Payne PG9YAA036060 Installation Instructions Manual Download

Page: 35 / 42

Changing Orifices for High Altitude

ELECTRICAL

SHOCK,

FIRE

EXPLOSION

HAZARD

Failure to follow this warning could result in personal injury,

death, and/or property damage.
Turn OFF electric power (at disconnect) and gas supply (at

manual valve in gas line) when installing orifices. Installation

of orifices requires a qualified service technician.

WARNING

NOTE

: Main burner orifices can be changed for high altitudes.

1. Disconnect gas line from gas valve.
2. Remove manifold from furnace.
3. Remove the orifices from the manifold and replace them

with properly sized orifices.

4. Tighten orifices so it is seated and gas tight. (See Fig. 35)
5. Reinstall manifold. Ensure burners do

NOT

bind on new

orifices.

Natural Gas Input Rating Check

SEE CHECKS AND ADJUSTMENTS, Natural Gas Input

Rating Check

in this manual.

Measure from face of orifice
to the back side of the
manifold.

1.11

″

(28.2mm)

1.21

″

(30.8mm)

A07725

Fig. 35 -- Changing Orifices

Final Gas Piping Check

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal injury,

death, and/or property damage.
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 could result causing property damage, personal

injury and/or loss of life.

WARNING

1. The furnace and the equipment shut off valve must be dis-

connected from the gas supply piping system during any

pressure testing of that system at test pressures in excess of

″

PSIG. Close the manual shut--off valve before testing

at such pressures.

2. When installation is complete, test all pipe connections for

leaks with the gas pressure less than

″

PSIG to the gas

valve.

3. The furnace must be isolated from the gas supply system

by closing the equipment shut off valve during any pres-

sure testing of the gas supply system at test pressure equal

to or less than

″

PSI (3.5 kPa).

4. Apply a commercial soap solution to all joints to test for

leaks. Correct any leaks indicated by bubbles.

5. Correct even the smallest leak at once.
6. Check for leaks at gas valve and orifice connections to the

burner manifold while the furnace is operating.

ELECTRICAL WIRING

Power Supply Wiring

The furnace

MUST

be electrically wired and grounded in

accordance with local codes, or in the absence of local codes with

the latest edition of The National Electric Code, ANSI NFPA 70

and/or The Canadian Electric Code CSA C22.1.
The power supply to the furnace connections must be between

104 VAC and 127 VAC during furnace operation for acceptable

performance.
Field wiring connections must be made inside the furnace

connection box. A suitable strain relief should be used at the

point the wires exit the furnace casing.

Copper conductors shall be used.

Line voltage wires should

conform to temperature limitation of 63

F (35

C) rise and be

sized for the unit maximum amps stated on the rating plate. Add

the full load amps for potential field--installed accessories such as

electronic air cleaners and humidifiers that would receive power

from the furnace control. The furnace control is rated for a

maximum of 1.0 amp combined for EAC and HUM. Consult

NEC or local codes for proper wire and circuit sizing.

NOTE

: Furnace will not have normal operation if line polarity is

reversed. Check ALL field and control connections prior to
operation.

Junction Box (J- Box) Relocation

The J--box is installed on left side of casing. An alternate j--box

location on right side can be used.

1. Remove bag containing two hole plugs and two self tap-

ping screws from loose parts bag in blower compartment.

2. Remove two screws holding J--Box to casing.
3. Move large hole plug from right to left J--Box location.
4. Clip wire tie holding J--Box wires.
5. Move J--Box to alternate location and attach using two self

tapping screws from bag.

6. Apply two hole plugs from bag at left J--Box location.

Thermostat

Thermostat location has an important effect on the operation of

the unit. Follow instructions included with thermostat for correct

mounting and wiring.
Low voltage connections to furnace must be made on terminal

board of furnace control.
Heat anticipator setting will need to be measured if 24VAC

humidifier is installed. Measure current in series from R to W at

the thermostat. Be sure 24VAC humidifier is wired up to control.

