Payne PG96VAT Installation, Start-Up, Operating And Service And Maintenance Instructions
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Payne PG96VAT Installation, Start-Up, Operating And Service And Maintenance Instructions

Two-stage 4-way multipoise condensing gas furnace
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Installation, Start- -up, Operating and
Service and Maintenance Instructions
NOTE: Read the entire instruction manual before starting the installation.
SECTIONS
INTRODUCTION
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ACCESSORIES
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LOCATION
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INSTALLATION
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VENTING
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PARTS REPLACEMENT GUIDE
Use of the AHRI Certified
Mark indicates a
TM
manufacturer's participation in the program. For
verification of certification for individual products,
go to www.ahridirectory.org.
Portions of the text and tables are reprinted from the current edition of
NFPA 54/ANSI Z223.1E, with permission of National Fire
Protection Association, Quincy, MA 02269 and American Gas
Association, Washington DC 20001. This reprinted material is not the
complete and official position of the NFPA or ANSI on the referenced
subject, which is represented only by the standard in its entirety.
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CERTIFIED
TWO- -STAGE 4- -WAY MULTIPOISE
CONDENSING GAS FURNACE
SERIES C SIZES 60080, 60100, 66120
3
Loose Parts Bag Contents
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4
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Filter Size Information
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Opening Dimensions
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Air Delivery CFM
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16
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Hangar Spacing
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Combustion- -Air Vent Pipe, Fitting & Cement Material..
33
Maximum Allowable Exposed Vent Lengths Insulation
40
64
75
Deductions from Maximum Equivalent Vent Length
84
90
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PG96VAT
SERIES B ALL
TABLES
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  • Page 1: Table Of Contents

    PG96VAT TWO- -STAGE 4- -WAY MULTIPOISE CONDENSING GAS FURNACE SERIES B ALL SERIES C SIZES 60080, 60100, 66120 Installation, Start- -up, Operating and Service and Maintenance Instructions NOTE: Read the entire instruction manual before starting the installation. SECTIONS TABLES SAFETY CONSIDERATIONS .
  • Page 2 Required Notice for Massachusetts Installations IMPORTANT The Commonwealth of Massachusetts requires compliance with regulation 248 CMR as follows: 5.08: Modifications to NFPA- -54, Chapter 10 2) Revise 10.8.3 by adding the following additional requirements: a. For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:...

  • Page 3: Safety Considerations

    SAFETY CONSIDERATIONS installer or agency must use factory-authorized kits or accessories when modifying this product. Refer to the individual instructions packaged with the kits or accessories when installing. WARNING Installing and servicing heating equipment can be hazardous due to gas and electrical components. Only trained and qualified FIRE, EXPLOSION, ELECTRICAL SHOCK, AND personnel should install, repair, or service heating equipment.

  • Page 4: Codes And Standards

    duct(s) sealed to the furnace casing and terminating outside lower. Use Air Conditioning Contractors of America (Manual J the space containing the furnace. See “Air Ducts” section. and S); American Society of Heating, Refrigerating, and Air-Conditioning Engineers; or other approved engineering 8.

  • Page 5: Electrostatic Discharge (Esd) Precautions

    ACCESSORIES 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 See Product Data Sheet for a list of accessories for this product. state of Massachusetts.

  • Page 6: Minimum Clearances To Combustible Materials

    label. S Masonry acid washing materials All fuel- -burning equipment must be supplied with air for fuel WARNING combustion. Sufficient air must be provided to avoid negative pressure in the equipment room or space. A positive seal must be CARBON MONOXIDE POISONING / COMPONENT made between the furnace cabinet and the return- -air duct to DAMAGE HAZARD prevent pulling air from the burner area.
  • Page 7 *Consult local building codes. A180203 PG96VAT SHIP WT. FURNACE SIZE CABINET WIDTH OUTLET WIDTH BOTTOM INLET WIDTH AIR INTAKE LB (KG) 30040 14--- 3/16 (361) 12--- 1/2 (319) 12--- 9/16 (322) 7--- 1/8 (181) 121.0 (54.4) 42060 141.5 (63.7) 17--- 1/2 (445)
  • Page 8 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 CONDITIONED AIR IS DISCHARGED TO THE LEFT. THE BLOWER IS THE BLOWER IS LOCATED TO THE LEFT LOCATED ABOVE THE OF THE BURNER SECTION, BURNER SECTION, AND...

