Table of Contents
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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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WINTERIZATION
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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 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
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4
4
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5
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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..
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Maximum Allowable Exposed Vent Lengths Insulation
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Deductions from Maximum Equivalent Vent Length
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80
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PG96XAT
TABLES
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SERIES B
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Table of Contents
Related Manuals for Payne PG96XAT
Summary of Contents for Payne PG96XAT
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Page 1: Table Of Contents
PG96XAT TWO- -STAGE 4- -WAY MULTIPOISE CONDENSING GAS FURNACE SERIES B 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:...
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Page 3: Safety Considerations
SAFETY CONSIDERATIONS 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 personnel should install, repair, or service heating equipment. FIRE, EXPLOSION, ELECTRICAL SHOCK, AND Untrained personnel can perform basic maintenance functions such CARBON MONOXIDE POISONING HAZARD... -
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
not exceed 36 in. (914 mm). 1. Disconnect all power to the furnace. Multiple disconnects may be required. DO NOT TOUCH THE CONTROL S When lever type gas shutoffs are used they shall be T- -handle type. OR ANY WIRE CONNECTED TO THE CONTROL S The use of copper tubing for gas piping is not approved by the PRIOR TO DISCHARGING YOUR BODY’S ELEC- state of Massachusetts. - Page 6 A180203 SHIP WT. PG95XAT FURNACE SIZE LB (KG) CABINET WIDTH OUTLET WIDTH BOTTOM INLET WIDTH AIR INTAKE 30040 125.0 (56.8) 14--- 3/16 (361) 12--- 1/2 (319) 12--- 9/16 (322) 7--- 1/8 (181) 36060 136.0 (61.7) 36040 135.0 (61.2) 42060 17--- 1/2 (445) 15--- 7/8 (403) 16 (406) 8--- 3/4 (222)
- Page 7 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 8 LOCATION WARNING CAUTION CARBON MONOXIDE POISONING / COMPONENT DAMAGE HAZARD PERSONAL INJURY AND/OR PROPERTY Failure to follow this warning could result in personal injury DAMAGE HAZARD or death and unit component damage. Improper use or installation of this furnace may result in Corrosive or contaminated air may cause failure of parts premature furnace component failure.
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Page 9: Air For Combustion And Ventilation
CAUTION WARNING FIRE HAZARD FURNACE CORROSION HAZARD Failure to follow this warning could result in personal Failure to follow this caution may result in furnace damage. injury, death and/or property damage. Air for combustion must not be contaminated by halogen Do not install the furnace on its back or hang furnace with compounds, which include fluoride, chloride, bromide, and control compartment facing downward. - Page 10 in. (25 mm) from the sides and back and 6 in. (150 mm) from the The following requirements apply to the Standard Method and to front. The opening shall directly communicate with the outdoors or the Known Air Infiltration Rate Method. shall communicate through a vertical or horizontal duct to the 1.
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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.
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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 Horizontal Orientation 6. From the outside of the casing, insert the angled end of the Z-pipe through drain hole in the left side of the casing and 1. The condensate trap outlet extends 2- -in. (51 mm) below the behind the inducer or gas valve. Allow the Z-pipe to furnace casing.
- 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 Return Air Connections 3. Construct plenum to dimensions specified in Table 8 and Fig. 20. WARNING 4. Install special base coil assembly or coil box as shown in in Fig. 20. NOTE: It is recommended that the perforated supply- -air duct FIRE HAZARD flanges be completely removed from furnace when installing the A failure to follow this warning could cause personal injury,...
- Page 22 accessories MUST be connected to duct external to furnace main WARNING casing. Return Air Connections FIRE, EXPLOSION, AND CARBON MONOXIDE The return- -air duct may be connected to bottom of the furnace. POISONING HAZARD The side of casing that faces downward may also be used for return Failure to follow this warning could result in personal air connection.
- Page 23 Provide duct transitions, as required, to smoothly transition airflow For horizontal applications, the filter rack (or field supplied from the return duct system to the filter (or IAQ device) to the accessory air cleaner) can be connected to the bottom opening on furnace when the dimensions of the ductwork or furnace return air the furnace.
