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PG95XAT
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Installation, Start---up, Operating and
Service and Maintenance Instructions
NOTE: Read the entire instruction manual before starting the
installation.
INTRODUCTION
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ACCESSORIES
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LOCATION
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General
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Introduction
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Upflow
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Downflow
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Horizontal
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INSTALLATION
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Upflow
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Downflow
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Horizontal
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115- -V Wiring
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24- -V Wiring
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Accessories
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VENTING
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General
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Materials
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Installing the Termination
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General
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Two---Stage 4---Way Multipoise
Condensing Gas Furnace
Adjustments
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PARTS REPLACEMENT GUIDE
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Loose Parts Bag
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Filter Size Information
Opening Dimensions
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Air Delivery CFM
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Combustion- -Air Vent Pipe, Fitting & Cement Material..
Maximum Allowable Exposed Vent Lengths Insulation
Deductions from Maximum Equivalent Vent Length
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Use of the AHRI Certified
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 NFPA 54/ANSI
Z223.1- -2012E, 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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Series B
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TABLES
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Table of Contents
Related Manuals for Carrier PG95XAT
Summary of Contents for Carrier PG95XAT
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Page 1: Table Of Contents
Two---Stage 4---Way Multipoise PG95XAT Condensing Gas Furnace Series B CLICK ANYWHERE on THIS PAGE to RETURN to PAYNE HVAC MANUALS & GUIDES at InspectApedia.com Installation, Start---up, Operating and Service and Maintenance Instructions NOTE: Read the entire instruction manual before starting the Prime Condensate Trap . - 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 Follow all safety codes. Wear safety glasses, protective clothing, and work gloves. Have a fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions WARNING included in literature and attached to the unit. CAUTION FIRE, EXPLOSION, ELECTRICAL SHOCK, AND CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in dangerous CUT HAZARD... -
Page 4: Codes And Standards
12. Maintain a 1- -in. (25 mm) clearance from combustible ma- regulations of the serving gas supplier, local building, heating, terials to supply air ductwork for a distance of 36 in. (914 plumbing, and other codes. In absence of local codes, the mm) horizontally from the furnace. -
Page 5: Electrostatic Discharge (Esd) Precautions
ELECTROSTATIC DISCHARGE (ESD) 6. Before removing a new control from its container, discharge your body’s electrostatic charge to ground to protect the PRECAUTIONS PROCEDURE control from damage. If the control is to be installed in a furnace, follow items 1 through 4 before bringing the con- trol or yourself in contact with the furnace. -
Page 6: Minimum Clearances To Combustible Materials
Table 1 – Factory- -Supplied Installation Parts DESCRIPTION QUANTITY Outlet Choke Plate (provided with 40K BTUH furnaces only; see Note) Air Intake Pipe Flange Vent Pipe Flange Pipe Flange Gaskets Sharp Tip Screws (Vent and Inlet Flanges) Vent Pipe Coupling Vent Pipe Coupling Clamps Pressure Switch Tube Rubber Drain Elbow... - Page 7 A12267 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)
- 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 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 10: 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 11 in. (25 mm) from the sides and back and 6 in. (150 mm) from the of the total input rating of all gas appliances in the space, front. The opening shall directly communicate with the outdoors or but not less than 100 in. (0.06 m ).
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Page 12: 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 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.
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Page 17: Condensate Drain
CONDENSATE DRAIN CONNECTION For Right Side Condensate Drain: 1. Remove the 7/8- -in. knock- -out from the right side of the CAUTION casing. See Fig. 12 For suggested knockout removal tech- nique.) 2. Remove the pre- -formed rubber drain elbow and two spring FROZEN AND BURST WATER PIPE HAZARD clamps from the loose parts bag. - Page 18 7. After inserting the Z pipe through the casing, slide a spring 2. To allow for servicing the trap, the condensate drain elbow clamp over each end of the Z pipe. in the loose parts bag can be used to make a coupler to allow for future service of the condensate trap and drain 8.
