Payne PG8 Installation And Operating Instructions Manual Download

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Summary of Contents for PG8

Page 1: ...e PG8J is also approved for use in Low Nox Air Quality Management Districts STANDARD FEATURES Four position furnace upflow horizontal right horizontal left downflow Electronic control center Adjustable heating air temperature rise LED diagnostics and self test feature Hot surface ignition HSI Twinning in Upflow Downflow and Horizontal LIMITED WARRANTY 20 year warranty on Super STM heat exchanger 5...

Page 2: ...ired 10 Downftow Installation 10 Bottom Return Air Inlet 11 Horizontal Installation 11 Suspended Furnace Support 11 Platfbrm Furnace Support i 1 Roll Out Protection 11 Bottom Return Air Inlet 1l Side Return Air Inlet 11 Filter Arrangement 11 Air Ducts 11 General Requirements 11 Ductwork Acoustical Treatment 12 Supply Ai onnections 12 Return Air Connections 14 Gas Piping 15 Electrical onnections 19...

Page 3: ...ment can be hazardous due to gas and electrical components Only trained and qualified personnel should instMl repair or service heating equipment Untrained personnel can perfoma basic maintenance _imctions such as cleaning and replacing air filters All other operations must be performed by trained service personnel When working on heating equipment observe precautions in literature on tags and on ...

Page 4: ...ce libredes materiauxcombustibles tel Vent Clearanceto combustibles qu indique sur le diagramme ForSingle WalJ vents6 inches 6po Cettefournaise peut eutiliseeavec un For Type B 1venttype 1inch 1 po Degagementde I entavec combustibles conduitd acuationde Type B 1 ou connectee Pourconduit d aouation a paroi simpb6 po 6inches au conduit ommun d autres appareilsa gaz Pourcor_duit d evaouatbn deTypeB 1...

Page 5: ...fbrmerly A G A and LG A0 design certified for use with natural and propane gases see furnace rating plate and for installation in alcoves attics basements closets utility rooms crawlspaces and garages The furnace is factory shipped _br use with natural gas A CSA listed gas conversion kit is required to convert furnace or use with propane gas 11 See Fig 2 for required clearances to combustible cons...

Page 6: ...cautions during thrnace installation and servicing to protect tl_e furnace electronic control Precautions will pre vent electrostatic discharges ti om personnel and hand tools which are held during the procedure These precautions will help to avoid exposing the control to electrostatic discharge by putting the thrnace the control and the person at the same electrostatic potential 1 Disconnect all ...

Page 7: ...ive seal must be made between the filrnace cabinet and the return air duct to prevent pulling air fl om the burner area and from draft safeguard opening The llowing types of furnace installations may require OLT DOOR AIR br combustion due to chemical exposures Commercial buildings Buildings with indoor pools Laundv rooms Hobby or craft rooms and Chemical storage areas If air is exposed to the fbll...

Page 8: ... adversely affected Never connect retumoair dacts to back of furnace See Fig 6 LOCATION RELATIVE TO OOLING EQL IPMENT The cooling coil must be installed parallel with or on d_e downstream side of the unit to avoid condensation in the heat exchangers When installed parallel with the farnace dampers or other flow contlol must prevent chilled air fi om entering d_e furnace If the dampers are manually...

Page 9: ...ri zontal or vertical duct s or opening s directly communicat ing with the ontdoors or spaces that freely communicate with the ontdoors 2 Fig 7 illustrates how to provide TWO OUTDOOR OPEN INGS one inlet and one outlet combustion and ventilation air opening to the outdoors a One opening MUST commence within 12 300 ram of the ceiling and the second opening MUST commence within 12 300 ram of the floo...

Page 10: ... 0 60 ACH shall not be used The mininlum required volume of the space varies with the number of A H and shall be detem_ined per Table 3 or Equations 1 and 2 Determine the mininmm required volume for each appliance in the space and add the volumes together to get the total n_inin mm required volume for the space Table 3 Minimum Space Volumes were determined by using the following equations fiom the...

Page 11: ...m closure panel perfbrrn die following 1 Tilt or raise furnace and remove 2 screws holding bottom filler panel See Fig 9 2 Rotate bottom filler panel downward to release holding tabs 3 Remove bottom closm e panel 4 Reinstall bottom filler panel and screws Side Return Air Inlet These fk rnaces are shipped with bottom closure panel installed in bottom return air opening This panel MUST be in place w...

