Payne PG95ESA Installation, Start-Up, Operating And Service And Maintenance Instructions Download

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(clips) on blower wheel vanes. Do not bend wheel or blades
as balance will be affected.

7. If greasy residue is present on blower wheel, remove wheel

from the blower housing and wash it with an appropriate
degreaser. To remove wheel:

NOTE

: The DIBC composite wheel used in some models should

be cleaned with mild soapy water only. Allow wheel to dry prior to

reassembly.

a. Mark blower wheel location on shaft before disassembly

to ensure proper reassembly.

b. Loosen setscrew holding blower wheel on motor shaft.

NOTE:

Mark blower mounting arms and blower housing so each

arm is positioned at the same hole location during reassembly.

c. Mark blower wheel orientation and cutoff plate location to

ensure proper reassembly.

d. Remove screws securing cutoff plate and remove cutoff

plate from housing.

e. Remove bolts holding motor mounts to blower housing

and slide motor and mounts out of housing.

f. Remove blower wheel from housing.

g. Clean wheel per instructions on degreaser cleaner. Do not

get degreaser in motor.

8. Reassemble motor and blower wheel by reversing items 7b

through 7f. Ensure wheel is positioned for proper rotation.

9. Torque motor mounting bolts to 40 +/-- 10 lb--in. when re-

assembling.

NOTE

: Ensure that the removable inlet ring is installed before the

motor on furnaces with a DIBC composite blower.

10. Torque blower wheel set screw to 160 +/-- 20 lb--in. when

reassembling.

SET SCREW

MOTOR WHEEL HUB

MOTOR SHAFT FLAT

SCREW

MOTOR ARM

GROMMET

SCREW LOCATION

BLOWER HSG ASSY

BRACKET

BRACKET
ENGAGEMENT

SEE DETAIL

CAPACITOR
OR POWER CHOKE
(WHEN USED)

BRACKET

SCREW

(GND)

BLOWER HSG ASSY

MOTOR, BLOWER

WHEEL, BLOWER

CUTOFF, BLOWER

DETAIL

Representative drawing only, some models may vary in appearance.

A11584

Representative drawing of DIBC blower wheel only,

some models may vary in appearance.

A190094

Fig. 63 -- Blower Assembly

11. Verify that blower wheel is centered in blower housing and

set screw contacts the flat portion of the motor shaft. Loosen
set screw on blower wheel and reposition if necessary.

12. Spin the blower wheel by hand to verify that the wheel does

not rub on the housing.

13. Reinstall blower assembly in furnace.
14. Reinstall 2 screws securing blower assembly to blower

deck.

15. Reconnect blower leads to furnace control. Refer to furnace

wiring diagram, and connect thermostat leads if previously

disconnected.

NOTE:

Be sure to attach ground wire and reconnect blower

harness plugs to blower motor.

ELECTRICAL OPERATION HAZARD

Failure to follow this warning could result in personal injury

or death.
Blower door switch opens 115--v power to control. No

component operation can occur unless switch is closed.

Caution must be taken when manually closing this switch for

service purposes.

WARNING

16. Downflow or horizontal furnaces with vent pipe through

furnace only:

a. Install and connect short piece of vent pipe inside furnace

to existing vent.

b. Connect vent connector to vent elbow.

17. Turn on electrical supply. Manually close blower door

switch. Use a piece of tape to hold switch closed. Check for

Summary of Contents for PG95ESA

Page 1: ...6 Opening Dimensions 29 Air Delivery CFM 30 Maximum Capacity of Pipe 32 Electrical Data 36 Vent Termination Kit for Direct Vent 2 Pipe System 39 Hangar Spacing 46 Combustion Air Vent Pipe Fitting Cement Material 49 Maximum Allowable Exposed Vent Lengths Insulation 50 Maximum Equivalent Vent Length 51 Deductions from Maximum Equivalent Vent Length 51 Blower Off Delay Setup Switch 70 Altitude Derate...

Page 2: ... 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 vented gas fueled equipment shall not approve the installation unless upon inspection the inspector obs...

Page 3: ...rking on heating equipment observe precautions in literature on tags and on labels attached to or shipped with furnace and other safety precautions that may apply These instructions cover minimum requirements and conform to existing national standards and safety codes In some instances these instructions exceed certain local codes and ordinances especially those that may not have kept up with chan...

Page 4: ...an be converted in the field for use with propane gas when a factory supplied conversion kit is used Refer to the furnace rating plate for conversion kit information These furnaces are not approved for installation in recreational vehicles or outdoors Single stage furnaces 40 000 through 120 000 are approved for installation in manufactured housing mobile homes with manufacturer approved accessory...

