Payne PG96XAT, Installation, Start-Up, Operating And Service And Maintenance Instructions

Page 1: ...hridirectory org Portions of the text and tables are reprinted from current edition of NFPA 54 ANSI Z223 1E 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 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: ...ions 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 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 ...

Page 4: ...ould 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 lower Use Air Conditioning Contractors of America Manual J and S American Society of Heating Refrigerating and Air Conditioning Engineers or other approved engineeri...

Page 5: ... feet do not touch ungrounded objects etc 4 If you 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 unground ed furnaces 6 Before removing a new control from its container discharge your body s electrostatic charge to ground to...

Page 6: ...16 361 12 1 2 319 12 9 16 322 7 1 8 181 125 0 56 8 36060 136 0 61 7 36040 17 1 2 445 15 7 8 403 16 406 8 3 4 222 135 0 61 2 42060 146 0 66 4 48080 156 0 70 9 60080 21 533 19 3 8 492 19 1 2 495 10 1 2 267 160 5 73 0 60100 170 5 77 5 66120 24 1 2 622 22 7 8 581 23 584 12 1 4 311 194 5 88 4 Fig 1 Dimensional Drawing PG95XAT ...

Page 7: ...DITIONED AIR IS DISCHARGED DOWNWARD THE BLOWER 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 A10490 Fig 3 Freeze Protection and Return Air Temperature BACK POSITIONED DOWNWARD AIR RETURN CUT IN BACK BACK POSITIONED UPWARD A12182 Fig 4 Prohibited Installations 18 IN 457 2 mm MINIMUM TO BURN...

Page 8: ...tion system Refer to Air Ducts section S 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 or contaminated a...

Page 9: ... accordance with S 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 S 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 caution may result in furnace damage Air for combustion must no...

Page 10: ...ble doors between rooms b Combining spaces on same floor level Each opening shall havefreeareaofat least1 in 2 1 000Btuh 2 000mm2 kW of the total input rating of all gas appliances in the space but not less than 100 in 2 0 06 m2 One opening shall commence within 12 in 300 mm of the ceiling and the second opening shall commence within 12 in 300 mm of the floor The minimum dimension of air openings ...

Page 11: ...able 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 60 80 100 120 140 Space Volume Ft3 M3 0 60 1 050 29 7 1 400 39 6 1 750 49 5 1 400 39 6 1 500 42 5 2 000 56 6 2 500 70 8 3 000 84 9 3 500 99 1 0 50 1 260 35 6 1 680 47 5 2 100 59 4 1 680 47...

Page 12: ... 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 application...

Page 13: ... 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 14: ...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 15: ...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 16: ... 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 familiarize...

Page 17: ...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 18: ...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 19: ...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 20: ...ain Trap Connection and Routing Appearance may vary INSTALLATION This furnace is certified to leak 2 or less of nominal air conditioning CFM delivered when pressurized to 1 in water column with all present air inlets including bottom closure in upflow and horizontal applications air outlets and plumbing and electrical ports sealed NOTICE Upflow Installation NOTE The furnace must be pitched as show...

Page 21: ...use on combustible flooring when any one of the following 3 accessories are used S Special Base KGASB S Cased Coil Assembly Part No CNPV CNRV CAP or CAR S Coil Box Part No KCAKC 1 Determine application being installed from Table 8 2 Construct hole in floor per Table 8 and Fig 20 3 Construct plenum to dimensions specified in Table 8 and Fig 20 4 Install special base coil assembly or coil box as sho...

Page 22: ...en used DO NOT cut main furnace casing side to attach supply air duct humidifier or other accessories All supply side accessories MUST be connected to duct external to furnace main casing Return Air Connections The return air duct may be connected to bottom of the furnace The side of casing that faces downward may also be used for return air connection A combination of the bottom and downward faci...

Page 23: ... 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 in 5 cm 600 283 0 04 10 0 05 13 0 06 15 0 09 22 0 20 51 0 13 34 800 378 0 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...

Page 24: ...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 these models Air Filter Located in Filter Cabinet FILTER CABINET HEIGHT IN MM FILTER SIZE IN MM FILTER TYP...

