Payne PG9MAB Service And Maintenance Instructions Download

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SERVICE TRAINING

Packaged Service Training

programs are an excellent way to increase your

knowledge of the equipment discussed in this manual, including:

• Unit Familiarization • Maintenance

• Installation Overview • Operating Sequence

A large selection of product, theory, and skills programs is available, using popular

video-based formats and materials. All include video and/or slides, plus companion

book.

Classroom Service Training

plus "hands-on" the products in our labs can mean

increased confidence that really pays dividends in faster troubleshooting, fewer

callbacks. Course descriptions and schedules are in our catalog.

CALL FOR FREE CATALOG 1-800-644-5544

[ ] Packaged Service Training [ ] Classroom Service Training

A94328

2008 Payne Heating & Cooling Systems

7310 W. Morris St.

Indianapolis, IN 46231

Printed in U.S.A.

Edition Date: 12/08

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

Catalog No: SG---PG9MAB---03

Replaces: SG--- PG9MAB--- 02

Summary of Contents for PG9MAB

Page 1: ...otential for personal injury Understand the signal words DANGER WARNING and CAUTION These words are used with the safety alert symbol DANGER identifies the most serious hazards which will result in severe personal injury or death WARNING signifies a hazard which could result in personal injury or death CAUTION is used to identify unsafe practices which may result in minor personal injury or produc...

Page 2: ... operation CAUTION GENERAL This furnace can be installed as a direct vent 2 pipe or non direct vent 1 pipe condensing gas furnace These instructions are written as if the furnace is installed in an upflow application An upflow furnace application is where the blower is located below the combustion and controls section of the furnace and conditioned air is discharged upward Since this furnace can b...

Page 3: ...on the label attached to the furnace WARNING The minimum maintenance that should be performed on this equipment is as follows 1 Check and clean or replace air filter each month as needed 2 Check blower motor and wheel for cleanliness annually 3 Check electrical connections for tightness and controls for proper operation each heating season Service as necessary 4 Check for proper condensate drainag...

Page 4: ...If equipped with permanent washable filter s clean filter by spraying cold tap water through filter in opposite direc tion of airflow 6 Rinse filter and let dry Oiling or coating filter is not recom mended 7 Slide filter into furnace 8 Recapture filter retaining wire 9 Replace blower access panel and main furnace door 10 Turn on electrical supply to furnace Step 2 Blower Motor and Wheel Maintenanc...

Page 5: ...l affect operation 1 Connect one tube blue or blue and white striped from collector box 2 Connect one tube violet or unmarked from in ducer housing 3 Connect one tube relief port green or pink from collector box c Connect field drain to condensate trap NOTE Ensure tubes are not kinked or pinched as this will affect operation 13 Reinstall control box transformer and door switch as sembly on blower ...

Page 6: ...ed in slot in manifold grommet or else they could become pinched or severed and electrically shorted WARNING 16 Reconnect wires to gas valve and igniter Refer to furnace wiring diagram for proper wire location 17 Reinstall burner box pressure tube to gas valve regulator fit ting 18 Reinstall gas supply pipe to furnace gas control valve using backup wrench on gas valve to prevent rotation and im pr...

Page 7: ... for any damage If gasket is damaged in any way it must be repaired To repair remove damaged gasket section apply sealant releasing agent such as PAM cooking spray or equivalent must not contain corn nor canola oil halogenated hydrocarbons nor aromatic content to prevent inadequate seal from occurring to burner box and apply a small bead of G E RTV 162 G E RTV 6702 or Dow Corning RTV 738 sealant t...

Page 8: ...ctor box pressure tube to be relocated between the inducer housing and the blower shelf to prevent a trap Refer to the Installation Instructions for further details NOTE 324999 201 REV C FIELD INSTALLED FACTORY SUPPLIED DRAINTUBE COUPLING RIGHT DRAIN OPTION BURNER ENCLOSURE PRESSURE REFERENCE TUBE ASSEMBLY BURNER ENCLOSURE PRESSURE REFERENCE TUBE ASSEMBLY BURNER ENCLOSURE PRESSURE REFERENCE TUBE A...

