Payne PG9MAA Installation Manual

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Installation manual (72 pages)

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Page 1: Table Of Contents
FIXED-CAPACITY DUAL-VENT Series F CONDENSING GAS FURNACE SIZES 040 THRU 140 As an ENERGY STAR® Partner, Payne Heating and Cooling has determined that this product meets the ENERGY STAR® guidelines for energy efficiency. NOTE: Read the entire instruction manual before starting the installation.
Page 2: Safety Considerations
Return Air Connections.....................................25 Filter Arrangement ......................................26 Bottom Closure Panel......................................27 Gas Piping..........................................27 Electrical Connections ......................................28 115-v Wiring........................................29 24-v Wiring........................................30 Accessories ........................................30 Wiring Diagram.........................................33 Removal of Existing Furnaces from Common Vent Systems ..........................31 Direct Venting (ALL SIZES)....................................31 General..........................................31 Combustion-Air and Vent Piping ..................................33 Concentric Vent and Combustion-Air Termination Kit Installation .......................41 Multiventing and Vent Termination .................................45 Non-Direct Venting (SIZES 040 THROUGH 120 ONLY)..........................45...
Page 3: Clearances To Combustibles
INSTALLATION This forced air furnace is equipped for use with natural gas at altitudes 0 - 10,000 ft (0 - 3,050m), except 140 size furnaces are only approved for altitudes 0 - 7,000 ft. (0 - 2,135m). An accessory kit, supplied by the manufacturer, shall be used to convert to propane gas use or may be required for some natural gas applications. This furnace is for indoor installation in a building constructed on site.
Page 4: Dimensional Drawing
—4—...
Page 5 AIRFLOW UPFLOW HORIZONTAL HORIZONTAL LEFT RIGHT DOWNFLOW AIRFLOW AIRFLOW AIRFLOW A93041 Fig. 3—Multipoise Orientations Maintain a 1-in. clearance from combustible materials to supply air ductwork for a distance of 36 inches horizontally from the furnace. See NFPA 90B or local code for further requirements. These furnaces SHALL NOT be installed directly on carpeting, tile, or any other combustible material other than wood flooring.
Page 6: Codes And Standards
FURNACE BLOWER SHELF CONDENSATE DOOR TRAP FURNACE CONDENSATE DOOR FURNACE TRAP (INSIDE) FURNACE SIDE SIDE FIELD FIELD DRAIN DRAIN CONN CONN ALTERNATE DRAIN TUBE LOCATION SIDE VIEW FRONT VIEW END VIEW FRONT VIEW CONDENSATE TRAP DRAIN TUBE LOCATION HORIZONTAL DOWNFLOW AND ALTERNATE UPFLOW APPLICATIONS APPLICATIONS EXTERNAL UPFLOW APPLICATIONS...
Page 7: Electrostatic Discharge (Esd) Precautions
In the United States and Canada, follow all codes and standards for the following: PROCEDURE 1—SAFETY • US: National Fuel Gas Code (NFGC) NFPA 54-2002/ANSI Z223.1-2002 and the Installation Standards, Warm Air Heating and Air Conditioning Systems ANSI/NFPA 90B • CANADA: National Standard of Canada, Natural Gas and Propane Installation Code (NSCNGPIC) CSA B149.1-00 PROCEDURE 2—GENERAL INSTALLATION •...
Page 8: Introduction
PLUG COLLECTOR BOX DRAIN TUBE (BLUE & WHITE STRIPED) COLLECTOR BOX TUBE (PINK) PLUG COLLECTOR BOX COLLECTOR BOX DRAIN TUBE (BLUE TUBE (GREEN) & WHITE STRIPED) COLLECTOR BOX TUBE (PINK) INDUCER HOUSING (MOLDED) DRAIN TUBE (BEHIND COLLECTOR BOX COLLECTOR BOX DRAIN TUBE) TUBE (GREEN) COLLECTOR BOX...
Page 9 1. Collector Box Drain, Inducer Housing Drain, Relief Port, and Pressure Switch Tubes These tubes should be factory attached to condensate trap and pressure switch ready for use in UPFLOW applications. These tubes can be identified by their connection location and also by a color label on each tube. These tubes are identified as follows: collector box drain tube (blue label), inducer housing drain tube (violet label or molded), relief port tube (green label), and pressure switch tube (pink label).
