CAC / BDP PG92SAS Installation, Start-Up, Operating And Service And Maintenance Instructions
  1. Manuals
  2. Brands
  3. CAC / BDP Manuals
  4. Furnace
  5. PG92SAS
  6. Installation, start-up, operating and service and maintenance instructions

CAC / BDP PG92SAS Installation, Start-Up, Operating And Service And Maintenance Instructions

Single ---stage 4 ---way multipoise condensing gas furnace
Hide thumbs
Table of Contents

Advertisement

Quick Links

PG92SAS
Installation, Start---up, Operating and
Service and Maintenance Instructions
NOTE: Read the entire instruction manual before starting the
installation.
INTRODUCTION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCESSORIES
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOCATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upflow
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Downflow
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Horizontal
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upflow
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Downflow
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Horizontal
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
115- -V Wiring
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24- -V Wiring
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VENTING
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Materials
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
. . .
. . . . . .
Single---Stage 4---Way Multipoise
Condensing Gas Furnace
Adjustments
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
4
4
PARTS REPLACEMENT GUIDE
. . .
4
5
Loose Parts Bag
8
8
9
Filter Size Information
9
Opening Dimensions
13
Air Delivery CFM
13
13
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
17
Combustion- -Air Vent Pipe, Fitting & Cement Material..
20
Maximum Allowable Exposed Vent Lengths Insulation
20
Deductions from Maximum Equivalent Vent Length
20
Blower Off Delay Setup Switch
21
21
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
29
29
31
32
32
33
33
33
33
Use of the AHRI Certified
37
manufacturer's participation in the program. For
verification of certification for individual products,
.
37
go to www.ahridirectory.org.
38
38
Portions of the text and tables are reprinted from NFPA 54/ANSI
38
Z223.1- -2009E, with permission of National Fire Protection
Association, Quincy, MA 02269 and American Gas Association,
39
Washington DC 20001. This reprinted material is not the complete
41
and official position of the NFPA or ANSI on the referenced
62
subject, which is represented only by the standard in its entirety.
62
62
62
1
Series A
. . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
TABLES
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
CERTIFIED
Mark indicates a
TM
62
. . . . . . . .
70
75
79
83
5
. . . . . . . . . . . . .
5
11
11
24
25
30
32
34
. . . . . . .
39
. . . . .
45
. . . . . .
46
47
. . . . . . . .
47
64
65
67
68

Advertisement

Table of Contents
loading

Related Manuals for CAC / BDP PG92SAS

Summary of Contents for CAC / BDP PG92SAS

  • Page 1: Table Of Contents

    PG92SAS Single---Stage 4---Way Multipoise Condensing Gas Furnace Series A Installation, Start---up, Operating and Service and Maintenance Instructions NOTE: Read the entire instruction manual before starting the Adjustments ........
  • 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 CAUTION WARNING CUT HAZARD Failure to follow this caution may result in personal injury. FIRE, EXPLOSION, ELECTRICAL SHOCK, AND CARBON MONOXIDE POISONING HAZARD Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing, safety glasses and Failure to follow this warning could result in dangerous gloves when handling parts, and servicing furnaces.

  • Page 4: Codes And Standards

    13. These furnaces SHALL NOT be installed directly on carpet- S CANADA: National Standard of Canada, Natural Gas and ing, combustible tile, or any other combustible material oth- Propane Installation Code (NSCNGPIC) CAN/CSA er than wood flooring. In downflow installations, factory B149.1- -2010 accessory floor base MUST be used when installed on com- General Installation...

  • Page 5: Minimum Clearances To Combustible Materials

    1. Disconnect all power to the furnace. Multiple disconnects surface of the furnace again before touching control or may be required. DO NOT TOUCH THE CONTROL wires. OR ANY WIRE CONNECTED TO THE CONTROL 5. Use this procedure for installed and uninstalled (ungroun- PRIOR DISCHARGING YOUR...
  • Page 6 A12267 PG92SAS SHIP WT. LB (KG) FURNACE SIZE CABINET WIDTH OUTLET WIDTH BOTTOM INLET WIDTH AIR INTAKE 30040 14--- 3/16 (361) 12--- 1/2 (319) 12--- 9/16 (322) 7--- 1/8 (181) 123.0 (55.4) 42060 144.0 (64.8) 17--- 1/2 (445) 15--- 7/8 (403)
  • 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.

