Bryant 4-WAY MULTIPOISE TWO-STAGE CONDENSING GAS FURNACE 352AAV Instruction manual

352AAV
Deluxe 4--Way
Multipoise Fixed--Capacity
Condensing Gas Furnace
Service and Maintenance Instructions
for Sizes 060--120, Series A
NOTE: Read the entire instruction manual before starting the
installation.
!
ELECTRICAL
HAZARD
TABLE OF CONTENTS
PAGE
WARNING
SHOCK,
FIRE,
OR
EXPLOSION
Failure to follow safety warnings exactly could result in
dangerous operation, personal injury, death, or property
damage.
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
-- 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.
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
WARNING
ELECTRICAL SHOCK, FIRE, OR EXPLOSION
HAZARD
Secondary Heat Exchangers . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Flushing Collector Box and Drainage System . . . . . . . . . . . . . 8
Failure to follow this warning could result in possible
damage to this equipment, personal injury, or death.
Servicing Hot Surface Igniter . . . . . . . . . . . . . . . . . . . . . . . . . 10
Electrical Controls and Wiring . . . . . . . . . . . . . . . . . . . . . . . . 11
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.
Checking Heat Tape Operation (If Applicable) . . . . . . . . . . . 11
Winterizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Component Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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WARNING
FIRE OR EXPLOSION HAZARD
ama
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.
ISO 9001:2000
CERTIFIED
REGISTERED
1
352AAV
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.
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.
!
A05085
Fig. 1 -- Multipoise Furnace in Upflow Orientation
AIRFLOW
UPFLOW
CAUTION
UNIT DAMAGE HAZARD
HORIZONTAL
LEFT
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.
HORIZONTAL
RIGHT
DOWNFLOW
AIRFLOW
AIRFLOW
AIRFLOW
GENERAL
A93041
Fig. 2 -- Multipoise Orientation
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
installed in any of the 4 positions shown in Fig. 2, you may need to
revise your orientation to component location accordingly.
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.
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 for maintenance and maintenance
contract availability.
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death.
Turn off the gas and electrical supplies to the unit before
performing any maintenance or service. Follow the operating
instructions on the label attached to the furnace.
The minimum maintenance that should be performed on this
equipment is as follows:
1. Check and clean or replace air filter each month as needed.
2. Check blower motor and wheel for cleanliness annually.
3. Check electrical connections for tightness and controls for
proper operation each heating season. Service as necessary.
4. Check for proper condensate drainage. Clean as necessary.
5. Check for blockages in combustion--air and vent pipes annually.
6. Check burners for cleanliness annually.
!
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.
!
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:
1. Turn off electrical supply to furnace.
2. Remove filter cabinet door.
3. Slide filter out of cabinet.
4. Furnaces with a washable filter, clean filter by spraying cold
tap water through filter in opposite direction of airflow.
Rinse filter and let dry. Oiling or coating of the filter is not
recommended.
5. If equipped with factory specified disposable media filter,
replace only with a factory specified media filter of the same
size.
6. Slide filter into cabinet.
7. Replace filter cabinet door.
8. Turn on electrical supply to furnace.
If filter is installed in furnace blower compartment:
1. Turn off electrical supply to furnace.
2. Remove main furnace door and blower access panel.
3. Release filter retainer wire. (See Fig. 3 or 4.)
NOTE: Filters shown in Fig. 3 and 4 can be in furnace blower
compartment or in filter cabinet, but not in both.
4. Slide filter out of furnace.
5. Furnaces with washable filter(s) should clean filter by
spraying cold tap water through filter in opposite direction
of airflow.
6. Rinse filter and let dry. Oiling or coating filter is not recommended.
7. Slide filter into furnace.
8. Recapture filter retaining wire.
9. Replace blower access panel and main furnace door.
10. Turn on electrical supply to furnace.
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.
3
352AAV
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.
Table 1 – Furnace Air Filter Table
FURNACE CASING WIDTH
IN (MM)
17--- 1/2 (445)
21 (533 )
24--- 1/2 (610)
FILTER QUANTITY AND SIZE *
SIDE RETURN*
BOTTOM RETURN*
IN (MM)
IN (MM)
(1) 16 x 25 x 3/4
(1) 16 x 25 x 3/4
(406 x 635 x 19)
(406 x 635 x 19)
(1) 16 x 25 x 3/4
(1) 20 x 25 x 3/4
(406 x 635 x 19)
(508 x 635 x 19)
(1) 16 x 25 x 3/4
(1) 24 x 25 x 3/4
(406 x 635 x 19)
(610 x 635 x 19)
FILTER TYPE*
3/4” (19 mm) thick washable
3/4” (19 mm) thick washable
3/4” (19 mm) thick washable
Table 2 – Air Filter Located in Filter Cabinet
352AAV
FILTER CABINET HEIGHT --- IN (MM)
FILTER SIZE --- IN (MM)
(1) 16 x 25 x 3/4*
(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)
16 (406)
20 (508)
24 (610)
FILTER TYPE
Washable
Washable
Washable
* Filters with a side return--air may have a different filter size. Measure the filter to obtain the correct size.
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.
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.
FILTER
FILTER
SUPPORT
FILTER
RETAINER
WASHABLE FILTER OR
DISPOSABLE MEDIA FILTER
IN FILTER CABINET
A08588
Fig. 3 -- Bottom Filter Arrangement
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. 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 do not need to
be removed from motor.
f. Remove blower wheel from housing.
4
!
FILTER
IN FURNACE
CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in noise or furnace
component failure.
FILTER
RETAINER
WASHABLE FILTER OR
DISPOSABLE MEDIA
FILTER IN FILTER CABINET
A08589
Fig. 4 -- Filter Installed for Side Inlet
PLUG
CAP
COLLECTOR BOX
DRAIN TUBE (BLUE
& WHITE STRIPED)
COLLECTOR BOX
TUBE (PINK)
COLLECTOR BOX
TUBE (GREEN)
INDUCER HOUSING
(MOLDED) DRAIN
TUBE (BEHIND
COLLECTOR BOX
DRAIN TUBE)
COLLECTOR BOX
DRAIN TUBE (BLUE)
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.
