Payne PG8M Installation, Start-Up And Service Instructions Manual
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Payne PG8M Installation, Start-Up And Service Instructions Manual

80% afue gas furnaces series a
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See also: Owner's Manual , Instruction and Installation Manual
Installation, Start-up, Operating, and
Service and Maintenance Instructions
Catalog No: 53PG-8J2
-Series A
The Payne PG8M/PG8J 80% AFUE Gas Furnaces feature 4-
way multipoise design and through-the-furnace downflow
venting. The PG8M/PG8J furnaces are approved for use with
natural or propane gas and the PG8J is also approved for use in
Low Nox Air Quality Management Districts.
STANDARD FEATURES
Four-position furnace: upflow, horizontal right, horizontal
•
left, downflow
Electronic control center
•
Adjustable heating air temperature rise
LED diagnostics and self test feature
Hot surface ignition (HSI)
•
Twinning in Upflow, Downflow and Horizontal
•
LIMITED WARRANTY
• 20-year warranty on "Super S™" heat exchanger
• 5-year parts warranty on all other components
Form No. IM-PG8J-03
PG8M/PG8J
12-02

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  • Page 1 Installation, Start-up, Operating, and Service and Maintenance Instructions -Series A The Payne PG8M/PG8J 80% AFUE Gas Furnaces feature 4- way multipoise design and through-the-furnace downflow venting. The PG8M/PG8J furnaces are approved for use with natural or propane gas and the PG8J is also approved for use in Low Nox Air Quality Management Districts.

  • Page 2: Table Of Contents

    Single-Stage Induced-Combustion 4-Way Multipoise Furnace Cancels: II 310A-45-2/IM-PG8J-02 II 310A- 45-3 / IM-PG8J-03 Installation, Start-up, Operating, and Service and Maintenance Instructions Series 100/A NOTE: Read the entire instruction manual before starting the EFFICIENCY installation. RATING CERTIFIED This symbol → indicates a change since the last issue. TABLE OF CONTENTS SAFETY CONSIDERATIONS .............2 INTRODUCTION ................4...

  • Page 3: Safety Considerations

    28-7/8" 25-1/4" 1-9/16" 22-9/16" AIRFLOW 2-9/16" 19" 13/16" JUNCTION BOX 13/16" LOCATION OUTLET 4-13/16" 7/8" DIA 11/16" 8-7/16" ACCESSORY 1-1/2" DIA. RIGHT HAND 1/2" DIA THERMOSTAT GAS ENTRY WIRE ENTRY 1/2" DIA. THERMOSTAT 3-15/16" WIRE ENTRY 1-7/16" LEFT HAND GAS ENTRY ALTERNATE 33-5/16"...
  • Page 4 INSTALLATION MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION DISTANCE MINIMALE EN POUCES AUX CONSTRUCTIONS COMBUSTIBLES This forced air furnace is equipped for use with This furnace is approved for UPFLOW, DOWNFLOW, and HORIZONTAL installations. natural gas at altitudes 0-10,000 ft (0-3,050m). accessory kit, supplied...

  • Page 5: Introduction

    Table 1—Dimensions (IN.) VENT UNIT SIZE SHIP WT. (LB) CONN* 045-08/024045 14-3/16 12-9/16 12-11/16 045-12/036045 14-3/16 12-9/16 12-11/16 070-08/024070 14-3/16 12-9/16 12-11/16 070-12/036070 14-3/16 12-9/16 12-11/16 070-16/048070 17-1/2 15-7/8 090-14/042090 17-1/2 15-7/8 090-16/048090 19-3/8 19-1/2 090-20/060090 19-3/8 19-1/2 110-12/036110 17-1/2 15-7/8 110-16/048110 19-3/8...

  • Page 6: Duct Systems

    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: Location Relative To Cooling Equipment

    furnace. If the dampers are manually operated, they must be equipped with means to prevent operation of either unit unless the This gas furnace may be used for construction heat provided damper is in the full-heat or full-cool position. that: AIR FOR COMBUSTION AND VENTILATION -The furnace is permanently installed with all electrical Provisions for adequate combustion and ventilation air must be...

  • Page 8: Unconfined Space

    Table 2–Minimum Free Area of Combustion Air Opening* AIR FROM INDOOR OUTDOOR AIR THROUGH OUTDOOR AIR THROUGH OUTDOOR AIR THROUGH UNCONFINED SPACE VERTICAL DUCTS HORIZONTAL DUCTS SINGLE DUCT FURNACE INPUT Free Area Free Area of Free Area of Free Area of Round Pipe Round Pipe Round Pipe...