Allow furnace to operate for 2 minutes before recording the AC

amperage reading. Set anticipator on thermostat to recorded

value.

PG9Y

Summary of Contents for PG9YAA036060

Page 1: ...tc should be consulted before installation to determine the need to obtain a permit Consignes spéciales pour l installation de ventillation au Canada L installation faite au Canada doit se conformer aux exigences du code CSA B149 Ce systême de ventillation doit se composer de tuyaux raccords ciments et apprêts conformes au ULC S636 La tuyauterie de ventillation des gaz ses accessoires le terminal ...

Page 2: ...ior of the building at a minimum height of eight 8 feet above grade directly in line with the 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...

Page 3: ...hut Off Upstream of Furnace Drip Leg Gas Valve turned ON Type of Gas Natural Propane Filter Type and Size Calculated Firing Rate See Checks and Adjustments Section Heating Check Measured Line Pressure when Firing Unit Measured Manifold Gas Pressure Temperature of Supply Air Temperature of Return Air Temperature Rise supply return temperature In Rise see furnace rating plate Static Pressure Ducts S...

Page 4: ...rve precautions in literature on tags and on labels attached to or shipped with unit and other safety precautions that may apply These instructions cover the minimum requirements and conform to existing national standards and safety codes In some instances these instructions exceed certain local codes and ordinances especially those that may not have kept up with changing residential construction ...

Page 5: ...lation of these instructions S This furnace is not to be used for temporary heating of buildings or structures under construction S This furnace is NOT approved for installation in mobile homes trailers or recreation vehicles S Seal around supply and return air ducts S Install correct filter type and size S Unit MUST be installed so electrical components are protected from direct contact with wate...

Page 6: ...stub on the vent drain fitting Secure with the hose clamp 2 Disconnect the 3 4 OD rubber hose from the condensate trap Insert a funnel into the hose and and pour four 4 ounces of sanitary type RV antifreeze into the plastic Transition box Squeeze the hose together near the end and quickly reconnect the 3 4 OD rubber hose to the stub on the condensate trap Secure with the hose clamp When you return...

Page 7: ... bolts The preferred method is to use an angle iron frame bolted to the rafters or joists 9 Local codes may require a drain pan under the entire fur nace and condensate trap when the furnace is installed in attic application This furnace may be used for construction heat provided that all the following conditions are met S The furnace is permanently installed with all electrical wiring piping vent...

Page 8: ...evaporator specifications for duct size requirements Furnace is designed for bottom return or side return Return air through back of furnace is NOT allowed C KO KO Knockout KO Specifications are subject to change without notice MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS FOR ALL UNITS REAR 0 FRONT combustion air openings in furnace and in structure 3 Required For Service 24 ALL SIDES Of SUPPLY PLE...

Page 9: ... systems that are certified to the standard for Type BH Gas Venting Systems ULC S636 ULC S636 certified plastic vent system material or the components of ULC S636 certified vent systems must not be interchanged with other vent systems or unlisted pipe fittings Vent components supplied with the furnace and components in factory authorized vent kits may be used with ULC S636 certified vent systems T...

Page 10: ...el Gas Code NFGC ANSI Z223 1 2006 NFPA 54 2006 in the U S 2 Sections 8 2 8 3 8 5 8 6 8 7 and 8 8 of National Stand ard of Canada Natural Gas and Propane Installation Code NSCNGPIC CSA B149 1 05 in Canada 3 Applicable provisions of the local building code This furnace can NOT be common vented or connected to any type B BW or L vent or vent connector nor to any portion of a factory built or masonry ...