  • 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 The opening shall commence within 12 in. (300 mm) of the The following requirements apply to the Standard Method and to ceiling. Appliances in the space shall have clearances of at least 1 the Known Air Infiltration Rate Method. in. (25 mm) from the sides and back and 6 in. (150 mm) from the 1.

  • 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) (1 SQ. IN./4,000 BTUH) (1,100 SQ.
  • Page 12 * Minimum opening size is 100 sq in. (64516 sq. mm) with *Minimum dimensions of 3‐in. (76mm) minimum dimensions of 3‐in. (76mm) NOTE: Use any of the following combinations of openings: { Minimum of 3‐in. (76mm) when type‐B1 vent is used. A &...

  • Page 13: 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 14 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 15 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 16 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 17: Condensate Drain

    CONDENSATE DRAIN CONNECTION 4. From inside the casing, insert the formed grommet end of the elbow through the 7/8- -in. knockout in the casing. CAUTION 5. Pull the grommet through the casing from the outside until it is seated in the knockout 6.
  • Page 18 the other side of the casing should be facing the front of the 7. The remaining drain line can be constructed from field- - furnace. supplied 1/2- -in. CPVC or 3/4- -in. PVC pipe, in compliance with local building codes. A factory- -supplied 1/2- -in. 11.
  • Page 19 INSTALL CLAMPS ON DRAIN TUBE ATTACH DRAIN TUBE TO CONDENSATE DRAIN TRAP PULL DRAIN STUB THROUGH CASING NOTE: Trap grommet is required only for direct-vent applications. Remove knockout. Install grommet before relocating condensate OPEN SPRING CLAMP trap. INSERT FACTORY SUPPLIED 1/2 IN. CPVC TO 3/4 IN.
  • Page 20 INSTALLATION Leveling Legs (If Desired) In upflow position with side return inlet(s), leveling legs may be NOTICE used. See Fig. 22. Install field- -supplied, 5/16 x 1- -1/2 in. (8 x 38 mm) (max) corrosion- -resistant machine bolts, washers and nuts. NOTE: Bottom closure must be used when leveling legs are used.

  • Page 21: Filter Arrangement

    Return Air Connections Suspended Furnace Support The furnace must be supported under the entire length of the WARNING furnace with threaded rod and angle iron. See Fig. 29. Secure angle iron to bottom of furnace as shown. Roll- - Out Protection FIRE HAZARD Provide a minimum 12- -in.
  • Page 22 There are no provisions for an internal filter rack in these furnaces. An external filter is required and is purchased separately. A field supplied accessory air cleaner may also be used in place of the filter rack. For upflow applications, the filter can be installed on either side of the furnace, the bottom of the furnace or any combination of side and bottom of the furnace.
  • 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. 20 - - Installation on Combustible Flooring Table 8 –...
  • Page 26 UPFLOW DOWNFLOW HORIZONTAL PERFORATED DISCHARGE DUCT 90° 90° FLANGE 120° 120° 120° A10493 Fig. 21 - - Duct Flanges ″ 5/ 16 (8mm) (8mm) ″ 5/ 16 ″ (44mm) ″ (44mm) (8mm) ″ BOTTOM CLOSURE PANEL (8mm) 5/ 16 ″ (44mm) 3/ 4 ″...
  • Page 27 ANY COMBINATION OF 1, 2, OR 3 PERMITTED. A11036 A11037 Fig. 25 - - Upflow Return Air Configurations and Restrictions Fig. 26 - - Downflow Return Air Configurations and Restrictions HORIZONTAL TOP RETURN NOT PERMITTED FOR ANY MODEL A11038 Fig. 27 - - Horizontal Return Air Configurations and Restrictions...
  • 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” (305 x 559 mm) sheet metal in front of burner compartment area. A11154 Fig. 28 - - Working Platform for Attic Installation NOTE: Local codes may require a drain pan and condensate trap when a condensing furnace is installed over a finished ceiling.