- Page 19 INSTALL CLAMPS ON DRAIN TUBE ATTACH DRAIN TUBE TO CONDENSATE DRAIN TRAP PULL DRAIN STUB THROUGH CASING CAUTION OPEN SPRING CLAMP CUT HAZARD INSERT FACTORY SUPPLIED 1/2 IN. CPVC TO 3/4 IN. PVC ADAPTER OR 1/2 IN. CPVC PIPE Failure to follow this caution may result in personal injury. *CLAMP MAY BE LOCATED ON OUTSIDE OF DRAIN TUBE Sheet metal parts may have sharp edges or burrs.
- Page 20 Upflow Installation NOTE: Trap grommet is required only for direct-vent applications. NOTE: The furnace must be pitched as shown in Fig. 23 for proper condensate drainage. Supply Air Connections For a furnace not equipped with a cooling coil, the outlet duct shall be provided with a removable access panel.
- Page 21 2. For each leg, install nut on bolt and then install bolt with Bypass humidifier connections should be made at ductwork or coil nut in hole. (Install flat washer if desired.) casing sides exterior to furnace. See Fig. 25. 3. Install another nut on other side of furnace base. (Install flat Bottom Return Air Inlet washer if desired.) These furnaces are shipped with bottom closure panel installed in...
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Page 22: Filter Arrangement
bottom of furnace is used for return air connection. See Fig. 27 for Due to the relatively high pressure drops of 1- -in. (25 mm) thick proper orientation of roll- -out shield. after- -market filter media, it is recommended that the filtration system be designed for at least 2- -in. - 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 RETURN BOTTOM 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 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. 19 - - Installation on Combustible Flooring Table 8 –...
- Page 27 UPFLOW DOWNFLOW HORIZONTAL PERFORATED DISCHARGE DUCT 90° 90° FLANGE 120° 120° 120° A10493 Fig. 20 - - Duct Flanges 5/ 16 (8mm) (8mm) 5/ 16 (44mm) (44mm) (8mm) BOTTOM CLOSURE PANEL (8mm) 5/ 16 (44mm) 3/ 4 ...
- Page 28 ANY COMBINATION OF 1, 2, OR 3 PERMITTED. A11036 A11037 Fig. 24 - - Upflow Return Air Configurations and Restrictions Fig. 25 - - Downflow Return Air Configurations and Restrictions HORIZONTAL TOP RETURN NOT PERMITTED FOR ANY MODEL A11038 Fig. 26 - - Horizontal Return Air Configurations and Restrictions...
- 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” (305 x 559 mm) sheet metal in front of burner compartment area. A11154 Fig. 27 - - 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.
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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
Table 10 – Maximum Capacity of Pipe WARNING NOMINAL LENGTH OF PIPE --- FT. (M) IRON PIPE SIZE ELECTRICAL SHOCK HAZARD (3.0) (6.0) (9.1) (12.1) (15.2) IN. (MM) 1/2 (13) Failure to follow this warning could result in personal 3/4 (19) injury or death. -
Page 34: J- -Box Installation
9. Complete external disconnect wiring and installation. Con- WARNING nect line voltage leads as shown in Fig. 32. Use best prac- tices (NEC in U.S.A. for wire bushings, strain relief, etc., CANADA: Canadian Electrical Code CSA C22.1) FIRE HAZARD Power Cord Installation in Furnace J- - Box Failure to follow this warning could result in personal injury, death, or property damage. -
Page 35: Alternate Power Supplies
Accessories isolation relay to the HUM and COM/24V screw terminal on the (See Fig. 33 and 35.) control board thermostat strip. See Fig. 33. 1. Electronic Air Cleaner (EAC) Alternate Power Supplies Connect an accessory Electronic Air Cleaner (if used) using 1/4- -in. - Page 36 GROUND NEUTRAL LINE VOLTAGE ELECTRIC DISCONNECT SWITCH COPPER WIRE ONLY ALUMINUM WIRE A11146 A12226 Fig. 32 - - Field- -Supplied Electrical Box on Furnace Casing Fig. 31 - - Installing J- -Box (When Used) To HUM Terminal On To Humidifier Leads Furnace Control Board 24 V Coil...
