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

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7. Install the remaining manifold mounting screws.
8. Check the igniter alignment. See Fig. 65, 66 and 71.
9. Attach the wires to the roll-out switches.

10. Align the burner assembly with the openings in the primary

cell inlet panel and attach the burner assembly to the cell

panel.

11. Connect the wire for the flame sensor.
12. Connect the wire for the Hot Surface Igniter.

NOTE

: Use propane-resistant pipe dope to prevent leaks. Do not

use Teflon tape.

13. Install the gas pipe to the gas valve.

FIRE OR EXPLOSION HAZARD

Failure to follow 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 check all connections. A fire or explosion may

result causing property damage, personal injury or loss of

life.

WARNING

14. Check for gas leaks with a commercially available soap so-

lution made specifically for the detection of leaks.

15. Turn gas on at electric switch on gas valve and at external

shut-off or meter

16. Turn power on at external disconnect, fuse or circuit break-

er.

17. Run the furnace through two complete heating cycles to

check for proper operation

18. Install control door when complete.

Servicing Hot Surface Igniter

The igniter does

NOT

require annual inspection. Check igniter

resistance before removal. Refer to Fig. 65, 66 and 71.

1. Turn off gas and electrical supplies to furnace.

2. Remove control door.

3. Disconnect igniter wire connection.

4. Check igniter resistance. Igniter resistance is affected by

temperature. Only check resistance when the igniter is at

room temperature.

a. Using an ohm meter, check resistance across both igniter

leads in connector.

b. Cold reading should be between 40 ohms and 70 ohms.

5. Remove igniter assembly.

a. Using a 1/4

−

in. driver, remove the two screws securing the

igniter mounting bracket to the burner assembly See Fig.

71.

b. Carefully withdraw the igniter and bracket assembly

through the front of the burner assembly without striking

the igniter on surrounding parts.

c. Inspect igniter for signs of damage or failure.

d. If replacement is required, remove the screw that secures

the igniter on igniter bracket and remove the igniter.

6. To replace igniter and bracket assembly, reverse 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. 71.

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 HAZARD

Failure to follow this warning could result in personal injury,

death, and/or property damage.
Turn off the gas and electrical supplies 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 collector box opening or water
will flow out of tube.

4. Remove the collector box plug from the top port on the up-

per corner of the collector box. See Fig. 67.

5. Attach a funnel with a flexible tube to port on the collector

box.

6. Flush inside of collector box with water until discharge wa-

ter from condensate trap is clean and runs freely.

7. Repeat steps 4 thru 6 with middle plug on upper corner of

collector box.

8. Remove the pressure switch tube from the collector box.

NOTE

: Do

NOT

blow into tube with tube connected to the

pressure switch.

9. Clean pressure switch port on collect box with a small wire.

Shake any water out of pressure switch tube.

10. Reconnect tube to pressure switch and pressure switch port.

11. Remove the relief tube from the port on the collector box

and the trap.

12. Clean the relief port on collect box and the trap with a small

wire. Shake any water out of the tube.

13. Reconnect relief tube to trap and collector box ports.

Cleaning Condensate Drain and Trap

NOTE

: If the condensate trap is removed, a new gasket between

the trap and collector box is required. Verify a condensate trap
gasket is included in the service kit or obtain one from your local
distributor.

1. Disconnect power at external disconnect, fuse or circuit

breaker.

2. Turn off gas at external shut-off or gas meter.

3. Remove control door and set aside.

4. Turn electric switch on gas valve to OFF.

5. Disconnect external drain from condensate drain elbow or

drain extension pipe inside the furnace and set aside.

6. Disconnect the condensate trap relief hose from collector

box port and condensate trap.

NOTE

: If condensate has a heat pad attached to the trap, trace the

wires for the pad back to the connection point and disconnect the
wires for the heat pad.

7. Remove the screw that secures the condensate trap to the

collector box, remove the trap and set aside.

