Bryant Series G Service And Maintenance Procedures Manual

service and

350MAV

maintenance procedures

4-WAY MULTIPOISE
FIXED-CAPACITY DIRECT-VENT
CONDENSING GAS FURNACE

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 indury, 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.

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.

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

This symbol → indicates a change since the last issue.

TABLE OF CONTENTS

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

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

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

CARE AND MAINTENANCE.....................................................2

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

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

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

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

Primary Heat Exchangers....................................................5

Secondary Heat Exchangers................................................6

Series G

Cancels: SP05-47 SP05-52

8-02

A93040

Flushing Collector Box and Drainage

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

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

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

Checking Heat Tape Operation

(If Applicable)...........................................................................8

Winterizing................................................................................8

WIRING DIAGRAM.....................................................................9

TROUBLESHOOTING .................................................................9

Status Codes..............................................................................9

Component Test........................................................................9

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 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.

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
such as cleaning and replacing air filters. All other operations must
be performed by trained and qualified service agency 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 54-1999/ANSI Z223.1-1999 in the USA; National
Standard of Canada, Natural Gas and Propane Installation Code

.

—1—

CSA B149.1-00 (NSCNGPIC) in Canada; and the Installation
Standards, Warm Air Heating and Air Conditioning Systems
(NFPA 90B) ANSI/NFPA 90B. In Canada, refer to the
CAN/CGA-B/49.1- and .2-M95 National Standard of Canada,
Natural Gas and Propane Installation Codes (NSCNGPIC). Wear
safety glasses and work gloves. Have a fire extinguisher available
during start-up and adjustment procedures and service calls.

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 may need to revise your orientation to component location
accordingly.

HIGH EFFICIENCYGAS FURNACE• VARIABLECAPACITYSYSTEM

THE INTELLIGENT HEATING MACHINE

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 electro-

static 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.

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

Fig. 1—Multipoise Furnace in Upflow Orientation

EFFICIENCY
RATING
CERTIFIED

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C

o

r

r

e

i

r

r

a

C

R

E

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I

S

I

T

S

O

9

0

a

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i

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R

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1

M

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3

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REGISTERED QUALITY SYSTEM

A98308

CERTIFIED

—2—

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 about proper maintenance and mainte­nance contract availability.

AIRFLOW

UPFLOW

HORIZONTAL

RIGHT

AIRFLOW

A93041

AIRFLOW

HORIZONTAL

LEFT

DOWNFLOW

AIRFLOW

Fig. 2—Multipoise Orientation

WASHABLE
FILTER

FILTER
SUPPORT

FILTER
RETAINER

WASHABLE FILTER OR
DISPOSABLE MEDIA FILTER
IN FILTER CABINET

Fig. 3—Bottom Filter Arrangement

A00232

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.

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: Personal injury could result from sharp
metal edges, etc. Use care and wear protective clothing
safety glasses, and gloves when removing parts.

I. CLEANING AND/OR REPLACING AIR FILTER

The air filter arrangement may vary depending on the application
or orientation. Filter could be located in furnace blower compart­ment or in filter cabinet.

WARNING: 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.

CAUTION: 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:

WASHABLE

FILTER

IN FURNACE

FILTER
RETAINER

WASHABLE FILTER OR
DISPOSABLE MEDIA
FILTER IN FILTER CABINET

Fig. 4—Filter Installed for Side Inlet

A00233

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-authorized 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 Figs. 3 or 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 filter is not
recommended.

7. Slide filter into furnace.

8. Recapture filter retainer wire.

9. Replace blower access panel and main furnace door.

10. Turn on electrical supply to furnace.

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:

—3—

1. Turn off electrical supply to furnace.

2. Remove main furnace door and blower access panel.

3. Disconnect blower motor wires from furnace control.
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. 8, top left):

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:

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: The blower wheel should not be dropped or
betn as balance will be affected.

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. Tighten set-screw to 140 to
160 in.-lb torque.

10. Reinstall blower assembly in furnace.

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. 8 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 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.

13. Reconnect wires.
Refer to furnace wiring diagram and connect thermostat
leads if previously disconnected. (See Fig. 15.)

NOTE: Refer to Table 1 for motor speed lead reconnection if
leads were not identified before disconnection.

CAUTION: Heating speed selection MUST be adjusted
to provide proper temperature rise as specified on the
rating table. Failure to adjust the heating speed may
shorten heat exchanger life.