  • 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 – Air Delivery - - CFM (With Filter) EXTERNAL STATIC PRESSURE (IN.W.C.) UNIT RETURN-AIR SPEED SIZE CONNECTION TAPS Black 1100 1055 1010 Yellow 030040 SIDE/BOTTOM Blue Black 1665 1615 1550 1485 1420 1345 1270 1190 1105 Yellow 1340 1320 1295 1260...

  • Page 31: 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 32: Electrical Connections

    Table 10 – Maximum Capacity of Pipe Field- -supplied wiring shall conform with the limitations of 63_F (33_C) rise. 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 AND FIRE HAZARD 3/4 (19) 1 ( 25) Failure to follow this warning could result in personal...

  • Page 33: J- -Box Installation

    J- -Box Installation 3. Secure power cord to J- -Box bracket with a strain relief bushing or a connector approved for the type of cord used. WARNING 4. Pull furnace power wires through 1/2- -in. (12 mm) diameter hole in J- -Box. If necessary, loosen power wires from strain—relief wire- -tie on furnace wiring harness.

  • Page 34: Electrical Data

    alternate power supply must generate the same voltage, phase, and Contact the alternate power supply manufacturer for specifications frequency (Hz) as shown in Table 11 or the furnace rating plate. and details. Power from an alternate power supply that is non-sinusoidal may damage the furnace electronics or cause erratic operation.
  • Page 35 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. 34 - - Field- -supplied Isolation Relay for Humidifiers with Internal Power Supply FIELD 24-V WIRING FIELD 115-, 208/230-, 460-V WIRING FACTORY 24-V WIRING FACTORY 115-V WIRING...
  • Page 36 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 37: Special Venting Requirements For Installations In Canada

    VENTING NOTE: Planning for the venting system should be done in conjunction with planning for the ductwork, drainage, and furnace accessories, such as air cleaners and humidifiers. Begin assembling the venting system AFTER the furnace is set in place in the required orientation. Venting for this furnace shall follow all Local codes for Category IV venting systems.

  • Page 38: Venting Systems

    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 39: Locating The Vent Termination

    Table 12 – Vent Termination Kit for Direct Vent (2- -pipe) NOTICE Systems DIAMETER OF DIRECT VENT TERMINATION COMBUSTION AIR (2--- PIPE) OPTIONAL VENTING BELOW THE FURNACE SYSTEM AND VENT PIPES --- TERMINATION KIT IN. (mm) The venting system may be positioned below the furnace 2 ---in.
  • Page 40 required by National Code authorities. Allowable vent NOTICE terminations are shown in Fig. 48. A combustion air inlet pipe to the outdoors is not required for a Non- -Direct (single- -pipe) Vent System. A 12- -in. long section of RECOMMENDED SUPPORT FOR VENT TERMINATIONS pipe with a tight radius 2- -in.

