Installation Manual 4-WAY MULTIPOISE FIXED-CAPACITY DUAL-VENT CONDENSING GAS FURNACE SIZES 040 THRU 140 PG9MAB Series A As an ENERGY STAR® Partner, Payne Heating and Cooling has determined that this product meets the ENERGY STAR® guidelines for energy efficiency. NOTE: Read the entire instruction manual before starting the installation. This symbol → indicates a change since the last issue. INDEX Page SAFETY CONSIDERATIONS...................................................................................
Return Air Connections.....................................................................................................................................................................................25 Filter Arrangement ............................................................................................................................................................................................26 Bottom Closure Panel............................................................................
INSTALLATION This forced air furnace is equipped for use with natural gas at altitudes 0 - 10,000 ft (0 - 3,050m), except 140 size furnaces are only approved for altitudes 0 - 7,000 ft. (0 - 2,135m). An accessory kit, supplied by the manufacturer, shall be used to convert to propane gas use or may be required for some natural gas applications. This furnace is for indoor installation in a building constructed on site.
—4— 11⁄4" 1" 14 1⁄2" TYP 26 15⁄16" 1⁄2-IN. 26 15⁄16" TYP 23 1⁄4" TYP SIDE INLET SIDE INLET DIA THERMOSTAT ENTRY 22 11⁄16" 2-IN. VENT CONN DIA GAS CONN 1⁄2-IN. 2-IN. COMBUSTIONAIR CONN 22 5⁄16" 24 1⁄2" 26 1⁄4" UNIT SIZE 024040 036040 024060 036060 048060 036080 048080 060080 048100 060100 060120 060140 11/16" E INLET OUTLET D 11/16" 18 1⁄4" D 15-7/8 15-7/8 15-7/8 15-7/8 15-7/8 15-7/8 15-7/8 19-3/8 19-3/8 19-3/8 22-7/8 22-7/8 → Fig.
AIRFLOW UPFLOW HORIZONTAL RIGHT HORIZONTAL LEFT DOWNFLOW AIRFLOW AIRFLOW AIRFLOW A93041 Fig. 3—Multipoise Orientations Maintain a 1-in. clearance from combustible materials to supply air ductwork for a distance of 36 inches horizontally from the furnace. See NFPA 90B or local code for further requirements. These furnaces SHALL NOT be installed directly on carpeting, tile, or any other combustible material other than wood flooring.
→ This gas furnace may be used for construction heat provided that: • The furnace is permanently installed with all electrical wiring, piping, air filters, venting and ducting installed according to these installation instructions. A return air duct is provided, sealed to the furnace casing, and terminated outside the space containing the furnace.
FURNACE DOOR BLOWER SHELF CONDENSATE TRAP CONDENSATE TRAP (INSIDE) FURNACE DOOR FURNACE SIDE 4 78 FURNACE SIDE 4 534 534 4 FIELD DRAIN CONN ALTERNATE DRAIN TUBE LOCATION 26 1 4 26 1 4 11 2 SIDE VIEW CONDENSATE TRAP DRAIN TUBE LOCATION FIELD DRAIN CONN FRONT VIEW END VIEW SLOT FOR SCREW HORIZONTAL APPLICATION (OPTIONAL) FRONT VIEW HORIZONTAL APPLICATIONS DOWNFLOW AND ALTERNATE EXTERNAL UPFLOW APPLICATIONS UPFLOW APPLICATIONS 34 1⁄4 OD COLLECTOR BOX TO TRAP RELIEF PORT 11 2 1⁄2 OD
PLUG CAP COLLECTOR BOX DRAIN TUBE (BLUE & WHITE STRIPED) COLLECTOR BOX TUBE (PINK) PLUG COLLECTOR BOX TUBE (GREEN) COLLECTOR BOX DRAIN TUBE (BLUE & WHITE STRIPED) CAP COLLECTOR BOX TUBE (PINK) INDUCER HOUSING (MOLDED) DRAIN TUBE (BEHIND COLLECTOR BOX DRAIN TUBE) COLLECTOR BOX DRAIN TUBE (BLUE) COLLECTOR BOX TUBE (GREEN) COLLECTOR BOX DRAIN TUBE (BLUE) CONDENSATE TRAP FIELD-INSTALLED FACTORY-SUPPLIED DRAIN TUBE COUPLING (LEFT DRAIN OPTION) CONDENSATE TRAP INDUCER HOUSING DRAIN TUBE (VIOLET) FIELD
PROCEDURE 2—UPFLOW APPLICATIONS An upflow furnace application is where furnace blower is located below combustion and controls section of furnace, and conditioned air is discharged upwards. A. Condensate Trap Location (Factory-Shipped Orientation) The condensate trap is factory installed in the blower shelf and factory connected for UPFLOW applications. A factory-supplied tube is used to extend the condensate trap drain connection to the desired furnace side for field drain attachment.
