Payne PG92ESA Installation, Start-Up, Operating And Service And Maintenance Instructions Download

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Installation, Start--up, Operating and

Service and Maintenance Instructions

PG92ESA

SINGLE--STAGE 35--IN. (889 MM) Tall

4--WAY MULTIPOISE

CONDENSING GAS FURNACE

NOTE

: Read the entire instruction manual before starting the installation.

SECTIONS

SAFETY CONSIDERATIONS

. . . . . . . . . . . . . . . . . . . . . . . . .

INTRODUCTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CODES AND STANDARDS

. . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

. . .

ACCESSORIES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LOCATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR FOR COMBUSTION AND VENTILATION

. . . . . . . . . .

CONDENSATE TRAP

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONDENSATE DRAIN

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR DUCTS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GAS PIPING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL CONNECTIONS

. . . . . . . . . . . . . . . . . . . . . . .

VENTING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

START--UP, ADJUSTMENT, AND SAFETY CHECK

. . . . . .

SERVICE AND MAINTENANCE PROCEDURES

. . . . . . . .

SEQUENCE OF OPERATION

. . . . . . . . . . . . . . . . . . . . . . . .

PARTS REPLACEMENT GUIDE

. . . . . . . . . . . . . . . . . . . . . .

Portions of the text and tables are reprinted from current edition of
NFPA 54/ANSI Z223.1, with permission of National Fire

Protection Association, Quincy, MA 02269 and American Gas
Association, Washington DC 20001. This reprinted material is not

the complete and official position of the NFPA or ANSI on the

referenced subject, which is represented only by the standard in its
entirety.

TABLES

Loose Parts Bag

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Minimum Clearances to Combustible Materials

. . . . . . . . . . . . .

Minimum Free Area Required

. . . . . . . . . . . . . . . . . . . . . . . . .

Minimum Space Volumes

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filter Size Information

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Opening Dimensions

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Delivery CFM

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maximum Capacity of Pipe

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Data

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vent Termination Kit for Direct Vent (2--Pipe) System

. . . . . . .

Hangar Spacing

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Combustion--Air Vent Pipe, Fitting & Cement Material..

. . . . .

Maximum Allowable Exposed Vent Lengths Insulation

. . . . . .

Maximum Equivalent Vent Length

. . . . . . . . . . . . . . . . . . . . . .

Deductions from Maximum Equivalent Vent Length

. . . . . . . .

Blower Off Delay Setup Switch

. . . . . . . . . . . . . . . . . . . . . . . .

Altitude Derate Multiplier for U.S.A.

. . . . . . . . . . . . . . . . . . . .

Gas Rate

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Orifice Size and Manifold Pressure

. . . . . . . . . . . . . . . . . . . . .

Summary of Contents for PG92ESA

Page 1: ...ANSI Z223 1 with permission of National Fire Protection Association Quincy MA 02269 and American Gas Association Washington DC 20001 This reprinted material is not the complete and official position of the NFPA or ANSI on the referenced subject which is represented only by the standard in its entirety TABLES Loose Parts Bag 4 Minimum Clearances to Combustible Materials 8 Minimum Free Area Required...

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: ...her operations must be performed by trained service personnel When working 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 code...

Page 4: ... exceed 80_F 27_C db Failure to follow these return air temperature limits may affect reliability of heat exchangers motors and controls See Fig 2 The furnace should be sized to provide 100 percent of the design heating load requirement plus any margin that occurs because of furnace model size capacity increments None of the furnace model sizes can be used if the heating load is 20 000 BTU or lowe...

Page 5: ...re to follow this caution may result in unit component damage Electrostatic discharge can affect electronic components Take precautions during furnace installation and servicing to protect the furnace electronic control Precautions will prevent electrostatic discharges from personnel and hand tools which are held during the procedure These precautions will help to avoid exposing the control to ele...

Page 6: ...06 8 3 4 222 122 5 55 6 36060A 14 3 16 361 12 1 2 319 12 9 16 322 7 1 8 181 122 0 55 3 42060B 17 1 2 445 15 7 8 403 16 406 8 3 4 222 132 0 59 9 48080B 17 1 2 445 15 7 8 403 16 406 8 3 4 222 142 0 64 4 60080C 21 533 19 3 8 492 19 1 2 495 10 1 2 267 150 0 68 0 60100C 21 533 19 3 8 492 19 1 2 495 10 1 2 267 160 0 72 6 60120D 24 1 2 622 22 7 8 581 23 584 12 1 4 311 183 0 83 0 Fig 1 Dimensional Drawing...