Page 5: ...censed plumber or gas fitter S When flexible connectors are used the maximum length shall not exceed 36 in 914 mm S When lever type gas shutoffs are used they shall be T handle type S The use of copper tubing for gas piping is not approved by the state of Massachusetts Electrical Connections S US Current edition of National Electrical Code NEC NFPA 70 S CANADA Current edition of Canadian Electrica...

Page 6: ...6 406 8 3 4 222 126 5 57 4 36060A 14 3 16 361 12 1 2 319 12 9 16 322 7 1 8 181 129 58 5 42060B 17 1 2 445 15 7 8 403 16 406 8 3 4 222 138 5 62 8 48080B 17 1 2 445 15 7 8 403 16 406 8 3 4 222 146 5 66 4 60080C 21 533 19 3 8 492 19 1 2 495 10 1 2 267 154 5 70 1 60100C 21 533 19 3 8 492 19 1 2 495 10 1 2 267 164 5 74 6 66120D 24 1 2 622 22 7 8 581 23 584 12 1 4 311 179 5 81 4 66140D 24 1 2 622 22 7 8...

Page 7: ...e parts bag contents This furnace must S be installed so the electrical components are protected from water S not be installed directly on any combustible material other than wood flooring refer to SAFETY CONSIDERATIONS S be located close to the chimney or vent and attached to an air distribution system Refer to Air Ducts section S be provided ample space for servicing and cleaning Always comply w...

Page 8: ...e must be installed in accordance with the current edition of NFPA 54 ANSI Z223 1 or CAN CSA B149 2 See Fig 4 WARNING 18 IN 457 2 mm MINIMUM TO BURNERS A93044 Fig 4 Installation in a Garage FIRE HAZARD Failure to follow this warning could result in personal injury death and or property damage Do not install the furnace on its back or hang furnace with control compartment facing downward Safety con...

Page 9: ...fe Air contaminants are found in aerosol sprays detergents bleaches cleaning solvents salts air fresheners and other household products CAUTION CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury or death The operation of exhaust fans kitchen ventilation fans clothes dryers attic exhaust fans or fireplaces could create a NEGATIVE PRESSURE CONDITION at th...

Page 10: ...m2 kW of the total input rating of all gas appliances in the space but not less than 100 in 2 0 06 m2 One opening shall commence within 12 in 300 mm of the ceiling and the second opening shall commence within 12 in 300 mm of the floor The minimum dimension of air openings shall be at least 3 in 80 mm See Fig 7 c Combining space on different floor levels The volumes of spaces on different floor lev...

Page 11: ...ace Volumes for 100 Combustion Ventilation 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 1...

Page 12: ...ox for proper condensate drainage See the bottom images in Fig 11 and 12 A field supplied accessory Horizontal Installation Kit trap grommet is required for all direct vent horizontal installations only The kit contains a rubber casing grommet designed to seal between the furnace casing and the condensate trap See Fig 8 Remove knockout Install grommet before relocating condensate trap NOTE Trap gr...

Page 13: ...ox Plugs Pressure Switch Port Condensate Trap Outlet Condensate Trap Relief Port Collector Box Plug Vent Elbow Vent Elbow Clamp Vent Pipe Clamp UPFLOW TRAP CONFIGURATION 1 2 Stage Units A11307 Fig 9 Upflow Trap Configuration Appearance may vary ...

Page 14: ...pen ports of the collector box Connect relief tube to port on collector box Rotate elbow to desired position and tighten clamp to 15 lb ïin Slide tube in standïoffs to adjust length Connect the new pressure switch tube from Loose Parts bag to port on front pressure switch Route tube through inducer standïoffs to adjust position of the tube Trim excess tube Connect pressure switch tube to port on c...

Page 15: ...ation Attach condensate trap with screw to collector box Slide relief tube in standïoffs to adjust length Vent elbow shown in alternate orientation Tighten clamp on inlet to vent elbow 15 lb ïin Align trap over middle and rightïhand port on collector box NOTE Remove knockout in casing before reïinstalling the condensate trap Install plug on open port of collector box Horizontal Right Trap Configur...

Page 16: ...ed position and torque clamp on inlet 15 lb in Slide relief tube in stand offs to adjust length Attach condensate trap with screw to collector box Align trap over middle and right hand port on collector box Install two plugs previously removed in open ports on collector box Connect relief tube to port on collector box Connect the new pressure switch tube from Loose Parts bag to port on front press...

Page 17: ...d together and b There is an air gap at the point where the two drain lines meet or 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 in Fig 18 NOTE On narrower casings it may be easier to remove the condensate trap connect the drain line components and re install the condensate trap Read the steps thoroughly to familiarize your...

Page 18: ...from field supplied 1 2 in CPVC or 3 4 in PVC pipe in compliance with local building codes A factory supplied 1 2 in CPVC to 3 4 in PVC adapter is supplied in the loose parts bag for use as required 15 Install the adapter or connect the 1 2 in CPVC pipe by sliding a spring clamp over the open end of the grommet on the outside the furnace casing 16 Open the spring clamp and insert the long end of t...

