Bryant Plus 80, 330AAV, 331AAV Manual

WELCOME TO TODAY'S GENERATION OF COMFORT

Your new, high efficiency gas furnace is a sound investment which will reward you and your family with years of warm memories winter after winter. Not only is your new furnace energy ef- ficient, it is also extremely reliable and supplies superior home comfort. Spend just a few minutes with this booklet to learn about the operation of your new furnace and the small amount of maintenance it takes to keep it operating at peak efficiency. Years went into the development of your new furnace. Take a little time now to assure its most efficient operation for years to come.

UPFLOW FURNACE COMPONENTS

1. Relief Box
2. Gas Valve Control Knob (On/Off)
3. 2-Stage Gas Valve
4. Gas Burner
5. Hot Surface Ignitor
6. Blower Door Safety Switch
7. Blower and Blower Motor
8. Draft Safeguard Tube and Switch
9. Rating Plate

10. Gas Manifold
11. Filter Retainer
12. Air Filter
13. Flame Sensor
14. Manual Reset Flame Rollout Switch
15. Status LED Light

4. Remove the furnace access door(s).
   1. Downflow/Horizontal—Re-move blower door after removing 2 screws first, then remove the control door. (See Fig. 10.)
      
   2. Upflow—Remove control door. (See Fig. 11.)
      
5. Turn the control knob on the gas valve to the OFF position and wait 5 minutes. (See Fig. 12.)
   
6. After waiting 5 minutes, turn the control knob on the gas valve to the ON position. (See Fig. 13.)
   
7. Replace the access door(s). See Fig. 14 for upflow and Fig. 15 for downflow. Replace control door first on downflow furnaces. Replace blower door and secure with 2 screws.
   
8. Turn on electrical supply to the furnace. (See Fig. 16.)
   
9. Open the external manual gas valve. (See Fig. 17.)
   
10. Set the room thermostat to a temperature slightly above the room temperature. This will automatically signal the furnace to start. The inducer motor will start, and the hot surface ignitor will energize. When hot, the ignitor will have an orange glow.
11. After 15 to 70 sec, the gas valve permits gas to flow to the main burners where it is ignited. Hot flames begin to warm the furnace's heat exchanger. After a time delay of approximately 45 sec, the furnace blower is switched on.
    NOTE: If the main burners fail to ignite, the furnace control system will go through 3 more ignition cycles. If burners still fail to ignite, the system will lockout. (Under some circumstances the furnace may reset from lockout and attempt to ignite if a call for heat still exists.) If lockout occurs or the blower does not come on, refer to the shutdown procedures on the furnace or see "Shutting Down Your Furnace" section in this manual, and call your dealer for service.
12. Set your thermostat to the temperature that satisfies your comfort requirements. SUGGESTION: Setting the thermostat back a few degrees and compensating for the difference with warmer clothing can make a big difference in your fuel consumption. The few degrees at the top of your thermostat "comfort level'' are the most costly degrees to obtain.

When the room temperature drops below the temperature selected on the thermostat, the furnace will switch on automatically. When the room temperature reaches the setting selected on the thermostat, the furnace will automatically switch off.
Some thermostats have a "FAN'' switch with 2 selections, AUTO and ON. When thermostat is set to AUTO, the furnace blower cycles on and off, controlled by the thermostat. In ON position, the furnace blower runs continuously except for a 77-sec delay at the "call for heat.'' This keeps the temperature level in your home more evenly balanced. It also continuously filters the indoor air. When FAN switch is moved from ON to AUTO, the furnace blower will continue running for 90 sec before stopping.

SHUTTING DOWN YOUR FURNACE

Should you ever suspect a malfunction in your furnace, you will need to turn the furnace off. The following procedures must be followed:

1. Set your room thermostat to the lowest temperature setting. (See Fig. 18.)
   
2. Close the external manual gas valve. (See Fig. 8.)
3. Turn off electrical power to your furnace. (See Fig. 19.)
   
4. Remove the control access door on your furnace. (See Fig. 10 or 11.) On upflow furnaces, removing the blower access door is not required.
5. Turn the control knob on the gas valve to the OFF position. (See Fig. 20.)
   
6. Replace the control access door. (See Fig. 14 or 15.)
7. If the furnace is being shut down because of a malfunction, call your dealer as soon as possible.

PERFORMING ROUTINE MAINTENANCE

With proper maintenance and care, your furnace will operate economically and dependably. Basic maintenance, which can easily be accomplished by someone who follows the directions, is found on this and the following pages. However, before beginning maintenance, follow these safety precautions:

Turn off electrical power supply to your furnace before removing the access doors to service or perform maintenance. A failure to follow this warning could result in personal injury or death.