Page 7: ...ccupancy The furnace ductwork and filters are cleaned as necessary to remove drywall dust and construction debris from all HVAC system components after construction is completed Verify proper furnace operating conditions including ignition gas input rate air temperature rise and venting according to these installation instructions CAUTION General These furnaces are shipped with materials to assist...

Page 8: ...he furnace is installed in a residential garage the burners and burner ignition devices must be located at least 18 in 457 mm above the floor The furnace must be located or protected to avoid damage by vehicles When the furnace is installed in a public garage airplane hangar or other building having a hazardous atmosphere the furnace must be installed in accordance with the current edition of NFPA...

Page 9: ...ombustion Non Direct Vent 1 pipe Applications When the furnace is installed as a non direct vent 1 pipe furnace it will be necessary to insure there is adequate air for combustion Other gas appliances installed with the furnace may also require air for combustion and ventilation in addition to the amount of combustion air and ventilation air required for the furnace Follow the guidelines below to ...

Page 10: ...in 645 sq mm of free area per 3 000 Btuh 734 mm2 kW for combined input of all gas appliances in the space per Fig 6 and Table 3 b Not less than the sum of the areas of all vent connectors in the space The opening shall commence within 12 in 300 mm of the ceiling Appliances in the space shall have clearances of at least 1 in 25 mm from the sides and back and 6 in 150 mm from the front The opening s...

Page 11: ...od be low b Outdoor opening size reduction Factor is 1 minus the Ra tio in a above c Minimum size of Outdoor openings shall be the size re quired in Outdoor Combustion Air Method above multi plied by reduction Factor in b above The minimum di mensionofairopeningsshallbenotlessthan 3in 80mm Table 3 Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors FURNACE INPUT BTUH TWO...

Page 12: ... to install the condensate drain Condensate Trap Horizontal Orientation When the furnace is installed in the horizontal right position the condensate trap will be initially located at the bottom of the collector box as received from the factory See the top image in Fig 11 When the furnace is installed in the horizontal left position the condensate trap will be initially located at the top of the c...

Page 13: ...ter relocation in the horizontal right position S Fig 12 shows the condensate trap and tubing before and after relocation in the horizontal left position S Refer to the appropriate figure to begin the trap conversion S Refer to Condensate Drain section for information how to install the condensate drain Condensate Trap Relief Port Collector Box Plugs Pressure Switch Port Condensate Trap Outlet Con...

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: ...hard piped 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 familia...

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: ...XP LQFK high Condensing Furnace Evaporator ÄÄÄÄÄÄÄÄÄ Coil ÄÄÄÄÄÄÄÄÄ ÄÄÄÄÄÄÄÄÄ ÄÄÄÄÄÄÄÄÄ ÄÄÄÄÄÄÄÄÄ ÄÄÄÄÄÄÄÄÄ ÄÄÄÄÄÄÄÄÄ Blower 3 4 PVC 3 4 3 4 3 4 3 4 3 4 3 4 Positive pressure Pressure lower than areas with ï 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 Exa...

Page 22: ... return air ducts to the back of the furnace Follow instructions below WARNING The return air duct must be connected to bottom sides left or right or a combination of bottom and side s of main furnace casing Bypass humidifier may be attached into unused return air side of the furnace casing See Fig 22 23 and 24 Bottom Return Air Inlet These furnaces are shipped with bottom closure panel installed ...

Page 23: ...actory approved air conditioning coil casing DO NOT cut main furnace casing to attach supply side air duct humidifier or other accessories All supply side accessories MUST be connected to duct external to furnace casing Return Air Connections FIRE HAZARD A failure to follow this warning could cause personal injury death and or property damage Never connect return air ducts to the back of the furna...

Page 24: ...re angle iron to bottom of furnace as shown Roll Out Protection Provide a minimum 12 in x 22 in 305 x 559 mm piece of sheet metal for flame roll out protection in front of burner area for furnaces closer than 12 in 305 mm above the combustible deck or suspended furnaces closer than 12 in 305 mm to joists The sheet metal MUST extend underneath the furnace casing by 1 in 25 mm with the door removed ...

Page 25: ...ttic Installation 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: ...ing and remove the panel SCREWS 2 BOTTOM CLOSURE Representative drawing only 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 r...