Page 25: ...1091 OPENING TABS TYP 3 4 OPENING 14 1 2 16 1 8 23 8 1 2 3 8 11 4 11 4 25 1 8 17 1 8 23 1 8 32 mm 10 mm 13 mm 60 mm 19 mm 410 mm 368 mm 587 mm 435 mm 32 mm 638 mm A11095 Accessory Side Filter Rack Accessory Bottom Filter Rack A11188 Fig 19 Media Filter PG95XAT ...

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: ...e panel SCREWS 2 BOTTOM CLOSURE Representative drawing Models may vary A170123 Fig 22 Removing Bottom Closure Panel 2 Screws BOTTOM PLATE SCREWS 4 1 Lay furnace on the back or side 2 Remove the four 4 screws that secure the bottom plate to the furnace casing 3 Remove the bottom closure from the casing 4 Re install the bottom plate to the furnace casingand re install the four 4 screws Representativ...

Page 28: ...TAL MIN 1 4 IN 6 MM TO 1 2 IN 13 MM MAX A11237 Fig 25 Furnace Pitch Requirements ANY COMBINATION OF 1 2 OR 3 PERMITTED A11036 Fig 26 Upflow Return Air Configurations and Restrictions A11037 Fig 27 Downflow Return Air Configurations and Restrictions HORIZONTAL TOP RETURN NOT PERMITTED FOR ANY MODEL A11038 Fig 28 Horizontal Return Air Configurations and Restrictions PG95XAT ...

Page 29: ... 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 30: ...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 31: ...0 1725 1685 1640 1600 1555 1520 1480 1415 Blue 1385 1340 1285 1240 1200 1140 1090 1050 995 950 Orange 1560 1520 1475 1430 1385 1335 1295 1240 1200 1150 Red 1055 985 910 860 795 750 680 615 565 495 060100 BOTTOM or TWO SIDES 4 5 Gray 2340 2295 2250 2195 2110 2030 1935 1835 1725 1605 Yellow 1950 1900 1855 1800 1755 1705 1655 1605 1560 1485 Blue 1750 1700 1650 1605 1555 1500 1455 1395 1350 1300 Orang...

Page 32: ...e 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 burn...

Page 33: ...ous injury death or property damage Before servicing disconnect all electrical power to furnace When servicing controls label all wires prior to disconnection Reconnect wires correctly Verify proper operation after servicing Always reinstall access doors after completing service and maintenance WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death ...

Page 34: ...electrical box Do not leave splice connections unprotected inside the furnace The J Box cover mounting bracket and screws are shipped in the loose parts bag included with the furnace See Fig 34 for J Box mounting locations The J Box mounting bracket and green ground screw is used as a grounding point for all line voltage wiring options The J Box cover may be omitted when electrical connections are...

Page 35: ...Connect terminal Y Y2 as shown in Fig 37 for proper cooling operation Use only AWG No 18 color coded copper thermostat wire NOTE Use AWG No 18 color coded copper thermostat wire for lengths up to 100 ft 31 M For wire lengths over 100 ft use AWG No 16 wire The 24 v circuit contains an automotive type 3 amp fuse located on the control Any direct shorts during installation service or maintenance coul...

Page 36: ... 60 1 127 104 13 5 17 7 12 32 9 8 20 66120 115 60 1 127 104 12 0 15 9 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 wa...

Page 37: ...WER SPEED TERMINALS 115 VAC L2 NEUTRAL CONNECTIONS LED OPERATION DIAGNOSTIC LIGHT 3 AMP FUSE 24 V THERMOSTAT TERMINALS SET UP SWITCHES LOW HEAT ONLY AND BLOWER OFF DELAY TWINNING AND OR COMPONENT TEST TERMINAL ACRDJ AIR CONDITIONING RELAY DISABLE JUMPER HUMIDIFIER TERMINAL 24 VAC 0 5 AMPS MAX TRANSFORMER 24 VAC CONNECTIONS PL1 LOW VO LTAGE MAIN HARNESS CONNECTOR PL2 HOT SURFACE IGNITER INDUCER MOT...

Page 38: ...age Furnace with Single Speed Heat Pump Modulating and 2 Stage Furnace with Two Speed Heat Pump See notes 2 5 7 10 11 16 and 17 See notes 1 2 4 6 7 9 10 11 15 16 and 17 THERMOSTAT THERMOSTAT THERMOSTAT THERMOSTAT D D D D See notes 2 5 8 10 11 12 16 and 17 See notes 1 2 3 4 6 8 9 10 12 13 15 16 and 17 A12222 Fig 39 Thermostat Wiring Diagrams PG95XAT ...