- Page 24 Table 6 – Filter Media Pressure Drop (Clean) Versus Face Velocity- - In. W.C. (Pa) Representative After-Market Filter Media* Factory-Accessory Face Velocity Washable Fiberglass* Pleated* (m/s) (1-in. / 2.5 cm) (1-in. / 2.5 cm) (2-in. / 5 cm) (1-in. / 2.5 cm) (2-in.
- Page 25 FURNACE FILTER FRAME DOOR TABS FILTER (FIELD SUPPLIED) (10 mm) 2” 8” (32 mm) (13 mm) TABS 4” (TYP.) (60 mm) 8” 8” 4” 4” (19 mm) (638 mm) (32 mm) (587 mm) 8” (410 mm) 8” 8” OPENING (435 mm) 2”...
- Page 26 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. 20 - - Installation on Combustible Flooring Table 8 –...
- Page 27 UPFLOW DOWNFLOW HORIZONTAL PERFORATED DISCHARGE DUCT 90° 90° FLANGE 120° 120° 120° A10493 Fig. 21 - - Duct Flanges SCREWS (4) BOTTOM CLOSURE SCREWS (2) BOTTOM PLATE Representative drawing. Models may vary. Representative drawing. Models may vary. Lay furnace on the back or side Lay furnace on the back or side Remove the four (4) screws that secure the bottom Remove the two (2) screws that secure the bottom...
- Page 28 5/ 16 (8mm) (8mm) 5/ 16 (44mm) (44mm) (8mm) (8mm) 5/ 16 (44mm) 3/ 4 3/ 4 (44mm) A89014 A11037 Fig. 24 - - Leveling Legs Fig. 27 - - Downflow Return Air Configurations and Restrictions LEVEL 0-IN.
- Page 29 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.
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Page 30: 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 31 Table 9 – Air Delivery - - CFM (With Filter) EXTERNAL STATIC PRESSURE (IN.W.C.) UNIT RETURN-AIR SPEED 2, 3 SIZE CONNECTION TAPS Gray 1120 1080 1030 Yellow 030040 SIDE/BOTTOM Blue Orange Gray 1255 1220 1175 1130 1085 1040 Yellow 036040 SIDE/BOTTOM Blue Orange...
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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 38.
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Page 36: Electrical Data
Table 11 – Electrical Data MINIMUM MAXIMUM MAXIMUM OPERATING VOLTAGE VOLTS--- MAXIMUM UNIT WIRE WIRE FUSE OR CKT RANGE* HERTZ--- UNIT UNIT SIZE AMPACITY# SIZE LENGTH PHASE AMPS Maximum* Minimum* FT (M)} AMPS{ 30040 115--- 60--- 1 10.3 36 (11.0) 36040 115--- 60--- 1 10.3... - 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. 36 - - Field- -supplied Isolation Relay for Humidifiers with Internal Power Supply W/W1 Y/Y2 A11401 Fig.
- Page 38 THERMOSTAT THERMOSTAT See notes 2, 5, 7, 10, 11, 16, and 17 See notes 1, 2, 4, 6, 7, 9, 10, 11, 15, 16, and 17 Modulating and 2-Stage Furnace with Single-Speed Heat Pump Modulating and 2-Stage Furnace with Single-Speed Air Conditioner THERMOSTAT THERMOSTAT See notes 1, 2, 3, 4, 6, 8, 9, 10, 12, 13, 15, 16, and 17...
- Page 39 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 40 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...
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Page 41: 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 42 Ventilated Combustion Air prevailing winds. The roof location is preferred since the vent and combustion air system is less susceptible to damage or The vent pipe for a Ventilated Combustion Air System must contamination. The termination is usually located away from terminate outdoors.
