Payne R95ESN Installation Instructions Manual Download

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440 01 6101 00

Specifications subject to change without notice.

15. Wipe excess cement from joint. A continuous bead of ce-

ment will be visible around perimeter of a properly made

joint.

16. Handle pipe joints carefully until cement sets.
17. Horizontal portions of the venting system shall be

supported to prevent sagging. Space combustion air piping
and vent piping hangers as shown in Table 13. Support

pipes using perforated metal hanging strap or commercially
available hangers or straps designed to support plastic pipe.

18. 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 hangers is required. See Caution Box below.

FURNACE RELIABILITY HAZARD

Failure to follow this caution may result in nuisance short

cycling, frozen vent termination, and/or no heat.
Slope the vent and combustion air piping downward towards

furnace a minimum of 1/4--in. (6 mm) per linear ft. of pipe.

CAUTION

19. Use appropriate methods to seal openings where combus-

tion air pipe and vent pipe pass through roof or sidewall.

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury

or death.

DO NOT

use cement to join polypropylene venting systems.

Follow the polypropylene venting system manufacturer’s

instructions for installing polypropylene venting systems.

WARNING

Optional Installation of the Vent Pipe

NOTE

DO NOT USE THIS TECHNIQUE FOR

POLYPROPYLENE VENTING SYSTEMS.

This option provides a disconnect point for the vent pipe. The vent

pipe must be cemented to the plastic vent pipe adapter to maintain
a sealed vestibule. See Fig. 49.

1. Insert a length of vent pipe through the casing into the

outlet of the vent elbow.

2. Slide the plastic vent pipe adapter over the length of the

vent pipe down to the furnace casing. Mark the pipe where

it is flush with the outlet of the adapter.

3. Remove the pipe from the furnace and the adapter and cut

off any excess pipe.

4. Clean and prime the end of the pipe that is flush with the

vent adapter with a primer that is appropriate for the type of

pipe being used.

5. Re--insert the pipe through the casing into the vent elbow.
6. Tighten the clamp around the outlet of the vent elbow.

Torque the clamp to 15 lb--in.

7. Apply cement to the end of the pipe and to the inside of the

plastic vent adapter.

8. Slide the adapter over the vent pipe and align the screw

holes in the adapter with the dimples in the furnace casing.

9. Pilot drill 1/8--in. screw holes for the adapter in the casing

and secure the adapter to the furnace with sheet metal

screws.

10. Loosen the clamps on the rubber vent coupling.

11. Slide the end of the coupling with notches in it over the

standoffs in the vent pipe adapter.

12. Tighten the clamp of the coupling over the vent pipe

adapter. Torque the lower clamp around the vent pipe
adapter to 15 lb--in.

13. Pilot drill a 1/8--in. hole in the combustion air pipe adapter.
14. Complete the vent and combustion air pipe as shown in

“Install the Vent and Combustion Air Pipe.”

FOR POLYPROPYLENE VENTING SYSTEMS

When using polypropylene venting systems, all venting

materials used, including the vent terminations, must be from

the same manufacturer.

NOTICE

Installing the Vent Termination

Roof Terminations

A roof termination of any type will require a 4-in. (102 mm)

flashing for a 2 in. (50 mm ND) concentric vent or a 5--in. diameter

(127 mm) flashing for a 3-in. (80 mm ND) concentric vent kit. For
two-pipe or single pipe vent systems, a flashing for each pipe of the

required diameter will be necessary.
It is recommended that the flashing be installed by a roofer or

competent professional prior to installing the concentric vent. The

terminations can be installed on a flat or pitched roof.

Concentric Vent

Single or multiple concentric vent must be installed as shown in

Fig. 53. Maintain the required separation distance between vents

or pairs of vents as shown in Fig. 53 and all clearance shown in
Fig. 51.

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 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 of pipe assembly when installing it through hole.
Disassemble loose pipe fittings. Clean and cement using same

procedures as used for system piping.

DO NOT CEMENT

POLYPROPYLENE FITTINGS.
Two--Pipe and Single--Pipe Terminations

Single and two pipe vent must be installed as shown in Fig. 53 and

54. Maintain the required separation distance between vents or

pairs of vents as shown in Fig. 53 and 54 and all clearance shown
in Fig. 51 and 52 .