Page 39: ...sory external drain trap available from the furnace manufacturer have been certified to ULC S636 for use with those Royal Pipe and IPEX PVC vent components which have been certified to this standard In Canada the primer and cement must be of the same manufacturer as the vent system GVS 65 Primer Purple for Royal Pipe or IPEX System 636 PVC CPVC Primer Purple Violet for Flue Gas Venting and GVS 65 ...

Page 40: ... 54 for single pipe or ventilated combustion air option A furnace shall not be connected to a chimney flue serving a separate appliance 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 installati...

Page 41: ...e 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 55 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 extr...

Page 42: ...ipe terminates in a well ventilated attic or crawl space Follow the clearances as shown in Fig 56 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 pipe for ...

Page 43: ...lent 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 16 Include a deduction for a Tee when used for Alberta and Saskatchewan terminations...

Page 44: ...here the knockout meets the casing Fold the knockout down with duct pliers and work the knockout back and forth until it is removed Trim any excess metal from the knockout with tin snips The vent elbow can be rotated to the required location on the casing if necessary See Fig 41 To rotate the vent elbow 1 Loosen the clamp on the inlet of the vent elbow attached to the inducer 2 Rotate the vent elb...

Page 45: ... of socket to prevent buildup of excess cement Apply second coat DO NOT CEMENT POLYPROPYLENE FITTINGS 13 While cement is still wet twist pipe into socket with 1 4 in turn Be sure pipe is fully inserted into 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 Horiz...

Page 46: ...ce 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 in kit Slide assembled kit with rain shield REMOVED through hole in wall or roof flashing NOTE Do not allow insulation or other materials to accumulate inside...

Page 47: ...que vent elbow clamp 15 lb in Table 14 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 standards and Ameri can Society for Testing and Materials ASTM standards or ULC S636 where required by code 2 See Table below for approved materials for use in ...

Page 48: ...n 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 1 6 1 4 6 3 0 1 5 6 1 7 6 6 1 4 6 6 1 9 1 7 6 6 1 40 4 6 3 0 1 5 4 6 4 6 3 0 1 5 6 1 4 6 4 6 3 0 6 1 6 1 4 6 3 0 Win...

Page 49: ...h Replacement Components required under 10 ft 3 0 M TEVL in all orientations Required for installations from 0 2000 ft 0 to 610 M above sea level Failure to use outlet restrictor on 40K model when required may result in flame disturbance or flame sense lockout 2 Inducer Outlet Restrictor disk P N 337683 401 1 25 in 32 mm Dia available through Replacement Components required for no greater than 5 f...

Page 50: ...EVL 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 pip...

Page 51: ...nd Adapter A13074 Fig 40 Vent Coupling and Adapter with Gaskets TABS ON THE INDUCER OUTLET RESTRICTOR SNAP INTO THE SLOTS AT THE OUTLET OF THE INDUCER FOR USAGE SEE MAXIMUM EQUIVALENT VENT LENGTH TABLE 10FT 3 1 M OF VENT OR LESS ONLY A170006 Fig 41 Inducer Vent Elbow PG95XAT ...

Page 52: ...o the Inside Corner Clearance Table No operable windows doors or intakes of any type within the shaded areas of Wall A and B For all other 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...

Page 53: ...he 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 intakes of any type are...

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

Page 55: ...T RIGHT VENT CONFIGURATION A11329A Fig 47 Horizontal Left Appearance may vary See Notes for Venting Options ALTERNATE COMBUSTION AIR CONNECTIONS HORIZONTAL RIGHT VERTICAL VENT CONFIGURATION A11337 Requires Internal Vent Kit See Product Data for Current Kit Number HORIZONTAL RIGHT LEFT VENT CONFIGURATION A11336 ALTERNATE COMBUSTION AIR CONNECTIONS HORIZONTAL RIGHT RIGHT VENT CONFIGURATION A11335 Fi...

Page 56: ...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 57: ...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 direct vent intake or exhaust 12 in 305 mm 12 in 305 mm N Furnace combustion air intake clearance to a water heater vent dryer vent or other types of applianc...