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Page 43: Maximum Equivalent Vent Length
The Maximum Vent Length for the vent and combustion air pipe The measured length of pipe used in a single or 2- -pipe termination (when used) is determined from the Maximum Equivalent Vent is included in the total vent length. Include deductions from the Length in Table 16 minus the number of fittings multiplied by the Maximum Equivalent Vent Length (MEVL) contained in the deduction for each type of fitting used from Table 17. - Page 44 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 45 Table 13 – Hanger Spacing Material Diameter PVC Sch 40 SDR 21 & 26 CPVC Polypropylene 1 1/2--in. 3--ft. 2 1/2--ft. 3--ft. 3--ft. 3.25--ft. 38--mm 914--mm 762--mm 914--mm 914--mm 1000 mm 2--in. 3--ft. 3--ft. 3--ft. 3--ft. 3.25--ft. 51--mm 914--mm 914--mm 914--mm 914--mm 1000 mm...
- Page 46 5. Re- -insert the pipe through the casing into the vent elbow. NOTE: Follow the instructions of the vent terminal manufacturer. These instructions are provided as a reference, only. 6. Tighten the clamp around the outlet of the vent elbow. Torque the clamp to 15 lb- -in.
- Page 47 (Direct Vent / 2-Pipe System ONLY) NOTICE When two or more furnaces are vented near each other, two vent terminations may be installed as shown in Fig. 53, but next vent RECOMMENDED SUPPORT FOR VENT termination, or pair of vent terminations, must be at least 36 in. TERMINATIONS (914 mm) away from the first two terminations.
- Page 48 Table 15 – Maximum Allowable Exposed Vent Lengths in Unconditioned Space 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...
- Page 49 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 50 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 51 Attach gaskets to vent pipe and Vent Coupling and Adapter combustion air adapters. A13074 Fig. 40 - - 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 52 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 53 Inside Corner Terminations Inside corner vent terminations are permitted provided that: S Only two exterior walls come together to form an angle of 90 degrees to 135 degrees. There are no other exterior walls attached to either wall to form an alcove. S The clearance distances apply when the vent is at least 3 feet (1 meter) from, but not more than 6 feet (2 meters) away from an inside corner.
- Page 54 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 55 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 56 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 57 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 58 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 59 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. 53 - - Combustion Air and Vent Pipe Termination for Direct Vent (2- -Pipe) System Roof Termination (Preferred) Vent Maintain 12 in...
- Page 60 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 61 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. 56 - - Vent Terminations for Ventilated Combustion Air...
- Page 62 EXAMPLE FOR UPFLOW INSTALLATIONS. MAY BE APPLIED TO OTHER CONFIGURATIONS. A12220 Fig. 57 - - 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...
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Page 63: Start- -Up, Adjustment, And Safety Check
START- -UP, ADJUSTMENT, AND SAFETY If a 2- -stage heating thermostat is to be used, move SW- -1 (LHT) to ON position before starting furnace. This overrides built- -in control CHECK process for selecting high and low fire and allows the 2- -stage thermostat to select gas heating modes. - Page 64 Adjustments required orifice to the manifold pressure to the heat content and specific gravity of the gas. To do this: WARNING 1. Obtain average yearly gas heat value (at installed altitude) from local gas supplier. 2. Obtain average yearly gas specific gravity from local gas FIRE HAZARD supplier.
- Page 65 13. Remove manometer from the inlet pressure tap of the gas NOTICE valve. WARNING DO NOT set high- -heat manifold pressure less than 3.2- -in. w.c. (797 Pa) or more than 3.8 in. w.c. (947 Pa) for natural FIRE HAZARD gas.
- Page 66 Adjust Temperature Rise (Read following caution before changing taps). NOTE: Blower door must be installed when taking temperature CAUTION rise reading. Leaving blower door off will result in incorrect temperature measurements, due to possible changes in duct static pressure and airflow. UNIT DAMAGE HAZARD To avoid operating outside the rise range and avoid CAUTION...
- Page 67 3. Connect an amp. meter across the R and W subbase 7. Verify that the Status LED glows. If not, check that the terminals or R and W wires at wall. power supply is energized and that the blower door is secure.
- Page 68 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 EXAMPLE: ANTICIPATOR SETTING 10 TURNS AROUND JAWS A96316 Fig.
- Page 69 A170152 Fig. 62 - - Service Label Information...
