Page 1: Table Of Contents
SINGLE---STAGE DELUXE, INDUCED---COMBUSTION PG8MAA PG8JAA 4---WAY MULTIPOISE GAS FURNACE Installation, Start---Up Operating and Service and Maintenance Instructions Series G SAFETY CONSIDERATIONS ......Appliance Application Requirements .
Page 2: Safety Considerations
SAFETY CONSIDERATIONS which could result in personal injury or death. CAUTION is used to identify unsafe practices which may result in minor personal injury or product and property damage. NOTE is used WARNING to highlight suggestions which will result in enhanced installation, reliability, or operation.
Page 3 [130.5] [130.5] 2 1/16 2 1/16 [51.6] [51.6] [43.5] [43.5] Ø7/8 Ø7/8 [22.2] [22.2] ACCESSORY (2) ACCESSORY (2) 8 5/8 8 5/8 [219] [219] 6 13/16 6 13/16 [172.3] [172.3] 5 7/8 5 7/8 1 15/16 1 15/16 [148.5] [148.5] 5 5/8 5 5/8 [49.2]...
Page 4: Introduction
A10269 Fig. 2 --- Clearances to Combustibles chamber and/or heat exchanger. The furnace is factory- -shipped for use with natural gas. This furnace is not approved for / 27 C installation in mobile homes, recreational vehicles, or outdoors. This furnace is designed for minimum continuous return- -air temperature of 60_F (16_C) db or intermittent operation down to 55_F (13_C) db such as when used with a night setback thermostat.
Page 5: General Installation
ANY WIRE CONNECTED TO THE CONTROL PRIOR National Fuel Gas Code (NFGC) NFPA 54- -2012/AN- DISCHARGING YOUR BODY’S SI Z223.1- -2012 and the Installation Standards, Warm ELECTROSTATIC CHARGE TO GROUND. Air Heating and Air Conditioning Systems ANSI/ NFPA 90B 2. Firmly touch the clean, unpainted, metal surface of the fur- nace chassis which is close to the control.
Page 6 THE BLOWER IS LOCATED BELOW THE BURNER SECTION, AND CONDITIONED AIR IS DISCHARGED UPWARD. THE BLOWER IS LOCATED TO THE RIGHT OF THE BURNER SECTION, AND AIR CONDITIONED AIR IS DISCHARGED TO THE LEFT. THE BLOWER IS THE BLOWER IS LOCATED TO THE LEFT LOCATED ABOVE THE OF THE BURNER SECTION,...
Page 7: Air For Combustion And Ventilation
CAUTION WARNING FIRE HAZARD PERSONAL INJURY AND/OR PROPERTY DAMAGE HAZARD Failure to follow this warning could result in personal injury, death and/or property damage. Failure to follow this caution may result in furnace component damage. Do not install the furnace on its back or hang furnace with control compartment facing downward.
Page 8 f. Size openings and ducts per Fig. 7 and Table 2. WARNING g. TWO HORIZONTAL DUCTS require 1 sq./in. of free area per 2,000 Btuh (1,100 mm /kW) of combined CARBON MONOXIDE POISONING HAZARD input for all gas appliances in the space per Fig. 7 and Table 2.
Page 9 Table 3—Minimum Space Volumes for 100% Combustion, Ventilation, and Dilution from Indoors OTHER THAN FAN-ASSISTED TOTAL FAN-ASSISTED TOTAL (1,000’S BTUH GAS INPUT RATE) (1,000’S BTUH GAS INPUT RATE) Space Volume Ft 1,050 1,400 1,750 1,100 1,650 2,200 2,750 3,300 3,850 0.60 (29.7) (39.6)
Page 10: Installation
The Standard Method: However, in buildings with unusually tight construction, additional air MUST be provided using the methods de- 1. The space has no less volume than 50 cu/ft. per 1,000 scribed in the Outdoor Combustion Air Method section. Btuh of the maximum input ratings for all gas appliances installed in the space and Unusually tight construction is defined as Construction with: 2.
Page 11: Leveling Legs (If Desired)
NOTE: Side return- -air openings can be used in UPFLOW and 4. If downflow subbase, KGASB is used, install as shown in Fig. 12. If Coil Assembly Part No. CNPV, CNRV, CAR, most HORIZONTAL configurations. Do not use side return- -air or CAP or Coil Box Part No.
Page 12: Bottom Return Air Inlet
If the screws are attached to ONLY the furnace sides and not the FURNACE bottom, the straps must be vertical against the furnace sides and not pull away from the furnace sides, so that the strap attachment APPROVED screws are not in tension (are loaded in shear) for reliable support. COIL ASSEMBLY Platform Furnace Support COIL BOX...
