service and
330JAV
331JAV
Series D
maintenance procedures
PLUS 80 2-STAGE GAS-FIRED
INDUCED-COMBUSTION FURNACES
Cancels: SP04-65
SP04-73
11-01
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
INTRODUCTION..........................................................................2
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
PROCEDURE ................................................................................2
CARE AND MAINTENANCE.....................................................2
Cleaning and/or Replacing Air Filter.......................................2
Blower Motor and Wheel.........................................................3
Cleaning Heat Exchanger.........................................................4
Electrical Controls and Wiring.................................................6
WIRING DIAGRAMS...................................................................7
TROUBLESHOOTING .................................................................7
EFFICIENCY
RATING
CERTIFIED
A94086
Fig. 2—Model 331JAV Downflow
CERTIFIED
R
M
®
I
REGISTERED QUALITY SYSTEM
A95137
Fig. 1—Model 330JAV Horizontal
SAFETY CONSIDERATIONS
A94085
Installing and servicing heating equipment can be hazardous due to
gas and electrical components. Only trained and qualified person-
nel should install, repair, or service heating equipment.
Untrained personnel can perform basic maintenance functions
such as cleaning and replacing air filters. All other operations must
be performed by trained service personnel. When working on
heating equipment, observe precautions in the literature, tags, and
labels attached to or shipped with the unit and other safety
precautions that may apply.
Fig. 3—Model 330JAV Upflow
Follow all safety codes. In the United States, follow all safety
codes including the National Fuel Gas Code (NFGC) NFPA No.
54-1999/ANSI Z223.1-1999. In Canada, refer to the current
edition of the National Standard of Canada CAN/CGA-B149.1-
and .2-M00 Natural Gas and Propane Gas Installation Codes
(NSCNGPIC) and Amendment No. 1. Wear safety glasses and
work gloves. Have fire extinguisher available during start-up and
adjustment procedures and service calls.
—1—
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FLUE
COLLAR
AIRFLOW
BLOCKED
MOUNTING
SCREWS
VENT
INSTALLATION
POSITION
SAFEGUARD
OF FILTERS
PRESSURE
SWITCH
RELIEF
BOX
RETURN-AIR
FLUE
COLLECTOR
BOX
PLENUM
GAS
VALVE
CONTROL
FILTER
RETAINER
H U M
C
2V4
OM
W
Y
R
G
WASHABLE
FILTER
FURNACE
WASHABLE
FILTER OR
DISPOSIBLE
MEDIA FILTER
IN FILTER
CABINET
A00293
ACCESS DOOR
Fig. 5—Model 330JAV Upflow
e. Rinse and let dry. Oiling or coating of filter is not
recommended or required.
A88486
f. Place filter in furnace.
Fig. 4—Downflow Filter Arrangement
g. Replace blower and control access doors and turn on
electrical supply to furnace.
f. Rinse and let dry. Oiling or coating of filters is not
recommended or required.
II. BLOWER MOTOR AND WHEEL
g. Reinstall filters.
The following items should be performed by a qualified service
technician:
h. Replace blower access door and turn on electrical supply
to furnace.
For long life, economy, and high efficiency, clean accumulated dirt
and grease from blower wheel and motor annually.
2. Upflow/Horizontal–filters installed in media cabinet adja-
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.
cent to furnace (See Fig. 5.)
a. Turn off electrical supply to furnace
b. Remove filter cabinet door.
c. Slide filter out of cabinet.
Clean blower motor and wheel as follows:
1. Turn off electrical supply to furnace.
2. Remove blower access door.
3. Downflow only:
d. 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.
a. Disconnect vent connector from furnace flue collar. (See
Fig. 6.)
e. If equipped with factory-specified disposable media
filter, replace only with media filter having the same part
number and size.
b. Remove internal vent pipe enclosure cover.
c. Disconnect and remove short piece of vent pipe from
within furnace.
f. Slide filter into cabinet.
d. Disconnect and remove vent pipe enclosure. Push bot-
tom side backward to release tabs.
g. Replace filter cabinet door.
h. Turn on electrical supply to furnace.
NOTE: Vent pipe is SCREWED and RTV sealed to relief box.
3. Upflow/Horizontal–filter(s) installed in side(s) and/or bot-
4. Disconnect blower leads from furnace control. Note wire
color and location for reassembly. Also, disconnect auxil-
iary limit switch leads (downflow only, if present).
All other factory wires can be left connected, but field
thermostat connections may need to be disconnected de-
pending on their length and routing.
tom of blower compartment (See Fig. 5.)
a. Turn off electrical supply before removing blower and
control access doors.
b. Release filter retainer from clip at front of furnace
casing. (See Fig. 5.) For side return, clips may be used
on either or both sides of the furnace.
5. Remove 2 screws securing control and transformer support
to furnace.
c. Slide filter out.
d. Clean filters by spraying tap water through filter from
opposite direction of airflow.
6. Hang control and transformer support to front of furnace
casing.
—3—
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NOTE: Refer to Table 1 for motor speed lead relocation if leads
were not identified before disconnection.