  • Page 9: Air For Combustion And Ventilation

    AIR FOR COMBUSTION AND WARNING VENTILATION Introduction CARBON MONOXIDE POISONING HAZARD Direct Vent (2- - pipe) Applications Failure to follow this warning could result in personal injury or death. When the furnace is installed as a direct vent (2-pipe) furnace, no special provisions for air for combustion are required.
  • Page 10 Indoor Combustion AirE NFPA & AGA of the floor. The minimum dimension of air openings shall be at least 3 in. (80 mm). See Fig. 7. Standard and Known- - Air- - Infiltration Rate Methods c. Combining space on different floor levels. The volumes of Indoor air is permitted for combustion, ventilation, and dilution, if spaces on different floor levels shall be considered as com- the Standard or Known- -Air- -Infiltration Method is used.

  • Page 11: Minimum Free Area Required

    Table 3 – Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors TWO OPENINGS OR TWO HORIZONTAL DUCTS SINGLE DUCT OR OPENING VERTICAL DUCTS (1 SQ. IN./2,000 BTUH) (1 SQ. IN./3,000 BTUH) FURNACE (1 SQ. IN./4,000 BTUH) (1,100 SQ.

  • Page 12: Condensate Trap

    CONDENSATE TRAP NOTICE Condensate Trap - - Upflow Orientation When the furnace is installed in the upflow position, it is not The field- -supplied, accessory horizontal drain trap grommet is necessary to relocate the condensate trap or associated tubing. ONLY REQUIRED FOR DIRECT VENT APPLICATIONS. Refer to Fig.
  • Page 13 Remove pressure switch tube from front pressure switch and discard. A new tube is shipped in the loose parts bag. Remove relief tube from relief Remove tube from relief port. port on condensate trap. Remove the screw that secures the trap to the collector box and remove trap.
  • Page 14 Remove plug from If alternate vent position collector box. is required, loosen clamp DO NOT DISCARD. on inlet of vent elbow. Remove the screw that secures the trap to the collector box and remove trap. Unconverted Factory Configuration As Viewed in the Horizontal Right Orientation NOTE: Remove knockout in casing before re installing the condensate trap.
  • Page 15 Remove the screw that secures the condensate trap to the collector box and remove trap. If alternate vent position is required, loosen clamp on vent elbow inlet. Remove relief tube from relief port on condensate trap. Remove front pressure switch tube and discard. A new tube is shipped in the Loose Parts bag.