Page 19: ... trap 5 Remove the pre formed rubber drain elbow and two spring clamps from the loose parts bag 6 Connect the full or modified elbow and or grommet to the outlet of the condensate trap with one spring clamp Avoid misalignment of the drain pipe which may cause kinks in the elbow or grommet 7 The remaining drain line can be constructed from field supplied 1 2 in CPVC or 3 4 in PVC pipe in compliance...

Page 20: ...ssure DIRECTION OF AIRFLOW Condensing Furnace Evaporator Coil Blower 3 4 PVC 1 2 3 4 1 2 CPVC or larger Positive pressure Pressure lower than areas with Negative pressure 3 4 PVC DIRECTION OF AIRFLOW 1 2 3 4 3 4 3 4 Open standpipe 3 4 Condensing Furnace Evaporator Coil Blower 3 4 PVC 3 4 1 2 CPVC or larger Positive pressure Pressure lower than areas with Negative pressure 3 4 PVC DIRECTION OF AIRF...

Page 21: ...Negative pressure 3 4 PVC Open standpipe Optional when coil drain is not connected to furnace drain TEE 1 2 CPVC to 3 4 PVC adapter from loose parts bag DIRECTION OF AIRFLOW A170135 Fig 18 Example of Field Drain Attachment INSTALLATION Cabinet air leakage is less than 2 at 1 0 in W C Cabinet air leakage is less than 1 4 at 0 5 in W C when tested in accor dance with ASHRAE Standard 193 NOTICE Upflo...

Page 22: ...guration See Fig 22 23 and 24 Leveling Legs If Desired In upflow position with side return inlet s leveling legs may be used See Fig 20 Install field supplied 5 16 x 1 1 2 in 8 x 38 mm max corrosion resistant machine bolts washers and nuts NOTE Bottom closure must be used when leveling legs are used It may be necessary to remove and reinstall bottom closure panel to install leveling legs To remove...

Page 23: ... air opening Remove and discard this panel when bottom return air is used To remove bottom closure panel see Fig 27 and 28 Horizontal Installation NOTE The furnace must be pitched forward as shown in Fig 21 for proper condensate drainage FIRE EXPLOSION AND CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury death or property damage Do not install the fur...

Page 24: ... be used for flame roll out protection when bottom of furnace is used for return air connection See Fig 25 for proper orientation of roll out shield ANY COMBINATION OF 1 2 OR 3 PERMITTED A11036 Fig 22 Upflow Return Air Configurations and Restrictions A11037 Fig 23 Downflow Return Air Configurations and Restrictions HORIZONTAL TOP RETURN NOT PERMITTED FOR ANY MODEL A11038 Fig 24 Horizontal Return A...

Page 25: ... finished ceiling 2 IN 51 mm COMBUSTION AIR PIPE SEE VENTING SECTION Install 12 x 22 204 x 559 mm sheet metal in front of and above the burner compartment area The sheet metal MUST extend above the furnace casing by 1 in 25 mm with the door removed A 1 in 25 mm clearance minimum between top of furnace and combustible material is required The entire length of furnace must be supported when furnace ...

Page 26: ... some models may vary in appearance A170123 Fig 27 Removing Bottom Closure Panel 2 Screws BOTTOM PLATE SCREWS 4 1 Lay furnace on the back or side 2 Remove the four 4 screws that secure the bottom plate to the furnace casing 3 Remove the bottom closure from the casing 4 Re install the bottom plate to the furnace casingand re install the four 4 screws Representative drawing only some models may vary...

Page 27: ...pening do not match the required filter or IAQ device dimensions See the instructions supplied with factory accessory duct adapters Table 5 Filter Media Pressure Drop Clean Versus Airflow In W C Pa 14 x 25 Filter Factory Accy Washable Representative After Market Filter Media Fiberglass Pleated CFM L s 1 in 2 5 cm 1 in 2 5 cm 2 in 5 cm 1 in 2 5 cm 2 in 5 cm 600 283 0 04 12 0 07 17 0 10 26 0 24 60 0...

Page 28: ...8 x 635 x 19 Washable 24 1 2 622 16 x 25 x 3 4 406 x 635 x 19 24 x 25 x 3 4 610 x 635 x 19 Washable Recommended to maintain air filter face velocity See Product Data for part number Not all families have these models Air Filter Located in Filter Cabinet FILTER CABINET HEIGHT IN MM FILTER SIZE IN MM FILTER TYPE 14 3 16 360 14 x 25 x 3 4 356 x 635 x 19 Washable or Media 16 406 1 16 x 25 x 3 4 406 x ...