Tighten setscrew to between 140--160 in.--lb torque.
NOTE: Be sure to attach ground wire to blower housing.
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. 5 or tubing
diagram on main furnace door for proper tube location.
(1.) Connect 1 tube (blue or blue and white striped) from
collector box.
(2.) Connect 1 tube (violet or unmarked) from inducer
housing.
(3.) Connect 1 tube (relief port, green or pink) from collector box.
NOTE: Ensure tubes are not kinked or pinched, as this will affect
operation.
c. Connect field drain to condensate trap.
13. Reconnect wires. Refer to furnace wiring diagram and connect thermostat leads if previously disconnected. (See Fig.
16.)
NOTE: Refer to Table 3 for motor speed lead reconnection if
leads were not identified before disconnection.
!
CAUTION
UNIT DAMAGE HAZARD
CONDENSATE
TRAP
Failure to adjust the heating speed may shorten heat exchanger
life.
Heating air speed selection MUST be adjusted to provide
proper temperature rise as specified on the rating plate.
FIELD-INSTALLED
FACTORY-SUPPLIED
DRAIN TUBE
COUPLING (LEFT
DRAIN OPTION)
Table 3 – Speed Selection
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)
A01030
Fig. 5 -- Factory--Shipped Upflow Tube Configuration
(Shown with Blower Access Panel Removed)
COLOR
SPEED
White
Black
Yellow
Orange{
Common
High
Medium High
Medium
Blue
Medium Low
Red
Low*
*Continuous blower speed.
{Available on 5 ---speed blowers only.
5
FACTORY
ATTACHED TO
Com
Cool
Spare
High--- Gas Heat
Spare/High--- Gas
Heat
Low--- Gas Heat
352AAV
The blower wheel should not be dropped or bent as balance
will be affected.
!
CELL
PANEL
WARNING
MANIFOLD
MOUNTING
SCREWS
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death.
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.
352AAV
GASKET
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 performing
a component self--test as shown at the bottom of Service label. (See Fig. 20.)
15. If furnace is operating properly, remove tape to release
blower access door switch, replace blower access door, and
replace main furnace door.
MANIFOLD
GAS VALVE
REGULATOR
FITTING
GAS
CONTROL
VALVE
Step 3 — Cleaning Burners
A02312
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.
!
Fig. 6 -- Burner Box Assembly
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.
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 1 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 1 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.)
IGNITER WIRES MUST
BE PLACED IN THIS SLOT
A05074
Fig. 7 -- Igniter Wire Placement
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in electrical shock,
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.
6
NOTE: Use propane gas resistant pipe dope to prevent gas leaks.
DO NOT use Teflon tape.
!
PRIMARY HX
INLET OPENINGS
WARNING
FIRE, EXPLOSION, UNIT DAMAGE HAZARD
Failure to follow this warning could result in property damage,
personal injury, or death.
Gas valve switch MUST be facing forward or tilted upward.
!
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.
21. Check for gas leaks.
22. Replace main furnace door.
Step 4 — Cleaning Heat Exchangers
The following items should be performed by a qualified service
technician.
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 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 orifices(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
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 hazardous operation.
3. Disconnect wires or connectors to flame rollout switch, gas
valve, igniter, and flame sensor.
4. Disconnect combustion-air intake pipe from intake housing.
5. Remove the pressure switch tube from intake housing.
6. Remove screws attaching intake housing to burner box, and
rotate intake housing away from burner box for removal.
7. Using backup wrench, disconnect gas supply pipe from furnace gas control valve.
8. Disconnect pressure tubing from gas valve.
Fig. 8 -- Cleaning Inlet Openings of Primary
A96305
Heat Exchangers
9. Remove 2 screws attaching top filler panel and rotate upwards to gain access to screws attaching burner box to cell
panel.
10. Remove screws attaching burner box to cell panel. (See Fig.
6).
NOTE: Burner box, cover, manifold, gas valve, and burner
assembly should be removed as one assembly.
11. Clean heat exchanger openings with a vacuum and a soft
brush. (See Fig. 8.)
NOTE: After cleaning, inspect the heat exchanger to ensure they
are free of all foreign objects that may restrict flow of combustion
products.
12. Reverse items 4 through 10 for reassembly.
!
CAUTION
UNIT MAY NOT OPERATE
Failure to attach this ground wire to an adequate casing
ground may cause the furnace control to lock out.
The ground wire from the gas valve MUST be attached to the
burner box attachment screw.
NOTE: Be sure burner box gasket is installed between burner box
and cell panel. (See Fig. 6.) If gasket is damaged, replace it.
NOTE: Inspect combustion--air intake housing. If foamed gasket
was removed, check for any damage. If gasket is damaged in any
way, it must be repaired. To repair, remove damaged gasket
section, apply sealant releasing agent such as PAM cooking spray
or equivalent (must not contain corn nor canola oil, halogenated
hydrocarbons nor aromatic content, to prevent inadequate seal
from occurring) 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. 9.)
13. Refer to furnace wiring diagram and reconnect wires to
flame rollout switch, gas valve, igniter, and flame sensor.
14. Reconnect pressure switch tubes to gas valve and intake
housing. Refer to tube routing label on main furnace door
or Fig. 10 for proper tube location. Be sure tubes are not
kinked.
15. Turn on gas and electrical supplies to furnace.
7
352AAV
19. Replace burner box cover.
20. 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. 11.)
!
WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warnings exactly could result in
serious injury, death, or property damage.
352AAV
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.
17. Check for gas leaks.
18. Replace main furnace door.
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.
10. Reassemble inducer assembly by reversing items 5-7. Tighten vent coupling clamp screw(s) to 15 in.-lb of torque.
NOTE: If seal between the inducer housing and the collector box
is damaged in any way, it must be repaired. To repair, apply
sealant releasing agent such as PAM cooking spray or equivalent
(must not contain corn nor canola oil, halogenated hydrocarbons
nor aromatic content, to prevent inadequate seal from occurring) to
inducer housing. Apply a small bead of G.E. RTV 162, G.E. RTV
6702, or Dow--Corning RTV 738 sealant to groove in collector
box. (See Fig. 12.)