Page 27: ... 0 04 12 0 05 12 0 07 17 0 10 26 0 24 60 0 16 40 800 378 0 06 15 0 07 19 0 10 25 0 15 39 0 34 85 0 23 59 1000 472 0 07 18 0 10 27 0 13 34 0 21 52 0 32 81 1200 566 0 08 20 0 14 36 0 17 43 0 27 68 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 in 2 5 cm 2...

Page 28: ...25 x 3 4 406 x 635 x 19 14 x 25 x 3 4 356 x 635 x 19 Washable 17 1 2 445 16 x 25 x 3 4 406 x 635 x 19 16 x 25 x 3 4 406 x 635 x 19 Washable 21 533 16 x 25 x 3 4 406 x 635 x 19 20 x 25 x 3 4 508 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 thes...

Page 29: ...urnace Filler plates Screw 14 3 16 in Furnace with Filler Plates Centered 14 3 16 in Furnace Filler plate Screws 14 3 16 in Furnace with Filler Plates Off Set to Right Media Cabinet Installation Option for 4 Ton or Less A C Capacity 20 or 24 in Media Cabinet Installation with Angled Transition 20 or 24 in Media Cabinet Installation for Combination Side and Bottom Return Media Cabinet Installation ...

Page 30: ...se not required 15 7 8 403 19 483 16 1 2 419 19 5 8 498 Downflow applications on combustible flooring Subbase required 15 1 8 384 19 483 16 3 4 425 20 5 8 600 Downflow Applications on Combustible Flooring with coil assembly coil or coil box Subbase not required 15 1 2 394 19 483 16 1 2 419 20 508 21 533 Upflow Applications on Combustible or Noncombustible Flooring Subbase not required 19 1 2 495 2...

Page 31: ...onnections to furnace with code approved tape or duct sealer NOTE Flexible connections should be used between ductwork and furnace to prevent transmission of vibration Ductwork passing through unconditioned space should be insulated to enhance system performance When air conditioning is used a vapor barrier is recommended Maintain a 1 in 25 mm clearance from combustible materials to supply air duc...

Page 32: ...45 Yellow Alt Cooling or alt Heating 1650 1590 1535 1475 1425 1370 1315 1260 1205 1145 Blue Heating or alt Cooling 1495 1430 1365 1310 1260 1200 1145 1085 1030 970 Orange Alt Cooling or alt Heating 1420 1355 1290 1235 1175 1120 1060 1005 945 890 Red Alt Cooling Do not use for heating 1200 1120 1060 995 940 875 810 750 685 625 60100C BOTTOM or TWO SIDES 5 6 Gray Cooling Do not use for heating 2060 ...

Page 33: ... 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 b...

Page 34: ...n 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 death Blower door switch opens 115 v power to control No component operation can occur Do not bypass or close switch with blower door removed WARNING See Fig 36 fo...

Page 35: ... attached to the outside of the furnace casing The field ground wire and furnace main ground wire are grounded when the J Box bracket is attached to the furnace and the field ground wire and factory ground wire are secured to the bracket grounding screw If the J Box cover is not used the field and factory spliced connections must be located inside the external electrical box Do not leave splice co...

Page 36: ... 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 manufacturer s listings 1 Install J Box mounting bracket to inside of furnace casing See Fig 34 2 Route listed power cord through 7 8 in 22 mm diameter hole in casing and J Box bracket 3 Secure power cord to J Box bracket with a strain relief bushing ...

Page 37: ...ng a call for heat Connect an accessory 24 VAC 0 5 amp maximum humidifier if used to the in male quick connect HUM terminal and COM 24V screw terminal on the control board thermostat strip NOTE If the humidifier has its own 24 VAC power supply an isolation relay may be required Connect the 24 VAC coil of the isolation relay to the HUM and COM 24V screw terminal on the control board thermostat stri...

Page 38: ... 127 104 7 2 9 9 14 37 11 4 15 48080B 115 60 1 127 104 7 2 9 9 14 37 11 4 15 60080C 115 60 1 127 104 9 6 12 9 14 28 8 7 15 60100C 115 60 1 127 104 9 7 13 0 14 28 8 7 15 60120D 115 60 1 127 104 9 7 13 0 14 28 8 7 15 Permissible limits of the voltage range at which the unit operates satisfactorily Unit ampacity 125 percent of largest operating component s full load amps plus 100 percent of all other...

Page 39: ...e connected This is used internally to sense defrost operation 11 If thermostat has internal control of heat pump balance point DO NOT SELECT the FURNACE INTERFACE or BALANCE POINT option on the two speed heat pump control board Refer to thermostat instructions 12 Thermostat signals may vary Consult thermostat installation instructions for more information VENTING NOTE Planning for the venting sys...

