Carrier PG80VTLB Installation, Start-Up, Operating And Service And Maintenance Instructions
Carrier PG80VTLB Installation, Start-Up, Operating And Service And Maintenance Instructions

Carrier PG80VTLB Installation, Start-Up, Operating And Service And Maintenance Instructions

80% afue, variable 25-speed, ecm motor, two-stage, 4-way multipoise, non condensing gas furnace

Advertisement

Quick Links

PG80VTLB
80% AFUE, Variable 25-Speed, ECM Motor,
Two-Stage, 4-Way Multipoise, Non-Condensing Gas Furnace
NOTE: Read the entire instruction manual before starting the
installation.

TABLE OF CONTENTS

Table 1 - Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Table 2 - Minimum Free Area Required for Each Combustion Air
opening of Duct to Outdoors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Table 3 - Minimum Space Volumes for 100% Combustion, Ventila-
tion, and Dilution from Indoors . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Table 4 - Opening Dimensions - In. (mm) . . . . . . . . . . . . . . . . . 11
FILTER ARRANGMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
AIR DUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
GAS PIPING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Table 5 - Maximum Capacity of Pipe . . . . . . . . . . . . . . . . . . . . . 14
ELECTRICAL CONNECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Table 6 - Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
VENTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Table 7 - Combined Appliance Maximum Input Rating
in Thousands of BTUh per Hour . . . . . . . . . . . . . . . . . . . . . . . . . 21
Table 8 - Minimum Allowable Input Rating of
Table 9 - Recommended Minimum Vent Height Per Furnace and Vent
Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
AIR DELIVERY - CFM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Table 10 - Air Delivery - CFM (with Filter)* . . . . . . . . . . . . . . . 25
Table 11 - Default Airflow Settings . . . . . . . . . . . . . . . . . . . . . . 28
AND NAVIGATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Table 12 - System Status Display Codes. . . . . . . . . . . . . . . . . . . 29
Table 13 - Main Menu Options . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SERVICE LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Table 14 - Test Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Table 15 - Altitude Derate Multiplier for U.S.A. . . . . . . . . . . . . 33
Portions of the text and tables are reprinted from 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
Installation, Start-up, Operating and
Service and Maintenance Instructions
on the referenced subject, which is represented only by the standard in its entirety.
Table 16 - Gas Rate (CU ft./hr). . . . . . . . . . . . . . . . . . . . . . . . . . 34
Table 17 - Orifice Size and Manifold Pressure (in. w.c.) for Gas Input
Rate (Tabulated Data Based on 22,000 BTUh High-Heat/14,500
Ft.(305 M) Above Sea Level) . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Table 18 - Orifice Size and Manifold Pressure (in. w.c.) for Gas Input
Rate (Tabulated Data Based on 21,000 BTUh High-Heat/14,500
Ft.(305 M) Above Sea Level) . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
SERVICE AND MAINTENANCE PROCEDURES. . . . . . . . . . . . 39
CARE AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Table 19 - Filter Size Information - In. (mm) . . . . . . . . . . . . . . . 41
Table 20 - Filter Size Information - In. (mm) . . . . . . . . . . . . . . . 41
SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
GAS FURNACE CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
PARTS REPLACEMENT INFORMATION GUIDE . . . . . . . . . . . 51
MODEL NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
To learn more about this appliance and installation via a mobile device,
go to
http://www.payne.com/NFC
airflow tables or troubleshooting guide on your mobile device go to
/mlctraining.com/training/techdocs/76/
or use the QR code below. To access
or use the QR code below.
A221532
A200103

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the PG80VTLB and is the answer not in the manual?

Questions and answers

Summary of Contents for Carrier PG80VTLB

  • Page 1: Table Of Contents

    PG80VTLB 80% AFUE, Variable 25-Speed, ECM Motor, Two-Stage, 4-Way Multipoise, Non-Condensing Gas Furnace Installation, Start-up, Operating and Service and Maintenance Instructions NOTE: Read the entire instruction manual before starting the Table 16 – Gas Rate (CU ft./hr)......34 installation.
  • Page 2 PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions A190084 Fig. 1 – Dimensional Drawing Table 1 – Dimensions ACCESSORY VENT SHIP WT. FILTER TOP AND FURNACE SIZE CONNECTION CABINET OUTLET BOTTOM LB (KG) MEDIA BOTTOM FLUE SIZE WIDTH WIDTH...
  • Page 3: Safety Considerations

    PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions SAFETY CONSIDERATIONS exceed certain local codes and ordinances, especially those that may not have kept up with changing residential construction practices. We WARNING require these instructions as a minimum for a safe installation.
  • Page 4: Introduction

    PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions 5. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections, as specified in the “Gas Piping” section.
  • Page 5 PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions (SMACNA), or American Society of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE) 2001 Fundamentals Handbook Chapter 35 or 2005 HVAC Systems and Equipment Handbook Chapters 9 and 16. Acoustical Lining and Fibrous Glass Duct Current edition of SMACNA and NFPA 90B as tested by UL Standard 181 for Class I Rigid Air Ducts.
  • Page 6: Location

    PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions LOCATION WARNING GENERAL This multipoise furnace is shipped in packaged configuration. Some CARBON MONOXIDE POISONING / COMPONENT assembly and modifications are required when used in any of four DAMAGE HAZARD applications (as shown in Fig.
  • Page 7 PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions The requirements for combustion and ventilation air depend upon CAUTION whether or not the furnace is located in a space having a volume of at least 50 cubic feet per 1,000 BTUh input rating for all gas appliances installed in the space.
  • Page 8 PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions The opening shall commence within 12 in. (300 mm) of the ceiling. Appliances in the space shall have clearances of at least 1 in. (25 mm) from the sides and back and 6 in. (150 mm) from the front. The opening...
  • Page 9: Installation

    PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions Then the following requirements apply to both the Standard Method and c. Combining space on different floor levels. The volumes of to the Known Air Infiltration Rate Method: spaces on different floor levels shall be considered as communicating spaces if connected by one or more permanent 1.
  • Page 10 PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions Side Return Air Inlet 1. Determine application being installed from Table 2. Construct hole in floor, see Table 4 Fig. These furnaces are shipped with bottom closure panel installed in bottom 3.
  • Page 11 PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions 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 CASING WIDTH APPLICATION IN.
  • Page 12 PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions WARNING FIRE, EXPLOSION, AND CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury, death, or property damage. Do not install the furnace on its back or hang furnace with control compartment facing downward.
  • Page 13: Filter Arrangment

    PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions Not all horizontal furnaces are approved for side return air connections. flanges or air conditioning coil casing (when used). DO NOT cut main (Refer to Horizontal Return Air Configurations and Restrictions furnace casing side to attach supply air duct, humidifier, or other (Fig.
  • Page 14: Gas Piping

    PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions 4. The use of copper tubing for gas piping is NOT approved by the state of Massachusetts. WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury, death, and/or property damage.
  • Page 15: Electrical Connections

    PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions below level of furnace gas controls. Place a ground joint union between WARNING furnace gas control valve and exterior manual equipment gas shutoff valve. FIRE OR EXPLOSION HAZARD A 1/8-in. (3 mm) NPT plugged tapping, accessible for test gauge...
  • Page 16 PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions 115-V Wiring WARNING Verify that the voltage, frequency, and phase correspond to that specified on unit rating plate. Also, check to be sure that service provided by ELECTRICAL SHOCK HAZARD utility is sufficient to handle load imposed by this equipment. Refer to Failure to follow this warning could result in personal injury or death.
  • Page 17 PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions Electrical Connection to J-Box Electrical Box on Furnace Casing Side WARNING FIRE OR ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury, death, or property damage. High voltage field connections must be located in J-Box with furnace or in field supplied external disconnect mounted to furnace.
  • Page 18: Accessories

    PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions 2. Route listed power cord through 7/8-in. (22 mm) diameter hole in J-Box. To HUM Terminal On 3. Secure power cord to J-Box bracket with a strain relief bushing or a...
  • Page 19: Venting

    PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions 13. Thermostat terminal connection order on furnace control may vary- reference furnace control labeling for designations. VENTING The furnace shall be connected to a listed factory built chimney or vent, or a clay-tile lined masonry or concrete chimney. Venting into an unlined masonry chimney or concrete chimney is prohibited.
  • Page 20 PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death.
  • Page 21: In Thousands Of Btuh Per Hour

    PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions Exterior Masonry Chimney Fan + Nat Refer to the Fig. 31 to perform a chimney inspection. If the inspection of a previously used tile-lined chimney: Installations with Type-B Double-Wall Vent a. Shows signs of vent gas condensation, the chimney should be Connectors ENFPA &...
  • Page 22: Orientation

    PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions Air for combustion must not be contaminated by halogen compounds 1. Attach the single wall vent connector to the furnace vent elbow, and which include chlorides, fluorides, bromides, and iodides. These...
  • Page 23 PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions A03208 Fig. 32 – Upflow Application - Vent Elbow Up A03211 Fig. 36 – Downflow Application - Vent Elbow Up A03218 Fig. 37 – Horizontal Right Application - Vent Elbow Right A03209 Fig.
  • Page 24 PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions A03219 Fig. 43 – Horizontal Right Application - Vent Elbow Left then Up A03212 Fig. 39 – Downflow Application - Vent Elbow Up then Right A02068 Fig. 44 – Horizontal Right Application-Vent Elbow Left Notes for Venting 1.
  • Page 25: Air Delivery - Cfm

    PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions AIR DELIVERY - CFM Table 10 – Air Delivery - CFM (with Filter)* Airflow External Static Pressure (in.w.c.) Unit Size Default Setting Setting Cont. Fan Low Heating High Heating 36045A Low Cooling...
  • Page 26 PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions Table 10 – Air Delivery - CFM (with Filter)* (Continued) Airflow External Static Pressure (in.w.c.) Unit Size Default Setting Setting Cont. Fan 1030 1095 1050 1005 Low Heating 1130 1080 1035...
  • Page 27 PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions Table 10 – Air Delivery - CFM (with Filter)* (Continued) Airflow External Static Pressure (in.w.c.) Unit Size Default Setting Setting Cont. Fan 1030 1125 1035 1210 1125 1035 1285 1210 1125...
  • Page 28: Furnace Control Programming

    PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions Table 10 – Air Delivery - CFM (with Filter)* (Continued) Airflow External Static Pressure (in.w.c.) Unit Size Default Setting Setting Cont. Fan 1075 1160 1070 1240 1160 1070 1295 1215 1135...
  • Page 29 PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions Table 12 – System Status Display Codes Display Operating Mode Notes Idle/Standby Mode No active demands High Heating Mode Gas Heating active Low Heating Mode Gas Heating active High Cooling Mode...
  • Page 30 PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions CAUTION FURNACE OVERHEATING HAZARD Failure to follow this caution could result in reduced furnace life. Do NOT program the control board with a Model Program Number different than what is specified on the rating plate. Parameter options will not match design values.
  • Page 31: Service Label

    PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions SERVICE LABEL A221515 Fig. 46 – Service Label START-UP, ADJUSTMENT, AND SAFETY Start-Up Procedures CHECK WARNING GENERAL WARNING FIRE OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury, death, and/or property damage.
  • Page 32: Wiring Diagram

    PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions component test (Ct) from menu select buttons to start the 4. Operate furnace per instruction on door. component test sequence. Once initiated the furnace control will 5. Verify furnace shut down by lowering thermostat setting below...
  • Page 33: Adjustments

    PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions ADJUSTMENTS a. Obtain average yearly gas heat value (at installed altitude) from local gas supplier. Furnace gas input rate on rating plate is for installations at altitudes up to b. Obtain average yearly gas specific gravity from local gas 2000 Ft.
  • Page 34 PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions c. When correct input is obtained, replace caps that conceal gas Table 16 – Gas Rate (CU ft./hr) valve regulator adjustment screws. Main burner flame should be SIZE OF TEST clear blue, almost transparent.
  • Page 35: Btuh For Low-Heat Per Burner, Derated 4 Percent For Each 1000 Ft.(305 M) Above Sea Level)

    PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions Table 17 – Orifice Size and Manifold Pressure (in. w.c.) for Gas Input Rate (Tabulated Data Based on 22,000 BTUh High-Heat/14,500 BTUh for Low-Heat per Burner, Derated 4 Percent for Each 1000 Ft.(305 M) Above Sea Level) SPECIFIC GRAVITY OF NATURAL GAS AVG.
  • Page 36: Btuh For Low-Heat Per Burner, Derated 4 Percent For Each 1000 Ft.(305 M) Above Sea Level)

    PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions Table 17 – Orifice Size and Manifold Pressure (in. w.c.) for Gas Input Rate (Tabulated Data Based on 22,000 BTUh High-Heat/14,500 BTUh for Low-Heat per Burner, Derated 4 Percent for Each 1000 Ft.(305 M) Above Sea Level) (Continued) SPECIFIC GRAVITY OF NATURAL GAS AVG.
  • Page 37 PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions Table 18 – Orifice Size and Manifold Pressure (in. w.c.) for Gas Input Rate (Tabulated Data Based on 21,000 BTUh High-Heat/14,500 BTUh for Low-Heat per Burner, Derated 4 Percent for Each 1000 Ft.(305 M) Above Sea Level) (Continued) SPECIFIC GRAVITY OF NATURAL GAS AVG.
  • Page 38 PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions 4. Refer to the FURNACE CONTROL PROGRAMMING AND CAUTION NAVIGATION section of this manual for instructions on adjusting the blower speed. FURNACE DAMAGE HAZARD 5. Replace blower door. Failure to follow this caution may result in: 6.
  • Page 39: Service And Maintenance Procedures

    PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions e. Furnace should cycle off within 2 minutes. If gas does not shut CAUTION off within 2 minutes, determine reason draft safeguard switch did not function properly and correct condition. ELECTRICAL OPERATION HAZARD NOTE: Should switch remain open longer than 3 minutes, furnace control board will lockout the furnace for 3 hours.
  • Page 40: Care And Maintenance

    PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions at the sight glass in blower access door. The furnace control LED is WARNING either ON continuously, rapid flashing, or a code composed of 2 digits. The major status code is displayed on the LED indicator through the...
  • Page 41 PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions Blower Motor and Wheel Maintenance 1. Turn off electrical supply to furnace before removing filter access door. The following steps should be performed by a qualified service agency. 2. Remove filter cabinet door.
  • Page 42 PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions 14. Reinstall 2 screws securing blower assembly to blower deck. f. Hot surface igniter. g. Flame-sensing electrode. 15. Reconnect blower leads to furnace control. Refer to furnace wiring diagram, and connect thermostat leads if previously disconnected.
  • Page 43: Sequence Of Operation

    PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions SEQUENCE OF OPERATION NOTE: Furnace control must be grounded for proper operation or else control will lock out. Control is grounded through green/yellow wire routed to gas valve and burner box screw. Using the schematic diagram Fig.
  • Page 44 PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions b. Igniter Warm-Up -At the end of the prepurge period, the furnace control performs a self-check, verifies the low-heat and Hot-Surface Igniter HSI is energized for a 17-second igniter high-heat pressure switch contacts LPS and HPS are open, and starts the warm-up period.
  • Page 45 PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions BLWM at low-cooling airflow. Low cooling airflow is based on the low Terminal EAC-1 is energized as long as the blower motor BLWM is cooling blower speed (CL1) selection. See Fig.
  • Page 46 PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions Wiring Diagram Refer to Fig. 47 for wiring diagram. Troubleshooting Refer to the service label (see Fig. 46) for some troubleshooting information. Also, the Troubleshooting Guide (see Fig. 52) can be a useful tool in isolating furnace operation problems.
  • Page 47: Troubleshooting Guide

    PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions TROUBLESHOOTING GUIDE A221563 Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
  • Page 48 PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions A220342 Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
  • Page 49 PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions A221565 Fig. 52 – Troubleshooting Guide Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
  • Page 50: Gas Furnace Checklist

    PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions GAS FURNACE CHECKLIST GAS FURNACE CHECKLIST Installation Date: ____________________________ Equipment Model Furnace Thermostat Humidifier Serial # Indoor Coil Outdoor Unit Furnace Location_____________________________ Installed altitude __________________ Furnace Orientation: ____Upflow Downflow Horizontal Right...
  • Page 51: Parts Replacement Information Guide

    PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions PARTS REPLACEMENT INFORMATION GUIDE CASING GROUP GAS CONTROL GROUP Outer door Manifold Blower door Burner assembly Top filler plate Orifice Bottom filler plate Flame sensor Bottom enclosure Hot surface igniter Gas valve...
  • Page 52 PG80VTLB: Installation, Start-up, Operating and Service and Maintenance Instructions © 2023 Carrier. All rights reserved. Edition Date: 06/23 Catalog No: IM-PG80VTLB-01 REV A A Proud Member of the Carrier Family IM-PG80VTLB-01 Replaces: Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

Table of Contents