TABLE 1—SPEED SELECTION

COLOR SPEED

Black High Cool

Yellow (When Present) Medium High Spare

Blue Medium Low Heat

Red Low Spare

White Common Com

FACTORY

ATTACHED TO

14. Turn on electrical supply. Manually close blower access
door switch. Use a piece of tape to hold switch closed.
Check for proper rotation and speed changes by perroming
a componenet self-test as shown at the bottom of Service
Label. (See Fig. 17.)

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

15. If furnace is operating properly, release blower access door
switch, replace blower access door, 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
furnace gas control 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.

—4—

7. Remove screws that secure manifold to burner box. (See
Fig. 5.)

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.

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: Gas valve 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.

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.

18. Check for gas leaks.

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.

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

MANIFOLD
MOUNTING
SCREW

Fig. 5—Burner Box Assembly

CELL

PANEL

MANIFOLD

GAS VALVE
REGULATOR
FITTING

GAS VALVE

A96304

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 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.

—5—

PRIMARY HX
INLET OPENINGS

A96305

Fig. 6—Cleaning Inlet Openings of Primary Heat

Exchangers

CAUTION: 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
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. 7.)

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.

17. Check for gas leaks.

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.

RTV

Fig. 7—Combustion-Air Intake Housing Gasket Repair

13. Refer to furnace wiring diagram and reconnect wires to
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. Be sure tubes are not kinked. (See
Fig. 8.)

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. 9.)

PAM

A93087

CAUTION: 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
will occur. Flush with water only.

10. Reassemble inducer assembly by reversing items 5-7.
Tighten the 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. 10.) 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. 8.)

13. Turn on gas and electrical supplies to furnace.

—6—

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.

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.

15. Check for gas leaks.

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.

CAUTION: 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 secur-

ing bracket and igniter 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

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

TUBE ROUTING

Condensate Trap; Factory Installed

in Blower Shelf

(Blower access panel removed)

COLLECTOR BOX TUBE

(PINK)

COLLECTOR BOX TUBE

INDUCER HOUSING (MOLDED) DRAIN TUBE

(BEHIND COLLECTOR BOX DRAIN TUBE)

FIELD-INSTALLED FAC TORY-SUPPLIED

Condensate Trap on

BURNER ENCLOSURE PRESSURE

REFERENCE TUBE ASSEMBLY
INDUCER HOUSING DRAIN TUBE (VIOLET)

(GREEN)

COLLECTOR BOX DRAIN TUBE

(BLUE )

FIELD-INSTALLED
FACTORY-SUPPLIED DRAIN TUBE
COUPLING (LEFT DRAIN OPTION)

DRAIN TUBE

LEFT Side

COLLECTOR BOX

TUBE (GREEN)

COLLECTOR BOX DRAIN TUBE

(BLUE & WH IT E S T R IPED)

COLLECTOR BOX
EXTENSION TUBE

CONDENSATE TRAP

CAP

T u be location when used on

HORIZONTAL - LEFT application

PLUG

BURNER ENCLOSURE

PRESSURE REFERENCE

TUBE ASSEMBLY

COLLECTOR BOX EXTENSION DRAIN TUBE

NOTE:

1. All tubing m ust 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. HORIZONTA L-LEFT installations require the collector box pressure tu be to be relocated between the inducer housing and the blow er shelf to
prev e nt a tra p .Refer to the Insta llation In struc tion s for fu rthe r deta ils.

CAP

COLLECTOR BOX

EXTENSION TUBE

CONDENSATE TRAP

T ube location when used in UPFLOW application

BURNER ENCLOSURE

PRESSURE REFERENCE

TUBE ASSEMBLY

CAP

PLUG

COLLECTOR BOX DRAIN

TUBE

(BLUE & WH IT E S T R IPED)

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 TUBE

(PINK)

COLLECTOR BOX TUBE (GREEN)

COLLECTOR BOX DRAIN TUBE

(BLUE)

CONDENSATE TRAP

T ube location when used in DOWNFLOW application

COLLECTOR BOX

DRAIN TUBE (BLUE)

COLLECTOR BOX DRAIN TUBE

DRAIN TUBE

COUPLING

PLUGGED END

PLUG

COLLECTOR BOX
EXTENSION TUBE

COLLECTOR BOX

TUBE (PINK)

(BLUE & WHITE STRIPED)

COLLECTOR BOX

TUBE (GREEN)

INDUCER HOUSING

DRAIN TUBE

(VIOLE T)

COLLECTOR BOX

DRAIN TUBE (BLUE)

COLLECTOR BOX TUBE (PINK)