Although special care has been taken to minimize sharp edges, be extremely careful when handling parts or reaching into the furnace.

FILTERING OUT TROUBLE

A dirty filter will cause excessive stress on the furnace blower motor and can cause it to overheat and automatically shut down. The furnace filter should be checked every 3 or 4 weeks and cleaned if necessary.
If your furnace filter needs replacing, be sure to use the same size and type of filter that was originally supplied. Use the Furnace Filter Table and match your furnace size with the proper filter size.

Never operate your furnace without a filter in place. Doing so may damage the furnace blower motor. An accumulation of dust and lint on internal parts of your furnace can cause a loss of efficiency.
The air filter for upflow furnaces is normally located in the blower compartment. Filters for the downflow furnaces are normally located in the return-air plenum above the blower. If the filters have been installed in another location, contact your dealer for instructions. To inspect, clean and/or replace the air filter(s), follow these steps:

• UPFLOW FURNACES ONLY—

1. Turn off electrical supply to the furnace. (See Fig. 19.)
2. Remove control and blower access doors. (See Fig. 11.)
3. Push filter retainer toward the bracket opening to release the filter. (See Fig. 21.)
   
4. Gently remove the filter and carefully turn the dirty side up (if dirty) to avoid spilling dirt from the filter. (See Fig. 22.)
   
5. Inspect the filter. If torn, replace the filter.
6. Wash the filter (if dirty) in a sink, bathtub, or outside with a garden hose. Always use cold tap water. A mild liquid detergent may be used if necessary. Spray water through the filter in opposite direction of airflow through the cross-mesh binding (when present) side. Allow filter to dry.
7. Reinstall the clean filter with the cross-mesh binding (when present) side facing the furnace blower.
8. Put filter retainer back in the bracket opening and lock it in place.
9. Replace blower and control access doors and turn on electrical supply to the furnace. (See Fig. 23, 14, and 16.)
   

NOTE: For upflow models only—Two filters may be required in some models if side return ducts are used. The producedure listed above may be used to remove side filters.

DOWNFLOW/HORIZONTAL FURNACE FILTER TABLE (IN.)

*Filters are factory provided with the furnace. Filters may be field modified by cutting and folding the frame as indicated on the filter. Alternate sizes and additional filters may be ordered from your dealer.

COMBUSTION AREA AND VENT SYSTEM

Inspect the combustion area and vent system before each heating season. An accumulation of dirt, soot, or rust can mean a loss of efficiency and improper performance. Buildups on the main burners can cause faulty firing. This "delayed ignition'' is characterized by an alarmingly loud sound. If your furnace makes a loud noise when the main burners are ignited, shut down the furnace and call your servicing dealer.
Use your flashlight and follow these steps for inspecting the combustion area and vent system of your furnace:

1. Turn off the electrical supply to furnace and remove the access doors. (See Fig. 9, and 10 or 11.)
2. Carefully inspect the gas burner for dirt, rust, or scale. (See Fig. 26.) Inspect the relief box, flue connection area, and the vent pipe for rust.
   NOTE: If dirt, rust, soot, or scale accumulations are found, call your servicing dealer. DO NOT OPERATE THE FURNACE.
   
3. Inspect the vent pipe for a sag, holes, or a disconnection. A horizontal vent pipe must slope upward. If rusty joints or seams, or signs of water leakages are found, call your dealer for service.
   
   If holes are found or if the vent pipe is obstructed or is not connected, toxic fumes can escape into your home. DO NOT OPERATE YOUR FURNACE. Call your dealer for service. A failure to follow this warning could result in personal injury or death.
4. Replace the access doors and restore electrical supply to the furnace. Be sure bottom door flange is inside of the furnace casing. (See Fig. 14 and 15.)
5. Start the furnace and observe its operation. If possible, watch the burner flames. Are they burning bright blue? If not or if you suspect some other malfunction, call your servicing dealer.

BEFORE YOU REQUEST A "SERVICE CALL''

BEFORE YOU CALL FOR SERVICE, CHECK FOR SEVERAL EASILY SOLVED PROBLEMS:

• Check for sufficient airflow. Check the air filter for dirt. Check for blocked return-air or supply-air grilles. Be sure they are open and unobstructed. If this isn't the cause of the problem, call your servicing dealer.

