service and maintenance instructions for sizes 040--120 ...€¦ · fig. 1 -- furnace in upflow...

1

350AAVDeluxe 4--WayMultipoise Fixed--CapacityCondensing Gas Furnace

Service and Maintenance InstructionsFor Sizes 040--120, Series B & C

NOTE: Read the entire instruction manual before starting theinstallation.

TABLE OF CONTENTSPAGE

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

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

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS 2. . .

CARE AND MAINTENANCE 3. . . . . . . . . . . . . . . . . . . . . . . . .

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

Blower Motor and Wheel Maintenance 5. . . . . . . . . . . . . . . . . .

Cleaning Burners 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning Heat Exchangers 7. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Primary Heat Exchangers 7. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Secondary Heat Exchangers 8. . . . . . . . . . . . . . . . . . . . . . . . . .

Flushing Collector Box and Drainage System 8. . . . . . . . . . . . .

Servicing Hot Surface Igniter 9. . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Controls and Wiring 11. . . . . . . . . . . . . . . . . . . . . . . .

Checking Heat Tape Operation (If Applicable) 11. . . . . . . . . . .

Winterizing 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAM 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Status Codes 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Component Tests 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL SHOCK, FIRE, OR EXPLOSIONHAZARD

Failure to follow safety warnings exactly could result indangerous operation, personal injury, death, or propertydamage.

-- Before servicing, disconnect all electrical power to furnace.-- When servicing controls, label all wires prior todisconnecting. Reconnect wires correctly.-- Verify proper operation after servicing.

! WARNING

SAFETY CONSIDERATIONSRecognize safety information. This is the safety--alert symbol .When you see this symbol on the furnace and in instructions ormanuals, be alert to the potential for personal injury.Understand the signal words DANGER, WARNING, andCAUTION. These words are used with the safety--alert symbol.DANGER identifies the most serious hazards which will result insevere personal injury or death. WARNING signifies a hazardwhich could result in personal injury or death. CAUTION is usedto identify unsafe practices which may result in minor personalinjury or product and property damage. NOTE is used to highlightsuggestions which will result in enhanced installation, reliability, oroperation.Installing and servicing heating equipment can be hazardous due togas and electrical components. Only trained and qualified serviceagency personnel should install, repair, or service heatingequipment.

ELECTRICAL SHOCK, FIRE, OR EXPLOSIONHAZARD

Failure to follow this warning could result in possibledamage to this equipment, personal injury, or death.

The ability to properly perform maintenance on thisequipment requires certain expertise, mechanical skills,tools, and equipment. If you do not possess these, do notattempt to perform any maintenance on this equipmentother than those procedures recommended in the User’sManual.

! WARNING

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could property damage,personal injury, or death.

Never store anything on, near, or in contact with the furnace,such as:1. Spray or aerosol cans, rags, brooms, dust mops, vacuumcleaners, or other cleaning tools.2. Soap powders, bleaches, waxes or other cleaningcompounds, plastic or plastic containers, gasoline, kerosene,cigarette lighter fluid, dry cleaning fluids, or other volatilefluids.3. Paint thinners and other painting compounds, paper bags,or other paper products.

! WARNING

2

A05085

Fig. 1 -- Furnace in Upflow Orientation

ama

REGISTERED

ISO 9001:2000

CERTIFIED

Installing and servicing heating equipment can be hazardous due togas and electrical components. Only trained and qualifiedservice agency personnel should install, repair, or serviceheating equipment. Untrained personnel can perform basicmaintenance functions described in User’s InformationManual such as cleaning and replacing air filters. All otheroperations must be performed by trained service personnel. Whenworking on heating equipment, observe precautions in theliterature, on tags, and on labels attached to or shipped with theunit 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, CSAB149.1--05 National Standard of Canada, Natural Gas and PropaneInstallation Codes (NSCNGPIC) in Canada, and the InstallationStandards, Warm Air Heating and Air Conditioning Systems(NFPA 90B) ANSI/NFPA 90B. Wear safety glasses and workgloves. Have a fire extinguisher available during start--up andadjustment procedures and service calls.

UNIT DAMAGE HAZARD

Failure to follow this caution may result in damage tofurnace.

Label all wires prior to disconnection when servicingcontrols. Wiring errors can cause improper and dangerousoperation.

CAUTION!

GENERALThis furnace can be installed as a direct vent (2--pipe) or non--directvent (1--pipe) condensing gas furnace. These instructions arewritten as if the furnace is installed in an upflow application. Anupflow furnace application is where the blower is located belowthe combustion and controls section of the furnace, andconditioned air is discharged upward. Since this furnace can beinstalled in any of the 4 positions shown in Fig. 2, you may need torevise your orientation to component location accordingly.

UPFLOW

DOWNFLOW

HORIZONTALLEFT

AIRFLOW AIRFLOW

AIRFLOW

AIRFLOW

HORIZONTALRIGHT

A93041

Fig. 2 -- Multipoise Orientation

ELECTROSTATIC DISCHARGE (ESD)PRECAUTIONS

UNIT DAMAGE HAZARD

Failure to follow this caution may damage furnacecomponents.

Electrostatic discharge can affect electronic components.Take precautions during furnace installation and servicingto protect the furnace electronic control. Precautions willprevent electrostatic discharges from personnel and handtools which are held during the procedure. Theseprecautions will help to avoid exposing the control toelectrostatic discharge by putting the furnace, the control,and the person at the same electrostatic potential.

CAUTION!

1. Disconnect all power to the furnace. DO NOT TOUCHTHE CONTROL OR ANY WIRE CONNECTED TO THECONTROL PRIOR TO DISCHARGING YOUR BODY’SELECTROSTATIC CHARGE TO GROUND.

350AAV

3

2. Firmly touch a clean, unpainted, metal surface of thefurnace chassis which is close to the control. Tools held in aperson’s hand during grounding will be satisfactorilydischarged.

3. After touching the chassis, you may proceed to service thecontrol or connecting wires as long as you do nothing thatrecharges your body with static electricity (for example; DONOT move or shuffle your feet, DO NOT touchungrounded objects, etc.).

4. If you touch ungrounded objects (recharge your body withstatic electricity), firmly touch furnace again beforetouching control or wires.

5. Use this procedure for installed and uninstalled(ungrounded) furnaces.

6. Before removing a new control from its container, dischargeyour body’s electrostatic charge to ground to protect thecontrol from damage. If the control is to be installed in afurnace, follow items 1 through 5 before bringing thecontrol or yourself into contact with the furnace. Put allused AND new controls into containers before touchingungrounded objects.

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

CARE AND MAINTENANCEFor continuing high performance and to minimize possible furnacefailure, it is essential that maintenance be performed annually.Consult your local dealer for maintenance and maintenancecontract availability.

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personalinjury or death.

Turn off the gas and electrical supplies to the unit beforeperforming any maintenance or service. Follow theoperating instructions on the label attached to the furnace.

! WARNING

The minimum maintenance that should be performed on thisequipment 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 forproper 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 pipesannually.

6. Check burners for cleanliness annually.

CUT HAZARD

Failure to follow this caution may result in personal injury.

Be careful of sharp metal edges, etc. Use care and wearprotective clothing, gloves, and safety glasses whenremoving parts.

CAUTION!

Step 1 — Cleaning and/or Replacing Air FilterThe air filter arrangement may vary depending on the applicationor orientation. See Tables 1 or 2 for filter size and typeinformation.