RELOCATE TUBE BETW EEN BLOW ER

SHELF AND INDUCER HOUSING FOR

040,060, AND 080 HEATING INPUT

FURNACES

COLLECTOR BOX DRAIN

TUBE

(BLUE & WHITE STRIPED)

INDUCER HOUSING DRAIN

TUBE (VIOLET)

DRAIN TUBE COUPLING

DRAIN TUBES ROUTED IN

FRONT OF GAS VALVE

COLLECTOR BOX DRAIN TUBE

(BLUE )

PLUG

CAP

COLLECTOR BOX

TUBE (GREEN)

COLLECTOR BOX DRAIN TUBE

(BLUE AND WHITE STRIPED)

Tube location when used on

HORIZONTAL - RIGHT application

Condensate Trap on LEFT

Side Optional

BURNER ENCLOSURE

PRESSURE REFERENCE

TUBE ASSEMBLY

CAP

PLUG

COLLECTOR BOX DRAIN TUBE

(BLUE & WHITE STRIPED)

INDUCER HOUSING DRAIN TUBE

Condensate Trap on

PLUG

CAP

COLLECTOR BOX DRAIN TUBE

(BLUE)

COLLECTOR BOX TUBE

(PINK)

COLLECTOR BOX TUBE

(GREEN)

COLLECTOR BOX EXTENSION TUBE

BURNER ENCLOSURE PRESSURE

REFERENCE TUBE ASSEMBLY

CONDENSATE TRAP

COLLECTOR BOX

GAS VALVE

COLLECTOR BOX EXTENSION TU BE

COLLECTOR BOX TUBE (PINK)

INDUCER HOUSING DRAIN TUBE (VIOLET)

EXTENSION DRAIN TUBE

AUXILIARY "J" BOX RELOCATED HERE

BURNER ENCLOSURE

PRESSURE REFERENCE

TUBE ASSEMBLY

COLLECTOR BOX

EXTENSION TUBE

CONDENSATE TRAP

324999-201 RE V. C

(VIOLE T)

RIGHT Side

Fig. 8—Furnace Pressure and Drain Tubing Diagram

A00308

—7—

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.

CAUTION: 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.

BURNER FLAME

BURNER

8. Turn on gas and electrical supplies to furnace.

9. Verify igniter operation by initiating furnace control self­test feature or by cycling thermostat.

10. Replace main furnace door.

VII. ELECTRICAL CONTROLS AND WIRING

CAUTION: 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. 11 for field wiring information
and to Fig. 15 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.

The 24-v circuit contains an automotive-type, 3-amp fuse located
on the control center. (See Fig. 11.) 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 (3 amp). The 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 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 heat
tape has been applied, check to ensure it will operate when low
temperatures are present.

MANIFOLD

Fig. 9—Burner Flame

PAM

RTV

Fig. 10—Gasket on Collector Box

A89020

A93081

CAUTION: 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 Fig. 13.)

NOTE: See CONDENSATE DRAIN PROTECTION section of
Installation, Start-Up, and Operating Instructions.

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.

IX. WINTERIZING

CAUTION: Freezing condensate left in the furnace will

damage the equipment.

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

—8—

FIVE WIRE

THREE-WIRE

HEATING-ONLY

BLOWER DOOR SWITCH

BLK

WHT

115-V FIELD-

SUPPLIED

DISCONNECT

BLK

WHT

GND

AUXILIARY
J-BOX

GND

FURNACE

NOTE 2

C
O
N
T
R
O
L

24-V

TERMINAL

BLOCK

WCR GY

W

R

G

COM

Y/Y2

NOTE 1

NOTES: Connect Y-terminal in furnace as shown for proper blower operation.

Fig. 11—Field Wiring

1. Turn off electrical supply to furnace.

2. Remove main furnace door.

3. Disconnect cap from unused drain tap on inducer housing.
(See Fig. 14.)

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

5. Insert funnel in drain tube and pour up to 1 quart antifreeze,
propylene glycol (RV, swimming pool antifreeze, or
equivalent) into funnel until it is visible at point where
condensate enters open drain. (See Fig. 15.)

6. Reconnect drain cap to inducer housing.

7. Replace main furnace door.

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

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

WIRING DIAGRAM

See Fig. 16 for Wiring Diagram.

TROUBLESHOOTING

Use the Troubleshooting Guide, the status code LED on the
cotntrol and the Component Test to isolate furnace operation
problems.

A. Status Codes

For an explanation of status codes, refer to service label located on
back of main furnace door or Fig. 17 and the Troubleshooting
Guide. The stored status codes will NOT be erased from the
control memory if 115- or 24-v power in interrupted. The control
will store up to 7 Status Codes.