  • Page 16: Condensate Drain

    CONDENSATE DRAIN CONNECTION 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 CAUTION in Fig. 14. NOTE: On narrower casings, it may be easier to remove the condensate trap, connect the drain line components and re-install FROZEN AND BURST WATER PIPE HAZARD the condensate trap.
  • Page 17 6. From the outside of the casing, insert the angled end of the 2. To allow for servicing the trap, the condensate drain elbow Z-pipe through drain hole in the left side of the casing and in the loose parts bag can be used to make a coupler to behind the inducer or gas valve.
  • Page 18 Evaporator Coil + + + + = Positive pressure < + = Pressure lower than areas with + − = Negative pressure Condensing Furnace Blower creates positive pressure. Positive pressure extends into coil condensate drain (no trap). < + < + <...
  • Page 19 Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Evaporator Coil + + + Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä 3/4” PVC Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä Ä...
  • Page 20 INSTALL CLAMPS ON DRAIN TUBE ATTACH ELBOW TO ATTACH DRAIN TUBE TO CONDENSATE FORMED END CONDENSATE TRAP DRAIN TRAP OF GROMMET CUT FORMED END OFF PULL DRAIN STUB CONDENSATE DRAIN THROUGH CASING ELBOW CONNECT SHORT END OF ’Z’ PIPE TO MODIFIED DRAIN ELBOW FACTORY SUPPLIED 1/2 IN.
  • Page 21 The return- -air duct must be connected to bottom, sides (left or supply- -air duct must be connected to ONLY the furnace supply right), or a combination of bottom and side(s) of main furnace outlet or air conditioning coil casing (when used). When installed casing.
  • Page 22 Suspended Furnace Support supplied accessory air cleaner may also be used in place of the filter rack. The furnace must be supported under the entire length of the For upflow applications, the filter can be installed on either side of furnace with threaded rod and angle iron.
  • Page 23 Table 5 – Filter Media Pressure Drop (Clean) Versus Airflow - - In. W.C. (Pa) Representative After-Market Filter Media* 14 x 25 Filter Factory-Accessory Factory-Accessory (356 x 635 mm) Washable Media* Fiberglass* Pleated* (1-in. / 2.5 cm) (4-in. / 10 cm) (1-in.
  • Page 24 Table 7 – Air Filter Selection and Duct Sizing - - In. (mm) FILTER SIZE FURNACE CASING WIDTH FILTER TYPE SIDE BOTTOM RETURN RETURN 16 x 25 x 3/4 14 x 25 x 3/4 14 ---3/16{ (360) Washable* (406 x 635 x 19) (356 x 635 x 19) 16 x 25 x 3/4 16 x 25 x 3/4...
  • Page 25 FURNACE FURNACE (OR COIL CASING WHEN USED) APPROVED COIL ASSEMBLY COIL BOX COMBUSTIBLE COMBUSTIBLE FLOORING FLOORING PLENUM OPENING DOWNFLOW SUBBASE SHEET METAL PLENUM FLOOR SHEET METAL PLENUM OPENING FLOOR FLOOR OPENING OPENING A10491 Fig. 21 - - Installation on Combustible Flooring Table 8 –...
  • Page 26 UPFLOW DOWNFLOW HORIZONTAL PERFORATED DISCHARGE DUCT 90° 90° FLANGE 120° 120° 120° A10493 Fig. 22 - - Duct Flanges BOTTOM CLOSURE SCREWS (2) Representative drawing only, SCREWS (4) some models may vary in appearance. Lay furnace on the back or side BOTTOM PLATE Remove the two (2) screws that secure the bottom...
  • Page 27 5/ 16  (8mm) (8mm) 5/ 16   (44mm)  (44mm) (8mm)  (8mm) 5/ 16  (44mm) 3/ 4  3/ 4  (44mm) A89014 A11037 Fig. 25 - - Leveling Legs Fig. 28 - - Downflow Return Air Configurations and Restrictions LEVEL 0-IN.
  • Page 28 COMBUSTION - AIR PIPE (SEE VENTING SECTION) 30 IN. (762 mm) MIN. WORK AREA 2-IN. (51 mm) ROLLOUT PROTECTION REQUIRED Install 12” x 22” (305x559 mm) sheet metal in front of burner compartment area. The sheet metal MUST extend underneath the furnace casing by 1-in. (25 mm) with the door removed.

  • Page 29: Air Ducts

    AIR DUCTS NOTICE Many states, provinces and localities are considering or have implemented standards and/or restrictions on duct sizing practices, ductwork leakage, and/or ductwork thermal, airflow and electrical efficiencies. CONSULT LOCAL CODE OFFICIALS ductwork design performance requirements in your area. General Requirements The duct system should be designed and sized according to accepted national standards such as those published by: Air...
  • Page 30 Table 9 – Cooling and Heating Air Delivery - - CFM (Bottom Return with Filter) (SW1-5 and SW2---2 set to OFF, except as indicated. See notes 1 and 2.) Unit Size Cooling Switch Settings External Static Pressure (ESP) In. W.C. SW2-8 SW2-7 SW2-6...
  • Page 31 Table 9 - - Cooling and Heating Air Delivery - - CFM (Bottom Return with Filter) (Continued) (SW1-5 and SW2---2 set to OFF, except as indicated. See notes 1 and 2.) Unit Size Cooling Switch Settings External Static Pressure (ESP) In. W.C. SW2-8 SW2-7 SW2-6...

