Payne PG9MAB060140 Installation manual

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.....................................................................................................................................................................................2

CLEARANCES TO COMBUSTIBLES .......................................................................................................................................................................3

DIMENSIONAL DRAWING .......................................................................................................................................................................................4

CODES AND STANDARDS .......................................................................................................................................................................................6

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS .......................................................................................................................................7

INTRODUCTION..........................................................................................................................................................................................................8

APPLICATIONS ...........................................................................................................................................................................................................8

General......................................................................................................................................................................................................................8

Upflow Applications ................................................................................................................................................................................................9

Downflow Applications..........................................................................................................................................................................................10

Horizontal Left (Supply-Air Discharge) Applications ..........................................................................................................................................12

Horizontal Right (Supply-Air Discharge) Applications........................................................................................................................................15

LOCATION .................................................................................................................................................................................................................17

General....................................................................................................................................................................................................................17

Furnace Location Relative to Cooling Equipment................................................................................................................................................18

Location with Respect to Combustion and Circulating Air Requirements..........................................................................................................18

Hazardous Locations ..............................................................................................................................................................................................18

AIR FOR COMBUSTION AND VENTILATION....................................................................................................................................................20

INSTALLATION.........................................................................................................................................................................................................22

Leveling Legs (If Desired).....................................................................................................................................................................................22

Installation In Upflow or Downflow Applications ...............................................................................................................................................22

Installation In Horizontal Applications..................................................................................................................................................................23

Air Ducts ................................................................................................................................................................................................................23

General ..............................................................................................................................................................................................................23

Ductwork Acoustical Treatment .......................................................................................................................................................................23

Supply Air Connections....................................................................................................................................................................................25

Catalog No.

IM-PG9MAB-01 Cancels: IM-PG9M-10 Printed in U.S.A.

8-05

Return Air Connections.....................................................................................................................................................................................25

Filter Arrangement ............................................................................................................................................................................................26

Bottom Closure Panel........................................................................................................................................................................................27

Gas Piping..........................................................................................................................................................................................................28

Electrical Connections ............................................................................................................................................................................................28

115-v Wiring......................................................................................................................................................................................................29

24-v Wiring........................................................................................................................................................................................................31

Accessories ........................................................................................................................................................................................................31

Wiring Diagram.................................................................................................................................................................................................32

Removal of Existing Furnaces from Common Vent Systems ..............................................................................................................................33

Combustion Air and Vent Pipe Systems ...............................................................................................................................................................33

Condensate Drain .........................................................................................................................................................................................................47

General ....................................................................................................................................................................................................................47

Application ..............................................................................................................................................................................................................47

Condensate Drain Protection ..................................................................................................................................................................................48

START-UP, ADJUSTMENTS AND SAFETY CHECK ...........................................................................................................................................48

General ....................................................................................................................................................................................................................48

Prime Condensate Trap With Water ......................................................................................................................................................................48

Purge Gas Lines......................................................................................................................................................................................................49

Sequence of Operation............................................................................................................................................................................................49

Heating Mode ....................................................................................................................................................................................................49

Cooling Mode ....................................................................................................................................................................................................50

Continuous Blower Mode .................................................................................................................................................................................50

Heat Pump Mode...............................................................................................................................................................................................50

Component Test.................................................................................................................................................................................................50

Adjustments.............................................................................................................................................................................................................51

Set Gas Input Rate ............................................................................................................................................................................................51

Set Temperature Rise ........................................................................................................................................................................................58

Blower Off Delay (Heat Mode)........................................................................................................................................................................59

Set Thermostat Heat Anticipator ......................................................................................................................................................................59

Check Safety Controls.......................................................................................................................................................................................59

Check Primary Limit Control ......................................................................................................................................................................60

Check Pressure Switch.................................................................................................................................................................................60

CHECKLIST ................................................................................................................................................................................................................61

SAFETY CONSIDERATIONS

CAUTION: FURNACE RELIABILITY HAZARD

Improper installation or misapplication of furnace may require excessive servicing or cause premature component failure.

Application of this furnace should be indoors with special attention given to vent sizing and material, gas input rate, air temperature rise, unit leveling, and unit sizing.

WARNING: FIRE, EXPLOSION, ELECTRICAL SHOCK AND CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in electrical shock, fire, personal injury, or death.

Improper installation, adjustment, alteration, service, maintenance, or use can cause carbon monoxide poisoning, explosion, fire, electrical shock, or other conditions which may cause personal injury or property damage. Consult a qualified installer, service agency, local gas supplier, or your distributor or branch for information or assistance. The qualified installer or agency must use only factory-authorized and listed kits or accessories when modifying this product.

Installing and servicing heating equipment can be hazardous due to gas and electrical components. Only trained and qualified personnel should

install, repair, or service heating equipment. Untrained personnel can perform basic maintenance functions such as cleaning and replacing air filters. All other operations must be performed by trained service personnel. When working on heating equipment, observe precautions in literature, on tags, and on labels attached to or shipped with unit and other safety precautions that may apply.

—2—

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. This furnace may be installed in a manufactured (mobile) home when stated on rating plate and using factory authorized kit..

This furnace may be installed on combustible flooring in alcove or closet at Minimum Inches Clearance To Combustible Construction as described below.

This furnace requires a special venting system. Refer to the installation instructions for parts list and method of installation. This furnace is for use with schedule-40 PVC,

PVC-DWV, CPVC, or ABS-DWV pipe, and must not be vented in common with other gas-fired appliances. Construction through which vent/air intake pipes may be installed is maximum 24 inches (600 mm), minimum 3/4 inches (19 mm) thickness (including roofing materials).

Cette fournaise à air pulsé est équipée pour utilisation avec gaz naturel et altitudes comprises entre 0 - 3,050m (0 - 10,000 pi),excepté queles fournaises de 140 taille sont pour altitudes comprises entre 0 - 2,135m (0 - 7,000pi).

Utiliser une trousse de conversion, fournie par le fabricant, pour passer au gaz propane ou pour certaines installations au gaz naturel.

Cette fournaise à air pulsé est pour installation à líntérieur dans un bâtiment construit sur place. Cette fournaise à air pulse peut être installée dans une maison préfabriquée (maison mobile) si prescrit par la plaque signalétique et si l' on utilise une trousse specifiée par le fabricant.

Cette fournaise peut être installée sur un plancher combustible dans un enfoncement ou un placard en observant les Dégagement Minimum En Pouces Avec

Éléments De Construction Combustibles.

Cette fournaise nécessite un système d´évacuation spécial. La méthode dínstallation et la liste des pièces nécessaires figurent dans les instructions dínstallation. Cette fournaise doit sútiliser avec la tuyauterie des nomenclatures 40 PVC, PVC-DWV, CPVC, ou ABS-DWV et elle ne peut pas être ventilée conjointment avec dáutres appareils à gaz. Épaisseur de la construction au travers de laquelle il est possible de faire passer les tuyaux d'aération (admission/évacuation): 24 po (600 mm) maximum, 3/4 po (19mm) minimum (y compris la toiture).

For upflow and downflow applications, furnace must be installed level, or pitched within 1/2" of level. For a horizontal application, the furnace must be pitched minimum 1/4" to maximum of 1/2" forward for proper drainage. See Installation Manual for IMPORTANT unit support details on horizontal applications.

LEVEL (0") TO

1/2" MAX

MIN 1/4" TO 1/2" MAX

Pour des applications de flux ascendant et descendant, la fournaise doit être installée de niveau ou inclinée à pas plus de 1/2" du niveau. Pour une application horizontale, la fournaise doit être inclinée entre minimum

1/4" et maximum 1/2" du niveau pour le drainage approprié. En cas dínstallation en position horizontale, consulter les renseignements IMPORTANTS sur le support dans le manuel dínstallation.

UPFLOW OR

DOWNFLOW

FRONT

FRONT

HORIZONTAL

MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION

ALL POSITIONS:

Minimum front clearance for service 24 inches (610mm).

140 size furnaces require 1 inch back clearance to combustible materials.

† For installation on combustible floors only when installed on special base No. KGASB0201ALL,

Coil Assembly, Part No. CD5 or CK5, or Coil Casing, Part No. KCAKC.

HORIZONTAL POSITIONS::

Line contact is permissible only between lines formed by intersections of top and two sides of

§

Ø furnace jacket, and building joists, studs, or framing.

Clearance shown is for air inlet and air outlet ends.

120 and 140 size furnaces require 1 inch bottom clearance to combustible materials.

DÉGAGEMENT MINIMUM EN POUCES AVEC ÉLÉMENTS DE CONSTRUCTION COMBUSTIBLES

§

Dégagement avant minimum de 610mm (24 po) pour léntretien.

Pour les fournaises de 140 taille, 1 po (25mm) dégagement des matériaux combustibles est requis au-arriere.

POUR LA POSITION COURANT DESCENDANT:

† Pour línstallation sur le plancher combustible seulement quand on utilise la base spéciale, pièce nº KGASB0201ALL, lénsemble serpentin, pièce nº CD5 ou CK5, ou le carter de serpentin, pièce nº KCAKC.

POUR LA POSITION HORIZONTALE:

Le contact nést permis qúentre les lignes formées par les intersections du dessus et des deuxcôtés de la chemise de la fournaise, et des solives, des montants ou de la charpente du bátiment.

La distance indiquée concerne léxtrémité du tuyau dárrivée dáir et léxtrémité du tuyau de sortie

Ø dáir.

Pour les fournaises de 120 et 140 taille, 1 po (25mm) dégagement des matériaux combusitbles est requis au-dessous.

This furnace is approved for UPFLOW, DOWNFLOW and

HORIZONTAL installations.

Cette fournaise est approuvée pour línstallation HORIZONTALE et la circulation dáir VERS LE HAUT et VERS LE BAS.

1"

Clearance arrows do not change with furnace orientation.

††

A

0"

B

R

A

R I

C

E

K

R

E

§

0"

S I

C

D E

E S

O T

Clearance in inches

Dégagement (po).

S I

C

D E

E

O T

S

0"

F

A C

U

R N

U

R N

F O

F R

A

A

V

E

I

ON

A

S

T

N

E

T

A

F

V

R

A

O

N

N

T

T

3"

L È

S

NT

E

R

R V

E

T

I

I

C

E

N

E

0"

Ø

†

Les fléches de dégagement ne change pas avec lórientation de la générateur dáir chaud.

Vent clearance to

combustibles 0".

0 (po) Dégagement d´évent avec combustibles.

328066-201 REV. B LIT TOP

§

*

MIN

A04110

Fig. 1—Clearances to Combustibles

These instructions cover the minimum requirements and conform to existing national standards and safety codes. In some instances, these instructions exceed certain local codes and ordinances, especially those that may not have kept up with changing residential construction practices.

We require these instructions as a minimum for a safe installation.

Wear safety glasses and work gloves. Have a fire extinguisher available during start-up and adjustment procedures and service calls.

CAUTION: CUT HAZARD

Failure to follow this caution may result in personal injury.

Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing and gloves when handling parts.

Recognize safety information. This is the safety-alert symbol . When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal injury.

Understand these signal words DANGER, WARNING, and CAUTION. These words are used with the safety-alert symbol. DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices which may result in minor personal injury or product and property damage. NOTE is used

→ to highlight suggestions which will result in enhanced installation, reliability, or operation.

The PG9MAB Multipoise Condensing Gas-Fired Furnaces are CSA (formerly AGA and CGA) design-certified for natural and propane gases (see furnace rating plate) and for installation in alcoves, attics, basements, closets, utility rooms, crawlspaces, and garages. The furnace is factory-shipped for use with natural gas. A CSA listed gas conversion kit is required to convert furnace for use with propane gas.

See Fig. 1 for required clearances to combustibles.

—3—

—4—

AIRFLOW

UPFLOW

AIRFLOW

HORIZONTAL

LEFT

DOWNFLOW

HORIZONTAL

RIGHT

AIRFLOW

AIRFLOW

Fig. 3—Multipoise Orientations

A93041

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. In downflow installations, factory accessory floor base MUST be used when installed on combustible materials and wood flooring. Special base is not required

→ when this furnace is installed on manufacturer’s Coil Assembly Part No. CD5 or CK5, or when Coil Box Part No. KCAKC is used.

The PG9MAB 040 through 120 size units are CSA (formerly CGA and AGA) design-certified for use in manufactured (mobile) homes when factory accessory conversion kit is used. The 140 size unit is NOT design-certified for use in manufactured (mobile) homes. These furnaces are suitable for installation in a structure built on site or a manufactured building completed at final site. The design of this furnace line is NOT CSA design-certified for installation in recreation vehicles or outdoors.

This furnace is designed for continuous return-air minimum temperature of 60°F db or intermittent operation down to 55°F db such as when used with a night setback thermostat. Return-air temperature must not exceed 80°F db. Failure to follow these return-air limits may affect reliability of heat exchangers, motors and controls. (See Fig. 4.)