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

THERMOSTAT
TERMINALS

CONDENSING
UNIT

TWO
WIRE

1.
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.

FIELD-SUPPLIED
DISCONNECT

208/230- OR
460-V
THREE
PHASE

208/230-V
SINGLE
PHASE

GND

NOTE: Removing the blower access door will open the blower
access door switch and terminate 115-v power to the control.

To read current status code, remove main furnace door. The status
code LED can be viewed through the sight glass on the blower
access door.

NOTE: NO thermostat signals may be present at control and all
blower off delays must be completed to view previous codes.

To retrieve previous codes, remove 1 of the red main limit or flame
rollout switch wires for 1 to 4 sec until the LED light goes out, then
reconnect it. (Do not leave red wire disconnected for longer
periods of time as the control will assume an overtemperature
condition exists and will respond with blower operation.) This
places the control in the status recall mode and displays the first
code stored in memory.

Record the code and repeat the disconnect and reconnect of the red
wire, recording each code until code 11 is displayed indicating no
addition codes. After the last code is displayed or after 2 minutes
in the code recall mode the control will return to normal standby
mode.

B. Component Test

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 electrical shock, personal injury,
or death.

Use the Component Test to check furnace components for proper
operation. To initiate the component self-test sequence, shut off
the room thermostat or disconnect the ″R″ thermostat lead. Briefly
(approximately 2 sec) short the TWIN/TEST terminal to the C
24V terminal. The status LED will turn off. The test sequence will
be as follows:

A99440

OM

—9—

BLOWER OFF-DELAY

24-V THERMOST AT

TERMINALS

Y1 DHUM G COM W/W1 Y/Y2 R

24V

BLOWER OFF-DELAY

90 150

120 180

TWINNING AND/OR
COMPONENT TEST

TERMINAL

HUMIDIFIER TERMINAL

(24-VAC 0.5 AMP MAX.)

3-AMP FUSE

LED OPERATION &

DIAGNOSTIC LIGHT

115-VAC(L2)NEUTRAL

CONNECTIONS

COOL

HEAT

BLOWER SPEED

SELECTION TERMINALS

STATUS CODE LED

FUSE 3-AMP

SEC-2 SEC-1

EAC-2 L2

NUETRAL

BLW

COOL HEAT

SPARE-1 SPARE-2

SPARE-1

SPARE-2 FAN

TEST/TWIN

HUM

0.5 AMP@24VAC

PLT 1

PLT

1-AMP@

FAN

EAC-1

115VAC

PR-1

L1

115 VAC (L1) LINE

VOLTAGE CONNECTION

EAC-1 TERMINAL

(115-VAC 1.0 AMP MAX.)

TRANSFORMER 24-VAC

CONNECTIONS

PL1-LOW VOLT A GE MAIN
HARNESS CONNECTOR

PL2 1

PL2-HOT SURFACE

IGNITER & INDUCER

MOTOR CONNECTOR

1. LED flashes a current status code, or code 11, 4 times.
Record this status code for further troubleshooting.

2. The inducer will start and continue to run until test is over.

3. Hot surface igniter (HSI) is energized for 15 sec, then
de-energized.

4. The blower motor operates on HEATING speed for 10 sec,
then turns off.

5. The blower motor operates on COOLING speed for 10 sec,
then turns off.

6. Blower operates on continuous fan speed, then turns off.

7. Inducer turns off.

8. The gas valve and humidifier terminal HUM are not
energized for safety reasons.

A02142

Fig. 12— Control Center

32°F MINIMUM INSTALLED
AMBIENT OR FREEZE
PROTECTION REQUIRED

A93058

Fig. 13—Winterizing the Furnace

—10—

Fig. 14—Inducer Housing Drain Tube

A99118

Fig. 15—Funnel in Drain and Antifreeze Running

Through Trap

A99119

—11—

Fig. 16—Wiring Diagram A02157

PCB

TRAN

FRS

NOTE #11

LS

PRS

(WHEN USED)

LGPS

FUSED OR CIRCUIT BREAKER

DISCONNECT SWITCH (WHEN REQ’D)

NOTE #2

JB

L1

L1

BLWR

HI/LO

TO 115VAC FIELD DISCONNECT
NOTE #2

EQUIPMENT GROUND

SPARE-1

HEAT

FAN

COOL

HSIR

EAC-1

START

OL

HI

MED HI

MED LO

LO

BLWM

SCHEMATIC DIAGRAM

(NATUR AL GAS & P RO PANE)