- Page 37 W/W1 Y/Y2 A11401 Fig. 34 - - Typical Two- -Stage Field Wiring Diagram SET UP SWITCHES LOW HEAT ONLY AND BLOWER OFF-DELAY TWINNING AND/OR COMPONENT TEST TERMINAL ACRDJ - AIR CONDITIONING RELAY DISABLE JUMPER 24-V THERMOSTAT TERMINALS TEST / TWIN HUMIDIFIER TERMINAL (24 VAC 0.5 AMPS MAX) TRANSFORMER...
- 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...
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Page 39: Special Venting Requirements For Installations In Canada
NOTES FOR THERMOSTAT WIRING DIAGRAMS 1. Heat pump MUST have a high pressure switch for 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: 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 41: Vent Termination Kit For Direct Vent (2- -Pipe) Systems
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 42 Non-Direct Vent / 1-Pipe System NOTICE The vent pipe for a Non Direct Vent (1- -pipe) system must terminate outdoors. See Fig. 47 for references to vent clearances RECOMMENDED SUPPORT FOR required by National Code authorities. Allowable vent VENT TERMINATIONS terminations are shown in Fig.
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Page 43: Combustion Air And Vent Piping Insulation Guidelines
Length in Table 15 or 17, minus the number of fittings multiplied Venting Tables for elbows and flexible vent pipe. Factory by the deduction for each type of fitting used from Table 16. accessory concentric vent terminations or pipe lengths and elbows used for “standard”... - 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 14. Pipe Adapter 1. Using winter design temperature (used in load calculations), WARNING find appropriate temperature for your application and fur- nace model.
- Page 45 3. Chamfer outside edge of pipe for better distribution of 1. Insert a length of vent pipe through the casing into the primer and cement. outlet of the vent elbow. 4. Clean and dry all surfaces to be joined. 2. Slide the plastic vent pipe adapter over the length of the vent pipe down to the furnace casing.
- Page 46 or pairs of vents as shown in Fig. 48 and all clearance shown in NOTE: Do not allow insulation or other materials to accumulate Fig. 46. inside of pipe assembly when installing it through hole. 4. Locate assembly through sidewall with rain shield posi- WARNING tioned no more than 1- -in.
- Page 47 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 48 Table 14 – Maximum Allowable Exposed Vent Lengths Insulation Table - - Ft. / M No Insulation 3/8-in. (9.5 mm) 1/2-in. (12.7 mm) Two Stage Pipe Pipe Diameter-inches (mm) Pipe Diameter-inches (mm) Pipe Diameter-inches (mm) Winter Design Furnace High Length in Temp °...
- Page 49 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. Table 15 – Maximum Equivalent Vent Length - - Ft. (M) 0 to 4500 Ft.
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Page 50: Venting System Length Calculations
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 51 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. Table 17 – Maximum Equivalent Vent Length - - Ft. (M) 4501 to 10,000 Ft.
- Page 52 Attach gaskets to vent pipe and Vent Coupling and Adapter combustion air adapters. A13074 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 53 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 54 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 55 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 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 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. 48 - - Combustion Air and Vent Pipe Termination for Direct Vent (2- -Pipe) System Roof Termination (Preferred) Vent Maintain 12 in...
- Page 59 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 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. 51 - - Vent Terminations for Ventilated Combustion Air...
- Page 61 EXAMPLE FOR UPFLOW INSTALLATIONS. MAY BE APPLIED TO OTHER CONFIGURATIONS. A12220 Fig. 52 - - 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.
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Page 62: 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 63 Adjustments 1. Obtain average yearly gas heat value (at installed altitude) from local gas supplier. WARNING 2. Obtain average yearly gas specific gravity from local gas supplier. 3. Find installation altitude in Table 21. FIRE HAZARD 4. Find closest natural gas heat value and specific gravity in Failure to follow this warning could result in personal Table 21.
- Page 64 j. Reinstall manifold pressure tap plug from gas valve. e. Move setup SW-1 (LHT) on furnace control to position re- quired for attached thermostat (OFF for single-stage ther- k. Move setup switch SW- -1 (LHT) to off position after com- mostats, ON for two-stage thermostats).