Page 13: General Requirements
Table 4—Opening Dimensions - - In. (mm) FURNACE PLENUM OPENING FLOOR OPENING CASING APPLICATION WIDTH Upflow Applications on Combustible or Noncombustible Floor- 12--- 11/16 21--- 5/8 13--- 5/16 22--- 1/4 ing (KGASB subbase not required) (322) (549) (338) (565) Downflow Applications on Noncombustible Flooring (KGASB 12--- 9/16 13--- 3/16 19--- 5/8...
Page 14 Table 5—Air Delivery - - CFM (with Filter)* FURNACE RETURN---AIR EXTERNAL STATIC PRESSURE (In. W.C.) SPEED SIZE INLET High 1035 045---08/ Bottom or Med --- High 024045 Side(s) Med --- Low High 1440 1375 1305 1240 1160 1070 045---12/ Bottom or Med --- High 1360 1300...
Page 15 Table 5 Air Delivery - - CFM (with Filter)* (Continued) EXTERNAL STATIC PRESSURE (In. W.C.) FURNACE RETURN---AIR SPEED SIZE INLET High 2065 2000 1930 1835 1710 1590 1420 1235 1025 135---16/ Bottom or Med --- High 1790 1755 1705 1640 1550 1465 1295...
Page 16 " (6mm) THREADED ROD 4 REQ. OUTER DOOR A S SEMBLY SECURE ANGLE IRON TO BOTTOM OF FURNACE WITH 3 #8 x " (19mm) SCREWS TYPICAL FOR 2 SUPPORTS 8" (203mm) MIN FOR DOOR REMOVAL 1” (25mm) SQUARE, 1-1/4”x1-1/4”x1/8” (32x32x3mm) ANGLE IRON OR UNI-STRUT MAY BE USED (2) HEX NUTS, (2) WASHERS &...
Page 17 LINE CONT A CT ONL Y PERMISSIBLE BETWEEN LINES FORMED BY INTERSECTIONS OF THE T OP AND TW O SIDES OF THE FURNA CE JA CKET AND BUILDING JOISTS , STUDS , OR FRAMING. ″ (451mm)OVERALL ″ (121mm) UNDER DOOR 1 ″...
Page 18 A02163 Fig. 19 --- Downflow Return Air Configurations and Restrictions A02162 Fig. 20 --- Horizontal Return Air Configurations and Restrictions Upflow and Horizontal Furnaces temporarily while the remaining attachment and sealing of the coil are performed. Connect supply- -air duct to flanges on furnace supply- -air outlet. Bend flange upward to 90_ with wide duct pliers.
Page 19: Return Air Connections
accessories. All accessories MUST be connected to duct external Refer to Table 6 for recommended gas pipe sizing. Risers must be to furnace casing. used to connect to furnace and to meter. Support all gas piping with appropriate straps, hangers, etc. Use a minimum of 1 hanger WARNING every 6 ft.
Page 20 Factory Factory Installed Installed Alternate Alternate Location Location 2” (51mm) Street Elbow A08551 A10291 Fig. 21 --- Burner and Manifold Fig. 23 --- Relocating J- -Box SUPPLY MANUAL SHUTOFF VALVE (REQUIRED) SEDIMENT TRAP UNION A02035 A10141 Fig. 22 --- Typical Gas Pipe Arrangement Fig.
Page 21: 115- -V Wiring
while swinging the front edge of the J- -Box outboard of the WARNING casing. 2. Cut wire tie on loop in furnace wires attached to J- -box. ELECTRICAL SHOCK AND FIRE HAZARD 3. Move J- -Box to desired location. Failure to follow this warning could result in personal 4.
Page 22: Power Cord Installation In Furnace J- -Box
Table 7—Electrical Data MAXIMUM MAXIMUM OPERATING VOLTAGE VOLTS--- MINIMUM WIRE FUSE OR MAXIMUM UNIT RANGE FURNACE SIZE HERTZ--- WIRE LENGTH FT. CKT BKR UNIT AMPS AMPACITY# PHASE GAUGE (M)‡ AMPS† Maximum* Minimum* 045---08/024045 115--- 60--- 1 7.26 49 (14.9) 045---12/036045 115--- 60--- 1 9.79 37 (11.2)
Page 23 TWINNING AND/OR COMPONENT TEST BLOWER OFF-DELAY TERMINAL J2 JUMPER BLOWER OFF-DELAY HUMIDIFIER TERMINAL (24-VAC 0.5 AMP MAX.) 24-V THERMOSTAT TERMINALS TRANSFORMER 24-VAC CONNECTIONS TEST/TWIN 0.5 AMP@24VAC 3-AMP FUSE FUSE 3-AMP SEC-2 SEC-1 LED OPERATION & EAC-2 DIAGNOSTIC LIGHT PL1-LOW VOLTAGE MAIN HARNESS CONNECTOR 115-VAC(L2)NEUTRAL CONNECTIONS...