Page 10: Downflow Applications
COLLECTOR BOX DRAIN TUBE (BLUE) PLUG PLUG COLLECTOR BOX TUBE (GREEN) COLLECTOR BOX COLLECTOR BOX DRAIN TUBE (BLUE) EXTENSION TUBE COLLECTOR BOX COLLECTOR BOX TUBE (PINK) TUBE (PINK) COLLECTOR BOX TUBE (GREEN) COLLECTOR BOX COLLECTOR BOX DRAIN TUBE (BLUE EXTENSION TUBE &...
Page 11 B. Condensate Trap Tubing NOTE: See Fig. 8 or 9 or tube routing label on main furnace door to check for proper connections. 1. Collector Box Drain Tube a. Remove factory-installed plug from LOWER collector box drain tube (blue and white striped label). b.
Page 12: Horizontal Left (Supply-Air Discharge) Applications
6. Determine appropriate length, cut, and connect tube. 7. Clamp tube to relief port connection. E. Condensate Trap Freeze Protection Refer to Condensate Drain Protection section for recommendations and procedures. PROCEDURE 4—HORIZONTAL LEFT (SUPPLY-AIR DISCHARGE) APPLICATIONS A horizontal left furnace application is where furnace blower is located to the right of combustion and controls section of furnace, and conditioned air is discharged to the left.
Page 13: Horizontal Right (Supply-Air Discharge) Applications
PLUG COLLECTOR BOX AUXILIARY "J" BOX DRAIN TUBE (BLUE AND WHITE STRIPED) CONDENSATE COLLECTOR BOX TRAP TUBE (GREEN) INDUCER HOUSING COLLECTOR DRAIN TUBE (VIOLET) BOX EXTENSION COLLECTOR BOX DRAIN TUBE DRAIN TUBE (BLUE) COLLECTOR BOX EXTENSION TUBE DRAIN TUBE COUPLING COLLECTOR BOX TUBE (PINK) RELOCATE TUBE BETWEEN BLOWER SHELF AND INDUCER HOUSING FOR 040, 060, AND 080 HEATING INPUT FURNACES...
Page 14 COMBUSTION – AIR INTAKE VENT A 12-IN. MIN HORIZONTAL PIPE SECTION IS RECOMMENDED WITH SHORT (5 TO 8 FT) VENT SYSTEMS TO REDUCE EXCESSIVE CONDENSATE DROPLETS FROM ″ EXITING THE VENT PIPE. WORK AREA ″ ⁄ MANUAL SHUTOFF ACCESS OPENING GAS VALVE FOR TRAP DRAIN...
Page 15 COLLECTOR BOX DRAIN TUBE (BLUE) COLLECTOR BOX TUBE (GREEN) COLLECTOR BOX EXTENSION TUBE PLUG COLLECTOR BOX TUBE (PINK) AUXILARY “J” BOX RELOCATED HERE CONDENSATE TRAP COLLECTOR BOX DRAIN TUBE (BLUE AND WHITE STRIPED) INDUCER HOUSING DRAIN TUBE (VIOLET) COLLECTOR BOX EXTENSION TUBE A00214 Fig.
Page 16: Location
e. Determine appropriate length, cut, and connect tube to condensate trap. f. Clamp tube to prevent any condensate leakage. 3. Relief Port Tube Refer to Pressure Switch Tubing section for connection procedure. C. Condensate Trap Field Drain Attachment Refer to Condensate Drain section for recommendations and procedures. D.
Page 17: Furnace Location Relative To Cooling Equipment
LEVEL (0″) FRONT FRONT ⁄ ″ ⁄ ″ MAX ⁄ ″ MAX UPFLOW OR DOWNFLOW HORIZONTAL A02146 Fig. 14—Furnace Location for Proper Condensate Drainage FRONT BACK FRONT A93043 Fig. 15—Prohibit Installation on Back → CAUTION: UNIT DAMAGE HAZARD This gas furnace may be used for construction heat provided that: -The furnace is permanently installed with all electrical wiring, piping, air filters, venting and ducting installed according to these installation instructions.
Page 18: Location With Respect To Combustion And Circulating Air Requirements
32°F MINIMUM INSTALLED AMBIENT OR FREEZE PROTECTION REQUIRED A93058 Fig. 16—Freeze Protection PROCEDURE 3—LOCATION WITH RESPECT TO COMBUSTION AND CIRCULATING AIR REQUIREMENTS 18-IN. MINIMUM TO BURNERS A93044 Fig. 17—Installation in a Garage WARNING: FIRE, EXPLOSION, INJURY, OR DEATH HAZARD Improper location or inadequate protection could result in fire or explosion. When furnace is installed in a residential garage, it must be installed so that burners and ignition sources are located a minimum of 18-in.
