Payne PG80ESAA Installation, Start-Up, Operating And Service And Maintenance Instructions
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Payne PG80ESAA Installation, Start-Up, Operating And Service And Maintenance Instructions

Single--stage, 4--way multipoise 33--1/3 in. non--condensing gas furnace input capacities 45,000 thru 155,000 btuh
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Installation, Start- -up, Operating and
Service and Maintenance Instructions
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PG80ESAA/PG80ESLA
SINGLE- -STAGE, 4- -WAY MULTIPOISE
33- - 1/3 IN. NON- -CONDENSING GAS FURNACE
INPUT CAPACITIES 45,000 THRU 155,000 BTUH
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2
4
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5
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5
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NOTE: Read the entire instruction manual before starting the
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installation.
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Portions of the text and tables are reprinted from current edition
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of NFPA 54/ANSI Z223.1E, with permission of National Fire
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Protection Association, Quincy, MA 02269 and American Gas
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Association, Washington DC 20001. This reprinted material is
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not the complete and official position of the NFPA or ANSI on
the referenced subject, which is represented only by the standard
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in its entirety.
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SAFETY CONSIDERATIONS
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23
!
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FIRE, EXPLOSION, ELECTRICAL SHOCK, AND
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CARBON MONOXIDE POISONING HAZARD
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Failure to follow this warning could result in dangerous
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operation, serious injury, death, or property damage.
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Improper installation, adjustment, alteration, service,
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maintenance, or use could cause carbon monoxide
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poisoning, explosion, fire, electrical shock, or other
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conditions which may cause personal injury or property
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damage. Consult a qualified service agency, local gas
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supplier, or your distributor or branch for information or
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assistance. The qualified service agency must use only
factory- -authorized and listed kits or accessories when
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modifying this product.
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WARNING
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Summary of Contents for Payne PG80ESAA

  • Page 1: Table Of Contents

    PG80ESAA/PG80ESLA SINGLE- -STAGE, 4- -WAY MULTIPOISE 33- - 1/3 IN. NON- -CONDENSING GAS FURNACE INPUT CAPACITIES 45,000 THRU 155,000 BTUH Installation, Start- -up, Operating and Service and Maintenance Instructions SAFETY CONSIDERATIONS ..... . .

  • Page 2: Safety Considerations

    6. Always install furnace to operate within the furnace’s in- CAUTION tended temperature- -rise range with a duct system which has an external static pressure within the allowable range, as specified in the “Start- -Up, Adjustments, and Safety FURNACE RELIABILITY HAZARD Check”...
  • Page 3 A190084 NOTES: 1. Two additional 7/8 ---in. (22 mm) diameter holes are located in the top plate. 2. Minimum return ---air openings at furnace, based on metal duct. If flex duct is used, see flex duct manufacturer’s recommendations for equivalent diameters. a.

  • Page 4: Codes And Standards

    A10269 Fig. 2 - - Clearances to Combustibles having jurisdiction. In the United States, follow all codes and standards for the following: Safety USA: Current edition of National Fuel Gas Code (NFGC) NFPA 54/ANSI Z223.1 and the Installation Standards, Warm Air Heating and Air Conditioning Systems ANSI/NFPA 90B General Installation Current edition of the NFGC and the NFPA 90B.

  • Page 5: Acoustical Lining And Fibrous Glass Duct

    Acoustical Lining and Fibrous Glass Duct 1. Disconnect all power to the furnace. Multiple disconnects maybe required. DO NOT TOUCH THE CONTROL OR Current edition of SMACNA and NFPA 90B as tested ANY WIRE CONNECTED TO THE CONTROL PRIOR by UL Standard 181 for Class I Rigid Air Ducts DISCHARGING YOUR BODY’S...
  • Page 6 WARNING WARNING CARBON MONOXIDE POISONING HAZARD FIRE HAZARD Failure to follow this warning could result in personal Failure to follow this warning could result in personal injury or death, and unit component damage. injury, death, and/or property damage. Corrosive or contaminated air may cause failure of parts When the furnace is installed in a residential garage, the containing flue gas, which could leak into the living space.

  • Page 7: Air For Combustion And Ventilation

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

  • Page 8: Outdoor Combustion Air Method

    g. TWO HORIZONTAL DUCTS require 1 square inch of U.S. installations: Section 9.3 of the current edition of free area per 2,000 Btuh (1,100 mm /kW) of combined NFGC NFPA54/ANSI Z223.1, Air for Combustion input for all gas appliances in the space per Fig. 7 and and Ventilation, and applicable provisions of the local Table 2.