Page 12: ...l and the furnace set on blocks or bricks Roll Out Protection Provide a minimum 17 3 4 X 22 piece of sheet metal for flame roll out protection in fl ont of burner area tbr fhmaces closer than 12 inches above the combustible deck or suspended furnaces closer than 12 in to joists The sheet metal MUST extend underneath the fllmace casing by 1 in with the door removed The bottom closure panel on furna...

Page 13: ...as outside the space containing the _ rnace the return air shall also be handled by a duct s sealed to the furnace casing and terminating outside the space containing the _ rnace Secure ductwork with proper fasteners for type of doctwork used Seal supply_ and return duct connections to _ rnace with code approved tape or duct sealer NOTE Flexible connections should be used between ductwork and L_ur...

Page 14: ...lled on a Combustible Floor Downflow Furnaces Connect supply air duct to supply air outlet on _iu_ace Bend flange inward past 90 with wide duct pliers_ See Fig 14 The supply air duct must be connected to ONLY the fi rnace supply outlet or air conditioning coil casing when used When installed on combustible material supply air duct must be connected to ONLY the accessory subbase KGASB0201ALL or _Sc...

Page 15: ...ver connect return air ducts to the back of the furnace Follow instl t ctions below DownJ low Furnaces The return air duct must be connected to return air opening bottom inlet as shown in Fig 19 DO NOT cut into casing sides left or right Side opening is pem_itted for only upflow and most horizontal Parnaces Bypass humidifier connections should be made at ductwork or coil casing sides exterior to f...

Page 16: ...VALVE SEDIMENT TRAP Fig 17 Typical Attic Installation A02164 GAS PIPING U _ _ _ _ _ iiii_ iiii FIRE OR EXPLOSION HAZARD Failure to L ollow this warning could result in personal injury death and or property damage Never purge a gas line into a combustion chamber Never test for gas leaks with an open flame Use a commercially available soap solution made specifically for the detection of leaks to che...

Page 17: ...010 820 Med Low 1505 1505 1480 1440 1375 1300 1190 1045 890 740 High 2405 2310 2220 2130 2025 1920 1790 1660 1530 1350 Med High 2225 2155 2080 1995 1895 1785 1675 1565 1420 1260 Med Low 2020 1955 1880 1805 1730 1630 1535 1420 1275 1135 High 2530 2450 2365 2270 2165 2065 1940 1805 1670 1505 Med High 2285 2215 2150 2075 1985 1890 1780 1660 1525 1360 Med Low 1995 1945 1900 1840 1770 1685 1600 1480 13...

Page 18: ...ger every 6 J t Joint compound pipe dope should be applied sparingly and only to male threads of joints Pipe dope must be resistant to the action of propane gas FIRE OR EXPLOSION HAZARD Failure to llow this warning could result in death personal injury an_or property damage If local codes allow the use of a flexible gas appliance connector always use a new listed connector Do not use a connector w...

Page 19: ...R CONNECTION 1 CONNECTION 2 CONNECTUON 3 COMBUN _ ONS ONLY ONLY ONLY OF 1 2 AND 3 066 060 22 AND YES NO NO NO 20 MODELS ALL OTHER MODELS YES NO NO NO Fig 19 Downflow Return Air Configurations and Restrictions _ErURN A02163 suPP_ i J _ S_DE RETURN A_R O66O6O 22 20 i i HORIZONA L RETURN R URNA R HORIZONAL NOTE RESTRICTIONE _ SAME FOR _ A_R RESTR_CTIONS HORIZONTAL RETURN A_RCONFIGURATIONS AND RESTRIC...

Page 20: ... caution may result in u nace operation stopping and water pipes fi eezing during cold weather Furnace control must be grounded _br proper operation or control will lock out ontrol is grounded through green ellow wire routed to gas valve and manifbld bracket SCrew 15 V Wiring Verif _ tl_at the voltage frequency and phase correspond to that specified on unit rating plate Also check to be sure that ...

Page 21: ...fier etc full load amps 1 Time delay type is recommended Length shown is as measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop FACTORY INSTALLED LOCATION TWO ALTERNATE FIELD LOCATION Fig 22 Relocating J Bo A02099 2 Cut wire tie on loop in L_umace wires attached to J Box 3 Move box to desired location 4 Fasten J Box to casing with two screws removed in ...