  • Page 32: Gas Piping

    GAS PIPING WARNING WARNING FIRE OR EXPLOSION HAZARD A failure to follow this warning could result in personal FIRE OR EXPLOSION HAZARD injury, death, and/or property damage. Failure to follow this warning could result in personal If local codes allow the use of a flexible gas appliance injury, death, and/or property damage.

  • Page 33: Electrical Connections

    ELECTRICAL CONNECTIONS Table 10 – Maximum Capacity of Pipe NOMINAL LENGTH OF PIPE --- FT (M) IRON PIPE WARNING SIZE (3.0) (6.0) (9.1) (12.1) (15.2) IN. (MM) 1/2 (13) ELECTRICAL SHOCK, FIRE OR EXPLOSION 3/4 (19) HAZARD 1 ( 25) Failure to follow safety warnings could result in 1-1/4 (32) 1400...
  • Page 34 bracket grounding screw. If the J- -Box cover is not used, the field CAUTION and factory spliced connections must be located inside the external electrical box. Do not leave splice connections unprotected inside the furnace. FURNACE MAY NOT OPERATE HAZARD The J- -Box cover, mounting bracket and screws are shipped in the Failure to follow this caution may result in intermittent loose parts bag included with the furnace.
  • Page 35 24- -V Wiring 5. Pull furnace line voltage power wires through strain- -relief bushing of the external electrical box. Make field 24- -v connections at the 24- -v terminal strip. See Fig. 6. Pull the ground wire of the field line voltage wiring through 39.

  • Page 36: Electrical Data

    Table 11 – Electrical Data TWO---STAGE PWM FURNACES UNIT VOLTS--- OPERATING VOLTAGE MAXIMUM UNIT MINIMUM MAXIMUM MAXIMUM SIZE HERTZ--- RANGE* UNIT AMPACITY# WIRE WIRE LENGTH FUSE OR CKT PHASE AMPS SIZE FT (M)} Maximum* Minimum* AMPS{ 30040 115--- 60--- 1 10.3 (10.9) 42060...
  • Page 37 To HUM Terminal On To Humidifier Leads Furnace Control Board 24 V Coil To Humidifier Leads To Com/24V Screw Terminal on Thermostat Strip A11157 Fig. 37 - - Field- -supplied Isolation Relay for Humidifiers with Internal Power Supply W/W1 Y/Y2 A11401 Fig.
  • Page 38 MODEL PLUG AIR CONDITIONING (A/C) & SW1 SETUP OUTDOOR HUMIDIFIER CONNECTOR CONTINUOUS FAN (CF) SWITCHES AND AIR TEMP TERMINAL (24-VAC AIRFLOW SETUP SWITCHES BLOWER OFF- CONNECTOR 0.5 AMP MAX). ACRDJ – AIR DELAY CONDITIONING RELAY DISABLE JUMPER TWINNING CONNECTOR 24-V THERMOSTAT TERMINALS FLASH UPGRADE...
  • Page 39 THERMOSTAT THERMOSTAT 11, and 16 15, and 16 2-Stage Furnace with Single-Speed Heat Pump 2-Stage Furnace with Single-Speed Air Conditioner THERMOSTAT THERMOSTAT 15, and 16 12 and 16 2-Stage Furnace with Two-Speed Heat Pump 2-Stage Furnace with Two-Speed Air Conditioner A12096 Fig.
  • Page 40 NOTES FOR THERMOSTAT WIRING DIAGRAMS 1. Heat pump MUST have a high pressure switch for HYBRID HEATr dual fuel applications. 2. Refer to outdoor equipment Installation Instructions for additional information and setup procedure. 3. If the heat pump date code is 1501E or earlier, select the “ZONE” position on the two speed heat pump control. Heat pumps with date code 1601E and later do not have or require a “ZONE”...
  • Page 41 Other gas appliances with their own venting system may also use WARNING the abandoned chimney as a raceway providing it is permitted by local code, the current edition of the National Fuel Gas Code, and the vent or liner manufacturer’s installation instructions. Care must CARBON MONOXIDE POISONING HAZARD be taken to prevent the exhaust gases from one appliance from Failure to follow the steps outlined below for each appliance...

