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PG8MEA
PG8JEA
Installation, Start---Up Operating and
Service and Maintenance Instructions
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24 Volt Wiring
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Series 110/B
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4---WAY MULTIPOISE INDUCED---COMBUSTION
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Use of the AHRI Certified TM Mark indicates a
manufacturer's participation in the program. For
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verification of certification for individual products,
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go to www.ahridirectory.org.
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NOTE: Read the entire instruction manual before starting the
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installation.
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Portions of the text and tables are reprinted from NFPA 54/ANSI
Z223.1- -2009E, with permission of National Fire Protection
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Association, Quincy, MA 02269 and American Gas Association,
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Washington DC 20001. This reprinted material is not the
complete and official position of the NFPA or ANSI on the
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referenced subject, which is represented only by the standard in
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its entirety.
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GAS FURNACE
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ISO 9001:2000
Always Ask For
REGISTERED
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Summary of Contents for AHRI PG8MEA
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Page 1: Table Of Contents
....... Use of the AHRI Certified TM Mark indicates a manufacturer’s participation in the program. -
Page 2: Safety Considerations
SAFETY CONSIDERATIONS 1. Use only with type of gas approved for this furnace. Refer to the furnace rating plate. WARNING 2. Install this furnace only in a location and position as spe- cified in the “Location” section of these instructions. 3. - Page 3 used with a night setback thermostat. Return- -air temperature For accessory installation details, refer to the applicable must not exceed 85_F (29_C) db. Failure to follow these instruction literature. return- -air temperature limits may affect reliability of heat NOTE: Remove all shipping brackets and materials before exchangers, motors, and controls.
- Page 4 A10269 Fig. 2 - - Clearances to Combustibles...
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Page 5: Codes And Standards
Electrical Connections National Electrical Code (NEC) ANSI/NFPA 70- -2008. Venting NFGC NFPA 54 / ANSI Z223.1- -2009; Chapters 12 and 13. ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS PROCEDURE CAUTION FURNACE RELIABILITY HAZARD Improper installation or service of furnace may cause premature furnace component failure. A02055 Electrostatic discharge can affect electronic components. -
Page 6: Location
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 All fuel- -burning equipment must be supplied with air for fuel CAUTION combustion. Sufficient air must be provided to avoid negative pressure in the equipment room or space. A positive seal must be made between the furnace cabinet and the return- -air duct to PERSONAL INJURY AND/OR PROPERTY prevent pulling air from the burner area and from draft safeguard DAMAGE HAZARD...
- Page 8 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) ACH* Space Volume (ft. 0.60 1,050 1,400 1,750 1,100 1,650 2,200 2,750 3,300...
- Page 9 1 SQ IN. CIRCULATING AIR PER 4000 VENT THROUGH ROOF DUCTS DUCTS BTUH* O UTDOORS 12 ″ MAX 12" MAX (305mm) 12 ″ (305mm) (305mm) 1 SQ IN. VENT 1 SQ IN. PER 2000 THR OUGH PER 1000 BTUH* R OOF BTUH* IN DOOR 1 SQ IN .
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Page 10: Installation
INSTALLATION Ifan = combined input of all fan- -assisted appliances in Btuh/hr ACH = air changes per hour (ACH shall not exceed 0.60.) UPFLOW INSTALLATION The following requirements apply to the Standard Method and to Bottom Return Air Inlet the Known Air Infiltration Rate Method. These furnaces are shipped with bottom closure panel installed in 1. -
Page 11: Downflow Installation
5/ 16 ″ (8mm) (8mm) 5/ 16 ″ ″ (44mm) PLENUM OPENING ″ (44mm) FLOOR (8mm) OPENING ″ (8mm) ″ 5/ 16 (44mm) 3/ 4 ″ 3/ 4 ″ (44mm) A89014 A96283 Fig. 10 - - Leveling Legs Fig. 11 - - Floor and Plenum Opening Dimensions 4. - Page 12 FURNACE APPROVED COIL ASSEMBLY COIL BOX COMBUSTIBLE FLOORING SHEET METAL PLENUM FLOOR OPENING A08556 Fig. 13 - - Furnace, Plenum, and Coil Assembly or Coil Box Installed on a Combustible Floor Table 4 – Opening Dimensions - - In. (mm) FURNACE PLENUM OPENING FLOOR OPENING...