Page 9: ...river remove the single screw securing the igniter bracket to the burner box bracket See Fig 13 and carefully withdraw the igniter and bracket as sembly through the front of the burner box without striking the igniter on surrounding parts Note that the igniter bracket has a handle that extends to the front of the burner box to aid in handling See Fig 13 d Inspect igniter for signs of damage or fai...

Page 10: ...uring installation service or maintenance will cause this fuse to blow If fuse replacement is required use ONLY a fuse of identical size The furnace control LED will flash status code 24 when fuse needs to be replaced With power to the unit disconnected check all electrical connections for tightness Tighten all screws on electrical connections If any smoky or burned connections are found disassemb...

Page 11: ... same type or equivalent wire W Y GND THERMOSTAT TERMINALS 1 2 3 A02174 Fig 15 Field Wiring BLW NUETRAL STATUS CODE LED SEC 2 SEC 1 EAC 2 L2 FUSE 3 AMP 0 5 AMP 24VAC HUM TEST TWIN G Com W Y R 24V 120 180 90 150 BLOWER OFF DELAY PLT 1 COOL HEAT SPARE 1 SPARE 2 EAC 1 1 AMP 115VAC PR 1 L1 PL2 1 24 V THERMOSTAT TERMINALS 3 AMP FUSE LED OPERATION DIAGNOSTIC LIGHT 115 VAC L2 NEUTRAL CONNECTIONS COOL HEA...

Page 12: ...omotive type CAUTION 6 Replace drain connection cap and clamp to inducer housing 7 Replace main furnace door 8 Propylene glycol need not be removed before restarting fur nace A07911 Fig 17 Freeze Protection WIRING DIAGRAMS See Fig 21 for wiring diagram TROUBLESHOOTING Use the troubleshooting guide the status code LED on the furnace control and the component test to isolate furnace operation proble...

Page 13: ... COM 24v terminals are jumpered longer than 2 sec LED will flash rapidly and ignore component test request A99119 Fig 19 Funnel in Drain Tube and Antifreeze Running Through Trap Component test sequence for single stage furnace is as follows a LED will display status code 11 four times b Inducer motor starts and continues to run until Step f of component test sequence c After 7 sec the hot surface ...

Page 14: ...T CLOSE OR REOPENED If open longer than five minutes inducer shuts off for 15 minutes before retry Check for Excessive wind Proper vent sizing Defective inducer motor Low inducer voltage 115VAC Defective pressure switch Inadequate combustion air supply Restricted vent Disconnected or obstructed pressure tubing Low inlet gas pressure if LGPS used If it opens during blower on delay period blower wil...

Page 15: ...AFT MOTOR RELAY SPST N O ILK BLOWER ACCESS PANEL INTERLOCK SWITCH SPST N O J1 BLOWER OFF DELAY JUMPER SELECTOR J2 COOLING OFF DELAY JUMPER JB JUNCTION BOX LED LIGHT EMITTING DIODE FOR STATUS CODES RED LGPS LOW GAS PRESSURE SWITCH SPST N O LS LIMIT SWITCH AUTO RESET SPST N C OL AUTO RESET INTERNAL MOTOR OVERLOAD TEMPERATURE SWITCH N C PCB PRINTED CIRCUIT BOARD CONTROL PL1 11 CIRCUIT PCB CONNECTOR P...

Page 16: ...est 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 humidifier will not be turned on Was there a previous status code other than 11 Is door switch closed Is there 115V going to switch Replace door switch Replace transformer Does the control respond to W...

Page 17: ... switch open Restricted vent Proper vent sizing Excessive wind Blower motor on incorrect speed tap Input rate to furnace set too high 34 IGNITION PROVING FAILURE If flame is not sensed during the trial for ignition period the control will repeat the ignition sequence 3 more times before lockout 14 occurs If flame signal is lost during the blower on delay period blower will come on for the selected...

Page 18: ...lassroom ServiceTraining plus hands on the products in our labs can mean increased confidence that really pays dividends in faster troubleshooting fewer callbacks Course descriptions and schedules are in our catalog CALL FOR FREE CATALOG 1 800 644 5544 Packaged Service Training Classroom Service Training A94328 E2008 Payne Heating Cooling Systems D 7310 W Morris St D Indianapolis IN 46231 Printed ...

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