FLUE
COLLAR
VENT PIPE
ENCLOSURE
TABLE 1—SPEED SELECTOR
AUXILIARY
LIMIT
FACTORY-
SWITCH
COLOR
SPEED
ATTACHED
TO
CONTROL
Black
High
Medium High
Medium Low
Low
Cool
Spare
Heat
Yellow (When Present)
Blue
Red
White
Spare
COM
MOUNTING
SCREWS
Common
Medium
Orange (When Present)
Spare
DRAFT
SAFEGUARD
SWITCH
CAUTION: Heating speed selection MUST be adjusted
to provide proper temperature rise as specified on the
rating plate. Failure to adjust the heating speed may
shorten heat exchanger life.
PRESSURE
SWITCHES
RELIEF
BOX
14. Reinstall internal vent pipe and enclosure on downflow
furnaces only by reversing items 3a through 3c.
NOTE: A releasing agent such as PAM cooking spray or equiva-
lent (must not contain corn or canola oil, aromatic or halogenated
hydrocarbons or inadequate seal may occur) and RTV sealant
(G.E. 162, 6702, or Dow-Corning 738) are needed before starting
installation. DO NOT substitute any other type of RTV sealant.
G.E. 162 (P771-9003) is available through RCD in 3-oz tubes.
MANUAL
RESET
LIMIT
SWITCHES
15. Reinstall vent connector to furnace flue collar. After fully
assembling vent connector to furnace flue collar, securely
fasten vent connector to flue collar with 2 field-supplied,
corrosion-resistant, sheet metal screws located 180 degrees
apart and midway up the collar.
A99092
Fig. 6—Model 331JAV Downflow
7. Remove screws holding blower assembly to blower deck
and slide blower assembly out of furnace.
16. 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 between
heating and cooling by jumpering R to W and then R to Y
on furnace control thermostat terminals.
8. Clean blower wheel and motor using a vacuum with soft
brush attachment. Do not remove or disturb balance weights
(clips) on blower wheel blades. The blower wheel should
not be dropped or bent as balance will be affected.
9. If greasy residue is present on blower wheel, remove wheel
from the blower housing and wash it with an appropriate
degreaser. To remove wheel:
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 warn-
ing could result in electrical shock, personal injury, or
death.
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, motor, and blower housing
so motor and each arm is positioned at the same location during
reassembly.
NOTE: If thermostat terminals are jumpered before blower ac-
cess door switch is closed, blower will run for 90 sec before
beginning a heating or cooling cycle.
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.
17. If furnace is operating properly, remove tape to release
blower access door switch, replace blower access door.
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.
III. CLEANING HEAT EXCHANGER
The following steps should be performed by a qualified service
technician:
NOTE: If the heat exchangers get a heavy accumulation of soot
and carbon, they 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, incorrect size, or
damaged manifold orifice(s), improper gas, or a restricted heat
exchanger. Action must be taken to correct the problem.
If it becomes necessary to clean heat exchanger because of light
dust or corrosion proceed as follows:
f. Remove blower wheel from housing.
10. Reassemble motor and blower by reversing items 9a
through 9f. Be sure to reattach ground wire.
11. Reinstall blower assembly in furnace.
12. Reinstall control box and support assembly in furnace.
13. Reconnect blower leads to furnace control and auxiliary
limit switch leads (downflow only).
Refer to furnace wiring diagram, and connect thermostat
leads if previously disconnected. (See Fig. 11.)
—4—
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1. Turn gas and power to furnace to OFF.
11
13
32"
32"
BURNER
2. Remove control and blower access doors.
3. Disconnect vent connector from furnace flue collar.
4. Disconnect internal vent pipe and enclosure on downflow
furnaces only.
CELL
PANEL
a. Remove vent pipe enclosure cover.
b. Disconnect and remove short piece of vent pipe from
within furnace.
HOT
NOTE: Vent pipe is SCREWED and RTV sealed to relief box.
SURFACE
IGNITOR
c. Remove vent pipe enclosure by removing screw in upper
back. Push bottom side backward to release tabs.
ASSEMBLY
5. Remove 2 screws that secure relief box. (See Fig. 5 or 6.)
6. Disconnect wires to the following components. Mark wires
to aid in reconnection of:
a. Draft safeguard switch.
b. Inducer motor.
c. Pressure switch(es).
C
IGNITOR
BURNER
L
7
8"
d. Limit overtemperature switch(es).
e. Gas valve.
C
L
f. Hot surface ignitor.
IGNITOR
ASSEMBLY
g. Flame-sensing electrode.
h. Flame rollout switch(es), if applicable.
A93347
7. Remove complete inducer assembly and relief box from
furnace.
Fig. 7—Position of Ignitor to Burner
8. Remove screws that secure flue collector box to center
panel. Be careful not to damage collector box.
9. Remove cell outlet plates.
IMPORTANT: Replace screws in center panel before cleaning.
10. Remove burner assembly and cell inlet plates.
IMPORTANT: Replace screws in center panel before cleaning.
NOTE: Be very careful when removing burner assembly to avoid
breaking ignitor. See Fig. 7 for correct ignitor location.
11. Using field-provided small wire brush, steel spring cable,
reversible electric drill, and vacuum cleaner, clean cells as
follows:
A91252
a. Assemble wire brush and steel spring cable.
Fig. 8—Cleaning Heat Exchanger Cell
(1.) Use 48 in. of 1/4-in. diameter high-grade steel
spring cable (commonly known as drain clean-out
or Roto-Rooter® cable).