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. 10.)
13. Turn on gas and electrical supplies to furnace.
14. Check furnace operation through 2 complete heat operating
cycles. Check area below inducer housing, vent pipe, and
condensate trap to ensure no condensate leaks occur. If
leaks are found, correct the problem.
!
ELECTRICAL OPERATION HAZARD
Step 5 — 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. 10.)
NOTE: Ensure the drain tube disconnected from the inducer
housing is higher than the collector box opening or water will flow
out of tube.
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.
9. Inspect inside area of collector box for any pieces of foreign
materials and remove them if present.
!
WARNING
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.
15. Check for gas leaks.
16. Replace main furnace door.
RTV
PAM
CAUTION
Fig. 9 -- Combustion-- Air Intake Housing
Gasket Repair
UNIT DAMAGE HAZARD
Failure to follow this caution may result in furnace component
damage.
DO NOT use wire brush or other sharp object to inspect or
dislodge materials in secondary heat exchangers as cutting the
secondary heat exchanger protective coating may occur. Flush
with water only.
8
A93087
TUBE ROUTING
Furnace is shipped from factory in upflow configuration. Pressure tube and drain tube routing MUST match the diagrams below.
Tube location when used in UPFLOW application
(Blower access panel removed)
CAP
CAP
COLLECTOR BOX TUBE
(PINK)
PLUG
COLLECTOR BOX TUBE
(GREEN)
COLLECTOR BOX DRAIN
TUBE
(BLUE & WHITE STRIPED)
INDUCER HOUSING (MOLDED) DRAIN TUBE
(BEHIND COLLECTOR BOX DRAIN TUBE)
CONDENSATE TRAP
COLLECTOR BOX DRAIN TUBE
(BLUE)
COLLECTOR BOX TUBE (GREEN)
CONDENSATE TRAP
INDUCER HOUSING DRAIN TUBE
(VIOLET)
Tube location when used in DOWNFLOW application
PLUG
CAP
COLLECTOR BOX DRAIN TUBE
(BLUE)
COLLECTOR BOX DRAIN
TUBE
(BLUE & WHITE STRIPED)
COLLECTOR BOX
TUBE (GREEN)
COLLECTOR BOX TUBE
(PINK)
PLUG
COLLECTOR BOX DRAIN TUBE
(BLUE & WHITE STRIPED)
COLLECTOR BOX TUBE
(GREEN)
INDUCER HOUSING DRAIN
TUBE (VIOLET)
COLLECTOR BOX
EXTENSION TUBE
COLLECTOR BOX
EXTENSION TUBE
CONDENSATE TRAP
Tube location when used on
HORIZONTAL - LEFT application
COLLECTOR BOX
TUBE (GREEN)
BURNER ENCLOSURE
PRESSURE REFERENCE
TUBE ASSEMBLY
COLLECTOR BOX DRAIN TUBE
(BLUE)
COLLECTOR BOX
DRAIN TUBE (BLUE)
CONDENSATE TRAP
DRAIN TUBE
COUPLING
COLLECTOR BOX
EXTENSION DRAIN TUBE
COLLECTOR BOX TUBE (PINK)
RELOCATE TUBE BETWEEN BLOWER
SHELF AND INDUCER HOUSING FOR
060 AND 080 HEATING INPUT
FURNACES
COLLECTOR BOX EXTENSION TUBE
COLLECTOR BOX TUBE (PINK)
AUXILIARY "J" BOX RELOCATED HERE
PLUG
INDUCER HOUSING
DRAIN TUBE
(VIOLET)
COLLECTOR BOX
EXTENSION TUBE
GAS VALVE
Tube location when used on
HORIZONTAL - RIGHT application
COLLECTOR BOX DRAIN TUBE
(BLUE & WHITE STRIPED)
PLUG
CAP
CONDENSATE TRAP
DRAIN TUBES ROUTED IN
FRONT OF GAS VALVE
INDUCER HOUSING DRAIN TUBE (VIOLET)
AUXILIARY "J" BOX
COLLECTOR BOX EXTENSION TUBE
BURNER ENCLOSURE PRESSU
REFERENCE TUBE ASSEMBL
DRAIN TUBE COUPLING
COLLECTOR BOX
TUBE (PINK)
BURNER ENCLOSURE PRESSURE
REFERENCE TUBE ASSEMBLY
COLLECTOR BOX EXTENSION DRAIN TUBE
Condensate Trap on
RIGHT Side
T
COLLECTOR BOX
DRAIN TUBE (BLUE)
PLUGGED END
CAP
NOTE:
COLLECTOR BOX DRAIN TUBE
(BLUE & WHITE STRIPED)
COLLECTOR BOX DRAIN TUBE
(BLUE)
FIELD-INSTALLED
FACTORY-SUPPLIED 1/2-IN.
CPVC STREET ELBOWS (2)
FOR LEFT DRAIN OPTION
FIELD-INSTALLED FACTORY-SUPPLIED
DRAIN TUBE
BURNER ENCLOSURE
PRESSURE REFERENCE
TUBE ASSEMBLY
PLUG
COLLECTOR BOX TUBE
(PINK)
FIELD-INSTALLED
FACTORY- SUPPLIED
DRAIN TUBE COUPLING
(RIGHT DRAIN OPTION)
FIELD-INSTALLED
FACTORY-SUPPLIED DRAIN TUBE
COUPLING (LEFT DRAIN OPTION)
Condensate Trap on
LEFT Side
Condensate Trap on LEFT
Side Optional
BURNER ENCLOSURE
PRESSURE REFERENCE
TUBE ASSEMBLY
352AAV
Condensate Trap; Factory Installed
in Blower Shelf
CAP
BURNER ENCLOSURE
PRESSURE REFERENCE
TUBE ASSEMBLY
COLLECTOR BOX
EXTENSION TUBE
COLLECTOR BOX
TUBE (GREEN)
COLLECTOR BOX DRAIN TUBE
(BLUE AND WHITE STRIPED)
CONDENSATE TRAP
INDUCER HOUSING DRAIN TUBE (VIOLET)
1. All tubing must be connected securely and routed to avoid kinks and traps.
2. Pressure tubing must always slope away from pressure switch to collector box connection as shown.
3. HORIZONTAL-LEFT installations require the collector box pressure tube to be relocated between the inducer housing and the blower shelf to
prevent a trap. Refer to the Installation Instructions for further details.