COLLECTOR BOX DRAIN TUBE (BLUE) CAP PLUG PLUG CAP COLLECTOR BOX TUBE (GREEN) COLLECTOR BOX DRAIN TUBE (BLUE) COLLECTOR BOX EXTENSION TUBE COLLECTOR BOX TUBE (PINK) COLLECTOR BOX TUBE (PINK) COLLECTOR BOX DRAIN TUBE (BLUE & WHITE STRIPED) COLLECTOR BOX TUBE (GREEN) COLLECTOR BOX EXTENSION TUBE COLLECTOR BOX DRAIN TUBE (BLUE & WHITE STRIPED) COLLECTOR BOX EXTENSION TUBE COLLECTOR BOX EXTENSION TUBE INDUCER HOUSING DRAIN TUBE (VIOLET) CONDENSATE TRAP CONDENSATE TRAP COLLECTOR BOX EXTENSION DRAIN TUBE
2. Remove trap from blower shelf by gently pushing tabs inward and rotating trap. 3. Install casing hole filler cap (factory-supplied in loose parts bag) into blower shelf hole where trap was removed. WARNING: CARBON MONOXIDE POISONING HAZARD Failure to follow this warning could result in personal injury or death. Casing hole filler cap must be installed in blower shelf hole when condensate trap is relocated to prevent combustion products being drawn in from appliances in the equipment room. 4.
NOTE: See Fig. 8 or 9 or tube routing label on main furnace door to check for proper connections. Relocate tubes as described below. 1. Disconnect collector box pressure tube (pink label) attached to pressure switch. 2. Extend collector box pressure tube (green label) which was previously connected to condensate trap relief port connection by splicing to small diameter tube (factory-supplied in loose parts bag). 3.
PLUG CAP COLLECTOR BOX DRAIN TUBE (BLUE AND WHITE STRIPED) AUXILIARY "J" BOX CONDENSATE TRAP COLLECTOR BOX TUBE (GREEN) COLLECTOR BOX EXTENSION DRAIN TUBE COLLECTOR BOX EXTENSION TUBE INDUCER HOUSING DRAIN TUBE (VIOLET) COLLECTOR BOX DRAIN TUBE (BLUE) DRAIN TUBE COUPLING COLLECTOR BOX TUBE (PINK) RELOCATE TUBE BETWEEN BLOWER SHELF AND INDUCER HOUSING FOR 040, 060, AND 080 HEATING INPUT FURNACES A00215 Fig. 10—Horizontal Left Tube Configuration d. Clamp tube to prevent any condensate leakage. C.
COMBUSTION – AIR INTAKE VENT 30″ MIN WORK AREA 5 3⁄4″ MANUAL SHUTOFF GAS VALVE A 12-IN. MIN HORIZONTAL PIPE SECTION IS RECOMMENDED WITH SHORT (5 TO 8 FT) VENT SYSTEMS TO REDUCE EXCESSIVE CONDENSATE DROPLETS FROM EXITING THE VENT PIPE. ACCESS OPENING FOR TRAP SEDIMENT TRAP DRAIN CONDENSATE TRAP NOTE: LOCAL CODES MAY REQUIRE A DRAIN PAN UNDER THE FURNACE AND CONDENSATE TRAP WHEN A CONDENSING FURNACE IS INSTALLED ABOVE FINISHED CEILINGS. A93031 Fig.
CAP PLUG COLLECTOR BOX DRAIN TUBE (BLUE) COLLECTOR BOX TUBE (GREEN) COLLECTOR BOX EXTENSION TUBE COLLECTOR BOX TUBE (PINK) AUXILARY “J” BOX RELOCATED HERE CONDENSATE TRAP COLLECTOR BOX DRAIN TUBE (BLUE AND WHITE STRIPED) INDUCER HOUSING DRAIN TUBE (VIOLET) COLLECTOR BOX EXTENSION TUBE A00214 Fig. 13—Horizontal Right Tube Configuration NOTE: Combustion-air and vent pipes are restricted to a minimum length of 5 ft. (See Table 11.) NOTE: A 12-in.
b. Install removed clamp and plug into UPPER collector box drain tube (blue label) which was previously connected to condensate trap. c. Connect LOWER collector box drain tube (blue and white striped label) to condensate trap. Tube does not need to be cut. d. Clamp tube to prevent any condensate leakage. 2. Inducer Housing Drain Tube a. Remove factory-installed cap and clamp from LOWER inducer housing drain connection. b.