Page 58: ...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 Note 4 1...

Page 59: ... 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 mini...

Page 60: ...305 MM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL OR GRADE WHICHEVER IS GREATER COMBUSTION AIR ELBOW PARALLEL TO WALL OVERHANG 12 IN 305 MM MIN GROUND LEVEL OR ANTICIPATED SNOW LEVEL EXHAUST CLEARANCE TO OVERHANG PER CODE OPTIONAL BRACKET COUPLING 12 IN 305 MM MIN SEPARATION BETWEEN BOTTOM OFCOMBUSTION AIR AND BOTTOM OF VENT A13078 Fig 55 Alberta and Saskatchewan Vent Termination PG95XAT ...

Page 61: ...ipe hangar Ventilated Combustion Air intake termination in crawl space Ventilated Combustion Air intake pipe CRAWL SPACE ATTIC highest level of insulation A10497 Fig 56 Vent Terminations for Ventilated Combustion Air PG95XAT ...

Page 62: ...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 58 Recommended Combustion Air Inlet Moisture Trap PG95XAT ...

Page 63: ... determine based on length of previous heating on and off cycles when to operate in low and high gas heat for optimum comfort Setup switch SW 1 LHT must be in the factory shipped OFF position See Fig 37 and 71 for setup switch information If a 2 stage heating thermostat is to be used move SW 1 LHT to ON position before starting furnace This overrides built in control process for selecting high and...

Page 64: ... 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 installation altitude in Table 21 4 Find closest natural gas heat value and specific gravity i...

Page 65: ...ifold pressure less than 3 2 in w c 797 Pa or more than 3 8 in w c 947 Pa for natural gas If required manifold pressure is outside this range change main burner orifices to obtain manifold pressure in this range NOTICE c When correct input is obtained replace caps that conceal gas valve regulator adjustment screws Main burner flame should be clear blue almost transparent See Fig 64 d Remove jumper...

Page 66: ...r to the Air Delivery Tables to determine which airflows and settings are allowed for proper heating airflow DO NOT use the highlighted settings for High Stage Heating airflow The highlighted settings are to be used for Low Stage Heating and Cooling ONLY CAUTION Change the blower speed taps as required to maintain proper temperature rise for Heating and Cooling as described above To change blower ...

Page 67: ...urn off 115 v power to furnace g Reconnect inducer motor wires replace outer door and turn on 115 v power h Blowerwill runfor 90sec beforebeginning thecall forheat again i Furnace should ignite normally 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 there ...

Page 68: ...ERMOSTAT REMOVED ANITICIPATOR CLOCK ETC MUST BE OUT OF CIRCUIT HOOK AROUND AMMETER EXAMPLE 5 0 AMPS ON AMMETER 10 TURNS AROUND JAWS 0 5 AMPS FOR THERMOSTAT ANTICIPATOR SETTING FROM UNIT 24 V CONTROL TERMINALS A96316 Fig 61 Amp Draw Check with Ammeter PG95XAT ...

Page 69: ...69 A170152 Fig 62 Service Label Information PG95XAT ...

Page 70: ...9 138 346 13 277 555 1385 53 68 136 340 14 257 514 1286 54 67 133 333 15 240 480 1200 55 65 131 327 16 225 450 1125 56 64 129 321 17 212 424 1059 57 63 126 316 18 200 400 1000 58 62 124 310 19 189 379 947 59 61 122 305 20 180 360 900 60 60 120 300 21 171 343 857 62 58 116 290 22 164 327 818 64 56 112 281 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 ...

Page 71: ...4 3 6 1 5 44 3 7 1 6 43 3 4 1 4 43 3 5 1 5 4000 900 44 3 4 1 4 44 3 5 1 5 44 3 7 1 5 44 3 8 1 6 1219 925 44 3 2 1 4 44 3 4 1 4 44 3 5 1 5 44 3 6 1 5 950 45 3 7 1 6 44 3 2 1 3 44 3 3 1 4 44 3 4 1 4 750 42 3 3 1 4 42 3 4 1 4 42 3 5 1 5 42 3 6 1 5 4001 775 43 3 7 1 6 43 3 8 1 6 42 3 3 1 4 42 3 4 1 4 1220 800 43 3 5 1 5 43 3 6 1 5 43 3 7 1 6 43 3 8 1 6 825 44 3 8 1 6 43 3 4 1 4 43 3 5 1 5 43 3 6 1 5 8...