These furnaces are shipped with the drain and pressure tubes connected for UPFLOW applications. Minor modifications are required when used in DOWNFLOW, HORIZONTAL RIGHT, or HORIZONTAL LEFT (supply-air discharge direction) applications as shown in Fig. 3. See details in Applications section.

Install this furnace only in a location and position as specified in LOCATION and INSTALLATION sections of these instructions.

Combustion products must be discharged outdoors. Connect this furnace to an approved vent system only, as specified in the Combustion Air and

Vent piping sections of these instructions.

Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for detection of leaks to check all connections as specified in the GAS PIPING section of these instructions.

Always install the furnace to operate within the furnace’s intended rise range with a duct system which has an external static pressure within the allowable range as specified in the SET TEMPERATURE RISE section of these instructions.

When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by ducts sealed to the furnace casing and terminating outside the space containing the furnace.

A gas-fired furnace for installation in a residential garage must be installed as specified in the Hazardous Locations section of these instructions.

The furnace is not to be used for temporary heating of buildings or structures under construction unless the furnace installation and operation complies with the first CAUTION in the LOCATION section of these instructions.

0

Fig. 4—Return-Air Temperature

—5—

60

A05004

→

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. This prevents a negative pressure condition as created by the circulating air blower, causing a flame rollout and/or drawing combustion products into the structure.

• The furnace is controlled by a thermostat. It may not be ″hot wired″ to provide heat continuously to the structure without thermostatic control.

• Clean outside air is provided for combustion. This is to minimize the corrosive effects of adhesives, sealers and other construction materials.

It also prevents the entrainment of drywall dust into combustion air, which can cause fouling and plugging of furnace components.

• The temperature of the return air to the furnace is maintained between 55°F (13°C) and 80°F (27°C), with no evening setback or shutdown.

The use of the furnace while the structure is under construction is deemed to be intermittent operation per our installation instructions.

• The air temperature rise is within the rated rise range on the furnace rating plate, and the firing rate has been set to the nameplate value.

• The filters used to clean the circulating air during the construction process must be either changed or thoroughly cleaned prior to occupancy.

• The furnace, ductwork and filters are cleaned as necessary to remove drywall dust and construction debris from all HVAC system components after construction is completed.

• After construction is complete, verify furnace operating conditions including ignition, input rate, temperature rise and venting, according to the manufacturer’s instructions.

→

The furnace shall be installed so that the electrical components are protected by water.

These furnaces are shipped with the following materials to assist in proper furnace installation. These materials are shipped in the main blower compartment.

Installer Packet includes:

Installation Manual

Service Guide

User’s Information Manual

Warranty Certificate

Loose Parts Bag includes:

Pressure tube extension

Collector box or condensate trap extension tube

Inducer housing drain tube

1/2-in. CPVC street elbow

Drain tube coupling

Drain tube coupling grommet

Vent and combustion-air pipe support

Condensate trap hole filler plug

Vent and combustion-air intake hole filler plug

Combustion-air pipe perforated disk assembly

Vent Pipe Extension (ONLY supplied with some furnaces)

Quantity

1

1

1

2

1

3

2

1

2

1

1

For accessory installation details, refer to accessory installation instructions.

CODES AND STANDARDS

Follow all national and local codes and standards in addition to these instructions. The installation must comply with regulations of the serving gas supplier, local building, heating, plumbing, and other codes. In absence of local codes, the installation must comply with the national codes listed below and all authorities having jurisdiction.

In the United States and Canada, follow all codes and standards for the following:

PROCEDURE 1—SAFETY

• US: National Fuel Gas Code (NFGC) NFPA 54-2002/ANSI Z223.1-2002 and the Installation Standards, Warm Air Heating and Air

Conditioning Systems ANSI/NFPA 90B

→

• CANADA: National Standard of Canada, Natural Gas and Propane Installation Code (NSCNGPIC) CSA B149.1-05

PROCEDURE 2—GENERAL INSTALLATION

• US: NFGC and the NFPA 90B. For copies, contact the National Fire Protection Association Inc., Batterymarch Park, Quincy, MA 02269; or for only the NFGC contact the American Gas Association, 400 N. Capitol, N.W., Washington DC 20001

• CANADA: NSCNGPIC. For a copy, contact Standard Sales, CSA International, 178 Rexdale Boulevard, Etobicoke (Toronto), Ontario, M9W

1R3, Canada.

• A manufactured (Mobile) home installation must conform with the Manufactured Home Construction and Safety Standard, Title 24 CFR, Part

3280, or when this standard is not applicable, the Standard for Manufactured Home Installation (Manufactured Home Sites, Communities, and

Set-Ups), ANSI/NCS A225.1, and/or CAN/CSA-Z240, MH Series Mobile Homes

PROCEDURE 3—COMBUSTION AND VENTILATION AIR

• US: Section 8.3 of the NFGC, Air for Combustion and Ventilation

• CANADA: Part 7 of the NSCNGPIC, Venting Systems and Air Supply for Appliances

PROCEDURE 4—DUCT SYSTEMS

• US and CANADA: Air Conditioning Contractors Association (ACCA) Manual D, Sheet Metal and Air Conditioning Contractors National

Association (SMACNA), or American Society of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE) 2001 Fundamentals

Handbook Chapter 34.

—6—

BLOWER SHELF

CONDENSATE

TRAP (INSIDE)

FURNACE

DOOR

CONDENSATE

TRAP

FURNACE

SIDE

FURNACE

DOOR FURNACE

SIDE

ALTERNATE DRAIN

TUBE LOCATION

CONDENSATE TRAP

DRAIN TUBE LOCATION

UPFLOW APPLICATIONS

4

78

FIELD

DRAIN

CONN

26

1 4

SIDE VIEW

1

1 2

FRONT VIEW

DOWNFLOW AND ALTERNATE

EXTERNAL UPFLOW APPLICATIONS

4

5

3 4

5

3 4

4

26

1 4

FIELD

DRAIN

CONN

END VIEW

3 4

FRONT VIEW

HORIZONTAL

APPLICATIONS

3 4

SLOT FOR SCREW

HORIZONTAL

APPLICATION

(OPTIONAL)

1

1 2

7

1 8

1 ⁄

4

OD

COLLECTOR BOX TO

TRAP RELIEF PORT

1 ⁄

2

OD

INDUCER HOUSING

DRAIN CONNECTION

5 ⁄

8

OD

COLLECTOR BOX

DRAIN CONNECTION

SCREW HOLE FOR

UPFLOW OR DOWN-

FLOW APPLICATIONS

(OPTIONAL)

1 ⁄

2

-IN. PVC OR CPVC

1

3 4

WIRE TIE

GUIDES

(WHEN USED)

FRONT VIEW

7 8

2

1 4

SIDE VIEW

A93026

Fig. 5—Condensate Trap

PROCEDURE 5—ACOUSTICAL LINING AND FIBROUS GLASS DUCT

• US and CANADA: current edition of SMACNA, NFPA 90B as tested by UL Standard 181 for Class I Rigid Air Ducts

PROCEDURE 6—GAS PIPING AND GAS PIPE PRESSURE TESTING

• US: NFGC; chapters 5, 6, 7, and 12 and national plumbing codes

• CANADA: NSCNGPIC Part 3, 4, 5, A, B, E, and H.

NOTE: In the state of Massachusetts:

1. Gas supply connections MUST be performed by a licensed plumber or gas fitter.

2. When flexible connectors are used, the maximum length shall not exceed 36 inches (915 mm).

3. When lever handle type manual equipment shutoff valves are used, they shall be T-handle valves.

4. The use of copper tubing for gas piping is NOT approved by the state of Massachusetts.

PROCEDURE 7—ELECTRICAL CONNECTIONS

• US: National Electrical Code (NEC) ANSI/NFPA 70-2002

• CANADA: Canadian Electrical Code CSA C22.1

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

CAUTION: UNIT DAMAGE HAZARD

Failure to follow this caution may result in damage to unit components.

Electrostatic discharge can affect electronic components. Take precautions during furnace installation and servicing to protect the furnace electronic control. Precautions will prevent electrostatic discharges from personnel and hand tools which are held during the procedure. These precautions will help to avoid exposing the control to electrostatic discharge by putting the furnace, the control, and the person at the same electrostatic potential.

1. Disconnect all power to the furnace. Multiple disconnects may be required. DO NOT TOUCH THE CONTROL OR ANY WIRE

CONNECTED TO THE CONTROL PRIOR TO DISCHARGING YOUR BODY’S ELECTROSTATIC CHARGE TO GROUND.

—7—

PLUG

CAP

COLLECTOR BOX

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX

TUBE (PINK)

COLLECTOR BOX

TUBE (GREEN)

INDUCER HOUSING

(MOLDED) DRAIN

TUBE (BEHIND

COLLECTOR BOX

DRAIN TUBE)

COLLECTOR BOX

DRAIN TUBE (BLUE)

PLUG

CAP

COLLECTOR BOX

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX

TUBE (PINK)

COLLECTOR BOX

TUBE (GREEN)

COLLECTOR BOX

DRAIN TUBE (BLUE)

CONDENSATE

TRAP

FIELD-INSTALLED

FACTORY-SUPPLIED

DRAIN TUBE

COUPLING (LEFT

DRAIN OPTION)

CONDENSATE

TRAP

FIELD-INSTALLED

FACTORY-SUPPLIED

DRAIN TUBE

FIELD-INSTALLED

1

FACTORY-SUPPLIED

⁄

2

-IN. CPVC STREET

ELBOWS (2) FOR

LEFT DRAIN OPTION

FIELD-INSTALLED

FACTORY-SUPPLIED

DRAIN TUBE

COUPLING (RIGHT

DRAIN OPTION)

A00288

Fig. 6—Factory-Shipped Upflow Tube Configuration

(Shown With Blower Access Panel Removed)

INDUCER

HOUSING

DRAIN TUBE

(VIOLET)

A00289

Fig. 7—Alternate Upflow Tube Configuration and

Trap Location

2. Firmly touch a clean, unpainted, metal surface of the furnace chassis which is close to the control. Tools held in a person’s hand during grounding will be satisfactorily discharged.

3. After touching the chassis, you may proceed to service the control or connecting wires as long as you do nothing that recharges your body with static electricity (for example; DO NOT move or shuffle your feet, DO NOT touch ungrounded objects, etc.).

4. If you touch ungrounded objects (recharge your body with static electricity), firmly touch a clean, unpainted metal surface of the furnace again before touching control or wires.

5. Use this procedure for installed and uninstalled (ungrounded) furnaces.

6. Before removing a new control from its container, discharge your body’s electrostatic charge to ground to protect the control from damage.

If the control is to be installed in a furnace, follow items 1 through 5 before bringing the control or yourself into contact with the furnace.

Put all used AND new controls into containers before touching ungrounded objects.

7. An ESD service kit (available from commercial sources) may also be used to prevent ESD damage.

INTRODUCTION

The model PG9MAB 4-way multipoise, Gas-Fired, Category IV, direct-vent and non-direct vent, condensing furnace is available in model sizes ranging in input capacities of 40,000 to 138,000 Btuh.

CAUTION: MINOR PROPERTY DAMAGE

Failure to follow this caution may result in minor property damage.

Local codes may require a drain pan under entire furnace and condensate trap when a condensing furnace is used in an attic application or over a finished ceiling.

APPLICATIONS

PROCEDURE 1—GENERAL

Some assembly and modifications are required for furnaces installed in any of the 4 applications shown in Fig. 3. All drain and pressure tubes are connected as shown in Fig. 6. See appropriate application instructions for these procedures.

—8—

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. See Condensate Trap Tubing (Factory-Shipped

Orientation) section for drain tube extension details. (See Fig. 5.)

B.

Condensate Trap Tubing (Factory-Shipped Orientation)

NOTE: See Fig. 6 or tube routing label on main furnace door to confirm location of these tubes.

1. Collector Box Drain, Inducer Housing Drain, Relief Port, and Pressure Switch Tubes

These tubes should be factory attached to condensate trap and pressure switch ready for use in UPFLOW applications. These tubes can be identified by their connection location and also by a color label on each tube. These tubes are identified as follows: collector box drain tube

(blue label), inducer housing drain tube (violet label or molded), relief port tube (green label), and pressure switch tube (pink label).

2. Condensate Trap Drain Tube

The condensate trap drain connection must be extended for field attachment by doing the following: a. Determine location of field drain connection. (See Fig. 2 or 6.)