LEVEL (0″) TO 1⁄2″ MAX FRONT MIN 1⁄4″ TO 1⁄2″ MAX UPFLOW OR DOWNFLOW FRONT HORIZONTAL A02146 Fig. 14—Furnace Location for Proper Condensate Drainage LOCATION PROCEDURE 1—GENERAL This furnace must • be installed so the electrical components are protected from water. • • not be installed directly on any combustible material other than wood flooring (refer to SAFETY CONSIDERATIONS). be located so combustion-air and vent pipe maximum lengths are not exceeded. Refer to Table 11.
CAUTION: UNIT DAMAGE HAZARD This gas furnace may be used for construction heat provided that: -The furnace is permanently installed with all electrical wiring, piping, air filters, venting and ducting installed according to these installation instructions. A return air duct is provided, sealed to the furnace casing, and terminated outside the space containing the furnace.
1 SQ IN. PER 4000 BTUH* 1 SQ IN. PER 2000 BTUH* 12″ MAX A VENT THROUGH ROOF 12″ MAX F 1 SQ IN. PER 4000 BTUH* INTERIOR HEATED SPACE 1 SQ IN. PER 4000 BTUH* E G 12″ MAX C 12″ MAX CLEARANCE IN FRONT OF COMBUSTION AIR OPENINGS SHALL BE AT LEAST 3 IN. DUCTS TO OUTDOORS D VENT THROUGH ROOF OUTDOORS B CIRCULATING AIR DUCTS CLEARANCE IN FRONT OF COMBUSTION AIR OPENINGS SHALL BE AT LEAST 3 IN. 12″ MAX 1 SQ IN. PER 2000 BTUH* CIRCULATING AIR DUCTS DUCTS TO OUTDOORS 12" MAX 1 SQ IN.
AIR FOR COMBUSTION AND VENTILATION Provisions for adequate combustion, ventilation, and dilution air must be provided in accordance with: • • U.S. Installations: Section 8.3 of the NFGC, Air for Combustion and Ventilation and applicable provisions of the local building codes. Canadian Installations: Part 7 of the NSCNGPIC, Venting Systems and Air Supply for Appliances and all authorities having jurisdiction.
Table 1—Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors TWO HORIZONTAL DUCTS SINGLE DUCT OR OPENING TWO OPENINGS OR VERTICAL DUCTS FURNACE (1 SQ. IN./2,000 BTUH) (1,100 SQ. MM/KW) (1 SQ. IN./3,000 BTUH) (734 SQ. MM/KW) (1 SQ. IN./4,000 BTUH) (550 SQ. MM/KW) INPUT Free Area of Free Area of Free Area of Round Duct Round Duct Round Duct (BTUH) Opening and Duct Opening and Duct Opening and Duct (in. Dia) (in. Dia) (In. Dia) (Sq. In.) (sq In.) (Sq In.) 44,000 22 6 14.
Table 3-Minimum Space Volumes were determined by using the following equations from the National Fuel Gas Code ANSI Z223.1-2002/NFPA 54-2002,8.3.2.2: 1. For other than fan-assisted appliances, such as a draft hood-equipped water heater: Volume Other 3 I other = 21ft ACH 1000 Btu/hr A04002 2.
5⁄16″ 5⁄16″ 1 3⁄4″ 1 3⁄4″ 5⁄16″ 5⁄16″ 1 3⁄4″ 1 3⁄4″ A89014 Fig. 20—Leveling Legs 1. Determine application being installed from Table 3. 2. Construct hole in floor per dimensions specified in Table 3 and Fig. 21. 3. Construct plenum to dimensions specified in Table 3 and Fig. 21. 4. If downflow subbase (KGASB) is used, install as shown in Fig. 22. If coil assembly CD5, CK5 or Coil Box KCAKC is used, install as shown in Fig. 23.
A PLENUM OPENING D B FLOOR OPENING C A96283 Fig. 21—Floor and Plenum Opening Dimensions FURNACE FURNACE (OR COIL CASING WHEN USED) CD5 OR CK5 COIL ASSEMBLY OR KCAKC COIL BOX COMBUSTIBLE FLOORING COMBUSTIBLE FLOORING DOWNFLOW SUBBASE SHEET METAL PLENUM SHEET METAL PLENUM FLOOR OPENING FLOOR OPENING A96284 A96285 Fig. 23—Furnace, Plenum, and Coil Assembly or Coil Box Installed on a Combustible Floor Fig.