Page 29: ... requirements in your area NOTICE General Requirements The duct system should be designed and sized according to accepted national standards such as those published by Air Conditioning Contractors Association ACCA Manual D Sheet Metal and Air Conditioning Contractors National Association SMACNA or American Society of Heating Refrigerating and Air Conditioning Engineers ASHRAE or consult The Air Sy...

Page 30: ...ooling Do not use for heating 1665 1625 1575 1530 1480 1435 1385 1340 1285 1240 Orange Alt Cooling or alt Heating 1475 1420 1370 1320 1270 1220 1170 1125 1070 1025 Blue Heating or alt Cooling 1345 1290 1235 1180 1130 1080 1025 975 935 885 Red Alt Cooling Do not use for heating 1155 1080 1015 960 895 845 790 735 675 620 60100C Gray Cooling Do not use for heating 2280 2240 2200 2165 2125 2085 2020 1...

Page 31: ...s use a new listed connector Do not use a connector which has previously served another gas appliance Black iron pipe shall be installed at the furnace gas control valve and extend a minimum of 2 in 51 mm outside the furnace WARNING FURNACE DAMAGE HAZARD Failure to follow this caution may result in furnace damage Connect gas pipe to furnace using a backup wrench to avoid damaging gas controls and ...

Page 32: ...erious injury death or property damage Before servicing disconnect all electrical power to furnace When servicing controls label all wires prior to disconnection Reconnect wires correctly Verify proper operation after servicing Always reinstall access doors after completing service and maintenance WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or dea...

Page 33: ...nace If field supplied manual disconnect switch is to be mounted on furnace casing side select a location where a drill or fastener cannot damage electrical or gas components WARNING The J Box must be used when field line voltage electrical connections are made to the furnace wiring harness inside the furnace casing The J Box cover is not required if a field supplied external electrical box is att...

Page 34: ...ket and attach both ground wires to the green ground screw 8 Connect any code required external disconnect s to field power wiring 9 Connect field power and neutral leads to furnace power leads inside the external electrical box as shown in Fig 34 Power Cord Installation in Furnace J Box NOTE Power cords must be able to handle the electrical requirements listed in Table 11 Refer to power cord manu...

Page 35: ...al size See Fig 36 Accessories See Fig 36 1 Electronic Air Cleaner EAC Connect an accessory Electronic Air Cleaner if used using 1 4 in female quick connect terminals to the two male 1 4 in quick connect terminals on the control board marked EAC 1 and EAC 2 The terminals are rated for 115VAC 1 0 amps maximum and are energized during blower motor operation 2 Humidifier HUM The HUM terminal is a 24 ...

Page 36: ... 104 9 6 12 9 14 28 8 7 15 48080B 115 60 1 127 104 10 13 4 14 27 8 4 15 60080C 115 60 1 127 104 12 3 16 3 12 35 10 7 20 60100C 115 60 1 127 104 12 6 16 6 12 34 10 5 20 66120D 115 60 1 127 104 12 4 16 4 12 35 10 7 20 66140D 115 60 1 127 104 12 6 16 6 12 34 10 5 20 Permissible limits of the voltage range at which the unit operates satisfactorily Unit ampacity 125 percent of largest operating compone...

Page 37: ... in the required orientation Venting for this furnace shall follow all Local codes for Category IV venting systems This furnace is CSA approved for venting with PVC ABS DWV venting systems This furnace is also CSA approved for venting with M G DuraVentR PolyProR polypropylene venting systems NOTE THESE INSTRUCTIONS DO NOT CONTAIN DETAILED INSTALLATION INSTRUCTIONS FOR POLYPROPYLENE VENTING SYSTEMS...

Page 38: ... being placed into operation could result in carbon monoxide poisoning or death The following steps shall be followed for each appliance connected to the venting system being placed into operation while all other appliances connected to the venting system are not in operation 1 Seal any unused openings in venting system 2 Inspect the venting system for proper size and horizontal pitch as required ...

Page 39: ... supplied brackets or supports attached to the structure A factory accessory vent termination kit may be used for direct vent terminations Termination kits are available for 2 in or 3 in pipe See Table 12 for available options NOTICE Table 12 Vent Termination Kit for Direct Vent 2 pipe Systems Vent and Combustion Air Pipe Diameters Approved Two Pipe Termination Fittings Allowable Concentric Vent K...

Page 40: ...since the vent and combustion air system is less susceptible to damage or contamination The termination is usually located away from adjacent structures or other obstacles such as inside corners windows doors or other appliances It is less prone to icing conditions and it often has less visible vent vapors Sidewall terminations may require sealing or shielding of building surfaces with a corrosive...

Page 41: ...ion section above for locating the vent termination If the unobstructed distance from the foundation to the property line of the adjacent lot is no less than 4 ft 1 2 M and no greater than 8 ft 2 4 M it will be necessary to re direct the flue gas plume In this situation a concentric vent kit cannot be used A 2 pipe termination or single pipe termination when permitted that re directs the flue gas ...