Page 72: ... such as cleaning and replacing air filters All other operations must be performed by trained service personnel A qualified service person should inspect the furnace once a year FIRE INJURY OR DEATH HAZARD Failure to follow this warning could result in personal injury death and or property damage The ability to properly perform maintenance on this equipment requires certain knowledge mechanical sk...

Page 73: ...butor Retrieving Stored Fault Codes NOTE Fault codes cannot be retrieved if a thermostat signal 24 v on W Y G etc is present or if any delays such as blower off delays are active The stored status codes will NOT be erased from the control memory when 115 or 24 v power is interrupted See the Service Label Fig 62 for more information The most recent fault code may be retrieved as follows 1 Leave 115...

Page 74: ...ny maintenance or service Follow the operating instructions on the label attached to the furnace WARNING CARBON MONOXIDE POISONING AND FIRE HAZARD Failure to follow this warning could result in personal injury death and or property damage Never operate furnace without a filter or filtration device installed Never operate a furnace with filter or filtration device access doors removed WARNING CUT H...

Page 75: ...se care 6 Clean blower wheel and motor by using a vacuum with soft brush attachment Be careful not to disturb balance weights clips on blower wheel vanes Do not bend wheel or blades as balance will be affected 7 If greasy residue is present on blower wheel remove wheel from the blower housing and wash it with an appropriate degreaser To remove wheel a Mark blower wheel location on shaft before dis...

Page 76: ...tance Nominal resistance is 40 to 70 ohms at room temperature and is stable over the life of the igniter 19 Clean burner with a brush and a vacuum 20 Clean the flame 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 on...

Page 77: ...ect 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 t...

Page 78: ...rent See Fig 64 12 Check for gas leaks 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...

Page 79: ...rner Manifold A11461 Fig 64 Burner Flame 2ïin 2 5 mm 3 8ïin 3 16ïin 0 8 ï1 5 mm 50 mm 9 6 mm 4 6 mm 1 10ïin 1 32 ï 1 16ïin L12F041 Fig 65 Igniter Position Side View A11392 Fig 66 Priming Condensate Trap A11273 Fig 67 Cleaning Heat Exchanger Cell SET SCREW MOTOR WHEEL HUB MOTOR SHAFT FLAT SCREW MOTOR ARM GROMMET SCREW LOCATION BLOWER HSG ASSY BRACKET BRACKET ENGAGEMENT SEE DETAIL A CAPACITOR OR POW...

Page 80: ...LPS closes If the high heat pressure switch HPS fails to close and the low heat pressure switch LPS closes the fur nace will operate at low heat gas flow rate until the high heat pressure switch closes for a maximum of 2 minutes after ignition b Igniter Warm Up At the end of the prepurge period the Hot Surface Igniter HSI is energized for a 17 second ig niter warm up period c Trial for Ignition Se...

Page 81: ...t in either low or high cooling If starting up in low cooling the furnace control CPU determines the low cooling on time from 0 to 20 minutes which is permitted before switching to high cooling If the power is interrupted the stored history is erased and the furnace control CPU will select low cooling for up to 20 minutes and then energize the air conditioning relay ACR to energize the Y Y2 termin...

Page 82: ...wer speeds from the room thermostat momentarily turn off the FAN switch or push button on the room thermostat for 1 3 sec after the blower motor BLWM is operating The furnace control CPU will shift the continuous blower speed from the factory setting of LO HEAT to HI HEAT speed Momentarily turning off the FAN switch again at the thermostat will shift the contin uous blower speed from HI HEAT to CO...

Page 83: ...previous fault After the control repeats the code 4 times the control will start the component test sequence Once initiated the control will turn the inducer ON at high heat speed The inducer will run for the entire component test The HSI blower motor LO HEAT speed HI HEAT speed and COOL speed will run for 10 15 seconds each Gas valve and humidifier will not be turned on When the blower motor is t...

Page 84: ...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 the gas valve igniter or flame sensor the system can be operated in the component test mode to ch...

Page 85: ...85 338314 2 Rev I A170153 Fig 71 Wiring Diagram PG95XAT ...

Page 86: ...or 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 PG95 X ...