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Page 70: 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 (SW---2 AND SW---3) DESIRED HEATING MODE DERATE FACTOR* POSITION BLOWER OFF DELAY (SEC.) 0–2000 0---610 1.00 SW---2 SW---3 2001–3000 610---914 4--- 6... -
Page 71: 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 72: Service And Maintenance Procedures
Table 21 - - Orifice Size and Manifold Pressure (in. w.c.) for Gas Input Rate (Cont.) 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 73 Electrical Controls and Wiring 2. Observe the status LED through the blower door (the lower door on upflow applications) indicator. Refer to the Service Each pressure switch is labeled with the reference location (noted Label (Fig. 62) to interpret the LED. as “COLLECTOR BOX- -LPS”...
- Page 74 Checklist WARNING 1. Put away tools and instruments. Clean up debris. 2. Verify that the jumper is removed from the TEST/TWIN CARBON MONOXIDE POISONING AND FIRE terminal. Verify that there is nothing plugged into the PLT HAZARD connector. (Note: If there is a jumper connector plugged Failure to follow this warning could result in personal into PLT, remove it and discard.) See Fig.
- Page 75 6. Clean blower wheel and motor by using a vacuum with soft WARNING brush attachment. Be careful not to disturb balance weights (clips) on blower wheel vanes. Do not bend wheel or blades ELECTRICAL SHOCK, FIRE OR EXPLOSION as balance will be affected. HAZARD 7.
- Page 76 NOTE: If R- -W/W1 thermostat terminals are jumpered at the time 19. Clean burner with a brush and a vacuum. blower door switch is closed, blower will run for 90 sec before 20. Clean the flame sensor with fine steel wool (0000 grade). beginning a heating cycle.
- Page 77 5. Remove igniter assembly. 5. Disconnect external drain from condensate drain elbow or drain extension pipe inside the furnace and set aside. a. Using a 1/4- -in. driver, remove the two screws securing the 6. Disconnect the condensate trap relief hose from collector igniter mounting bracket to the burner assembly See Fig.
- Page 78 that a problem exists which needs to be corrected, such as improper WARNING adjustment of manifold pressure, insufficient or poor quality combustion air, improper vent termination, incorrect size or damaged manifold orifice(s), improper gas, or a restricted heat FIRE OR EXPLOSION HAZARD exchanger (primary or secondary).
- Page 79 11. If a condensate pump is used, check with pump manufacturer to verify pump is safe for use with antifreeze used. Allow pump to start and pump anti- -freeze to open drain. 12. Replace main door. 13. When furnace is re- -started, flush condensate pump with clear water to check for proper operation before re- -starting furnace.
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Page 80: Sequence Of Operation
SEQUENCE OF OPERATION nace will operate at low- -heat gas flow rate until the high- -heat pressure switch closes for a maximum of NOTE: Furnace control must be grounded for proper operation or 2 minutes after ignition. control will lockout. Control is grounded through green wire b. - Page 81 2. Two- -Stage Thermostat and Two- -Stage Heating energize the Y/Y2 terminal and switch the outdoor unit to Fig. 38 and 39 for thermostat connections) high- -cooling. NOTE: In this mode the LHT must be ON to select the low- -heat The furnace control CPU can start up the cooling unit in either only operation mode in response to closing the thermostat low- - or high- -cooling.
- Page 82 6. Heat Pump The cooling operation described in item 3. above also ap- See Fig. 38 and 39 for thermostat connections. plies to operation with a dehumidification thermostat.. The When installed with a heat pump, the furnace control auto- exceptions are listed below: matically changes the timing sequence to avoid long blower off times during demand defrost cycles.
- Page 83 A11323A Fig. 70 - - Troubleshooting Guide...
- Page 84 A11323B Troubleshooting Guide (Cont)
- Page 85 338314- -2 Rev. I A170153 Fig. 71 - - Wiring Diagram...
- Page 86 PARTS REPLACEMENT INFORMATION GUIDE Casing Group Gas Control Group Blower door Burner Bottom plate Flame sensor Control door Gas valve Door knob assembly Hot surface igniter Top filler plate Manifold Orifice Electrical Group Heat Exchanger Group 3- -Amp fuse Circuit board Containment plate Control box Coupling box...
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