Page 42: ...le Tee Dry Well Cap water tight and removable Recommend T fitting with 4 inch minimum height standpipe A of same diameter or larger extending upward A A A A170122A Fig 39 Recommended Combustion Air Inlet Moisture Trap FURNACE PIPE DIAMETER TRANSITION IN VERTICAL SECTION NOT IN HORIZONTAL SECTION A93034 Fig 40 Combustion Air and Vent Pipe Diameter Transition Location and Elbow Configuration ...

Page 43: ...n equivalent lengths of vent terminations and flexible vent pipes and for calculating total vent lengths To calculate the Total Equivalent Vent Length TEVL of the venting system 1 Measure the individual distance from the furnace to the ter mination for each pipe 2 Count the number of elbows for each pipe 3 For each pipe multiply the number of elbows by the equi valent length for the type of elbow ...

Page 44: ...t pipe Trapped water in the vent pipe may result in nuisance pressure switch tripping Avoid short horizontal offsets with 90 deg Elbows Short offsets can be difficult to slope and may trap con densate Use 45 deg Elbows where possible to ensure conden sate drainage Slope vent pipe back to the furnace at least per foot A14546 Fig 41 Near Furnace Vent Connections Install the Vent and Combustion Air P...

Page 45: ...upling that attaches to the vent pipe adapter must be used The adapter seals the vent pipe to the casing and reduces the strain on the vent elbow attached to the inducer 1 Apply the gaskets to the vent pipe and combustion air pipe adapters If supplied remove and discard round center slug from interior of gasket See Fig 42 NOTE The vent pipe adapter can be distinguished from the inlet pipe adapter ...

Page 46: ...ibution of primer and cement 4 Complete the vent and combustion air pipe installation by connecting the concentric vent or by installing the required termination elbows as shown in Figs 53 54 and 55 For Ventilated Combustion Air Termination See Fig 56 5 Clean and dry all surfaces to be joined 6 Check dry fit of pipe and mark insertion depth on pipe 7 Insert the vent pipe into the vent elbow 8 Torq...

Page 47: ...upling 11 Slide the end of the coupling with notches in it over the standoffs in the vent pipe adapter 12 Tighten the clamp of the coupling over the vent pipe adapter Torque the lower clamp around the vent pipe adapter to 15 lb in 13 Pilot drill a 1 8 in hole in the combustion air pipe adapter 14 Complete the vent and combustion air pipe as shown in Install the Vent and Combustion Air Pipe FOR POL...

Page 48: ...kit using the guidelines provided in section Locating The Vent Termination in this instruction 1 Cut two holes one for each pipe of appropriate size for pipe size being used 2 Loosely install elbow in bracket if used and place as sembly on combustion air pipe 3 Install bracket as shown in Fig 53 and 55 NOTE For applications using vent pipe option indicated by dashed lines in Fig 53 and 54 rotate v...

Page 49: ... Type ASTM or ULC Specification Pipe Solvents Primers Cements PVC Pressure Pipe Schedule 40 D1785 D2466 or D2665 F656 D2564 DWV Schedule 40 D1785 D2665 Cellular Core Schedule 40 F891 SDR 26 N A D2241 SDR 21 N A D2241 IPEX Schedule 40 ULC S636 ULC S636 ULC S636 ULC S636 Royal Pipe Schedule 40 ULC S636 ULC S636 ULC S636 ULC S636 ABS ABS Schedule 40 D1527 D2468 Clear Cleaner For ABS D2235 DWV IPS Siz...

Page 50: ...mm 0 Insulation 3 8 Insulation 1 2 Insulation 38 51 38 51 38 51 7 6 1 6 1 15 2 13 7 18 3 15 2 18 1 5 1 5 7 6 6 1 9 1 7 6 29 4 6 3 0 6 1 4 6 40 3 0 1 5 4 6 3 0 Unit Size 40 000 BTUH 60 000 BTUH Winter Design Temp C Pipe Dia mm Uninsulated 3 8 in Insulation 1 2 in Insulation Uninsulated 3 8 in Insulation 1 2 in Insulation 38 51 64 38 51 64 38 51 64 38 51 64 76 38 51 64 76 38 51 64 76 7 6 1 6 1 6 1 6...

Page 51: ... 33 5 27 4 28 9 1 5 18 2 35 0 38 1 10 0 24 3 33 5 35 0 15 2 35 0 38 1 13 1 36 5 4 5 9 1 2744 3048 9 1 28 9 1 5 24 3 25 9 NA 16 7 32 0 35 0 9 1 22 8 30 4 32 0 13 7 30 4 35 0 11 8 35 0 3 0 4 5 NOTES 1 Inducer Outlet Restrictor disk P N 337683 401 1 25 in 32 mm Dia shipped in the loose parts bag or available through Replacement Components required under 10 ft 3 M TEVL in all orientations Required for...