8. Remove the trap gasket from the collector box if it did not

come off when the trap was removed.

9. Discard the old trap gasket.

10. Rinse condensate trap in warm water until trap is clean.
11. Flush condensate drain lines with warm water. Remember

to check and clean the relief port on the collector box.

12. Shake trap dry.
13. Clean port on collector box with a small wire.

PG92S*S

Summary of Contents for B Series

Page 1: ... ahridirectory org 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 referencedsubject which is represented only by the standard in its entirety T...

Page 2: ...aust 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 observe...

Page 3: ...al injury Sheet metal parts may have sharp edges or burrs Use care and wear appropriate protective clothing safety glasses and gloves when handling parts and servicing furnaces CAUTION This is the safety alert symbol When you see this symbol on the furnace and in instructions or manuals be alert to the potential for personal injury Understand the signal words DANGER WARNING and CAUTION These words...

Page 4: ...sidered faulty installation and or misapplication of the furnace and resulting failure damage or repairs may impact warranty coverage For accessory installation details refer to the applicable instruction literature NOTE Remove all shipping materials loose parts bag and literaturebefore operating the furnace See Table 1 CODES AND STANDARDS Follow all national and local codes and standards in addit...

Page 5: ...touch ungrounded objects and recharge your body with static electricity firmly touch a clean unpainted metal surface of the furnace again before touching control or wires 5 Use this procedure for installed and uninstalled ungroun ded furnaces 6 Before removing a new control from its container discharge your body s electrostatic charge to ground to protect the control from damage If the control is ...

Page 6: ...H MM 22 2 7 8 7 8 22 2 POWER CONN AIR FLOW SEE NOTE 3 NOTES 1 Doors may vary by model 2 Minimum return air openings at furnace based on metal duct If flex duct is used see flex duct manufacturer s recommendations for equivalent diameters a For 800 CFM 16 in 406 mm round or 14 1 2 x 12 in 368 x 305 mm rectangle b For 1200 CFM 20 in 508 mm round or 14 1 2 x 19 1 2 in 368 x 495 mm rectangle c For 160...

Page 7: ... IS LOCATED TO THE LEFT OF THE BURNER SECTION AND CONDITIONED AIR IS DISCHARGED TO THE RIGHT A12181 Fig 2 Multipoise Orientations 60 80 27 C 16 C SUPPLY AIR SEE PRODUCT DATA FOR ACCESSORY CONDENSATE TRAP HEATER AND CONDENSATE DRAIN LINE PROTECTION A150573 Fig 3 Freeze Protection and Return Air Temperature BACK POSITIONED DOWNWARD AIR RETURN CUT IN BACK BACK POSITIONED UPWARD A12182 Fig 4 Prohibite...

Page 8: ... to an air distribution system Refer to Air Ducts section be provided ample space for servicing and cleaning Always comply with minimum fire protection clearances shown in Table 2 or on the furnace clearance to combustible construction label CARBON MONOXIDE POISONING COMPONENT DAMAGE HAZARD Failure to follow this warning could result in personal injury or death and unit component damage Corrosive ...

Page 9: ...uate combustion ventilation and dilution air must be provided in accordance with U S A Installations Section 9 3 of the current edition of NFPA 54 ANSI Z223 1 Air for Combustion and Ventilation and applicable provisions of the local building codes Canada Part 8 of the current edition of CAN CSA B149 1 Venting Systems and Air Supply for Appliances FURNACE CORROSION HAZARD Failure to follow this cau...

Page 10: ...e considered part of a space if a There are no closeable doors between rooms b Combining spaces on same floor level Each opening shall have free area of at least 1 in 2 1 000 Btuh 2 000 mm2 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 i...