FILTER

FILTERSUPPORT

FILTERRETAINER

WASHABLE FILTER ORDISPOSABLE MEDIA FILTERIN FILTER CABINET

A08588

Fig. 3 -- Bottom Filter Arrangement

FILTERRETAINER

FILTERIN FURNACE

WASHABLE FILTER ORDISPOSABLE MEDIAFILTER IN FILTER CABINET

A08589

Fig. 4 -- Filter Installed for Side Inlet

FIRE, CARBON MONOXIDE POISONINGHAZARD

Failure to follow this warning could result in personalinjury, death or property damage.

Never operate unit without a filter or with the blower accesspanel removed. Operating a unit without a filter or with theblower access door removed could cause damage to thefurnace blower motor. Dust and lint on internal parts offurnace can cause a loss of efficiency.

! WARNING

NOTE: If the filter has an airflow direction arrow, the arrow mustpoint 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.

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Table 1 – Furnace Air Filter Table

FURNACE CASING WIDTHIN (MM)

FILTER QUANTITY AND SIZE *FILTER TYPE*SIDE RETURN*

IN (MM)BOTTOM RETURN*

IN (MM)

17---1/2 (445) (1) 16 x 25 x 3/4(406 x 635 x 19)

(1) 16 x 25 x 3/4(406 x 635 x 19) 3/4” (19 mm) thick washable

21 (533 ) (1) 16 x 25 x 3/4(406 x 635 x 19)


24---1/2 (610) (1) 16 x 25 x 3/4(406 x 635 x 19)


Table 2 – Air Filter Located in Filter CabinetFILTER CABINET HEIGHT --- IN (MM) FILTER SIZE --- IN (MM) FILTER TYPE

16 (406)

(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)

washable

20 (508)

(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)

washable

24 (610)

(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)

washable

* Filters with a side return--air may have a different filter size. Measure the filter to obtain the correct size.

350AAV

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COLLECTOR BOXTUBE (PINK)

COLLECTOR BOXTUBE (GREEN)

INDUCER HOUSING(MOLDED) DRAIN

TUBE (BEHINDCOLLECTOR BOX

DRAIN TUBE)

COLLECTOR BOXDRAIN TUBE (BLUE)

FIELD-INSTALLEDFACTORY-SUPPLIED

DRAIN TUBECOUPLING (LEFT

DRAIN OPTION)


DRAIN TUBE

FIELD-INSTALLEDFACTORY-SUPPLIED1⁄2-IN. CPVC STREET

ELBOWS (2) FORLEFT DRAIN OPTION


DRAIN TUBECOUPLING (RIGHT

DRAIN OPTION)

CAP

COLLECTOR BOXDRAIN TUBE (BLUE& WHITE STRIPED)

PLUG

CONDENSATETRAP

A05110

Fig. 5 -- Factory--Shipped Upflow Tube Configuration(Shown with Blower Access Panel Removed)

4. Furnaces with a washable filter, clean filter by spraying coldtap water through filter in opposite direction of airflow.Rinse filter and let dry. Oiling or coating of the filter is notrecommended.

5. If equipped with factory specified disposable media filter,replace only with a factory specified media filter of the samesize.

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 blowercompartment or in filter cabinet, but not in both.

4. Slide filter out of furnace.5. Furnaces with washable filter(s), clean filter by sprayingcold tap water through filter in opposite direction of airflow.

6. Rinse filter and let dry. Oiling or coating filter is notrecommended.

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.

Step 2 — Blower Motor and Wheel MaintenanceTo ensure long life, economy, and high efficiency, cleanaccumulated dirt and grease from blower wheel and motorannually.The inducer and blower motors are pre--lubricated and require noadditional lubrication. These motors can be identified by theabsence of oil ports on each end of the motor.The following items should be performed by a qualified servicetechnician.Clean blower motor and wheel as follows:

1. Turn off electrical supply to furnace.2. Remove main furnace door and blower access panel.3. Disconnect wiresAll factory wires can be left connected, but field thermostatconnections may need to be disconnected depending ontheir length and routing.

4. Position control box, transformer, and door switch assemblyto right side of furnace casing.

5. If condensate trap is located in left-- or right--hand side offurnace casing, proceed to item 6. Otherwise remove trapand tubing as described below (See Fig. 5.):a. Disconnect field drain connection from condensate trap.b. Disconnect drain and relief port tubes from condensatetrap.

c. Remove condensate trap from blower shelf.6. Remove screws securing blower assembly to blower shelfand slide blower assembly out of furnace. Detach groundwire and disconnect blower motor harness plugs fromblower motor.

NOTE: Blower wheel is fragile. Use care.7. Clean blower wheel and motor by using a vacuum with softbrush attachment. Be careful not to disturb balance weights(clips) on blower wheel vanes. Do not bend wheel or bladesas balance will be affected.

8. If greasy residue is present on blower wheel, remove wheelfrom the blower housing and wash it with an appropriatedegreaser. To remove wheel:a. Mark blower wheel location on shaft before disassemblyto ensure proper reassembly.

b. Loosen setscrew holding blower wheel on motor shaft.NOTE: Mark blower mounting arms and blower housing so eacharm is positioned at the same hole location during reassembly.

c. Mark blower wheel orientation and cutoff plate locationto ensure proper reassembly.

d. Remove screws securing cutoff plate and remove cutoffplate from housing.

e. Remove bolts holding motor mounts to blower housingand slide motor and mounts out of housing.

f. Remove blower wheel from housing.

UNIT DAMAGE HAZARD

Failure to follow this caution may result in noise or furnacecomponent failure.

The blower wheel should not be dropped or bent as balancewill be affected.

CAUTION!

g. Clean wheel per instructions on degreaser cleaner. Donot get degreaser in motor.

350AAV

6

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

NOTE: Be sure to attach ground wire to blower housing.10. Reinstall blower assembly in furnace.11. Reinstall condensate trap and tubing if previously removed.

a. Reinstall condensate trap in hole in blower shelf.b. Connect condensate trap drain tubes. See Fig. 5 ortubing diagram on main furnace door for proper tubelocation.

NOTE: Ensure tubes are not kinked or pinched, as this will affectoperation.

(1.) Connect 1 tube (blue or blue and white striped)from collector box.

(2.) Connect 1 tube (violet or unmarked) from inducerhousing.

(3.) Connect 1 tube (relief port, green or pink) fromcollector box.

c. Connect field drain to condensate trap.NOTE: Ensure tubes are not kinked or pinched, as this will affectoperation.12. Reinstall control box, transformer, and door switch

assembly on blower shelf.13. Reconnect wires. Refer to furnace wiring diagram and

connect thermostat leads if previously disconnected. (SeeFig. 21.)

NOTE: Refer to Table 3 for motor speed lead reconnection ifleads were not identified before disconnection.

UNIT DAMAGE HAZARD

Failure to adjust the heating speed may shorten heatexchanger life.

Heating speed selection MUST be adjusted to provideproper temperature rise as specified on the rating plate.

CAUTION!

Table 3 – Speed Selection

COLOR SPEED FACTORYATTACHED TO

Black High CoolYellow (When Present) Medium High Spare

Blue Medium Low HeatRed Low FanWhite Common Com



Blower access panel door switch opens 115--v power tofurnace control. No component operation can occur.Caution must be taken when manually closing thisswitch for service purposes.