Page 11: ...ing sq in 3 000 BTUH Two Vertical Ducts or Openings sq in 4 000 BTUH Round Duct sq in 4 000 BTUH 60 000 30 sq in 20 sq in 15 sq in 5 80 000 40 sq in 26 7 sq in 20 0 sq in 5 100 000 50 sq in 33 3 sq in 25 sq in 6 EXAMPLE Determining Free Area Furnace 100 000 Furnace 100 000 Water Heater 30 000 Water Heater 30 000 Total Input 130 000 4 000 Total Input 130 000 2 000 32 5 Sq In Vertical 65 Sq In Horiz...

Page 12: ...uch spaces are connected by one or more openings in doors or floors having a total minimum free area of 2 in 2 1 000 BTUH 4 400 mm2 kW of total input rating of all appliances S An attic or crawl space may be considered a space that freely communicates with the outdoors provided there are adequate ventilation openings directly to outdoors Openings MUST remain open and NOT have any means of being cl...

Page 13: ...heir previous conditions of use WARNING For Two Pipe Installation Direct Vent This furnace can NOT be common vented or connected to any type B BW or L vent or vent connector nor to any portion of a factory built or masonry chimney If this furnace is replacing a previously common vented furnace it may be necessary to resize the existing vent and chimney to prevent oversizing problems for the other ...

Page 14: ...e 12 The minimum pipe run length is 2 6 M 13 The piping can be run in the same chase or adjacent to supply or vent pipe for water supply or waste plumbing It can also be run in the same chase with a vent from another 90 furnace NOTE In NO case can the piping be run in a chase where temperatures can exceed 140 F 60 C or where radiated heat from adjacent surfaces would exceed 140 F 60 C 14 The vent ...

Page 15: ...ameter Table NOTE It is allowable to use larger diameter pipe and fitting than shown in the tables but not smaller diameters than shown For Concentric Termination Kit Venting see Table 4 in this manual Vent Termination Clearances CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury or death Inlet and outlet pipes may NOT be vented directly above each othe...

Page 16: ...16 12 inches 30 cm for applieances 10 000 Btuh 3 kW and 100 000 Btuh 30kW 36 inches 91cm for appliances 100 000 Btuh 30kW A06675 Fig 7 Direct Vent Termination Clearance PG9YAA ...

Page 17: ...17 Fig 8 Other than Direct Vent Termination Clearance PG9YAA ...

Page 18: ... in the furnace between the door switch plate and the blower shelf Fig 9 during operation See Fig 17 for proper routing and installation of the overflow DO NOT trap the drain line in any other location than at the condensate drain trap supplied with the furnace FROZEN AND BURST WATER PIPE HAZARD Failure to follow this caution may result in property damage If a condensate pump is installed a plugge...

Page 19: ...bber 5 8 ID grommet in loose parts bag S Install the 1 2 CPVC street elbow on discharge of trap S Install the black PVC tube connector 3 4 PVC x 1 2 CPVC from loose parts bag as shown in the illustration above S Cut the black drain tube 5 8 ID in loose parts bag to length to fit between trap and tube connector through grommet S Clamp both ends of the drain tube using clamps provided S Glue the CPV...

Page 20: ...ropriate length of 2 PVC pipe long enough to exit the cabinet and connect the vent drain to either A standard field supplied 2 PVC tee or A 2 PVC coupling fastened onto the drain tee S Install tee trap into bottom of tee S Remove knockout from the side of the furnace casing where drain tube will exit S Install the 1 2 CPVC street elbow on discharge of trap S Install the black PVC drain connector 3...

Page 21: ...ge port of the vent drain to the trap Secure all connections with clamps S Install the vent pipe grommet into the casing S Cut an appropriate length of 2 PVC pipe long enough to exit the cabinet and connect the vent drain to either A standard field supplied 2 PVC tee or A 2 PVC coupling fastened onto the drain tee S Install tee trap into bottom section of tee S Remove knockout from the side of the...

Page 22: ...side of the unit using the 2 screws provided in the location shown S Cut the corrugated tube as shown in the illustration above Connect the corrugated hose from the transition to the trap Secure connections with clamps S Remove the black 1 2 ID drain tube from the drain tee Install a yellow cap and clamp over the open drain port of the drain tee S Connect the black 1 2 ID drain tube from the Vent ...