Page 11: ...tical Ducts or Openings 60 000 40 000 100 000 divided by 3 000 33 3 Sq In for each Single Duct or Opening 80 000 30 000 110 000 divided by 2 000 55 0 Sq In for each two Horizontal Ducts Table 4 Minimum Space Volumes for 100 Combustion Ventilation and Dilution Air from Outdoors OTHER THAN FAN ASSISTED TOTAL 1 000 S BTUH GAS INPUT RATE FAN ASSISTED TOTAL 1 000 S BTUH GAS INPUT RATE ACH 30 40 50 40 6...

Page 12: ...B C D D E F G L12F012 Fig 6 Air for Combustion Ventilation and Dilution for Outdoors Minimum opening size is 100 sq in 64516 sq mm with minimum dimensions of 3 in 76mm Minimum of 3 in 76mm when type B1 vent is used L12F013 Fig 7 Air for Combustion Ventilation and Dilution from Indoors PG92S S ...

Page 13: ...n Fig 10 and 11 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 17 The field supplied accessory horizontal drain trap grommet is ONLY REQUIRED FOR DIRECT VENT APPLICATIONS It it NOT required for applic...

Page 14: ... 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 coll...

Page 15: ...n 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 Configuratio...

Page 16: ...osition 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 pressure ...

Page 17: ...not 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 14 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 fam...

Page 18: ...n trap grommet is ONLY REQUIRED FOR DIRECT VENT APPLICATIONS It is NOT required for applications using single pipe or ventilated combustion air venting NOTICE TIP FROM CONTRACTORS When installing the furnace horizontally use the entire drain elbow that is do NOT cut as shown in Fig 16 to connect the trap to the drain line This helps to prevent bumps and shocks to the drain line from damaging the f...

Page 19: ...e 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 AIRFLOW ...

Page 20: ...g Furnace ï ï ï ï ï Evaporator Coil Blower ï 3 4 PVC 3 4 1 2 CPVC or larger Positive pressure Pressure lower than areas with Negative pressure 3 4 PVC DIRECTION OF AIRFLOW 3 4 3 4 3 4 3 4 Open standpipe Optional when coil drain is not connected to furnace drain Recommend T fitting standpipe of same diameteror larger H WHQGLQJ XSZDUG ZLWK PLQLPXP LQFK high Condensing Furnace Evaporator ÄÄÄÄÄÄÄÄÄ Co...

Page 21: ...PIPE ORIENTATION FOR CONDENSATE DISCHARGE A170128 Fig 18 Drain Trap Connection and Routing Appearance may vary 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 Upflow Installation NOTE The furnace must be pitched as shown in Fig 26 for proper condensate drainage Supply Air Con...

Page 22: ...1 Determine application being installed from Table 8 2 Construct hole in floor per Table 8 and Fig 21 3 Construct plenum to dimensions specified in Table 8 and Fig 21 4 Install special base coil assembly or coil box as shown in Fig 21 NOTE It is recommended that the perforated supply air duct flanges be completely removed from furnace when installing the furnace on a factory supplied cased coil or...

Page 23: ...ottom Return Air Inlet These furnaces are shipped with bottom closure panel installed in bottom return air opening Remove and discard this panel when bottom return air is used To remove bottom closure panel see Fig 23 and 24 Side Return Air Inlet These furnaces are shipped with bottom closure panel installed in bottom return air opening This panel MUST be in place when side return air inlet s are ...

Page 24: ...05 13 0 07 18 0 08 21 0 13 32 0 29 72 0 20 49 1000 472 0 06 16 0 11 28 0 11 28 0 17 43 0 27 67 1200 566 0 07 18 0 15 37 0 14 36 0 22 56 1400 661 0 08 21 0 19 48 0 18 45 0 28 70 1600 755 0 09 23 0 24 60 0 21 54 1800 850 0 10 25 0 26 64 20 x 25 Filter 508 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 1...

Page 25: ... RETURN BOTTOM RETURN 14 3 16 360 16 x 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...