  • Page 41: Combustion Air And Vent Piping Insulation Guidelines

    Optional Combustion Air Inlet Moisture Trap 2. Count the number of elbows for each pipe. 3. For each pipe, multiply the number of elbows by the equi- As an option to prevent moisture from trickling into the furnace valent length for the type of elbow used. Record the equi- vestibule, a trap can be installed in the intake air pipe near the valent length of all the elbows for each pipe.
  • Page 42 NOTE: Pipe length (ft. / M) specified for maximum pipe lengths WARNING located in unconditioned spaces cannot exceed total allowable pipe length as calculated from Table 15 or 17. CARBON MONOXIDE POISONING HAZARD Configure the Furnace Failure to follow this warning could result in personal injury WARNING or death.
  • Page 43 11. Seal around the combustion air pipe with silicone or foil 6. Tighten the clamp around the outlet of the vent elbow. tape. SILICONE SEALERS MAY NOT BE APPRO- Torque the clamp to 15 lb- -in. PRIATE FOR POLYPROPYLENE VENT SYSTEMS. 7.
  • Page 44 4. Disassemble loose pipe fittings. Clean and cement using NOTICE same procedures as used for system piping. DO NOT CE- MENT POLYPROPYLENE FITTINGS. (Direct Vent / 2-Pipe System ONLY) RECOMMENDED SUPPORT FOR VENT TERMINATIONS When two or more furnaces are vented near each other, two vent It is recommended that rooftop vent terminations in excess of terminations may be installed as shown in Fig.
  • Page 45 Table 13 – Approved Combustion-Air and Vent Pipe, Fitting and Cement Materials (U.S.A. Installations) ASTM SPECIFICATION SOLVENT CEMENT MATERIAL PIPE FITTINGS DESCRIPTION (MARKED ON MATERIAL) AND PRIMERS D1527 Pipe — — Schedule--- 40 D1785 Pipe — — Schedule--- 40 D2235 For ABS —...
  • Page 46 Table 14 – Maximum Allowable Exposed Vent Lengths Insulation Table - - Ft. / M Maximum Length of Uninsulated and Insulated Vent Pipe-Ft (M) No Insulation 3/8-in. (9.5 mm) Insulation 1/2-in. (12.7 mm) Insulation Single Stage Pipe Pipe Diameter-inches (mm) Pipe Diameter-inches (mm) Pipe Diameter-inches (mm) Winter Design...
  • Page 47 Table 15 – Maximum Equivalent Vent Length - - Ft. (M) 0 to 4500 Ft. (0 to 1370 M) Altitude NOTE: Maximum Equivalent Vent Length (MEVL) includes standard and concentric vent termination and does NOT include elbows. Use Table 16 - Deductions from Maximum Equivalent Vent Length to determine allowable vent length for each application. Unit Size DIRECT VENT (2-PIPE) AND NON-DIRECT VENT (1-PIPE) BTU/Hr...
  • Page 48 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 16. 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 49 Table 17 – Maximum Equivalent Vent Length - - Ft. (M) 4501 to 10,000 Ft. (0 to 1370 M) Altitude NOTE: Maximum Equivalent Vent Length (MEVL) includes standard and concentric vent termination and does NOT include elbows. Use Table 16 - Deductions from Maximum Equivalent Vent Length to determine allowable vent length for each application. DIRECT VENT (2-PIPE) AND SINGLE-PIPE Altitude Vent Pipe Diameter (in.)
  • Page 50 Attach gaskets to vent pipe and Vent Coupling and Adapter combustion air adapters. A11314 Fig. 37 - - Vent Coupling and Adapter with Gaskets INDUCER OUTLET VENT ELBOW CLAMP TORQUE 15 LB-IN. VENT PIPE CLAMP TORQUE 15 LB-IN. PSC INDUCER ASSEMBLY VENT ELBOW INDUCER OUTLET CHOKE 40,000 BTUH MODELS ONLY...
  • Page 51 Any other unused knockout may be used for combustion air connection. Any other unused knockout may be used Rotate vent elbow to for combustion air required position. connection. Rotate vent elbow to & A11309 required position. A11308 Any other unused knockout may be used for combustion air connection.
  • Page 52 Rotate vent elbow to required position. Rotate vent elbow to required position. Any other unused knockout may be used for combustion air connection. A11311 A11312 A11313 Downflow Vertical Requires Accessory Internal Vent Kit. See Product Data for current kit number. Attach vent pipe adapter with gasket to furnace casing.
  • Page 53 HORIZONTAL LEFT - HORIZONTAL LEFT - VERTICAL VENT CONFIGURATION LEFT VENT CONFIGURATION HORIZONTAL LEFT - RIGHT VENT CONFIGURATION* *Requires Accessory Internal Vent Kit See Product Data for Current Kit Number Attach vent pipe adapter with gasket to furnace casing. Align notches in rubber coupling over standoffs on adapter. Slide clamps over the coupling. Slide vent pipe through adapter and coupling into vent elbow.
  • Page 54 HORIZONTAL RIGHT - HORIZONTAL RIGHT - VERTICAL VENT CONFIGURATION LEFT VENT CONFIGURATION* *Requires Internal Vent Kit See Product Data for Current Kit Number HORIZONTAL RIGHT - RIGHT VENT CONFIGURATION Attach vent pipe adapter with gasket to furnace casing. Align notches in rubber coupling over standoffs on adapter. Slide clamps over the coupling. Slide vent pipe through adapter and coupling into vent elbow.
  • Page 55 ALIGN NOTCHES IN VENT PIPE COUPLING OVER STAND-OFF ON ADAPTER. TORQUE LOWER CLAMP 15 LB-IN. WHEN REMAINING VENT PIPE ADAPTER WITH GASKET VENT PIPE IS INSTALLED, TORQUE INSTALLED ON FURNACE VENT UPPER CLAMP TO 15 LB-IN. PIPE IS CUT FLUSH WITH TOP OF ADAPTER.
  • Page 56 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 57 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 58 Roof Termination (Preferred) Note: 36 in. separation between pairs of inlets only required for direct vent systems Note: Vertical separation between At least 36 in. “A” denotes 0 To 2 in. (51mm) combustion air and vent (914mm) Between the first 2 vents Third 8 ¾...
  • Page 59 OPTIONAL TERMINATION BRACKET FOR 2-PIPE TERMINATIONS OPTIONAL BRACKET 12-IN. COUPLING (305 MM) 12 IN. (305 MM) SEPARATION BETWEEN BOTTOM OF COMBUSTION AIR AND BOTTOM OF VENT. MAINTAIN 12 IN. (305 MM) CLEARANCE ABOVE HIGHEST ANTICIPATED 12-IN. (305 MM) SNOW LEVEL OR GRADE, ABOVE ANTICIPATED WHICHEVER IS GREATER.
  • Page 60 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. 50 - - Vent Terminations for Ventilated Combustion Air...
  • Page 61 EXAMPLE FOR UPFLOW INSTALLATIONS. MAY BE APPLIED TO OTHER CONFIGURATIONS. A12220 Fig. 51 - - Sample Inlet Air Pipe Connection for Polypropylene Venting Systems TO CODE APPROVED DRAIN OR CONDENSATE PUMP Representative drawing only, some models may vary in appearance L12F028 Fig.