RECOMMENDED SUPPORT FOR VENT

TERMINATIONS

It is recommended that rooftop vent terminations in excess of

36 inches (1 M) in vertical length be supported by

EITHER

the Direct Vent Termination Kit shown in Table 12 or by

field--supplied brackets or supports fastened to the structure.

NOTICE

Cut the required number of holes in the roof or sidewall for vent

and (when used) combustion air pipes. Sidewall holes for two-pipe
vent terminations should be side-by-side, allowing space between

the pipes for the elbows to fit on the pipes.

Summary of Contents for R95ESN

Page 1: ...ning Dimensions 29 Air Delivery CFM 30 Maximum Capacity of Pipe 32 Electrical Data 36 Vent Termination Kit for Direct Vent 2 Pipe System 39 Hangar Spacing 46 Combustion Air Vent Pipe Fitting Cement Material 49 Maximum Allowable Exposed Vent Lengths Insulation 50 Maximum Equivalent Vent Length 51 Deductions from Maximum Equivalent Vent Length 51 Blower Off Delay Setup Switch 70 Altitude Derate Mult...

Page 2: ...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 fueled equipment shall not approve the installation unless up...

Page 3: ...rained service personnel When working on heating equipment observe precautions in literature on tags and on labels attached to or shipped with furnace and other safety precautions that may apply These instructions cover minimum requirements and conform to existing national standards and safety codes In some instances these instructions exceed certain local codes and ordinances especially those tha...

Page 4: ... with natural gas The furnace can be converted in the field for use with propane gas when a factory supplied conversion kit is used Refer to the furnace rating plate for conversion kit information These furnaces are not approved for installation in recreational vehicles or outdoors Single stage furnaces 40 000 through 120 000 are approved for installation in manufactured housing mobile homes with ...

Page 5: ...oduct must be installed by a licensed plumber or gas fitter S When flexible connectors are used the maximum length shall not exceed 36 in 914 mm S When lever type gas shutoffs are used they shall be T handle type S The use of copper tubing for gas piping is not approved by the state of Massachusetts Electrical Connections S US Current edition of National Electrical Code NEC NFPA 70 S CANADA Curren...

Page 6: ...401712 17 1 2 445 15 7 8 403 16 406 8 3 4 222 126 5 57 4 0601412 14 3 16 361 12 1 2 319 12 9 16 322 7 1 8 181 129 58 5 0601714 17 1 2 445 15 7 8 403 16 406 8 3 4 222 138 5 62 8 0801716 17 1 2 445 15 7 8 403 16 406 8 3 4 222 146 5 66 4 0802120 21 533 19 3 8 492 19 1 2 495 10 1 2 267 154 5 70 1 1002120 21 533 19 3 8 492 19 1 2 495 10 1 2 267 164 5 74 6 1202420 24 1 2 622 22 7 8 581 23 584 12 1 4 311...

Page 7: ...compartment See Table 2 for loose parts bag contents This furnace must S be installed so the electrical components are protected from water S not be installed directly on any combustible material other than wood flooring refer to SAFETY CONSIDERATIONS S be located close to the chimney or vent and attached to an air distribution system Refer to Air Ducts section S be provided ample space for servic...

Page 8: ...hazardous atmosphere the furnace must be installed in accordance with the current edition of NFPA 54 ANSI Z223 1 or CAN CSA B149 2 See Fig 4 WARNING 18 IN 457 2 mm MINIMUM TO BURNERS A93044 Fig 4 Installation in a Garage FIRE HAZARD Failure to follow this warning could result in personal injury death and or property damage Do not install the furnace on its back or hang furnace with control compart...

Page 9: ...changers and shorten furnace life Air contaminants are found in aerosol sprays detergents bleaches cleaning solvents salts air fresheners and other household products CAUTION CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury or death The operation of exhaust fans kitchen ventilation fans clothes dryers attic exhaust fans or fireplaces could create a NE...

Page 10: ...at 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 shall be at least 3 in 80 mm See Fig 7 c Combining space on different floor levels The volumes o...