NOTE: If internal filter is used, drain tube should be located to opposite side of casing from return duct attachment to assist in filter removal.

b. Remove and discard casing drain hole plug button from desired side.

c. Install drain tube coupling grommet (factory-supplied in loose parts bag) in selected casing hole.

d. Slide drain tube coupling (factory-supplied in loose parts bag) through grommet ensuring long end of coupling faces blower.

e. Cement 2 factory-supplied 1/2-in. street CPVC elbows to the rigid drain tube connection on the condensate trap. (See Fig. 6.) These elbows must be cemented together and cemented to condensate trap drain connection.

NOTE: Failure to use CPVC elbows may allow drain to kink and prevent draining.

f. Connect larger diameter drain tube and clamp (factory-supplied in loose parts bag) to condensate trap and clamp securely.

g. Route tube to coupling and cut to appropriate length.

h. Attach tube to coupling and clamp securely.

C.

Condensate Trap Location (Alternate Upflow Orientation)

An alternate location for the condensate trap is the left-hand side of casing. (See Fig. 2 and 7.)

NOTE: If the alternate left-hand side of casing location is used, the factory-connected drain and relief port tubes must be disconnected and modified for attachment. See Condensate Trap Tubing (Alternate Upflow Orientation) section for tubing attachment.

To relocate condensate trap to the left-hand side, perform the following:

1. Remove 3 tubes connected to condensate trap.

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. Install condensate trap into left-hand side casing hole by inserting tube connection stubs through casing hole and rotating until tabs snap into locking position.

5. Fill unused condensate trap casing holes with plastic filler caps (factory-supplied in loose parts bag).

D.

Condensate Trap Tubing (Alternate Upflow Orientation)

NOTE: See Fig. 7 or tube routing label on main furnace door to confirm location of these tubes.

1. Collector Box Drain Tube

Connect collector box drain tube (blue label) to condensate trap.

NOTE: On 17-1/2-in. wide furnaces ONLY, cut tube between corrugated sections to prevent kinks from occurring.

2. Inducer Housing Drain Tube a. Remove and discard LOWER (molded) inducer housing drain tube which was previously connected to condensate trap.

b. Use inducer housing drain extension tube (violet label and factory-supplied in loose parts bag) to connect LOWER inducer housing drain connection to the condensate trap.

c. Determine appropriate length, cut, and connect tube.

d. Clamp tube to prevent any condensate leakage.

—9—

COLLECTOR BOX

DRAIN TUBE (BLUE)

CAP

PLUG

COLLECTOR BOX

TUBE (GREEN)

COLLECTOR BOX

EXTENSION TUBE

COLLECTOR BOX

TUBE (PINK)

COLLECTOR BOX

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX

EXTENSION TUBE

CONDENSATE

TRAP

PLUG

CAP

COLLECTOR BOX

DRAIN TUBE (BLUE)

COLLECTOR BOX

TUBE (PINK)

COLLECTOR BOX

TUBE (GREEN)

COLLECTOR BOX

EXTENSION TUBE

COLLECTOR BOX

DRAIN TUBE (BLUE

& WHITE STRIPED)

COLLECTOR BOX

EXTENSION TUBE

INDUCER HOUSING

DRAIN TUBE

(VIOLET)

CONDENSATE

TRAP

COLLECTOR BOX

EXTENSION

DRAIN TUBE

INDUCER HOUSING

DRAIN TUBE (VIOLET)

DRAIN TUBE

COUPLING

A00262

Fig. 8—Downflow Tube Configuration

(Left-Hand Trap Installation)

Fig. 9—Downflow Tube Configuration

(Right-Hand Trap Installation)

3. Relief Port Tube a. Connect relief port tube (green label) to condensate trap.

b. Extend this tube (if required) by splicing to small diameter tube (factory-supplied in loose parts bag).


A00296

E.

Condensate Trap Field Drain Attachment

Refer to Condensate Drain section for recommendations and procedures.

F.

Pressure Switch Tubing

The LOWER collector box pressure tube (pink label) is factory connected to the pressure switch and should not require any modification.

NOTE: See Fig. 6 or 7 or tube routing label on main furnace door to check for proper connections.

G.

Upper Collector Box and Inducer Housing (Unused) Drain Connections

UPPER COLLECTOR BOX DRAIN CONNECTION

Attached to the UPPER collector box drain connection is a factory-installed corrugated, plugged tube (blue and white striped label). This tube is plugged to prevent condensate leakage in this application. Ensure this tube is plugged.


UPPER INDUCER HOUSING DRAIN CONNECTION

Attached to the UPPER (unused) inducer housing drain connection is a cap and clamp. This cap is used to prevent condensate leakage in this application. Ensure this connection is capped.


H.

Condensate Trap Freeze Protection

Refer to Condensate Drain Protection section for recommendations and procedures.

PROCEDURE 3—DOWNFLOW APPLICATIONS

A downflow furnace application is where furnace blower is located above combustion and controls section of furnace, and conditioned air is discharged downwards.

A.

Condensate Trap Location

The condensate trap must be removed from the factory-installed blower shelf location and relocated in selected application location as shown in

Fig. 2, 8, or 9.

To relocate condensate trap from the blower shelf to desired location, perform the following:


—10—








B.

Condensate Trap Tubing


1. Collector Box Drain Tube a. Remove factory-installed plug from LOWER collector box drain tube (blue and white striped label).

b. Install removed clamp and plug into UPPER collector box drain tube (blue label) which was connected to condensate trap.

c. Connect LOWER collector box drain connection to condensate trap.

Condensate Trap Located on Left Side of Casing

(1.) Connect LOWER collector box drain tube (blue and white striped label) to condensate trap. Tube does not need to be cut.

(2.) Clamp tube to prevent any condensate leakage.

Condensate Trap Located on Right Side of Casing

(1.) Install drain tube coupling (factory-supplied in loose parts bag) into collector box drain tube (blue and white striped label) which was previously plugged.

(2.) Connect larger diameter drain tube (factory-supplied in loose parts bag) to drain tube coupling, extending collector box drain tube for connection to condensate trap.

(3.) Route extended collector box drain tube directly from collector box drain to condensate trap as shown in Fig. 9.

(4.) Determine appropriate length and cut.

(5.) Connect to condensate trap.


2. Inducer Housing Drain Tube a. Remove factory-installed cap and clamp from LOWER inducer housing drain connection.

b. Remove and discard UPPER (molded) inducer housing drain tube which was previously connected to condensate trap.

c. Install cap and clamp on UPPER inducer housing drain connection where molded drain tube was removed.

d. Use inducer housing drain tube (violet label and factory-supplied in loose parts bag) to connect LOWER inducer housing drain connection to the condensate trap.

e. Connect inducer housing drain connection to condensate trap.

Condensate Trap Located on Left Side of Casing


(2.) Connect tube to condensate trap.


Condensate Trap Located on Right Side of Casing

(1.) Route inducer housing drain tube (violet label) directly from inducer housing to condensate trap as shown in Fig. 9.


(3.) Connect tube to condensate trap.


3. Relief Port Tube

Refer to Pressure Switch Tubing section for connection procedure.

C.



D.


One collector box pressure tube (pink label) is factory connected to the pressure switch for use when furnace is installed in UPFLOW applications.

This tube MUST be disconnected and used for the condensate trap relief port tube. The other collector box pressure tube (green label) which was factory connected to the condensate trap relief port connection MUST be connected to the pressure switch in DOWNFLOW or HORIZONTAL

RIGHT applications.

—11—


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. Connect collector box pressure tube (green label) to pressure switch connection labeled COLLECTOR BOX.

4. Extend collector box pressure tube (pink label) which was previously connected to pressure switch by splicing to remaining small diameter tube (factory-supplied in loose parts bag).

5. Route this extended tube (pink label) to condensate trap relief port connection.

6. Determine appropriate length, cut, and connect tube.

7. Clamp tube to relief port connection.

E.



PROCEDURE 4—HORIZONTAL LEFT (SUPPLY-AIR DISCHARGE) APPLICATIONS

A horizontal left furnace application is where furnace blower is located to the right of combustion and controls section of furnace, and conditioned air is discharged to the left.

NOTE: The auxiliary junction box (J-Box) MUST be relocated to opposite side of furnace casing. (See Fig. 10.) See Electrical Connection section for J-Box relocation.

A.



Fig. 2 or 10.










B.


NOTE: See Fig. 10 or tube routing label on main furnace door to check for proper connections.

1. Collector Box Drain Tube a. Install drain tube coupling (factory-supplied in loose parts bag) into collector box drain tube (blue label) which was previously connected to condensate trap.

b. Connect large diameter drain tube and clamp (factory-supplied in loose parts bag) to drain tube coupling, extending collector box drain tube.

c. Route extended tube (blue label) to condensate trap and cut to appropriate length.


2. Inducer Housing Drain Tube a. Remove and discard LOWER (molded) inducer housing drain tube which was previously connected to condensate trap.

b. Use inducer housing drain extension tube (violet label and factory-supplied in loose parts bag) to connect LOWER inducer housing drain connection to the condensate trap.



3. Relief Port Tube a. Extend collector box tube (green label) which was previously connected to the condensate trap by splicing to small diameter tube

(factory-supplied in loose parts bag).

b. Route extended collector box pressure tube to relief port connection on the condensate trap.


—12—

PLUG

AUXILIARY " J " BOX

CAP

COLLECTOR BOX

DRAIN TUBE

(BLUE AND WHITE STRIPED)

CONDENSATE

TRAP

COLLECTOR BOX

TUBE (GREEN)

COLLECTOR

BOX EXTENSION

DRAIN TUBE

COLLECTOR BOX

EXTENSION TUBE

DRAIN TUBE COUPLING

COLLECTOR BOX TUBE (PINK)

RELOCATE TUBE BETWEEN BLOWER SHELF AND INDUCER HOUSING FOR

040, 060, AND 080 HEATING INPUT FURNACES

INDUCER HOUSING

DRAIN TUBE (VIOLET)

COLLECTOR BOX

DRAIN TUBE (BLUE)

A00215

Fig. 10—Horizontal Left Tube Configuration d. Clamp tube to prevent any condensate leakage.

C.



D.


The LOWER collector box pressure tube (pink label) is factory connected to the pressure switch for use when furnace is installed in UPFLOW applications. This tube MUST be disconnected, extended, rerouted, and then reconnected to the pressure switch in HORIZONTAL LEFT applications.


Modify tube as described below.


2. Use smaller diameter tube (factory-supplied in loose parts bag) to extend tube disconnected in item 1.

3. Route extended tube: a. Behind inducer housing.

b. Between blower shelf and inducer housing.

c. Behind inducer motor bracket.

d. Between inducer motor and pressure switch.

4. Determine appropriate length, cut, and reconnect tube to pressure switch connection labeled COLLECTOR BOX.

E.



F.

Construct a Working Platform

Construct working platform where all required furnace clearances are met. (See Fig. 2 and 11 or 12.)

CAUTION: UNIT MAY NOT OPERATE

Failure to follow this caution may result in intermittent unit operation.

The condensate trap MUST be installed below furnace. See Fig. 5 for dimensions. The drain connection to condensate trap must also be properly sloped to an open drain.

—13—

COMBUSTION – AIR

INTAKE

VENT

A 12-IN. MIN HORIZONTAL PIPE

SECTION IS RECOMMENDED WITH

SHORT (5 TO 8 FT) VENT SYSTEMS

TO REDUCE EXCESSIVE

30

″

MIN

WORK AREA

CONDENSATE DROPLETS FROM

EXITING THE VENT PIPE.

5

3

⁄

4

″

MANUAL

SHUTOFF

GAS VALVE

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.

Fig. 11—Attic Location and Working Platform for Direct Vent Applications (All Sizes)

A93031

COMBUSTION–AIR

INTAKE

A 3-IN. MINIMUM CLEARANCE

TO COMBUSTION-AIR INTAKE

IS REQUIRED.

VENT

A 12-IN. MIN HORIZONTAL PIPE

SECTION IS RECOMMENDED WITH

SHORT (5 TO 8 FT) VENT SYSTEMS

TO REDUCE EXCESSIVE

CONDENSATE DROPLETS FROM

30-IN. MIN

WORK AREA

EXITING THE VENT PIPE.

5

3

⁄

4

″

MANUAL

SHUTOFF

GAS VALVE

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.

Fig. 12—Attic Location and Working Platform for Non-Direct Vent Applications (Sizes 040 through 120 Only)

A96184

—14—

PLUG

CAP

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. minimum offset pipe section is recommended with short (5 to 8 ft) vent systems. This recommendation is to reduce excessive condensate droplets from exiting the vent pipe. (See Fig. 11, 12, or 40.)

NOTE: The 140 Size unit may not be installed in non-direct vent applications.

PROCEDURE 5—HORIZONTAL RIGHT (SUPPLY-AIR DISCHARGE) APPLICATIONS

A horizontal right furnace application is where furnace blower is located to the left of combustion and controls section of furnace, and conditioned air is discharged to the right.

CAUTION: MINOR PROPERTY DAMAGE

Failure to follow this caution may result in minor property damage.

