Payne PG95 Installation, Start-Up, Operating And Service And Maintenance Instructions
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Payne PG95 Installation, Start-Up, Operating And Service And Maintenance Instructions

Single-stage 4-way multipoise condensing gas furnace
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PG95SAS
Installation, Start-up, Operating and
Service and Maintenance Instructions
NOTE: Read the entire instruction manual before starting the installation.
SECTIONS
INTRODUCTION
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ACCESSORIES
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LOCATION
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INSTALLATION
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VENTING
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PARTS REPLACEMENT GUIDE
Use of the AHRI Certified
manufacturer's participation in the program. For
verification of certification for individual products,
go to www.ahridirectory.org.
Portions of the text and tables are reprinted from current edition of
NFPA 54/ANSI Z223.1E, with permission of National Fire
Protection Association, Quincy, MA 02269 and American Gas
Association, Washington DC 20001. This reprinted material is not
the complete and official position of the NFPA or ANSI on the
referenced subject, which is represented only by the standard in its
entirety.
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CERTIFIED
Mark indicates a
TM
Single-Stage 4-Way Multipoise
Condensing Gas Furnace
3
MIN. CLEARANCES TO COMBUSTIBLE MATERIALS
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4
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5
FILTER SIZE INFORMATION
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8
AIR DELIVERY CFM
9
12
VENT TERM. KIT FOR DIRECT VENT (2−PIPE) SYSTEMS 39
16
Combustion−Air Vent Pipe, Fitting & Cement Material..
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Maximum Allowable Exposed Vent Lengths Insulation
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32
Blower Off Delay Setup Switch
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86
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Series A and B
TABLES
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  • Page 1: Table Of Contents

    PG95SAS Single-Stage 4-Way Multipoise Condensing Gas Furnace Series A and B Installation, Start-up, Operating and Service and Maintenance Instructions NOTE: Read the entire instruction manual before starting the installation. SECTIONS TABLES LOOSE PARTS BAG ....... . . SAFETY CONSIDERATIONS .
  • Page 2 Required Notice for Massachusetts Installations IMPORTANT The Commonwealth of Massachusetts requires compliance with regulation 248 CMR as follows: 5.08: Modifications to NFPA−54, Chapter 10 2) Revise 10.8.3 by adding the following additional requirements: a. For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:...

  • Page 3: Safety Considerations

    SAFETY CONSIDERATIONS CAUTION WARNING CUT HAZARD Failure to follow this caution may result in personal injury. FIRE, EXPLOSION, ELECTRICAL SHOCK, AND CARBON MONOXIDE POISONING HAZARD Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, safety glasses and Failure to follow this warning could result in dangerous gloves when handling parts, and servicing furnaces.

  • Page 4: Codes And Standards

    NOTE: 13. These furnaces SHALL NOT be installed directly on carpet- Remove all shipping materials, loose parts bag, and ing, combustible tile, or any other combustible material oth- literature before operating the furnace. See Table 1. er than wood flooring. In downflow installations, factory CODES AND STANDARDS accessory floor base MUST be used when installed on com- Follow all national and local codes and standards in addition...

  • Page 5: Electrostatic Discharge (Esd) Precautions

    S The use of copper tubing for gas piping is not approved by the 1. Disconnect all power to the furnace. Multiple disconnects may be required. DO NOT TOUCH THE CONTROL state of Massachusetts. OR ANY WIRE CONNECTED TO THE CONTROL Gas furnaces manufactured on or after May 1, 2017 are not PRIOR TO DISCHARGING YOUR BODY’S ELEC- permitted to be used in Canada for heating of buildings or...
  • Page 6 A12267 PG95SAS SHIP WT. LB (KG) FURNACE SIZE CABINET WIDTH OUTLET WIDTH BOTTOM INLET WIDTH AIR INTAKE 24026 118.0 (53.5) 14-3/16 (361) 12-1/2 (319) 12-9/16 (322) 7-1/8 (181) 30040 123.0 (55.4) 42060 144.0 (64.8) 17-1/2 (445) 15-7/8 (403) 16 (406) 8-3/4 (222) 48080 154.0 (69.3)
  • Page 7 THE BLOWER IS LOCATED BELOW THE BURNER SECTION, AND CONDITIONED AIR IS DISCHARGED UPWARD. THE BLOWER IS LOCATED TO THE RIGHT OF THE BURNER SECTION, AND CONDITIONED AIR IS DISCHARGED TO THE LEFT. THE BLOWER IS THE BLOWER IS LOCATED TO THE LEFT LOCATED ABOVE THE OF THE BURNER SECTION, BURNER SECTION, AND...
  • Page 8 LOCATION WARNING CAUTION CARBON MONOXIDE POISONING / COMPONENT DAMAGE HAZARD PERSONAL INJURY AND/OR PROPERTY Failure to follow this warning could result in personal injury DAMAGE HAZARD or death and unit component damage. Improper use or installation of this furnace may result in Corrosive or contaminated air may cause failure of parts premature furnace component failure.

  • Page 9: Air For Combustion And Ventilation

    CAUTION WARNING FIRE HAZARD FURNACE CORROSION HAZARD Failure to follow this warning could result in personal Failure to follow this caution may result in furnace damage. injury, death and/or property damage. Air for combustion must not be contaminated by halogen Do not install the furnace on its back or hang furnace with compounds, which include fluoride, chloride, bromide, and control compartment facing downward.
  • Page 10 The following requirements apply to the Standard Method and to The opening shall commence within 12 in. (300 mm) of the the Known Air Infiltration Rate Method. ceiling. Appliances in the space shall have clearances of at least 1 in. (25 mm) from the sides and back and 6 in. (150 mm) from the 1.

  • Page 11: Minimum Free Area Required

    Table 3 – Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors TWO OPENINGS OR TWO HORIZONTAL DUCTS SINGLE DUCT OR OPENING VERTICAL DUCTS (1 SQ. IN./2,000 BTUH) (1 SQ. IN./3,000 BTUH) (1 SQ. IN./4,000 BTUH) (1,100 SQ.

  • Page 12: Condensate Trap

    CONDENSATE TRAP NOTICE Condensate Trap − Upflow Orientation When the furnace is installed in the upflow position, it is not The field−supplied, accessory horizontal drain trap grommet is necessary to relocate the condensate trap or associated tubing. ONLY REQUIRED FOR DIRECT VENT APPLICATIONS. Refer to Fig.
  • Page 13 Remove pressure switch tube from front pressure switch and discard. A new tube is shipped in the loose parts bag. Remove relief tube from relief Remove tube from relief port. port on condensate trap. Remove the screw that secures the trap to the collector box and remove trap.
  • Page 14 Remove plug from If alternate vent position collector box. is required, loosen clamp DO NOT DISCARD. on inlet of vent elbow. Remove the screw that secures the trap to the collector box and remove trap. Unconverted Factory Configuration As Viewed in the Horizontal Right Orientation NOTE: Remove knockout in casing before re installing the condensate trap.
  • Page 15 Remove the screw that secures the condensate trap to the collector box If alternate vent position and remove trap. is required, loosen clamp on vent elbow inlet. Remove relief tube from relief port on condensate trap. Remove front pressure switch tube and discard. A new tube is shipped in the Loose Parts bag.

  • Page 16: Condensate Drain

    CONDENSATE DRAIN CONNECTION c. All condensate piping is at least 3/4-in. PVC and there is a relief tee at the top of condensate drain piping as shown CAUTION in Fig. 14. NOTE: On narrower casings, it may be easier to remove the condensate trap, connect the drain line components and re-install FROZEN AND BURST WATER PIPE HAZARD the condensate trap.
  • Page 17 6. From the outside of the casing, insert the angled end of the 2. To allow for servicing the trap, the condensate drain elbow Z-pipe through drain hole in the left side of the casing and in the loose parts bag can be used to make a coupler to behind the inducer or gas valve.
  • Page 18 Evaporator Coil + + + + = Positive pressure < + = Pressure lower than areas with + − = Negative pressure Condensing Furnace Blower creates positive pressure. Positive pressure extends into coil condensate drain (no trap). < + < + <...
  • Page 19 Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Evaporator Coil + + + Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä 3/4” PVC Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä...
  • Page 20 INSTALL CLAMPS ON DRAIN TUBE ATTACH ELBOW TO ATTACH DRAIN TUBE TO CONDENSATE FORMED END CONDENSATE TRAP DRAIN TRAP OF GROMMET CUT FORMED END OFF PULL DRAIN STUB CONDENSATE DRAIN THROUGH CASING ELBOW CONNECT SHORT END OF ’Z’ PIPE TO MODIFIED DRAIN ELBOW FACTORY SUPPLIED 1/2 IN.
  • Page 21 Return Air Connections 4. Install special base coil assembly or coil box as shown in Fig. 21. WARNING NOTE: It is recommended that the perforated supply−air duct flanges be completely removed from furnace when installing the furnace on a factory−supplied cased coil or coil box. To remove the FIRE HAZARD supply−air duct flange, use wide duct pliers or hand seamers to A failure to follow this warning could cause personal injury,...
  • Page 22 bottom return air is used. To remove bottom closure panel, see Fig. CAUTION 23 and 24. Side Return Air Inlet MINOR PROPERTY HAZARD These furnaces are shipped with bottom closure panel installed in bottom return−air opening. This panel MUST be in place when Failure to follow this caution may result in minor property side return air inlet(s) are used without a bottom return air inlet.
  • Page 23 TIPS FROM CONTRACTORS: Install a media cabinet capable Provide duct transitions, as required, to smoothly transition airflow of incorporating a 4−in. (102 mm) thick media filter. This allows from the return duct system to the filter (or IAQ device) to the room for future upgrades to other IAQ devices.
  • Page 24 Table 6 – Filter Media Pressure Drop (Clean) Versus Face Velocity− In. W.C. (Pa) Representative After­Market Filter Media* Factory­Accessory Face Velocity Washable Fiberglass* Pleated* (m/s) (1­in. / 2.5 cm) (1­in. / 2.5 cm) (2­in. / 5 cm) (1­in. / 2.5 cm) (2­in.

  • Page 25: Opening Dimensions

    FURNACE FURNACE (OR COIL CASING WHEN USED) APPROVED COIL ASSEMBLY COIL BOX COMBUSTIBLE COMBUSTIBLE FLOORING FLOORING PLENUM OPENING DOWNFLOW SUBBASE SHEET METAL PLENUM FLOOR SHEET METAL PLENUM OPENING FLOOR FLOOR OPENING OPENING A10491 Fig. 21 − Installation on Combustible Flooring Table 8 –...
  • Page 26 UPFLOW DOWNFLOW HORIZONTAL PERFORATED DISCHARGE DUCT 90° 90° FLANGE 120° 120° 120° A10493 Fig. 22 − Duct Flanges BOTTOM CLOSURE SCREWS (2) Representative drawing only, SCREWS (4) some models may vary in appearance. Lay furnace on the back or side BOTTOM PLATE Remove the two (2) screws that secure the bottom...
  • Page 27 5/ 16  (8mm) (8mm) 5/ 16   (44mm)  (44mm) (8mm)  (8mm) 5/ 16  (44mm) 3/ 4  3/ 4  (44mm) A89014 A11037 Fig. 25 − Leveling Legs Fig. 28 − Downflow Return Air Configurations and Restrictions LEVEL 0-IN.
  • Page 28 COMBUSTION - AIR PIPE (SEE VENTING SECTION) 30 IN. (762 mm) MIN. WORK AREA 2-IN. (51 mm) ROLLOUT PROTECTION REQUIRED Install 12” x 22” (305x559 mm) sheet metal in front of burner compartment area. The sheet metal MUST extend underneath the furnace casing by 1-in. (25 mm) with the door removed.

  • Page 29: Air Ducts

    AIR DUCTS NOTICE Many states, provinces and localities are considering or have implemented standards and/or restrictions on duct sizing practices, ductwork leakage, and/or ductwork thermal, airflow and electrical efficiencies. CONSULT LOCAL CODE OFFICIALS ductwork design performance requirements in your area. General Requirements The duct system should be designed and sized according to accepted national standards such as those published by: Air...
  • Page 30 Table 9 – Air Delivery − CFM (With Filter) EXTERNAL STATIC PRESSURE (IN. W.C.) RETURN­AIR SPEED UNIT SIZE CONNECTION TAPS Black 1000 Yellow ­ 024026 SIDE/BOTTOM Blue ­ ­ ­ ­ ­ ­ ­ Black 1100 1055 1010 Yellow 030040 SIDE/BOTTOM Blue Black...

  • Page 31: Gas Piping

    GAS PIPING WARNING WARNING FIRE OR EXPLOSION HAZARD A failure to follow this warning could result in personal FIRE OR EXPLOSION HAZARD injury, death, and/or property damage. Failure to follow this warning could result in personal If local codes allow the use of a flexible gas appliance injury, death, and/or property damage.

  • Page 32: Electrical Connections

    Table 10 – Maximum Capacity of Pipe ELECTRICAL CONNECTIONS NOMINAL LENGTH OF PIPE - FT (M) WARNING IRON PIPE SIZE (3.0) (6.0) (9.1) (12.1) (15.2) IN. (MM) 1/2 (13) ELECTRICAL SHOCK, FIRE OR EXPLOSION 3/4 (19) HAZARD 1 ( 25) Failure to follow safety warnings could result in 1‐1/4 (32) 1400...
  • Page 33 115−V Wiring NOTE: If electrical entry through the furnace top panel is used, a 7/8−in. (22 mm) hole must be drilled through the top panel. Furnace must have a 115-v power supply properly connected and 2. Drill two (2) 1/8−in. (3 mm) pilot holes through the dimples grounded.

  • Page 34: Electrical Data

    3. Secure power cord to J−Box bracket with a strain relief operation. Use only AWG No. 18, color−coded, copper thermostat bushing or a connector approved for the type of cord used. wire. 4. Pull furnace power wires through 1/2−in. (12 mm) diameter NOTE: Use AWG No.
  • Page 35 GROUND NEUTRAL LINE VOLTAGE ELECTRIC DISCONNECT SWITCH COPPER WIRE ONLY ALUMINUM WIRE A11146 A12226 Fig. 36 − Field−Supplied External Electrical Box on Furnace Fig. 35 − Installing J−Box (When Used) Casing To HUM Terminal On To Humidifier Leads Furnace Control Board 24 V Coil To Humidifier Leads...
  • Page 36 FIELD 24-V WIRING FIELD 115-, 208/230-, 460-V WIRING FACTORY 24-V WIRING FACTORY 115-V WIRING NOTE 2 THERMOSTAT FIVE WIRE FIELD-SUPPLIED TERMINALS DISCONNECT THREE-WIRE HEATING-ONLY 208/230- OR BLOWER DOOR SWITCH 460-V THREE PHASE 208/230-V SINGLE PHASE AUXILIARY 115-V FIELD- J-BOX SUPPLIED NOTE 1 DISCONNECT CONDENSING...
  • Page 37 VENTING NOTE: Planning for the venting system should be done in conjunction with planning for the ductwork, drainage, and furnace accessories, such as air cleaners and humidifiers. Begin assembling the venting system AFTER the furnace is set in place in the required orientation. Venting for this furnace shall follow all Local codes for Category IV venting systems.
  • Page 38 Other gas appliances with their own venting system may also use WARNING the abandoned chimney as a raceway providing it is permitted by local code, the current edition of the National Fuel Gas Code, and the vent or liner manufacturer’s installation instructions. Care must CARBON MONOXIDE POISONING HAZARD be taken to prevent the exhaust gases from one appliance from Failure to follow the steps outlined below for each appliance...
  • Page 39 Table 12 – Vent Termination Kit for Direct Vent (2−pipe) Systems Approved Two−Pipe Termination Fittings Vent and Allowable 1 1/2−in. 2−in. 2 1/2−in. 3−in. 4−in. Combustion Air Concentric Vent (38 mm) (51 mm) (64 mm) (76−mm) (102 mm) Pipe Diameters 1 1/2−in.
  • Page 40 combustion air system is less susceptible to damage or required by National code authorities. Allowable vent terminations contamination. The termination is usually located away from are shown in Fig. 54. The combustion air pipe terminates in a adjacent structures or other obstacles such as inside corners, well−ventilated attic or crawl space.
  • Page 41 accessory concentric vent terminations or pipe lengths and elbows NOTICE used for “standard” vent terminations do not require a deduction from the Maximum Equivalent Vent Length. See vent termination figures associated with Table 16. Include a deduction for a Tee OPTIONAL CONFIGURATION FOR COMBUSTION when used for Alberta and Saskatchewan terminations.
  • Page 42 Installing the Vent Pipe Adapter and Combustion Air The vent pipe may pass through unconditioned areas. The amount of exposed pipe allowed is shown in Table 15. Pipe Adapter 1. Using winter design temperature (used in load calculations), WARNING find appropriate temperature for your application and fur- nace model.
  • Page 43 3. Chamfer outside edge of pipe for better distribution of hangers as shown in Table 13. Support pipes using perforated primer and cement. metal hanging strap or commercially available hangers or straps designed to support plastic pipe. 4. Clean and dry all surfaces to be joined. 17.
  • Page 44 Optional Installation of the Vent Pipe Cut one 4−in. (102 mm) diameter hole for 2−in. (50 mm ND) kit, or one 5−in. (127 mm) diameter hole for 3−in. (80 mm ND) kit in NOTE: DO NOT USE THIS TECHNIQUE FOR the desired location.
  • Page 45 termination, or pair of vent terminations, must be at least 36 in. NOTICE (914 mm) away from the first two terminations. It is important that vent terminations be made as shown in Fig. 53 to avoid recirculation of vent gases. RECOMMENDED SUPPORT FOR VENT Inducer Outlet Restrictor TERMINATIONS...
  • Page 46 Table 15 – Maximum Allowable Exposed Vent Lengths in Unconditioned Space − Ft. Unit Size 26,000* BTUH 0" Insulation 3/8" Insulation 1/2" Insulation Pipe Dia. 1½ 1½ 1½ Winter Design Temp °F Unit Size 40,000* BTUH 60,000 BTUH Uninsulated 3/8­in. Insulation 1/2­in.
  • Page 47 Maximum Allowable Exposed Vent Length in Unconditioned Space (Metric) Unit Size 26,000* BTUH 0" Insulation 3/8" Insulation 1/2" Insulation Pipe Dia. 15.2 13.7 18.3 15.2 Winter Design Temp °C Unit Size 40,000* BTUH 60,000 BTUH Uninsulated 3/8­in. Insulation 1/2­in. Insulation Uninsulated 3/8­in.

  • Page 48: Maximum Equivalent Vent Length

    Table 16 – Maximum Equivalent Vent Length − Ft. NOTE: Maximum Equivalent Vent Length (MEVL) includes standard and concentric vent termination and does NOT include elbows. Use Table 17 − Deductions from Maximum Equivalent Vent Length to determine allowable vent length for each application. Unit Size 26,000 40,000...
  • Page 49 Venting System Length Calculations The Total Equivalent Vent Length (TEVL) for EACH combustion air or vent pipe equals the length of the venting system, plus the equivalent length of elbows used in the venting system from Table 17. Standard vent terminations or factory accessory concentric vent terminations count for zero deduction. See vent system manufacturer’s data for equivalent lengths of flexible vent pipe or other termination systems.
  • Page 50 Attach gaskets to vent pipe and Vent Coupling and Adapter combustion air adapters. A13074 Fig. 40 − Vent Coupling and Adapter with Gaskets TABS ON THE INDUCER OUTLET RESTRICTOR SNAP INTO THE SLOTS AT THE OUTLET OF THE INDUCER FOR USAGE: SEE MAXIMUM EQUIVALENT VENT LENGTH TABLE (10FT.
  • Page 51 FURNACE NOT IN HORIZONTAL SECTION PIPE DIAMETER TRANSITION IN VERTICAL SECTION A93034 Fig. 43 − Combustion Air and Vent Pipe Diameter Transition Location and Elbow Configuration No operable windows, doors or Clearance distances for intakes of any type within the items greater than 3 feet shaded areas of Wall A and B.
  • Page 52 Inside Corner Terminations Inside corner vent terminations are permitted provided that: S Only two exterior walls come together to form an angle of 90 degrees to 135 degrees. There are no other exterior walls attached to either wall to form an alcove. S The clearance distances apply when the vent is at least 3 feet (1 meter) from, but not more than 6 feet (2 meters) away from an inside corner.
  • Page 53 Rotate vent elbow to required position. Any other unused knockout may be used for combustion air connection. Rotate vent elbow to required position. & UPFLOW LEFT CONFIGURATION DOWNFLOW LEFT CONFIGURATION A11309A A11311A Rotate vent elbow to required position. Any other unused Any other unused knockout may be used knockout may be used...
  • Page 54 ALTERNATE COMBUSTION AIR CONNECTIONS HORIZONTAL LEFT-VERTICAL VENT CONFIGURATION HORIZONTAL RIGHT-VERTICAL VENT CONFIGURATION A11327A A11337 Alternate combustion air connection. Rotate vent elbow to required position. Vent Pipe Requires Internal Vent Kit See Product Data for Current Kit Number HORIZONTAL RIGHT-LEFT VENT CONFIGURATION HORIZONAL LEFT-LEFT VENT CONFIGURATION A11328A A11336...
  • Page 55 NOTES FOR VENTING OPTIONS 1. Attach vent pipe adapter with gasket to furnace casing. 2. Align notches in rubber coupling over standoffs on adapter. Slide clamps over the coupling. 3. Slide vent pipe through adapter and coupling into vent elbow. 4.
  • Page 56 A12326 NOTE: The following is based upon National codes for gas appliances and is provided as a reference. Refer to local codes which may supersede these standards and/or recommendations. (1 ) (2 ) Canadian Installations U.S. Installations Item Clearance Description (per CAN/CSA B149.1) (per ANSI Z223.1/NFPA 54) Clearance above grade, veranda, porch, deck, balcony...
  • Page 57 A12325 NOTE: The following is based upon National codes for gas appliances and is provided as a reference. Refer to local codes which may supersede these standards and/or recommendations. (1 ) (2 ) Canadian Installations U.S. Installations Item Clearance Description (per CAN/CSA B149.1) (per ANSI Z223.1/NFPA 54) Clearance above grade, veranda, porch, deck, balcony or...
  • Page 58 ¾ in. (222mm) for 3 in. (76mm) ¾ in. (172mm) for 2 in. (51mm) 12 in. (305mm) min. separation between bottom of combustion air and bottom of vent (Typ.) A13305 Fig. 53 − Combustion Air and Vent Pipe Termination for Direct Vent (2−Pipe) System Roof Termination (Preferred) Vent Maintain 12 in...
  • Page 59 OPTIONAL TERMINATION BRACKET FOR 2-PIPE TERMINATIONS OPTIONAL 12 IN. (305 MM) MIN. BRACKET SEPARATION BETWEEN COUPLING BOTTOM OFCOMBUSTION 12 IN. (305 MM) MIN. SEPARATION AIR AND BOTTOM OF VENT. BETWEEN BOTTOM OF COMBUSTION AIR AND BOTTOM OF VENT. MAINTAIN 12 IN. (305 MM) CLEARANCE ABOVE HIGHEST ANTICIPATED 12-IN.
  • Page 60 Ventilated Combustion Air intake pipe Pipe hangar 3” (76 mm) 12” (305 mm) Ventilated Combustion Air intake termination in crawl space CRAWL SPACE highest level of insulation ATTIC A10497 Fig. 56 − Vent Terminations for Ventilated Combustion Air...
  • Page 61 EXAMPLE FOR UPFLOW INSTALLATIONS. MAY BE APPLIED TO OTHER CONFIGURATIONS. A12220 Fig. 57 − Sample Inlet Air Pipe Connection for Polypropylene Venting Systems TO CODE−APPROVED DRAIN OR CONDENSATE PUMP Recommend “T” fitting with 4−inch minimum height standpipe (A) of same diameter or larger extending upward. Dry Well Dry Well (water tight...

  • Page 62: Start−Up, Adjustment, And Safety Check

    START−UP, ADJUSTMENT, AND SAFETY Prime Condensate Trap with Water CHECK WARNING NOTICE CARBON MONOXIDE POISONING HAZARD Failure to follow these warnings could result in personal injury Important Installation and Start−up Procedures or death. Failure to follow this procedure may result in a nuisance Failure to use a properly configured trap or NOT smoke or odor complaint.
  • Page 63 Adjustments In the USA, the input rating for altitudes above 2000 ft. (609.6M) must be reduced by 2 percent for each 1000 ft. (304.8M) above sea WARNING level. Refer to Table 19. The natural gas manifold pressures in Table 21 or 22 adjust for BOTH altitude and natural gas heating value.
  • Page 64 4. Turn on furnace power supply. CAUTION 5. Turn gas supply manual shutoff valve to ON position. 6. Turn furnace gas valve switch to ON position. FURNACE DAMAGE HAZARD 7. Jumper R and W thermostat connections at the furnace control board. Failure to follow this caution may result in reduced furnace 8.
  • Page 65 Adjust Temperature Rise Change these settings as required to maintain proper temperature rise for Heating and Cooling as described above. To change blower NOTE: Blower door must be installed when taking temperature motor speed selections for heating mode, remove blower motor rise reading.

  • Page 66: Altitude Derate Multiplier For U.s.a

    Checklist c. Unblock return air to permit normal circulation. d. Burners will re−light when furnace cools down. 1. Put away tools and instruments. Clean up debris. 2. Check Pressure Switch(es) 2. Verify that the jumper is removed from the TEST/TWIN This control proves operation of the draft inducer blower.
  • Page 67 SINGLE-STAGE MANIFOLD PRESSURE TAP SET SCREW: 3/32” HEX HEAD ACCEPTS 5/16” HOSE CONNECTION ON/OFF Switch 1/2” NPT 1/2” NPT INLET OUTLET OUTP 1/2” NPT Inlet Regulator Seal Cap Regulator Adjustment Regulator Seal Cap under Cap INLET PRESSURE TAP SET SCREW: 1/8”...
  • Page 68 338309-201 Rev. E A11602 Fig. 62 − Service Label Information...

  • Page 69: Gas Rate

    Table 20 – Gas Rate (CU ft./hr) SECONDS SECONDS SIZE OF TEST DIAL SIZE OF TEST DIAL FOR 1 FOR 1 1 Cu Ft. 2 Cu Ft. 5 Cu Ft. 1 Cu Ft. 2 Cu Ft. 5 Cu Ft. REVOLUTION REVOLUTION 1800 1636...
  • Page 70 Table 21 – Orifice Size and Manifold Pressure (in. w.c.) for Gas Input Rate 40,000 BTUH to 120,000 BTUH SINGLE-STAGE FURNACE (TABULATED DATA BASED ON 20,000 BTUH PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE RANGE HEAT VALUE 0.58 0.60 0.62...
  • Page 71 Table 21 − Orifice Size and Manifold Pressure (in. w.c.) for Gas Input Rate (Cont.) 40,000 BTUH to 120,000 BTUH SINGLE-STAGE FURNACE (TABULATED DATA BASED ON 20,000 BTUH PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE RANGE HEAT VALUE 0.58 0.60 0.62...