PERFORATED DISCHARGE DUCT FLANGE NO YES 210° MIN YES A93029 Fig. 24—Duct Flanges Secure ductwork with proper fasteners for type of ductwork used. Seal supply- and return-duct connections to furnace with code approved tape or duct sealer. Flexible connections should be used between ductwork and furnace to prevent transmission of vibration. Ductwork passing through unconditioned space should be insulated to enhance system performance. When air conditioning is used, a vapor barrier is recommended.
3⁄8-IN. ANGLE IRON OR EQUIVALENT ROD 5 3⁄4″ ALTERNATE SUPPORT LOCATION 4-IN. MIN 8-IN. MAX (B) (A) DRAIN (B) (A) (A) ROD LOCATION USING DIMPLE LOCATORS (SEE DIMENSIONAL DWG FOR LOCATIONS) (B) 3/8-IN. HEX NUT & WASHER (4) REQD PER ROD (A) PREFERRED ROD LOCATION (B) ALTERNATE ROD LOCATION (A) (B) 13/16-IN. MAX ALTERNATE SUPPORT LOCATION FROM BACK NOTES: 1. A 1 In. clearance minimum between top of furnace and combustible material. 2.
A 3-IN. MINIMUM CLEARANCE TO COMBUSTION-AIR INTAKE IS REQUIRED. COMBUSTION-AIR INTAKE VENT 3⁄8-IN. ANGLE IRON OR EQUIVALENT ROD 5 3⁄4″ ALTERNATE SUPPORT LOCATION 4-IN. MIN 8-IN. MAX (B) (A) DRAIN (B) (A) (A) ROD LOCATION USING DIMPLE LOCATORS (SEE DIMENSIONAL DWG FOR LOCATIONS) (B) 3/8-IN. HEX NUT & WASHER (4) REQD PER ROD (A) PREFERRED ROD LOCATION (B) ALTERNATE ROD LOCATION (A) (B) 13/16-IN. MAX ALTERNATE SUPPORT LOCATION FROM BACK NOTES: 1. A 1 In.
Table 5—Maximum Capacity of Pipe* NOMINAL IRON PIPE SIZE (IN.) INTERNAL DIAMETER (IN.) 1/2 3/4 1 1-1/4 1-1/2 0.622 0.824 1.049 1.380 1.610 10 175 360 680 1400 2100 LENGTH 20 120 250 465 950 1460 OF PIPE (FT) 30 40 97 82 200 170 375 320 770 660 1180 990 50 73 151 285 580 900 * Cubic ft of gas per hr for gas pressures of 0.5 psig (14-in. wc) or less, and a pressure drop of 0.5-in. wc (based on a 0.60 specific gravity gas). Ref: Table 9.2 NFPA 54-2002 G.
171⁄2-IN. WIDE CASINGS ONLY: INSTALL FIELD-SUPPLIED FILTER FILLER STRIP UNDER FILTER. 21-IN. WIDE CASINGS ONLY: SUPPORT RODS (3) EXTEND 1/4" ON EACH SIDE OF FILTER AND REST ON CASING FLANGE 3″ 24 1/2″ 1″ A00217 Fig. 28—Filter Installed for Side Inlet WASHABLE FILTER BOTTOM CLOSURE PANEL FILTER SUPPORT FILTER RETAINER FRONT FILLER PANEL A00290 Fig. 27—Bottom Filter Arrangement A93047 Fig.
FIELD 24-V WIRING FIELD 115-, 208/230-, 460-V WIRING FACTORY 24-V WIRING FACTORY 115-V WIRING NOTE 2 W FIVE WIRE THREE-WIRE HEATING-ONLY C R G Y THERMOSTAT TERMINALS FIELD-SUPPLIED DISCONNECT 208/230- OR 460-V THREE PHASE BLOWER DOOR SWITCH BLK BLK WHT WHT GND 115-V FIELDSUPPLIED DISCONNECT W GND AUXILIARY J-BOX C O N T R O L R 208/230-V SINGLE PHASE G COM GND NOTE 1 CONDENSING UNIT Y 24-V TERMINAL BLOCK FURNACE TWO WIRE NOTES: 1.