1

1HSI
2

PL32

PL2

115VAC

PR1

TRAN

24VAC

M

IDR

TEST/TWIN

F U 1

NOTE #6

IDM

OL

AUX

CAP - 2

CAP-1

L2

FRS

LS

LGPS

(WHEN USED)

NOTE #11

PRS

FSE

9

1

5

CPU

PCB

Y1

G

C

R

W

SEC-1

GVR-1

NOTES:

326796-101 REV. A

OM

10

4

6

2

PL4

2

3

1

NEUTRAL

ILK

FU2

L1

ILK

GND

RED

BLU

ORN

WHT

RED RED

ORN

RED

RED

GRN/YEL

YEL

BLU

BLU

RED

WHT

BLK

LED 1

12345678910

BLOWER OFF DELAY
JUMPE R SELECT

YEL

OL

START

BLK

WHT

WHT

BRN

IDM

BRN

CAP -2

AUX

OL

M

HSI

WHT

BLK

BLK

WHT

WHT (COM)

BLK

BLK

WHT

WHT

2

1

PL2

WHT

BLK

BLK

BLWM

CAP -1

SPARE 1

SPARE 2

EAC-1

PR1

SEC-2

SEC-1

EAC-2

SEC-2

8

7
3

PL1

2
1

PL3

3
2
1

PL4

BRN

BRN

RED (LO)

WHT

(COM)

YEL

BLU

(MED LO )

COM

HUM

GVR-2

DHUM

Y/Y2

(MED HI)

FAN

11

WHT

PL1

11

L2

GRN/YEL

GRN/YEL

GRN/YEL

GND

NOTE #3

GV

M

C

NOTE #3

GV

M

C

GRN/YEL

GRN/YEL

FSE

NOTE #10

WHT

Y1

R

Y/Y2

W

C

HUM

om

TEST/TWIN

24V

FU1

J1

180

150

120

90

G

DHUM

NOTE #6

EAC-2

L2

NEUTRAL

NOTE #8

BLW

L1

FAN

BHT/CLR BFANR BLWR
COOL

HEAT

BLK (HI)

L
E
G
E
N
D

BFANR CONTINUOUS-FAN SELECT RELAY, SPDT
BHT/CLR BLOWER MOTOR SPEED CHANGE RELAY, SPDT
BLWR BLOWER MOTOR RELAY, SPST-(N.O.)
BLWM BLOWER MOTOR, PERMANENT-SPLIT-CAPACITOR
CAP 1, 2 CAPACITOR
CPU MICROPROCESSOR AND CIRCUITRY
EAC-1 ELECTRONIC AIR CLEANER CONNECTION (115 VAC 1.0 AMP MAX.)
EAC-2 ELECTRONIC AIR CLEANER CONNECTION (COMMON)
FRS FLAME ROLLOUT SW. -MANUAL RESET, SPST-(N.C.)
FSE FLAME-PROVING ELECTRODE
FU 1 FUSE, 3 AMP, AUTOMOTIVE BLADE TYPE, FACTORY INSTALLED
FU 2 FUSE OR CIRCUIT BREAKER CURRENT INTERRUPT DEVICE

(FIELD INSTALLED & SUPPLIED)
GND EQUIPMENT GROUND
GV GAS VALVE-REDUNDANT
GVR 1, 2 GAS VALVE RELAY, DPST-(N.O.)
HSI HOT SURFACE IGNITER (115 VA C )
HSIR HOT SURFACE IGNITER RELAY, SPST-(N.O.)
HUM 24VAC HUMIDIFIER CONNECTION (0.5 AMP. MAX.)
IDM INDUCED DRAFT MOTOR, PSC
IDR INDUCED DRAFT MOTOR RELAY, SPST-(N.O.)
ILK BLOWER ACCESS PANEL INTERLOCK SWITCH, SPST-(N.O.)
J1 BLOWER - OFF DELAY JUMPER SELECTOR
JB JUNCTION BOX
LED LIGHT-EMITTING DIODE FOR STATUS CODES - AMBER
LGPS LOW GAS PRESSURE SWITCH, SPST-(N.O.)
LS LIMIT SWITCH, AUTO-RESET, SPST (N.C.)

OL AUTO-RESET INTERNAL MOTOR OVERLOAD

TEMPERATURE SWITCH (N.C.)
PCB PRINTED CIRCUIT BOARD CONTROL
PL1 11-CIRCUIT PCB CONNECTOR
PL2 2-CIRCUIT CONNECTOR
PL3 2-CIRCUIT HSI, CONNECTOR
PL4 3-CIRCUIT IDM EXTENSION CONNECTOR
PRS PRESSURE SWITCH, SPST-(N.O.)
TEST/TWIN COMPONENT TEST & TWIN TERMINAL
TRAN TRANSFORMER-115VAC/24VAC

JUNCTION
UNMARKED TERMINAL
PCB CONTROL TERMINAL
FACTORY WIRING (115V AC)
FACTORY WIRING (24V AC)
FIELD WIRING (115VAC)
FIELD WIRING (24VAC)
CONDUCTOR ON CONTROL PCB
FIELD WIRING SCREW TERMINAL
FIELD EARTH GROUND
EQUIPMENT GROUND
FIELD SPLICE
PLUG RECEPTACLE

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

2. Use only copper wire between the disconn e ct switch and the furnac e junction box (J B ).

3. This wire must be connected to furnace sheet metal for control to prove flame.

4. Symbols are electrical representation only.

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

6. Replace only with a 3 amp fuse.

7. Inducer (IDM) and blower (BL WM) motors contain internal auto-reset thermal overload s w itches (O L).

8. Neutral connections are interchangeable within the NEUTRAL connector block.

9. Blower motor speed selections are for average conditions, see installation instructions for details on
optimum speed selection.

10. YELLOW lead not on all motors.

11. Factory connected when LGPS is not used.

12. Ig nition-lockout will occ ur after four cons e c u t ive unsucc e ssful trials-f o r- ignition. Co ntrol will
auto-res et after thre e h ours.

13. Blower-on dela y: gas heating 60 seconds, cooling or heat pump 2 seconds.

14. Blower-off delay: gas heating selections are 90, 120, 150 or 180 seconds, cooling or heat pump
90 seconds or 5 seconds when dehumidify call is active.

NOTE #10

PRINTED CIRCIUT BOARD

PRINTED CIRCIUT BOARD

NOTE #5

A02157

—12—

If status code recall is needed, briefly remove then reconnect one m ain limit wire to display

SERVICE

stored status code. O n R ED LED boards do not remove power or blower door before initiat­ing status code recall. A fter status code recall is completed component test will occur.

LED CODE

CONTINUOUS OFF - Check for 115VAC at L1 & L2, & 24VAC at SEC-1 & SEC-2.
CONTINUOUS ON - Control has 24VAC power.
RAPID FLASHIN G - Line voltage (115VAC) polarity reversed. If twinned,

EACH OF THE FOLLOWING STATUS CODES IS A TWO DIGIT NUMBER WITH THE FIRST
DIGIT DETERMINED BY THE NUMBER OF SHORT FLASHES AND THE SECOND DIGIT BY
THE NUMBER O F LO NG FLASHES .

11 NO PREVIOUS CODE - Stored status code is erased automatically after 72

hours. On RED LED boards stored status codes can also be erased when power
(115 VAC or 24 VAC) to control is interrupted.

12 BLOWER ON AFTER POWER UP (115 VAC or 24 V AC) -Blower runs for 90

seconds, if unit is powered u p during a call for heat (R-W closed) or R-W opens
during blower on-delay.

13 LIMIT CIRCUI T LOCKOUT - Lockout occurs if the limit or flame rollout switch is

open longer than 3 minutes.

- Control will auto reset after three hours. - Refer to #33.

14 IGNITION LOCKOUT - Control will auto-reset after three hours. Refer to #34.
21 GAS HEATING LOCKOUT - Control will NOT auto reset.

Check for: - Mis-wired gas valve -Defective control (valve relay)

22 ABNORMAL FLAME-PROVING SIGNAL - Flame is proved while gas valve is

de-energized. 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 (24VAC) wiring.

31 PRESSURE SWITCH DID NOT CLOSE OR REOPENED - If open longer than

five minutes, inducer shuts off for 15 minutes before retry. Check for:

- Excessive wind - Proper vent sizing - Defective inducer motor

- Low inducer voltage (115VAC) - Defective pressure switch

- Inadequate combustion air supply - Restricted vent

- Disconnected or obstructed pressure tubing

- Low inlet gas pressure (if LGPS used)
If it opens during blower on-delay period, blower will come on for the selected
blower off-delay.