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Page 13: Horizontal Installation
HORIZONTAL INSTALLATION Not all horizontal furnaces are approved for side return air connections. (See Fig. 20). WARNING FILTER ARRANGEMENT WARNING FIRE, EXPLOSION, AND CARBON MONOXIDE POISONING HAZARD CARBON MONOXIDE AND POISONING Failure to follow this warning could result in personal HAZARD injury, death, and/or property damage. - Page 14 Upflow and Horizontal Furnaces Downflow Furnaces Connect supply- -air duct to flanges on furnace supply- -air outlet. Connect supply- -air duct to supply- -air outlet on furnace. Bend Bend flange upward to 90_ with wide duct pliers. (See Fig. 14.) flange inward past 90_ with wide duct pliers.
- Page 15 METHOD 2 USE (4) #8 x 3/4 (19 mm) SHEET METAL SCREWS FOR EACH STRAP. THE STRAPS SHOULD BE VERTICAL AGAINST THE FURNACE SIDES AND NOT PULL AWAY FROM THE FURNACE SIDES. METHOD 1 FOLD ALL STRAPS UNDER FURNACE AND SECURE WTH (4) #8 x 3/4 (19 mm) SHEET METAL SCREWS (2 SCREWS IN SIDE AND 2 SCREWS IN BOTTOM).
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Page 16: Gas Piping
Return Air Connections WARNING WARNING FIRE OR EXPLOSION HAZARD FIRE HAZARD Failure to follow this warning could result in personal injury, death, and/or property damage. Failure to follow this warning could cause personal injury, death and/or property damage. If local codes allow the use of a flexible gas appliance connector, always use a new listed connector. - Page 17 Table 5 – Air Delivery - - CFM (With Filter)* RETURN---AIR EXTERNAL STATIC PRESSURE (In. W.C.) UNIT SIZE SPEED SUPPLY 1185 1145 1115 1075 1035 045---08/ Bottom or 024045 Side(s) --- --- 1625 1585 1535 1495 1460 1415 1365 1295 1220 1125 1405...
- Page 18 A02075 Fig. 18 - - Upflow Return Air Configurations and Restrictions A02163 Fig. 19 - - Downflow Return Air Configurations and Restrictions...
- Page 19 A02162 Fig. 20 - - Horizontal Return Air Configurations and Restrictions 2” (51mm) Street Elbow A08551 Fig. 21 - - Burner and Manifold...
- Page 20 Table 7 – Electrical Data OPERATING VOLTS--- UNIT MAX WIRE MAX FUSE/ VOLTAGE* FURNACE MAX UNIT MIN WIRE HERTZ--- AMPACITY# LENGTH CKT BKR (VOLTS) MODEL (AMPS) GAGE PHASE (AMPS) FT. (M) (AMPS) 045--- 08 / 024045 115--- 60--- 1 10.9 34 (10) 070--- 16 / 048070 115--- 60--- 1...
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Page 21: Electrical Connection
ELECTRICAL CONNECTION TO J- -BOX CAUTION Electrical Box on Furnace Casing Side WARNING FURNACE MAY NOT OPERATE Failure to follow this caution may result in intermittent furnace operation. FIRE OR ELECTRICAL SHOCK HAZARD Furnace control must be grounded for proper operation or Failure to follow this warning could result in personal else control will lock out. -
Page 22: Accessories
BX CABLE INSTALLATION IN FURNACE J- -BOX 1. Remove cover from J- -Box. 2. Route BX cable into 7/8- -inch diameter hole in J- -Box. 3. Secure BX cable to J- -Box bracket with connectors ap- proved for the type of cable used. 4. - Page 23 BLOWER OFF-DELAY TWINNING AND/OR COMPONENT TEST TERMINAL 24-V THERMOSTAT TERMINALS HUMIDIFIER TERMINAL (24-VAC 0.5 AMP. MAX) 3-AMP FUSE LED OPERATION & DIAGNOSTIC LIGHT HEAT TRANSFORMER 24-VAC CONNECTIONS COOL BLOWER SPEED SELECTION TERMINALS SPARE 2 SPARE 1 PL1-LOW VOLTAGE DRAIN HARNESS CONNECTOR 115-VAC (L2) NEUTRAL...