Page 26: ...2 419 19 5 8 498 Downflow applications on combustible flooring KGASB sub base required 15 1 8 384 19 483 16 3 4 425 20 5 8 600 Downflow Applications on Combustible Flooring with CNPV CNRV CAR or CAP Coil Assembly or KCAKC coil box KGASB subbase not required 15 1 2 394 19 483 16 1 2 419 20 508 21 533 Upflow Applications on Combustible or Noncombustible Floor ing KGASB subbase not required 19 1 2 49...

Page 27: ...LOSURE Representative drawing only some models may vary in appearance A170123 Fig 23 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 casing and re install the four 4 screws Representativ...

Page 28: ...L MIN 1 4 IN 6 MM TO 1 2 IN 13 MM MAX A11237 Fig 26 Furnace Pitch Requirements ANY COMBINATION OF 1 2 OR 3 PERMITTED A11036 Fig 27 Upflow Return Air Configurations and Restrictions A11037 Fig 28 Downflow Return Air Configurations and Restrictions HORIZONTAL TOP RETURN NOT PERMITTED FOR ANY MODEL A11038 Fig 29 Horizontal Right Return Air Configuration and Restrictions PG92S S ...

Page 29: ... OF 1 2 40 000 14 3 16 YES YES NO YES 17 1 2 YES YES NO YES 60 000 14 3 16 YES YES NO YES 17 1 2 YES NO NO YES 80 000 17 1 2 YES YES NO YES 21 YES YES NO YES 100 000 21 YES YES NO YES 120 000 24 1 2 YES YES NO YES INPUT CASING WIDTH INCHES HORIZONTAL RIGHT RETURN AIR CONNTECIONS CONNECTION AT 1 ONLY CONNECTION AT 2 ONLY CONNECTION AT 3 ONLY COMBINATION OF 1 2 40 000 14 3 16 YES YES NO YES 17 1 2 Y...

Page 30: ... 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 is u...

Page 31: ...ctions 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 ductwor...

Page 32: ... 1065 1035 990 935 870 805 Red 3 2 0 433 940 920 910 890 865 830 790 745 690 625 048100 SIDE BOTTOM Black 4 0 373 1715 1660 1610 1555 1490 1420 1340 1245 1150 1065 Yellow 3 3 5 379 1535 1480 1435 1380 1325 1260 1180 1095 1010 910 Blue 3 3 0 367 1300 1255 1205 1160 1100 1035 970 905 810 730 Red 3 2 0 445 1110 1055 1005 955 890 835 770 690 610 535 060100 BOTTOM or TWO SIDES4 5 Black 5 0 394 2270 220...

Page 33: ... 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 burne...

Page 34: ...y 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 death Blower do...

Page 35: ...d as a grounding point for all line voltage wiring options The J Box cover may be omitted when electrical connections are made inside an external electrical box mounted external to the casing External Electrical Box on Furnace Casing NOTE Check to ensure that external electrical box does not interfere with duct work gas piping or the indoor coil drain See Fig 34 for alternate electric entry throug...

Page 36: ...drill into blower shelf of furnace to route control wiring Route any control or accessory wiring to the blower compartment through external knockouts on the casing WARNING 24 V Wiring Make field 24 v connections at the 24 v terminal strip See Fig 40 Connect terminal Y as shown in Fig 39 for proper cooling operation Use only AWG No 18 color coded copper thermostat wire NOTE Use AWG No 18 color code...

Page 37: ... 36 11 0 20 60120 115 60 1 127 104 11 9 15 8 12 36 11 0 20 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 potential operating components EAC humidifier etc full load amps Time delay type is recommended Length shown is as measured one way along wire path between...

Page 38: ...ECT CONDENSING UNIT TWO WIRE FURNACE C O N T R O L R G COM W C R G Y GND GND FIELD 24 V WIRING FIELD 115 208 230 460 V WIRING FACTORY 24 V WIRING FACTORY 115 V WIRING 208 230 OR 460 V THREE PHASE 208 230 V SINGLE PHASE BLOWER DOOR SWITCH WHT BLK WHT BLK NOTES Connect Y terminal in furnace as shown for proper blower operation Some thermostats require a C terminal connection as shown If any of the o...