  • Page 9: Installation

    1 SQ IN. PER 4000 DUCTS BTUH * OUTDOORS 12 ″ MAX 12″ 1 SQ IN. VENT PER 2000 THROUGH BTUH * ROOF 1 SQ IN. DUCTS 4000 BTUH* DUCTS OUTDOORS A02098 1 SQ IN. Fig. 9—Removing Bottom Closure Panel 4000 BTUH* 1 SQ IN.

  • Page 10: Bottom Return Air Inlet

    ⁄ ″ PLATFORM UNIT SUPPORT Construct working platform at location where all required furnace clearances are met. (See Fig. 2 and 17.) For furnaces with 1-in. ⁄ ″ clearance requirement on side, set unit on non-combustible blocks, bricks or angle iron. For crawlspace installations, if the unit is not ⁄...
  • Page 11 FURNACE (OR COIL CASING WHEN USED) PLENUM COMBUSTIBLE OPENING FLOORING FLOOR DOWNFLOW OPENING SUBBASE SHEET METAL PLENUM FLOOR OPENING A96283 Fig. 11—Floor and Plenum Opening Dimensions A96285 Fig. 12—Furnace, Plenum, and Subbase Installed on a Combustible Floor FURNACE CD5 OR CK5 COIL ASSEMBLY OR KCAKC COIL BOX...

  • Page 12: Ductwork Acoustical Treatment

    Table 3—Opening Dimensions (In.) FURNACE PLENUM OPENING FLOOR OPENING CASING APPLICATION WIDTH Upflow Applications on Combustible or Noncombustible 12-11/16 21-5/8 13-5/16 22-1/4 Flooring (KGASB subbase not required) Downflow Applications on Noncombustible Flooring 12-9/16 13-3/16 19-5/8 (KGASB subbase not required) 14–3/16 Downflow applications on combustible flooring (KGASB 11-13/16 13-7/16...

  • Page 13: Supply Air Connections

    " THREADED ROD 4 REQ. OUTER DOOR ASSEMBLY SECURE ANGLE IRON TO BOTTOM OF FURNACE WITH 3 #8 x " SCREWS TYPICAL FOR 2 SUPPORTS 8" MIN FOR DOOR REMOVAL 1" SQUARE, 1 " x 1 " x " ANGLE IRON OR UNI-STRUT MAY BE USED (2) HEX NUTS, (2) WASHERS &...

  • Page 14: Return Air Connections

    LINE CONTACT ONLY PERMISSIBLE BETWEEN LINES FORMED BY INTERSECTIONS OF THE TOP AND TWO SIDES OF THE FURNACE JACKET AND BUILDING JOISTS, STUDS, OR FRAMING. ″ OVER ALL ″ UNDER DOOR 1″ UNDER FURNACE TYPE-B EXTEND OUT 12″ OUT ENTRY VENT FROM FACE OF DOOR I N *...
  • Page 15 A02075 Fig. 18—Upflow Return Air Configurations and Restrictions A02163 Fig. 19—Downflow Return Air Configurations and Restrictions A02162 Fig. 20—Horizontal Return Air Configurations and Restrictions...

  • Page 16: Electrical Connections

    → Table 4—Maximum Capacity of Pipe* SUPPLY NOMINAL LENGTH OF PIPE (FT) MANUAL IRON INTERNAL SHUTOFF PIPE DIAMETER VALVE SIZE (IN.) (REQUIRED (IN.) SEDIMENT 0.622 TRAP 0.824 UNION 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).

  • Page 17: 115-V Wiring

    → Table 5—Electrical Data OPERATING VOLTS- MAXIMUM MAXIMUM UNIT MAXIMUM MINIMUM VOLTAGE RANGE UNIT SIZE HERTZ- FUSE OR CKT BKR UNIT AMPS AMPACITY# WIRE LENGTH (FT)‡ WIRE GAGE PHASE AMPS† Maximum* Minimum* 045-08/024045 115-60-1 7.77 045-12/036045 115-60-1 9.47 070-08/024070 115-60-1 7.06 070-12/036070 115-60-1...