(3.) Work cable in and out of cell 3 or 4 times to obtain
sufficient cleaning. DO NOT pull cable with great
force. Reverse drill and gradually work cable out.
(2.) Use 1/4-in. diameter wire brush (commonly known
as 25-caliber rifle cleaning brush).
(4.) Insert brush end of cable in lower opening of cell,
and proceed to clean 2 lower passes of cell in same
manner as 2 upper passes.
NOTE: The materials needed in items (1.) and (2.) can usually be
purchased at local hardware stores.
(3.) Insert twisted wire end of brush into end of spring
cable, and crimp tight with crimping tool or strike
with ball-peen hammer. TIGHTNESS IS VERY
IMPORTANT.
(5.) Repeat foregoing procedures until each cell in
furnace has been cleaned.
(6.) Using vacuum cleaner, remove residue from each
cell.
(4.) Remove metal screw fitting from wire brush to
allow insertion into cable.
(7.) Using vacuum cleaner with soft brush attachment,
clean burner assembly.
b. Clean each heat exchanger cell.
(8.) Reinstall cell outlet plates and screws FIRST; then,
reinstall cell inlet plates and burner assembly. Care
must be exercised to center burners in cell openings.
(1.) Attach variable-speed, reversible drill to end of
spring cable (end opposite brush).
(2.) Insert brush end of cable into upper opening of cell
and slowly rotate with drill. DO NOT force cable.
Gradually insert at least 36 in. of cable into 2 upper
passes of cell. (See Fig. 8.)
12. Remove old sealant from center panel and collector box
flange and apply new sealant to collector box flange and
reinstall on center panel, making sure all screws are secure.
—5—
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FIELD 24-V WIRING
FIELD 115-, 208/230-, 460-V WIRING
FACTORY 24-V WIRING
FACTORY 115-V WIRING
1-STAGE THERMOSTAT TERMINALS
W
Y
R
G
C
FIVE
WIRE
FIELD-SUPPLIED
FUSED DISCONNECT
TWO-WIRE
HEATING-
ONLY
208/230- OR
460-V
THREE
PHASE
W2
BLK
BLK
GND
GND
GND
COM
W/W1
WHT
WHT
208/230-V
SINGLE
PHASE
GND
GND
Y/Y2
115-V FUSED
DISCONNECT
SWITCH
JUNCTION
BOX
GND
R
G
CONTROL
CONDENSING
UNIT
(WHEN REQUIRED)
BOX
24-V
TERMINAL
BLOCK
NOTES: 1. Connect Y-terminal as shown for proper operation.
FURNACE
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. 9—Heating and Cooling Application Wiring Diagram
for Single-Stage Thermostats and Single-Speed Condensing Units
NOTE: A releasing agent such as PAM cooking spray or equiva-
lent (must not contain corn or canola oil, aromatic or halogenated
hydrocarbons or inadequate seal may occur) and RTV sealant
(G.E. 162, 6702, or Dow-Corning 738) are needed before starting
installation. DO NOT substitute any other type of RTV sealant.
G.E. 162 (P771-9003) is available through RCD in 3-oz tubes.
19. Set thermostat and check furnace for proper operation.
20. Verify blower airflow and speed changes between heating
and cooling.
21. Check for gas leaks.
22. Replace control door.
13. Reinstall relief box and inducer assembly.
WARNING: Never use a match or other open flame to
check for gas leaks. Use a soap-and-water solution. A
failure to follow this warning could result in fire, personal
injury, or death.
NOTE: If inducer assembly gasket is damaged, use RTV sealant
to seal inducer assembly to collector box.
14. Reconnect wires to the following components:
a. Draft safeguard switch.
b. Inducer motor.
IV. ELECTRICAL CONTROLS AND WIRING
c. Pressure switches.
NOTE: There may be more than 1 electrical supply to unit.
d. Limit overtemperature switch(es).
e. Gas valve.
The electrical ground and polarity for 115-v wiring must be
maintained properly. Refer to Fig. 9 and 10 for field wiring
information and to Fig. 11 for unit wiring information. If the
polarity is NOT correct, the furnace control will display rapid
flashing on the status LED and prevent heat operation. The control
system also requires an earth ground for proper operation of the
microprocessor.
f. Hot surface ignitor.
g. Flame-sensing electrode.
h. Flame rollout switch(es), if applicable.
15. Reinstall internal vent pipe and enclosure on downflow
furnaces only by reversing items 4a through 4c.
With power disconnected to unit, check all electrical connections
for tightness. Tighten all screws on electrical connections. If any
smoky or burned connections are noticed, disassemble the connec-
tion, clean all parts and stripped wire, and reassemble properly and
securely. Electrical controls are difficult to check without proper
instrumentation; therefore, reconnect electrical power to unit and
observe unit through 1 complete operating cycle.
NOTE: A 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) and RTV
sealant (G.E. 162, 6702, or Dow-Corning 738) are needed before
starting installation. DO NOT substitute any other type of RTV
sealant. G.E. 162 (P771-9003) is available through RCD in 3-oz
tubes.
The 24-v circuit contains an automotive-type, 3-amp fuse located
on the main control. Any 24-v electrical shorts during installation,
service, or maintenance could cause this fuse to blow. If fuse
replacement is required, use ONLY a 3-amp fuse. The control will
display code 24 when fuse needs replacement.