If your furnace isn't operating at all, check the following list for easily solved problems:

• Is your thermostat set above room temperature? Is the switch in the HEAT position?
• Is the electrical power supply switch on? Is the blower access door firmly in place? Are any fuses blown? (There is a fuse on the furnace control.) Has a circuit breaker tripped?
• Is the manual shut-off valve in the gas supply pipe leading to the furnace open? Does the lever point in the same direction that the pipe runs (open)? Or is it at a right angle to the pipe (closed)?
  NOTE: Before proceeding with the next checks, turn off the electrical power supply to the furnace. Remove access doors.
• Is the control knob on the gas valve turned to the ON position? If this or the preceding check shows an interruption in the gas supply, make sure the gas has not been shut off for safety reasons. If nothing else seems to be wrong, follow the startup procedures found on pages 4 and 5 of this booklet.
• If for some reason the vent is blocked, the draft safeguard switch will shut off the furnace. Reset the switch by pushing the button located on top of the switch.
  If the switch trips a second time, turn off the furnace and call for service.

DOWNFLOW/HORIZONTAL ONLY—Check the manual reset auxiliary limit switch located on the blower housing. If the blower motor fails, this switch will shut off the furnace. Reset it by pushing the button on the switch. If it trips again, turn off the furnace and call for service.

• Check the manual reset flame roll-out switch(es) located near the burners. If the furnace has experienced a high-temperature condition due to inadequate combustion air, these switches will shut off the furnace. Reset the switch(es) by pushing the button on the switch. If the switch trips a second time, turn off the furnace and call for service.
• If your furnace still fails to operate, call your servicing dealer for troubleshooting and repairs. Tell your dealer the model and serial numbers for your furnace. (You should have them recorded of this booklet.) By knowing exactly which furnace you have, the dealer may be able to offer suggestions over the phone or save valuable time through knowledgeable preparation for the service call.
• Your furnace control board has an LED fault code light that indicates the furnace status. The LED will flash short and long flashes. Look through the sight glass on the furnace door and determine the code (number of short and long flashes). Give the code and furnace model number to your dealer when you call. By knowing exactly which furnace you have and the LED code being displayed, your dealer can save valuable time through knowledgeable preparation for the service call.

REGULAR DEALER MAINTENANCE

In addition to the type of routine maintenance you might be willing to do, your furnace should be inspected regularly by a properly trained service technician. A semiannual inspection (or annual inspection, at least) should include the following:

1. Inspection of all flue product passages including the burners, heat exchanger, relief box, and vent pipe.
2. Inspection of all combustion and ventilation air passages and openings.
3. Close check of all gas pipes leading to and inside of your furnace.
4. Inspection, cleaning, and lubrication (when required) of the blower motor and wheel.NOTE: Refer to the unit Service Procedures for blower motor oiling information. When required, the motor must be oiled by a qualified service technician.
5. Routine inspection and cleaning/replacement of the air filter.
6. Inspection of all supply- and return-air ducts for obstructions, air leaks, and insulation. Any problems found should be resolved at this time.
7. Inspect the return-air duct connection(s) at the furnace to ensure it is physically sound, sealed to the furnace casing, and terminates outside the space containing the furnace.
8. Inspection of furnace installation for proper support and any obvious deterioration of the furnace. The support must be sound and without sags, gaps, cracks, etc., around the furnace base so as to provide an air seal between the support and furnace.
9. A check for loose connections attaching individual components. Inspection of all electrical wiring and their connections.
10. Operational check of the furnace itself to determine working condition. Repair or adjustment should be made at this time.
    Ask your servicing dealer for further details about an economical service contract that covers seasonal inspections.

STARTING YOUR FURNACE

Instead of a continuously burning pilot flame, your furnace uses an automatic hot surface ignition system to light the burners each time the thermostat turns your furnace on. Follow these important safeguards:

• Never attempt to manually light the burners with a match or other source of flame.
  
• Read and follow the operating instructions on the furnace, especially the item that reads as follows:
  Wait 5 minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! Follow "B'' in the above safety information on this label. If you don't smell gas, go to the next step.
  
  Should overheating occur or the gas valves fail to shut off the gas supply, turn off the manual gas valve to the furnace BEFORE turning off the electrical supply. (See Fig. 8.) A failure to follow this warning could result in a fire or explosion, and personal injury or death.
• If a suspected malfunction occurs with your gas control system, such as the burners do not light when they should, refer to the shutdown procedures on the furnace or see "Shutting Down your Furnace" section in this manual, then call your dealer as soon as possible.

• Check Air Filter: Before attempting to start your furnace, be sure the furnace filter is clean and in place. (See the maintenance section of this manual.) Then proceed as follows: