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PG95ESU: Installation, Start-up, Operating and Service Maintenance Instructions

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

36

A11308A

Representative drawing only, some models may vary.

UPFLOW RIGHT CONFIGURATION

A11310A

Representative drawing only, some models may vary.

UPFLOW VERTICAL VENT

Fig. 50 – Upflow Configurations (Appearance may vary)

See “Notes for Venting Options”

A11327A

Representative drawing only, some models may vary.

HORIZONTAL LEFT-VERTICAL VENT CONFIGURATION

A11328A

Representative drawing only, some models may vary.

HORIZONAL LEFT-LEFT VENT CONFIGURATION

A11329A

Representative drawing only, some models may vary.

HORIZONTAL LEFT-RIGHT VENT CONFIGURATION

Fig. 51 – Horizontal Left (Appearance may vary)

See “Notes for Venting Options”

A11337

Representative drawing only, some models may vary.

HORIZONTAL RIGHT-VERTICAL VENT CONFIGURATION

1

2

3

4

5

6

7

5

Rotate vent elbow to
required position.

Any other unused
knockout may be used
for combustion air
connection.

1

2

3

4

5

6

7

5

Any other unused
knockout may be used
for combustion air
connection.

6

4

Alternate combustion air
connection.

Rotate vent
elbow to
required
position.

4

5

Vent Pipe

Requires Accessory Vent Kit

See Product Data for

Current Kit Number

ALTERNATE
COMBUSTION
AIR CONNECTIONS

«
...
34
35
36
37
38
...
»

Summary of Contents for PG95ESU

Page 1: ... Gas Valve Outlet Pressure for Gas Heat Values at Altitude 60 000 48 Table 24 Gas Valve Outlet Pressure for Gas Heat Values at Altitude 80 000 49 Table 25 Gas Valve Outlet Pressure for Gas Heat Values at Altitude 100 000 49 SERVICE AND MAINTENANCE PROCEDURES 50 WINTERIZATION 55 PARTS REPLACEMENT INFORMATION GUIDE 58 MODEL NOMENCLATURE 58 Most states in the USA and jurisdictions in Canada have laws...

Page 2: ...exterior of the building at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 INSPECTION The state or local gas inspector of the side wall horizontally vente...

Page 3: ...installation adjustment alteration service maintenance or use can cause carbon monoxide poisoning explosion fire electrical shock or other conditions which may cause personal injury or property damage Consult a qualified service agency local gas supplier or your distributor or branch for information or assistance The qualified service agency must use only factory authorized and listed kits or acce...

Page 4: ...scharged outdoors Connect this furnace to an approved vent system only as specified in the Venting section of these instructions 5 Never test for gas leaks with an open flame Use a commercially available soap solution made specifically for the detection of leaks to check all connections as specified in the Gas Piping section 6 Always install furnace to operate within the furnace s intended tempera...

Page 5: ...None of the furnace model sizes can be used if the heating load is less than half of the furnace model s output capacity Use Air Conditioning Contractors of America Manual J and S American Society of Heating Refrigerating and Air Conditioning Engineers or other approved engineering method to calculate heating load estimates and select the furnace Excessive oversizing of the furnace may cause the f...

Page 6: ... In the state of Massachusetts This product must be installed by a licensed plumber or gas fitter When flexible connectors are used the maximum length shall not exceed 36 in 914 mm When lever type gas shutoffs are used they shall be T handle type The use of copper tubing for gas piping is not approved by the state of Massachusetts Electrical Connections US Current edition of National Electrical Co...

Page 7: ...servicing and cleaning Always comply with minimum fire protection clearances Table 1 The following types of furnace installations may require OUTDOOR AIR for combustion due to chemical exposures Commercial buildings Buildings with indoor pools Laundry rooms Hobby or craft rooms Chemical storage areas If air is exposed to the following substances it should not be used for combustion air and outdoor...

Page 8: ...n the space Spaces having less than 50 cubic feet per 1 000 BTUh 4 8 cubic meters per kW require the Outdoor Combustion Air Method Spaces having at least 50 cubic feet per 1 000 BTUh 4 8 cubic meters per kW may use the Indoor Combustion Air Standard or Known Air Infiltration Method Outdoor Combustion Air Method 1 Provide the space with sufficient air for proper combustion ventilation and dilution ...

Page 9: ...pace may be considered a space that freely communicates with the outdoors provided there are adequate permanent ventilation openings directly to outdoors having free area of at least 1 in 2 4 000 BTUh of total input rating for all gas appliances in the space 3 In spaces that use the Indoor Combustion Air Method infiltration should be adequate to provide air for combustion permanent ventilation and...

Page 10: ...ilation and Dilution Air from Outdoors AIR CHANGES PER HOUR ACH OTHER THAN FAN ASSISTED TOTAL 1 000 S BTUH GAS INPUT RATE FAN ASSISTED TOTAL 1 000 S BTUH GAS INPUT RATE 30 40 50 26 40 60 80 100 120 140 Space Volume Ft3 M3 0 60 1 050 29 7 1 400 39 6 1 750 49 5 910 25 8 1 400 39 6 1 500 42 5 2 000 56 6 2 500 70 8 3 000 84 9 3 500 99 1 0 50 1 260 35 6 1 680 47 5 2 100 59 4 1092 30 9 1 680 47 5 1 800 ...

Page 11: ... An indoor coil condensate drain or humidifier drain can be connected to the external furnace condensate drain provided The drains are not hard piped together and There is an air gap at the point where the two drain lines meet or All condensate piping is at least 3 4 PVC and there is a relief tee at the top of condensate drain piping as shown see Fig 11 A200069 A200070 WARNING CARBON MONOXIDE POIS...

Page 12: ...74 NOTE Coil may require metal spacer or shield between furnace and coil See coil install requirements Table 6 Fig 11 Example of Field Drain Attachment Table 5 Condensate Trap Configurations Part Installation Configuration Horizontal Upflow Upflow Offset Required Required Required Not Required Required Required Not Required Required Required Not Required Not Required Required accessory kit purchas...

Page 13: ...TICE Upflow installations utilizing the right side air return opening should follow the Upflow Specific Steps Offset Installation to ensure the full opening is available for return ductwork CAUTION CUT HAZARD Failure to follow this caution may result in personal injury Sheet metal parts may have sharp edges or burrs Use care and wear appropriate protective clothing safety glasses and gloves when h...

Page 14: ... 2 Screw the trap to the trap offset adapter see Fig 16 3 Screw the trap adapter plate to the casing using the supplied sheet metal screw see Fig 16 4 Remove factory installed collector box cap Run tube from port on upper left of the collector box to the relief port on the trap adapter Fig 19 If the tube is too long cut any extra length from the tube Horizontal Specific Steps 1 Accessory Horizonta...

Page 15: ... machine screw see Fig 23 Drilling pilot holes is recommended to better align the plate with the knockout opening 4 Install the second trap plate at the remote location 5 ft or less away from the furnace Fig 23 5 Using two field supplied 1 2 in CPVC tubes of the desired length 5 ft or less and 2 field supplied CPVC elbows run the drain from the adapter plate on the furnace to the remote adapter pl...

Page 16: ...elded should be treated as un shielded and require a spacer Dimensional requirements see Fig 26 3 For 3rd party unshielded coils consult manufacturer for design of a field fabricated shield that completely shields all plastic composite materials from direct exposure to any part of the heat exchanger All adapters are field fabricated according to the dimensions for the metal shield see Fig 25 and f...

Page 17: ...urnace must be pitched for proper condensate drainage see Fig 31 Supply Air Connections For a furnace not equipped with a cooling coil the outlet duct shall be provided with a removable access panel This opening shall be accessible when the furnace is installed and shall be of such a size that the heat exchanger can be viewed for possible openings using light assistance or a probe can be inserted ...

Page 18: ... bottom closure panel to install leveling legs To remove bottom closure panel see Fig 34 To install leveling legs 1 Position furnace on its back Locate and drill a hole in each bottom corner of furnace 2 For each leg install nut on bolt and then install bolt with nut in hole Install flat washer if desired 3 Install another nut on other side of furnace base Install flat washer if desired 4 Adjust o...

Page 19: ...d for return air connection A200088 Fig 32 Working Platform for Attic Installation NOTE Furnace shown is a direct vent application Refer to the venting section for allowable vent configurations NOTE N Coil only add 8 in separation between coil and furnace for all other unshielded coils See evaporator coil spacer or shield requirements NOTE Local codes may require a drain pan and condensate trap wh...

Page 20: ... 29 each opening used will require a filter A filter rack or any field supplied accessory air cleaner can also be installed in the common return duct prior to entering the return air opening in any orientation The furnace may be used with an optional external media filter cabinet The optional media filter cabinet uses either a standard 1 in 25 mm filter or 4 in 102 mm wide media filter which can b...

Page 21: ...oring subbase not required 19 1 2 495 21 5 8 549 20 1 8 511 22 1 4 565 24 1 2 622 Upflow Applications on Combustible or Noncombustible Flooring subbase not required 23 584 21 1 8 537 23 5 8 600 22 1 4 565 16 x 25 Filter 406 x 635 mm Factory Accessory Washable Factory Accessory Media Representative After Market Filter Media Fiberglass Pleated CFM L s 1 in 2 5 cm 4 in 10 cm 1 in 2 5 cm 2 in 5 cm 1 i...

Page 22: ...ns air entering from one side into both the side of the furnace and a return air base counts as a side and bottom return 7 The entry indicates an unstable operating condition Ductwork Acoustical Treatment NOTE Metal duct systems that do not have a 90 degree elbow and 10 ft 3 M of main duct to the first branch take off may require internal acoustical lining As an alternative fibrous ductwork may be...

Page 23: ...ure test After all connections have been made purge lines and check for leakage at furnace prior to operating furnace The gas supply pressure shall be within the maximum and minimum inlet supply pressures marked on the rating plate with the furnace burners ON and OFF Gas entry can be from left or right side or top panel see Fig 35 and Fig 36 Gas Pipe Grommet For direct vent 2 pipe applications the...

Page 24: ...7 8 inch for 115 VAC Electric GAS SUPPLY MANUAL SHUT OFF VALVE REQUIRED SEDIMENT TRAP UNION NOTE Union may be inside the vestibule where permitted by local codes FRONT WARNING ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to follow safety warnings could result in dangerous operation serious injury death or property damage Improper servicing could result in dangerous operation serious injury de...

Page 25: ... in 22 mm knock out on the desired side of the casing Remove the knock out from the casing 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 2 Drill two 2 1 8 in 3 mm pilot holes through the dimples in the furnace casing near the 7 8 in knock out NOTE If electrical entry through the furnace top panel is used mark the screw hole...

Page 26: ...J Box bracket 3 Secure BX cable to J Box bracket with connectors approved for the type of cable used 4 Connect field ground wire and factory ground wire to green ground screw on J Box mounting bracket see Fig 38 5 Connect field power and neutral leads to furnace power leads see Fig 40 6 Attach furnace J Box cover to mounting bracket with screws supplied in loose parts bag Do not pinch wires betwee...

Page 27: ...CONDENSING UNIT TWO WIRE FURNACE C O N T R O L R G COM W C R G Y GND GND FIELD 24 V WIRING FIELD 115 208 230 460 V WIRING FACTORY 24 V WIRING FACTORY 115 V WIRING 208 230 OR 460 V THREE PHASE 208 230 V SINGLE PHASE 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 origi...

Page 28: ... Standards Institute ANSI standards and American Society for Testing and Materials ASTM standards For approved materials for use in the U S A Table 16 This furnace is also CSA approved for venting with M G DuraVentRPolyProR or Centrotherm InnoFlueR polypropylene venting systems using single Table 13 Electrical Data FURNACE SIZE VOLTS HERTZ PHASE OPERATING VOLTAGE RANGE Permissible limits of the vo...

Page 29: ... Vent 2 Pipe system see Fig 54 and for Ventilated Combustion Air Non direct Vent 1 Pipe system see Fig 55 For exterior termination arrangements for Direct Vent 2 Pipe system see Fig 56 WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow the instructions outlined below for each appliance being placed into operation could result in carbon monoxide poisoning or death For all venting configurat...

Page 30: ...ional code authorities see Fig 54 Allowable vent and combustion air terminations see Fig 56 Ventilated Combustion Air The vent pipe for a Ventilated Combustion Air System must terminate outdoors For references to vent clearances required by National code authorities see Fig 55 Allowable vent terminations see Fig 57 The combustion air pipe terminates in a well ventilated attic or crawl space Follow...

Page 31: ...pe connected to the tee or the External Vent Trap Kit to help prevent contaminants from entering the furnace see Fig 43 The External Vent Trap Kit accessory may be used as a trap for the combustion air inlet pipe if a large amount of moisture must be removed The drain line may be connected to the same drain as the furnace condensate and the evaporator coil condensate line ONLY if the inlet air tra...

Page 32: ...alent Vent Length is still longer than the longer TEVL of the vent pipe or combustion air pipe then that diameter of pipe selected may be used When installing vent systems pipe lengths of 10 ft 3 M or less use the smallest allowable pipe diameter Using a pipe size greater than required for short venting systems may result in loss of efficiency incomplete combustion flame disturbance or flame sense...

Page 33: ... Insert a length of vent pipe through the coupling into the outlet of the vent elbow 6 Tighten the clamp around the outlet of the vent elbow Torque the clamp to 15 lb in A13074 Fig 47 Vent Coupling and Adapter with Gaskets A210034 Fig 48 Inducer Vent Elbow Install the remaining vent and combustion air pipes as shown below It is recommended that all pipes be cut prepared and pre assembled before pe...

Page 34: ...pter 3 Remove the pipe from the furnace and the adapter and cut off any excess pipe 4 Clean and prime the end of the pipe that is flush with the vent adapter with a primer that is appropriate for the type of pipe being used 5 Re insert the pipe through the casing into the vent elbow 6 Tighten the clamp around the outlet of the vent elbow Torque the clamp to 15 lb in 7 Apply cement to the end of th...

Page 35: ...structions are provided as a reference only Determine an appropriate location for termination kit using the guidelines provided in section Locating The Vent Termination in this instruction 1 Cut one 4 in diameter hole for 2 in kit or one 5 in diameter hole for 3 in kit 2 Loosely assemble concentric vent combustion air termination components together using instructions in kit 3 Slide assembled kit ...

Page 36: ...entative drawing only some models may vary HORIZONAL LEFT LEFT VENT CONFIGURATION A11329A Representative drawing only some models may vary HORIZONTAL LEFT RIGHT VENT CONFIGURATION Fig 51 Horizontal Left Appearance may vary See Notes for Venting Options A11337 Representative drawing only some models may vary HORIZONTAL RIGHT VERTICAL VENT CONFIGURATION 1 2 3 4 5 6 7 5 Rotate vent elbow to required ...

Page 37: ...s for use in the U S A 3 UL 1738 vent systems must be composed of pipe fittings cements and primers from the same supplier Material Description Type ASTM ULC UL Specification Pipe Fittings Solvents Primers Cements PVC Pressure Pipe Schedule 40 D1785 UL 1738 DWV Schedule 40 D1785 D2665 D2466 Cellular Core Schedule 40 F891 or F656 D2564 SDR 26 N A D2241 D2665 SDR 21 N A D2241 IPEX Schedule 40 ULC S6...

Page 38: ...0 20 30 25 15 15 10 10 20 40 30 25 20 45 40 30 20 5 20 15 10 20 20 15 10 5 20 25 20 15 20 30 25 20 40 15 10 5 15 15 10 5 20 15 15 10 20 20 15 10 Unit Size 80 000 BTUH Winter Design Temp F Pipe Dia in Uninsulated 3 8 in Insulation 1 2 in Insulation 1 2 2 3 4 1 2 2 3 4 1 2 2 3 4 20 15 40 40 35 30 15 50 90 75 65 15 50 70 70 70 0 15 20 15 10 5 15 50 45 35 30 15 50 50 40 35 20 15 10 5 15 35 30 20 15 15...

Page 39: ...70 ft 22 M Use length of the longer of the vent or air inlet piping system Add equiv length of 3 90º long radius elbows use the highest number of elbows for either the vent or inlet pipe 3 x 3 ft 0 9 M 9 ft 2 7 M From Table 19 Add equiv length of 2 45º long radius elbows use the highest number of elbows for either the vent or inlet pipe 2 x 1 5 ft 0 5 M 3 ft 0 9 M From Table 19 Add equiv length of...

Page 40: ...istances when vent termination is located more than 6 ft 2 M away from an inside corner refer to the appropriate Direct Vent or Non Direct Vent Clearance Table Clearance description when termination is at least 3 ft 1 M away and not more than 6 ft 2 M away from an inside corner Clearance above grade veranda porch deck balcony or anticipated snow level 12 in 305 mm Clearance to a permanently closed...

Page 41: ...chanical air supply inlet 6 ft 1 8 M 3ft 9 M above if within 10 ft 3 M horizontally L Clearance under a veranda porch deck or balcony 12 in 305 mm Permitted only if veranda porch deck or balcony is fully open on a minimum of two sides beneath the floor See Note 4 Manufacturer s Recommendation See Notes 3 8 M Clearance to each side of the centerline extended above or below vent terminal of the furn...

Page 42: ...mmendation See Note 8 K Clearance to a mechanical air supply inlet 6 ft 1 8 M 3ft 9 M above if within 10 ft 3 M horizontally L Clearance under a veranda porch deck or balcony 12 in 305 mm Permitted only if veranda porch deck or balcony is fully open on a minimum of two sides beneath the floor See Note 4 Manufacturer s Recommendation See Notes 3 8 M Clearance to each side of the centerline extended...

Page 43: ...172mm for 2 in 51mm Abandoned masonry used as raceway per code 12 in 305 mm min from overhang or roof Maintain 12 in 305mm minimum clearance above highest anticipated snow level or grade whichever is greater Side wall termination with 2 elbows preferred 12 in min 305 mm from overhang or roof Maintain 12 in 305mm minimum clearance above highest anticipated snow level or grade whichever is greater 6...

Page 44: ... Pour one quart liter of water into funnel tube Water should run through collector box overfill condensate trap and flow into open field drain 7 Remove funnel and tube from collector box and replace collector box drain plug A190304 Fig 59 Prime Condensate Trap WARNING FIRE HAZARD Failure to follow this warning could result in personal injury death and or property damage This furnace is equipped wi...

Page 45: ...as supply manual shutoff valve to OFF position l Turn off furnace power supply m Remove manometer from the inlet pressure tap of the gas valve n Tighten set screw on inlet tower pressure tap with 3 32 in hex wrench or if 1 8 in NPT plug was removed apply pipe dope sparingly to end of plug and re install in the gas valve 2 4 Adjust gas valve outlet pressure determined in Step 2 to obtain correct in...

Page 46: ... 2 Return and supply ducts for excessive restrictions causing static pressures greater than the maximum heating static listed on the rating plate c Adjust air temperature rise by adjusting blower speed Increase blower speed to reduce temperature rise Decrease blower speed to increase temperature rise d Turn thermostat down below room temperature and remove blower access door e To change motor spee...

Page 47: ...l Main or upper door in upflow position doors are properly installed 5 Verify that the Status LED glows If not check that the power supply is energized and that the blower door is secure Interpret diagnostic codes see Fig 63 6 Cycle test furnace with room thermostat to be sure that it operates properly with the room thermostat Check all modes including Heat Cool and Fan 7 Check operation of access...

Page 48: ...1 2 2 2 3 2 3 2 4 2 5 875 2 0 2 1 2 1 2 2 2 3 2 3 900 1 9 2 0 2 0 2 1 2 1 2 2 5400 925 1 8 1 8 1 9 2 0 2 0 2 1 1646 950 1 8 1 8 1 8 1 9 1 9 2 0 975 1 8 1 8 1 8 1 8 1 8 1 9 1000 1 8 1 8 1 8 1 8 1 8 1 8 Table 23 Gas Valve Outlet Pressure for Gas Heat Values at Altitude 60 000 Tabulated Data Based on 60 000 BTUH Input for 0 ft 0m to 5400 ft 1646 M above sea level ALTITUDE RANGE ft m AVG GAS HEAT VALU...

Page 49: ... 2 2 2 2 2 3 2 4 2 4 875 2 0 2 0 2 1 2 2 2 2 2 3 900 1 9 1 9 2 0 2 0 2 1 2 2 5400 925 1 8 1 8 1 9 1 9 2 0 2 1 1646 950 1 8 1 8 1 8 1 8 1 9 2 0 975 1 8 1 8 1 8 1 8 1 8 1 9 1000 1 8 1 8 1 8 1 8 1 8 1 8 Table 25 Gas Valve Outlet Pressure for Gas Heat Values at Altitude 100 000 Tabulated Data Based on 100 000 BTUH Input for 0 ft 0m to 5400 ft 1646 M above sea level ALTITUDE RANGE ft m AVG GAS HEAT VAL...

Page 50: ... interrupted 1 To retrieve status code proceed with the following NOTE NO thermostat signal may be present at control and all blower OFF delays must be completed a Remove blower access door b Close blower door interlock switch c Using a length of wire briefly short the TEST TWIN terminal to the C terminal on the furnace control 2 When above items have been completed the LED flashes the most recent...

Page 51: ...set lockout Check for Blocked burner inlet Blocked burner mesh Poor inducer flow Excess wind 31 PRESSURE TRANSDUCER INPUT DOES NOT SENSE TARGET PRESSURE OR PRESSURE IS OUT OF RANGE Check for Excessive wind Proper vent sizing Restricted vent Defective inducer motor Inadequate combustion air supply Defective pressure transducer Low inlet gas pressure if LGPS used Low inducer voltage 115 VAC Frozen o...

Page 52: ...ground wire attached to blower housing b Remove screws securing cutoff plate and remove cutoff plate from housing c Loosen set screw holding blower wheel on motor shaft 160 20 in lb when reassembling d Remove bolts holding motor to blower housing and slide motor out of wheel 40 10 in lb when reassembling e Remove blower wheel from housing f Clean wheel and housing 8 Reassemble motor and blower by ...

Page 53: ... flame sensor wire to the wire harness dressing the sensor wires to ensure there is no tension on the flame sensor itself see Fig 65 9 Turn gas on at electric switch on gas valve and at external shut off or meter 10 Turn power on at external disconnect fuse or circuit breaker 11 Run the furnace through two complete heating cycles to check for proper operation 12 Install control door when complete ...

Page 54: ... trap and collector box is required Verify a condensate trap gasket is included in the service kit or obtain one from your local distributor 1 Reverse installation instructions found in Condensate Trap Section to disassemble the condensate trap 2 Use water or a slight brush to clean components Do NOT cut into glued PVC sections to service the trap 3 Ensure all instructions cautions and warning fro...

Page 55: ...al supplies to your furnace 3 Remove furnace control door 4 Remove the top unused rubber plug from the port on the collector box opposite the condensate trap 5 Connect a field supplied 3 8 in 9 5 mm ID tube to the open port on the collector box 6 Insert a field supplied funnel into the tube 7 Pour one quart liter of anti freeze solution into the funnel tube Antifreeze should run through the induce...

Page 56: ... will open the gas valve relay GVR de energizing the gas valve solenoid GV The control CPU will repeat the ignition sequence for up to three more Trials For Ignition before going to an Ignition Lockout Lockout will be reset automatically after three hours or by momentarily interrupting 115 vac power to the furnace or by interrupting 24 vac power at SEC1 or SEC2 to the furnace control CPU not at W ...

Page 57: ...uit board conductors and are not included in legend 6 Replace only with a 3 amp fuse 7 Inducer IDM motor contains internal auto reset thermal overload switches OL 8 Blower motor speed selections are for average conditions see installation instructions for details on optimum speed selection 9 Ignition lockout will occur after four consecutive unsuccessful trials for ignition Control will auto reset...

Page 58: ...ensate trap Condensate trap elbow Gaskets Transducer Inducer motor Inducer wheel Vent elbow assembly TO OBTAIN INFORMATION ON PARTS Consult your installing dealer or a licensed Heating and Air Conditioning company of your choice CAC BDP a division of Carrier Corporation 7310 West Morris Street Indianapolis IN 46231 U S A Have available the model number series number and serial number located on th...

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