  • Page 42: Vent Termination Kit For Direct Vent (2- -Pipe) Systems

    Table 12 – Vent Termination Kit for Direct Vent (2- -pipe) Systems Approved Two- Pipe Termination Fittings Vent and Allowable 1 1/2--in. 2--in. 2 1/2--in. 3--in. 4--in. Combustion Air Concentric Vent (38 mm) (51 mm) (64 mm) (76--mm) (102 mm) Pipe Diameters 1 1/2--in.
  • Page 43 prevailing winds. The roof location is preferred since the vent and required by National code authorities. Allowable vent terminations combustion air system is less susceptible to damage or are shown in Fig. 55. The combustion air pipe terminates in a contamination.

  • Page 44: Maximum Equivalent Vent Length

    accessory concentric vent terminations or pipe lengths and elbows NOTICE used for “standard” vent terminations (see vent termination figures associated with Table 16) do not require a deduction from the Maximum Equivalent Vent Length. Include a deduction for a Tee OPTIONAL CONFIGURATION FOR COMBUSTION when used for Alberta and Saskatchewan terminations.
  • Page 45 Installing the Vent Pipe Adapter and Combustion Air The vent pipe may pass through unconditioned areas. The amount of exposed pipe allowed is shown in Table 15. Pipe Adapter 1. Using winter design temperature (used in load calculations), WARNING find appropriate temperature for your application and fur- nace model.
  • Page 46 1. Working from furnace to outside, cut pipe to required WARNING length(s). 2. De- -burr inside and outside of pipe. CARBON MONOXIDE POISONING HAZARD 3. Chamfer outside edge of pipe for better distribution of primer and cement. Failure to follow this warning could result in personal injury or death.
  • Page 47 Table 13 – Hanger Spacing Material Diameter PVC Sch 40 SDR 21 & 26 CPVC Polypropylene 1 ½--- in. 3--- ft. 2 ½--- ft. 3--- ft. 3--- ft. 3.25--- ft. 38--- mm 914--- mm 762--- mm 914--- mm 914--- mm 1000 mm 2--- in.
  • Page 48 2-Pipe and 1-Pipe Vent Termination (Direct Vent / 2-Pipe System ONLY) NOTE: Follow the instructions of the vent terminal manufacturer. When two or more furnaces are vented near each other, two vent terminations may be installed as shown in Fig. 54, but next vent These instructions are provided as a reference, only.
  • Page 49 Table 15 – Maximum Allowable Exposed Vent Lengths Insulation Table - - Ft. / In. Unit Size 40,000* BTUH 60,000 BTUH Uninsulated 3/8-in. Insulation 1/2-in. Insulation Uninsulated 3/8-in. Insulation 1/2-in. Insulation Pipe Dia. 1 ½ 2 ½ 1 ½ 2 ½ 1 ½...
  • Page 50 NOTE: Maximum Equivalent Vent Length (MEVL) includes standard and concentric vent termination and does NOT include elbows. Use Table 17 - Deductions from Maximum Equivalent Vent Length to determine allowable vent length for each application. Table 16 – Maximum Equivalent Vent Length - - Ft./In. Unit Size 40,000 60,000...
  • Page 51 Venting System Length Calculations The Total Equivalent Vent Length (TEVL) for EACH combustion air or vent pipe equals the length of the venting system, plus the equivalent length of elbows used in the venting system from Table 17. Standard vent terminations or factory accessory concentric vent terminations count for zero deduction. See vent system manufacturer’s data for equivalent lengths of flexible vent pipe or other termination systems.
  • Page 52 Attach gaskets to vent pipe and Vent Coupling and Adapter combustion air adapters. A13074 Fig. 41 - - Vent Coupling and Adapter with Gaskets TABS ON THE INDUCER OUTLET RESTRICTOR SNAP INTO THE SLOTS AT THE OUTLET OF THE INDUCER FOR USAGE: SEE MAXIMUM EQUIVALENT VENT LENGTH TABLE (10FT.