Local codes may require a drain pan under entire furnace and condensate trap when a condensing furnace is used in attic application or over a finished ceiling.

NOTE: In Canada, installations shall be in accordance with current NSCNGPIC Installation Codes and/or local codes.

NOTE: The auxiliary junction box (J-Box) MUST be relocated to opposite side of furnace casing. (See Fig. 13.) See Electrical Connection section for J-Box relocation.

A.



Fig. 2 or 13.










B.



1. Collector Box Drain Tube a. Remove factory-installed plug from LOWER collector box drain tube (blue and white striped label).

—15—

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.


2. Inducer Housing Drain Tube a. Remove factory-installed cap and clamp from LOWER inducer housing drain connection.

b. Remove and discard UPPER (molded) inducer housing drain tube which was previously connected to condensate trap.

c. Install cap and clamp on UPPER inducer housing drain connection where molded drain tube was removed.

d. Use inducer housing drain extension tube (violet label and factory-supplied in loose parts bag) to connect LOWER inducer housing drain connection to condensate trap.

e. Determine appropriate length, cut, and connect tube to condensate trap.

f. Clamp tube to prevent any condensate leakage.

3. Relief Port Tube

Refer to Pressure Switch Tubing section for connection procedure.

C.



D.


One collector box pressure tube (pink label) is factory connected to the pressure switch for use when furnace is installed in UPFLOW applications.

This tube MUST be disconnected and used for the condensate trap relief port tube. The other collector box pressure tube (green label) which was factory connected to the condensate trap relief port connection MUST be connected to the pressure switch in DOWNFLOW or HORIZONTAL

RIGHT applications.


Relocate tubes as described below.


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. Route extended collector box pressure tube behind inducer motor bracket then between inducer motor and pressure switch.

4. Connect collector box pressure tube (green label) to pressure switch connection labeled COLLECTOR BOX.

5. Use remaining smaller diameter tube (factory-supplied in loose parts bag) to extend collector box pressure tube (pink label) which was previously connected to pressure switch.

6. Route this extended tube (pink label) to condensate trap relief port connection.

7. Determine appropriate length, cut, and connect tube.

8. Clamp tube to relief port connection.

E.



F.

Construct a Working Platform

Construct working platform where all required furnace clearances are met. (See Fig. 2 and 11 or 12.)



The condensate trap MUST be installed below furnace. See Fig. 5 for dimensions. The drain connection to condensate trap must also be properly sloped to an open drain.

NOTE: Combustion-air and vent pipes are restricted to a minimum length of 5 ft. (See Table 9 or 11.)

NOTE: A 12-in. minimum offset pipe section is recommended with short (5 to 8 ft) vent systems. This recommendation is to reduce excessive condensate droplets from exiting the vent pipe. (See Fig. 11, 12, and 40.)


—16—

LEVEL (0

″

)

TO

1 ⁄

2

″

MAX

FRONT

UPFLOW OR DOWNFLOW

MIN 1 ⁄

4

″

1

TO

⁄

2

″

MAX

FRONT

HORIZONTAL

A02146

Fig. 14—Furnace Location for Proper Condensate

Drainage

LOCATION


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.

• be located where available electric power and gas supplies meet specifications on the furnace rating plate.

• be attached to an air distribution system and be located as close to the center of the distribution system as possible. Refer to Air Ducts section.

• be provided with ample space for servicing and cleaning. Always comply with minimum fire protection clearances shown on the furnace clearance to combustibles label.

NOTE: For upflow/downflow applications install furnace so that it is level or pitched forward within 1/2-in. for proper furnace operation. For horizontal applications pitch 1/4-in. minimum to 1/2-in. maximum forward to ensure proper condensate drainage from secondary heat exchangers.

(See Fig. 14.)

When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by duct(s) sealed to furnace casing and terminating outside the space containing the furnace to ensure there will not be a negative pressure condition within equipment room or space.

FRONT

B

A

C

K

BACK

FRONT

Fig. 15—Prohibit Installation on Back

A93043

WARNING: FIRE, INJURY OR DEATH HAZARD

Failure to follow this warning could result in fire, property damage, personal injury, or death.

Do not install furnace on its back. Safety control operation will be adversely affected. Never connect return-air ducts to back of furnace.

(See Fig. 15.)

—17—


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. This prevents a negative pressure condition as created by the circulating air blower, causing a flame rollout and/or drawing combustion products into the structure.

-The furnace is controlled by a thermostat. It may not be ″ hot wired ″ to provide heat continuously to the structure without thermostatic control.

-Clean outside air is provided for combustion. This is to minimize the corrosive effects of adhesives, sealers and other construction materials. It also prevents the entrainment of drywall dust into combustion air, which can cause fouling and plugging of furnace components.

-The temperature of the return air to the furnace is maintained between 55°F (13°C) and 80°F (27°C), with no evening setback or shutdown. The use of the furnace while the structure is under construction is deemed to be intermittent operation per our installation instructions.

-The air temperature rise is within the rated rise range on the furnace rating plate, and the firing rate has been set to the nameplate value.

-The filters used to clean the circulating air during the construction process must be either changed ot thoroughly cleaned prior to occupancy.

-The furnace, ductwork and filters are cleaned as necessary to remove drywall dust and construction debris from all HVAC system components after construction is completed.

-After construction is complete, verify furnace operating conditions including ignition, input rate, temperature rise and venting, according to the manufacturer’s instructions.

PROCEDURE 2—FURNACE LOCATION RELATIVE TO COOLING EQUIPMENT

The cooling coil must be installed parallel with or on downstream side of furnace to avoid condensation in heat exchanger. When installed parallel with a furnace, dampers or other means used to control flow of air shall prevent chilled air from entering furnace. If dampers are manually operated, they must be equipped with a means to prevent operation of either unit unless damper is in full-heat or full-cool position.

32 ° F MINIMUM INSTALLED

AMBIENT OR FREEZE

PROTECTION REQUIRED

A93058

Fig. 16—Freeze Protection


Failure to follow this caution may result in minor property or unit damage.

If these furnaces are installed in an unconditioned space where ambient temperatures may be 32°F or lower, freeze protection measures must be taken. (See Fig. 16.)

PROCEDURE 3—LOCATION WITH RESPECT TO COMBUSTION AND CIRCULATING AIR REQUIREMENTS

WARNING: FIRE, EXPLOSION, INJURY, OR DEATH HAZARD

Improper location or inadequate protection could result in fire or explosion.

When furnace is installed in a residential garage, it must be installed so that burners and ignition sources are located a minimum of

18-in. above floor. The furnace must be located or protected to avoid physical damage by vehicles. When furnace is installed in a public garage, airplane hangar, or other building having a hazardous atmosphere, unit must be installed in accordance with NFGC or

NSCNGPIC (See Fig. 17.)

PROCEDURE 4—HAZARDOUS LOCATIONS

A.

Direct Vent Applications

Furnace may be located in a confined space without special provisions for dilution or ventilation air.

—18—

DUCTS

TO

OUTDOORS

1 SQ IN.

PER 4000

BTUH*

CIRCULATING AIR

DUCTS

VENT THROUGH ROOF

12

″

MAX

1 SQ IN.

PER 2000

BTUH*

B

D

VENT

THROUGH

ROOF

F

12

″

MAX

1 SQ IN.

PER

4000

BTUH*

DUCTS

TO

OUTDOORS

1 SQ IN.

PER 2000

BTUH*

12

″

MAX

A

E G

C

12 ″ MAX

1 SQ IN.

PER

4000

BTUH*

12

″

MAX

CIRCULATING AIR DUCTS

DUCT

TO

OUTDOORS

1 SQ IN.

PER 4000

BTUH*

*Minimum dimensions of 3 in.

NOTE: Use any of the following combinations of openings:

A & B C & D D & E F & G

A03174

Fig. 18—Air for Combustion, Ventilation, and Dilution for

Outdoors

INTERIOR

HEATED

SPACE

12" MAX

1 SQ IN.

PER 1000

BTUH* IN DOOR

OR WALL

UNCONFINED

SPACE

6" MIN

(FRONT)

†

1 SQ IN.

PER 1000

BTUH* IN DOOR

OR WALL

12" MAX

CIRCULATING AIR DUCTS

* Minimum opening size is 100 sq in. with

minimum dimensions of 3 in.

† Minimum of 3 in. . when type-B1 vent is used.

A03175

Fig. 19—Air for Combustion, Ventilation, and Dilution from

Indoors

18-IN. MINIMUM

TO BURNERS

Fig. 17—Installation in a Garage

A93044

B.

Non-Direct Vent Applications



Do not install furnace in a corrosive or contaminated atmosphere. Make sure all combustion and circulating air requirements are met.

Refer to the Air for Combustion and Ventilation section for details.

—19—

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.

WARNING: FURNACE CORROSION HAZARD

Air for combustion must not be contaminated by halogen compounds, which include fluoride, chloride, bromide, and iodide. These elements may corrode heat exchangers and shorten furnace life. Air contaminants are found in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air fresheners, and other household products.

The following types of furnace installations may require OUTDOOR AIR for combustion due to chemical exposures:

• Commercial buildings

• Buildings with indoor pools

• Laundry rooms

• Hobby or craft rooms, and

• Chemical storage areas

If air is exposed to the following substances, it should not be used for combustion air, and outdoor air may be required for combustion:

• Permanent wave solutions

• Chlorinated waxes and cleaners

• Chlorine based swimming pool chemicals

• Water softening chemicals

• De-icing salts or chemicals

• Carbon tetrachloride

• Halogen type refrigerants

• Cleaning solvents (such as perchloroethylene)

• Printing inks, paint removers, varnishes, etc.

• Hydrochloric acid

• Cements and glues

• Antistatic fabric softeners for clothes dryers

• Masonry acid washing materials

All fuel-burning equipment must be supplied with air for fuel combustion. Sufficient air must be provided to avoid negative pressure in the equipment room or space. A positive seal must be made between the furnace cabinet and the return-air duct to prevent pulling air from the burner area and from draft safeguard opening.


The operation of exhaust fans, kitchen ventilation fans, clothes dryers, attic exhaust fans or fireplaces could create a NEGATIVE

PRESSURE CONDITION at the furnace. Make-up air MUST be provided for the ventilation devices, in addition to that required by the furnace. Refer to the Carbon Monoxide Poisoning Hazard warning in the venting section of these instructions to determine if an adequate amount of make-up air is available.

The requirements for combustion and ventilation air depend upon 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.

• Spaces having less than 50 cubic feet per 1,000 Btuh require the OUTDOOR COMBUSTION AIR METHOD.

• Spaces having at least 50 cubic feet per 1,000 Btuh may use the INDOOR COMBUSTION AIR, STANDARD or KNOWN-AIR

INFILTRATION METHOD.

Outdoor Combustion Air Method

1. Provide the space with sufficient air for proper combustion, ventilation, and dilution of flue gases using permanent horizontal or vertical duct(s) or opening(s) directly communicating with the outdoors or spaces that freely communicate with the outdoors.

2. Fig. 18 illustrates how to provide TWO OUTDOOR OPENINGS, one inlet and one outlet combustion and ventilation air openings to the outdoors.

a. One opening MUST commence within 12 ″ (300 mm) of the ceiling and the second opening MUST commence within 12″ (300 mm) of the floor.

b. Size openings and ducts per Fig. 18 and Table 1.

c. TWO HORIZONTAL DUCTS require 1 square inch of free area per 2,000 Btuh (1,100 mm

2

/kW) of combined input for all gas appliances in the space per Fig. 18 and Table 1.

d. TWO OPENINGS OR VERTICAL DUCTS require 1 square inch of free area per 4,000 Btuh (550 mm

2

/kW) for combined input of all gas appliances in the space per Fig. 18 and Table 1.

—20—

Table 1—Minimum Free Area Required for Each Combustion Air Opening or Duct to Outdoors

FURNACE

INPUT

(BTUH)

44,000

66,000

88,000

110,000

132,000

154,000

TWO HORIZONTAL DUCTS

(1 SQ. IN./2,000 BTUH) (1,100 SQ. MM/KW)

Free Area of

Opening and Duct

(Sq. In.)

Round Duct

(in. Dia)

22

33

44

55

66

77

6

7

8

9

10

10

SINGLE DUCT OR OPENING

(1 SQ. IN./3,000 BTUH) (734 SQ. MM/KW)

Free Area of

Opening and Duct

(sq In.)

Round Duct

(in. Dia)

14.7

22

29.3

36.7

44

51.3

5

6

7

7

8

9

TWO OPENINGS OR VERTICAL DUCTS

(1 SQ. IN./4,000 BTUH) (550 SQ. MM/KW)

Free Area of

Opening and Duct

(Sq In.)