16. Reinstall vent connector to furnace flue collar. After fully
assembling vent connector to furnace flue collar, securely
fasten vent connector to flue collar with 2 field-supplied,
corrosion-resistant, sheet metal screws located 180 degrees
apart and midway up the collar.
The control in this furnace is equipped with an LED status light to
aid in installation, servicing, and troubleshooting. It can be viewed
through the sight glass or window on blower access door. The
control indicates status with the LED on continuously, rapid
17. Replace blower access door only.
18. Turn power and gas to ON.
—6—
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FIELD 24-V WIRING
FIELD 115-, 208/230-, 460-V WIRING
FACTORY 24-V WIRING
FACTORY 115-V WIRING
2-STAGE THERMOSTAT TERMINALS
W2 W1 Y2
R
G
Y1
C
SEVEN
WIRE
FIELD-SUPPLIED
FUSED DISCONNECT
THREE-WIRE
HEATING-
ONLY
208/230- OR
460-V
THREE
PHASE
W2
COM
W/W1
BLK
BLK
GND
C
GND
GND
WHT
WHT
208/230-V
SINGLE
PHASE
GND
GND
Y/Y2
115-V FUSED
DISCONNECT
SWITCH
JUNCTION
BOX
Y1
Y2
GND
R
G
CONTROL
2-SPEED
CONDENSING
UNIT
(WHEN REQUIRED)
BOX
24-V
TERMINAL
BLOCK
NOTES: 1. Connect Y-terminal as shown for proper operation.
FURNACE
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.
A99072
Fig. 10—Heating and Cooling Application Wiring Diagram
for 2-Stage Thermostats and/or 2-Speed Condensing Units
flashing, or a code composed of 2 digits. (The first digit is the
number of short flashes, the second is the number of longs flashes.)
Refer to service label on blower compartment door for code
explanations and useful troubleshooting suggestions. (See Fig. 12.)
Use any recorded fault codes, service label, and troubleshooting
diagram on following pages to diagnose and correct any problem
condition.
It is important to note that power to furnace must not be interrupted
and furnace blower door must not be removed until the LED status
code(s) is recorded. When power to control is interrupted, status
memory is erased.
WIRING DIAGRAMS
Refer to Fig. 9, 10, and 11 for appropriate wiring diagrams.
TROUBLESHOOTING
The control will store up to 5 previous codes but will not store
non-current codes longer than 48 hr. To retrieve previous codes, if
present, no thermostat inputs to control must be present and all
time delays must expire. Remove 1 of the red main limit wires 1
to 4 sec until the LED light goes out, then reconnect it. (See Fig.
5 and 6.) (Do not leave red wire disconnected for longer than 4 sec
as control will assume an overtemperature condition exists and
will respond with indoor blower operation.) This places control in
status recall mode and displays first code stored in memory.
Record code and repeat the disconnect and reconnect of red wire,
recording each code until code 11 is displayed indicating no
additional faults. After last code is displayed or after 2 minutes in
the code recall mode, the control will return to normal standby
mode.
Refer to service label. (See Fig. 12.) The Troubleshooting Guide
can be a useful tool in isolating furnace operation problems.
Beginning with the word “Start,” answer each question and follow
the appropriate arrow to the next item.
The Guide will help you identify the problem or failed component.
After replacing any component, verify correct operation sequence.
More information is available in a seperate Troubleshooting Guide
for 2-stage Gas-Fired Induced-Combustion Furnaces.
—7—
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CONNECTION DIAGRAM
SCHEMATIC DIAGRAM (NATURAL GAS & PROPANE)
NOTE #1
TO 115VAC FIELD
DISCONNECT SWITCH
ILK
EQUIPMENT
GROUND
LPS
LS
FRS2
NOTE #8
RED
HI
HPS
BRN
GRY
BRN
LO-GAS-HEAT
P
BHI / LOR
BHT / CLR
L2
LO
MED LO
BLWM
BRN
GV
LGPS
HI-GAS-HEAT
NOTE #15
HI
DSS
C
M
BLU
MED
MED HI
SPARE
SPARE
GRN/YEL
L1
GRN/YEL
BLWR
COM
NOTE #4
HI-COOL
IDM
FRS1
BRN
CAP
HSI
PL6
FUSED DISCONNECT
SWITCH (WHEN REQ’D)
NOTE #1
COMMON
(WHEN USED)
ALS1
GRN/YEL
ILK
JB
EAC-1
EAC-2
HSIR
IDR
BLK
L1
L2
(WHEN USED)
NOTE #6
1
3
9
PL2
ORN
ORN
HSI
WHT
HEAT
FU2
PL6
PL3
2
WHT
SET-UP
SWITCH
SWITCH
1
2
IHI / LOR
GND
1
2
LO
NORM
HI HT
LO HT
BLK
1
ALS2
*
BLK
2
1
4
HI
COM
2
3
PL3
7
8
3
IDM
PR2
PR1
BLOWER-
OFF DELAY
(SEC.)