33 LIMIT CIRCUI T FAULT - Indicates a limit, or flame rollout is open. Blower will

run for 4 minutes or until open switch remakes whichever is longer. If open
longer than 3 minutes, code changes to lockout #13. If open less than 3 minutes
status code #33 continues to flash until blower shuts off. Flame rollout switch
requires manual reset. Chec k f or: - Restricted ven t

- Proper vent sizing - Loose blower wheel - Excessive wind

- Dirty filter or restricted duct system.

- Defective blower motor or capacitor. - Defective switch or connections.

- Inadequate combustion air supply (Flame Roll-out Switch open).

34 IGNITION PROVING FAILURE - Control will try th ree more times before locko u t

#14 occurs. If flame signal lost during blower on-delay period, blower will come
on for the selected blower off-delay. Check for: - Control ground continuity

- Flame sensor must not be grounded

- Oxide buildup on flame sensor (clean with fine steel wool).

- Proper flame sense microamps (.5 microamps D.C. min., 4.0 - 6.0 nominal).

- Gas valve defective or ga s v alve turned off - Manual valve shut-off

- Defective Hot Surface Ignitor

- Low inlet gas pressure

- Inadequate flame carryover or rough ignition

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

45 CO NTROL CIRCUITRY LOCKOUT Auto-reset after one hour lockout due to;

- Gas valve relay stuck open - Flame sense circuit failure

- Software check error
Reset power to clear lockout. Replace control if status code repeats.

refer to tw in n ing kit instructions.

COMPONENT TEST

To initiate the component test sequence, shut OFF the room thermost at or disconnect
the "R" thermostat lead. Briefly short the TEST/TWIN ter m inal to the "Com 24V" ter­minal. Status LED will flash code and then turn ON the inducer motor. The inducer
motor will run for the entire component test. The hot surface ignitor, blower motor
FAN speed (AMBER LED boards only) blower motor HEAT speed, and blower motor
COOL speed will be turned ON for 10-15 seconds each. Gas Valve and Humidifier
will not be turned on.

STATUS

327884-101 REV. A

A02154

Fig. 17—Service Label

—13—

A02204a

Is LED status light on?

Is LED status light blinking rapidly without a
pause?

Is LED status light blinking ON/OFF slowly
with a combination of short and long flashes?

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.

Is there 115V at L1 and L2?

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.

To recall status code briefly remov e and reconnect one RED wire from the Limit
Switch or Flame Rollout switch to display stored status code. On RED LED
control do not remove power or blower access panel before initiating status
code recall. You can also recall the previous status code by momentarily shorting
the TEST/TWIN terminal to Com24V terminal until the LED goes out. LED will
flash the previous status code or status code #11 (1 short and 1 long flash) if
there was no previous code. After the control repeats the code 4 times, the
control will go through a brief component test sequence. The inducer will start
and run for the entire component test. The HSI, blower motor FAN speed
(AMBER LED boards only) HEAT speed, and COOL speed will run for 10 – 15
seconds each. Gas valve and humidifier will not be turned on.

Was there a previous status code
other than #11?

Is door switch closed?

Is there 115V going to switch?

Replace door switch.

Replace transformer.

Does the control respond to W, Y1 (if present),
Y/Y2, and G (24V) thermostat signals?

Run system through a heating or cooling cycle
to check operation. Status codes are erased
after 72 hours. On RED LED boards stored
status codes can also be erased whenever
(115V or 24V) is interrupted.

Replace furnace control.

Close door switch and go back to START.

Is circuit breaker closed?

Check for continuity in wire from circuit breaker
to furnace.

Close circuit breaker and go back to START.

Check room thermostat or
interconnecting cable.

Is 24V present at W, Y1 (if present), Y/Y2 or
G thermostat terminals on the furnace control?

Disconnect all the thermostat wires from the
furnace control.

Does the problem repeat when using
a 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.

NO

YES

YES

NO

NO

YES

YES

YES

YES

NO

YES

YES

NO

YES

NO

YES

NO

NO

NO

YES

NO

YES

NO

START

TROUBLESHOOTING GUIDE

NO

—14—

A02204b

11 NO PREVIOUS CODE – Stored codes

are erased after 72 hours. On RED LED
boards stored status codes can also be
erased whenever power (115V or 24V)
is interrupted. Run system through a
heating or cooling cycle to check system.

12 BLOWER ON AFTER POWER UP –

(115V OR 24V) – Normal operation.
Blower runs for 90 seconds, if unit is
powered up during a call for heat (R-W
closed) or when (R-W opens) during the
blower on-delay period.

13 LIMIT CIRCUIT LOCKOUT – Lockout

occurs if the limit or flame rollout switch is
open longer than 3 minutes. Control will
auto-reset after 3 hours. See code 33.