Page 19: Air For Combustion And Ventilation
1 SQ IN. PER 4000 DUCTS BTUH* OUTDOORS CIRCULATING AIR VENT THROUGH ROOF DUCTS 12″ MAX 12″ 1 SQ IN. VENT PER 2000 THROUGH 12" MAX BTUH* ROOF 1 SQ IN. 1 SQ IN. 4000 PER 1000 BTUH* BTUH* IN DOOR OR WALL DUCTS UNCONFINED...
Page 20 • Printing inks, paint removers, varnishes, etc. • Hydrochloric acid • Cements and glues • Antistatic fabric softeners for clothes dryers • Masonry acid washing materials All fuel-burning equipment must be supplied with air for fuel combustion. Sufficient air must be provided to avoid negative pressure in the equipment room or space.
Page 21 Table 1—Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors TWO HORIZONTAL DUCTS SINGLE DUCT OR OPENING TWO OPENINGS OR VERTICAL DUCTS (1 SQ. IN./2,000 BTUH) (1,100 SQ. MM/KW) (1 SQ. IN./3,000 BTUH) (734 SQ. MM/KW) (1 SQ.
Page 22: Installation
Unusually tight construction is defined as Construction with: a. Walls and ceilings exposed to the outdoors have a continuous, sealed vapor barrier. Openings are gasketed or sealed and b. Doors and openable windows are weatherstripped and c. Other openings are caulked or sealed. These include joints around window and door frames, between sole plates and floors, between wall-ceiling joints, between wall panels, at penetrations for plumbing, electrical and gas lines, etc.
Page 23 PLENUM OPENING FLOOR OPENING A96283 Fig. 21—Floor and Plenum Opening Dimensions FURNACE FURNACE (OR COIL CASING WHEN USED) CD5 OR CK5 COIL ASSEMBLY OR KCAKC COIL BOX COMBUSTIBLE FLOORING COMBUSTIBLE FLOORING DOWNFLOW SHEET METAL SUBBASE PLENUM SHEET METAL FLOOR PLENUM OPENING FLOOR OPENING...
Page 24: Installation In Horizontal Applications
PERFORATED DISCHARGE DUCT FLANGE 210° A93029 Fig. 24—Duct Flanges → CAUTION: UNIT MAY NOT OPERATE Failure to follow this caution may result in intermittent unit operation. Do not bend duct flanges inward as shown in Fig. 24. This will affect airflow across heat exchangers and may cause limit cycling or premature heat exchanger failure.
Page 25: Supply Air Connections
⁄ -IN. ROD ANGLE ″ ⁄ IRON OR EQUIVALENT ALTERNATE SUPPORT LOCATION 4-IN. MIN 8-IN. MAX DRAIN (A) ROD LOCATION USING DIMPLE LOCATORS -IN. MAX -IN. HEX NUT (SEE DIMENSIONAL ALTERNATE SUPPORT DWG FOR & WASHER (4) LOCATION FROM BACK REQD PER ROD LOCATIONS) NOTES:...
Page 26: Filter Arrangement
COMBUSTION-AIR A 3-IN. MINIMUM INTAKE CLEARANCE TO COMBUSTION-AIR INTAKE IS REQUIRED. VENT ⁄ -IN. ROD ANGLE ″ ⁄ IRON OR EQUIVALENT ALTERNATE SUPPORT LOCATION 4-IN. MIN 8-IN. MAX DRAIN (A) ROD LOCATION USING DIMPLE LOCATORS -IN. MAX -IN. HEX NUT (SEE DIMENSIONAL ALTERNATE SUPPORT &...
Page 27: Bottom Closure Panel
Table 4—Filter Information FILTER SIZE (IN.)* FURNACE CASING FILTER TYPE WIDTH (IN.) FRAMED Side Return Bottom Return 17-1/2 (1) 16 X 25 X 1† (1) 16 X 25 X 1 Cleanable (1) 16 X 25 X 1 (1) 20 X 25 X 1† Cleanable 24-1/2 (1 or 2) 16 X 25 X 1...