- Page 65 WARNING CAUTION ELECTRICAL OPERATION HAZARD FURNACE OVERHEATING HAZARD Failure to follow this warning could result in personal injury Failure to follow this caution may result in reduced furnace or death. life. Disconnect 115vac electrical power before changing speed tap. Recheck temperature rise. It must be within limits specified on the rating plate.
- Page 66 Checklist 1. Put away tools and instruments. Clean up debris. 2. Verify that the jumper is removed from the TEST/TWIN terminal. Verify that there is nothing plugged into the PLT connector. (Note: If there is a jumper connector plugged into PLT, remove it and discard.) See Fig. 35. 3.
- Page 67 338314-201 Rev. D A11598 Fig. 57 - - Service Label Information...
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Page 68: 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 69: 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 70 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...
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Page 71: Service And Maintenance Procedures
SERVICE AND MAINTENANCE “W.C.” The maximum and minimum break point of the switch is +/- - 0.05 inches of water column from the nominal break point of PROCEDURES the switch. The maximum make point of the switch is 0.10 inches Untrained personnel can perform basic maintenance functions such of water above the maximum break point of the switch. - Page 72 5. The LED will flash the last stored fault code. Refer to the 3. Verify that Low Heat Only switch (LHT) is set properly. Service Label (Fig. 57) to interpret the LED. See Fig. 35. 6. A component test sequence will follow. 4.
- Page 73 of airflow. Rinse filter and let dry. Oiling or coating of the CAUTION filter is not recommended. 5. If equipped with factory specified disposable media filter, replace only with a factory specified media filter of the same CUT HAZARD size. Failure to follow this caution may result in personal injury.
- Page 74 g. Clean wheel per instructions on degreaser cleaner. Do not WARNING get degreaser in motor. 8. Reassemble motor and blower wheel by reversing items 7b through 7f. Ensure wheel is positioned for proper rotation. ELECTRICAL SHOCK AND FIRE HAZARD 9. Torque motor mounting bolts to 40 +/- - 10 lb- -in. when reas- Failure to follow this warning could result in personal injury, sembling.
- Page 75 Flushing Collector Box and Drainage System 7. Install the remaining manifold mounting screws. 8. Check the igniter alignment. See Fig. 58, 60 and 64. WARNING 9. Attach the wires to the roll-out switches. 10. Align the burner assembly with the openings in the primary cell inlet panel and attach the burner assembly to the cell ELECTRICAL SHOCK AND FIRE HAZARD panel.
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Page 76: Cleaning Heat Exchangers
2. Install gasket on collector box WARNING 3. Align the condensate trap with the drain opening on the col- lector box and secure the trap with the screw ELECTRICAL SHOCK AND FIRE HAZARD 4. Attach the relief hose to the relief port on the condensate trap and collector box. - Page 77 WINTERIZATION Burner Flame CAUTION Burner UNIT AND PROPERTY DAMAGE HAZARD Failure to follow this caution may result in unit component or property damage. If the furnace is installed in an unconditioned space where the Manifold ambient temperatures may be 32_ F (0_ C) or lower, freeze protection measures must be taken to prevent minor property A11461 or product damage.
- Page 78 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.
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Page 79: 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 80 control CPU is factory- -set for a 120- -sec blower- -OFF call for cooling. See Fig. 35. When ACRDJ is in place, the furnace delay. control CPU can turn on the air conditioning relay ACR to energize the Y/Y2 terminal and switch the outdoor unit to 2.
- Page 81 ated. If the DHUM input is low for more than 48 hours, the NOTE: If the blower- -off delay is set to the maximum, the furnace control reverts back to non- -Thermidistat mode. adjustable continuous- -fan feature is locked (i.e., fan speed cannot The cooling operation described in item 3.
- Page 82 A11323A Fig. 65 - - Troubleshooting Guide...
- Page 83 A11323B Troubleshooting Guide (Cont)
- Page 84 338314- -2 Rev. H A13302 Fig. 66 - - Wiring Diagram...
- Page 85 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 86 Catalog No: IM---PG95XAT ---09 Copyright 2013 CAC / BDP D 7310 W. Morris St. D Indianapolis, IN 46231 Edition Date: 11/13 Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. Replaces: IM--- PG95XAT--- 08...