Round Duct

(In. Dia)

11

16.5

22

27.5

33

38.5

4

5

6

6

7

8

EXAMPLES: Determining Free Area

FURNACE

110,000

66,000

88,000

+

+

+

WATER HEATER

30,000

40,000

30,000

=

=

=

TOTAL INPUT

(140,000 divided by 4,000)

(106,000 divided by 3,000)

(118,000 divided by 2,000)

=

=

=

35.0 Sq. In. for each two Vertical Ducts or Openings

35.3 Sq. In. for a Single Duct or Opening

59.0 Sq. In. for each of two Horizontal Ducts

ACH

0.60

0.50

0.40

0.30

0.20

0.10

0.00

Table 2—Minimum Space Volumes for 100% Combustion, Ventilation and Dilution Air from Outdoors

OTHER THAN FAN-ASSISTED TOTAL

(1,000’S BTUH GAS INPUT RATE)

30 40 50

1,050

1,260

1,575

2,100

3,150

6,300

NP

1,400

1,680

2,100

2,800

4,200

8,400

NP

1,750

2,100

2,625

3,500

5,250

10,500

NP

44 66

Space Volume (ft

3

)

FAN-ASSISTED TOTAL

(1,000’S BTUH GAS INPUT RATE)

88 110 132

1,100

1,320

1,650

2,200

1,650

1,980

2,475

3,300

2,200

2,640

3,300

4,400

2,750

3,300

4,125

5,500

3,300

3,960

4,950

6,600

3,300

6,600

NP

4,950

9,900

NP

6,600

13,200

NP

8,250

16,500

NP

9,900

19,800

NP

154

3,850

4,620

5,775

7,700

11,550

23,100

NP

3. ONE OUTDOOR OPENING requires: a. 1 square inch of free area per 3,000 Btuh (734 mm

2

/kW) for combined input of all gas appliances in the space per Table 1 and b. Not less than the sum of the areas of all vent connectors in the space.

The opening shall commence within 12

″ (300 mm) of the ceiling. Appliances in the space shall have clearances of at least 1″ (25 mm) from the sides and back and 6

″ (150 mm) from the front. The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces (crawl or attic) that freely communicate with the outdoors.

Indoor Combustion Air© NFPA & AGA

Standard and Known-Air-Infiltration Rate Methods

Indoor air is permitted for combustion, ventilation, and dilution, if the Standard or Known-Air-Infiltration Method is used.


Failure to supply outdoor air via grilles or ducts could result in death and/or personal injury.

Many homes require air to be supplied from outdoors for furnace combustion, ventilation, and dilution of flue gases.

The furnace combustion air supply must be provided in accordance with this instruction manual.

The Standard Method:

1. The space has no less volume than 50 cubic feet per 1,000 Btuh of the maximum input ratings for all gas appliances installed in the space and

2. The air infiltration rate is not known to be less than 0.40 air changes per hour (ACH).

The Known Air Infiltration Rate Method shall be used, if the infiltration rate is known to be:

1. Less than 0.40 ACH and

2. Equal to or greater than 0.10 ACH

Infiltration rates greater than 0.60 ACH shall not be used. The minimum required volume of the space varies with the number of ACH and shall be determined per Table 2 or Equations 1 and 2. Determine the minimum required volume for each appliance in the space and add the volumes together to get the total minimum required volume for the space.

—21—

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

= 21ft

3

ACH

I other

1000 Btu/hr

A04002

2. For fan-assisted appliances such as this furnace:

Volume

Fan

= 15ft

3

ACH

I fan

1000 Btu/hr

A04003

If:

I other

= combined input of all other than fan-assisted appliances in Btu/hr

I fan

= combined input of all fan-assisted appliances in Btu/hr

ACH = air changes per hour (ACH shall not exceed 0.60.)

The following requirements apply to the Standard Method and to the Known Air Infiltration Rate Method.

1. Adjoining rooms can be considered part of a space if: a. There are no closable doors between rooms.

b. Combining spaces on same floor level. Each opening shall have free area of at least 1 in.

2

/1,000 Btuh (2,000 mm

2

/kW) of the total input rating of all gas appliances in the space, but not less than 100 in.

2

(0.06 m

2

). One opening shall commence within 12 ″ (300 mm) of the ceiling and the second opening shall commence within 12

″ (300 mm) of the floor. The minimum dimension of air openings shall be at least 3 in. (80 mm). (See Fig. 19.) c. Combining space on different floor levels. The volumes of spaces on different floor levels shall be considered as communicating spaces if connected by one or more permanent openings in doors or floors having free area of at least 2 in.

2

/1,000 Btuh (4,400 mm

2

/kW) of total input rating of all gas appliances.

2. An attic or crawlspace may be considered a space that freely communicates with the outdoors provided there are adequate permanent ventilation openings directly to outdoors having free area of at least 1-in.

2

/4,000 Btuh of total input rating for all gas appliances in the space.

3. In spaces that use the Indoor Combustion Air Method, infiltration should be adequate to provide air for combustion, permanent ventilation and dilution of flue gases. However, in buildings with unusually tight construction, additional air MUST be provided using the methods described in the Outdoor Combustion Air Method section.

Unusually tight construction is defined as

Construction with: a. Walls and ceilings exposed to the outdoors have a continuous, sealed vapor barrier. Openings are gasketed or sealed and b. Doors and openable windows are weatherstripped and c. Other openings are caulked or sealed. These include joints around window and door frames, between sole plates and floors, between wall-ceiling joints, between wall panels, at penetrations for plumbing, electrical and gas lines, etc.

NOTE: In determining the free area of an opening, the blocking effect of the louvers, grilles, and screens must be considered. If the free area of a louver or grille design is unknown, it may be assumed that wood louvers have a 20 percent free area, and metal louvers or grilles have a 60 percent free area. Screens, when used, must not be smaller than 1/4-in. mesh. Louvers and grilles must be constructed so they cannot be closed.

When combustion air ducts are used, they must be of the same cross sectional area as the free area of the openings to which they connect. The minimum dimension of ducts must not be less than 3 in. (80mm).

INSTALLATION

PROCEDURE 1—LEVELING LEGS (IF DESIRED)

When furnace is used in upflow position with side inlet(s), leveling legs may be desired. (See Fig. 20.) Install field-supplied, corrosion-resistant

5/16-in. machine bolts and nuts.

NOTE: The maximum length of bolt should not exceed 1-1/2 in.

1. Position furnace on its back. Locate and drill a 5/16-in. diameter hole in each bottom corner of furnace. (See Fig. 20.) Holes in bottom closure panel may be used as guide locations.

2. For each hole, install nut on bolt and then install bolt and nut in hole. (Install flat washer if desired.)

3. Install another nut on other side of furnace base. (Install flat washer if desired.)

4. Adjust outside nut to provide desired height, and tighten inside nut to secure arrangement.

NOTE: Bottom closure must be used when leveling legs are used. See Bottom Closure Panel section.

PROCEDURE 2—INSTALLATION IN UPFLOW OR DOWNFLOW APPLICATIONS

NOTE: For downflow applications, this furnace is approved for use on combustible flooring when manufacturer’s accessory floor base Part No.

KGASB0201ALL is used. Manufacturer’s accessory floor base in not required when this furnace is installed on manufacturer’s Coil Assembly Part

No. CD5, CK5, or Coil Box Part No. KCAKC is used.

—22—

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.

NOTE: Remove furnace perforated, discharge duct flanges when they interfere with mating flanges on coil on downflow subbase. To remove furnace perforated, discharge duct flange, use wide duct pliers or duct flange tool to bend flange back and forth until it breaks off. Be careful of sharp edges. (See Fig. 24.)



Do not bend duct flanges inward as shown in Fig. 24. This will affect airflow across heat exchangers and may cause limit cycling or premature heat exchanger failure. Remove duct flange completely or bend it inward a minimum of 210° as shown in Fig. 24.

NOTE: For 140 size unit when installed in downflow orientation, cut the white jumper wire off between terminals PL1-7 and PL1-9. Do not cut white jumper between terminals PL1-7 and PLI-11. Refer to Fig. 35 for location of jumper. Cut jumper close to connector and remove wire to avoid a short circuit.

PROCEDURE 3—INSTALLATION IN HORIZONTAL APPLICATIONS



The entire length of furnace MUST be supported when furnace is used in a horizontal position to ensure proper draining. When suspended, bottom brace supports sides and center blower shelf. When unit is supported from the ground, blocks or pad should support sides and center blower shelf area.

These furnaces can be installed horizontally in either horizontal left or right discharge position. In a crawlspace, furnace can either be hung from floor joist or installed on suitable blocks or pad. Furnace can be suspended from each corner by hanger bolts and angle iron supports. (See Fig.

25 or 26.) Cut hanger bolts (4 each 3/8-in. all-thread rod) to desired length. Use 1 X 3/8-in. flat washers, 3/8-in. lockwashers, and 3/8-in. nuts on hanger rods as shown in Fig. 25 or 26. Dimples are provided for hole locations. (See Fig. 2.)


PROCEDURE 4—AIR DUCTS

A.

General Requirements

The duct system should be designed and sized according to accepted national standards such as those published by: Air Conditioning Contractors

Association (ACCA), Sheet Metal and Air Conditioning Contractors National Association (SMACNA) or American Society of Heating,

Refrigerating and Air Conditioning Engineers (ASHRAE) or consult The Air Systems Design Guidelines reference tables available from your local distributor. The duct system should be sized to handle the required system design CFM at the design static pressure.

When a furnace is installed so that the supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by a duct(s) sealed to the furnace casing and terminating outside the space containing the furnace.

—23—

B

A

PLENUM

OPENING

D

FLOOR

C

OPENING

FURNACE

(OR COIL CASING

WHEN USED)

COMBUSTIBLE

FLOORING

DOWNFLOW

SUBBASE

SHEET METAL

PLENUM

FLOOR

OPENING

A96283

Fig. 21—Floor and Plenum Opening Dimensions

FURNACE

CD5 OR CK5

COIL ASSEMBLY

OR KCAKC

COIL BOX

COMBUSTIBLE

FLOORING

SHEET METAL

PLENUM

FLOOR

OPENING

A96285

Fig. 22—Furnace, Plenum, and Subbase

Installed on a Combustible Floor

Table 3—Opening Dimensions (In.)

FURNACE

CASING

WIDTH

17-1/2

21

24-1/2

APPLICATION

Upflow Applications

Downflow Applications on Non-Combustible Flooring

Downflow Applications on Combustible Flooring Using KGASB Subbase

Furnace with or without CD5, CK5 Coil Assembly or KCAKC Coil Box

Downflow Applications on Combustible Flooring NOT Using KGASB Subbase

Furnace with CD5, CK5 Coil Assembly or KCAKC Coil Box

Upflow Applications






Upflow Applications






—24—

Assembly or Coil Box Installed on a Combustible Floor

PLENUM OPENING

A

16

15-7/8

B

24-1/8

19

15-1/8 19

15-1/2

19-1/2

19-3/8

18-5/8

19

23

22-7/8

22-1/8

22-1/2

19

24-1/8

19

19

19

24-1/8

19

19

19

A96284

Fig. 23—Furnace, Plenum, and Coil

FLOOR OPENING

C

16-5/8

16-1/2

D

24-3/4

19-5/8

16-3/4 20-3/8

16-1/2

20-1/8

20

20-1/4

20

23-5/8

23-1/2

23-3/4

23-1/2

20

24-3/4

19-5/8

20-3/8

20

24-3/4

19-5/8

20-3/8

20

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.

Maintain a 1-in. clearance from combustible materials to supply air ductwork for a distance of 36 in. horizontally from the furnace. See NFPA

90B or local code for further requirements.

For a furnace not equipped with a cooling coil, the outlet duct shall be provided with a removable access panel. This opening shall be accessible when the furnace is installed and shall be of such a size that the heat exchanger can be viewed for possible openings using light assistance or a probe can be inserted for sampling the air stream. The cover attachment shall prevent leaks.

B.

Ductwork Acoustical Treatment

Metal duct systems that do not have a 90 degree elbow and 10 ft of main duct to the first branch take-off may require internal acoustical lining.

As an alternative, fibrous ductwork may be used if constructed and installed in accordance with the latest edition of SMACNA construction standard on fibrous glass ducts. Both acoustical lining and fibrous ductwork shall comply with NFPA 90B as tested by UL Standard 181 for Class

1 Rigid air ducts.

C.

Supply Air Connections

UPFLOW FURNACES

Connect supply-air duct to 3/4-in. flange on furnace supply-air outlet. The supply-air duct attachment must ONLY be connected to furnace supply-/outlet-air duct flanges or air conditioning coil casing (when used). DO NOT cut main furnace casing to attach supply side air duct, humidifier, or other accessories. All accessories MUST be connected external to furnace main casing.