ALTERNATE FIELD LOCATION FACTORY INSTALLED LOCATION A00212 Fig. 33—Relocating J-Box WARNING: FIRE HAZARD Failure to follow this warning could result in serious injury, death, or property damage. Do not connect aluminum wire between disconnect switch and furnace. Use only copper wire. (See Fig. 32.) Use a separate, fused branch electrical circuit containing a properly sized fuse or circuit breaker for this furnace. See Table 6 for wire size and fuse specifications.
L E G E N D R Y BHT/CLR COOL —32— GND GV GVR 1, 2 HSI HSIR HUM IDM IDR ILK J1 J2 JB LED LGPS LS BHT/CLR BLWR BLWM CAP 1,2 CPU EAC-1 EAC-2 FRS FSE FU 1 FU 2 BLU (MED LO) HUM START BLWM EAC-1 PL1 RED BRN BRN 1 CAP -1 GRN/YEL PR1 2 PL2 GRN/YEL YEL WHT RED GRN/YEL WHT WHT ORN BLU BLK BLK WHT ILK WHT (COM) BLK FSE RED ORN BLOWER MOTOR SPEED CHANGE RELAY, SPDT BLOWER MOTOR RELAY, SPST-(N.O.
2. Humidifier (HUM) A quick-connect terminal (HUM) and screw terminal (COM 24v) are provided for 24-v humidifier connection. (See Fig. 35.) HUM terminal is energized with 24v (0.5-amp maximum) when gas valve is energized. NOTE: A field-supplied, 115-v controlled relay connected to EAC terminals may be added if humidifier operation is desired during blower operation.
Table 7—Approved Combustion-Air and Vent Pipe, Fitting and Cement Materials ASTM SPECIFICATION MATERIAL PIPE FITTINGS SOLVENT CEMENT AND PRIMERS DESCRIPTION (MARKED ON MATERIAL) D1527 ABS Pipe — — Schedule-40 D1785 PVC Pipe — — Schedule-40 Solvent D2235 For ABS — — For ABS Cement D2241 PVC Pipe — — SDR-21 & SDR-26 D2466 PVC — Fittings — Schedule-40 D2468 ABS — Fittings — Schedule-40 Solvent D2564 For PVC — — For PVC Cement D2661 ABS Pipe Fittings — DWV at Schedule-40 IPS sizes D2665 PVC Pipe Fittings — DWV
TWINNING AND/OR COMPONENT TEST TERMINAL BLOWER OFF-DELAY J2 JUMPER BLOWER OFF-DELAY 120 180 90 150 J2 HUMIDIFIER TERMINAL (24-VAC 0.5 AMP MAX.) G Com 24V 24-V THERMOSTAT TERMINALS W TRANSFORMER 24-VAC CONNECTIONS PLT Y TEST/TWIN R HUM 0.
A05009 Table 8—Direct Vent Termination Clearance —36—
A05013 Table 9—Other than Direct Vent Termination Clearance —37—
Table 10—Maximum Allowable Exposed Vent Pipe Length (ft) With and Without Insulation in Winter Design Temperature Ambient* FURNACE SIZE 040 060 080 100 120 140 WINTER DESIGN TEMPERATURE (°F) 20 0 -20 20 0 -20 20 0 -20 20 0 -20 20 0 -20 20 0 -20 20 0 -20 20 0 -20 20 0 -20 20 0 -20 20 0 -20 MAX PIPE DIAMETER (IN.) 1.5 1.5 1.5 2 2 2 2 2 2 2 2 2 2.5 2.5 2.5 2.5 2.5 2.5 3 3 3 3 3 3 4 4 4 3 3 3 4 4 4 WITHOUT INSULATION WITH 3/8–IN.
NOTE: Select 1 vent pipe connection and NOTE: Select 1 vent pipe connection and 1 combustion-air pipe connection. 1 combustion-air pipe connection. COMBUSTIONAIR AIR FLOW COMBUSTIONAIR VENT VENT VENT * VENT * COMBUSTIONAIR UPFLOW COMBUSTIONAIR AIR FLOW COMBUSTIONAIR DOWNFLOW COMBUSTIONAIR FIELD-SUPPLIED 2-IN. DIAMETER PVC 90° ELBOW VENT VENT ** ** AIR FLOW AIR FLOW † HORIZONTAL-LEFT DISCHARGE FIELD-SUPPLIED 2-IN.