Page 23: ...here drain tube will exit S Mount the trap externally to the bottom side of the unit using the 2 screws provided in the location shown S Cut the corrugated tube as shown in the illustration above Connect the corrugated hose from the transition to the trap Secure connections with clamps S Connect the black 1 2 ID drain tube from the Vent Drain to the trap If an extension is required use the black 1...

Page 24: ... drain tube will exit S Mount the trap externally to the bottom side of the unit using the 2 screws provided in the location shown S Cut the corrugated tube as shown in the illustration above Connect the corrugated hose from the transition to the trap Secure connections with clamps S Connect the black 1 2 ID drain tube from the Vent Drain to the trap If an extension is required use the black 1 2 O...

Page 25: ...casing where drain tube will exit S Mount the trap externally to the bottom side of the unit using the 2 screws provided in the location shown S Cut the corrugated tube as shown in the illustration above Connect the corrugated hose from the transition to the trap Secure connections with clamps S Connect the black 1 2 ID drain tube from the Vent Drain to the trap If an extension is required use the...

Page 26: ... of flue gasses WARNING Refer to Fig 10 through Fig 16 that corresponds to the installation position of the furnace for the application Preassemble the vent and combustion air piping from the furnace to the vent termination Do not cement the pipe joints until the pipe preassembly process is complete Combustion Air Pipe Connection Dual Certified or Direct Vent Install the air intake coupling and ga...

Page 27: ...ttings with a slight twisting movement until it bottoms out NOTE Cement MUST be fluid while inserting pipe If NOT recoat pipe 4 Hold the pipe in the fitting for 30 seconds to prevent the tapered socket from pushing the pipe out of the fitting 5 Wipe all excess cement from the joint with a rag Allow 15 minutes before handling Cure time varies according to fit temperature and humidity Connecting Ven...

Page 28: ...elow for 24 or more consecutive hours then 18 Min A07717 Fig 21 Rooftop Termination Vertical Termination 1 Fig 21 shows the proper installation and clearances for vertical vent termination The vertical roof termination should be sealed with a plumbing roof boot or equivalent flashing The inlet of the intake pipe and end of the ex haust vent must be terminated no less than 12 304 8 mm above the roo...

Page 29: ... below for 24 or more con secutive hours Inlet A A 12 Min Grade or Snow Level A07697 Fig 25 Sidewall Inlet Vent and Exhaust Air Termination with Exterior Risers 12 Min Grade or Snow Level Exhaust 8 Min 20 Max 18 Min for Cold Climates Sustained temperatures 0 F and below for 24 or more consecutive hours Inlet A07698 Fig 26 Rooftop Inlet Vent and Exhaust Air Termination OVERHANG 12 MIN 12 MIN Ground...

Page 30: ...lation Vertical Horizontal Termination 1 Determine the pipe diameters required for the installation from Table 4 and Fig 30 2 Determine the best location for the termination kit See Fig 29 for vertical termination or Fig 33 for horizontal termination Roof termination is preferred since it is less susceptible to damage has reduced intake contaminants and less visible vent vapor For side wall termin...

Page 31: ...rew assembly method drill a clearance hole in the rain cap and a pilot hole in the vent pipe for the screw size being used Failure to drill adequate holes may cause cracking of the PVC components allowing flue gasses to be recirculated WARNING Drill clearance hole in rain cap and pilot hole in vent pipe Stainless steel screw Field supplied A07722 Fig 31 Rain Cap to Vent Pipe Assembly 6 Install the...

Page 32: ...ance with all building codes NOTE In the state of Massachusetts a Gas supply connections MUST be performed by a li censed plumber or gas fitter b When flexible connectors are used the maximum length shall not exceed 36 914 4 mm c When lever handle type manual equipment shutoff valves are used they shall be T handle valves d The use of copper tubing for gas piping is NOT ap proved by the state of M...