  • Page 53 Slope vent pipe back to the furnace at least ¼” per foot Use 45 deg. Elbows where Avoid short horizontal offsets with 90 possible, to ensure conden- deg. Elbows. Short offsets can be sate drainage. difficult to slope and may trap con- densate.
  • Page 54 No operable windows, doors or Clearance distances for intakes of any type within the items greater than 3 feet shaded areas of Wall A and B. (1 meter ) away from the inside corner, refer to the For all other items, refer to the Inside Inside Corner Clearance Corner Clearance Table.
  • Page 55 Rotate vent elbow to required position. Any other unused knockout may be used for combustion air connection. Rotate vent elbow to required position. & UPFLOW LEFT CONFIGURATION DOWNFLOW LEFT CONFIGURATION A11309A A11311A Rotate vent elbow to required position. Any other unused Any other unused knockout may be used knockout may be used...
  • Page 56 ALTERNATE COMBUSTION AIR CONNECTIONS HORIZONTAL LEFT ---VERTICAL VENT CONFIGURATION HORIZONTAL RIGHT ---VERTICAL VENT CONFIGURATION A11327A A11337 Alternate combustion air connection. Rotate vent elbow to required position. Vent Pipe Requires Internal Vent Kit See Product Data for Current Kit Number HORIZONTAL RIGHT ---LEFT VENT CONFIGURATION HORIZONAL LEFT ---LEFT VENT CONFIGURATION A11328A A11336...
  • Page 57 NOTES FOR VENTING OPTIONS 1. Attach vent pipe adapter with gasket to furnace casing. 2. Align notches in rubber coupling over standoffs on adapter. Slide clamps over the coupling. 3. Slide vent pipe through adapter and coupling into vent elbow. 4.
  • Page 58 A12326 NOTE: The following is based upon National codes for gas appliances and is provided as a reference. Refer to local codes which may supersede these standards and/or recommendations. (1 ) (2 ) Canadian Installations U.S. Installations Item Clearance Description (per CAN/CSA B149.1) (per ANSI Z223.1/NFPA 54) Clearance above grade, veranda, porch, deck, balcony...
  • Page 59 A12325 NOTE: The following is based upon National codes for gas appliances and is provided as a reference. Refer to local codes which may supersede these standards and/or recommendations. (1 ) (2 ) Canadian Installations U.S. Installations Item Clearance Description (per CAN/CSA B149.1) (per ANSI Z223.1/NFPA 54) Clearance above grade, veranda, porch, deck, balcony or...
  • Page 60 ¾ in. (222mm) for 3 in. (76mm) ¾ in. (172mm) for 2 in. (51mm) 12 in. (305mm) min. separation between bottom of combustion air and bottom of vent (Typ.) A13305 Fig. 54 - - Combustion Air and Vent Pipe Termination for Direct Vent (2- -Pipe) System Roof Termination (Preferred) Vent Maintain 12 in...
  • Page 61 OPTIONAL TERMINATION BRACKET FOR 2-PIPE TERMINATIONS OPTIONAL 12 IN. (305 MM) MIN. BRACKET SEPARATION BETWEEN COUPLING BOTTOM OFCOMBUSTION 12 IN. (305 MM) MIN. SEPARATION AIR AND BOTTOM OF VENT. BETWEEN BOTTOM OF COMBUSTION AIR AND BOTTOM OF VENT. MAINTAIN 12 IN. (305 MM) CLEARANCE ABOVE HIGHEST ANTICIPATED 12-IN.
  • Page 62 Ventilated Combustion Air intake pipe Pipe hangar 3” (76 mm) 12” (305 mm) Ventilated Combustion Air intake termination in crawl space CRAWL SPACE highest level of insulation ATTIC A10497 Fig. 57 - - Vent Terminations for Ventilated Combustion Air...
  • Page 63 EXAMPLE FOR UPFLOW INSTALLATIONS. MAY BE APPLIED TO OTHER CONFIGURATIONS. A12220 Fig. 58 - - Sample Inlet Air Pipe Connection for Polypropylene Venting Systems TO CODE- - APPROVED DRAIN OR CONDENSATE PUMP Recommend “T” fitting with 4--inch minimum height standpipe (A) of same diameter or larger extending upward. Dry Well Dry Well (water tight...