  • Page 72: Orifice Size And Manifold Pressure

    Table 22 – Orifice Size and Manifold Pressure (in. w.c.) for Gas Input Rate 26,000 BTUH ONLY ORIFICE SIZE* AND MANIFOLD PRESSURE (IN WC) FOR GAS INPUT RATE (TABULATED DATA BASED ON 13,000 BTUH PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL ALTITUDE SPECIFIC GRAVITY OF NATURAL GAS AVG.
  • Page 73 Table 21 (Continued) − Orifice Size and Manifold Pressure (in. w.c.) for Gas Input Rate 26,000 BTUH ONLY ORIFICE SIZE* AND MANIFOLD PRESSURE (IN WC) FOR GAS INPUT RATE (TABULATED DATA BASED ON 13,000 BTUH PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL 7001 (2134) 8000...

  • Page 74: Service And Maintenance Procedures

    SERVICE AND MAINTENANCE label below the reference location in inches of water column, “W.C.” The maximum and minimum break point of the switch is PROCEDURES +/− 0.05 inches of water column from the nominal break point of Untrained personnel can perform basic maintenance functions such the switch.
  • Page 75 3. Remove the Main/Control door (the upper door on upflow connector. (Note: If there is a jumper connector plugged installations). into PLT, remove it and discard.) See Fig. 39. 4. BRIEFLY disconnect and reconnect ONE of the main limit 3. Verify that the Blower/Heat Off Delay jumpers are set as wires.
  • Page 76 4. If equipped with permanent, washable filter, clean filter by CAUTION 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. CUT HAZARD 5. If equipped with factory specified disposable media filter, Failure to follow this caution may result in personal injury.
  • Page 77 NOTE: Use a back-up wrench on the gas valve to prevent the g. Clean wheel per instructions on degreaser cleaner. Do not get degreaser in motor. valve from rotating on the manifold or damaging the mounting to the burner assembly. 8.
  • Page 78 and check burner positioning in the burner assembly assembly 9. Verify igniter operation by initiating control board self−test before re-installing the manifold. feature or by cycling thermostat. 10. Replace control door. 6. Attach the green/yellow wire and ground terminal to one of the manifold mounting screws.
  • Page 79 12. Shake trap dry. WARNING 13. Clean port on collector box with a small wire. To re-install Condensate Drain and Trap: ELECTRICAL SHOCK, FIRE OR EXPLOSION 1. Remove adhesive backing from condensate trap gasket HAZARD 2. Install gasket on collector box Failure to follow this warning could result in personal 3.
  • Page 80 10. Repeat Steps 5 through 8. WARNING 11. If a condensate pump is used, check with pump manufacturer to verify pump is safe for use with antifreeze used. Allow FIRE OR EXPLOSION HAZARD pump to start and pump anti−freeze to open drain. 12.
  • Page 81 GROMMET MOTOR SHAFT FLAT MOTOR ARM SCREW SET SCREW MOTOR WHEEL HUB SEE DETAIL SCREW LOCATION BLOWER HSG ASSY BRACKET BRACKET ENGAGEMENT DETAIL CUTOFF, BLOWER A11273 Fig. 66 − Cleaning Heat Exchanger Cell WHEEL, BLOWER BLOWER HSG ASSY BRACKET Burner Flame Burner CAPACITOR OR POWER CHOKE...

  • Page 82: Sequence Of Operation

    SEQUENCE OF OPERATION Simultaneously, the electronic air cleaner terminal EAC−1 is energized and remains energized as long as the blower NOTE: Furnace control must be grounded for proper operation or motor BLWM is energized. control will lock out. Control is grounded through green/yellow f.
  • Page 83 A11622 Fig. 70 − Troubleshooting Guide...
  • Page 84 A12421 Troubleshooting Guide (Cont)
  • Page 85 A12420 Fig. 71 − Wiring Diagram...
  • Page 86 STAGES CAPACITY CAPACITY SERIES/ VARIATIONS PG95 AAAA WARNING FIRE, EXPLOSION, ELECTRICAL SHOCK AND CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in dangerous operation, personal injury, death or property damage. Improper installation, adjustment, alteration, service, or maintenance can cause personal injury, property damage, or death. Consult a qualified installer, service agency, or your local gas supplier for information or assistance.

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