Page 40: ...avec ce système doivent être des matériaux listés UL L acceptation du standard Canadien CAN CSA B149 est directement relié à l installation conforme aux instructions ci haut mentionnées Le standard Canadien recommande l inspection par un personel qualifié et ce une fois par année Les autoritées ayant juridiction inspecteurs de gas inspecteurs en bâtiments département des incendies etc devraient êt...

Page 41: ...ld 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...

Page 42: ...ations provide better performance against sustained prevailing winds The roof location is preferred 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...

Page 43: ...n these instructions are adhered to Refer to the appropriate Vent Termination 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 terminati...

Page 44: ...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 41 Recommended Combustion Air Inlet Moisture Trap FURNACE PIPE DIAMETER TRANSITION IN VERTICAL SECTION NOT IN HORIZONTAL SECTION A93034 Fig 42 Combustion Air and Vent Pipe Diameter Transition Location and Elbow Configuration ...

Page 45: ...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 equiv alent length for the type of elbow ...

Page 46: ...Furnace Vent Connections Install the Vent and Combustion Air Pipes With the furnace installed in the required position remove the desired knockouts from the casing It will be necessary to remove one knockout for the vent pipe and the other knockout for the combustion air connection See Fig 16 Use a flat blade screwdriver and tap on the knockout on opposite sides where the knockout meets the casing...

Page 47: ...ing ring The vent pipe can pass through the vent pipe adapter it cannot pass through the inlet pipe adapter 2 Align the screw holes in the plastic vent pipe adapter with the dimples in the casing 3 Pilot drill the screw holes for the adapter in the casing and attach the vent pipe adapter to the furnace with sheet metal screws 4 Slide the end of the rubber vent coupling with notches in it over the ...

Page 48: ... fitting socket 14 Wipe excess cement from joint A continuous bead of ce ment will be visible around perimeter of a properly made joint 15 Handle pipe joints carefully until cement sets 16 Horizontal portions of the venting system shall be supported to prevent sagging Space combustion air piping and vent piping hangars as shown in Table 13 Support pipes using perforated metal hanging strap or comm...

Page 49: ...n in Fig 55 and 56 Maintain the required separation distance between vents or pairs of vents as shown in Fig 55 and 56 and all clearance shown in Fig 53 and 54 RECOMMENDED SUPPORT FOR VENT TERMINATIONS It is recommended that rooftop vent terminations in excess of 36 inches 1 M in vertical length be supported by EITHER the Direct Vent Termination Kit shown in Table 12 or by field supplied brackets ...

Page 50: ...Society for Testing and Materials ASTM standards or ULC S636 where required by code 2 See Table below for approved materials for use in the U S A 3 ULC S636 vent systems must be composed of pipe fittings cements and primers from the same supplier 4 Factory accessory concentric vent kits are ULC S636 listed CANADA 1 Installation in Canada must conform to the requirements of CAN CSA B149 code 2 Vent...

Page 51: ... 000 BTUH 60 000 BTUH Uninsulated 3 8 in Insulation 1 2 in Insulation Uninsulated 3 8 in Insulation 1 2 in Insulation Pipe Dia mm 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 1 15 2 13 7 6 1 18 3 15 2 6 1 9 1 9 1 7 6 6 1 22 9 19 8 18 3 6 1 25 9 22 9 19 8 18 3 0 1 5 1 5 6 1 7 6 6 1 6 1 9 1 7 6 4 6 4 6 3 0 3 0 6 1 12 2 9 1 7 6 6 1 13 7 12 2 9 1 29 1 5 6 1 4 6 3 0 6 ...

Page 52: ...pped in the loose parts bag or available through Replacement Components required under 10 ft 3 M TEVL in all orientations Required for installations from 0 2000 0 to 610 M above sea level Failure to use an outlet restric tor may result in flame disturbances or flame sense lock out 2 Inducer Outlet Restrictor disk P N 337683 401 1 25 in 32 mm Dia available through Replacement Components required fo...

Page 53: ...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 54: ... 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 55: ... for combustion air connection UPFLOW VERTICAL VENT A11310A Fig 47 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 56: ... LEFT RIGHT VENT CONFIGURATION A11329A Fig 49 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 57: ...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 58: ...en 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 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 applia...

Page 59: ...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 60: ...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 61: ... 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 57 Alberta and Saskatchewan Vent Termination ...