115VAC
SWITCH
RED
FU1
TRAN
3
4
SEC1
SEC2
1
5
6
90 SEC
N/A
N/A
PL2
24VAC
HPSR
BLK
135 SEC
180 SEC
225 SEC
*
WHT
NOTE #5
2-STAGE
FURNACE
CONTROL
2
12
2
N/A
FRS2
BLK
PR1
L1
PR2
L2
MGVR-2
WHT
HUM
R
BLK
FRS1
(WHEN USED)
CAP
LS
WHT
3
COMMON
BRN
ORN
RED
BRN
NOTE #4
*
HI-COOL
ALS2
ALS1
9
6
BLOWER-OFF DELAY
COM
HI
MED HI
NOTE #15
WHT
BLK
YEL
TWIN
TEST
TRAN
BLOWER-OFF DELAY
LOW-HEAT ONLY
HIGH-HEAT ONLY
RED
HI-GAS
HEAT
LO-GAS
HEAT
EAC-2
TWINNING
JUMPER
TJ
P1
S
DSS
NOTE #8 LPS
MED
PL1
ORN
BLU
EAC-1
TWIN
TEST
MED LO
BLWM
TJ
SPARE
SPARE
SEC1
LO
RED
W/W1
M
RED
(WHEN USED)
LGPS
M
S
W2 Com W/W1 Y/Y2
24V
R
G
HUM
LED
BLU
SEC2
FU1
5
4
SW1
NOTE #8
LEGEND
HPS
MGVR
MA-IN1 =GAVASLVVAELVE RELAY-,2D=PHSUTM(NID.OIF.)IER
12-CIRCUIT CONNECTOR
9-CIRCUIT CONNECTOR
3-CIRCUIT IDM CONNECTOR
2-CIRCUIT HSI CONNECTOR
ALS1
ALS2
AUXILIARY LIMIT SWITCH, OVERTEMP. MANUAL RESET, SPST (N.C.)
AUXILIARY LIMIT SWITCH, OVERTEMP. AUTO RESET, SPST (N.C.)
W2
CPU
P
PL1
PL2
PL3
PL6
MGVR-1
BHI / LOR BLOWER MOTOR SPEED CHANGE RELAY, SPDT
BHT / CLR BLOWER MOTOR SPEED CHANGE RELAY, SPDT
HI
1
M
BLWM
BLWR
CAP
CPU
DSS
EAC-1
EAC-2
FRS1
FRS2
FSE
BLOWER MOTOR, 4 or 5 -SPEED, PERMANENT-SPLIT-CAPACITOR
BLOWER MOTOR RELAY, SPST (N.O.)
CAPACITOR
MICROPROCESSOR AND CIRCUITRY
DRAFT SAFEGUARD SWITCH (N.C.)
ELECTRONIC AIR CLEANER CONNECTION (115 VAC, 1 AMP MAX.)
ELECTRONIC AIR CLEANER CONNECTION (COMMON)
FLAME ROLLOUT SWITCH OVERTEMP. MANUAL RESET, SPST (N.C.)
FLAME ROLLOUT SWITCH OVERTEMP. MANUAL RESET, SPST (N.C.)
FLAME-PROVING SENSOR ELECTRODE
10
GV
Y/Y2
C
SW1
SW2
SW3 & 4
HIGH-HEAT-ONLY SWITCH, SPST (MANUAL)*
LOW-HEAT-ONLY SWITCH, SPST (MANUAL)*
BLOWER-OFF DELAY SETTING SWITCHES,
SPST (MANUAL)*
NOTE#7
G
TJ
TWINNING JUMPER, SPDT FOR MAIN OR
SECONDARY STATUS (MANUAL CHANGE OVER)
TRANSFORMER-115VAC/24VAC
FSE
7
8
TRAN
N/A
N/A
TWIN/TEST 1-CIRCUIT TWINNING BUSS CONNECTOR,
ALSO STATUS CODE RECALL
11
COM
FU1
FU2
GV
HPS
HPSR
HSI
HSIR
HUM
IDM
FUSE, 3 AMP, AUTOMOTIVE BLADE TYPE, FACTORY INSTALLED
FUSE, FIELD INSTALLED
GAS VALVE, REDUNDANT LOW-HEAT OPERATORS, 2-STAGE
HIGH-HEAT PRESSURE SWITCH, SPST (N.O.)
HIGH-HEAT PRESSURE SWITCH RELAY, SPST (N.C.)
HOT-SURFACE IGNITER (115 VAC)
HOT-SURFACE IGNITOR RELAY, SPST (N.O.)
24VAC HUMIDIFIER CONNECTION (0.5 AMP. MAX.)
INDUCED DRAFT MOTOR, 2-SPEED, SHADED-POLE
INDUCER MOTOR RELAY, SPST (N.O.)
JUNCTION
TERMINAL
NOTES:
CONTROL TERMINAL
1. Use only copper wire between the disconnect switch and
the unit.
9. Symbols are an electrical representation only.
10. BLOWER-ON DELAY: Gas heating 45 seconds,
Cooling/Heat Pump 2 seconds.
11. Cooling/Heat Pump BLOWER-OFF DELAY is 90
seconds.
12. IGNITION-LOCKOUT will occur after four
consecutive unsuccessful trials-for-ignition.
Control will automatically reset after three hours.
13. Control must be grounded at pin 10 of 12-pin
connector.