! WARNING

14. Turn on electrical supply. Manually close blower accesspanel door switch. Use a piece of tape to hold switch closed.Check for proper rotation and speed changes betweenheating and cooling by jumpering R to G and R to Y/Y2 onfurnace control thermostat terminals. (See Fig. 15.)

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

MANIFOLDMOUNTINGSCREWS

MANIFOLD

GAS VALVEREGULATORFITTING

GASCONTROLVALVE

CELLPANEL

GASKET

A02312

Fig. 6 -- Burner Box Assembly

Step 3 — Cleaning BurnersThe following items should be performed by a qualified servicetechnician. If the burners develop an accumulation of light dirt ordust, 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 fromfurnace gas control valve.

UNIT DAMAGE HAZARD

Failure to follow this caution may result in furnacecomponent damage.

Label all wires prior to disconnection when servicingcontrols. Wiring errors can cause improper and dangerousoperation.

CAUTION!

5. Remove wires from gas valve. Note location for reassembly.6. Remove burner box pressure tube from gas valve regulatorfitting.

7. Unplug igniter from harness.8. Remove igniter leads from slot in manifold grommet.9. Remove screws that secure manifold to burner box. (SeeFig. 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 tostrike the hot surface igniter.

350AAV

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IGNIT ER WIRES MUST BE PLACED IN THIS SLOT

A05074

Fig. 7 -- Igniter Wire Placement

12. Remove burner assembly from burner box.NOTE: All burners are attached to burner bracket and can beremoved 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 installedproperly and burners fit over orifices.

15. Reinsert the igniter wires in the slot in the manifoldgrommet, dressing the wires to ensure there is no tension onthe igniter itself. (See Fig. 7.)



Igniter wires must be securely placed in slot in manifoldgrommet or else they could become pinched or severedand electrically shorted.

! WARNING

16. Reconnect wires to gas valve and igniter. Refer to furnacewiring diagram for proper wire location.

17. Reinstall burner box pressure tube to gas valve regulatorfitting.

18. Reinstall gas supply pipe to furnace gas control valve usingbackup wrench on gas valve to prevent rotation andimproper orientation.

NOTE: Use propane gas resistant pipe dope to prevent gas leaks.DO NOT use Teflon tape.

FIRE, EXPLOSION, UNIT DAMAGE HAZARD

Failure to follow this warning could result in personalinjury, death, or property damage.

Gas valve switch MUST be facing forward or tiltedslightly.

! WARNING

19. Replace burner box cover.20. Turn on gas and electrical supplies to furnace.



Never test for gas leaks with an open flame. Use acommercially available soap solution made specificallyfor the detection of leaks to check all connections.

! WARNING

21. Check for gas leaks.22. Replace main furnace door.

Step 4 — Cleaning Heat ExchangersThe following items should be performed by a qualified servicetechnician.

Primary Heat ExchangersIf the heat exchangers get an accumulation of light dirt or dust onthe inside, they may be cleaned by the following procedure:NOTE: If the heat exchangers get a heavy accumulation of sootand carbon, both the primary and secondary heat exchangersshould be replaced rather than trying to clean them thoroughly dueto their intricate design. A build--up of soot and carbon indicatesthat a problem exists which needs to be corrected, such as improperadjustment of manifold pressure, insufficient or poor qualitycombustion air, improper vent termination, incorrect size ordamaged manifold orifice(s), improper gas, or a restricted heatexchanger (primary or secondary). Action must be taken to correctthe problem.

1. Turn off gas and electrical supplies to furnace.2. Remove main furnace door.

UNIT DAMAGE HAZARD


Label all wires prior to disconnection when servicingcontrols. Wiring errors can cause improper and hazardousoperation.

CAUTION!

3. Disconnect wires or connectors to flame rollout switch, gasvalve, igniter, and flame sensor.

4. Disconnect combustion--air intake pipe from intakehousing.

5. Remove the pressure switch tube from intake housing.6. Remove screws attaching intake housing to burner box, androtate intake housing away from burner box for removal.

7. Using backup wrench, disconnect gas supply pipe fromfurnace gas control valve.

8. Disconnect pressure tubing from gas valve.9. Remove 2 screws attaching top filler panel and rotateupwards to gain access to screws attaching burner box tocell panel.

10. Remove screws attaching burner box to cell panel. (See Fig.6.)

NOTE: Burner box, cover, manifold, gas valve, and burnerassembly should be removed as 1 assembly.

11. Clean heat exchanger openings with a vacuum and a softbrush. (See Fig. 8.)

NOTE: After cleaning, inspect the heat exchangers to ensure theyare free of all foreign objects that may restrict flow of combustionproducts.

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PRIMARY HXINLET OPENINGS

A96305

Fig. 8 -- Cleaning Inlet Openings of PrimaryHeat Exchangers

UNIT MAY NOT OPERATE

Failure to follow this caution may result in improper orintermittent unit operation.

The ground wire from the gas valve MUST be attached tothe burner box attachment screw.

CAUTION!

12. Reverse items 3 through 10 for reassembly.NOTE: Be sure burner box gasket is installed between burner boxand cell panel. (See Fig. 6.) If gasket is damaged, replace it.NOTE: Inspect combustion--air intake housing. If foamed gasketwas removed, check for any damage. If gasket is damaged in anyway, it must be repaired. To repair, remove damaged gasketsection, apply sealant releasing agent such as PAM cooking sprayor equivalent (must not contain corn nor canola oil, halogenatedhydrocarbons nor aromatic content, to prevent inadequate sealfrom occurring) to burner box and apply a small bead of G.E. RTV162, G.E. RTV 6702, or Dow--Corning RTV 738 sealant to edgeof 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 doorfor proper tube location. (See Fig. 10.) Be sure tubes are notkinked.

15. Turn on gas and electrical supplies to furnace.16. Check furnace operation through 2 complete heat operating

cycles. Look through sight glass in burner enclosure tocheck burners. Burner flames should be clear blue, almosttransparent. (See Fig. 11.)

17. Check for gas leaks.



Never test for gas leaks with an open flame. Use acommercially available soap solution made specificallyfor the detection of leaks to check all connections.

! WARNING

18. Replace main furnace door.

Secondary Heat ExchangersNOTE: The condensing side (inside) of the secondary heatexchangers CANNOT be serviced or inspected. A small number ofbottom outlet openings can be inspected by removing the inducerassembly. See Flushing Collector Box and Drainage Systemsection for details on removing inducer assembly.

Step 5 — Flushing Collector Box and DrainageSystem

1. Turn off gas and electrical supplies to furnace.2. Remove main furnace door.3. Disconnect inducer motor and pressure switch wires orconnectors.

4. Disconnect pressure switch tubes.5. Disconnect vent pipe from inducer housing outlet byloosening coupling clamp on inducer outlet.

PAM

RTV

A93087

Fig. 9 -- Combustion--Air Intake HousingGasket Repair

6. Disconnect drain tube from inducer housing. (See Fig. 10.)NOTE: Ensure the drain tube disconnected from the inducerhousing is higher than the collector box opening or water will flowout of tube.