DOWNFLOW FURNACES

Connect supply-air duct to supply-air opening on furnace. The supply-air duct attachment must ONLY be connected to furnace supply/outlet or air conditioning coil casing (when used), when installed on non-combustible material. When installed on combustible material, supply-air duct attachment must ONLY be connected to an accessory subbase or factory approved air conditioning coil casing. DO NOT cut main furnace casing to attach supply side air duct, humidifier, or other accessories. All accessories MUST be connected external to furnace main casing.

HORIZONTAL FURNACES

Connect supply-air duct to supply air opening on furnace. The supply-air duct attachment must ONLY be connected to furnace supply/outlet or air conditioning coil casing (when used). DO NOT cut main furnace casing to attach supply side air duct, humidifier, or other accessories. All accessories MUST be connected external to furnace main casing.

D.

Return Air Connections

The furnace and its return air system shall be designed and installed so that negative pressure created by the air circulating fan cannot affect another appliance’s combustion air supply or act to mix products of combustion with circulating air, and that the air circulating fan of the furnace, if installed in an enclosure communicating with another fuel-burning appliance not of the direct-vent type, shall be operable only when any door or panel covering an opening in the furnace fan compartment or in a return air plenum on ducts is in the closed position.

WARNING: FIRE HAZARD

A failure to follow this warning could result in fire, personal injury, or death.

Never connect return-air ducts to the back of the furnace. Return-air duct connections on furnace side(s) permitted in upflow applications only.

UPFLOW FURNACES

The return-air duct must be connected to bottom, sides (left or right), or a combination of bottom and side(s) of main furnace casing as shown in Fig. 2. Bypass humidifier may be attached into unused side return air portion of the furnace casing. DO NOT connect any portion of return-air duct to back of furnace casing.

—25—

3 ⁄

8

-IN. ROD

ANGLE

IRON OR

EQUIVALENT

5 3 ⁄

4

″

(B)

(A)

(B) DRAIN

(A) ROD LOCATION

USING DIMPLE

LOCATORS

(SEE DIMENSIONAL

DWG FOR

LOCATIONS)

3 /

8

-IN. HEX NUT

& WASHER (4)

REQD PER ROD

(A) PREFERRED ROD LOCATION

(B) ALTERNATE ROD LOCATION

(A) (B)

(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. The entire length of furnace must be supported when furnace is used in horizontal position to ensure proper drainage.

ALTERNATE SUPPORT

LOCATION 4-IN. MIN

8-IN. MAX

A93304

Fig. 25—Crawlspace Location in Direct Vent Application (All Sizes)

DOWNFLOW AND HORIZONTAL FURNACES

The return-air duct must be connected to return-air opening provided as shown in Fig. 2. DO NOT cut into casing sides or back to attach any portion of return-air duct. Bypass humidifier connections should be made at ductwork or coil casing sides exterior to furnace.

E.

Filter Arrangement

CAUTION: FIRE, CARBON MONOXIDE AND POISONING HAZARD

Failure to follow this warning could result in fire, personal injury, or death.

Never operate a unit without a filter or with filter access door removed.

Factory-supplied washable framed filters are shipped in blower compartment. Determine location for filter and relocate filter retaining wire if necessary. See Table 4 to determine correct filter size for desired filter location. Table 4 indicates filter size, location, and quantity shipped with furnace. See Fig. 2 for location and size of bottom and side return-air openings.

CAUTION: CUT HAZARD

Failure to follow this caution may result in minor personal injury.

Use care when cutting support rods in filters to protect against flying pieces and sharp rod ends. Wear safety glasses, gloves, and appropriate protective clothing.

—26—

A 3-IN. MINIMUM

CLEARANCE TO

COMBUSTION-AIR INTAKE

IS REQUIRED.

COMBUSTION-AIR

INTAKE

VENT

3 ⁄

8

-IN. ROD

ANGLE

IRON OR

EQUIVALENT

5

3

⁄

4

″

(B)

(A)

(B) DRAIN

(A)

(B)

(A) ROD LOCATION

USING DIMPLE

LOCATORS

(SEE DIMENSIONAL

DWG FOR

LOCATIONS)

3 /

8

-IN. HEX NUT

& WASHER (4)

REQD PER ROD

(A) PREFERRED ROD LOCATION

(B) ALTERNATE ROD LOCATION

(A)

NOTES:

(B)

13 /

16

-IN. MAX

ALTERNATE SUPPORT

LOCATION FROM BACK

1. A 1 In. clearance minimum between top of furnace and combustible material.

2. The entire length of furnace must be supported when furnace is used in horizontal position to ensure proper drainage.

3. Bottom side combustion-air entry cannot be used when furnace is installed with hangers as shown.

ALTERNATE SUPPORT

LOCATION 4-IN. MIN

8-IN. MAX

Fig. 26—Crawlspace Location in Non-Direct Vent Application (Sizes 040 through 120 Only)

Table 4—Filter Information

FURNACE CASING

WIDTH (IN.)

17-1/2

21

24-1/2

Side Return

(1) 16 X 25 X 1†

(1) 16 X 25 X 1

FILTER SIZE (IN.)*

(1 or 2) 16 X 25 X 1

Bottom Return

(1) 16 X 25 X 1

(1) 20 X 25 X 1†

(1) 24 X 25 X 1†

FILTER TYPE

FRAMED

Cleanable

Cleanable

Cleanable

* Filters can be field modified by cutting frame as marked and folding to desired size. Alternate sizes can be ordered from your distributor or dealer.

† Factory-provided with furnace.

A96209



For airflow requirements above 1800 CFM, see Air Delivery table in Product Data literature for specific use of single side inlets. The use of both side inlets, a combination of 1 side and the bottom, or the bottom only will ensure adequate return air openings for airflow requirements above 1800 CFM.

Bottom return-air opening may be used with all 4 orientations. Filter may need to be cut to fit some furnace widths. Install filter as shown in Fig.

27.

NOTE: Remove and discard bottom closure panel when bottom inlet is used.

NOTE: Side return-air openings can ONLY be used in UPFLOW configurations. Install filter(s) as shown in Fig. 28.

F.

Bottom Closure Panel

These furnaces are shipped with bottom enclosure panel installed in bottom return-air opening. This panel MUST be in place when side return air is used.

To remove bottom closure panel, perform following:

1. Tilt or raise furnace and remove 2 screws holding front filler panel. (See Fig. 29.)

2. Rotate front filler panel downward to release holding tabs.

3. Remove bottom closure panel.

4. Reinstall front filler panel and screws.

—27—

Table 5—Maximum Capacity of Pipe*

NOMINAL IRON PIPE SIZE

(IN.)

1/2

3/4

1

1-1/4

1-1/2

INTERNAL DIAMETER

(IN.)

0.622

0.824

1.049

1.380

1.610

10

175

360

680

1400

2100

20

LENGTH OF PIPE (FT)

30

120

250

97

200

465

950

1460

375

770

1180

40

82

170

320

660

990

* 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.

Gas Piping

50

73

151

285

580

900

Gas piping must be installed in accordance with national and local codes. Refer to current edition of NFGC in the United States. Canadian installations must be made in accordance with NSCNGPIC and all authorities having jurisdiction. Gas supply line should be a separate line running directly from meter to furnace, if possible. Refer to Table 5 for recommended gas pipe sizing. Risers must be used to connect to furnace and to meter. Support all gas piping with appropriate straps, hangers, etc. Use a minimum of 1 hanger every 6 ft. Joint compound (pipe dope) should be applied sparingly and only to male threads of joints. Pipe dope must be resistant to propane gas.

WARNING: FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in fire, explosion, personal injury, or death.

-Connect gas pipe to furnace using a backup wrench to avoid damaging gas controls.

-Gas valve shutoff switch MUST be facing forward or tilted upward.

-Never purge a gas line into a combustion chamber. 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.

-Use proper length of pipe to avoid stress on gas control manifold.

-If a flexible connector is required or allowed by authority having jurisdiction, black iron pipe shall be installed at furnace gas valve and extend a minimum of 2 in. outside furnace casing.

Install a sediment trap in riser leading to furnace. Trap can be installed by connecting a tee to riser leading to furnace so straight-through section of tee is vertical. Then connect a capped nipple into lower end of tee. Capped nipple should extend below level of gas controls. Place a ground joint union between gas control manifold and manual gas shutoff valve. (See Fig. 30.)

If local codes allow the use of a flexible gas appliance connector, always use a new listed connector. Do not use a connector which has previously served another gas appliance.

WARNING: FIRE OR EXPLOSION HAZARD

Failure to follow the safety warnings exactly could result in serious injury, death or property damage.

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. A fire or explosion could result causing property damage, personal injury or loss of life.

An accessible manual shutoff valve MUST be installed external to furnace casing and within 6 ft of furnace. A 1/8-in. NPT plugged tapping, accessible for test gauge connection, MUST be installed immediately upstream of gas supply connection to furnace and downstream of manual shutoff valve.

NOTE: The gas valve inlet pressure tap connection is suitable to use as test gauge connection providing test pressure DOES NOT exceed maximum 0.5 psig (14-in. wc) stated on gas valve. (See Fig. 48.)

Piping should be pressure and leak tested in accordance with NFGC in the United States or NSCNGPIC in Canada, local, and national plumbing and gas codes before the furnace has been connected. After all connections have been made, purge lines and check for leakage at furnace prior to operating furnace.

If pressure exceeds 0.5 psig (14-in. wc), gas supply pipe must be disconnected from furnace and capped before pressure test. If test pressure is equal to or less than 0.5 psig (14-in. wc), turn off electric shutoff switch located on furnace gas valve and accessible manual shutoff valve before test.

The gas supply pressure shall be within the maximum and minimum inlet supply pressures marked on the rating plate with the furnace burners

ON and OFF.

PROCEDURE 5—ELECTRICAL CONNECTIONS

See Fig. 31 for field wiring diagram showing typical field 115-v and 24-v wiring. Check all factory and field electrical connections for tightness.

Field-supplied wiring shall conform with the limitations of 63°F (35°C) rise.

WARNING: ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in serious injury or death.

Blower access panel door switch opens 115-v power to control center. No component operation can occur. Do not bypass or close switch with panel removed.

CAUTION: FURNACE MAY NOT OPERATE

Failure to follow this caution may result in furnace operation stopping and water pipes freezing during cold weather.

Furnace control must be grounded for proper operation or control will lock out. Control is grounded through green/yellow wire routed to gas valve and burner box screw.

—28—

17 1 ⁄

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 ″

Fig. 28—Filter Installed for Side Inlet

A00217

WASHABLE

FILTER

FILTER

SUPPORT

FILTER

RETAINER

Fig. 27—Bottom Filter Arrangement

A00290

GAS

SUPPLY

MANUAL

SHUTOFF

VALVE

(REQUIRED)

SEDIMENT

TRAP

UNION

BOTTOM

CLOSURE

PANEL

FRONT FILLER

PANEL

Fig. 29—Removing Bottom Closure Panel

A93047

A93324

Fig. 30—Typical Gas Pipe Arrangement

A.

115-v Wiring

Before proceeding with electrical connections, make certain that voltage, frequency, and phase correspond to that specified on unit rating plate.

Check to be sure that service provided by power supply is sufficient to handle load imposed by this equipment. Refer to rating plate or Table 6 for equipment electrical specifications.

—29—

FIELD 24-V WIRING

FIELD 115-, 208/230-, 460-V WIRING

FACTORY 24-V WIRING

FACTORY 115-V WIRING

FIVE WIRE

THREE-WIRE

HEATING-ONLY

BLOWER DOOR SWITCH

NOTE 2

W C R G Y

THERMOSTAT

TERMINALS FIELD-SUPPLIED

DISCONNECT

208/230- OR

460-V

THREE

PHASE

BLK

WHT

GND

115-V FIELD-

SUPPLIED

DISCONNECT

BLK

WHT

GND

AUXILIARY

J-BOX

W

C

O

N

T

R

O

L

R

G

COM

Y

24-V

TERMINAL

BLOCK

FURNACE

208/230-V

SINGLE

PHASE

GND

NOTE 1

TWO

WIRE

CONDENSING

UNIT

NOTES: 1.

2.

3.

Connect Y-terminal in furnace as shown for proper blower operation.

Some thermostats require a "C" terminal connection as shown.

If any of the original wire, as supplied, must be replaced, use same type or equivalent wire.