Page 28: Electrical Connections
Table 5—Maximum Capacity of Pipe* LENGTH OF PIPE (FT) NOMINAL IRON PIPE SIZE INTERNAL DIAMETER (IN.) (IN.) 0.622 0.824 1.049 1-1/4 1.380 1400 1-1/2 1.610 2100 1460 1180 * Cubic ft of gas per hr for gas pressures of 0.5 psig (14-in. wc) or less, and a pressure drop of 0.5-in. wc (based on a 0.60 specific gravity gas). Ref: Table 9.2 NFPA 54-2002 21-IN.
Page 29: 115-V Wiring
SUPPLY MANUAL SHUTOFF VALVE (REQUIRED) SEDIMENT TRAP UNION A93324 Fig. 30—Typical Gas Pipe Arrangement FIELD 24-V WIRING FIELD 115-, 208/230-, 460-V WIRING FACTORY 24-V WIRING FACTORY 115-V WIRING NOTE 2 THERMOSTAT FIVE WIRE FIELD-SUPPLIED TERMINALS DISCONNECT THREE-WIRE HEATING-ONLY 208/230- OR BLOWER DOOR SWITCH 460-V THREE...
Page 30: 24-V Wiring
Table 6—Electrical Data OPERATING VOLTS— MAX WIRE MAX FUSE UNIT UNIT VOLTAGE RANGE HERTZ— UNIT WIRE LENGTH OR CKT BKR SIZE AMPACITY† PHASE AMPS GAUGE (FT)‡ AMPS** Max* Min* 024040 115—60—1 036040 115—60—1 10.0 024060 115—60—1 036060 115—60—1 048060 115—60—1 12.8 036080 115—60—1...
Page 31: Removal Of Existing Furnaces From Common Vent Systems
→ The PG9MAA can be vented as either a direct vent or as a non-direct vent (except for 140 size) application. A direct vent system shall be installed in accordance with the instructions in this section only. For non-direct vent applications, refer to the Non-Direct Venting section.
Page 32 PRINTED CIRCIUT BOARD PRINTED CIRCIUT BOARD —32—...
Page 33: Wiring Diagram
Fig. 35—Control Center Direct venting applications require a dedicated (one PG9MAA furnace only) direct vent system. In a direct vent system, all air for combustion is taken directly from outdoor atmosphere, and all flue gases are discharged to outdoor atmosphere.
Page 34 25--24--65--2 AREA WHERE TERMINAL IS NOT PERMITED VENT TERMINAL AIR SUPPL Y INLET U.S. Installation (2) Item Clearance Description Canadian Installation (1) Clearance above grade, veranda, porch, deck, balcony, or 12˝ (30cm) # 12˝ (30 cm) anticipated snow level Clearance to a window or door that may be opened 12 ˝(30 cm) for appliances >...
Page 35 NOTE: Select 1 vent pipe connection and NOTE: Select 1 vent pipe connection and 1 combustion-air pipe connection. 1 combustion-air pipe connection. FLOW COMBUSTION- COMBUSTION- VENT VENT VENT VENT COMBUSTION- COMBUSTION- FLOW UPFLOW DOWNFLOW COMBUSTION- FURNACE COMBUSTION- VENT VENT FLOW FLOW NOT IN HORIZONTAL...
Page 36 12 ″ MIN 12 ″ MIN VENT PIPE VENT PIPE COMBUSTION-AIR PIPE COMBUSTION-AIR PIPE HORIZONTAL TO ROOF HORIZONTAL TO SIDEWALL COMBUSTION-AIR PIPE VENT PIPE COMBUSTION-AIR PIPE 12 ″ MIN 12 ″ MIN VENT PIPE VERTICAL TO ROOF VERTICAL TO SIDEWALL NOTE: A 12 In.
Page 37 NOTE: Do not count elbows or pipe sections in terminations or within furnace. See shaded areas in Fig. 40, 41, 42, 43, and 44. EXAMPLE: An 036080 size furnace located in Indianapolis, elevation 650 ft above sea level, could be installed in an application requiring 3 elbows and 32 ft of vent pipe, along with 5 elbows and 34 ft of combustion-air pipe.
Page 38 TABLE 9—MAXIMUM ALLOWABLE PIPE LENGTH (FT) NUMBER OF 90° ELBOWS TERMINATION PIPE DIA ALTITUDE (FT) UNIT SIZE TYPE (IN.)* 024040 2 Pipe or 2-in 1-1/2 036040 Concentric 024060 1-1/2 2 Pipe or 2-in 036060 Concentric 048060 1-1/2 036080 2 Pipe or 2-in 048080 Concentric 060080...