7. Remove inducer housing assembly by removing 4 boltsattaching assembly to cell panel.

8. Flush inside of collector box with water until dischargefrom condensate trap is clean and runs freely.

9. Inspect inside area of collector box for any pieces of foreignmaterials and remove them if present.

UNIT DAMAGE HAZARD


DO NOT use wire brush or other sharp object to inspect ordislodge materials in secondary heat exchangers as cuttingof the secondary heat exchanger protective coating mayoccur. Flush with water only.

CAUTION!

350AAV

9

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

Tube location when used in DOWNFLOW application

Tube location when used onHORIZONTAL - RIGHT application

PLUG

CAP

COLLECTOR BOX DRAIN TUBE(BLUE & WHITE STRIPED)

COLLECTOR BOX TUBE(PINK)

COLLECTOR BOX DRAIN TUBE(BLUE)

INDUCER HOUSING DRAIN TUBE(VIOLET)


COLLECTOR BOX DRAINTUBE

(BLUE & WHITE STRIPED)


INDUCER HOUSING (MOLDED) DRAIN TUBE(BEHIND COLLECTOR BOX DRAIN TUBE)

FIELD-INSTALLEDFACTORY-SUPPLIED DRAIN TUBECOUPLING (LEFT DRAIN OPTION)

FIELD-INSTALLED FACTORY-SUPPLIEDDRAIN TUBE

FIELD-INSTALLEDFACTORY-SUPPLIED 1/2-IN.CPVC STREET ELBOWS (2)FOR LEFT DRAIN OPTION

COLLECTOR BOX TUBE(GREEN)

CONDENSATE TRAP

CAP

Condensate Trap; Factory Installedin Blower Shelf

CONDENSATE TRAP

COLLECTOR BOX TUBE (GREEN)

Condensate Trap on LEFTSide Optional

CAP

PLUGCOLLECTOR BOX

DRAIN TUBE (BLUE)PLUGGED END



COLLECTOR BOXTUBE (PINK)

COLLECTOR BOXEXTENSION TUBECONDENSATE TRAP

INDUCER HOUSING DRAIN TUBE (VIOLET)

COLLECTOR BOXEXTENSION TUBE



COLLECTOR BOX TUBE(GREEN)

CONDENSATE TRAP

INDUCER HOUSING DRAINTUBE (VIOLET)

COLLECTOR BOX EXTENSION TUBE

COLLECTOR BOX DRAINTUBE

(BLUE & WHITE STRIPED)

Condensate Trap onRIGHT Side

COLLECTOR BOXEXTENSION DRAIN TUBE

DRAIN TUBE COUPLING

GAS VALVE

DRAIN TUBES ROUTED INFRONT OF GAS VALVE

PLUG

CAP


CONDENSATE TRAP



INDUCER HOUSINGDRAIN TUBE

(VIOLET)

COLLECTOR BOX TUBE (PINK)RELOCATE TUBE BETWEEN BLOWERSHELF AND INDUCER HOUSING FOR

040,060, AND 080 HEATING INPUTFURNACES

CAP

PLUG


COLLECTOR BOX EXTENSION TUBECOLLECTOR BOX TUBE (PINK)


COLLECTOR BOX DRAIN TUBE(BLUE AND WHITE STRIPED)

INDUCER HOUSING DRAIN TUBE (VIOLET)

CONDENSATE TRAP

Condensate Trap onLEFT Side

COLLECTOR BOXDRAIN TUBE (BLUE)

PLUG

Tube location when used in UPFLOW application

Tube location when used onHORIZONTAL - LEFT application

CAP

PLUG


DRAIN TUBECOUPLINGCOLLECTOR BOX EXTENSION DRAIN TUBE

(Blower access panel removed)

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.

NOTE:

324999-201 REV. C


DRAIN TUBE COUPLING(RIGHT DRAIN OPTION)

BURNER ENCLOSUREPRESSURE REFERENCE

TUBE ASSEMBLY


TUBE ASSEMBLY

BURNER ENCLOSURE PRESSUREREFERENCE TUBE ASSEMBLY


TUBE ASSEMBLY


TUBE ASSEMBLY

BURNER ENCLOSURE PRESSUREREFERENCE TUBE ASSEMBLY

TUBE ROUTING

AUXILIARY "J" BOX RELOCATED HERE

A00308

Fig. 10 -- Furnace Pressure and Drain Tubing Diagram

10. Reassemble inducer assembly by reversing items 3--7.Tighten the vent coupling clamp screw(s) to 15 in.--lb oftorque.

NOTE: If seal between the inducer housing and the collector boxis damaged in any way, it must be repaired. To repair, apply sealantreleasing agent such as PAM cooking spray or equivalent (must notcontain corn nor canola oil, halogenated hydrocarbons noraromatic content, to prevent inadequate seal from occurring) toinducer housing. (See Fig. 12.) Apply a small bead of G.E. RTV162, G.E. RTV 6702, or Dow--Corning RTV 738 sealant to groovein collector box.11. Refer to furnace wiring diagram and reconnect wires to

inducer motor and pressure switches or connectors.12. Reconnect pressure tubes to pressure switches. See diagram

on main furnace door for proper location of tubes. Be suretubes 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, andcondensate trap to ensure no condensate leaks occur. If leaksare found, correct the problem.

15. Check for gas leaks.



Never test for gas leaks with an open flame. Use acommercially available soap solution made specifically forthe detection of leaks to check all connections.

! WARNING

16. Replace main furnace door.

Step 6 — Servicing Hot Surface IgniterThe igniter does NOT require annual inspection. Check igniterresistance before removal.

1. Turn off gas and electrical supplies to furnace.

BURN HAZARD

Failure to follow this caution may result in personal injury.

Allow igniter to cool before removal. Normal operatingtemperatures exceed 2000_F (1093_C).

CAUTION!

350AAV

10

2. Remove main furnace door.3. Disconnect igniter wire connection.4. Check igniter resistance. Igniter resistance is affected bytemperature. Only check resistance when the igniter is atroom temperature.a. Using an ohm meter, check resistance across both ig-niter leads in connector.

b. Cold reading should be between 40 ohms and 70 ohms.5. Remove igniter assembly.

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 securingthe igniter bracket to the burner box bracket (See Fig.13.) and carefully withdraw the igniter and bracket as-sembly through the front of the burner box withoutstriking the igniter on surrounding parts. Note that theigniter bracket has a handle that extends to the front ofthe burner box to aid in handling. (See Fig. 13.)

d. Inspect igniter for signs of damage or failure.

��BURNER FLAME

BURNER

MANIFOLD

A89020

Fig. 11 -- Burner Flame

RTV

PAM

A93081

Fig. 12 -- Gasket on Collector Box

BRACKET

IGNITER

9/16˝

11/16˝

EXTENDED IGNITERBRACKET HANDLE

IGNITER BRACKETMOUNTING SCREW

A05075

Fig. 13 -- Igniter Bracket

UNIT DAMAGE HAZARD

Failure to follow this caution may result in prematurefailure of the igniter.

The igniter is fragile. DO NOT allow it to hit burner boxparts while removing or replacing it.

CAUTION!

e. If replacement is required, replace igniter on igniterbracket and then install assembly into burner box toavoid damage to the igniter.

6. To replace igniter and bracket assembly, reverse items 5athrough 5c.

7. Reconnect igniter wire connection and insert the igniterwires in the slot in the manifold grommet, dressing theigniter wires to ensure there is no tension on the igniteritself. (See Fig.7.)