Page 39: ...UTRAL CONNECTIONS COOL HEAT SPARE 1 SPARE 2 BLOWER SPEED SELECTION TERMINALS EAC 1 TERMINAL 115 VAC 1 0 AMP MAX 115 VAC L1 LINE VOLTAGE CONNECTION PL2 HOT SURFACE IGNITER INDUCER MOTOR CONNECTOR PL1 LOW VOLTAGE MAIN HARNESS CONNECTOR TRANSFORMER 24 VAC CONNECTIONS HUMIDIFIER TERMINAL 24 VAC 0 5 AMP MAX TWINNING AND OR COMPONENT TEST TERMINAL BLOWER OFF DELAY J2 J2 JUMPER PLT PL1 SPARE 3 SPARE 3 1 ...

Page 40: ...is system must be UL listed material Acceptability under Canadian standard CAN CSA B149 is dependent upon full compliance with all installation instructions Under this standard it is recommended that the vent system be checked once a year by qualified service personnel The authority having jurisdiction gas inspection authority municipal building department fire department etc should be consulted b...

Page 41: ...5 for single pipe or ventilated combustion air option A furnace shall not be connected to a chimney flue serving a separateappliance designed to burn solid fuel Other gas appliances with their own venting system may also use the abandoned chimney as a raceway providing it is permitted by local code the current edition of the National Fuel Gas Code and the vent or liner manufacturer s installation ...

Page 42: ... to the outdoors is not required for a single pipe vent system A 12 in 304 mm long pipe with a 2 in 51 mm tight radius 90 degree elbow is required to be attached to the combustion air pipe adapter on the furnace See Fig 56 This short inlet air pipe helps to ensure stable combustion as well as allow for sound attenuation To aid sound attenuation point the inlet air pipe away from occupants An extra...

Page 43: ... air pipe terminates in a well ventilated attic or crawl space Follow the clearances as shown in Fig 57 The combustion air pipe cannot terminate in attics or crawl spaces that use ventilation fans designed to operate in the heating season If ventilation fans are present in these areas the combustion air pipe must terminate outdoors as a Direct Vent System Non Direct Vent 1 Pipe System The vent pip...

Page 44: ...vent length Include deductions from the Maximum Equivalent Vent Length MEVL contained in the Venting Tables for elbows and flexible vent pipe Factory accessory concentric vent terminations or pipe lengths and elbows used for standard vent terminations do not require a deduction from the Maximum Equivalent Vent Length See vent termination figures associated with Table 17 Include a deduction for a T...

Page 45: ...e the vent elbow 1 Loosen the clamp on the inlet of the vent elbow attached to the inducer 2 Rotate the vent elbow to the required position There are rounded notches on the vent elbow to align it with the inducer housing for each orientation 3 Tighten the clamp around the vent elbow Torque the clamp to 15 lb in See Fig 46 49 Installing the Vent Pipe Adapter and Combustion Air Pipe Adapter CARBON M...

Page 46: ... supported to prevent sagging Space combustion air piping and vent piping hangers as shown in Table 14 Support pipes using perforated metal hanging strap or commercially available hangers or straps designed to support plastic pipe 17 Slope the vent and combustion air piping downward towards furnace A minimum slope of at least 1 4 in 6 mm per linear ft 1 in 25 mm per 4 ft 1 2 M with no sags between...

Page 47: ...s shown in Fig 54 and all clearance shown in Fig 52 NOTE Follow the instructions of the vent terminal manufacturer These instructions are provided as a reference only Cut one 4 in 102 mm diameter hole for 2 in 50 mm ND kit or one 5 in 127 mm diameter hole for 3 in 80 mm ND kit in the desired location Loosely assemble concentric vent combustion air termination components together using instructions...