  • Page 18: For Bx Cable Installation

    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 19: Venting

    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 PHASE 208/230-V SINGLE PHASE AUXILIARY 115-V FIELD- J-BOX SUPPLIED NOTE 1 DISCONNECT CONDENSING...

  • Page 20: General Venting Requirements

    The following information and warning must be considered in addition to the requirements defined in the NFGC and the CARBON MONOXIDE POISONING HAZARD NSCNGPIC. Failure to follow the steps outlined below for each appliance 1. If a vent (common or dedicated) becomes blocked, the furnace connected to the venting system being placed into operation will be shut off by the draft safeguard switch located on the could result in carbon monoxide poisoning or death.
  • Page 21 NOTE: See the NFGC, 13.1.9 and 13.2.20 regarding alternative Table B—Minimum Allowable Input Rating of venting design and the exception, which cover installations such as Space-Heating Appliance in Chimney Adapter Kits KGACA02014FC Thousands of BTU per Hour KGACA02015FC, which are listed for use with these furnaces. INTERNAL AREA OF CHIMNEY The Chimney Adapter Kit is listed alternative venting design for VENT...

  • Page 22: Appliance Application Requirements

    NOTE: Vent connector length for connector sizing starts at A chimney without a clay tile liner, which is otherwise in good condition, shall be rebuilt to conform to ANSI/NFPA 211 or be furnace vent elbow. The 4 inch vent elbow is shipped for upflow lined with a UL listed (ULC listed in Canada) metal liner or UL configuration and may be rotated for other positions.
  • Page 23 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 in the U.S.A. or to the Canadian installation Codes CSA-B149.1 in Canada. Crown Rebuild condition: crown.

  • Page 24: Start-Up Procedures

    6. Verify furnace restarts by raising thermostat setting above room temperature. Personal injury can result form sharp metal edges, etc. Be careful when removing parts. Gloves and safety glasses Step 3—Adjustments should be worn when servicing equipment. 1. Maintain 115-v wiring and ground. Improper polarity will result in rapid flashing LED and no furnace operation.
  • Page 25 SEE NOTES: 1,2,4,7,8,9 SEE NOTES: 1,2,3,4,7,8,9 SEE NOTES:1,2,3,4,5,7,8,9 A02058 A02059 A02060 Fig. 26—Upflow Application- Fig. 27—Upflow Application- Fig. 28—Downflow Vent Elbow Up Vent Elbow Right Application-Vent Elbow Up then Left SEE NOTES: 1,2,4,5,7,8,9 SEE NOTES: 1,2,4,5,6,7,8,9 SEE NOTES: 1,2,3,4,7,8,9 A02061 A02062 A02063 Fig.
  • Page 26 SEE NOTES: 1,2,4,7,8,9 A02064 SEE NOTES: 1,2,4,5,7,8,9 Fig. 32—Horizontal Left Application-Vent Elbow Left A02067 Fig. 35—Horizontal Left Application-Vent Elbow Right SEE NOTES: 1,2,4,5,7,8,9 A02065 SEE NOTES: 1,2,4,5,7,8,9 Fig. 33—Horizontal Left Application-Vent Elbow Right then Up A02068 Fig. 36—Horizontal Right Application-Vent Elbow Left See Venting Notes on Page 26 SEE NOTES: 1,2,4,5,7,8,9 A02066...
  • Page 27 Venting Notes for Fig. 26-38 1. For common vent, vent connector sizing and vent material: United States, latest edition of the National Fuel Gas Code (NFGC), ANSI Z223.1/NFPA 54. In Canada, latest edition of the National Standards of Canada, Natural Gas and Propane Installation Code (NSCNGPIC), CSA B149.1-00.
  • Page 28 PRINTED CIRCIUT BOARD PRINTED CIRCIUT BOARD...
  • Page 29 Caution!! For the following applications, use the minimum vertical vent sections as specified below. For all other applications, follow exclusively the National Fuel Gas Code. MINIMUM FURNACE ORIENTATION VENT ORIENTATION FURNACE INPUT(BTU/HR) MINIMUM VERTICAL VENT HEIGHT (FT)** VENT DIAMETER (IN.)* 154,000 Vent elbow left, then up Downflow...

  • Page 30: Check Safety Controls

    Table 8–GAS RATE (CU FT/HR) SIZE OF TEST DIAL SIZE OF TEST DIAL SECONDS SECONDS THERMOSTAT SUBBASE FOR 1 FOR 1 TERMINALS WITH REVOLUTION REVOLUTION Cu Ft Cu Ft Cu Ft Cu Ft Cu Ft Cu Ft THERMOSTAT REMOVED (ANITICIPATOR, CLOCK, ETC., 1800 MUST BE OUT OF CIRCUIT.) 1636...