Page 24: 24- -V Wiring
24- -V WIRING WARNING Make field 24- -v connections at the 24- -v terminal strip. (See Fig. 25.) Connect terminal Y as shown in Fig. 26 for proper cooling CARBON MONOXIDE POISONING HAZARD operation. Use only AWG No. 18, color- -coded, copper thermostat wire.
Page 25: Masonry Chimney Requirements
1. If a vent (common or dedicated) becomes blocked, the fur- 1. Vent connector is Type- -B double- -wall, and nace will be shut off by the draft safeguard switch located 2. This furnace is common vented with at least 1 draft hood on the vent elbow.
Page 26: Single
CHIMNEY INSPECTION CHART For additional requirements refer to the National Fuel Gas Code NFPA 54/ANSI Z223.1 and ANSI/NFPA 211 Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances Crown Rebuild condition: crown. Missing mortar or brick? Is chimney property lined with clay tile liner? Repair Reline...
Page 27: Appliance Application Requirements
APPLIANCE APPLICATION REQUIREMENTS The vent connector can exit the cabinet of the furnace through one of 5 locations. Appliance operation has a significant impact on the performance 1. Attach the single wall vent connector to the furnace vent of the venting system. If the appliances are sized, installed, elbow, and fasten the vent connector to the vent elbow adjusted, and operated properly, the venting system and/or the appliances should not suffer from condensation and corrosion.
Page 28 Table 8—Exterior Masonry Chimney Fan + Nat Installations with Type- -B Double Wall Vent Connectors ENFPA & AGA Combined Appliance Maximum Input Rating in Thousands of Btuh per Hour INTERNAL AREA OF CHIMNEY SQ. IN. (SQ. MM) VENT HEIGHT FT. (M) (7741) (12258) (18064)
Page 29 Table 10—Minimum Vent Heights Caution!! for the following applications, use the minimum vertical vent heights as specified below. For all other applications, follow exclusively the national fuel gas code. MINIMUM VENT MINIMUM VERTICAL VENT FURNACE VENT FURNACE DIAMETER HEIGHT ORIENTATION ORIENTATION INPUT (BTUH/HR) IN.
Page 30 SEE NOTES: 1,2,4,5,6,7,8,9,10 SEE NOTES:1,2,3,4,5,7,8,9 on the page following these figures on the page following these figures A03210 A03207 Fig. 30 --- Downflow Application- -Vent Elbow Up then Left Fig. 32 --- Downflow Application- -Vent Elbow Left then Up SEE NOTES:1,2,3,4,5,7,8,9 SEE NOTES: 1,2,4,5,7,8,9 on the page following on the page following...
Page 31 SEE NOTES: 1,2,4,7,8,9 on the page SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures following these figures A03214 A03218 Fig. 35 --- Horizontal Left Application- -Vent Elbow Right Fig. 38 --- Horizontal Right Application- -Vent Elbow Right then Up SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures SEE NOTES: 1,2,4,5,7,8,9 on the page...
Page 32: Start- -Up, Adjustment, And Safety Check
START- - UP, ADJUSTMENT, AND SAFETY CHECK Step 1 —General WARNING WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal FIRE HAZARD injury, or death. Failure to follow this warning could result in personal Blower access door switch opens 115- -v power to control. injury, death and/or property damage.
Page 33 8001–9000 EXAMPLE 2: (0- -2000 ft. (0- -610 M) altitude) 32–36 0.66 (2438 ---2743) For 22,000 Btuh per burner application use Table 15. 9001–10,000 Heating value = 1000 Btuh/cu ft. 36–40 0.62 (2743 ---3048) Specific gravity = 0.62 * Derate multiplier factors are based on midpoint altitude for altitude Therefore: Orifice No.
Page 34 b. When thermometer readings stabilize, subtract return- - CAUTION air temperature from supply- -air temperature to determ- ine air temperature rise. NOTE: Blower access door must be installed for proper FURNACE OVERHEATING HAZARD temperature rise measurement. Failure to follow this caution may result in reduced furnace NOTE: If the temperature rise is outside this range, first check: life.
Page 35 A13111 Fig. 41 --- Wiring Diagram...
Page 36 BURNER ORIFICE A93059 A06666 Fig. 43 --- Orifice Hole Fig. 42 --- Gas Control Valve THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED (ANITICIPATOR, CLOCK, ETC., MUST BE OUT OF CIRCUIT.) HOOK-AROUND AMMETER R Y W G 10 TURNS FROM UNIT 24-V CONTROL TERMINALS 0.5 AMPS FOR THERMOSTAT 5.0 AMPS ON AMMETER...