Page 39 TABLE 9—MAXIMUM ALLOWABLE PIPE LENGTH (FT) (Continued) NUMBER OF 90° ELBOWS TERMINATION PIPE DIA ALTITUDE (FT) UNIT SIZE TYPE (IN.)* 1-1/2 024040 2 Pipe or 2-in 036040 Concentric 024060 1-1/2 2 Pipe or 2-in 036060 Concentric 048060 036080 2 Pipe or 2-in 048080 Concentric 2-1/2...
Page 40 TABLE 9—MAXIMUM ALLOWABLE PIPE LENGTH (FT) (Continued) NUMBER OF 90° ELBOWS TERMINATION PIPE DIA ALTITUDE (FT) UNIT SIZE TYPE (IN.)* 1-1/2 024040 2 Pipe or 2-in 036040 Concentric 024060 1-1/2 2 Pipe or 2-in 036060 Concentric 048060 036080 2 Pipe or 2-in 048080 8001 to 9000‡...
Page 41: Concentric Vent And Combustion-Air Termination Kit Installation
HOUSING COMBUSTION–AIR PLUG INTAKE HOUSING ″ ID TUBE BURNER ″ 3/16 DRILL COMBUSTION– AIR PIPE 4″ TRAP TO OPEN DRAIN A96190 Fig. 39—Intake Housing Plug Fitting Drain 14. Use appropriate methods to seal openings where vent and combustion-air pipes pass through roof or side wall. C.
Page 42 Table 10—Maximum Allowable Exposed Vent Pipe Length (ft) With and Without Insulation in Winter Design Temperature Ambient* WINTER DESIGN MAX PIPE FURNACE WITHOUT WITH 3/8–IN. OR TEMPERATURE DIAMETER SIZE INSULATION THICKER INSULATION† (°F) (IN.) * Pipe length (ft) specified for maximum pipe lengths located in unconditioned spaces. Pipes located in unconditioned space cannot exceed total allowable pipe length as specified in Table 10.
Page 43 ROOF 18″ MAXIMUM BRACKET COUPLING COMBUSTION VERTICAL SEPARATION VENT BETWEEN COMBUSTION AIR AND VENT 8 3 / 4 ″ FOR 3″ KIT 6 3 / 4 ″ FOR 2″ KIT MAINTAIN 12 IN. MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL. MAXIMUM OF 24 IN.
Page 44 A96128 Fig. 45—Direct Vent Rooftop Termination (Dimension "A" is Touching or 2-In. Maximum Separation) 1″ MAXIMUM VENT (TYP) VENT COMBUSTION AIR VENT COMBUSTION VENT A93057 A93056 Fig. 47—Direct Vent Concentric Vent and Combustion-Air Fig. 46—Direct Vent Concentric Vent and Combustion-Air Side Termination Roof Termination (Dimension "A"...
Page 45: Multiventing And Vent Termination
When 2 or more PG9MAA Furnaces are vented near each other, each furnace must be individually vented. NEVER common vent or breach vent PG9MAA furnaces. When 2 or more PG9MAA furnaces are vented near each other, 2 vent terminations may be installed as shown in Fig. 45, 46, 47, 48, and 49 , but next vent termination must be at least 36 in.
Page 46 NOTE: Select 1 vent pipe connection and NOTE: Select 1 vent pipe connection and 1 combustion-air pipe connection. 1 combustion-air pipe connection. FLOW COMBUSTION- COMBUSTION- VENT VENT VENT VENT COMBUSTION- COMBUSTION- FLOW FIELD-SUPPLIED 2-IN. DIAMETER FIELD-SUPPLIED UPFLOW DOWNFLOW PVC 90° ELBOW 2-IN.
Page 47 HOUSING COMBUSTION–AIR PLUG INTAKE HOUSING ″ ID TUBE BURNER FURNACE ″ 3/16 DRILL COMBUSTION– NOT IN AIR PIPE HORIZONTAL SECTION 4″ TRAP PIPE DIAMETER TRANSITION IN VERTICAL SECTION TO OPEN DRAIN A93034 Fig. 53—Vent Pipe Diameter Transition Location A96190 Fig. 52—Intake Housing Plug Fitting Drain and Elbow Configuration An abandoned masonry chimney may be used as a raceway for a properly insulated and supported vent pipe.
Page 48 12 ″ MIN 12 ″ MIN VENT PIPE VENT PIPE HORIZONTAL TO ROOF HORIZONTAL TO SIDEWALL VENT PIPE 12 ″ MIN 12 ″ MIN VENT PIPE VERTICAL TO ROOF VERTICAL TO SIDEWALL NOTE: A 12-In. minimum offset pipe section is recommended with short (5 to 8 ft) vent systems.
Page 49 Table 11—Maximum Allowable Vent Pipe Length (Ft) for Non-Direct Vent Applications For Use with 040 through 120 Size Furnaces Only VENT PIPE NUMBER OF 90° ELBOWS ALTITUDE UNIT SIZE DIAMETER (IN.)* 024040 1-1/2 036040 024060 1-1/2 036060 048060 1-1/2 036080 048080 0 to 2000 060080...
Page 50 Table 11—Maximum Allowable Vent Pipe Length (Ft) for Non-Direct Vent Applications Continued For Use with 040 through 120 Size Furnaces Only VENT PIPE NUMBER OF 90° ELBOWS ALTITUDE UNIT SIZE DIAMETER (IN.)* 1-1/2 024040 036040 024060 1-1/2 036060 048060 036080 5001 to 6000‡...
Page 51: Vent Termination
4. Termination should be positioned where vent vapors are not objectionable. D. Multiventing When 2 or more PG9MAA Furnaces are vented near each other, each furnace must be individually vented. NEVER common vent or breach vent PG9MAA furnaces. PROCEDURE 9—CONDENSATE DRAIN A.
Page 52 ROOF VENT MAINTAIN 12-IN. MINIMUM CLEARANCE ABOVE HIGHEST ANTICIPATED SNOW LEVEL. MAXIMUM OF 24 IN. ABOVE ROOF. A96191 Fig. 55—Direct Vent Roof Termination (Preferred) OVERHANG OR ROOF OVERHANG OR ROOF 12″ MINIMUM 12″ MINIMUM VENT VENT 90° 6-IN. MINIMUM CLEARANCE BETWEEN WALL AND END OF VENT PIPE.
Page 53 25--24--65--2 AIR SUPPL Y INLET AREA WHERE TERMINAL IS NOT PERMITED VENT TERMINAL Item Clearance Descriptions Canadian Installation (1) U.S. Installation (2) Clearance above grade, veranda, porch, deck, balcony, or 12 ˝ (30cm) # 12˝ (30 cm) anticipated snow level ≤...
Page 54: Application
CONDENSATE TRAP OPEN STAND PIPE FOR A/C OR HUMIDIFIER DRAIN WIRE TIE(S) TO OPEN HEAT TAPE DRAIN (3 WRAPS MINIMUM) A94054 A93036 Fig. 58—Example of Field Drain Attachment Fig. 59—Condensate Trap Heat Tape B. Application The furnace, A/C, and humidifier drains may be combined and drained together. The A/C drain must have an external, field-supplied trap prior to the furnace drain connection.
Page 55: Prime Condensate Trap With Water
A94208 A94209 Fig. 60—Inducer Housing Drain Cap Fig. 61—Filling Condensate Trap Before operating furnace, check flame rollout manual reset switch for continuity. If necessary, press button to reset switch. PROCEDURE 2—PRIME CONDENSATE TRAP WITH WATER CAUTION: UNIT MAY NOT OPERATE Failure to follow this caution may result in intermittent unit operation.
Page 56: Heating Mode
NOTE: If 115-v power supply to furnace or blower access panel switch is interrupted during a call for heat, blower operates for 90 sec when power is restored before heating cycle is resumed. A. Heating Mode (See Fig. 31 for thermostat connections.) The wall thermostat ″calls for heat″, closing the R to W circuit.
Page 57: Component Test
Obtain average gas specific gravity from local gas supplier. c. Verify furnace model and size. Table 12 can only be used for model PG9MAA furnaces with heating sizes of 040 through 120. Table 15 can only be used for model PG9MAA furnaces with heating size of 140.
Page 58 EXAMPLE: (0—2000 ft altitude using Table 14) Heating value = 1050 Btu/cu ft Specific gravity = 0.62 Therefore: Orifice No. 45 Manifold pressure 3.6-in. wc * Furnace is shipped with No. 45 orifices. In this example all main burner orifices are the correct size and do not need to be changed to obtain the proper input rate.