Page 22: ...cal box into casing steel 4 Remove and save two screws holding J Box See Fig 22 5 Pull furnace power wires om of 1 2 inch diameter hole in J Box Do not loosen wires from strain relief wire tie on outside of J Box 6 Route furnace power wires through holes in casing and electrical box and into electrical box 7 Pull field power wires into electrical box 8 Remove cover fiom furnace J Box 1 2_ 3 4 5 6 ...

Page 23: ...If time replacement is required use ONLY a 3 amp fuse of identical size ACCESSORIES 1 Electronic Air leaner EAC Connect an accesso_ Electronic Air leaner if used using 1 4 in female quick connect terminals to the two mab li4 in quick connect terminals on the control board marked EAC and EAC 2 The tem_inals are rated for 115 VAC 1 0 amps nmxinmm and are energized during blower motor operation See F...

Page 24: ...re approved for common venting and multistory venting with other fire assisted or aft hood equipped appliances in accordance with the NFCG or the NSCNGPIC the local building codes and Nmace and vent manufacturers instructions 23 The llowing in rotation and warning must be considered in addition to the requirements defined in the NFG and the NSCNGPI CARBON MONOXIDE POISONING HAZARD Failure to follo...

Page 25: ...ted and operated properly the venting system and or the appliances should not suffer from condensation and corrosion The venting system and all appliances shall be installed in accordance with applicable listings standards and codes The furnace should be sized to provide 100 percent of the design heating load requirement plus any margin that occurs because of Nnmce model size capacity increments H...

Page 26: ...il residue debris and tile debris Remove metal vent or liner Clay tile misalignment fes missing sections_ gaps No chimney Condensate lined with properly drainage at bottom sized_ listed liner or of chimne_ vent Yes No Part B of instructions for application uitable Not Suitable Install chimney adapter per instructions 4ot Suitable Line chimney with property sized listed flexible metal liner or Type...

Page 27: ...rt 2 Vent the furnace with the appropriate connector as shown in Fig 32 44 IT HAZARD Failure to 11ow this caution may result in personal injury Sheet metal parts may have sharp edges or bun s Use care and wear appropriate protective clothing safety glasses and gloves when handling parts and servicing _ rnaces 3 Orient the door to determine the correct location of the door cutout to be removed 4 Us...

Page 28: ...othing safety glasses and gloves when handling parts and sela icing _ maces 1 Maintain 115 v wiring and ground Improper polarity will result in rapid flashing LED and no _urnace operation 2 Make them_ostat wire connections at the 24 v terminal block on the furance control Failure to make proper connections will result in improper operation See Fig 25 3 Gas supply pressure to the furnace must be gr...

Page 29: ...ages following these figures A03209 Fig 33 Upflow Application Vent Elbow Right SEE NOTES 1 2 4 5 6 7 8 9 10 on the page following these figures Fig 36 Downflow Application Vent Elbow Left then Up A03207 SEE NOTES 1 2 3 4 5 7 8 9 on the page following these figures Fig 34 Downflow Application Vent Elbow Up then Left A03210 2S SEE NOTES l 2 3 4 5 7 8 9 on the page following these figures Fig 37 Down...

Page 30: ... 7 8 9 on the page following these figures Fig 40 Horizontal Left Application Vent Elbov_ _2_5 l SEE NOTES 1 2 4 5 7 8 9 on the page following these figures A03216 Fig 41 Horizonta_ Left Application Vent Elbow Right SEE NOTES 1 2 4 7 8 9 on the page following these figures Fig 42 Horizonta Right Application Vent Elbow Right A03218 SEE NOTES 1 2 4 5 7 8 9 on the page following these figures Fig 43 ...

Page 31: ...et metal screws spaced approximately 1 apart 9 Secure al other single wal vent connector joints with 3 corrosion resistant screws spaced approximately 120 apart Secure Type B gent connectors per vent connector manufacturers recommendations 10 The total height of the vent and connector shall be at least seven feet for the 154 000 Btuh gas input rate model when installed in a downflow application wi...