  • Page 62: Start- -Up, Adjustment, And Safety Check

    START- -UP, ADJUSTMENT, AND SAFETY 1. Remove upper and middle collector box drain plugs oppos- ite of the condensate trap. See Fig. 59. CHECK 2. Connect field-supplied 5/8- -in. (16 mm) ID tube with at- General tached funnel to upper collector box drain connection. See Fig.
  • Page 63 (Furnace is shipped with No. 44 orifices. In this example, all main NOTICE burner orifices are the correct size and do not need to be changed to obtain proper input rate.) Manifold pressure: 3.4- -in. w.c. (847 Pa). The NATURAL GAS manifold pressure adjustments in Table 21 compensate for BOTH altitude AND gas heating value.
  • Page 64 (Read following caution before changing taps). WARNING CAUTION FIRE HAZARD UNIT DAMAGE HAZARD Failure to follow this warning could result in personal injury, death, and/or property damage. To avoid operating outside the rise range and avoid Reinstall manifold pressure tap plug in gas valve to prevent component damage: gas leak.

  • Page 65: Altitude Derate Multiplier For U.s.a

    Check Safety Controls Table 19 – Altitude Derate Multiplier for U.S.A. PERCENT DERATE ALTITUDE The flame sensor, gas valve, and pressure switch were all checked MULTIPLIER in the Start- -up procedure section as part of normal operation. DERATE FACTOR* 1. Check Main Limit Switch 0–2000 0--- 610 1.00...
  • Page 66 338309-201 Rev. E A11602 Fig. 56 - - Service Label Information...

  • Page 67: Gas Rate

    Table 20 – Gas Rate (CU ft./hr) SIZE OF TEST DIAL SIZE OF TEST DIAL SECONDS SECONDS FOR 1 REVOLUTION FOR 1 REVOLUTION 1 Cu Ft. 2 Cu Ft. 5 Cu Ft. 1 Cu Ft. 2 Cu Ft. 5 Cu Ft. 1800 1636 1500...
  • Page 68 Table 21 – Orifice Size and Manifold Pressure (in. w.c.) for Gas Input Rate SINGLE-STAGE FURNACE (TABULATED DATA BASED ON 20,000 BTUH PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE RANGE HEAT VALUE 0.58 0.60 0.62 0.64 AT ALTITUDE Orifice Manifold Orifice...