FACTORY POWER WIRING (115VAC)
FACTORY CONTROL WIRING (24VAC)
FIELD POWER WIRING (115VAC)
FIELD CONTROL WIRING (24VAC)
CONDUCTOR ON CONTROL
FIELD WIRING SCREW TERMINAL
FIELD GROUND
2. If any of the original wire, as supplied, must be replaced,
use the same or equivalent type wire.
3. Inducer (IDM) and blower (BLWM) motors contain
internal auto-reset thermal overload switches.
4. Blower motor speed selections are for average
conditions. See Installation Instructions for details on
optimum speed selection.
IDR
IHI / LOR INDUCER MOTOR SPEED CHANGE RELAY, SPDT
ILK
JB
BLOWER DOOR INTERLOCK SWITCH, SPST (N.O.)
JUNCTION BOX
5. Replace only with a 3-AMP fuse.
6. Auxiliary limit switches (ALS1 & 2) used on some
horizontal and some downflow models.
LED
LGPS
LPS
LS
LIGHT-EMITTING DIODE FOR STATUS CODES
LOW GAS-PRESSURE SWITCH, SPST (N.O.)
LOW-HEAT PRESSURE SWITCH, SPST (N.O.)
LIMIT SWITCH, OVERTEMPERATURE-AUTO RESET, SPST (N.C.)
EQUIPMENT GROUND
FIELD SPLICE
14. NA - Not Applicable
15. Spare terminal and wire not available on some
applications. Insulate connector if not available.
7. This wire must be connected to furnace sheet metal for
control to prove flame.
PLUG RECEPTACLE
8. Factory connected when LGPS not used.
324459-101 REV. D
A01365
→ Fig. 11—Unit Wiring Diagram
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SERVICE
If sta tus c od e re c a ll is ne e d e d , d o not re mo ve p owe r or b lowe r d oor. Brie fly re move
a nd the n re c onne c t one ma in lim it wire to d isp la y store d sta tus c od e .
LED CODE
STATUS
CONTINUOUS OFF - Che c k for 115VAC a t L1 a nd L2, a nd 24VAC a t SEC1 a nd SEC2 .
CONTINUOUS ON - Control ha s 24VAC p owe r.
RAPID FLASHING - Line volta ge (115VAC) p ola rity re ve rse d . If twinne d , re fe r to
twinning kit instruc tions.
Ea c h o f the following sta tus c od e s is a two-d ig it numb e r with the first d ig it d e te rm ine d b y
the numb e r of short fla she s a nd the se c ond d ig it b y the num b e r of long fla she s.
11 NO PREVIOUS CODE - Store d sta tus c ode s a re e ra se d whe n p owe r (115VAC or
24VAC) to c ontrol is inte rrup te d or 48 hours a fte r e a c h fa ult is c le a re d .
12 BLOWER ON AFTER POWER UP (115VAC or 24VAC) - Blowe r runs for 90 se c onds,
if unit is p owe re d up d uring a c a ll for he a t (R-W c lose d ).
13 LIMIT OR FLAME ROLL-OUT SWITCH LOCKOUT - Control will a uto re se t a fte r thre e
hours. Re se t switc h or re pla c e fuse link. Re fe r to #33.
14 IGNITION LOCKOUT - Control will a uto-re se t a fte r thre e hours. Re fe r to #34.
21 GAS HEATING LOCKOUT - Control will NOT a uto-re se t.
Che c k for: - Mis-wire d ga s va lve
- De fe c tive c ontrol (va lve re la y)
22 ABNORMAL FLAME-PROVING SIGNAL - Fla me is p rove d while g a s va lve is d e -
e ne rgize d . Ind uc e r will run until fa ult is c le a re d . Che c k for:
- Le a ky ga s va lve
- Stuc k-op e n ga s va lve
23 PRESSURE SWITCH DID NOT OPEN Che c k for:
- Ob struc te d p re ssure tubing
- Pre ssure switc h stuc k c lose d .
24 SECONDARY VOLTAGE FUSE IS OPEN Che c k for: - Short-c irc uit in se c ond a ry
volta ge (24VAC) wiring
31 HIGH-HEAT PRESSURE SWITCH OR RELAY DID NOT CLOSE OR REOPENED
Che c k for: -Control re la y ma y b e d e fe c tive
- Re fe r to #32
32 LOW-HEAT PRESSURE, DRAFT SAFEGUARD (whe n use d ), OR AUX-LIMIT(whe n use d *)
SWITCH DID NOT CLOSE OR REOPENED (DOWNFLOW ONLY*) If op e n longe r tha n
five minute s, ind uc e r shuts off for 15 minute s b e fore re try. If it op e ns a fte r tria l for
ig nition p e riod , b lowe r will c ome on for 90 se c ond re c yc le d e la y. Che c k for:
*- De fe c tive b lowe r motor or c a p a c itor
- Prop e r ve nt sizing
- Re stric te d ve nt
- Low ind uc e r volta ge (115VAC)
- Exc e ssive wind
- Disc onne c te d or ob struc te d p re ssure tubing
- De fe c tive ind uc e r motor
- De fe c tive p re ssure switc h
- Low p ropa ne inle t ga s p re ssure
- Ina d e q ua te c omb ustion a ir sup p ly
33 LIMIT OR FLAME ROLL-OUT SWITCH IS OPEN - If op e n longe r tha n thre e minute s,
c od e c ha nge s to #13. Fla me roll-out switc h re q uire s ma nua l re se t. Che c k for:
- Dirty filte r or re stric te d d uc t syste m.