- Page 24 See notes 2,5,7, and 10 on the page following these figures. See notes 1, 2, 4, 6, 7, 9, 10 and 12 on the page following these figures. A04215 A04217 Fig. 26 - - Single- -Stage Furnace with Single- -Speed Air Fig.
- Page 25 HUMIDFIER HUMIDFIER (24VAC) (24VAC) See notes 1, 2, 4, 11, 12, and 13 on the page following these figures. See notes 1, 2, 3, 4, 11, 12, and 14 on the page following these figures. A04220 A04219 Fig. 31 - - Dual Fuel Thermostat with Single- -Stage Furnace Fig.
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Page 26: Venting
VENTING GENERAL VENTING REQUIREMENTS The furnace shall be connected to a listed factory built chimney Follow all safety codes for proper vent sizing and installation or vent, or a clay- -tile lined masonry or concrete chimney. Venting requirements, including local building codes, the National Fuel into an unlined masonry chimney or concrete chimney is Gas Code ANSI Z223.1- -2009/NFPA 54- -2009 (NFGC), Parts 12 prohibited. -
Page 27: Appliance Application Requirements
This furnace is permitted to be vented into a clay tile- -lined Table 9 – Minimum Allowable Input Rating of Space- -Heat- masonry chimney that is exposed to the outdoors below the roof ing Appliance in Thousands of BTUH per Hour line, provided: INTERNAL AREA OF CHIMNEY 1. - Page 28 A10133 Fig. 33 - - Chimney Inspection Chart...
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Page 29: Additional Venting Requirements
To prevent condensation in the furnace and vent system, the NOTE: An accessory flue extension is available to extend from following precautions must be observed: the furnace elbow to outside the furnace casing. See Table 16 for accessory listing. If flue extension is used, fasten the flue 1. - Page 30 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. MIN. VENT MIN. VERTICAL VENT FURNACE FURNACE INPUT VENT ORIENTATION DIAMETER HEIGHT ORIENTATION (BTUH/HR) IN (MM)* FT.
- Page 31 SEE NOTES: 1,2,4,7,8,9 on the page following these figures SEE NOTES: 1,2,4,5,6,7,8,9 on the page following these figures A03207 A03213 Fig. 38 - - Downflow Application- -Vent Elbow Left then Up Fig. 40 - - Horizontal Left Application- -Vent Elbow Left SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures SEE NOTES:1,2,3,4,5,7,8,9...
- Page 32 SEE NOTES: 1,2,4,7,8,9 on the page following these figures SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures A03214 A03219 Fig. 42 - - Horizontal Right Application- -Vent Elbow Right Fig. 44 - - Horizontal Right Application- -Vent Elbow Left then Up SEE NOTES: 1,2,4,5,7,8,9 on the page SEE NOTES: 1,2,4,5,7,8,9 on the page...
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Page 33: Start- -Up, Adjustment, And Safety Check
START- -UP, ADJUSTMENT, AND SAFETY WARNING CHECK General ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal WARNING injury, or death. Blower access door switch opens 115- -v power to control. FIRE HAZARD No component operation can occur unless switch is closed. Caution must be taken when manually closing this switch Failure to follow this warning could result in personal injury, death and/or property damage. - Page 34 be reduced by 4 percent for each 1,000 ft. (305 M) above f. Set thermostat to call for heat. sea level. For installations below 2000 ft. (610 M), refer to g. Remove regulator seal cap and turn regulator adjusting the unit rating plate. For installations above 2000 ft. (610 screw counterclockwise (out) to decrease input rate of M), multiply the input on the rating plate by the de- -rate clockwise (in) to increase input rate.
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Page 35: Check Safety Controls
c. Adjust air temperature rise by adjusting blower speed. In- WARNING crease blower speed to reduce temperature rise. Decrease blower speed to increase temperature rise d. Turn thermostat down below room temperature and re- FIRE HAZARD move blower access door. Failure to follow this warning could result in personal e. - Page 36 Table 11 – Air Delivery - - CFM (With Filter)* EXTERNAL STATIC PRESSURE (In. W.C.) UNIT SIZE COLOR SPEED Gray 1185 1145 1115 1075 1035 Yellow 045---08/ Blue Orange --- --- Gray 1625 1585 1535 1495 1460 1415 1365 1295 1220 1125 Yellow...