  • Page 64: Start- -Up, Adjustment, And Safety Check

    START- -UP, ADJUSTMENT, AND SAFETY 1. Remove blower door. 2. Locate setup switches on furnace control. CHECK 3. Configure the setup switches as necessary for the NOTICE application. 4. Replace blower door. NOTE: If a bypass humidifier is used, setup switch SW1-3 (Low Important Installation and Start- -up Procedures Heat Rise Adjust) should be in ON position.
  • Page 65 1. Remove upper and middle collector box drain plugs oppo- NOTICE site of the condensate trap. See Fig. 69. 2. Connect field-supplied 5/8-in. (16 mm) ID tube with at- tached funnel to upper collector box drain connection. The NATURAL GAS manifold pressure adjustments in Table 21 compensate for BOTH altitude AND gas heating value.
  • Page 66 Therefore: Orifice No. 44 e. Move setup SW1—2 on furnace control to ON position to lock furnace in low- -heat operation. See Fig. 66 and Fig. * Furnace is shipped with No. 44 orifices. In this example, all main burner orifices are the correct size and do not need to be changed to obtain proper input rate.
  • Page 67 f. Refer to Table 20 for cubic ft. of gas per hr. 2. When thermometer readings stabilize, subtract return- -air temperature from supply- -air temperature to determine air g. Multiply gas rate cu ft./hr by heating value (Btuh/cu ft.) to temperature rise.
  • Page 68 b. Turn Dip switch SW- -7 or SW- -8 ON or OFF for desired e. Set heat anticipator on thermostat per thermostat blower off delay. See Table 19 and Fig. 39, 66 and 75.) instructions and install on subbase or wall. Adjust Cooling Airflow –...
  • Page 69 TWO-STAGE ON/OFF Switch Regulator Seal Cap Regulator Adjustment Regulator Seal Cap under Cap 1/2” NPT Inlet 1/8” NPT Inlet Pressure Tap BURNER 1/2” NPT Outlet ORIFICE 1/8” NPT Manifold Pressure Tap A11152 A93059 Fig. 60 - - Gas Valve without Tower Pressure Ports Fig.
  • Page 70 A14317 Fig. 65 - - Service Label Information...
  • Page 71 Furnace Setup Switch Description SET UP NORMAL SW IT CH NAME DESCRIPT ION OF USE SW IT CH POSIT ION Turn ON to retrieve up to 7 stored status codes for SW1 -1 Status Code Recovery troubleshooting assistance when R thermostat lead is disconnected.

  • Page 72: Altitude Derate Multiplier For U.s.a

    Table 18 – Altitude Derate Multiplier for U.S.A. Table 19 – Blower Off Delay Setup Switch PERCENT DERATE SETUP SWITCH ALTITUDE MULTIPLIER (SW1---7 AND ---8) DESIRED HEATING MODE DERATE FACTOR* POSITION BLOWER OFF DELAY (SEC.) 0–2000 0---610 1.00 SW1--- 7 SW1--- 8 2001–3000 610---914...

  • Page 73: Orifice Size And Manifold Pressure

    Table 21 – Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate TWO-STAGE FURNACE (TABULATED DATA BASED ON 20,000 BTUH HIGH-HEAT / 13,000 BTUH LOW-HEAT PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE RANGE HEAT VALUE 0.58 0.60 0.62...
  • Page 74 Table 21 - - Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate (Continued) TWO-STAGE FURNACE (TABULATED DATA BASED ON 20,000 BTUH HIGH-HEAT / 13,000 BTUH LOW-HEAT PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE RANGE HEAT VALUE 0.58 0.60...