Page 62: ...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 58 Vent Terminations for Ventilated Combustion Air ...

Page 63: ...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 64: ...onal de rate factor to the pressures show in Table 21 The values in this table are NOT referenced to sea level they are AS MEASURED AT ALTITUDE The heating content of natural gas at altitude may already provide for a reduction in capacity of the furnace Be sure to obtain the expected in season gas heating value of the gas from the gas supplier BEFORE making any adjustments for capacity or altitude...

Page 65: ...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 gas valve electric switch to OFF position 11 Turn gas supply manual shutoff valve to OFF position 12 Tur...

Page 66: ... re install in the gas valve d Turn gas valve ON OFF switch to ON e Check for gas leaks and verify furnace operation FIRE HAZARD Failure to follow this warning could result in personal injury death and or property damage Manifold pressure tap set screw must be tightened and 1 8 in NPT pipe plug must be installed to prevent gas leaks WARNING Adjust Temperature Rise NOTE Blower door must be installe...

Page 67: ... HEAT heating blower tap terminal and the other will be connected to the COOL cooling blower tap Use the provided wire ties to secure the loose blower motor speed lead and any other loose wires being careful not to put tension on any wire connectors FIRE HAZARD Failure to follow this warning could result in personal injury death and or property damage Reinstall manifold pressure tap plug in gas va...

Page 68: ...ols and instruments Clean up debris 2 Verify that the jumper is removed from the TEST TWIN terminal Verify that there is nothing plugged into the PLT connector Note If there is a jumper connector plugged into PLT remove it and discard See Fig 38 3 Verify that the Blower Heat Off Delay jumpers are set as desired See Fig 38 and 72 4 Verify that the blower lower door in upflow position and control Ma...

Page 69: ...69 A190035 Fig 65 Service Label Information ...

Page 70: ... 281 23 157 313 783 66 54 109 273 24 150 300 750 68 53 106 265 25 144 288 720 70 51 103 257 26 138 277 692 72 50 100 250 27 133 267 667 74 48 97 243 28 129 257 643 76 47 95 237 29 124 248 621 78 46 92 231 30 120 240 600 80 45 90 225 31 116 232 581 82 44 88 220 32 113 225 563 84 43 86 214 33 109 218 545 86 42 84 209 34 106 212 529 88 41 82 205 35 103 206 514 90 40 80 200 36 100 200 500 92 39 78 196...

Page 71: ...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 44 3 6 44 3 7 ...

Page 72: ... 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 2743 775 44 3...

Page 73: ...he 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 74: ...r 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 plugged into the PLT connector Note If the...

Page 75: ...ifying 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 doo...

Page 76: ...rning 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 ven...

Page 77: ...lame sensor with fine steel wool 0000 grade Do not use sand paper or emery cloth To reinstall burner assembly 1 Install the Hot Surface Igniter HSI and bracket in burner assembly 2 Install flame sensor on burner 3 Align the edges of the one piece burner with the slots in the burner assembly and slide the burners forward until they are fully seated in the burner assembly 4 Align the orifices in the...

Page 78: ...pplies to the furnace and install lockout tag before performing any maintenance or service Follow the operating instructions on the label attached to the furnace WARNING 1 Turn off gas and electrical supplies to furnace 2 Remove control door 3 Disconnect pressure switch tube from pressure switch port NOTE Ensure the pressure switch tube disconnected from the pressure switch is higher than the coll...

Page 79: ...leaned by the following procedure NOTE If the heat exchangers get a heavy accumulation of soot and carbon both the primary and secondary heat exchangers should be replaced rather than trying to clean them thoroughly due to their intricate design A build up of soot and carbon indicates that a problem exists which needs to be corrected such as improper adjustment of manifold pressure insufficient or...

Page 80: ...e 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 follow this caution may result in damage to the furnace and other property damage Do not use ethylene glycol automotive antifreeze coolant or equival...

Page 81: ...tronic 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 ...

Page 82: ...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 83: ...83 A190093 Fig 71 Troubleshooting Guide ...

Page 84: ...84 A190036 Fig 72 Wiring Diagram ...

Page 85: ...onsult your installing dealer or classified section of your local telephone directory under Heating Equipment or Air Conditioning Contractors and Systems headings for dealer listing by brand name or contact 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 HEATIN...

Page 86: ...ng Systems D 7310 W Morris St D Indianapolis IN 46231 Edition Date 03 19 Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations Catalog No IM PG92ESA 01 Replaces NEW ...

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