Page 11: ...zontal Ducts Table 4 Minimum Space Volumes for 100 Combustion Ventilation and Dilution Air from Outdoors AIR CHANGES PER HOUR ACH OTHER THAN FAN ASSISTED TOTAL 1 000 S BTUH GAS INPUT RATE FAN ASSISTED TOTAL 1 000 S BTUH GAS INPUT RATE 30 40 50 26 40 60 80 100 120 140 Space Volume Ft3 M3 0 60 1 050 29 7 1 400 39 6 1 750 49 5 910 25 8 1 400 39 6 1 500 42 5 2 000 56 6 2 500 70 8 3 000 84 9 3 500 99 1...

Page 12: ... repositioned on the collector box for proper condensate drainage See the bottom images in Fig 11 and 12 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 8 Remove knockout Install grommet before relocat...

Page 13: ...te Trap Relief Port Collector Box Plugs Pressure Switch Port Condensate Trap Outlet Condensate Trap Relief Port Collector Box Plug Vent Elbow Vent Elbow Clamp Vent Pipe Clamp UPFLOW TRAP CONFIGURATION 1 2 Stage Units A11307 Fig 9 Upflow Trap Configuration Appearance may vary ...

Page 14: ...lugs previously removed on the open 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 p...

Page 15: ...d in the Horizontal Right Orientation 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 bo...

Page 16: ...ientation Rotate elbow to desired position and torque clamp on inlet 15 lb in Slide relief tube in stand offs to adjust length Attach condensate trap with screw to collector box Align trap over middle and right hand port on collector box Install two plugs previously removed in open ports on collector box Connect relief tube to port on collector box Connect the new pressure switch tube from Loose P...

Page 17: ...d a The drains are 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 18 NOTE On narrower casings it may be easier to remove the condensate trap connect the drain line components and re install the condensate trap Read the step...

Page 18: ... drain line can be constructed from field supplied 1 2 in CPVC or 3 4 in PVC pipe in compliance with local building codes A factory supplied 1 2 in CPVC to 3 4 in PVC adapter is supplied in the loose parts bag for use as required 15 Install the adapter or connect the 1 2 in CPVC pipe by sliding a spring clamp over the open end of the grommet on the outside the furnace casing 16 Open the spring cla...

Page 19: ...l the grommet and re install the trap 5 Remove the pre formed rubber drain elbow and two spring clamps from the loose parts bag 6 Connect the full or modified elbow and or grommet to the outlet of the condensate trap with one spring clamp Avoid misalignment of the drain pipe which may cause kinks in the elbow or grommet 7 The remaining drain line can be constructed from field supplied 1 2 in CPVC ...

Page 20: ...y when drain is at positive pressure 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 pre...

Page 21: ...ressure lower than areas with ï Negative pressure 3 4 PVC Open standpipe Optional when coil drain is not connected to furnace drain TEE 1 2 CPVC to 3 4 PVC adapter from loose parts bag DIRECTION OF AIRFLOW A170135 Fig 18 Example of Field Drain Attachment 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 ...

Page 22: ...e return air openings in DOWNFLOW configuration See Fig 22 23 and 24 Leveling Legs If Desired In upflow position with side return inlet s leveling legs may be used See Fig 20 Install field supplied 5 16 x 1 1 2 in 8 x 38 mm max corrosion resistant machine bolts washers and nuts NOTE Bottom closure must be used when leveling legs are used It may be necessary to remove and reinstall bottom closure p...

Page 23: ...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 27 and 28 Horizontal Installation NOTE The furnace must be pitched forward as shown in Fig 21 for proper condensate drainage FIRE EXPLOSION AND CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury death or proper...

Page 24: ...17 1 2 in 445 mm and larger may be used for flame roll out protection when bottom of furnace is used for return air connection See Fig 25 for proper orientation of roll out shield ANY COMBINATION OF 1 2 OR 3 PERMITTED A11036 Fig 22 Upflow Return Air Configurations and Restrictions A11037 Fig 23 Downflow Return Air Configurations and Restrictions HORIZONTAL TOP RETURN NOT PERMITTED FOR ANY MODEL A1...

Page 25: ...ing furnace is installed over a finished ceiling 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 ...