Page 32: ...t Furnace input rate must be within 2 percent of furnace rating plate input ___ 31 1 Determine the con ect gas input rate In the l_ S A The input rating t or ahimdes above 2 000 fL must be reduced by 4 percent fbr each 1 000 it above sea level For installa tions below 2000 it refer to the unit rating plate For installations above 2000 ft multiply the input on the rating plate by the de rate muhipl...

Page 33: ... _RMINAL TRAN _ANSFORMER 115VAC 24VAC JUNCTION O UNN_RKED TERMI_L I PCB CONTROL TERM_N_ l FACTORY WIRING 115_0 FACTORY WIRING 24_0 F ELDWIR NG 5_C FIELD WIRING 24_C CONDUCTOR ON CONTROL PCB FIELD WIRING SCREW TERMINAL J_ FIELD E_TH GROUND EQUIPMENT GROUND FIELD SPLICE _ PLUG RECEPTACLE TO 115VAC FIELD DiSC_NECT S_TCH _HEMATIC DIA_M _TU_L PR_A_ _SES LI Lq NEUTRAL _7 E_ _ENT _ND _ CAP ILK SPARE i HI...

Page 34: ...o Table 10 fbr cubic f_ of gas per hr e Multiply gas rate cu f_ r by heating value Btuicu ft to obtain input If clocked rate does not match required input from Step 1 increase manifold pressure to increase input or decrease manifold pressure to decrease input Repeat steps b through e until correct input is achieved Reinstall regulator seal cap on gas valve 5 Set temperatore rise The t lrnace must ...

Page 35: ...aw across terminals when furnace is in heating and after blower starts 4 Set heat anticapator on thermostat per thermostat instructions and install on subbase or wall b Electronic thermostat Set cycle rate for 4 cycles per hr 7 Adjust blower off delay The blower off delay has 4 adiustable settings f om 90 sec to 180 sec The blower off delay jumpers are located on the 34 10 TURNS FROM UNIT 24 V CON...

Page 36: ...nd wait 1 minute When pressure switch is flmctioning properly hot surface igniter should NOT glow and control diagnostic light flashes a 35 status code 32 If hot surfSce igniter glows when inducer motor is disconnected shut down furnace immediately e DeteImine reason pressure switch did not function properly and con ect condition f Turn off 115or power to ft_rnace g Reconnect inducer motor wires r...

Page 37: ...blower will come on for the selected blower off delay Check for Flame sensor must not be grounded Oxide buildup on flame sensor clean with fine steel wool Proper flame sense microamps 5 microamps DC rain 40 S0 nominal Gas valve defective or gas valve turned off Manual valve shut off Defective Hot Surface Ignitor Control ground continuity Low inlet gas pressure Inadequate flame carryover or rough i...

Page 38: ...on soot or excessive dust If necessa_ have _ul_ace and burner serviced by a qualified service agency 5 Inspect the vent pipe vent system before each heating season _br rust corrosion water leakage sagging pipes or broken fittings Have vent pipes vent system serviced by a qualified service agency 6 Inspect any accessories attached to the t_t_mace such as a humidifier or electronic air cleaner Pert ...

Page 39: ... 4 3 I 2 9 43 3 0 43 4 3 I 2 8 43 2 9 43 4 3 I 2 6 43 2 7 43 0 58 Orifice Manifold No Pressure 3 3 3 1 3 0 2 8 SPECIFIC GRAVITY OF NATURAL GAS 3 6 42 3 7 3 4 42 3 5 3 2 42 3 3 3 7 43 3 8 3 5 43 3 6 43 3 4 43 3 2 43 3 1 43 2 9 0 60 0 62 0 64 Orifice Manifold Orifice Manifold Orifice Manifold No Pressure No Pressure No Pressure 42 I 3 2 42 3 3 42 J 4 3 I 3 6 43 3 8 42 E 43 I 3 4 43 3 5 43 E 4 3 I 3 ...

Page 40: ...Pressure 2 9 2 7 2 5 2 3 2 2 2 0 3 6 0 60 Orifice Manifotd No Pressure 43 3 2 43 3 0 43 2 8 43 2 6 43 2 4 43 2 3 43 2 1 43 2 0 SPECIFIC GRAVITY OF 0 60 Manifold Pressure 3 0 2 8 2 6 2 4 2 2 2 1 3 7 Orifice No 43 43 43 43 43 43 48 Orifice No 43 43 43 43 43 43 NATURAL GAS 0 62 Manifold Pressure 3 4 3 1 2 9 2 7 2 5 2 4 43 2 2 43 2 1 NATURAL GAS 0 62 Orifice Mani_td No Pressure 43 3 1 43 2 9 43 2 7 43...