Page 33: ...e for a test gauge connection must be installed immediately upstream of the gas supply connection to the furnace 2 Gas input to burners MUST NOT exceed the rated input shown on rating plate 3 Do NOT allow minimum gas supply pressure to vary downward Doing so will decrease input to furnace Refer to Table 6 and Table 7 for normal gas supply and manifold pressures Manifold Gas Pressure Adjustment SEE...

Page 34: ...derating of these furnaces at 2 Natural Gas and 4 Propane Gas has been tested and design certified by CSA In Canada the input rating must be derated 5 Natural Gas and 10 Propane Gas for altitudes of 2 000 to 4 500 above sea level Use the 2001 to 3000 column in Table 6 and Table 7 Table 7 Propane Gas Manifold Pressure The burner orifice part nos are as follows Orifice 41 333730 701 Orifice 42 33373...

Page 35: ...e burner manifold while the furnace is operating ELECTRICAL WIRING Power Supply Wiring The furnace MUST be electrically wired and grounded in accordance with local codes or in the absence of local codes with the latest edition of The National Electric Code ANSI NFPA 70 and or The Canadian Electric Code CSA C22 1 The power supply to the furnace connections must be between 104 VAC and 127 VAC during...

Page 36: ...ry in appearance A07726 Fig 36 Electrical Connections Furnace Control Fuse The 24V circuit contains a 5 amp automotive type fuse located on furnace control See Fig 37 Any electrical shorts of 24V wiring during installation service or maintenance may cause fuse to blow If fuse replacement is required use only a fuse of identical size 5 amp Blower Off Delay Jumper FUSE Diagnostic Light 24 VAC HUM 11...

Page 37: ... system s air flow 4 Non combustible flexible duct connectors are recommen ded for return and supply connections to furnace 5 If air return grille is located close to the fan inlet install at least one 90 air turn between fan and inlet grille to re duce noise NOTE To further reduce noise install acoustical air turning vanes and or line the inside of duct with acoustical material Sizing Existing or...

Page 38: ...or plastic tubing for the condensate drain line UNIT OPERATIONAL HAZARD Failure to follow this caution may result in improper unit operation This furnace is not approved for use with N style evaporator coils If installed with an N style evaporator coil improper limit operation may occur CAUTION CHECKS AND ADJUSTMENTS NOTE Verify the input rate of the furnace FIRE OR EXPLOSION HAZARD Failure to fol...

Page 39: ...in burner See Fig 44 Check for the following Fig 44 S Stable and blue flames Dust may cause orange tips or wisps of yellow but flames MUST NOT have solid yellow tips S Flames extending directly from burner into heat exchanger S Flames do NOT touch sides of heat exchanger If any problems with main burner flames are noted it may be necessary to adjust gas pressures or check for drafts Burner Face A0...

Page 40: ...ower compartment for operation of the continuous fan option This connection is intended for the low speed motor tap and has a lower contact rating 8 amps than the heat and cool taps When the low speed blower lead is connected to this terminal this will provide low speed blower operation whenever the other two speeds Heat or Cool are not energized Thoroughly check the system after modification to e...

Page 41: ...5 second postpurge period S The fan stays at Heat speed S The fan de energizes after the selected Heat Fan Off Delay time expires timed from the gas valve de energizing HUMIDIFIER The 24V HUM is energized when the pressure switch closes on a call for heat The 115V HUM called HUM on Control is energized when the inducer is energized ELECTRONIC AIR CLEANER EAC is energized when there is a blower spe...

Page 42: ...ay roll out switch requires manual reset 8 Flashes Permanent Lockout Gas valve relay contact stuck closed or miswired gas valve power reset only 10 Flashes Line voltage 115VAC polarity reversed If twinned refer to twinning kit instructions If status code recall is needed briefly 2 3 seconds remove then reconnect one limit switch wire main or rollout to display last stored status code Do not remove...

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