Page 48: ...equired may result in flame disturbance or flame sense lockout Table 15 Approved Combustion Air and Vent Pipe Fitting and Cement Materials U S A Installations MATERIALS USA 1 All pipe fittings primers and solvents must conform to American National Standards Institute ANSI stan dards and American Society for Testing and Materials ASTM standards or ULC S636 where required by code 2 See Table below f...

Page 49: ...gn Temp C Unit Size 40 000 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...

Page 50: ...d 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 for n...

Page 51: ...MEVL 95 ft 29 M For 2 pipe from Table 17 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 pi...

Page 52: ... THE INDUCER FOR USAGE SEE MAXIMUM EQUIVALENT VENT LENGTH TABLE 10FT 3 1 M OF VENT OR LESS ONLY A170006 Fig 42 Inducer Vent Elbow 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 43 Near Furnace Vent Conne...

Page 53: ...items refer to the Inside Corner Clearance Table 3 ft 1 M to 6 ft 2 M Notes For this illustration Wall A is the wall adjacent to the wall the vent termination is located Wall B is the wall the vent termination is located The termination can be located on either wall Minimum distance of a vent terminal to an inside corner is 3 ft 1 M Maximum distance from an inside corner is 6 ft 2 M If the vent te...

Page 54: ...ent 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 intakes of any type are per...

Page 55: ... combustion air connection UPFLOW VERTICAL VENT A11310A Fig 46 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 Acces...

Page 56: ...T RIGHT VENT CONFIGURATION A11329A Fig 48 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 A11335 Fi...

Page 57: ...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 IN A1...

Page 58: ...inimum 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 appliance exhau...

Page 59: ... 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 Note 4 12 in...

Page 60: ...ermination 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 minimum clearance above hig...

Page 61: ...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 56 Alberta and Saskatchewan Vent Termination PG92S S ...

Page 62: ...ipe hangar Ventilated Combustion Air intake termination in crawl space Ventilated Combustion Air intake pipe CRAWL SPACE ATTIC highest level of insulation A10497 Fig 57 Vent Terminations for Ventilated Combustion Air PG92S S ...

Page 63: ...some models may vary in appearance TO CODE APPROVED DRAIN OR CONDENSATE PUMP Tee Dry Well Cap water tight and removable Tee Dry Well Cap water tight and removable 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 59 Recommended Combustion Air Inlet Moisture Trap PG92S S ...

Page 64: ...r operates HUM 24vac terminal is only energized when the draft inducer is energized in heating Prime Condensate Trap with Water CARBON MONOXIDE POISONING HAZARD Failure to follow these warnings could result in personal injury or death Failure to use a properly configured trap or NOT water priming trap before operating furnace may allow positive pressure vent gases to enter the structure through dr...

Page 65: ...e 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 yearly gas heat value at installed altitude from local gas supplier 2 Obtain average yearly gas specific gravity from local gas supplier 3 Find installat...

Page 66: ...put rate If clocked rate does not match required input from Step 1 increase manifold pressure to increase input or decrease manifold pressure to decrease input Re peat steps b through e of Step 1 until correct heat input is achieved Re install regulator seal cap on gas valve 3 Restore furnace to normal operating condition a Turn gas valve ON OFF switch to OFF b Remove water column manometer or sim...

Page 67: ... blower starts 4 Set heat anticipator on thermostat per thermostat instruc tions and install on subbase or wall 5 Install blower access door Electronic thermostat Set cycle rate for 3 cycles per hr Check Safety Controls The flame sensor gas valve and pressure switch were all checked in the Start up procedure section as part of normal operation 1 Check Main Limit Switch This control shuts off combu...