- De fe c tive b lowe r motor or c a p a c itor.
- Loose b lowe r whe e l.
- De fe c tive switc h or c onne c tions.
- Ina d e q ua te c omb ustion a ir supp ly (Fla me roll-out switc h or fuse link op e n).
- Op e n fla me roll-out switc h, or fuse link. Ma nua l re se t or re p la c e .
34 IGNITION PROVING FAILURE - Control will try thre e more time s b e fore loc kout #14
oc c urs. If fla me signa l is lost a fte r tria l for ig nition pe riod , b lowe r will c ome on for
90 se c ond re c yc le d e la y. Che c k for:
- Ga s va lve d e fe c tive or ga s va lve turne d off.
- Oxid e build up on fla me se nsor (c le a n with fine ste e l wool).
- Prop e r fla me se nse c urre nt (.5 mic roa mp s D.C. min., 4.0 - 6.0 nom. in HIGH HEAT).
- Gre e n wire MUST b e c onne c te d to furna c e she e t me ta l.
- Fla me se nsor must b e ungrounde d .
- De fe c tive hot surfa c e ignitor
- Ina d e q ua te fla me c a rryove r or roug h ignition.
- Ma nua l va lve shut-off.
- Control ground c ontinuity.
- Low inle t g a s p re ssure .
43 LOW-HEAT PRESSURE, DRAFT SAFEGUARD (whe n use d ), OR AUX-LIMIT (whe n use d *)
SWITCH OPEN WHILE HIGH-HEAT PRESSURE SWITCH IS CLOSED Che c k for:
- Pre ssure switc h stuc k op e n
- Re fe r to #32 a nd #33
45 REPLACE CONTROL
- Disc onne c te d or ob struc te d p re ssure tub ing
- Low p ropa ne inle t ga s p re ssure
COMPONENT TEST
TWIN
TEST
12 - CIRCUIT
CONNECTOR
OM
C
R
G
LED
HUM
W2
W/ W1 Y/Y2
24 V
To initia te the c ompone nt se lf-te st se que nc e , shut off the room the rmosta t or
disc onne c t the "R" the rmosta t le a d. Brie fly short the TWIN/ TEST te rmina l to the
Com24V te rmina l. Sta tus LED will turn off. NON-CONDENSING FURNACE: The
c ontrol will turn ON the induc e r motor low spe e d, the n high spe e d a nd re ma in on
high spe e d for the e ntire te st. The othe r c ompone nts will be ON for 7 to 15
se c onds: Hot surfa c e ignitor, Low he a t blowe r spe e d, High he a t blowe r spe e d,
High c ooling blowe r spe e d. CONDENSING FURNACE: The induc e r motor will sta rt
in high spe e d a nd re ma in on high spe e d until the e nd of the te st, the n shift to low
spe e d for 7 to 15 se c onds. All othe r c ompone nts will be te ste d in the sa me
se que nc e a s the NON-CONDENSING.
320893-101 REV. F
A01368
→
Fig. 12—Service Label
—9—
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TROUBLESHOOTING
GUIDE
NOTES:
WARNING
!
1. Refer to information label on blower compartment door
for procedure for use of LED status codes and problem
solving suggestions.
2. LED indicator is viewed through window in blower
compartment door.
ELECTRICAL SHOCK HAZARD
3. If 115-vac power is de-energized or interrupted during a
call for heat, the indoor blower will run for 90 sec before
a gas heating cycle begins – Code 12.
4. After replacing any component, verify correct operating
sequence.
ONLY QUALIFIED AND TRAINED
SERVICE PERSONNEL SHOULD
PERFORM THIS PROCEDURE
If LED is flashing rapidly, check line voltage polarity.
If Code 24 is displayed, check for blown fuse.
If LED is OFF, check line voltage and 24-v transformer.
If Code 45 is displayed, replace control.
START
24v should be present across R
and Com. If not, check for:
1. Open flame rollout switch
(FRS) – Code 33.
2. Open limit switch (LS) –
Code 33.
Yes
Turn thermostat OFF.
Is indoor blower on ?
No
On furnace control, note current
settings for setup switches 1 (SW-1)
and 2 (SW-2) then set SW-1 to OFF
and SW-2 to ON.
24v should be present across Com and W at furnace control. If
not, check for:
1. Open thermostat.
3. Check all low-voltage wiring
connections.
2. Open 24-v fuse (FU1) – Code 24.
3. Failed transformer.
No
Cycle 115-v power
off for 3 sec, then on.
No
Replace control only if all checks
are OK.
If Code 23 is displayed, the pressure switch(es) is stuck closed.
Replace switch and/or check pressure tube for blockage.
System malfunction – Code 21.
No
115v should be present at the inducer motor. If so, replace inducer
motor. If not, check 115-v wiring.
Continuous LED?
Yes
If Code 32 is displayed check for:
Set thermostat to call for heat.