  • Page 9: Installation

    2. The air infiltration rate is not known to be less than 0.40 a. Walls and ceilings exposed to the outdoors have a con- air changes per hour (ACH). tinuous, sealed vapor barrier. Openings are gasketed or sealed and The Known Air Infiltration Rate Method shall be used, if the infiltration rate is known to be: b.

  • Page 10: Downflow Installation

    38 mm) (max) corrosion- -resistant machine bolts, washers and Bottom Return Air Inlet nuts. These furnaces are shipped with bottom closure panel installed in NOTE: Bottom closure must be used when leveling legs are bottom return- -air opening. Remove and discard this panel when used.
  • Page 11 FURNACE APPROVED COIL ASSEMBLY COIL BOX COMBUSTIBLE FLOORING SHEET METAL PLENUM FLOOR OPENING A08556 Fig. 13 - - Furnace, Plenum, and Coil Assembly or Coil Box Installed on a Combustible Floor Table 4 – Opening Dimensions - - In. (mm) FURNACE PLENUM OPENING FLOOR OPENING...

  • Page 12: Horizontal Installation

    HORIZONTAL INSTALLATION Not all horizontal furnaces are approved for side return air connections. (See Fig. 21.) WARNING FILTER ARRANGEMENT WARNING FIRE, EXPLOSION, AND CARBON MONOXIDE POISONING HAZARD CARBON MONOXIDE AND POISONING Failure to follow this warning could result in personal HAZARD injury, death, and/or property damage.
  • Page 13 Upflow and Horizontal Furnaces Downflow Furnaces Connect supply- -air duct to flanges on furnace supply- -air outlet. Connect supply- -air duct to supply- -air outlet on furnace. Bend Bend flange upward to 90_ with wide duct pliers. (See Fig. 14.) flange inward past 90_ with wide duct pliers.
  • Page 14 METHOD 2 USE (4) #8 x 3/4 (19 mm) SHEET METAL SCREWS FOR EACH STRAP. THE STRAPS SHOULD BE VERTICAL AGAINST THE FURNACE SIDES AND NOT PULL AWAY FROM THE FURNACE SIDES. METHOD 1 FOLD ALL STRAPS UNDER FURNACE AND SECURE WTH (4) #8 x 3/4 (19 mm) SHEET METAL SCREWS (2 SCREWS IN SIDE AND 2 SCREWS IN BOTTOM).

  • Page 15: Gas Piping

    Return Air Connections WARNING WARNING FIRE OR EXPLOSION HAZARD FIRE HAZARD Failure to follow this warning could result in personal injury, death, and/or property damage. Failure to follow this warning could cause personal injury, death and/or property damage. If local codes allow the use of a flexible gas appliance connector, always use a new listed connector.
  • Page 16 Table 5 – Air Delivery - - CFM (With Filter)* Wire Test Airflow Delivery @ Various External Static Pressures Furnace Lead Function Color Gray Cooling. Do not use for heating. 1230 1190 1155 1120 1080 1045 1010 Yellow Alt Cooling or alt Heating Orange Alt Cooling or alt Heating 36045A...
  • Page 17 Table 6 – Maximum Capacity of Pipe* NOMINAL IRON INTERNAL LENGTH OF PIPE --- FT. (M) PIPE DIAMETER SIZE IN. (mm) In. (mm) 1/2 (13) 0.622 (16) 175 (53) 120 (37) 97 (30) 82 (25) 73 (22) 3/4 (19) 0.824 (21) 360 (110) 250 (76) 200 (61)
  • Page 18 A02163 Fig. 20 - - Downflow Return Air Configurations and Restrictions A02162 Fig. 21 - - Horizontal Return Air Configurations and Restrictions 2” (51mm) Street Elbow A08551 Fig. 22 - - Burner and Manifold...

  • Page 19: Electrical Connections

    Table 7 – Electrical Data Maximum Operating Voltage* Maximum Wire Volts- Fuse Unit Minimum Wire Range Length Hertz- Unit Size Ampacity# Size AWG or CKT Phase Maximum Minimum feet BKR Amps 36045A 115--- 60--- 1 14.3 36045B 115--- 60--- 1 10.3 36070A 115--- 60--- 1...