  • Page 75: Service And Maintenance Procedures

    SERVICE AND MAINTENANCE Electrical Controls and Wiring PROCEDURES Each pressure switch is labeled with the reference location (noted as “COLLECTOR BOX- -LPS” or “HOUSING- -HPS” on the Untrained personnel can perform basic maintenance functions such switch). The nominal break point of each switch is shown on the as cleaning and replacing air filters.
  • Page 76 Care and Maintenance NOTE: The Status Codes cannot be retrieved by disconnecting the limit switch. To retrieve Status Codes, follow the procedure WARNING below. 2. Turn Setup Switch, SW1- -1 “ON.” 3. Manually close blower door switch. FIRE OR EXPLOSION HAZARD 4.
  • Page 77 4. Inspect burner compartment before each heating season for The inducer and blower motors are pre- -lubricated and require no rust, corrosion, soot or excessive dust. If necessary, have additional lubrication. These motors can be identified by the furnace and burner serviced by a qualified service agency. absence of oil ports on each end of the motor.
  • Page 78 13. Reinstall blower assembly in furnace. Refer to Fig. 72. 14. Reinstall 2 screws securing blower assembly to blower 1. Disconnect power at external disconnect, fuse or circuit deck. breaker. 15. Reconnect blower leads to furnace control. Refer to furnace 2.
  • Page 79 Flushing Collector Box and Drainage System 13. Install the gas pipe to the gas valve. WARNING WARNING FIRE OR EXPLOSION HAZARD ELECTRICAL SHOCK AND FIRE HAZARD Failure to follow this warning could result in personal Failure to follow this warning could result in personal injury, injury, death, and/or property damage.
  • Page 80 11. Flush condensate drain lines with warm water. Remember WARNING to check and clean the relief port on the collector box. 12. Shake trap dry. ELECTRICAL SHOCK, FIRE OR EXPLOSION 13. Clean port on collector box with a small wire. HAZARD To re-install Condensate Drain and Trap: Failure to follow this warning could result in personal...
  • Page 81 Secondary Heat Exchangers 13. When furnace is re- -started, flush condensate pump with clear water to check for proper operation before re- -starting The condensing side (inside) of the secondary heat exchanger furnace. CANNOT be serviced or inspected without complete removal of 14.
  • Page 82 Burner Flame Burner Manifold A11273 A89020 Fig. 70 - - Cleaning Heat Exchanger Cell Fig. 71 - - Burner Flame IGNITER BURNER SUPT. ASSY BRACKET, IGNITER BURNER ASSY FLAME ROLLOUT SWITCH FLAME SENSOR (BELOW BURNER) A11403 Fig. 72 - - Burner Assembly...
  • Page 83 GROMMET MOTOR SHAFT FLAT MOTOR ARM SCREW SET SCREW MOTOR WHEEL HUB SEE DETAIL SCREW LOCATION BLOWER HSG ASSY BRACKET BRACKET ENGAGEMENT DETAIL CUTOFF, BLOWER WHEEL, BLOWER BLOWER HSG ASSY BRACKET CAPACITOR OR POWER CHOKE (WHEN USED) MOTOR, BLOWER SCREW (GND) A11584 Fig.

  • Page 84: Sequence Of Operation

    SEQUENCE OF OPERATION after the low- -heat pressure switch LPS closes. If the high- -heat pressure switch HPS fails to close NOTE: Furnace control must be grounded for proper operation or and the low- -heat pressure switch LPS closes, the else control will lock out.
  • Page 85 heat airflow for 90, 120, 150, or 180 seconds (depending the length of previous cooling period of the single- -stage on selection at blower- -OFF delay switches). The furnace thermostat. control CPU is factory- -set for a 120- -second blower- -OFF NOTE: The air conditioning relay disable jumper ACRDJ must delay.
  • Page 86 4. Dehumidification Mode the thermostat is satisfied, the blower motor BLWM will op- See Fig. 39 and 40 for thermostat connections. erate an additional 90 seconds at high- -cooling airflow be- The dehumidification output, D or DHUM on the humidity fore transitioning back to continuous- -blower airflow.
  • Page 87 A113325A Fig. 74 - - Troubleshooting Guide...
  • Page 88 A113325B Troubleshooting Guide (Continued)
  • Page 89 A150087 Fig. 75 - - Wiring Diagram...
  • Page 90 The qualified installer or service agency must use only factory- -authorized replacement parts, kits, or accessories when modifying this product. Catalog No: IM---PG96VAT ---13 Copyright 2018 CAC / BDP D 7310 W. Morris St. D Indianapolis, IN 46231 Edition Date: 11/18 Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

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