Page 26: ...tive drawing only some models may vary in appearance A170123 Fig 27 Removing Bottom Closure Panel 2 Screws BOTTOM PLATE SCREWS 4 1 Lay furnace on the back or side 2 Remove the four 4 screws that secure the bottom plate to the furnace casing 3 Remove the bottom closure from the casing 4 Re install the bottom plate to the furnace casingand re install the four 4 screws Representative drawing only som...

Page 27: ...13 34 0 21 52 0 32 81 1200 566 0 08 20 0 17 43 0 27 68 16x 25 Filter Factory Accy Washable Representative After Market Filter Media Fiberglass Pleated CFM L s 1 in 2 5 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 06 15 0 09 22 0 20 51 0 13 34 800 378 0 05 13 0 08 21 0 13 32 0 29 72 0 20 49 1000 472 0 06 16 0 11 28 0 17 43 0 27 67 1200 566 0 07 18 0 14 36 0 22 56 1400 661 0 08 2...

Page 28: ...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 Specification 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 TYPE 14 3 16 360 14 x 25 x 3 4 356 x 635 x 19 Washable or Med...

Page 29: ... ductwork design and performance requirements in your area NOTICE General Requirements The duct system should be designed and sized according to accepted national standards such as those published by Air Conditioning Contractors Association ACCA Manual D Sheet Metal and Air Conditioning Contractors National Association SMACNA or American Society of Heating Refrigerating and Air Conditioning Engine...

Page 30: ... 1760 1710 1660 1615 Yellow Alt Cooling Do not use for heating 1665 1625 1575 1530 1480 1435 1385 1340 1285 1240 Orange Alt Cooling or alt Heating 1475 1420 1370 1320 1270 1220 1170 1125 1070 1025 Blue Heating or alt Cooling 1345 1290 1235 1180 1130 1080 1025 975 935 885 Red Alt Cooling Do not use for heating 1155 1080 1015 960 895 845 790 735 675 620 1002120 Gray Cooling Do not use for heating 22...

Page 31: ...e gas appliance connector always use a new listed connector Do not use a connector which has previously served another gas appliance Black iron pipe shall be installed at the furnace gas control valve and extend a minimum of 2 in 51 mm outside the furnace WARNING FURNACE DAMAGE HAZARD Failure to follow this caution may result in furnace damage Connect gas pipe to furnace using a backup wrench to a...

Page 32: ...result in dangerous operation serious 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 r...

Page 33: ...ernal disconnect mounted to furnace If field supplied manual disconnect switch is to be mounted on furnace casing side select a location where a drill or fastener cannot damage electrical or gas components WARNING The J Box must be used when field line voltage electrical connections are made to the furnace wiring harness inside the furnace casing The J Box cover is not required if a field supplied...

Page 34: ... ground screw to the J Box bracket and attach both ground wires to the green ground screw 8 Connect any code required external disconnect s to field power wiring 9 Connect field power and neutral leads to furnace power leads inside the external electrical box as shown in Fig 34 Power Cord Installation in Furnace J Box NOTE Power cords must be able to handle the electrical requirements listed in Ta...

Page 35: ...se ONLY a 3 amp fuse of identical size See Fig 36 Accessories See Fig 36 1 Electronic Air Cleaner EAC Connect an accessory Electronic Air Cleaner if used using 1 4 in female quick connect terminals to the two male 1 4 in quick connect terminals on the control board marked EAC 1 and EAC 2 The terminals are rated for 115VAC 1 0 amps maximum and are energized during blower motor operation 2 Humidifie...

Page 36: ...38 11 5 15 0601714 115 60 1 127 104 9 6 12 9 14 28 8 7 15 0801716 115 60 1 127 104 10 13 4 14 27 8 4 15 0802120 115 60 1 127 104 12 3 16 3 12 35 10 7 20 1002120 115 60 1 127 104 12 6 16 6 12 34 10 5 20 1202420 115 60 1 127 104 12 4 16 4 12 35 10 7 20 1402422 115 60 1 127 104 12 6 16 6 12 34 10 5 20 Permissible limits of the voltage range at which the unit operates satisfactorily Unit ampacity 125 ...

Page 37: ... Requirements for Installations in Canada Installation in Canada must conform to the requirements of CSA B149 code Vent systems must be composed of pipe fittings cements and primers listed to ULC S636 The special vent fittings accessory concentric vent termination kits and accessory external drain trap available from the furnace manufacturer have been certified to ULC S636 for use with those Royal...