Page 37: Adjustments
Step 4 —Check Safety Controls 3. Check Pressure Switch This control proves operation of the draft inducer blower. The flame sensor, gas valve, and pressure switch were all checked a. Turn off 115- -v power to furnace. in the Start- -up procedure section as part of normal operation. b.
Page 38 Table 13—Gas Rate (cu ft./hr) SIZE OF TEST DIAL SIZE OF TEST DIAL SECONDS FOR 1 SECONDS FOR 1 1 Cu Ft 2 Cu Ft 5 Cu Ft 1 Cu Ft 2 Cu Ft 5 Cu Ft REVOLUTION REVOLUTION 1800 1636 1500 1385...
Page 39 Table 15—Orifice Size* and Manifold Pressure (In. W.C.) for Gas Input Rate (Tabulated data based on 22,000 btuh per burner, derated 4 percent for each 1000 ft. (305 M) above sea level) SPECIFIC GRAVITY OF NATURAL GAS AVG. GAS HEAT VALUE ALTITUDE RANGE 0.58 0.60...
Page 40 Table 15–Orifice Size* and Manifold Pressure (In. W.C.) for Gas Input Rate (Continued) (Tabulated data based on 22,000 btuh per burner, derated 4 percent for each 1000 ft. (305 M) above sea level) SPECIFIC GRAVITY OF NATURAL GAS AVG. GAS 0.58 0.60 0.62...
Page 41 Table 16—Orifice Size* and Manifold Pressure (In. W.C.) for Gas Input Rate (Tabulated data based on 21,000 btuh per burner, derated 4 percent for each 1000 ft. (305 M) above sea level) SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE AVG. GAS 0.58 0.60 0.62...
Page 42 Table 16—Orifice Size* and Manifold Pressure (In. W.C.) for Gas Input Rate (Continued) (Tabulated data based on 21,000 btuh per burner, derated 4 percent for each 1000 ft. (305 M) above sea level) SPECIFIC GRAVITY OF NATURAL GAS AVG. GAS ALTITUDE HEAT VALUE 0.58...
Page 43: Service And Maintenance Procedures
SERVICE If status code recall is needed, briefly remove then reconnect one main limit wire to display stored status code. On RED LED boards do not remove power or blower door before initiating status code recall. After status code recall is completed component test will occur. LED CODE STATUS CONTINUOUS OFF - Check for 115VAC at L1 and L2, and 24VAC at SEC-1 and SEC-2.
Page 44: Care And Maintenance
The control system also requires an earth ground for proper For continuing high performance and to minimize possible equipment failure, periodic maintenance must be performed on operation of the control and flame- -sensing electrode. this equipment. Consult your local dealer about proper frequency The 24- -v circuit contains an automotive- -type, 3- -amp.
Page 45 6. Remove 2 screws holding blower assembly to blower CAUTION deck and slide blower assembly out of furnace. 7. Clean blower wheel and motor using a vacuum with soft brush attachment. Blower wheel blades may be cleaned CUT HAZARD with a small paint or flux brush. Do not remove or disturb Failure to follow this caution may result in personal injury.
Page 46 NOTE: If thermostat terminals are jumpered at the time blower Inducer assembly and elbow need not be removed from collector box. access door switch is closed, blower will run for 90 sec before beginning a heating or cooling cycle. 7. Disconnect gas line from gas manifold. c.
Page 47: Sequence Of Operation
i. Install NOx baffles (if removed). 14. Reinstall internal vent pipe, if applicable. 1-7/8 15. Reinstall vent connector on furnace vent elbow. Securely fasten vent connector to vent elbow with 2 field- -supplied, (47.6 mm) corrosion- -resistant, sheet metal screws located 180_ apart. 16.
Page 48: Wiring Diagrams
gized until the flame is sensed or until the 2- -second blower off times during demand defrost cycles. When the flame proving period begins. R- -to- -Wand- - Y or R- -to- -W- -and- -Y- -and- -G circuits are energized the furnace control CPU will continue to turn on d.
Page 49 Fig. 49 --- Troubleshooting Guide...
Page 51: Accessory Listing
Table 17—Accessory List DESCRIPTION PART NUMBER NOTES FILCABXX0016 Filter cabinet 16” (406 mm) for 4” (102 mm) wide filter FILCABXX0020 Filter cabinet 20” (508 mm) for 4” (102 mm) wide filter Media Filter Cabinet FILCABXX0024 Filter cabinet 24” (610 mm) for 4” (102 mm) wide filter FILXXCAR0016 Filter Cartridge replacements for FILCAB media cabinet FILXXCAR0020...
Page 52: Parts Replacement Information Guide
Edition Date: 04/13 Catalog No: IM- - PG8J- - 16 Copyright 2013 Payne Heating & Cooling S 7310 W. Morris St. S Indianapolis, IN 46206 Replaces: IM- -PG8J- -15 Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

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