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Page 37: Checklist
Table 12 – Gas Rate (Cu Ft./Hr.) SIZE OF TEST DIAL SIZE OF TEST DIAL SECONDS SECONDS FOR 1 REVOLUTION FOR 1 REVOLUTION 2 Cu Ft. 5 Cu Ft. 1 Cu Ft. 2 Cu Ft. 5 Cu Ft. Cu Ft. 1800 1636 1500... - Page 38 Table 13 – Orifice Size* and Manifold Pressure (In. W.C.) for Gas Input Rate A10180...
- Page 39 Table 13 - - Orifice Size* and Manifold Pressure (In. W.C.) for Gas Input Rate (CONT) A10180A...
- Page 40 Table 14 – Orifice Size* And Manifold Pressure (In. W.C.) For Gas Input Rate A10181...
- Page 41 Table 14- - Orifice Size* And Manifold Pressure (In. W.C.) For Gas Input Rate (CONT) A10181A...
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Page 42: Service And Maintenance Procedures
SERVICE AND MAINTENANCE PROCEDURES The electrical ground and polarity for 115- -v wiring must be WARNING properly maintained. Refer to Fig. 25 for field wiring information and to Fig. 54 for furnace wiring information. FIRE, INJURY, OR DEATH HAZARD NOTE: If the polarity is not correct, the STATUS LED on the control will flash rapidly and prevent the furnace from heating. -
Page 43: 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 44: Cleaning And/Or Replacing Filter
6. Inspect any accessories attached to the furnace such as a 3. For downflow or horizontal furnaces having vent pipes humidifier or electronic air cleaner. Perform any service or within the furnace that pass in front of the blower access maintenance to the accessories as recommended in the ac- door: cessory instructions. -
Page 45: Cleaning Heat Exchanger
15. Refer to furnace wiring diagram, and connect thermostat a. Draft safeguard switch. leads if previously disconnected. b. Inducer motor. 16. To check blower for proper rotation: c. Pressure switch(es). a. Turn on electrical supply. d. Limit over- -temperature switch. e. -
Page 46: Sequence Of Operation
NOTE: The materials needed in item 9 can usually be purchased at local hardware stores. (1.) Attach variable- -speed, reversible drill to the end of spring cable (end opposite brush). (2.) Insert brush end of cable into the outlet opening of cell and slowly rotate with drill. - Page 47 gized until the flame is sensed or until the 2- -second flame for an additional 90 seconds. Jumper Y1 to DHUM to re- proving period begins. duce the cooling off- -delay to 5 seconds. (See Fig. 24.) d. Flame- -Proving- - When the burner flame is proved at the 3.
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Page 48: Wiring Diagrams
room thermostat, momentarily turn off the FAN switch or blower- -OFF delay period then switch to continuous- - push button on the room thermostat for 1- -3 seconds after blower speed. When the R- -to- -W- -and- -Y/Y2, R- -to- - the blower motor BLWM is operating. - Page 49 A08176 Fig. 54 - - Wiring Diagram...
- Page 50 A02106A Fig. 55 - - Troubleshooting Guide...
- Page 51 A05032...
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Page 52: Accessory List
Table 16 – Accessory List DESCRIPTION PART NUMBER NOTES FILCABXX0016 Filter cabinet 16” (406 mm) for 4” (102 mm) wide filter Media Filter Cabinet FILCABXX0020 Filter cabinet 20” (508 mm) for 4” (102 mm) wide filter FILCABXX0024 Filter cabinet 24” (610 mm) for 4” (102 mm) wide filter FILXXCAR0016 Filter Cartridge replacements for FILCAB media cabinet Cartridge Media Filter... -
Page 53: Replacement Information Guide
PARTS REPLACEMENT INFORMATION GUIDE CASING GROUP GAS CONTROL GROUP Outer door Manifold Blower door Burner assembly Top filler plate Orifice Bottom filler plate Flame sensor Bottom enclosure Hot surface igniter Gas valve ELECTRICAL GROUP Manual reset limit switches Control bracket Burner support assembly Junction box HEAT EXCHANGER GROUP... - Page 54 Catalog No: IM- - PG8MEA- - 03 Printed in U.S.A. Edition Date: 08/10 Copyright 2010 Payne Heating & Cooling S 7310 W. Morris St. S Indianapolis, IN 46206 Replaces: IM- -PG8MEA- -02 Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
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