2-5/32˝(55 mm)

A04181

Fig. 14 -- Burner Flame



Igniter wires must be securely placed in slot in manifoldgrommet or else they could become pinched or severed andelectrically shorted.

! WARNING

350AAV

11

115-V FIELD-SUPPLIED

DISCONNECT

AUXILIARYJ-BOX

24-VTERMINAL

BLOCK

THREE-WIREHEATING-ONLY

FIVE WIRE

NOTE 1

NOTE 2FIELD-SUPPLIEDDISCONNECT

CONDENSINGUNIT

TWOWIRE

FURNACE

CONTROL

R

G

COM

W C R G Y

GND

GND

FIELD 24-V WIRINGFIELD 115-, 208/230-, 460-V WIRINGFACTORY 24-V WIRINGFACTORY 115-V WIRING

208/230- OR460-VTHREEPHASE

208/230-VSINGLEPHASE

BLOWER DOOR SWITCH

WHT

BLK

WHT

BLK

NOTES: Connect Y-terminal in furnace as shown for proper blower operation.Some thermostats require a "C" terminal connection as shown.If any of the original wire, as supplied, must be replaced, usesame type or equivalent wire.

W

Y/Y2

GND

THERMOSTATTERMINALS

1.2.3.

A99440

Fig. 15 -- Field Wiring

8. Reinstall burner box cover.9. Turn on gas and electrical supplies to furnace.10. Verify igniter operation by initiating control board self--test

feature or by cycling thermostat.11. Replace main furnace door.

Step 7 — Electrical Controls and Wiring



There may be more than one electrical supply to the unit.Check accessories and cooling unit for additional electricalsupplies.

! WARNING

The electrical ground and polarity for 115--v wiring must bemaintained properly. Refer to Fig. 15 for field wiring informationand to Fig. 21 for unit wiring information.NOTE: If the polarity is not correct or furnace is not properlygrounded, the STATUS LED on the furnace control will flashrapidly and prevent the furnace from operating. The control systemalso requires an earth ground for proper operation of the furnacecontrol and flame sensor.

The 24--v circuit contains an automotive--type, 3--amp fuse locatedon the furnace control. (See Fig. 16.) Any direct shorts of the 24--v

wiring during installation, service, or maintenance will cause thisfuse to blow. If fuse replacement is required, use ONLY a fuse ofidentical size. The furnace control LED will flash status code 24when fuse needs to be replaced.With power to the unit disconnected, check all electricalconnections for tightness. Tighten all screws on electricalconnections. If any smoky or burned connections are found,disassemble the connection, clean all parts, strip wire, andreassemble properly and securely.Reconnect electrical supply to unit and observe unit through 1complete operating cycle and check for proper operation.

Step 8 — Checking Heat Tape Operation(If Applicable)In applications where the ambient temperature around the furnaceis 32_F (0_C) or lower, freeze protection measures are required. Ifthis application is where heat tape has been applied, check toensure it will operate when low temperatures are present.NOTE: Heat tape, when used, should be wrapped around thecondensate drain trap and drain line. There is no need to use heattape within the furnace casing. Most heat tapes are temperatureactivated, and it is not practical to verify the actual heating of thetape. Check the following:

1. Check for signs of physical damage to heat tape such asnicks, cuts, abrasions, gnawing by animals, etc.

2. Check for discolored heat tape insulation. If any damage ordiscolored insulation is evident, replace heat tape.

3. Check that heat tape power supply circuit is on.

350AAV

12

BLW

NU

ET

RA

LS

TATU

S C

OD

E LE

D

SEC-2 SEC-1

EAC-2 L2

FUSE 3-AMP

0.5 AMP@24VAC

HUM

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Y1 D

HU

M G

CO

M W

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/Y2 R

24V

PLT

120 180

90 150

BLOWER OFF-DELAY

PLT

1

CO

OL H

EAT

SPARE-1 SPARE-2FAN

EAC-1

1-AMP@

115VAC PR-1

L1

PL2 1

24-V THERMOSTATTERMINALS

3-AMP FUSE

LED OPERATION &DIAGNOSTIC LIGHT

115-VAC(L2)NEUTRALCONNECTIONS

COOLHEAT

SPARE-1

SPARE-2 FANBLOWER SPEED

SELECTION TERMINALS

EAC-1 TERMINAL(115-VAC 1.0 AMP MAX.)

115 VAC (L1) LINEVOLTAGE CONNECTION

PL2-HOT SURFACEIGNITER & INDUCERMOTOR CONNECTOR

PL1-LOW VOLTAGE MAINHARNESS CONNECTOR

TRANSFORMER 24-VACCONNECTIONS

HUMIDIFIER TERMINAL(24-VAC 0.5 AMP MAX.)

TWINNING AND/ORCOMPONENT TEST

TERMINALBLOWER OFF-DELAY

A02142

Fig. 16 -- Control Center

UNIT AND PROPERTY DAMAGE

Failure to follow this caution may result in furnacecomponent failures or water property damage.

If this furnace is to be operated in an unconditioned spacewhere the ambient temperatures may be 32_F (0_C)orlower, freeze protection measures must be taken. SeeCONDENSATE DRAIN PROTECTION section ofInstallation, Start--up, and Operating Instructions. (See Fig.17.)

CAUTION!

Step 9 —Winterizing

UNIT DAMAGE HAZARD


Freezing condensate left in the furnace may damage thefurnace.

CAUTION!

If the furnace will be off for an extended period of time in astructure 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 upper inducer housing drain connection capfrom inducer housing. (See Fig. 18.)

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

5. Insert funnel in tube and pour one quart of antifreeze,propylene glycol (RV, swimming pool antifreeze, orequivalent) into funnel/tube until it is visible at point wherecondensate enters open drain. (See Fig. 19.)

UNIT DAMAGE HAZARD

Failure to follow this caution may result in unit componentdamage.

Do not use ethylene glycol (Prestone II antifreeze/coolant orequivalent automotive type).

CAUTION!

6. Replace drain connection cap and clamp to inducer housing.7. Replace main furnace door.8. Propylene glycol need not be removed before restartingfurnace.

350AAV

13

A07911

Fig. 17 -- Freeze Protection

WIRING DIAGRAMSSee Fig. 15, 16 and 21 for the Deluxe 4--Way Multipoise Furnacewiring diagrams.

TROUBLESHOOTINGUse the troubleshooting guide, the status code LED on the furnacecontrol and the component test to isolate furnace operationproblems.STATUS CODESFor an explanation of status codes, refer to service label located onback of main furnace door or Fig. 20 and the TroubleshootingGuide. The stored status code will NOT be erased from the controlmemory if 115-- or 24--v power is interrupted.NOTE: Removing the blower access door will open the bloweraccess door switch and terminate 115--v power to the control.To read current status code, remove main furnace door. The statuscode LED can be viewed through the sight glass on the bloweraccess door.NOTE: NO thermostat signals may be present at control and allblower off delays must be completed to view previous codes.

UNIT DAMAGE HAZARD

Failure to follow this caution may result in damage to unitcomponents.

Make sure limit switch or flame rollout switch wire doesnot contact any metal component, such as gas valve. If wireis shorted, 3--amp fuse on furnace control board will openand unit will not operate.

CAUTION!