Page 59 Table 14—Model PG9MAA Orifice Size and Manifold Pressure for Correct Input For Use With 040 Through 120 Size Furnaces Only (Tabulated Data Based on 20,000 Btuh per Burner, Derated 2% for Each 1000 Ft Above Sea Level)* SPECIFIC GRAVITY OF NATURAL GAS...
Page 60 Table 14—Model PG9MAA Orifice Size and Manifold Pressure for Correct Input (Continued) For Use With 040 Through 120 Size Furnaces Only (Tabulated Data Based on 20,000 Btuh per Burner, Derated 2% for Each 1000 Ft Above Sea Level) SPECIFIC GRAVITY OF NATURAL GAS...
Page 61 Table 14—Model PG9MAA Orifice Size and Manifold Pressure for Correct Input (Continued) For Use With 040 Through 120 Size Furnaces Only (Tabulated Data Based on 20,000 Btuh per Burner, Derated 2% for Each 1000 Ft Above Sea Level) SPECIFIC GRAVITY OF NATURAL GAS...
Page 62 Table 15—Model PG9MAA Orifice Size and Manifold Pressure for Correct Input For Use with 140 Size Furnaces Only (Tabulated Data Based on 23,000 Btuh per Burner, Derated 2% for Each 1000 Ft Above Sea Level) * SPECIFIC GRAVITY OF NATURAL GAS...
Page 63 Table 15—Model PG9MAA Orifice Size and Manifold Pressure for Correct Input (Continued) For Use with 140 Size Furnaces Only (Tabulated Data Based on 23,000 Btuh per Burner, Derated 2% for Each 1000 Ft Above Sea Level) SPECIFIC GRAVITY OF NATURAL GAS...
Page 64 REGULATOR SEAL CAP REGULATOR BURNER FLAME ADJUSTMENT SCREW BURNER ON/OFF SWITCH REGULATOR SPRING (PROPANE - WHITE, 6 TURNS NATURAL - SILVER, 10 TURNS) GAS PRESSURE REGULATOR ADJUSTMENT INLET PRESSURE TAP MANIFOLD PRESSURE TAP MANIFOLD A03142 A89020 Fig. 63—Redundant Automatic Gas Valve Fig.
Page 65: Set Temperature Rise
Table 17—Gas Rate (Cu Ft/Hr) SIZE OF TEST DIAL SIZE OF TEST DIAL SECONDS SECONDS FOR 1 FOR 1 REVOLUTION REVOLUTION cu ft cu ft cu ft cu ft cu ft cu ft 1800 1636 1500 1385 1286 1200 1125 1059 1000 EXAMPLE: (0—2000 ft altitude)
Page 66: Blower Off Delay (Heat Mode)
3. Adjust temperature rise by adjusting blower speed. Increase blower speed to reduce temperature rise. Decrease blower speed to increase temperature rise. WARNING: ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death. Disconnect 115-v electrical power before changing speed tap. 4.
Page 67: Check Primary Limit Control
Table 19—Blower Off Delay Setup Position PINS 1 AND 2 2 AND 3 3 AND 4 4 AND 5 Time (in sec) A. Check Primary Limit Control This control shuts off gas control system and energizes air-circulating blower motor if furnace overheats. Recommended method of checking this limit control is to gradually block off return air after furnace has been operating for a period of at least 5 minutes.
Page 68 CHECKLIST—DIRECT VENT INSTALLATIONS LOAD CALCULATION ____________ Heating Load (Btuh) ____________ Cooling Load (Btuh) ____________ Furnace Model Selection COMBUSTION AIR AND VENT PIPING Termination Location ________ Roof or Sidewall ________ Termination Kit — 2 Pipe or Concentric ________ Combustion-Air Pipe Length ________ Combustion-Air Pipe Elbow Quantity ________...
Page 69 CHECKLIST—NON-DIRECT VENT INSTALLATIONS LOAD CALCULATION ____________ Heating Load (Btuh) ____________ Cooling Load (Btuh) ____________ Furnace Model Selection VENT PIPING Termination Location ________ Roof or Sidewall ________ Vent Pipe Length ________ Vent Pipe Elbow Quantity ________ Pipe Diameter Determined from Sizing Table ________ Pipe Sloped To Furnace Pipe Insulation...
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Payne PG9MAA Installation Manual

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