  • Page 20: 24- -V Wiring

    NOTE: The J- -Box cover need not be removed from the J- -Box BX CABLE INSTALLATION IN FURNACE J- -BOX in order to move the J- -Box. Do NOT remove green ground 1. Remove cover from J- -Box. 2. Route BX cable into 7/8- -inch diameter hole in J- -Box. screw inside J- -Box.
  • Page 21 A190023 Fig. 24 - - Furnace Control FIELD 24-V WIRING FIELD 115-, 208/230-, 460-V WIRING FACTORY 24-V WIRING FACTORY 115-V WIRING NOTE 2 THERMOSTAT FIVE WIRE FIELD-SUPPLIED TERMINALS DISCONNECT THREE-WIRE HEATING-ONLY 208/230- OR BLOWER DOOR SWITCH 460-V THREE PHASE 208/230-V SINGLE PHASE AUXILIARY...
  • Page 22 A1900851 Fig. 26 - - Thermostat Wiring Diagrams 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.

  • Page 23: Venting

    VENTING GENERAL VENTING REQUIREMENTS The furnace shall be connected to a listed factory built chimney Follow all safety codes for proper vent sizing and installation or vent, or a clay- -tile lined masonry or concrete chimney. Venting requirements, including local building codes, the current edition into an unlined masonry chimney or concrete chimney is of National Fuel Gas Code ANSI Z223.1/NFPA 54 (NFGC), prohibited.

  • Page 24: Appliance Application Requirements

    This furnace is permitted to be vented into a clay tile- -lined Table 9 – Minimum Allowable Input Rating of Space- -Heat- masonry chimney that is exposed to the outdoors below the roof ing Appliance in Thousands of BTUH per Hour line, provided: INTERNAL AREA OF CHIMNEY 1.
  • Page 25 CHIMNEY INSPECTION CHART For additional requirements refer to the National Fuel Gas Code NFPA 54/ANSI Z223.1 and ANSI/NFPA 211 Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances Crown Rebuild condition: crown. Missing mortar or brick? Is chimney property lined with clay tile liner? Repair Reline...

  • Page 26: Additional Venting Requirements

    To prevent condensation in the furnace and vent system, the NOTE: An accessory flue extension is available to extend from following precautions must be observed: the furnace elbow to outside the furnace casing. See Product Data Sheet for accessory listing. If flue extension is used, fasten the 1.
  • Page 27 Caution!! For the following applications, use the minimum vertical vent heights as specified below. For all other applications, follow exclusively the National Fuel Gas Code. MIN. VENT MIN. VERTICAL VENT FURNACE VENT ORIENTATION FURNACE INPUT DIAMETER HEIGHT ORIENTATION (BTUH/HR) IN. (mm)* FT.
  • Page 28 SEE NOTES:1,2,3,4,5,7,8,9 on the page following these figures SEE NOTES: 1,2,4,5,6,7,8,9 on the page following these figures A03210 A03207 Fig. 30 - - Downflow Application- -Vent Elbow Up then Left Fig. 32 - - Downflow Application- -Vent Elbow Left then Up SEE NOTES: 1,2,4,5,7,8,9 on the page following SEE NOTES:1,2,3,4,5,7,8,9...
  • Page 29 SEE NOTES: 1,2,4,7,8,9 on the page following these figures SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures A03213 Fig. 34 - - Horizontal Left Application- -Vent Elbow Left A03219 Fig. 38 - - Horizontal Right Application- -Vent Elbow Left then Up SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures...

  • Page 30: Start- -Up, Adjustment, And Safety Check

    VENTING NOTES FOR FIGURES 28 - - 40 1. For common vent, vent connector sizing and vent material: United States- -- -use the NFGC. 2. Immediately increase to 5- -inch (127 mm) or 6- -inch (152 mm) vent connector outside furnace casing when 5- -inch (127 mm) vent connector is required, refer to Note 1 above.

  • Page 31: Adjustments

    g. Reconnect R lead to furnace control board, release blower g. Replace orifice with correct size if required by Table 10, door switch and re- -install blower door. 11, 12 and 13. Use only factory- -supplied orifices. See EXAMPLE 1. 4.
  • Page 32 e. Multiply gas rate (cu ft./hr) by heating value (Btuh/cu ft.) j. Reinstall manifold pressure tap plug in gas valve. to obtain input. If clocked rate does not match required input from Step 1, increase manifold pressure to increase input or decrease manifold pressure to decrease input.