Page 41: ... NOTE Refer to Table 9 fbr motor speed tend relocation if leads were not identified before disconnection 17 Reconnect blower leads to fimaace control Refer to furnace wiring diagram and connect them_ostat leads if previously disconnected 18 To check blower fbr proper rotation a Turn on electrical supply 4O i ELECTRICAL SHOCK HAZARD Failure to fbllow this warning could result in electrical shock pe...

Page 42: ... 42 3 7 43 3 5 43 3 3 43 3 1 43 2 9 43 3 0 2 8 43 2 9 2 6 43 2 7 2 5 43 2 6 0 58 0 60 Orifice Manifold Or rice Manifold No Pressure No Pressure 43 I 43 I 43 I 3 3 42 3 4 3 8 42 3 2 3 6 43 3 7 3 4 43 3 5 3 2 43 3 3 43 3 1 43 2 9 43 2 8 43 2 7 SPECIFIC GRAVITY OF NATURAL GAS Manifold Pressure Manifold Pressure 3 5 43 3 3 43 3 1 43 2 9 43 2 8 43 2 6 43 2 5 43 2 4 43 3 7 43 3 4 43 3 2 43 3 0 43 2 9 43...

Page 43: ...3 2 1 43 2 2 48 3 7 43 2 0 48 3 5 48 3 6 SPECIFIC GRAVITY OF NATURAL GAS 0 60 0 62 0 58 Manifold Pressure 2 7 2 5 2 3 2 1 3 7 3 5 3 8 Orifice Manifold No Pressure Orifice No 625 43 43 2 7 43 650 43 43 2 5 43 c O 8001 675 43 43 2 4 43 to 700 43 43 2 2 43 9000 725 48 43 2 0 43 750 48 48 3 6 48 775 49 48 3 4 48 0 62 Manifotd Pressure 43 3 3 43 3 1 43 2 9 43 2 7 43 2 5 43 2 4 43 2 3 43 2 1 NATURAL GAS...

Page 44: ...cell See Fig 52 3 Work cable in and out of cell 3 or 4 dines to obtain sufficient cleaning DO NOT pull cable with great force Reverse drill and gradually work cable out 4 Insert brush end of cable in burner inlet opening of col and proceed to clean 2 lower passes of cell in sal le nlanner as upper pass 5 Repeat foregoing procedures until each celt in Nrnace has been cleaned 6 Using vacuum cleaner ...

Page 45: ...econd flame proving period begins The HSI igniter will remain energized until the flame is sensed or until the 2 second flame proving period begins d Flame Proving When the burner flame is proved at the flame proving sensor eleckode FSE the flmaace control CPU begins the blower ON delay period and continues to hold the gas valve GV open If the burner flame is not proved within two seconds the cont...

Page 46: ... prepurge period then shut off for 24 seconds then come back on at HEAT speed When the W input signal disappears the Nmace control begins a normal inducer post purge period and the blower switches to OOL speed after a 3 second delay If the R to W and Y and G signals disappear at the same time the blower motor BLWM will remain on Ik r the selected blower OFF delay perio If the R to W an Y signals d...

Page 47: ...s code The status code is a was no previous fault After the control repeats the code 4 t nes the control 2 digit number with the first digit determined will go through a brief component test sequence The inducer will start and run by the number of short flashes and the second for the entire component test The HSl blower motor FAN speed AMBER LED dig t by the number of long flashes boards only HEAT...

Page 48: ...tective swtch or connections Detective blower motor or capacitor Inadequate combustion ar supply flame rollout switch open Restricted vent Proper vent szing Excessive wnd 34 IGNITION PROVING FAILURE If flame is not sensed during the trial for ignition period the contro will repeat the ignition sequence 3 more times before lockout 14 occurs If flame signal s _ost durng the b_ower on delay period bl...

Page 49: ...nufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations B kLL_ PC 101 Catalog No See Cover Printed Jn USA Form 58ST 13SI Pg 48 5 05 Replaces 58ST 12SI Tab 16al 8a ...

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