Page 38: ...al any unused openings in venting system 2 Inspect the venting system for proper size and horizontal pitch as required in the National Fuel Gas Code ANSI Z223 1 NFPA 54 or the CSA B149 Nat ural Gas and Propane Installation Code and these in structions Determine that there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition 3 As far as practi...

Page 39: ...ry vent termination kit or field supplied brackets or supports attached to the structure A factory accessory vent termination kit may be used for direct vent terminations Termination kits are available for 2 in or 3 in pipe See Table 12 for available options NOTICE Table 12 Vent Termination Kit for Direct Vent 2 pipe Systems Vent and Combustion Air Pipe Diameters Approved Two Pipe Termination Fitt...

Page 40: ...The roof location is preferred since the vent and combustion air system is less susceptible to damage or contamination The termination is usually located away from adjacent structures or other obstacles such as inside corners windows doors or other appliances It is less prone to icing conditions and it often has less visible vent vapors Sidewall terminations may require sealing or shielding of bui...

Page 41: ...o the appropriate Vent Termination section above for locating the vent termination If the unobstructed distance from the foundation to the property line of the adjacent lot is no less than 4 ft 1 2 M and no greater than 8 ft 2 4 M it will be necessary to re direct the flue gas plume In this situation a concentric vent kit cannot be used A 2 pipe termination or single pipe termination when permitte...

Page 42: ...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 39 Recommended Combustion Air Inlet Moisture Trap FURNACE PIPE DIAMETER TRANSITION IN VERTICAL SECTION NOT IN HORIZONTAL SECTION A93034 Fig 40 Combustion Air and Vent Pipe Diameter Transition Location...

Page 43: ...er s instructions for details on equivalent lengths of vent terminations and flexible vent pipes and for calculating total vent lengths To calculate the Total Equivalent Vent Length TEVL of the venting system 1 Measure the individual distance from the furnace to the ter mination for each pipe 2 Count the number of elbows for each pipe 3 For each pipe multiply the number of elbows by the equi valen...

Page 44: ...y and may trap water in the vent pipe Trapped water in the vent pipe may result in nuisance pressure switch tripping 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 41 Near Furnace Vent Connections Instal...

Page 45: ...stems WARNING NOTE The rubber coupling that attaches to the vent pipe adapter must be used The adapter seals the vent pipe to the casing and reduces the strain on the vent elbow attached to the inducer 1 Apply the gaskets to the vent pipe and combustion air pipe adapters If supplied remove and discard round center slug from interior of gasket See Fig 42 NOTE The vent pipe adapter can be distinguis...

Page 46: ...e edge of pipe for better distribution of primer and cement 4 Complete the vent and combustion air pipe installation by connecting the concentric vent or by installing the required termination elbows as shown in Figs 53 54 and 55 For Ventilated Combustion Air Termination See Fig 56 5 Clean and dry all surfaces to be joined 6 Check dry fit of pipe and mark insertion depth on pipe 7 Insert the vent ...

Page 47: ...the clamps on the rubber vent coupling 11 Slide the end of the coupling with notches in it over the standoffs in the vent pipe adapter 12 Tighten the clamp of the coupling over the vent pipe adapter Torque the lower clamp around the vent pipe adapter to 15 lb in 13 Pilot drill a 1 8 in hole in the combustion air pipe adapter 14 Complete the vent and combustion air pipe as shown in Install the Vent...

Page 48: ...riate location for termination kit using the guidelines provided in section Locating The Vent Termination in this instruction 1 Cut two holes one for each pipe of appropriate size for pipe size being used 2 Loosely install elbow in bracket if used and place as sembly on combustion air pipe 3 Install bracket as shown in Fig 53 and 55 NOTE For applications using vent pipe option indicated by dashed ...

Page 49: ...ng systems Material Description Type ASTM or ULC Specification Pipe Solvents Primers Cements PVC Pressure Pipe Schedule 40 D1785 D2466 or D2665 F656 D2564 DWV Schedule 40 D1785 D2665 Cellular Core Schedule 40 F891 SDR 26 N A D2241 SDR 21 N A D2241 IPEX Schedule 40 ULC S636 ULC S636 ULC S636 ULC S636 Royal Pipe Schedule 40 ULC S636 ULC S636 ULC S636 ULC S636 ABS ABS Schedule 40 D1527 D2468 Clear Cl...