Page 52: ...th MEVL 95 ft 29 M For 2 pipe from Table 16 Is TEVL less than MEVL YES Therefore 2 pipe MAY be used Example 2 A direct vent 60 000 BTUH furnace installed at 2100 ft 640M Venting system includes FOR EACH PIPE 100 feet 30 M of vent pipe 95 feet 29 M of combustion air inlet pipe 3 90º long radius elbows and a polypropylene concentric vent kit Also includes 20 feet 6 1 M of flexible polypropylene vent...

Page 53: ... soffitt located above the vent termination within a horizontal distance of 2 ft 61 cm from the centerline of the vent termination 6 ft 2 M Clearance to a ventilation exhaust including HRV ERV on either Wall A or Wall B 12 in 305 mm Clearance above paved sidewalk or paved driveway located on public property 7 ft 2 1 M Clearance under a veranda porch deck or balcony N P No operable windows doors or...

Page 54: ... for combustion air connection UPFLOW VERTICAL VENT A11310A Fig 45 Upflow Configurations Appearance may vary See Notes for Venting Options 1 2 3 4 5 6 7 5 Rotate vent elbow to required position DOWNFLOW LEFT CONFIGURATION A11311A 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 DOWNFLOW RIGHT CONFIGURATION A11312A Requires A...

Page 55: ... LEFT RIGHT VENT CONFIGURATION A11329A Fig 47 Horizontal Left Appearance may vary See Notes for Venting Options ALTERNATE COMBUSTION AIR CONNECTIONS HORIZONTAL RIGHT VERTICAL VENT CONFIGURATION A11337 Requires Internal Vent Kit See Product Data for Current Kit Number HORIZONTAL RIGHT LEFT VENT CONFIGURATION A11336 ALTERNATE COMBUSTION AIR CONNECTIONS HORIZONTAL RIGHT RIGHT VENT CONFIGURATION A1133...

Page 56: ...rew VENT PIPE FLUSH SHOWING COUPLING VENT PIPE FLUSH WITH ADAPTER VENT PIPE ADAPTER WITH GASKET INSTALLED ON FURNACE VENT PIPE IS CUT FLUSH WITH TOP OF ADAPTER PRIME AND CEMENT VENT PIPE TO ADAPTER ALLOW TO DRY BEFORE INSTALLING VENT COUPLING ALIGN NOTCHES IN VENT PIPE COUPLING OVER STAND OFF ON ADAPTER TORQUE LOWER CLAMP 15 LB IN WHEN REMAINING VENT PIPE IS INSTALLED TORQUE UPPER CLAMP TO 15 LB I...

Page 57: ...n 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 furnace to a dryer or water heater vent or other appliance s direct vent intake or exhaust 12 in 305 mm 12 in 305 mm N Furnace combustion air intake clearance to a water heater vent dryer vent or other types of app...

Page 58: ...ully 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 furnace to a dryer or water heater vent or other appliance s direct vent intake or exhaust 12 in 305 mm 12 in 305 mm N Clearance to a moisture exhaust duct dryer vent spa exhaust etc 12 in 305 mm See Not...

Page 59: ...ever 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 in 152mm minimum clearance between wall and end of vent pipe 10 in 254mm maximum pipe lengt h Sidewall Termination with Straight Pipe preferred Roof Termination Preferred Vent Maintain 12 in ...

Page 60: ... IN 305 MM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER IS GREATER COMBUSTION AIR ELBOW PARALLEL TO WALL OVERHANG 12 IN 305 MM MIN GROUND LEVEL OR ANTICIPATED SNOW LEVEL EXHAUST CLEARANCE TO OVERHANG PER CODE OPTIONAL BRACKET COUPLING 12 IN 305 MM MIN SEPARATION BETWEEN BOTTOM OFCOMBUSTION AIR AND BOTTOM OF VENT A13078 Fig 55 Alberta and Saskatchewan Vent Termination ...

Page 61: ...mm Pipe hangar Ventilated Combustion Air intake termination in crawl space Ventilated Combustion Air intake pipe CRAWL SPACE ATTIC highest level of insulation A10497 Fig 56 Vent Terminations for Ventilated Combustion Air ...

Page 62: ...ce positioning or improper venting condition before resetting switch DO NOT jumper this switch CAUTION Before operating furnace check flame rollout manual reset switch for continuity If necessary press button to reset switch EAC 1 115vac terminal is energized whenever blower operates HUM 24vac terminal is only energized when the gas valve is energized in heating Prime Condensate Trap with Water CA...

Page 63: ...AGE HAZARD Failure to follow this caution may result in reduced furnace life The 26 000 BTUH model has a lower nominal manifold pressure than other models Do not adjust the natural gas manifold pressure above 1 8 in W C The 26 000 BTUH model can be identified by the green label affixed to the solenoid of the gas valve Refer to the Adjustment section for setting the manifold pressure USE TABLE 19 W...