;;
;;
Fig. 10 -- Furnace Pressure and Draining Tube Diagram
326476-201 REV. B
(lit-bottom)
A01052
BURNER FLAME
BURNER
MANIFOLD
Fig. 11 -- Burner Flame
9
A89020
!
CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in premature failure
of the igniter.
PAM
The igniter is fragile. DO NOT allow it to hit the side of the
burner box parts while removing or replacing it.
RTV
352AAV
e. If replacement is required, replace igniter on igniter
bracket and then install assembly to burner box to avoid
damage to the igniter.
6. To replace igniter and bracket assembly, reverse items 5a
through 5d.
7. Reconnect igniter wire connection and insert the igniter
wires in the slot in the manifold grommet, dressing the igniter wires to ensure there is no tension on the igniter itself.
(See Fig. 7.)
!
A93081
ELECTRICAL SHOCK HAZARD
Fig. 12 -- Gasket on Collector Box
Failure to follow this warning could result in electrical shock,
personal injury, or death.
Step 6 — Servicing Hot Surface Igniter
Igniter wires must be securely placed in slot in manifold
grommet or else they could become pinched or severed and
electrically shorted.
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. Igniter resistance is affect by temperature. Only check resistance when the igniter is at room
temperature.
d. Using an ohm meter, check resistance across both igniter leads in connector.
e. Cold reading should be between 40 ohms and 70 ohms.
5. Remove igniter assembly.
!
WARNING
8. Reinstall burner box cover.
9. Turn on gas and electrical supplies to furnace.
10. Verify igniter operation by initiating furnace control board
self-test feature or by cycling thermostat.
11. Replace main furnace door.
CAUTION
BURN HAZARD
Failure to follow this caution may result in minor personal
injury.
A05075
Allow igniter to cool before removal. Normal operating
temperatures exceed 2000°F.
Fig. 13 -- Igniter Bracket
a. Remove burner box cover.
b. Remove igniter wires from slot in manifold grommet.
(See Fig. 7.)
c. Using a 1/4 in. driver, remove the single screw securing
the igniter bracket to the burner box bracket (See Fig.
13.) and carefully withdraw the igniter and bracket assembly through the front of the burner box without
striking the igniter on surrounding parts. Note that the
igniter bracket has a handle that extends to the front of
the burner box to aid in handling (See Fig. 13.).
d. Inspect igniter for signs of damage or failure.
10
2-5/32˝
(55 mm)
Fig. 14 -- Igniter
A04181
Step 7 — Electrical Controls and Wiring
!
In applications where the ambient temperature around the furnace
is 32°F (0_C) or lower, freeze protection measures are required. If
this application is where heat tape has been applied, check to
ensure it will operate when low temperatures are present.
NOTE: Heat tape, when used, should be wrapped around the
condensate drain trap and drain line. There is no need to use heat
tape within the furnace casing. Most heat tapes are temperature
activated, and it is not practical to verity 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.
Step 9 — Winterizing
!
WARNING
UNIT DAMAGE HAZARD
ELECTRICAL SHOCK HAZARD
Failure to follow this caution may result in furnace component
damage.
Failure to follow this warning could result in personal injury
or death.
Freezing condensate left in the furnace may damage the
furnace.
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. 15a or 15b for field wiring
information and to Fig. 21 for unit wiring information.
NOTE: If the polarity is not correct or the furnace is not
grounded, the STATUS LED on the furnace control board will
flash rapidly and prevent the furnace from operating. The control
system also requires an earth ground for proper operation of the
furnace control board and flame sensor.
The 24-v circuit contains an automotive-type, 3-amp fuse located
on the control. (See Fig. 16.) 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 3 amp fuse. The
control LED will display 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.
!
CAUTION
If the furnace will be off for an extended period of time in a
structure where the temperature will drop to 32°F (0_C)or below,
winterize as follows:
1. Turn off electrical supply to furnace.
2. Remove main furnace door.
3. Disconnect cap from unused drain tap on inducer housing.
(See Fig. 18.)
4. Connect field-supplied 1/2-in. I.D. tube to upper inducer
housing drain connection.
!
CAUTION
UNIT DAMAGE HAZARD
Failure of plastic components may occur.
Do not use ethylene glycol (Prestone II antifreeze/coolant or
equivalent automotive type).
CAUTION
UNIT AND PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in furnace component
failures or water property damage.
If this furnace is to be operated in an unconditioned space
where the ambient temperatures may be 32_F (0_C) or lower,
freeze protection measures must be taken. (See Fig. 17). See
CONDENSATE DRAIN PROTECTION section of
Installation, Start--up, and Operating Instructions.
11
352AAV
Step 8 — Checking Heat Tape Operation (If
Applicable)
FIELD 24-V WIRING
FIELD 115-, 208/230-, 460-V WIRING
FACTORY 24-V WIRING
FACTORY 115-V WIRING
1-STAGE THERMOSTAT TERMINALS
W
FIVE
WIRE
Y
R
G
C
FIELD-SUPPLIED
FUSED DISCONNECT
TWO-WIRE
HEATINGONLY
BLK
BLK
WHT
WHT
208/230- OR
460-V
THREE
PHASE
W2
GND
GND
COM
208/230-V
SINGLE
PHASE
W/W1
GND
352AAV
GND
Y/Y2
115-V FUSED
DISCONNECT
SWITCH
(WHEN REQUIRED)
JUNCTION
BOX
CONTROL
BOX
GND
R
GND
CONDENSING
UNIT
G
24-V
TERMINAL
BLOCK
FURNACE
NOTES: 1. Connect Y-terminal as shown for proper operation.