Page 50: ...H Winter Design Temp C Pipe Dia mm 0 Insulation 3 8 Insulation 1 2 Insulation 38 51 38 51 38 51 7 6 1 6 1 15 2 13 7 18 3 15 2 18 1 5 1 5 7 6 6 1 9 1 7 6 29 4 6 3 0 6 1 4 6 40 3 0 1 5 4 6 3 0 Unit Size 40 000 BTUH 60 000 BTUH Winter Design Temp C Pipe Dia mm Uninsulated 3 8 in Insulation 1 2 in Insulation Uninsulated 3 8 in Insulation 1 2 in Insulation 38 51 64 38 51 64 38 51 64 38 51 64 76 38 51 6...

Page 51: ... 0 39 6 7 6 13 7 2439 2743 10 6 33 5 27 4 28 9 1 5 18 2 35 0 38 1 10 0 24 3 33 5 35 0 15 2 35 0 38 1 13 1 36 5 4 5 9 1 2744 3048 9 1 28 9 1 5 24 3 25 9 NA 16 7 32 0 35 0 9 1 22 8 30 4 32 0 13 7 30 4 35 0 11 8 35 0 3 0 4 5 NOTES 1 Inducer Outlet Restrictor disk P N 337683 401 1 25 in 32 mm Dia shipped in the loose parts bag or available through Replacement Components required under 10 ft 3 M TEVL i...

Page 52: ...nes Maximum Equivalent Vent Length MEVL 95 ft 29 M For 2 pipe from Table 16 Is TEVL less than MEVL YES Therefore 2 pipe MAY be used Example 2 A direct vent 60 000 BTUH furnace installed at 2100 ft 640M Venting system includes FOR EACH PIPE 100 feet 30 M of vent pipe 95 feet 29 M of combustion air inlet pipe 3 90º long radius elbows and a polypropylene concentric vent kit Also includes 20 feet 6 1 ...

Page 53: ...n 305 mm Vertical clearance to a soffitt located above the vent termination within a horizontal distance of 2 ft 61 cm from the centerline of the vent termination 6 ft 2 M Clearance to a ventilation exhaust including HRV ERV on either Wall A or Wall B 12 in 305 mm Clearance above paved sidewalk or paved driveway located on public property 7 ft 2 1 M Clearance under a veranda porch deck or balcony ...

Page 54: ...her unused knockout may be used for 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 C...

Page 55: ...r Current Kit Number HORIZONTAL LEFT 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...

Page 56: ...with a 7 x 1 2 in sheet metal screw 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 INSTALL...

Page 57: ...deck or balcony is fully 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 Furnace combustion air intake clearance to a water heater vent d...

Page 58: ...anda porch deck or balcony is fully 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 e...

Page 59: ...ipated snow level or grade whichever 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 Terminatio...

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

Page 61: ... without notice 3 76 mm 12 305 mm Pipe hangar Ventilated Combustion Air intake termination in crawl space Ventilated Combustion Air intake pipe CRAWL SPACE ATTIC highest level of insulation A10497 Fig 56 Vent Terminations for Ventilated Combustion Air ...

Page 62: ...ing improper burner or gas orifice positioning or improper venting condition before resetting switch DO NOT jumper this switch CAUTION Before operating furnace check flame rollout manual reset switch for continuity If necessary press button to reset switch EAC 1 115vac terminal is energized whenever blower operates HUM 24vac terminal is only energized when the gas valve is energized in heating Pri...

Page 63: ...ger failures WARNING FURNACE DAMAGE HAZARD Failure to follow this caution may result in reduced furnace life The 26 000 BTUH model has a lower nominal manifold pressure than other models Do not adjust the natural gas manifold pressure above 1 8 in W C The 26 000 BTUH model can be identified by the green label affixed to the solenoid of the gas valve Refer to the Adjustment section for setting the ...

Page 64: ...ressure to obtain the proper input rate first determine if the furnace has the correct orifice installed At higher altitudes or different gas heat contents it may be necessary to change 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 g...