  • Page 31: Checklist

    Step 5—Checklist The control system also requires an earth ground for proper operation of the control and flame-sensing electrode. 1. Put away tools and instruments. Clean up debris. The 24-v circuit contains an automotive-type, 3-amp fuse located 2. Check that blower OFF-DELAY time is selected as desired. on the control.

  • Page 32: Care And Maintenance

    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 33: Cleaning And/Or Replacing Air Filter

    3. Check electrical connections for tightness and controls for BLOWER MOTOR AND WHEEL proper operation each heating season. Service as necessary. 4. Inspect burner compartment before each heating season for → rust, corrosion, soot or excessive dust. If necessary, have Blower access door switch opens 115-v power to control.

  • Page 34: Cleaning Heat Exchanger

    e. Remove blower wheel from housing. CLEANING HEAT EXCHANGER f. Clean wheel and housing. The following steps should be performed by a qualified service technician: 12. Reassemble motor and blower by reversing steps 11f, finish- ing with 11a. Be sure to reattach ground wire to the blower NOTE: If the heat exchangers get a heavy accumulation of soot housing.

  • Page 35: Sequence Of Operation

    7/8” A02151 A91252 Fig. 45—Position of Igniter to Burner Fig. 46—Cleaning Heat Exchanger Cell 9. Using field-provided 25-caliber rifle cleaning brush, 1/4″ diameter steel spring cable, 36 in. long, a variable speed, 13. Reconnect wires to the following components (Use connection reversible electric drill, and vacuum cleaner, clean cells as diagram on wiring label, if wires were not marked for follows:...

  • Page 36: Wiring Diagrams

    The blower door must be installed for power to be conducted circuit starts the outdoor unit, and the R-to-G and Y circuits through the blower door interlock switch ILK to the furnace start the furnace blower motor BLWM on COOL speed. control CPU, transformer TRAN, inducer motor IDM, blower The electronic air cleaner terminal EAC-1 is energized with motor BLWM, hot-surface igniter HSI, and gas valve GV.
  • Page 37 TABLE 10—Orifice Size* and Manifold Pressure For Gas Input Rate (Tabulated Data Based On 22,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level) SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE AVG GAS 0.58 0.60 0.62 0.64 RANGE HEAT VALUE Orifice...
  • Page 38 Table 10—Orifice Size* And Manifold Pressure For Gas Input Rate (Continued) (Tabulated Data Based On 22,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level) SPECIFIC GRAVITY OF NATURAL GAS AVG GAS ALTITUDE HEAT VALUE 0.58 0.60 0.62 0.64...
  • Page 39 Table 10—Orifice Size* And Manifold Pressure For Gas Input Rate (Continued) (Tabulated Data Based On 22,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level) SPECIFIC GRAVITY OF NATURAL GAS AVG GAS ALTITUDE HEAT VALUE 0.58 0.60 0.62 0.64...
  • Page 40 TABLE 11—Orifice Size* and Manifold Pressure For Gas Input Rate (Tabulated Data Based On 21,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level) SPECIFIC GRAVITY OF NATURAL GAS ALTITUDE AVG GAS 0.58 0.60 0.62 0.64 RANGE HEAT VALUE Orifice...
  • Page 41 Table 11—Orifice Size* And Manifold Pressure For Gas Input Rate (Continued) (Tabulated Data Based On 21,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level) SPECIFIC GRAVITY OF NATURAL GAS AVG GAS ALTITUDE HEAT VALUE 0.58 0.60 0.62 0.64...
  • Page 42 Table 11—Orifice Size* And Manifold Pressure For Gas Input Rate (Continued) (Tabulated Data Based On 21,000 Btuh Per Burner, Derated 4 Percent For Each 1000 Ft Above Sea Level) SPECIFIC GRAVITY OF NATURAL GAS AVG GAS ALTITUDE HEAT VALUE 0.58 0.60 0.62 0.64...
  • Page 45 Copyright 2002 Carrier Corporation 58st11si Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. Book 1 4 PC 101 Catalog No. See Cover Printed in U.S.A. Form 58ST-11SI Pg 44 12-02 Replaces: 58ST-2SI Tab 6a 8a...

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