To retrieve previous codes, remove 1 of the red main limit or flamerollout switch wires for 1 to 4 sec until the LED light goes out,then reconnect it. (Do not leave red wire disconnected for longerperiods of time as the control will assume an overtemperaturecondition exists and will respond with blower operation.) Thisplaces the control in the status recall mode and displays the lastcode stored in memory.Record the code. After the last code is displayed the control willperform the component test, and then return to normal standbymode.

COMPONENT TEST

ELECTRICAL SHOCK AND UNIT MAY NOTOPERATE HAZARD

Failure to follow this warning could result in electrical shock,personal injury, or death.

Blower access panel door switch opens 115--v power tocontrol board. No component operation can occur. Cautionmust be taken when manually closing this switch for servicepurposes.

! WARNING

Use the Component Test to check furnace components for properoperation. To initiate the component self--test sequence, shut off theroom thermostat or disconnect the “R” thermostat lead. Briefly(approximately 2 sec) short the TWIN/TEST terminal to the COM24V terminal. The status LED will turn off. The test sequence willbe as follows:

1. LED flashes last status code, or code 11, 4 times. Recordthis status code for further troubleshooting.

2. The inducer will start and continue to run until test is over.3. Hot surface igniter (HSI) is energized for 15 sec, thende--energized.

4. Blower operates on continuous FAN speed for 10 sec, thenturns off.

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

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

7. Inducer turns off.8. The gas valve and humidifier terminal HUM are notenergized for safety reasons.

350AAV

14

A99118

Fig. 18 -- Inducer Housing Drain TubeA99119

Fig. 19 -- Funnel in Drain Tube and AntifreezeRunning Through Trap

350AAV

15

SERVICE

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

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

refer to twinning kit instructions.

LED CODE

EACH OF THE FOLLOWING STATUS CODES IS A TWO DIGIT NUMBER WITH THE FIRSTDIGIT DETERMINED BY THE NUMBER OF SHORT FLASHES AND THE SECOND DIGIT BYTHE NUMBER OF LONG FLASHES.

STATUS

11 NO PREVIOUS CODE - Stored status code is erased automatically after 72hours. On RED LED boards stored status codes can also be erased when power(115 VAC or 24 VAC) to control is interrupted.

12 BLOWER ON AFTER POWER UP (115 VAC or 24 VAC) -Blower runs for 90seconds, if unit is powered up during a call for heat (R-W closed) or R-W opensduring blower on-delay.

13 LIMIT CIRCUIT LOCKOUT - Lockout occurs if the limit or flame rollout switch isopen longer than 3 minutes.- Control will auto reset after three hours. - Refer to #33.

14 IGNITION LOCKOUT - Control will auto-reset after three hours. Refer to #34.21 GAS HEATING LOCKOUT - Control will NOT auto reset.

Check for: - Mis-wired gas valve -Defective control (valve relay)22 ABNORMAL FLAME-PROVING SIGNAL - Flame is proved while gas valve is

de-energized. Inducer will run until fault is cleared. Check for:- Leaky gas valve - Stuck-open gas valve

23 PRESSURE SWITCH DID NOT OPEN Check for:- Obstructed pressure tubing. - Pressure switch stuck closed.

24 SECONDARY VOLTAGE FUSE IS OPEN Check for:- Short circuit in secondary voltage (24VAC) wiring.

31 PRESSURE SWITCH DID NOT CLOSE OR REOPENED - If open longer thanfive minutes, inducer shuts off for 15 minutes before retry. Check for:- Excessive wind - Proper vent sizing - Defective inducer motor- Low inducer voltage (115VAC) - Defective pressure switch- Inadequate combustion air supply - Restricted vent- Disconnected or obstructed pressure tubing- Low inlet gas pressure (if LGPS used)If it opens during blower on-delay period, blower will come on for the selectedblower off-delay.

33 LIMIT CIRCUIT FAULT - Indicates a limit, or flame rollout is open. Blower willrun for 4 minutes or until open switch remakes whichever is longer. If openlonger than 3 minutes, code changes to lockout #13. If open less than 3 minutesstatus code #33 continues to flash until blower shuts off. Flame rollout switchrequires manual reset. Check for: - Restricted vent- Proper vent sizing - Loose blower wheel - Excessive wind- Dirty filter or restricted duct system.- Defective blower motor or capacitor. - Defective switch or connections.- Inadequate combustion air supply (Flame Roll-out Switch open).

34 IGNITION PROVING FAILURE - Control will try three more times before lockout#14 occurs. If flame signal lost during blower on-delay period, blower will comeon for the selected blower off-delay. Check for: - Control ground continuity- Flame sensor must not be grounded- Oxide buildup on flame sensor (clean with fine steel wool).- Proper flame sense microamps (.5 microamps D.C. min., 4.0 - 6.0 nominal).- Gas valve defective or gas valve turned off - Manual valve shut-off- Defective Hot Surface Ignitor

- Low inlet gas pressure- Inadequate flame carryover or rough ignition- Green/Yellow wire MUST be connected to furnace sheet metal

45 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.

If status code recall is needed, briefly remove then reconnect one main limit wire to displaystored status code. On RED LED boards do not remove power or blower door before initiat-ing status code recall. After one status code recall is completed component test will occur.

COMPONENT TEST

327884-101 REV. B

A02270

Fig. 20 -- Service Label

350AAV

16

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r ave

rage

con

ditio

ns, s

ee in

stal

latio

n in

stru

ctio

ns fo

r det

ails

on

optim

um s

peed

sel

ectio

n.10

.YE

LLO

W le

ad n

ot o

n al

l mot

ors.

11.

Fact

ory

conn

ecte

d w

hen

LGPS

is n

ot u

sed.

12.

Igni

tion-

lock

out w

ill oc

cur a

fter f

our c

onse

cutiv

e un

succ

essf

ul tr

ials

-for-i

gniti

on. C

ontro

l will

auto

-rese

t afte

r thr

ee h

ours

.13

.Bl

ower

-on

dela

y: g

as h

eatin

g 60

sec

onds

, coo

ling

or h

eat p

ump

2 se

cond

s.14

.Bl

ower

-off

dela

y: g

as h

eatin

g se

lect

ions

are

90,

120

, 150

or 1

80 s

econ

ds, c

oolin

g or

hea

t pum

p90

sec

onds

or 5

sec

onds

whe

n de

hum

idify

cal

l is

activ

e.

NO

TE #

10

PRINTED CIRCIUT BOARD

PRINTED CIRCIUT BOARD

NO

TE #

5

A02157

Fig. 21 -- Wiring Diagram

350AAV

17

Is L

ED

sta

tus

light

on?

Is L

ED

sta

tus

light

blin

king

rap

idly

with

out a

paus

e?

Is L

ED

sta

tus

light

blin

king

ON

/OF

F s

low

lyw

ith a

com

bina

tion

of s

hort

and

long

flas

hes?

Det

erm

ine

stat

us c

ode.

The

sta

tus

code

is a

2 di

git n

umbe

r w

ith th

e fir

st d

igit

dete

rmin

edby

the

num

ber o

f sho

rt fl

ashe

s an

d th

e se

cond

digi

t by

the

num

ber

of lo

ng fl

ashe

s?

Go

to s

ectio

n be

low

for

the

stat

us c

ode

that

was

flas

hed.

Is th

ere

115V

at L

1 an

d L2

?

Is th

ere

24V

at S

EC

-1 a

nd S

EC

-2?

Rep

lace

furn

ace

cont

rol.