Page 65: ... 800 43 3 8 42 3 2 42 3 3 42 3 4 915 825 43 3 6 43 3 7 43 3 8 42 3 2 850 44 3 8 43 3 5 43 3 6 43 3 7 875 44 3 6 44 3 7 43 3 4 43 3 5 4000 900 44 3 4 44 3 5 44 3 7 44 3 8 1219 925 44 3 2 44 3 4 44 3 5 44 3 6 950 44 3 1 44 3 2 44 3 3 44 3 4 750 42 3 3 42 3 4 42 3 5 42 3 6 4001 775 43 3 7 43 3 8 42 3 3 42 3 4 1220 800 43 3 5 43 3 6 43 3 7 43 3 8 825 44 3 8 43 3 4 43 3 5 43 3 6 850 44 3 5 44 3 7 44 3 ...

Page 66: ...3 2 42 3 3 42 3 4 2134 700 43 3 5 43 3 7 43 3 8 42 3 2 725 44 3 8 43 3 4 43 3 5 43 3 6 750 44 3 5 44 3 7 44 3 8 43 3 4 8000 775 44 3 3 44 3 4 44 3 5 44 3 7 2438 800 44 3 1 44 3 2 44 3 3 44 3 4 825 44 2 9 44 3 0 44 3 1 44 3 2 625 42 3 4 42 3 5 42 3 6 42 3 7 8001 650 43 3 8 42 3 2 42 3 3 42 3 4 2439 675 43 3 5 43 3 6 43 3 7 42 3 2 700 44 3 7 43 3 4 43 3 5 43 3 6 725 44 3 5 44 3 6 44 3 7 44 3 8 9000 ...

Page 67: ... 6 44 1 6 44 1 7 900 44 1 4 44 1 5 44 1 5 44 1 6 4000 925 44 1 4 44 1 4 44 1 5 44 1 5 1219 950 44 1 3 44 1 3 44 1 4 44 1 4 750 43 1 7 43 1 7 43 1 8 43 1 8 775 44 1 8 43 1 6 43 1 7 43 1 7 4001 800 44 1 7 44 1 7 44 1 8 43 1 6 1220 825 44 1 6 44 1 6 44 1 7 44 1 8 850 44 1 5 44 1 5 44 1 6 44 1 7 to 875 44 1 4 44 1 5 44 1 5 44 1 6 5000 900 44 1 3 44 1 4 44 1 4 44 1 5 1524 925 44 1 3 44 1 3 44 1 4 44 1 ...

Page 68: ...furnace power supply 5 Turn gas supply manual shutoff valve to ON position 6 Turn furnace gas valve switch to ON position 7 Jumper R and W thermostat connections at the furnace control board 8 When main burners ignite confirm inlet gas pressure is between 4 5 in w c 1125 Pa and 13 6 in w c 3388 Pa 9 Remove jumper across thermostat connections to terminate call for heat Wait until the blower off de...

Page 69: ...s valve Refer to the Adjustment section for setting the manifold pressure USE TABLE 19 WHEN ADJUSTING 26 000 BTUH MODEL MANIFOLD PRESSURE CAUTION i When correct input is obtained replace cap that conceals gas valve regulator adjustment screws Main burner flame should be clear blue almost transparent See Fig 60 j Remove jumper R to W Burner Flame Burner Manifold A11461 Fig 60 Burner Flame FIRE HAZA...

Page 70: ...of the other motor leads and relocate it them to HEAT heating blower tap terminal s Reconnect original lead on SPARE terminal Adjust Blower Off Delay Heat Mode If desired the main blower off time delay period may be lengthened or shortened when operating in the heating mode to provide greater comfort For position and location of jumpers on control center see Fig 36 and Fig 69 The blower off delay ...

Page 71: ...unctioning properly hot surface igniter should NOT glow and control diagnostic light flashes a status code 31 If hot surface igniter glows when inducer motor is disconnected shut down furnaceimmedi ately e Determine reason low pressure switch did not function properly and correct condition f Turn off 115 v power to furnace g Reconnect inducer motor wires replace door and turn on 115 v power h Blow...

Page 72: ...72 440 01 6101 00 Specifications subject to change without notice A190099 Fig 62 Service Label Information ...