A02174

Fig. 31—Heating and Cooling Application Wiring Diagram

Table 6—Electrical Data

UNIT

SIZE

024040

036040

024060

036060

048060

036080

048080

060080

048100

060100

060120

060140

VOLTS—

HERTZ—

PHASE

115—60—1

115—60—1

115—60—1

115—60—1

115—60—1

115—60—1

115—60—1

115—60—1

115—60—1

115—60—1

115—60—1

115—60—1

OPERATING

VOLTAGE RANGE

Max*

127

Min*

104

127

127

127

127

127

127

127

104

104

104

104

104

104

104

127

127

127

127

104

104

104

104

MAX

UNIT

AMPS

6.1

7.3

6.1

7.1

9.5

7.6

10.0

14.1

10.2

14.8

14.6

14.3

UNIT

AMPACITY†

8.4

10.0

8.4

9.8

12.8

10.4

13.4

18.4

13.5

19.3

19.1

18.8

MIN

WIRE

GAUGE

14

14

14

14

14

14

14

12

14

12

12

12

MAX WIRE

LENGTH

(FT)‡

44

37

44

38

29

36

28

31

27

30

30

30

MAX FUSE

OR CKT BKR

AMPS**

15

15

15

15

15

15

15

20

15

20

20

20

* Permissible limits of voltage range at which unit will operate satisfactorily.

† Unit ampacity = 125 percent of full load amps of largest operating component plus 100 percent of full load amps of all other potential operating components (EAC, humidifier, etc.).

‡ Length shown is as measured 1 way along wire path between unit and service panel for maximum 2 percent voltage drop.

** Time-delay type is recommended.

Make all electrical connections in accordance with National Electrical Code (NEC) ANSI/NFPA 70-2002 and any local codes or ordinances that might apply. For Canadian installations, all electrical connections must be made in accordance with Canadian Electrical Code CSA C22.1 or authorities having jurisdiction.

ELECTRIC

DISCONNECT

SWITCH

COPPER

WIRE ONLY

ALUMINUM

WIRE

Fig. 32—Disconnect Switch and Furnace

—30—

A93033

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. A disconnecting means must be located within sight from and readily accessible to furnace.

NOTE: Proper polarity must be maintained for 115-v wiring. If polarity is incorrect, control center LED status indicator light will flash rapidly and furnace will NOT operate.

WARNING: ELECTRICAL SHOCK AND FIRE HAZARD


The cabinet MUST have an uninterrupted or unbroken ground according to NEC ANSI/NFPA 70-2002 and Canadian Electrical Code

CSA C22.1 or local codes to minimize personal injury if an electrical fault should occur. This may consist of electrical wire or conduit approved for electrical ground when installed in accordance with existing electrical codes. Do not use gas piping as an electrical ground.

J-BOX RELOCATION

1. Remove 2 screws holding auxiliary J-box. (See Fig. 33.)

2. Rotate J-box 180° and attach box to right side, using holes provided.

WARNING: ELECTRICAL SHOCK AND FIRE HAZARD


If manual disconnect switch is to be mounted on furnace, select a location where a drill or fastener will not contact electrical or gas components.

B.

24-v Wiring

Make field 24-v thermostat connections at 24-v terminal block on furnace control center. For proper cooling operation, Y wire from thermostat

MUST be connected to Y terminal on control center, as shown in Fig. 31. The 24-v terminal block is marked for easy connection of field wiring.

(See Fig. 34.) The 24-v circuit contains a 3-amp, automotive-type fuse located on furnace control center. (See Fig. 35.) Any electrical shorts of

24-v wiring during installation, service, or maintenance may cause fuse to blow. If fuse replacement is required, use only a fuse of identical size

(3 amp) and type. The control will flash code 24 when fuse needs replacement.

NOTE: Use AWG No. 18 color-coded copper thermostat wire for lengths up to 100 ft. For wire lengths over 100 ft, use AWG No. 16 wire.

C.

Accessories

1. Electronic Air Cleaner (EAC)

Two quick-connect terminals marked EAC-1 and EAC-2 are provided for EAC connection. (See Fig. 35.) These terminals are energized with 115v (1.0-amp maximum) during blower motor operation.


Failure to follow this caution may result in unit component damage.

DO NOT connect furnace control HUM terminal to HUM (humidifier) terminal on Thermidistat™, Zone Controller or similar device. See

Thermidistat™, Zone Controller, thermostat, or controller manufacturer’s instructions for proper connection.

—31—

N TRA

PRINTED CIRCIUT BOARD

HSI

PRINTED CIRCIUT BOARD

11 0 91 8 7 6 5 4 3 2 1

8 E #

RAL

NOT

NEUT

BLW

—32—

2. Humidifier (HUM)

A quick-connect terminal (HUM) and screw terminal (C

OM

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.

PROCEDURE 6—REMOVAL OF EXISTING FURNACES FROM COMMON VENT SYSTEMS

When an existing Category I furnace is removed or replaced, the original venting system may no longer be sized to properly vent the remaining attached appliances. An improperly sized Category I venting system could cause the formation of condensate in the furnace and vent, leakage of condensate and combustion products, spillage of combustion products into the living space, etc.


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.

The following steps shall be followed for each appliance connected to the venting system being placed into operation, while all other appliances connected to the venting system are not in operation:

1. Seal any unused openings in venting system.

2. Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas Code, ANSI Z223.1-2002/NFPA

54-2002 or the CSA B149.1, Natural Gas and Propane Installation Code and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies, which could cause an unsafe condition.

3. As far as practical, close all building doors and windows and all doors between the space in which the appliance(s) connected to the venting system are located and other spaces of the building.

4. Close fireplace dampers.

5. Turn on clothes dryers and any appliance not connected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they are operating at maximum speed. Do not operate a summer exhaust fan.

6. Follow the lighting instructions. Place the appliance being inspected into operation. Adjust the thermostat so appliance is operating continuously.

7. Test for spillage from draft hood equipped appliances at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle.

8. If improper venting is observed during any of the above tests, the venting system must be corrected in accordance with the National

Fuel Gas Code, ANSI Z223.1-2002/NFPA 54-2002 and/or CSA B149.1, Natural Gas and Propane Installation Code.

9. After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-fired appliance to their previous conditions of use.

Vent system or vent connectors may need to be resized. For any other appliances when resizing vent systems or vent connectors, system or connector must be sized to approach minimum size as determined using appropriate table found in the NFGC or NSCNGPIC.

PROCEDURE 7—COMBUSTION AIR AND VENT PIPE SYSTEMS

A.

General

Vent system or vent connectors may need to be resized. For any other appliances when resizing vent systems or vent connectors, system or connector must be sized to approach minimum size as determined using appropriate table found in the NFGC or NSCNGPIC.

→

The PG9MAB can be vented as either a direct vent (all sizes) or as a non-direct vent (except for 140 size) application. A direct vent system shall be installed in accordance with the direct vent procedures (2-pipe) in the following Combustion Air and Vent Pipe Systems section. For non-direct vent (1-pipe) applications, refer to the non-direct vent (1-pipe) procedures in the same section.

B.

Direct Vent/2-Pipe System (All Sizes)

In a direct-vent (2-pipe) system, all air for combustion is taken directly from outdoor atmosphere, and all flue products are discharged to outdoor atmosphere. A factory accessory vent termination kit MUST be used in a direct vent (2-pipe) system.

—33—

Table 7—Approved Combustion-Air and Vent Pipe, Fitting and Cement Materials

ASTM SPECIFICATION

(MARKED ON MATERIAL)

D1527

D1785

D2235

D2241

D2466

D2468

D2564

D2661

D2665

F438

F441

F442

F493

F628

F656

F891

MATERIAL PIPE FITTINGS SOLVENT CEMENT AND PRIMERS

ABS

PVC

For ABS

PVC

PVC

ABS

For PVC

ABS

PVC

CPVC

CPVC

CPVC

For CPVC

ABS

For PVC

PVC

Pipe

Pipe

—

Pipe

—

—

—

Pipe Fittings

Pipe Fittings

—

Pipe

Pipe

—

Pipe

—

Pipe

—

—

—

—

Fittings

Fittings

—

Fittings

—

—

—

—

—

—

—

—

Solvent

Cement

—

—

—

Solvent

Cement

—

—

—

—

—

Solvent

Cement

—

Primer

—

DESCRIPTION

Schedule-40

Schedule-40

For ABS

SDR-21 & SDR-26

Schedule-40

Schedule-40

For PVC

DWV at Schedule-40 IPS sizes

DWV

Schedule-40

Schedule-40

SDR

For CPVC

Cellular Core DWV at Schedule-40 IPS sizes

For PVC

Cellular Core Schedule-40 & DWV

→

C.

Non-Direct Vent/1-Pipe System Sizes 040 Through 120 Only)

In a non-direct vent (1-pipe) system, all air for combustion is taken from the area adjacent to furnace, and all flue products are discharged to outdoor atmosphere. A factory-supplied perforated disk assembly (in loose parts bag) MUST be used in combustion-air pipe elbow.


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.

The following steps shall be followed for each appliance connected to the venting system being placed into operation, while all other appliances connected to the venting system are not in operation:

1. Seal any unused openings in venting system.

2. Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas Code, ANSI Z223.1-2002/NFPA

54-2002 or the CSA B149.1, Natural Gas and Propane Installation Code and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies, which could cause an unsafe condition.

3. As far as practical, close all building doors and windows and all doors between the space in which the appliance(s) connected to the venting system are located and other spaces of the building.

4. Close fireplace dampers.

5. Turn on clothes dryers and any appliance not connected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they are operating at maximum speed. Do not operate a summer exhaust fan.

6. Follow the lighting instructions. Place the appliance being inspected into operation. Adjust the thermostat so appliance is operating continuously.

7. Test for spillage from draft hood equipped appliances at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle.

8. If improper venting is observed during any of the above tests, the venting system must be corrected in accordance with the National

Fuel Gas Code, ANSI Z223.1-2002/NFPA 54-2002 and/or CSA B149.1, Natural Gas and Propane Installation Code.

9. After it has been determined that each appliance connected to the venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-fired burning appliance to their previous conditions of use.

→

D.

Materials

Combustion-air and vent pipe, fittings, primers, and solvents must conform to American National Standards Institute (ANSI) standards and

American Society for Testing and Materials (ASTM) standards. See Table 7 for approved materials for use in the U.S.A.

WARNING: FIRE AND EXPLOSION HAZARD

Failure to follow this warning could result in fire, property damage, personal injury, or death.

Solvent cements are combustible. Keep away from heat, sparks, and open flame. Use only in well-ventilated areas. Avoid breathing in vapor or allowing contact with skin or eyes.

In Canada, construct all combustion-air and vent pipes for this unit of CSA or ULC listed schedule-40 PVC, PVC-DWV or ABS-DWV pipe and pipe cement. SDR pipe is NOT approved in Canada.

In direct vent (2-pipe) systems, combustion air and vent pipes must terminate together in same atmospheric pressure zone, either through roof or sidewall (roof termination preferred), using accessory termination kit. See Table 8 for required clearances.

—34—

BLOWER OFF-DELAY

J2 JUMPER

TWINNING AND/OR

COMPONENT TEST

TERMINAL

BLOWER OFF-DELAY

24-V THERMOSTAT

TERMINALS

3-AMP FUSE

LED OPERATION &

DIAGNOSTIC LIGHT

115-VAC(L2)NEUTRAL

CONNECTIONS

TEST/TWIN

HUM

0.5 AMP@24VAC

FUSE 3-AMP

SEC-2 SEC-1

EAC-2 L2

HUMIDIFIER TERMINAL

(24-VAC 0.5 AMP MAX.)

TRANSFORMER 24-VAC

CONNECTIONS

PL1-LOW VOLTAGE MAIN

HARNESS CONNECTOR

COOL

HEAT

SPARE-1 SPARE-2

BLOWER SPEED

SELECTION TERMINALS

SPARE-1

SPARE-2

1-AMP@

EAC-1

115VAC

PR-1

PL2 1

115 VAC (L1) LINE

VOLTAGE CONNECTION

EAC-1 TERMINAL

(115-VAC 1.0 AMP MAX.)

Fig. 35—Control Center

PL2-HOT SURFACE

IGNITER & INDUCER

MOTOR CONNECTOR

A02100

→

In non-direct vent (1-pipe) system, vent pipe termination must be installed with adequate clearances to building openings and equipment to comply with national and local codes. See Table 9 for required clearances.


Failure to follow this warning could result in property damage, personal injury, or death.

All combustion-air and vent pipes must be airtight and watertight. Pipes must also terminate exactly as shown in Fig. 40 for direct vnet

(2-pipe) system and Fig. 41 for non-direct vent (1-pipe) system.

→

An abandoned masonry chimney may be used as a raceway for properly insulated and supported combustion-air (when applicable) and vent pipes.

Each furnace must have its own set of combustion-air and vent pipes and be terminated individually, as shown in Fig. 40 for Direct Vent (2-Pipe) system and Fig. 41 for Non-Direct Vent (1-Pipe) system.

Other gas appliances with their own venting system may also use 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 be taken to prevent the exhaust gases from one appliance from contaminating the combustion air of other gas appliances.



When vent pipe is exposed to temperatures below freezing, such as when it passes through an unheated space or when a chimney is used as a raceway, pipe must be insulated as shown in Table 10 with Armaflex-type insulation.