Page 68: ...drawing only some models may vary in appearance A11153 Fig 60 Gas Valve without Tower Pressure Ports ON OFF SWITCH 1 8 NPT INLET PRESSURE TAP REGULATOR SEAL CAP REGULATOR ADJ UNDER CAP 1 2 NPT OUTLET MANIFOLD PRESSURE TAP SET SCREW 3 32 HEX HEAD ACCEPTS 5 16 HOSE CONNECTION OUTP INP VENT 1 2 NPT INLET INLET PRESSURE TAP SET SCREW 3 32 HEX HEAD ACCEPTS 5 16 HOSE CONNECTION Representative drawing on...

Page 69: ...69 338309 201 Rev E A11602 Fig 64 Service Label Information PG92S S ...

Page 70: ... 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 37 ...

Page 71: ... 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 1524...

Page 72: ...2 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 0 4...

Page 73: ...e 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 off during furnace servicing Lock out and tag switch with a suitable warning label WARNING The electrical ...

Page 74: ...rify 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 40 3 Verify that the Blower Heat Off Delay jumpers are set as desired See Fig 40 4 Verify that the blower and control Main doors are properly installed 5 Verify that the Status LED glows If not check that the power supply is energized and that the blower door...

Page 75: ...et 7 Replace filter cabinet door 8 Turn on electrical supply to furnace Blower Motor and Wheel Maintenance To ensure long life economy and high efficiency clean accumulated dirt and grease from blower wheel and motor annually The inducer and blower motors are pre lubricated and require no additional lubrication These motors can be identified by the absence of oil ports on each end of the motor The...

Page 76: ...r damaging the mounting to the burner assembly ELECTRICAL SHOCK AND FIRE HAZARD Failure to follow this warning could result in personal injury death and or property damage Turn off the gas and electrical supplies 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 Refer to Fig 71 1 Discon...

Page 77: ...ntrol door Flushing Collector Box and Drainage System ELECTRICAL SHOCK AND FIRE HAZARD Failure to follow this warning could result in personal injury death and or property damage Turn off the gas and electrical supplies 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 an...

Page 78: ... 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 poor quality combustion air improper vent termination incorrect size or damaged manifold orifice s improper gas or a restricted heat exchanger primary or secondary Action must be taken to correct the problem 1 Turn off gas and ...

Page 79: ...E 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 equivalent Failure of plastic components may occur CAUTION 1 Obtain propylene glycol RV swimming pool antifreeze or equivalent 2 Turn off gas and electrical supplies to your furnace 3 Remove furnace control door 4 Remove the top unused ru...

Page 80: ...ROMMET 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 A11584 Fig 70 Blower Assembly FLAME SENSOR BELOW BURNER FLAME ROLLOUT SWITCH BRACKET IGNITER IGNITER BURNER SUPT ASSY BURNER ASSY A11403 Fig 71 Burner Assembly PG92S S ...

Page 81: ...f the burner flame is proven the blower motor is energized on HEAT speed 25 sec after the gas valve GV is energized Simultaneously the electronic 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 the gas valve GV stopping gas flow to the burners a...

Page 82: ...ious 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 when equipped HEAT speed and COOL speed will run for 10 15 seconds each Gas valve and humidifier will not be turned on W...

Page 83: ...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 blower off delay Check the following items first before proceeding to the next step Gas valve turned off Manual shut off valve Green Yellow wire MUST be connected to furnace sheet metal Flame sensor must not be grounded To determine whether the problem is in...

Page 84: ...84 A12420 Fig 73 Wiring Diagram PG92S S ...

Page 85: ... for dealer listing by brand name or contact Consumer Relations Department P O Box 4952 Syracuse New York 13221 4952 1 800 428 4326 Have available the model number series number and serial number located on the unit rating plate to ensure correct replacement part Model Nomenclature MODEL VOLTAGE MOTOR MAJOR SERIES HEATING STAGES COOLING CAPACITY HEATING CAPACITY WIDTH MINOR SERIES VARIATIONS PG92 ...

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Payne B Series, Installation, Start-Up, Operating And Service And Maintenance Instructions

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