2. Some thermostats require a "C" terminal connection as shown.
3. If any of the original wire, as supplied, must be replaced,
use same type or equivalent wire.
A99071
Fig. 15 -- Field Wiring
FIELD 24-V WIRING
FIELD 115-, 208/230-, 460-V WIRING
FACTORY 24-V WIRING
FACTORY 115-V WIRING
2-STAGE THERMOSTAT TERMINALS
SEVEN
WIRE
W2
W1
Y2
R
G
Y1
C
FIELD-SUPPLIED
FUSED DISCONNECT
THREE-WIRE
HEATINGONLY
W2
BLK
BLK
WHT
208/230- OR
460-V
THREE
PHASE
GND
GND
COM
WHT
208/230-V
SINGLE
PHASE
W/W1
GND
GND
C
Y/Y2
115-V FUSED
JUNCTION
DISCONNECT
BOX
SWITCH
CONTROL
(WHEN REQUIRED)
BOX
Y1
Y2
R
G
24-V
TERMINAL
BLOCK
FURNACE
GND
GND
2-SPEED
CONDENSING
UNIT
NOTES: 1. Connect Y-terminal as shown for proper operation.
2. Some thermostats require a "C" terminal connection as shown.
3. If any of the original wire, as supplied, must be replaced,
use same type or equivalent wire.
Fig. 16 -- Field Wiring
12
A99072
SETUP SWITCHES
LOW-HEAT ONLY AND
BLOWER OFF-DELAY
TWINNING AND/OR
COMPONENT TEST
TERMINAL
TRANSFORMER 24-VAC
CONNECTIONS
0.5-AMP024 VAC
R
LE
SEC-2
PL3
NEUTRAL-L2
PL1
OD E
EAC-2
D
SEC-1
352AAV
PL1 - LOW VOLTAGE MAIN
HARNESS CONNECTOR
FUSE 3-AMP
US C
3-AMP FUSE
PLT
HUM
ACRDJ
TEST/TWIN
STAT
LED OPERATION &
DIAGNOSTIC LIGHT
1 2 3
LHT
OFF
DLY
Y1 DHUM G COM WW1 Y/Y2
24V
HUMIDIFIER TERMINAL
(24-VAC 0.5 AMP MAX.)
ON
OFF
W2
24-V-THERMOSTAT
TERMINALS
ACRDJ - AIR CONDITIONING
RELAY DISABLE JUMPER
PL3
1
1
BLW
115-VAC (L2) NEUTRAL
CONNECTIONS
BHI/LOR
BHT/CLR
BLWR
HI HEAT
IDM
COOL
IHI/LOR
SPARE-2
PR-1
PL2
EAC-1
1
SPARE-2
L1
1-AMP@115 VAC
COOL
SPARE-1
SPARE-1
BLOWER SPEED
SELECTION TERMINALS
HSIR
IDR
LO HEAT
HI HEAT
LO HEAT
HSI
HI LO
115-VAC (L1) LINE
VOLTAGE CONNECTION
PL2 - HOT SURFACE
IGNITER & INDUCER
MOTOR CONNECTOR
EAC-1 TERMINAL
(115-VAC 1.0 AMP MAX.)
A02017
Fig. 17 -- Two-- Stage Control
8. Propylene glycol need not be removed before restarting furnace.
WIRING DIAGRAM
See Fig. 21 for Wiring Diagram.
TROUBLESHOOTING
Use the Troubleshooting Guide, the status code LED on the
control and the Component Test to isolate furnace operation
problems.
Status Codes
Fig. 18 -- Winterizing the Furnace
A07911
5. Insert funnel in tube and pour up to 1 quart of antifreeze,
propylene glycol (RV, swimming pool antifreeze, or equivalent) into funnel until it is visible at point where condensate enters open drain. (See Fig. 19.)
6. Reconnect drain cap to inducer housing.
7. Replace main furnace door.
For an explanation of status codes, refer to service label located on
back of main furnace door or Fig. 20. The stored status codes will
NOT be erased from the control memory, if 115-or 24-v power is
interrupted. The control will store up to 7 Status Codes.
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 one of the red main limit or
flame rollout switch wires 1 to 4 sec until the LED light goes out,
the 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.
13
Record the code and repeat the disconnect and reconnect of the red
wire, recording each code until code 11 is displayed indicating no
additional codes. After the last code is displayed or after 2 minutes
in the code recall mode the control will return to normal standby
mode.
Component Test
352AAV
NOTE:
The furnace control component test allows all
components to run for a short time; except the gas valve and
humidifier terminal HUM are not energized for safety reasons. The
EAC--1 terminal is energized when blower is energized. This
feature helps diagnose a system problem in case of a component
failure. The component test feature will not operate if any
thermostat signal is present at control and not until all time delays
are completed.
To Begin Component Self-Test:
!
WARNING
ELECTRICAL SHOCK
OPERATE HAZARD
AND
UNIT
MAY
NOT
Failure to follow this warning could result in electrical shock,
personal injury, or death.
Fig. 19 -- Inducer Housing Drain Tube Cap
Blower access panel door switch opens 115-v power to control
board. No component operation can occur. Caution must be
taken when manually closing this switch for service purposes.
A99118
1.
2.
3.
4.
A99119
Fig. 20 -- Funnel in Drain Tube and Antifreeze
Running Through Trap
Remove blower access door.
Disconnect thermostat R lead from furnace control.
Manually close blower door switch.
For approximately 2 sec, short (jumper) the COM-24 v terminal on control to the TEST/TWIN 3/16-in. quick-connect
terminal on control until LED turns off. Remove jumper
from terminals. (See Fig.16.)
NOTE: If TEST/TWIN and COM--24v terminals are jumpered
longer than 2 sec, LED will flash rapidly and ignore status code
retrieval request.