→ Table 11—Maximum Allowable Vent Pipe Length (Ft) DIRECT VENT (2-PIPE) ONLY ALTITUDE (FT) UNIT SIZE (BTUH) 40,000 60,000 80,000 0 to 2000 100,000 120,000 140,000 ALTITUDE (FT) UNIT SIZE (BTUH) 40,000 60,000 80,000 2001 to 3000 100,000 120,000 140,000 ALTITUDE (FT) 3001 to 4000 UNIT SIZE (BTUH) TERMINATION TYPE PIPE DIA (IN.)* 1 1-1/2 2 1-1/2 2 Pipe or 2-in Concentric 2 1-1/2 2 Pipe or 2-in 2 Concentric 2-1/2 2 2 Pipe or 3-in 2-1/2 Concentric 3 2-1/2 one disk 2 Pipe or 3-in.
→ Table 11—Maximum Allowable Vent Pipe Length (Ft) (Continued) DIRECT VENT 1-1/2 2 1-1/2 2 2 2-1/2 2-1/2 3 3† no disk NA 4† no disk 3† no disk 4† no disk (2-PIPE) ONLY TERMINATION TYPE PIPE DIA (IN)* 40,000 2 Pipe or 2-in Concentric 60,000 2 Pipe or 2-in Concentric 80,000 2 Pipe or 2-in Concentric 100,000 2 Pipe or 3-in Concentric 120,000 2 Pipe or 3-in. Concentric 1-1/2 2 1-1/2 2 2 2-1/2 2-1/2 3 3† no disk NA 4† no disk NON-DIRECT VENT (1-PIPE) ONLY PIPE DIA (IN.
→ Table 11—Maximum Allowable Vent Pipe Length (Ft) (Continued) TERMINATION TYPE PIPE DIA (IN.)* 40,000 2 Pipe or 2-in Concentric 1-1/2 2 NON-DIRECT VENT (1-PIPE) ONLY PIPE DIA (IN.)* 1-1/2 2 1-1/2 2 2 2-1/2 2-1/2 3 NA 3† 4† no disk NA NON-DIRECT VENT (1-PIPE) ONLY PIPE DIA (IN.)* 1-1/2 2 1-1/2 2 2 2-1/2 2-1/2 3 NA 3† 4† no disk NA NON-DIRECT VENT (1-PIPE) ONLY PIPE DIA (IN.
HOUSING PLUG 3/8″ ID TUBE COMBUSTION–AIR INTAKE HOUSING BURNER BOX FURNACE 3/16″ DRILL COMBUSTION– AIR PIPE NOT IN HORIZONTAL SECTION 4″ MIN TRAP PIPE DIAMETER TRANSITION IN VERTICAL SECTION TO OPEN DRAIN A93034 A96190 Fig. 39—Intake Housing Plug Fitting Drain Fig. 38—Vent Pipe Diameter Transition Location and Elbow Configuration 6. Install a field-supplied No. 6 or No. 8 sheet metal screw into combustion air pipe. 7.
COMBUSTION AIR PIPE (DIRECT VENT /2-PIPE) COMBUSTION AIR PIPE (NON-DIRECT VENT/1-PIPE) 12″ MIN 12″ MIN COMBUSTION AIR PIPE (NON-DIRECT VENT/1-PIPE) VENT PIPE VENT PIPE COMBUSTION AIR PIPE (DIRECT VENT/2-PIPE) HORIZONTAL TO ROOF HORIZONTAL TO SIDEWALL COMBUSTION AIR PIPE (DIRECT VENT /2-PIPE) COMBUSTION AIR PIPE (NON-DIRECT VENT/1-PIPE) COMBUSTION AIR PIPE (DIRECT VENT /2-PIPE) VENT PIPE COMBUSTION AIR PIPE (NON-DIRECT VENT/1-PIPE) 12″ MIN 12″ MIN VENT PIPE VERTICAL TO ROOF VERTICAL TO SIDEWAL
Roof Termination (Preferred) At least 36 in. Concentric Vent and Combustion Air Roof Termination (preferred) Vertical separation between combustion air and vent 8 3/4 in. for 3 in. kit 6 3/4 in. for 2 in. kit A A At least 36 in. Maintain 12 in. min. clearance above highest anticipated snow level, maximum of 24 in. above roof 18 in. maximum Maintain 12 in. min. clearance above highest anticipated snow level Maximum of 24 in. above roof 1 in.
10. Handle pipe joints carefully until cement sets. 11. Support combustion air piping (if applicable) and vent piping a minimum of every 5 ft (3 ft for SDR-21 or -26 PVC) using perforated metal hanging strap. 12. Slope combustion air piping (if applicable) and vent piping downward towards furnace a minimum of 1/4 in. per linear ft with no sags between hangers. 13. Use appropriate methods to seal openings where combustion air pipe (if applicable) and vent pipe pass through roof or sidewall.