Page 73: ...300 750 78 46 92 231 25 144 288 720 80 45 90 225 26 138 277 692 82 44 88 220 27 133 267 667 84 43 86 214 28 129 257 643 86 42 84 209 29 124 248 621 88 41 82 205 30 120 240 600 90 40 80 200 31 116 232 581 92 39 78 196 32 113 225 563 94 38 76 192 33 109 218 545 96 38 75 188 34 106 212 529 98 37 74 184 35 103 206 514 100 36 72 180 36 100 200 500 102 35 71 178 37 97 195 486 104 35 69 173 38 95 189 474...

Page 74: ...essure switch is 0 68 in W C The minimum break point of the switch is 0 63 in W C The maximum break point of the switch is 0 73 in W C The maximum make point of the switch is 0 83 in W C ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death There may be more than one electrical supply to the furnace Check accessories and cooling unit for additional electri...

Page 75: ...tor stops 5 Reconnect R lead to furnace control remove tape from blower door switch and re install blower door 6 Verify furnace shut down by lowering thermostat setting below room temperature 7 Verify that furnace restarts by raising thermostat setting above room temperature Checklist 1 Put away tools and instruments Clean up debris 2 Verify that the jumper is removed from the TEST TWIN terminal V...

Page 76: ...rty damage Before installing modifying or servicing system main electrical disconnect switch must be in the OFF position and install a lockout tag There may be more than one disconnect switch Lock out and tag switch with a suitable warning label Verify proper operation after servicing Always reinstall access doors after completing service and maintenance WARNING 1 Turn off electrical supply to fur...

Page 77: ... 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 POWER CHOKE WHEN USED BRACKET SCREW GND BLOWER HSG ASSY MOTOR BLOWER WHEEL BLOWER CUTOFF BLOWER DETAIL A Representative drawing only some models may vary in appearance A11584 Representative drawing of DIBC blower wheel only some models may vary in ...

Page 78: ... secure the manifold assembly to the burner assembly and set aside Note the location of the green yellow wire and ground ter minal 10 Inspect the orifices in the manifold assembly for blockages or obstructions Remove orifice and clean or replace orifice 11 Remove the four screws that attach the top plate of the cas ing to the furnace 12 Raise top plate up slightly and prop it up with a small piece...

Page 79: ...iter 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 64 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...

Page 80: ...g 1 Check for signs of physical damage to heat tape such as nicks cuts abrasions gnawing by animals etc 2 Check for discolored heat tape insulation If any damage or discolored insulation is evident replace heat tape 3 Check that heat tape power supply circuit is on Cleaning Heat Exchangers The following items must be performed by a qualified service technician Primary Heat Exchangers If the heat e...

Page 81: ...minor property or product damage CAUTION Since the furnace uses a condensing heat exchanger some water will accumulate in the unit as a result of the heat transfer process Therefore once it has been operated it cannot be turned off and left off for an extended period of time when temperatures will reach 32_F 0_C or lower unless winterized Follow these procedures to winterize your furnace UNIT COMP...

Page 82: ...ergized 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 thegas valveGV stopping gas flowto theburners andde energizing thehu midifier terminal HUM The inducer motor IDM will re main energized for a 15 sec post purge...

Page 83: ...es out LED will flash the status code of the previous fault or status code 11 1 short and 1 long flash if there was no previous fault After the control repeats the code 4 times the control will go through a brief component test sequence The inducer will start and run for the entire component test The HSI blower motor FAN speed AMBER LED boards only HEAT speed and COOL speed will run for 10 15 seco...

Page 84: ...84 440 01 6101 00 Specifications subject to change without notice A190093 Fig 68 Troubleshooting Guide Cont ...

Page 85: ...440 01 6101 00 85 Specifications subject to change without notice 3344442 2 Rev B A190099 Fig 69 Wiring Diagram ...

Page 86: ... section of your local telephone directory under Heating Equipment or Air Conditioning Contractors and Systems headings for dealer listing by brand name or contact International Comfort Products Consumer Relations Department P O Box 128 Lewisburg TN 37091 USA 931 270 4100 Have available the model number series number and serial number located on the unit rating plate to ensure correct replacement ...

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Payne R95ESN, Installation Instructions Manual

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