Che

ck fo

r co

rrec

t lin

e vo

ltage

pol

arity

and

gro

und-

ing.

If u

nits

are

twin

ned,

che

ck fo

r pr

oper

low

-

volta

ge (

24V

) tr

ansf

orm

er p

hasi

ng.

To r

ecal

l sta

tus

code

brie

fly r

emov

e an

d re

conn

ect o

ne R

ED

wire

from

the

Lim

itS

witc

h or

Fla

me

Rol

lout

sw

itch

to d

ispl

ay s

tore

d st

atus

cod

e. O

n R

ED

LE

Dco

ntro

l do

not r

emov

e po

wer

or

blow

er a

cces

s pa

nel b

efor

e in

itiat

ing

stat

usco

de re

call.

You

can

als

o re

call

the

prev

ious

sta

tus

code

by

mom

enta

rily

shor

ting

the

TE

ST

/TW

IN te

rmin

al to

Com

24V

term

inal

unt

il th

e LE

D g

oes

out.

LE

D w

illfla

sh th

e pr

evio

us s

tatu

s co

de o

r st

atus

cod

e #1

1 (1

sho

rt a

nd 1

long

flas

h) if

ther

e w

as n

o pr

evio

us c

ode.

Afte

r th

e co

ntro

l rep

eats

the

code

4 ti

mes

, the

cont

rol w

ill g

o th

roug

h a

brie

f com

pone

nt te

st s

eque

nce.

The

indu

cer

will

sta

rtan

d ru

n fo

r th

e en

tire

com

pone

nt te

st.

The

HS

I, bl

ower

mot

or F

AN

spe

ed(A

MB

ER

LE

D b

oard

s on

ly)

HE

AT s

peed

, and

CO

OL

spee

d w

ill r

un fo

r 10

– 1

5se

cond

s ea

ch.

Gas

val

ve a

nd h

umid

ifier

will

not

be

turn

ed o

n.

Was

ther

e a

prev

ious

sta

tus

code

othe

r th

an #

11?

Is d

oor

switc

h cl

osed

?

Is th

ere

115V

goi

ng to

sw

itch?

Rep

lace

doo

r sw

itch.

Rep

lace

tran

sfor

mer

.

Doe

s th

e co

ntro

l res

pond

to W

, Y1

(if p

rese

nt),

Y/Y

2, a

nd G

(24

V)

ther

mos

tat s

igna

ls?

Run

sys

tem

thro

ugh

a he

atin

g or

coo

ling

cycl

eto

che

ck o

pera

tion.

Sta

tus

code

s ar

e er

ased

afte

r 72

hou

rs.

On

RE

D L

ED

boa

rds

stor

edst

atus

cod

es c

an a

lso

be e

rase

d w

hene

ver

(115

V o

r 24

V)

is in

terr

upte

d.

Rep

lace

furn

ace

cont

rol.

Clo

se d

oor

switc

h an

d go

bac

k to

STA

RT.

Is c

ircui

t bre

aker

clo

sed?

Che

ck fo

r con

tinui

ty in

wire

from

circ

uit b

reak

erto

furn

ace.

Clo

se c

ircui

t bre

aker

and

go

back

to S

TAR

T.

Che

ck r

oom

ther

mos

tat o

rin

terc

onne

ctin

g ca

ble.

Is 2

4V p

rese

nt a

t W, Y

1 (if

pre

sent

), Y

/Y2

orG

ther

mos

tat t

erm

inal

s on

the

furn

ace

cont

rol?

Dis

conn

ect a

ll th

e th

erm

osta

t wire

s fr

om th

efu

rnac

e co

ntro

l.

Doe

s th

e pr

oble

m r

epea

t whe

n us

ing

a ju

mpe

r w

ire?

The

ther

mos

tat i

s no

t com

patib

le w

ith th

efu

rnac

e co

ntro

l. E

ither

inst

all a

bal

last

resi

stor

,co

nnec

t the

Com

24V

ther

mos

tat t

erm

inal

toth

e th

erm

osta

t, or

rep

lace

the

ther

mos

tat.

NO

YE

S

YE

S

NO

NO

YE

S

YE

S

YE

S

YE

S

NO

YE

S

YE

S

NO

YE

S

NO

YE

S

NO

NO

NO Y

ES

NO YE

S

NO

STA

RT

TR

OU

BLE

SH

OO

TIN

G G

UID

E

NO

A05107

350AAV

18

11N

O P

RE

VIO

US

CO

DE

– S

tore

d co

des

are

eras

ed a

fter 7

2 ho

urs.

On

RE

D L

ED

boar

ds s

tore

d st

atus

cod

es c

an a

lso

beer

ased

whe

neve

r po

wer

(11

5V o

r 24

V)

is in

terr

upte

d. R

un s

yste

m th

roug

h a

heat

ing

or c

oolin

g cy

cle

to c

heck

sys

tem

.

12B

LOW

ER

ON

AF

TE

R P

OW

ER

UP

–(1

15V

OR

24V

) –

Nor

mal

ope

ratio

n.B

low

er r

uns

for

90 s

econ

ds, i

f uni

t is

pow

ered

up

durin

g a

call

for

heat

(R

-Wcl

osed

) or

whe

n (R

-W o

pens

) du

ring

the

blow

er o

n-de

lay

perio

d.

13LI

MIT

CIR

CU

IT L

OC

KO

UT

– L

ocko

utoc

curs

if th

e lim

it or

flam

e ro

llout

sw

itch

isop

en lo

nger

than

3 m

inut

es.

Con

trol w

illau

to-r

eset

afte

r 3 h

ours

. S

ee c

ode

33.

14IG

NIT

ION

LO

CK

OU

T –

Sys

tem

faile

d to

igni

te g

as a

nd p

rove

flam

e in

4 a

ttem

pts.

Con

trol

will

aut

o-re

set a

fter

3 ho

urs.

See

sta

tus

code

34.

21G

AS

HE

ATIN

G L

OC

KO

UT

– T

urn

off

pow

er a

nd w

ait 5

min

utes

to r

etry

.C

heck

for:

-S

tuck

clo

sed

gas

valv

e re

lay

on c

ontro

l.-

Mis

wire

or

shor

t to

gas

valv

e w

ire.

22A

BN

OR

MA

L F

LAM

E-P

RO

VIN

G S

IGN

AL

Fla

me

is p

rove

d w

hile

gas

val

ve is

de-

ener

gize

d. I

nduc

er w

ill r

un u

ntil

faul

t is

clea

red.

Che

ck fo

r:-

Stu

ck o

pen

or le

aky

gas

valv

e.

23P

RE

SS

UR

E S

WIT

CH

DID

NO

T O

PE

NC

heck

for:

-O

bstr

ucte

d pr

essu

re tu

be.

-P

ress

ure

switc

h st

uck

clos

ed.

24S

EC

ON

DA

RY

VO

LTA

GE

FU

SE

IS O

PE

NC

heck

for:

-S

hort

circ

uit i

n se

cond

ary

volta

ge (2

4V)

wiri

ng in

clud

ing

ther

mos

tat l

eads

.D

isco

nnec

t the

rmos

tat l

eads

to is

olat

esh

ort c

ircui

t.