→ Table 12—Vent Termination Kit for Direct Vent/2-Pipe System DIRECT VENT (2-PIPE) TERMINATION KIT TERMINATION SYSTEM 2-in. 3-in. 2-in. 3-in. Single Penetration of Wall or Roof Single Penetration of Wall or Roof 2-Pipe Termination System 2-Pipe Termination System Concentric Vent Kit Concentric Vent Kit Termination Bracket Kit Termination Bracket Kit DIAM. OF COMBUSTION AIR AND VENT PIPES (IN INCHES) 1, 1-1/2, 2, or 2-1/2 2-1/2, 3 or 4 1, 1-1/2 or 2 2-1/2, 3 or 4 3.
CONDENSATE TRAP OPEN STAND PIPE FOR A/C OR HUMIDIFIER DRAIN WIRE TIE(S) TEE TO OPEN DRAIN HEAT TAPE (3 WRAPS MINIMUM) A94054 A93036 Fig. 43—Example of Field Drain Attachment Fig. 44—Condensate Trap Heat Tape See Fig. 43 for example of possible field drain attachment using 1/2-in. CPVC or PVC tee for vent and A/C or humidifier drain connection. Outdoor draining of the furnace is permissible if allowed by local codes.
A94208 Fig. 45—Inducer Housing Drain Cap A94209 Fig. 46—Filling Condensate Trap 1. Remove upper inducer housing drain connection cap. (See Fig. 45.) 2. Connect field-supplied 1/2-in. ID tube to upper inducer housing drain connection. 3. Insert field-supplied funnel into tube. 4. Pour 1 quart of water into funnel/tube. Water should run through inducer housing, overfill condensate trap, and flow into open field drain. (See Fig. 46.) 5.
b. Igniter Warm-Up- At the end of the prepurge period, the Hot-Surface Igniter HSI is energized for a 17-second igniter warm-up period. c. Trial-for-Ignition Sequence- When the igniter warm-up period is completed the main gas valve relay contacts GVR close to energize the gas valve GV, the gas valve opens. The gas valve GV permits gas flow to the burners where it is ignited by the Hot Surface Igniter HSI. Five seconds after the GVR closes, a 2-second flame period begins.
To Begin Component Self-Test: WARNING: ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in electrical shock, personal injury, or death. Blower access panel door switch opens 115-v power to control center. No component operation can occur. Caution must be taken when manually closing this switch for service purposes. 1. Remove blower access door. 2. Disconnect the thermostat R lead from furnace control. 3. Manually close blower door switch. 4.
Table 13—Model PG9MAB Orifice Size and Manifold Pressure for Correct Input For Use With 040 Through 120 Size Furnaces Only (Tabulated Data Based on 20,000 Btuh per Burner, Derated 2% for Each 1000 Ft Above Sea Level)* U.S.A. and Canada ALTITUDE RANGE (FT) 0 to 2000 0% derate U.S.A. and Canada ALTITUDE RANGE (FT) U.S.A. Altitudes 2001 to 3000 or Canada Altitudes 2001 to 4500 5% derate U.S.A.
Table 13—Model PG9MAB Orifice Size and Manifold Pressure for Correct Input (Continued) For Use With 040 Through 120 Size Furnaces Only (Tabulated Data Based on 20,000 Btuh per Burner, Derated 2% for Each 1000 Ft Above Sea Level) U.S.A. Only ALTITUDE RANGE (FT) 4001 to 5000 9% derate U.S.A. Only ALTITUDE RANGE (FT) 5001 to 6000 11% derate U.S.A.
Table 13—Model PG9MAB Orifice Size and Manifold Pressure for Correct Input (Continued) For Use With 040 Through 120 Size Furnaces Only (Tabulated Data Based on 20,000 Btuh per Burner, Derated 2% for Each 1000 Ft Above Sea Level) U.S.A. Only ALTITUDE RANGE (FT) 7001 to 8000 15% derate U.S.A. Only ALTITUDE RANGE (FT) 8001 to 9000 17% derate U.S.A.
Table 14—Model PG9MAB Orifice Size and Manifold Pressure for Correct Input For Use with 140 Size Furnaces Only (Tabulated Data Based on 23,000 Btuh per Burner, Derated 2% for Each 1000 Ft Above Sea Level) * U.S.A. and Canada ALTITUDE RANGE (FT) 0 to 2000 0% derate U.S.A. and Canada ALTITUDE RANGE (FT) U.S.A. Altitudes 2001 to 3000 or Canade Altitudes 2001 to 4500 5% derate U.S.A.