Page 64: ...ut rate first determine if the furnace has the correct orifice installed At higher altitudes or different gas heat contents it may be necessary to change the factory orifice to a different orifice Tables have been provided in the furnace installation instructions to match the required orifice to the manifold pressure to the heat content and specific gravity of the gas To do this 1 Obtain average y...

Page 65: ... 915 825 43 3 6 43 3 7 43 3 8 42 3 2 850 44 3 8 43 3 5 43 3 6 43 3 7 875 44 3 6 44 3 7 43 3 4 43 3 5 4000 900 44 3 4 44 3 5 44 3 7 44 3 8 1219 925 44 3 2 44 3 4 44 3 5 44 3 6 950 44 3 1 44 3 2 44 3 3 44 3 4 750 42 3 3 42 3 4 42 3 5 42 3 6 4001 775 43 3 7 43 3 8 42 3 3 42 3 4 1220 800 43 3 5 43 3 6 43 3 7 43 3 8 825 44 3 8 43 3 4 43 3 5 43 3 6 850 44 3 5 44 3 7 44 3 8 43 3 4 5000 875 44 3 3 44 3 5 ...

Page 66: ... 5 43 3 7 43 3 8 42 3 2 725 44 3 8 43 3 4 43 3 5 43 3 6 750 44 3 5 44 3 7 44 3 8 43 3 4 8000 775 44 3 3 44 3 4 44 3 5 44 3 7 2438 800 44 3 1 44 3 2 44 3 3 44 3 4 825 44 2 9 44 3 0 44 3 1 44 3 2 625 42 3 4 42 3 5 42 3 6 42 3 7 8001 650 43 3 8 42 3 2 42 3 3 42 3 4 2439 675 43 3 5 43 3 6 43 3 7 42 3 2 700 44 3 7 43 3 4 43 3 5 43 3 6 725 44 3 5 44 3 6 44 3 7 44 3 8 9000 750 44 3 3 44 3 4 44 3 5 44 3 6...

Page 67: ... 5 44 1 5 44 1 6 4000 925 44 1 4 44 1 4 44 1 5 44 1 5 1219 950 44 1 3 44 1 3 44 1 4 44 1 4 750 43 1 7 43 1 7 43 1 8 43 1 8 775 44 1 8 43 1 6 43 1 7 43 1 7 4001 800 44 1 7 44 1 7 44 1 8 43 1 6 1220 825 44 1 6 44 1 6 44 1 7 44 1 8 850 44 1 5 44 1 5 44 1 6 44 1 7 to 875 44 1 4 44 1 5 44 1 5 44 1 6 5000 900 44 1 3 44 1 4 44 1 4 44 1 5 1524 925 44 1 3 44 1 3 44 1 4 44 1 4 725 43 1 7 43 1 7 43 1 8 43 1 ...

Page 68: ...supply manual shutoff valve to ON position 6 Turn furnace gas valve switch to ON position 7 Jumper R and W thermostat connections at the furnace control board 8 When main burners ignite confirm inlet gas pressure is between 4 5 in w c 1125 Pa and 13 6 in w c 3388 Pa 9 Remove jumper across thermostat connections to terminate call for heat Wait until the blower off delay is completed 10 Turn furnace...

Page 69: ... section for setting the manifold pressure USE TABLE 19 WHEN ADJUSTING 26 000 BTUH MODEL MANIFOLD PRESSURE CAUTION i When correct input is obtained replace cap that conceals gas valve regulator adjustment screws Main burner flame should be clear blue almost transparent See Fig 60 j Remove jumper R to W Burner Flame Burner Manifold A11461 Fig 60 Burner Flame FIRE HAZARD Failure to follow this warni...

Page 70: ...and relocate it them to HEAT heating blower tap terminal s Reconnect original lead on SPARE terminal Adjust Blower Off Delay Heat Mode If desired the main blower off time delay period may be lengthened or shortened when operating in the heating mode to provide greater comfort For position and location of jumpers on control center see Fig 36 and Fig 69 The blower off delay has four adjustable setti...

Page 71: ... igniter should NOT glow and control diagnostic light flashes a status code 31 If hot surface igniter glows when inducer motor is disconnected shut down furnaceimmedi ately e Determine reason low pressure switch did not function properly and correct condition f Turn off 115 v power to furnace g Reconnect inducer motor wires replace door and turn on 115 v power h Blower will run for 90 sec before b...

Page 72: ...72 A190099 Fig 62 Service Label Information ...