31P

RE

SS

UR

E S

WIT

CH

DID

NO

T C

LOS

EO

R R

EO

PE

NE

D –

If o

pen

long

er th

an 5

min

utes

, ind

ucer

shu

ts o

ff fo

r 15

min

utes

befo

re r

etry

. If

open

s du

ring

blow

er o

n-de

lay

perio

d, b

low

er w

ill c

ome

on fo

r th

ese

lect

ed b

low

er o

ff-de

lay.

Che

ck fo

r:-

Pro

per

vent

siz

ing.

-Lo

w in

duce

r vo

ltage

(11

5V).

-Lo

w in

let g

as p

ress

ure

(if L

GP

S u

sed)

.-

Inad

equa

te c

ombu

stio

n ai

r su

pply

.-

Dis

conn

ecte

d or

obs

truc

ted

pres

sure

tubi

ng.

-D

efec

tive

indu

cer

mot

or.

-D

efec

tive

pres

sure

sw

itch.

-E

xces

sive

win

d.-

Res

tric

ted

vent

.

33LI

MIT

CIR

CU

IT F

AU

LT –

Indi

cate

s th

elim

it or

flam

e ro

llout

sw

itch

is o

pen.

Blo

wer

will

run

for 4

min

utes

or u

ntil

open

sw

itch

rem

akes

whi

chev

er is

long

er.

If op

enlo

nger

than

3 m

inut

es, c

ode

chan

ges

tolo

ckou

t #13

. If

open

less

than

3 m

in.

stat

us c

ode

#33

cont

inue

s to

flas

h un

tilbl

ower

shu

ts o

ff. F

lam

e ro

llout

sw

itch

requ

ires

man

ual r

eset

. C

heck

for:

-D

irty

filte

r or

res

tric

ted

duct

sys

tem

.-

Loos

e bl

ower

whe

el.

-D

efec

tive

switc

h or

con

nect

ions

.-

Def

ectiv

e bl

ower

mot

or o

r ca

paci

tor.

-In

adeq

uate

com

bust

ion

air

supp

ly(f

lam

e ro

llout

sw

itch

open

).-

Res

tric

ted

vent

.-

Pro

per

vent

siz

ing.

-E

xces

sive

win

d.-

Blo

wer

mot

or o

n in

corr

ect s

peed

tap.

- In

put r

ate

to fu

rnac

e se

t too

hig

h.

34IG

NIT

ION

PR

OV

ING

FA

ILU

RE

– If

flam

eis

not

sen

sed

durin

g th

e tr

ial f

or ig

nitio

npe

riod,

the

cont

rol w

ill r

epea

t the

igni

tion

sequ

ence

3 m

ore

times

bef

ore

lock

out

#14

occu

rs.

If fla

me

sign

al is

lost

dur

ing

the

blow

er o

n-de

lay

perio

d, b

low

er w

illco

me

on fo

r the

sel

ecte

d bl

ower

off-

dela

y. C

heck

the

follo

win

g ite

ms

first

bef

ore

proc

eedi

ng to

the

next

ste

p.-

Gas

val

ve tu

rned

off.

-M

anua

l shu

t-of

f val

ve.

-G

reen

/Yel

low

wire

MU

ST

be

conn

ecte

dto

furn

ace

shee

t met

al.

-F

lam

e se

nsor

mus

t not

be

grou

nded

.To

det

erm

ine

whe

ther

the

prob

lem

is in

the

gas

valv

e, ig

nite

r, or

flam

e se

nsor

the

syst

em c

an b

e op

erat

ed in

the

com

pone

ntte

st m

ode

to c

heck

the

igni

ter.

Firs

tre

mov

e th

e R

ther

mos

tat c

onne

ctio

n fro

mth

e co

ntro

l and

initi

ate

the

com

pone

ntte

st s

eque

nce.

Doe

s th

e ig

nite

r gl

owor

ange

/whi

te b

y th

e en

d of

the

15 s

econ

dw

arm

-up

perio

d?

Unp

lug

igni

ter h

arne

ss fr

om c

ontro

l and

initi

ate

anot

her

com

pone

nt te

st s

eque

nce.

Che

ckfo

r 115

V b

etw

een

pin

1 an

d N

EU

TR

AL-

L2 o

nth

e co

ntro

l. W

as 1

15V

pre

sent

for

the

15se

cond

per

iod?

Rec

onne

ct th

e R

ther

mos

tat l

ead

and

set

ther

mos

tat t

o ca

ll fo

r hea

t. C

onne

ct v

oltm

eter

acro

ss g

as v

alve

con

nect

ions

. D

oes

gas

valv

ere

ceiv

e 24

V?

Doe

s ga

s va

lve

open

and

allo

w g

as to

flow

?

Do

the

mai

n bu

rner

s ig

nite

?

Do

the

mai

n bu

rner

s st

ay o

n?

Rep

eat c

all f

or h

eat a

nd c

heck

flam

e se

nsor

curr

ent d

urin

g tr

ial f

or ig

nitio

n pe

riod.

Is

the

DC

mic

roam

ps b

elow

0.5

?

Is c

urre

nt n

ear

typi

cal v

alue

?

Will

mai

n bu

rner

s ig

nite

and

sta

y on

?

Fix

ed.

Cle

an fl

ame

sens

or w

ith fi

ne s

teel

woo

l and

rech

eck

curr

ent.

Nom

inal

cur

rent

is 4

.0 to

6.0

mic

roam

ps.

45C

ON

TR

OL

CIR

CU

ITR

Y L

OC

KO

UT

Aut

o-re

set a

fter

1 ho

ur lo

ckou

t due

to:

-F

lam

e ci

rcui

t fai

lure

.-

Gas

val

ve r

elay

stu

ck o

pen.

-S

oftw

are

chec

k er

ror.

Res

et p

ower

to c

lear

lock

out.

Rep

lace

cont

rol i

f cod

e re

peat

s.

Rep

lace

furn

ace

cont

rol.

Che

ck fo

r con

tinui

ty in

the

harn

ess

and

igni

ter.

Rep

lace

def

ectiv

e co

mpo

nent

.

Che

ck c

onne

ctio

ns.

If O

K, r

epla

ce c

ontr

ol.

Che

ck th

at a

ll ga

s va

lves

are

turn

ed o

n.R

epla

ce v

alve

.

Che

ck fo

r:-

Inad

equa

te fl

ame

carr

yove

r or

rou

ghig

nitio

n.-

Low

inle

t gas

pre

ssur

e.-

Pro

per

firin

g ra

te.

Allo

w b

low

er to

com

e on

and

rep

eat t

est t

och

eck

for

inte

rmitt

ent o

pera

tion.

Che

ck c

onne

ctio

ns a

nd r

etry

. If

curr

ent i

sne

ar ty

pica

l val

ue (

4.0-

6.0

nom

inal

) an

dbu

rner

s w

ill n

ot s

tay

on, r

epla

ce c

ontr

ol.

Rep

lace

ele

ctro

de.

Rep

lace

furn

ace

cont

rol.

YE

S

YE

S

YE

S

YE

S

NO

YE

S

YE

S

YE

S

NO

YE

S

NO

NO

NO

YE

S

NO

NO

NO

NO

A05096

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

E2009 Bryant Heating & Cooling Systems D 7310 W. Morris St. D Indianapolis, IN 46231 Printed in U.S.A. Edition Date: 09/09

Replaces: SM350AAV---01

Catalog No. SM350AAV---02

350AAV

service and maintenance instructions for sizes 040--120 ...€¦ · fig. 1 -- furnace in upflow...

Documents