  • Page 33: Check Safety Controls

    6. Set thermostat heat anticipator. h. Re- -install vent connector. a. Mechanical thermostat - - Set thermostat heat anticipator NOTE: Should switch remain open longer than 3 minutes, to match the amp. draw of the electrical components in furnace control board will lockout the furnace for 3 hours. To the R- -W circuit.
  • Page 34 Table 11 – Gas Rate (Cu Ft./Hr.) SIZE OF TEST DIAL SIZE OF TEST DIAL SECONDS SECONDS FOR 1 REVOLUTION FOR 1 REVOLUTION 2 Cu Ft. 5 Cu Ft. 1 Cu Ft. 2 Cu Ft. 5 Cu Ft. Cu Ft. 1800 1636 1500...
  • Page 35 Table 12 – Orifice Size* and Manifold Pressure (In. W.C.) for Gas Input Rate A10180...
  • Page 36 Table 12 - - Orifice Size* and Manifold Pressure (In. W.C.) for Gas Input Rate (CONT) A10180A...
  • Page 37 Table 13 – Orifice Size* And Manifold Pressure (In. W.C.) For Gas Input Rate A10181...

  • Page 38: Service And Maintenance Procedures

    Table 13- - Orifice Size* And Manifold Pressure (In. W.C.) For Gas Input Rate (CONT) A10181A SERVICE AND MAINTENANCE CAUTION PROCEDURES Untrained personnel can perform basic maintenance functions ELECTRICAL OPERATION HAZARD such as cleaning and replacing air filters. All other operations Failure to follow this caution may result in improper must be performed by trained service personnel.

  • Page 39: Care And Maintenance

    The electrical ground and polarity for 115- -v wiring must be See Fig. 49 for a brief Troubleshooting Guide. properly maintained. Refer to Fig. 25 for field wiring information For Controls With an Amber LED and to Fig. 48 for furnace wiring information. The stored status code will not be erased from the control NOTE: If the polarity is not correct, the STATUS LED on the memory, if 115- - or 24- -v power is interrupted.

  • Page 40: Cleaning And/Or Replacing Air Filter

    3. Slide filter out of cabinet. WARNING 4. If equipped with permanent, washable 3/4- -in. (19 mm) fil- ter, clean filter by spraying cold tap water through filter in CARBON MONOXIDE POISONING AND opposite direction of airflow. Rinse filter and let dry. Oil- FIRE HAZARD ing or coating of the filter is not recommended.

  • Page 41: Cleaning Heat Exchanger

    b. Remove screws securing cutoff plate and remove cutoff connect any disconnected thermostat leads. Replace blow- plate from housing. er access door. c. Loosen set screw holding blower wheel on motor shaft 18. Downflow or horizontal furnaces with vent pipe through (160+/- -20 in.- -lb.
  • Page 42 b. Insert the twisted wire end of brush into end of spring ca- 11. Spray releasing agent on the heat exchanger cell panel ble, and crimp tight with crimping tool or crimp by strik- where collector box assembly contacts cell panel. ing with ball- -peen hammer.

  • Page 43: Sequence Of Operation

    SEQUENCE OF OPERATION inducer motor IDM will remain energized for a 5- -sec- ond post- -purge period. Then turn off the inducer mo- NOTE: Furnace control must be grounded for proper operation tor and HUM (115- -v) humidifier terminal. The blower or control will lock out.

  • Page 44: Wiring Diagrams

    Wiring Diagrams operation problems. Beginning with the word “Start,” answer each question and follow the appropriate arrow to the next item. Refer to Fig. 48 for wiring diagram. The Guide will help to identify the problem or failed component. Troubleshooting After replacing any component, verify correct operation Refer to the service label.
  • Page 45 A190024...
  • Page 46 A05032 Fig. 49 - - Troubleshooting Guide...

  • Page 47: Parts Replacement Information Guide

    TO OBTAIN INFORMATION ON PARTS: Consult your installing dealer or classified section of your local telephone directory under “Heating Equipment” or “Air Conditioning Contractors and Systems” headings for dealer listing by brand name or contact: PAYNE HEATING & COOLING Consumer Relations Department P.O.
  • Page 48 Catalog No: IM- - PG80ESAA- - 03 Copyright 2019 Payne Heating & Cooling S 7310 W. Morris St. S Indianapolis, IN 46206 Edition Date: 06/19 Replaces: IM- -PG80ESAA- -02 Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

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