Page 73: ... 720 80 45 90 225 26 138 277 692 82 44 88 220 27 133 267 667 84 43 86 214 28 129 257 643 86 42 84 209 29 124 248 621 88 41 82 205 30 120 240 600 90 40 80 200 31 116 232 581 92 39 78 196 32 113 225 563 94 38 76 192 33 109 218 545 96 38 75 188 34 106 212 529 98 37 74 184 35 103 206 514 100 36 72 180 36 100 200 500 102 35 71 178 37 97 195 486 104 35 69 173 38 95 189 474 106 34 68 170 39 92 185 462 10...

Page 74: ...e minimum break point of the switch is 0 63 in W C The maximum break point of the switch is 0 73 in W C The maximum make point of the switch is 0 83 in W C ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death There may be more than one electrical supply to the furnace Check accessories and cooling unit for additional electrical supplies that must be shut ...

Page 75: ... furnace control remove tape from blower door switch and re install blower door 6 Verify furnace shut down by lowering thermostat setting below room temperature 7 Verify that furnace restarts by raising thermostat setting above room temperature Checklist 1 Put away tools and instruments Clean up debris 2 Verify that the jumper is removed from the TEST TWIN terminal Verify that there is nothing plu...

Page 76: ...difying or servicing system main electrical disconnect switch must be in the OFF position and install a lockout tag There may be more than one disconnect switch Lock out and tag switch with a suitable warning label Verify proper operation after servicing Always reinstall access doors after completing service and maintenance WARNING 1 Turn off electrical supply to furnace 2 Remove filter cabinet do...

Page 77: ... SHAFT FLAT SCREW MOTOR ARM GROMMET SCREW LOCATION BLOWER HSG ASSY BRACKET BRACKET ENGAGEMENT SEE DETAIL A CAPACITOR OR POWER CHOKE WHEN USED BRACKET SCREW GND BLOWER HSG ASSY MOTOR BLOWER WHEEL BLOWER CUTOFF BLOWER DETAIL A Representative drawing only some models may vary in appearance A11584 Representative drawing of DIBC blower wheel only some models may vary in appearance A190094 Fig 63 Blower...

Page 78: ...o the burner assembly and set aside Note the location of the green yellow wire and ground ter minal 10 Inspect the orifices in the manifold assembly for blockages or obstructions Remove orifice and clean or replace orifice 11 Remove the four screws that attach the top plate of the cas ing to the furnace 12 Raise top plate up slightly and prop it up with a small piece of wood or folded cardboard 13...

Page 79: ...se items 5a through 5d 7 Reconnect igniter harness to the igniter dressing the igniter wires to ensure there is no tension on the igniter itself See Fig 64 8 Turn on gas and electrical supplies to furnace 9 Verify igniter operation by initiating control board self test feature or by cycling thermostat 10 Replace control door Flushing Collector Box and Drainage System ELECTRICAL SHOCK AND FIRE HAZA...

Page 80: ... damage to heat tape such as nicks cuts abrasions gnawing by animals etc 2 Check for discolored heat tape insulation If any damage or discolored insulation is evident replace heat tape 3 Check that heat tape power supply circuit is on Cleaning Heat Exchangers The following items must be performed by a qualified service technician Primary Heat Exchangers If the heat exchangers get an accumulation o...

Page 81: ... CAUTION Since the furnace uses a condensing heat exchanger some water will accumulate in the unit as a result of the heat transfer process Therefore once it has been operated it cannot be turned off and left off for an extended period of time when temperatures will reach 32_F 0_C or lower unless winterized Follow these procedures to winterize your furnace UNIT COMPONENT DAMAGE HAZARD Failure to f...

Page 82: ...ronic air cleaner terminal EAC 1 is energized and remains energized as long as the blower motor BLWM is energized f Blower Off Delay When the thermostat is satisfied the R to W circuit is opened de energizing thegas valveGV stopping gas flowto theburners andde energizing thehu midifier terminal HUM The inducer motor IDM will re main energized for a 15 sec post purge period The blow er motor BLWM a...

Page 83: ...s code of the previous fault or status code 11 1 short and 1 long flash if there was no previous fault After the control repeats the code 4 times the control will go through a brief component test sequence The inducer will start and run for the entire component test The HSI blower motor FAN speed AMBER LED boards only HEAT speed and COOL speed will run for 10 15 seconds each Gas valve and humidifi...

Page 84: ...84 A190093 Fig 68 Troubleshooting Guide Cont ...

Page 85: ...85 3344442 2 Rev B A190099 Fig 69 Wiring Diagram ...

Page 86: ...by brand name or contact PAYNE HEATING COOLING Consumer Relations Department P O Box 4952 Syracuse New York 13221 4952 1 800 417 2963 Have available the model number series number and serial number located on the unit rating plate to ensure correct replacement part Model Nomenclature MODEL MAJOR SERIES COOLING CAPACITY HEATING INPUT WIDTH MINOR SERIES VARIATIONS PG95ESA A 30 026 A A A FIRE EXPLOSI...

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