  • Page 69: Orifice Size And Manifold Pressure

    Table 21 - - Orifice Size and Manifold Pressure (in. w.c.) for Gas Input Rate (Cont.) SINGLE-STAGE FURNACE (TABULATED DATA BASED ON 20,000 BTUH PER BURNER, DERATED 2%/1000 FT (305M) ABOVE SEA LEVEL) ALTITUDE RANGE HEAT VALUE 0.58 0.60 0.62 0.64 AT ALTITUDE Orifice...

  • Page 70: Service And Maintenance Procedures

    SERVICE AND MAINTENANCE Electrical Controls and Wiring PROCEDURES WARNING WARNING ELECTRICAL SHOCK HAZARD FIRE, INJURY OR DEATH HAZARD Failure to follow this warning could result in personal injury or death. Failure to follow this warning could result in personal There may be more than one electrical supply to the furnace. injury, death and/or property damage.
  • Page 71 Component Self-Test 6. Cycle test furnace with room thermostat to be sure that it operates properly with the room thermostat. Check all NOTE: The furnace control component test allows all modes including Heat, Cool and Fan. components to run for a short time; except the gas valve and 7.
  • Page 72 2. Check blower motor and wheel for cleanliness each heating The inducer and blower motors are pre- -lubricated and require no and cooling season. Clean as necessary. additional lubrication. These motors can be identified by the absence of oil ports on each end of the motor. 3.
  • Page 73 13. Reinstall blower assembly in furnace. 1. Disconnect power at external disconnect, fuse or circuit breaker. 14. Reinstall 2 screws securing blower assembly to blower deck. 2. Turn off gas at external shut-off or gas meter. 15. Reconnect blower leads to furnace control. Refer to furnace 3.
  • Page 74 1. Turn off gas and electrical supplies to furnace. WARNING 2. Remove control door. 3. Disconnect pressure switch tube from pressure switch port. NOTE: Ensure the pressure switch tube disconnected from the FIRE OR EXPLOSION HAZARD pressure switch is higher than the collector box opening or water Failure to follow this warning could result in personal will flow out of tube.

  • Page 75: Cleaning Heat Exchangers

    9. Turn gas on at electric switch on gas valve and at external 2. Remove control door. shut-off or meter 3. Disconnect wires or connectors to flame rollout switch, gas 10. Turn power on at external disconnect, fuse or circuit break- valve, igniter, and flame sensor.
  • Page 76 reach 32_F (0_C) or lower unless winterized. Follow these procedures to winterize your furnace: CAUTION 2 − in. (50 mm) UNIT COMPONENT DAMAGE HAZARD Failure to follow this caution may result in damage to the furnace and other property damage. 3/8 −...
  • Page 77 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 78 IGNITER BURNER SUPT. ASSY BRACKET, IGNITER BURNER ASSY FLAME ROLLOUT SWITCH FLAME SENSOR (BELOW BURNER) A11403 Fig. 63 - - Burner Assembly...

  • Page 79: Sequence Of Operation

    SEQUENCE OF OPERATION Simultaneously, the electronic air cleaner terminal EAC- -1 is energized and remains energized as long as the blower NOTE: Furnace control must be grounded for proper operation or motor BLWM is energized. control will lock out. Control is grounded through green/yellow f.
  • Page 80 A11622 Fig. 64 - - Troubleshooting Guide...
  • Page 81 A12421 Troubleshooting Guide (Cont)
  • Page 82 A12420 Fig. 65 - - Wiring Diagram...
  • Page 83 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...
  • Page 84 Catalog No: IM---PG92SAS---03 Copyright 2012 CAC / BDP D 7310 W. Morris St. D Indianapolis, IN 46231 Edition Date: 08/12 Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. Replaces: IM--- PG92SAS--- 02...

Table of Contents