Table 14—Model PG9MAB Orifice Size and Manifold Pressure for Correct Input (Continued) For Use with 140 Size Furnaces Only (Tabulated Data Based on 23,000 Btuh per Burner, Derated 2% for Each 1000 Ft Above Sea Level) ALTITUDE RANGE (FT) U.S.A. Only 4001 to 5000 9% derate U.S.A. Only ALTITUDE RANGE (FT) 5001 to 6000 11% derate ALTITUDE RANGE (FT) U.S.A.
BURNER ORIFICE A93059 Fig. 47—Burner Orifice d. Turn adjusting screw, counterclockwise (out) to decrease manifold pressure or clockwise (in) to increase manifold pressure. NOTE: This furnace has been approved for a manifold pressure of 3.2 in. wc to 3.8 in. wc when installed at altitudes up to 2000 ft. For altitudes above 2000 ft, the manifold pressure can be adjusted from 2.0 in. wc to 3.8 in. wc. If manifold pressure is outside of this range, change burner orifice to obtain pressure in this range.
;;;; REGULATOR SEAL CAP REGULATOR ADJUSTMENT SCREW BURNER FLAME BURNER ON/OFF SWITCH REGULATOR SPRING (PROPANE - WHITE, 6 TURNS NATURAL - SILVER, 10 TURNS) GAS PRESSURE REGULATOR ADJUSTMENT INLET PRESSURE TAP MANIFOLD PRESSURE TAP MANIFOLD A03142 Fig. 48—Redundant Automatic Gas Valve A89020 Fig. 49—Burner Flame Table 15—Altitude Derate Multiplier for U.S.A.
Table 16—Gas Rate (Cu Ft/Hr) SECONDS FOR 1 REVOLUTION 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 1 cu ft 360 327 300 277 257 240 225 212 200 189 180 171 164 157 150 144 138 133 129 124 120 116 113 109 106 103 100 97 95 92 90 88 86 84 82 80 78 76 75 73 SIZE OF TEST DIAL 2 5 cu ft cu ft 720 1800 655 1636 600 1500 555 1385 514 1286 480 1200 450 1125 424 1059 400 1000 379 947 360 900 343 857 327 818 313 783 300 750 288 720 277 692 26
Table 17—Speed Selector COLOR SPEED Black Yellow (When Present) Blue Red White High Medium High Medium Low Low Common FACTORY-SHIPPED CONNECTION Cool Spare Heat Spare Com Table 18—Blower Off Delay Setup Position PINS Time (in sec) 1 AND 2 90 2 AND 3 120 3 AND 4 150 4 AND 5 180 THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED HOOK-AROUND VOLT/AMMETER R Y W G 10 TURNS FROM UNIT 24-VOLT TERMINAL BLOCK EXAMPLE: 5.0 AMPS ON AMMETER 10 TURNS AROUND JAWS = 0.
CHECKLIST 1. Put away tools and instruments. Clean up debris. 2. Verify flame rollout manual reset switch has continuity. 3. Verify that blower and main access doors are properly installed. 4. Cycle test furnace with room thermostat. 5. Check operation of accessories per manufacturer’s instructions. 6. Review User’s Guide with owner. 7. Leave literature packet near furnace.
CHECKLIST—DIRECT VENT INSTALLATIONS LOAD CALCULATION ____________ Heating Load (Btuh) ____________ Cooling Load (Btuh) ____________ Furnace Model Selection COMBUSTION AIR AND VENT PIPING Termination Location ________ Roof or Sidewall ________ Termination Kit — 2 Pipe or Concentric ________ Combustion-Air Pipe Length ________ Combustion-Air Pipe Elbow Quantity ________ Vent Pipe Length ________ Vent Pipe Elbow Quantity ________ Pipe Diameter Determined from Sizing Table ________ Pipe Slo
CHECKLIST—NON-DIRECT VENT INSTALLATIONS LOAD CALCULATION ____________ Heating Load (Btuh) ____________ Cooling Load (Btuh) ____________ Furnace Model Selection VENT PIPING Termination Location ________ Roof or Sidewall ________ Vent Pipe Length ________ Vent Pipe Elbow Quantity ________ Pipe Diameter Determined from Sizing Table ________ Pipe Sloped To Furnace Pipe Insulation ________ Over Ceilings ________ Low-Ambient Exposed Pipes Condensate Drain ________ Unit Level or Pitched Forwar
© 2005 Payne Heating & Cooling 7310 W. Morris St., Indianapolis, IN 46231 —64— impg9mab01 Catalog No.
