)
(1) 16 x 25 x 3/4
(406 x 635 x 19)
(1) 16 x 25 x 3/4
(406 x 635 x 19)
FILTER QUANTITY AND SIZE *
IN (MM)
BOTTOM RETURN*
IN (MM)
(1) 16 x 25 x 3/4
(406 x 635 x 19)
(1) 20 x 25 x 3/4
(508 x 635 x 19)
(1) 24 x 25 x 3/4
(610 x 635 x 19)
Table 2 – Air Filter Located in Filter Cabinet
FILTER CABINET HEIGHT --- IN (MM) F I L T E R S I Z E --- I N ( M M ) FILTER TYPE
(1) 16 x 25 x 3/4*
16 (406)
340AAV
* Filters with a side return--air may have a different filter size. Measure the filter to obtain the correct size.
20 (508)
24 (610)
(406 x 635 x 19) or
(1) 16 x 25 x 4 --- 5/16
(406 x 635 x 110)
(1) 20 x 25 x 3/4*
(508 x 635 x 19) or
(1) 20 x 25 x 4 --- 5/16
(508 x 635 x 110)
(1) 24 x 25 x 3/4*or
(610 x 635 x 19) or
(1) 24 x 25 x 4 --- 5/16
(610 x 635 x 110)
1. Turn off electrical supply to furnace.
2. Remove filter cabinet door.
3. Slide filter out of cabinet.
PLUG
CAP
COLLECTOR BOX
DRAIN TUBE (BLUE
& WHITE STRIPED)
COLLECTOR BOX
TUBE (PINK)
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.
COLLECTOR BOX
TUBE (GREEN)
INDUCER HOUSING
(MOLDED) DRAIN
TUBE (BEHIND
COLLECTOR BOX
DRAIN TUBE)
COLLECTOR BOX
DRAIN TUBE (BLUE)
CONDENSATE
TRAP
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. If furnaces are equipped with permanent, washable filter(s),
clean filter by spraying cold tap water through filter in op-
FIELD-INSTALLED
FACTORY-SUPPLIED
DRAIN TUBE
COUPLING (LEFT
DRAIN OPTION)
posite 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.
FIELD-INSTALLED
FACTORY-SUPPLIED
DRAIN TUBE
FIELD-INSTALLED
FACTORY-SUPPLIED
1
⁄2-IN. CPVC STREET
ELBOWS (2) FOR
LEFT DRAIN OPTION
FIELD-INSTALLED
FACTORY-SUPPLIED
DRAIN TUBE
COUPLING (RIGHT
DRAIN OPTION)
Fig. 5 -- Factory--Shipped Upflow Tube Configuration
(Shown with Blower Access Panel Removed)
A05110
9. Replace blower access panel and main furnace door.
10. Turn on electrical supply to furnace.
Step 2 — 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.
FILTER TYPE*SIDE RETURN*
3/4” (19 mm) thick washable
3/4” (19 mm) thick washable
3/4” (19 mm) thick washable
washable
washable
washable
4
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. Remove control box mounting screws, and 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. Disconnect
capacitor and ground wire attached to blower housing
before removing motor. Motor mounts need not be
removed from motor.
f. Remove blower wheel from housing.
!
CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in noise or furnace
component failure.
The blower wheel should not be dropped or bent as balance
will be affected.
11. Reinstall control box, transformer, and door switch assembly on blower shelf.
12. 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.
NOTE: Ensure tubes are not kinked or pinched, as this will affect
operation.
(1.) Connect one tube (blue or blue and white striped)
from collector box.
(2.) Connect one tube (violet or unmarked) from in-
ducer housing.
(3.) Connect one 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.
13. Reinstall control box, transformer, and door switch assembly on blower shelf.
14. Reconnect wires. Refer to furnace wiring diagram and connect thermostat leads if previously disconnected. (See Fig.
21.)
NOTE: Refer to Table 3 for motor speed lead reconnection if
leads were not identified before disconnection.
!
CAUTION
UNIT DAMAGE HAZARD
Failure to adjust the heating speed may shorten heat
exchanger life.
Heating speed selection MUST be adjusted to provide
proper temperature rise as specified on the rating plate.
Table 3 – Speed Selection
COLOR SPEED
Black High Cool
Yellow (When Present) Medium High Spare
Blue Medium Low Heat
Red Low Fan
White Common Com
!
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.
FACTORY
ATTACHED TO
340AAV
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 reattach ground wire. Tighten setscrew to 140 to
160 in--lb torque.
NOTE: Be sure to attach ground wire to blower housing.
10. Reinstall blower assembly in furnace.
15. 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. 15.)
16. If furnace is operating properly, release blower access panel
door switch, replace blower access panel, and replace main
furnace door.
5
CELL
PANEL
MANIFOLD
MOUNTING
SCREWS
GASKET
MANIFOLD
GAS VALVE
REGULATOR
FITTING
GAS
340AAV
Fig. 6 -- Burner Box Assembly
CONTROL
VALV E
A02312
Fig. 7 -- Igniter Wire Placement
IGNIT ER WIRES MUST
BE PLACED IN THIS SLOT
A05074
Step3—CleaningBurners
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 control valve.
!
CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in 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. Unplug igniter from harness.
8. Remove igniter leads from slot in manifold grommet.
9. Remove screws that secure manifold to burner box. (See
Fig. 6.)
NOTE: Do not remove burner box from cell panel.
10. Remove manifold, orifices, and gas valve as one assembly.
11. Remove screws attaching burner assembly in burner box.
NOTE: Use care when removing and reinstalling burners not to
strike the hot surface igniter.
12. Remove burner assembly from burner box.
NOTE: All burners are attached to burner bracket and can be
removed as one assembly.
13. Clean burners with soft brush and vacuum.
14. Reinstall manifold, orifice, and gas valve assembly in burner box. Ensure manifold seal grommet is installed properly
and burners fit over orifices.
15. Reinsert the igniter wires in the slot in the manifold grommet, dressing the wires to ensure there is no tension on the
igniter itself. (See Fig. 7.)
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Igniter wires must be securely placed in slot in manifold
grommet or else they could become pinched or severed
and electrically shorted.
16. Reconnect wires to gas valve and igniter. Refer to furnace
wiring diagram for proper wire location.
17. Reinstall burner box pressure tube to gas valve regulator fitting.
18. 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.
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