Component test sequence for 2-stage furnace is as follows:
a. LED will display previous status code 4 times.
b. Inducer motor starts on high--speed and continues to run
until Step g of component test sequence.
c. Hot surface igniter is energized for 15 sec, then off.
d. Blower motor operates on LO--HEAT speed for 10 sec.
e. Blower motor operates on HI--HEAT speed for 10 sec.
f. Blower motor operates on COOL speed for 10 sec.
g. Inducer motor goes to low--speed for 10 sec, then stops.
5. Reconnect R lead to furnace control, remove tape from
blower door switch, and re-install blower door.
6. Operate furnace per instruction on outer door.
7. Verify furnace shut down by lowering thermostat setting
below room temperature.
8. Verify that furnace restarts by raising thermostat setting
above room temperature.
14
SERVICE
If status code recall is needed, briefly remove then reconnect one main limit wire
to display last stored status code. Repeat remove-and-reconnect four more times
for previous four status codes, after which the five codes repeat. Status code 11
will display when less than four previous status codes exist. On RED LED controls
do not remove power or blower door before initiating status code recall.
LED CODE
STATUS
352AAV
CONTINUOUS OFF - Check for 115VAC at L1 & L2, & 24VAC at SEC-1 & SEC-2.
CONTINUOUS ON - Control has 24VAC power.
RAPID FLA SHING - Line voltage (115VAC) polarity reversed. If twinned,
refer to twinning kit instructions.
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 OF LONG FLASHES.
11 NO PREVIOUS CODE - Stored status codes are 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 BL OWER ON AFTER POWER UP (115 VAC or 24 VAC) -Blower runs for the
selected blower off-delay time, if unit is powered up during a call for heat
(R-W/W1 closed) or (R-W/W1) opens during blower on-delay.
13 LIMIT CIRCUIT LOCKOUT - Lockout occurs if a 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 ABNO RMAL 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 HIGH-HEAT PRESSURE SWITCH OR RELAY DID NOT CLOSE OR
REOPENED
Control relay may be defective, refer to status code #32
32 LOW-HEAT PRESSURE SWITCH DID NOT CLOSE OR REOPENED - If
open longer than five minutes, inducer shuts off for 15 minutes before retry. If
opens during blower on-delay period, blower will come on for the selected
blower off-delay. Check for: - Excessive wind
- Restricted vent
- Defective inducer motor
- Low inlet gas pressure (if LGPS used)
- Defective pressure switch
- Low inducer voltage (115 VAC)
- Inadequate combustion air supply
- Proper vent sizing
- Disconnected or obstructed pressure tubing
33 LIMIT CIRCUIT FAULT - Indicates a 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 minutes status code #33 continues to flash until blower shuts off. Flame rollout
switch requires manual reset. Check for: - Dirty filter or restricted duct system
- Proper vent sizing - Restricted vent - Loose blower wheel - Excessive wind
- 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 three more times before lock
out #14 occurs. If flame signal lost during blower on-delay period, blower will
come on for the selected blower off-delay. Check for:
- Oxide buildup on flame sensor (clean with fine steel wool)
- Proper flame sense microamps (.5 microamps D.C. min., 4.0 - 6.0 nominal)
- Manual valve shut-off
- Control ground continuity
- Gas valve defective or gas valve turned off
- Low inlet gas pressure
- Inadequate flame carryover or rough ignition
- Defective Hot Surface Ignitor
- Flame sensor must not be grounded
- Green/Yellow wire MUST be connected to furnace sheet metal
43 LOW-HEAT PRESSURE SWITCH OPEN WHILE HIGH-HEAT PRESSURE
SWITCH IS CLOSED - Check for: - Disconnected or obstructed pressure tubing
- Mis-wired pressure switches
- Low-heat pressure switch stuck open
- Low inlet gas pressure (if LGPS used)
45 CONTROL 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.
COMPONENT TEST
To initiate the component test sequence, shut OFF the room thermostat or
disconnect the "R" thermostat lead. Briefly short the TEST/TWIN terminal to the
"Com 24V" terminal. Status LED will flash last status code and then turn ON the
inducer motor. The inducer motor will start in HIGH speed and remain on HIGH
speed until the end of the test then shift to LOW speed for 7 to 15 seconds. The hot
surface ignitor, blower motor LO HEAT speed, blower motor HI 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. When the blower is turned OFF the inducer will
be switched to low-speed for 10 seconds.
327885-101 REV. B
A02258
Fig. 21 -- Service Label
15
BRN
GRN/YEL
BRN
HI
1 2 3
BLU
16
LEGEND
Fig. 22 -- Wiring Diagram
GND
GV
GVR 1, 2
HPS
HPSR
HSI
HSIR
HUM
IDM
IDR
IHI/LOR
ILK
JB
LED
LGPS
LPS
LS
OL
PCB
ACR
ACRDJ
BHI/LOR
BHT/CLR
BLWR
BLWM
CAP 1, 2
CPU
DHUM
EAC-1
EAC-2
FRS
FSE
FU1
FU2
PLT
ACRDJ
GRY
HPS
RED
PL1
FRS
STATUS CODE
LED
1
WHT
YEL
RED
LPS
LS
NOTE #8
AIR CONDITIONING RELAY, SPST (N.O.)
AIR CONDITIONING RELAY DISABLE JUMPER
BLOWER MOTOR SPEED CHANGE RELAY, SPDT
BLOWER MOTOR SPEED CHANGE RELAY, SPDT
BLOWER MOTOR RELAY, SPST-(N.O.)
BLOWER MOTOR, PERMANENT-SPLIT-CAPACITOR
CAPACITOR
MICROPROCESSOR AND CIRCUITRY
DHUM CONNECTION
ELECTRONIC AIR CLEANER CONNECTION (115 VAC 1.0 AMP MAX.)
ELECTRONIC AIR CLEANER CONNECTION (COMMON)
FLAME ROLLOUT SW. -MANUAL RESET, SPST-(N.C.)