14 IGNITION LOCKOUT – System failed to

ignite gas and prove flame in 4 attempts.
Control will auto-reset after 3 hours.
See status code 34.

21 GAS HEATING LOCKOUT – Turn off

power and wait 5 minutes to retry.
Check for:

- Stuck closed gas valve relay on control.

- Miswire or short to gas valve wire.

22 ABNORMAL FLAME-PROVING SIGNAL

Flame is proved while gas valve is de­energized. Inducer will run until fault is
cleared. Check for:

- Stuck open or leaky gas valve.

23 PRESSURE SWITCH DID NOT OPEN

Check for:

- Obstructed pressure tube.

- Pressure switch stuck closed.

24 SECONDARY VOL TAGE FUSE IS OPEN

Check for:

- Short circuit in secondary voltage (24V)
wiring including thermostat leads.
Disconnect thermostat leads to isolate
short circuit.

31 PRESSURE SWITCH DID NOT CLOSE

OR REOPENED – If open longer than 5
minutes, inducer shuts off for 15 minutes
before retry. If opens during blower on­delay period, blower will come on for the
selected blower off-delay. Check for:

- Proper vent sizing.

- Low inducer voltage (115V).

- Low inlet gas pressure (if LGPS used).

- Inadequate combustion air supply.

- Disconnected or obstructed pressure
tubing.

- Defective inducer motor.

- Defective pressure switch.

- Excessive wind.

- Restricted vent.

33 LIMIT CIRCUIT FAULT – Indicates the

limit or flame rollout switch is open. Blower
will run for 4 minutes or until open switch
remakes whichever is longer. If open
longer than 3 minutes, code changes to
lockout #13. If open less than 3 min.
status code #33 continues to flash until
blower shuts off. Flame rollout switch
requires manual reset. Check for:

- Dirty filter or restricted duct system.

- Loose blower wheel.

- Defective switch or connections.

- Defective blower motor or capacitor.

- Inadequate combustion air supply
(flame rollout switch open).

- Restricted vent.

- Proper vent sizing.

- Excessive wind.

- Blower motor on incorrect speed tap.

- Input rate to furnace set too high.

34 IGNITION PROVING FAILURE – If flame

is not sensed during the trial for ignition
period, the control will repeat the ignition
sequence 3 more times before lockout
#14 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 to the next step.

- Gas valve turned off.

- Manual shut-off valve.

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

- Flame sensor must not be grounded.

To determine whether the problem is in
the gas valve, igniter, or flame sensor the
system can be operated in the component
test mode to check the igniter. First
remove the R thermostat connection from
the control and initiate the component
test sequence. Does the igniter glow
orange/white by the end of the 15 second
warm-up period?

Unplug igniter harness from control and initiate
another component test sequence. Check
for 115V between pin 1 and NEUTRAL-L2 on
the control. Was 115V present for the 15
second period?

Reconnect the R thermostat lead and set
thermostat to call for heat. Connect voltmeter
across gas valve connections. Does gas v alve
receive 24V?

Does gas valve open and allow gas to flow?

Do the main burners ignite?

Do the main burners stay on?

Repeat call for heat and check flame sensor
current during trial for ignition period. Is the
DC microamps below 0.5?

Is current near typical value?

Will main burners ignite and stay on?

Fixed.

Clean flame sensor with fine steel wool and
recheck current. Nominal current is 4.0 to 6.0
microamps.

45 CONTROL CIRCUITRY LOCKOUT

Auto-reset after 1 hour lockout due to:

- Flame circuit failure.

- Gas valve relay stuck open.

- Software check error.
Reset power to clear lockout. Replace
control if code repeats.

Replace furnace control.

Check for continuity in the harness and igniter.
Replace defective component.

Check connections. If OK, replace control.

Check that all gas valves are turned on.
Replace valve.

Check for:

- Inadequate flame carryover or rough
ignition.

- Low inlet gas pressure.

- Proper firing rate.

- Check for air leakage around igniter bracket.

Allow blower to come on and repeat test to
check for intermittent operation.

Check connections and retry. If current is
near typical value (4.0-6.0 nominal) and
burners will not stay on, replace control.

Replace electrode.

Replace furnace control.

YES

YES

YES

YES

NO

YES

YES

YES

NO

YES

NO

NO

NO

YES

NO

NO

NO

NO

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© 2002 Bryant Heating & Cooling Systems 7310 W. Morris St. Indianapolis, IN 46231

—16—

Printed in U.S.A. sp0558 Catalog No. 5335-207