1. Open gas inlet pressure switch (when used).
2. Open pressure switch (LPS) and/or tube – Code 32.
3. Open draft safeguard switch (DSS) – Code 32.
4. Open auxiliary switch (ALS)(downflow only) – Code 32.
5. Check all low-voltage wiring connections.
Set FAN to AUTO mode.
No
Replace control only if Code 45 is
displayed, or if all checks are OK.
No
Draft inducer motor starts.
115v should be present at the ignitor. If so, replace the ignitor; if not,
check 115-vac wiring to ignitor.
Yes
No
LPS, DSS, or ALS open while HPS if closed (high-gas-heat only) –
Code 43.
Is Code 22 displayed?
Yes
Control will attempt to light burners 4 times (approximately 1 minute
between attempts – Code 34). Voltage is present at the gas valve for 7
sec during each ignition trial. System will lockout after 4 attempts.
Flame present when not normal.
Replace gas valve.
Is the gas valve control knob or switch in the OPEN or ON position?
24v should be present across the gas valve terminals C and M/P
(and C and HI for high-stage gas test) during the 7 sec ignition
trial. If not, check all low-voltage wiring connections to valve.
15-sec inducer pre-purge.
Yes
If 24v are present, and main gas does not flow:
1. Supply pressure between 4.5- and 13.6-in. wc. If not, adjust
supply pressure.
2. If supply pressure is between 4.5- and 13.6-in. wc, replace gas
valve.
No
Replace control only if Code 45 is
displayed, or if all checks are OK.
No
Ignitor warms up and glows
orange/yellow; 17-sec warm-up.
Yes
Check ignitor position.
No
Main burners ignite.
Check burner carryover gap.
Check gas supply pressure (4.5-in. wc minimum).
Yes
Check manifold pressure (1.3- to 1.7-in. wc for low-stage gas;
3.2- to 3.8-in. wc for high-stage gas).
Check for proper orifice size.
Is Code 31 (high-gas-heat only), 32, 33, or 34 displayed? Check
code information label to diagnose.
Replace control if Code 45 is dis-
played, or if all checks are OK.
Clean flame sensor if microamps
are below nominal.
No
No
No
Main burners stay on.
Check polarity of 115-v power at J-box and control. Twinned
furnace polarities must match – rapid flashing LED.
Yes
Check ground continutity from J-box to control.
Check flame sensor microamps (4.0 nominal; 0.5 minimum for
control to recognize flame).
Indoor blower motor starts on
No
Replace control only if Code 45 is
displayed, or if all checks are OK.
heating speed after 45-sec
warm-up period.
115v should be present at the blower motor. If so, check capacitor.
If capacitor is OK, replace blower motor. If 115v are not present at
the blower motor, check all 115-v wiring to motor.
Yes
If not, check for:
1. Satisfied thermostat.
No
Furnace runs until call for
heat ends.
2. Open inlet gas pressure switch (when used).
3. Open pressure switch (LPS) – Code 32.
4. Open draft safeguard switch (DSS) – Code 32.
5. Open auxilliary limit (ALS)(downflow only) – Code 32.
6. Open 24-v fuse (FU1) – Code 24.
7. Open limit switch (LS) – Code 13 or 33.
8. Open flame rollout switch (FRS) – Code 13 or 33.
9. Check 115-v line voltage – LED off.
No
Replace control only if Code 45 is
Yes
displayed, or if all checks are OK.
Turn thermostat to OFF; gas valve
shuts off burners; 5-sec inducer
post purge.
No
No
Yes
Check for sources of electrical noise interference (electronic air
cleaners, nearby TV, or radio antennas).
Indoor blower motor stops after
90, 135, 180, or 225 sec.
No
No
Replace control only if Code 45 is
displayed, or if all checks are OK.
If inducer and burners continue to operate, check for 24v at the
gas valve. If 24v are present, verify that the thermostat is open
across R and W. If no voltage is present, turn the gas valve
control knob or switch to the OFF position. Replace gas valve.
Yes
Heating sequence of operation
complete. Remove blower door,
move setup switch 1 (SW-1) to ON
position and repeat process to check
high-stage gas heat operation.
(When finished return SW-1 and
SW-2 to original desired settings.)
Replace control only if Code 45 is
displayed, or if all checks are OK.
24v should be present across R and Com. If not, check for:
1. Open limit switch (LS) – Code 13 or 33.
2. Open flame rollout switch (FRS) – Code 13 or 33.
24v should not be present across R and G. If so, set thermostat
FAN to AUTO mode.
A97544
—10—
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SERVICE TRAINING
Packaged Service Training programs are an excellent way to increase your
knowledge of the equipment discussed in this manual, including:
• Unit Familiarization
• Installation Overview
• Maintenance
• Operating Sequence
A large selection of product, theory, and skills programs is available, using popular
video-based formats and materials. All include video and/or slides, plus companion
book.
Classroom Service Training plus "hands-on" the products in our labs can mean
increased confidence that really pays dividends in faster troubleshooting, fewer
callbacks. Course descriptions and schedules are in our catalog.
CALL FOR FREE CATALOG 1-800-962-9212
[ ] Packaged Service Training
[ ] Classroom Service Training
A94328
—11—
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© 2001 Bryant Heating & Cooling Systems 7310 W. Morris St. Indianapolis, IN 46231
Printed in U.S.A.
sp0473
Catalog No. 5333-025
—12—
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