FLAME-PROVING ELECTRODE
FUSE, 3 AMP, AUTOMOTIVE BLADE TYPE, FACTORY INSTALLED
FUSE OR CIRCUIT BREAKER CURRENT INTERRUPT DEVICE
(FIELD SUPPLIED AND INSTALLED)
EQUIPMENT GROUND
GAS VALVE-REDUNDANT
GAS VALVE RELAY, DPST-(N.O.)
HIGH-HEAT PRESSURE SWITCH, SPST (N.O.)
HIGH-HEAT PRESSURE SWITCH RELAY, SPST (N.C.)
HOT SURFACE IGNITER (115VAC)
HOT SURFACE IGNITER RELAY, SPST (N.O.)
24VAC HUMIDIFIER CONNECTION (0.5 AMP. MAX.)
INDUCED DRAFT MOTOR, 2-SPEED, SHADED POLE
INDUCED DRAFT MOTOR RELAY, SPST-(N.O.)
INDUCER MOTOR SPEED CHANGE RELAY, SPDT
BLOWER ACCESS PANEL INTERLOCK SWITCH, SPST-(N.O.)
JUNCTION BOX
LIGHT-EMITTING DIODE FOR STATUS CODES - AMBER
LOW GAS PRESSURE SWITCH, SPST-(N.O.)
LOW-HEAT PRESSURE SWITCH, SPST (N.O.)
LIMIT SWITCH, AUTO-RESET, SPST (N.C.)
AUTO-RESET INTERNAL MOTOR OVERLOAD TEMPERATURE SWITCH (N.C.)
PRINTED CIRCUIT BOARD CONTROL
Y1 DHUM G Com W/W1 Y/Y2 R
24V
LHT
OFF
DLY
W2
ON
OFF
TEST/TWIN
SELECT CHART
BLOWER
SW LO-HT OFF-DELAY
ONLY
1 *
2 3
90
ON NORM
SEC.
OFF HEAT
1 LO 2 3 *
120
ON
HEAT
SEC.
OFF ONLY
2 3
ON
150
OFF
SEC.
2 3
ON
180
OFF
SEC.
* FACTORY SETTINGS
NOTE #3
C
GV
WHT
GRN/YEL
0.5 AMP
@ 24 VAC
WHT
FUSE 3-AMP
FU1
NOTE #6
IDR
HSIR
IHI/LOR
L1
NOTE #11
RED
PL1
PL2
PL3
PL4
PL5
PLT
TRAN
TEST/TWIN
PL2
IDM
WHT
BLK
YEL
ORN
BLU
RED
OL
RED
BLU
BLK
BRN
WHT
BRN
START
PL5
HSI
JUNCTION
FIELD EARTH GROUND
326797-101 REV. A
PLUG RECEPTACLE
FIELD SPLICE
EQUIPMENT GROUND
TRAN
ACR
PCB
COM 24V
Y1
G
Y/Y2
W2
DHUM
TEST/TWIN
W/W1
R
HUM
NOTE #5
L1
IDR
HSIR
IHI/LOR
L2
L2
1
3
2
NOTE #2
PL2
BHI/LOR
LO HEAT
EQUIPMENT
GROUND
1
2
PL5
HSI
PL4
CPU
GVR-2
FRS
EAC-1
GVR-1
HPSR
LS
PL1-7
PL1-11
PL1-9
PL1-1
CAP-1
LPS
C
FSE
PL1-5
HI
L2
24VAC SEC 2
SEC 1 TRAN
NOTE #11
GV
L2
L2
PR1 115VAC
START
BLWM
IDM
OL
LGPS
(WHEN USED)
HPS
PL1-10 M
PL1-3
PL1-4
PL1-2
PL1-12
PL1-8
NOTE #6
FU1
COM
NOTE #3
PL1-6
EAC-2
OL
4 LO
COM
3
HI
1
2
SCHEMATIC DIAGRAM
(NATURAL GAS & PROPANE)
LO
SPARE-1 MED LO
NOTE #10
BHT/CLR
MED
HI HEAT
SPARE-2
MED HI
COOLING
BLWR
HI
NOTE #9
ILK
TO 115VAC FIELD-DISCONNECT SWITCH
352AAV
If any of the original equipment wire is replaced use wire rated for 105°C.
Use only copper wire between the disconnect switch and the furnace junction box (JB).
This wire must be connected to furnace sheet metal for control to prove flame.
Symbols are electrical representation only.
Solid lines inside PCB are printed circuit board conductors and are not included in the legend.
Replace only with a 3 amp fuse.
Blower motor (BLWM) and inducer motor (IDM) contain internal auto-reset thermal overload switches (OL).
Neutral connections are interchangeable within the NEUTRAL connector block.
Blower motor speed selections are for average conditions, see installation instructions for optimum selection.
MED not available on some models.
Factory connected when LGPS is not used.
Ignition lockout will occur after four consecutive unsuccessful trials-for-ignition. Control will auto-reset after
three hours.
13. Blower-on delay: gas high-heat 60 seconds, gas low-heat 45 seconds, cooling or heat pump 2 seconds.
14. Blower off-delay: gas heating selections are 90, 120, 150, 180 seconds, cooling or heat pump 90 seconds or
5 seconds when dehumidify call is active.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
NOTES:
CAP-1
ILK
JB
GND
PRINTED CIRCIUT BOARD
FIELD WIRING SCREW TERMINAL
CONDUCTOR ON CONTROL PCB
FIELD CONTROL WIRING (24VAC)
FIELD CONTROL WIRING (115VAC)
FACTORY CONTROL WIRING (24VAC)
FACTORY POWER WIRING (115VAC)
CONTROL PCB TERMINAL
TERMINAL
FU2
L1 NOTE #2
WHT BLK
NEUTRAL
FUSE OR CIRCUIT
BREAKER & DISCONNECT
SWITCH (WHEN REQ’D)
BLWM
OL
2
1
GRN /YEL
2 3
4
BRN
IDM
WHT
12-CIRCUIT PCB CONNECTOR
3-CIRCUIT PCB HSI & IDM CONNECTOR
6-CIRCUIT ICM MOTOR CONNECTOR (NOT SHOWN)
4-CIRCUIT IDM CONNECTOR
2-CIRCUIT HSI CONNECTOR
3-CIRCUIT FACTORY TEST CONNECTOR
TRANSFORMER, 115VAC/24VAC
COMPONENT TEST & TWINNING TERMINAL
WHT
HI
MED HI
MED
MED LO
LO
BLK
WHT
PL3
1
RED
BLK
GRN/YEL
BLK
BLK
RED
WHT
FSE
ORN
LGPS (WHEN USED)
CAP-2
BRN
GRN/YEL
M
HUM
SEC-1
SEC-2
CAP-2
CONNECTION DIAGRAM
NEUTRAL - L2
EAC-2
BLWR
BHT/CLR
BLW
BHI/LOR
HI-HEAT
COOL
LO-HEAT
PR-1
SPARE-2
HSI HI LO
EAC-1
1 AMP
@ 115 VAC
SPARE - 1
PRINTED CIRCIUT BOARD
ACRDJ
A02176
A05095
17
YES
Go to section below for the status code that
was flashed.
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?
YES
Is LED status light blinking ON/OFF slowly
with a combination of short and long flashes?
NO
Is LED status light blinking rapidly
without a pause?
Is LED status light on?
START
YES
NO
YES
NO
NO
NO
Was there a previous status code other
than #11?
NO
YES
Replace furnace control.
YES
352AAV
Run system through a low-heat, high-heat,
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.
YES
Does the control respond to W/W1, W2, Y1,
Y/Y2, and G (24V) thermostat signals?
A05111
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
Does the problem repeat when using a
jumper wire?
Disconnect all the thermostat wires from the
furnace control.
YES
Is 24V present at W/W1, W2, Y1, Y/Y2 or G
thermostat terminals on the furnace control?
NO
Check room thermostat or
interconnecting cable.
Close circuit breaker and go back to START.
Replace transformer.
YES
Is circuit breaker closed?
Close door switch and go back to START.
Check for continuity in wire from circuit
breaker to furnace.
NO
NO
NO
Replace door switch.
YES
Is there 115V going to switch?
Is door switch closed?
To recall status code briefly remove 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 status of the previous 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 start the component test sequence. Once initiated
the control will turn ON at HI HEAT speed. The inducer will run for the entire
component test. The HSI, blower motor LO HEAT speed, HI HEAT speed, and
COOL speed will run for 10 – 15 seconds each. Gas valve and humidifier will
not be turned on. When the blower motor is turned OFF the inducer will be
switched to low-speed for 10 seconds.
Check for correct line voltage polarity and
grounding. If units are twinned, check for proper
low-voltage (24V) transformer phasing.
Replace furnace control.
YES
Is there 24V at SEC-1 and SEC-2?
YES
Is there 115V at L1 and L2?
TROUBLESHOOTING GUIDE — TWO-STAGE
NO
A05095
E2008 Bryant Heating & Cooling Systems D 7310 W. Morris St. D Indianapolis, IN 46231
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Printed in U.S.A.
18
Edition Date: 12/08
Catalog No. SM352AAV ---01
Replaces:SP05--- 69
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.
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?
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.
Flame rollout switch requires manual reset.
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.
31 HIGH-HEAT PRESSURE SWITCH OR
RELAY DID NOT CLOSE OR
REOPENED - Check for:
- Control relay may be defective.
- Gas valve is miswired.
- See status code 32.
24 SECONDARY VOLTAGE FUSE IS
OPEN Check for:
- Short circuit in secondary voltage
(24V) wiring including thermostat
leads. Disconnect thermostat leads
to isolate short circuit.
23 PRESSURE SWITCH DID NOT OPEN
Check for:
- Obstructed pressure tube.
- Pressure switch stuck closed.
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.
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.
12 BLOWER ON AFTER POWER UP –
(115V OR 24V) – Normal operation.
Blower runs for the selected blower offdelay, if unit is powered up during a call
for heat (R-W/W1 closed) or when (RW/W1 opens) during the blower on-delay
period.
32 LOW-HEAT 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 on-delay period, blower
will come on for the selected blower offdelay. 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.
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
low-heat, high-heat, or cooling cycle to
check system.
YES
NO
Fixed.
YES
Will main burners ignite and stay on?
YES
Is current near typical value?
Clean flame sensor with fine steel wool and
recheck current. Nominal current is 4.0 to
6.0 microamps.
YES
Repeat call for heat and check flame sensor
current during trial for ignition period. Is the
DC microamps below 0.5?
NO
Do the main burners stay on?
YES
Do the main burners ignite?
YES
Does gas valve open and allow gas to flow?
YES
Reconnect the R thermostat lead and set
thermostat to call for heat. Connect voltmeter
across gas valve connections. Does gas
valve receive 24V?
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?
43 LOW-HEAT PRESSURE SWITCH OPEN
WHILE HIGH-HEAT PRESSURE
SWITCH IS CLOSED - Check for:
- Low-heat pressure switch stuck open.
- Disconnected or obstructed pressure
tube.
- Miswired pressure switches.
- Low inlet gas pressure (if LGPS used).
352AAV
NO
NO
NO
YES
NO
NO
NO
YES
NO
Replace furnace control.
Replace electrode.
Check connections and retry. If current is
near typical value (4.0-6.0 nominal) and
burners will not stay on, repeat check in highheat. If burners will still not stay on replace
control. If burners operate in high-heat then
switch to low-heat, check manifold pressure.
If OK, check burner carryover and flame
sensor location.
Allow blower to come on and repeat test to
check for intermittent operation.
Check for:
- Inadequate flame carryover or rough
ignition.
- Low inlet gas pressure.
- Proper firing rate.
Check that all gas valves are turned on.
Replace valve.
Check connections. If OK, replace control.
Check for continuity in the harness and igniter.
Replace defective component.
Replace furnace control.
45 CONTROL CIRCUITRY LOCKOUT Autoreset 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.