→

Furnace combustion air and vent pipe connections are sized for 2-in. pipe. Any pipe size change should be made outside furnace casing in vertical pipe. The transition has to be made as close to the furnce as reasonably possible.

—35—

Table 8—Direct Vent Termination Clearance

—36—

A05009

Table 9—Other than Direct Vent Termination Clearance

—37—

A05013

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

40

38

70

50

28

70

48

30

70

47

28

40

45

22

10

65

51

28

16

35

20

55

60

44

70

57

30

61

37

70

48

23

60

WITH 3/8–IN. OR

THICKER INSULATION†

40

40

70

70

70

70

55

55

70

70

70

40

70

70

58

70

70

70

70

70

70

55

60

60

70

70

70

70

70

70

70

70

60

* Pipe length (ft) specified for maximum pipe lengths located in unconditioned spaces. Pipes located in unconditioned space cannot exceed total allowable pipe length as specified in Table 10.

† Insulation thickness based on R value of 3.5 per in.

→

E.

Combustion Air Pipe

GENERAL

Furnace combustion-air connection must be attached as shown in Fig. 35. Combustion-air intake housing plug may need to be relocated in some applications.

For Non-Direct Vent (1-Pipe) system, combustion-air must terminate outside of furnace casing with 1 elbow. Orient elbow so that its opening faces down for upflow or downflow applications. Orient elbow so that its opening faces sideways (left or right) for horizontal left or horizontal right applications (See Fig. 36.) Maintain a 3-in minimum clearance between the opening of the combustion-air inlet pipe and any object.

CAUTION: UNIT CORROSION HAZARD

Excessive exposure to contaminated combustion air may result in safety and performance related problems.

Combustion air must not be taken from inside structure because inside air is frequently contaminated by halogens, which include fluorides, chlorides, bromides, and iodides. These elements are found in aerosols, detergents, bleaches, cleaning solvents, salts, air fresheners, adhesives, paint, and other household products. Locate combustion-air inlet as far as possible from swimming pool and swimming pool pump house.

NOTE: All pipe joints must have cemented attachment of combustion-air inlet pipe to inlet housing connection, since it may be necessary to remove pipe for servicing.

ASSEMBLY OF COMBUSTION AIR PIPE (NON-DIRECT VENT/1-PIPE SYSTEM ONLY)

1. Permanently install perforated disk assembly (factory-supplied in loose parts bag) in combustion-air elbow using RTV or by cementing, as shown in Fig. 36. For 120,000 Btuh size units only: separate the 2 halves of perforated disk assembly and use only the shouldered disk half.

2. Determine the length of straight portion of combustion-air inlet pipe from Fig. 36.

3. Cut field-supplied 2-in. diameter PVC pipe to length as determined per Fig. 36.

—38—

NOTE: Select 1 vent pipe connection and

1 combustion-air pipe connection.

NOTE: Select 1 vent pipe connection and

1 combustion-air pipe connection.

COMBUSTION-

AIR

AIR

FLOW

COMBUSTION-

AIR

VENT

VENT

VENT

*

VENT

*

UPFLOW

COMBUSTION-

AIR

AIR

FLOW

COMBUSTION-

AIR

DOWNFLOW

COMBUSTION-

AIR

VENT

AIR

FLOW

**

COMBUSTION-

AIR

VENT

**

AIR

FLOW

FIELD-SUPPLIED

2-IN. DIAMETER

PVC 90

°

ELBOW

FIELD-SUPPLIED

2-IN. DIAMETER

PVC PIPE

†

HORIZONTAL-LEFT DISCHARGE

†

HORIZONTAL-RIGHT DISCHARGE

A

* For Non-Direct Vent (1-Pipe) system, orient elbow so that its opening faces down.

** For Non-Direct Vent (1-Pipe) system, orient elbow so that its opening faces sideways.

† An external trap kit (see furnace product data sheet) must be used.

A96188

COMBUSTION-AIR DISC

(FACTORY-SUPPLIED IN

LOOSE PARTS BAG)

→



Make sure there is adequate clearance (3-in. minimum) to any fixed or loose objects in order to ensure an adequate combustion-air supply.

Fig. 36—Combustion-Air and Vent Pipe Connections

Length of Straight Pipe Portion of

Combustion-Air Inlet Pipe Assembly (In.)

CASING WIDTH

17-1/2

21

24-1/2

A

8-1/2

±

1/2

10-1/2

±

1/2

12

±

1/2

Fig. 37—Combustion-Air Inlet Pipe Assembly

4. Permanently attach elbow/perforated disk assembly to straight portion of pipe using RTV or by cementing as shown in Fig. 36.

A96211

ASSEMBLY OF COMBUSTION AIR PIPE (DIRECT VENT-2-PIPE SYSTEM ONLY)

1. Using Table 11, determine the smallest combustion air diameter permitted. Pick the larger diameter and use it for both combustion and vent pipe.

NOTE: Do not count elbows or pipe sections in terminations or within furnace. See shaded areas in Fig. 40 for Direct Vent/2-Pipe system, and

Fig. 41 for Non-Direct Vent/1-Pipe system.


Failure to follow this caution may result in incomplete combusiton, flame disturbance, or flame sense lockout.

When installing combusiton air and vent system of short pipe length, the smallest allowable pipe diameter must be used.

NOTE: A 2-in. diameter pipe must be used within furnace casing. Make all pipe diameter transitions outside furnacec casing per Fig. 37.

2. If required per Table 11, insert perforated disk assembly (factory-supplied in loose parts bag) in intake housing where combustion air pipe will be connected. If half disk set is required, install only shouldered disk half.

ATTACHMENT OF COMBUSTION AIR PIPE

1. Determine location of combustion air intake pipe connection to combustion air intake housing as shown in Fig. 35 for application.

2. Reposition combustion air intake housing plug fitting in appropriate unused intake housing connection.

3. Install pipe support (factory-supplied in loose parts bag) into selected furnace casing combustion-air pipe hole. Pipe support should be positioned at bottom of casing hole.

4. Insert assembled combustion air inlet pipe into intake housing as shown in Fig. 35.

5. Drill a 1/8-in. hole in 2-in, combustion air pipe using the hole in intake housing as a guide.

—39—

→

ALTITUDE (FT)

UNIT SIZE

(BTUH)

0 to 2000

ALTITUDE (FT)

UNIT SIZE

(BTUH)

2001 to 3000

ALTITUDE (FT)

UNIT SIZE

(BTUH)

3001 to 4000

40,000

60,000

80,000

100,000

120,000

140,000

40,000

60,000

80,000

100,000

120,000

140,000

40,000

60,000

80,000

100,000

120,000

140,000

Table 11—Maximum Allowable Vent Pipe Length (Ft)

DIRECT VENT (2-PIPE) ONLY

TERMINATION

TYPE

TERMINATION

TYPE

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 3-in

Concentric

2 Pipe or 3-in.

Concentric

4† no disk

PIPE DIA

(IN.)*

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 3-in

Concentric

2 Pipe or 3-in.

Concentric

2 Pipe or 3-in.

Concentric

1

1-1/2

2

1-1/2

2

1-1/2

2

2-1/2

2

2-1/2

3

2-1/2 one disk

3†

3† no disk

2-1/2 one disk

3† one disk

3† no disk

4† no disk


2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 3-in

Concentric

2 Pipe or 3-in.

Concentric

2 Pipe or 3-in.

Concentric

1-1/2

2

1-1/2

2

2

2-1/2

2-1/2

3

3

NA

3† no disk

4† no disk

3† one disk

3† no disk

4† no disk


TERMINATION

TYPE

2 Pipe or 3-in.

Concentric

PIPE DIA

(IN.)*

PIPE DIA

(IN)*

1-1/2

2

1-1/2

2

2

2-1/2

2-1/2

3

3† no disk

NA

4† no disk

3† one disk

3† no disk

4† no disk

NON-DIRECT VENT

(1-PIPE) ONLY

PIPE DIA

(IN.)*

1

1-1/2

2

1-1/2

2

1-1/2

2

2-1/2

2

2-1/2

3

2-1/2

NA

3†

NA

NA

NA

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†

NA

4† no disk

NA

NA

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

NA

NA

1

70

65

59

70

11

30

70

64

70

16

68

46

70

33

70

5

40

70

10

45

70

5

40

60

70

5

70

70

20

70

10

55

1

35

70

14

63

70

70

67

70

17

70

49

70

20

39

70

1

NUMBER OF 90° ELBOWS

70

NA

20

70

NA

35

70

NA

30

52

70

NA

65

70

10

70

NA

35

2

70

NA

30

70

NA

40

70

NA

35

56

70

NA

70

70

15

70

NA

50

3 4 5


70

NA

20

70

NA

30

70

NA

25

48

70

NA

60

70

5

70

NA

30

6

NA NA

60 55

70 70

NA NA

70 70

NA NA

30 20

70 70

NA NA

10 NA

70 70

NA NA

25

70

20

70

NA NA

20 15

44

70

40

70

3

70

51

58

70

NA

22

70

54

70

6

62

28

70

15

2

70

58

59

70

6

26

70

59

70

11

63

41

70

24

16

70

NA

62

63

70

57

70

7

66

30

70

10

31

70

2

26

70

9

62

70

70

62

70

12

67

44

70

15

35

70

3 4 5


16

70

NA

61

56

70

52

70

NA

61

25

70

5

27

70

6

52

70

47

70

NA NA

61 61

25

70

15

70

6

66

NA

61

NA NA

61 61

50

70

43

70

NA NA

23 19

70 70

4

66

44

57

70

NA

18

70

49

70

NA

57

23

70

14

5 6

48

70

43

70

NA NA

57 56

22

70

5

13

70

NA

61

38

57

70

NA NA

14 10

70 70

56

31

56

70

See notes at end of table

—40—

→

ALTITUDE (FT)

4001 to 5000‡

ALTITUDE (FT)

5001 to 6000‡

ALTITUDE (FT)

6001 to 7000‡

See notes at end of table

UNIT SIZE

(BTUH)

40,000

60,000

80,000

100,000

120,000

140,000

UNIT SIZE

(BTUH)

40,000

60,000

80,000

100,000

120,000

140,000

UNIT SIZE

(BTUH)

40,000

60,000

80,000

100,000

120,000

Table 11—Maximum Allowable Vent Pipe Length (Ft) (Continued)


TERMINATION

TYPE

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 3-in

Concentric

PIPE DIA

(IN.)*

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

1-1/2

2

1-1/2

2

2

2-1/2

2-1/2 2 Pipe or 3-in

Concentric

2 Pipe or 3-in.

Concentric

3

3† no disk

NA

4† no disk

2 Pipe or 3-in.

Concentric

3† no disk

4† no disk


TERMINATION

TYPE

PIPE DIA

(IN.)*

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 3-in

Concentric

2 Pipe or 3-in.

Concentric

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

3† no disk

4† no disk


TERMINATION

TYPE

2 Pipe or 3-in.

Concentric

PIPE DIA

(IN)*

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.)*

1-1/2

2

1-1/2

2

2

2-1/2

2-1/2

3

NA

3†

4† no disk

NA

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

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

1

70

53

56

70

21

69

60

70

15

64

44

70

31

1

41

70

29

70

57

70

14

60

42

53

70

12

42

1

38

70

27

68

53

70

13

57

31

49

70


2

33

70

19

63

48

70

8

52

24

48

70

36

70

21

67

52

70

9

55

35

52

70

8

37

70

46

55

70

17

64

55

70

10

59

39

70

22

21

68

10

58

43

68

NA

50

18

47

70

23

70

12

62

47

70

NA

54

29

50

70

NA

32

16

67

9

53

38

67

NA

45

11

45

70

18

70

11

57

42

70

NA

49

22

49

70

NA

27

37

66

32

64

NA NA

44 43

15

66

6

64

NA NA

48 43

NA NA

44 43

67 62

40

70

35

70

NA NA

48 47

17

70

8

70

NA NA

52 47

15

48

70

9

47

70

NA NA

22 17

57

26

52

70

5

49

44

70

39

70

NA NA

52 52

20 11

70 70

NA NA

52

20

52

70

NA

44


2


2

3

67

40

54

70

13

59

50

70

5

58

26

70

13

3

3

4

62

33

53

70

9

54

45

70

NA

53

21

70

12

4

4

5

5

5

6

6

6

140,000

2 Pipe or 3-in.

Concentric

4† no disk NA 17 12 7 NA NA NA

—41—

→

Table 11—Maximum Allowable Vent Pipe Length (Ft) (Continued)

ALTITUDE (FT)

7001 to 8000‡

ALTITUDE (FT)

8001 to 9000‡

ALTITUDE (FT)

UNIT SIZE

(BTUH)

40,000

60,000

80,000

100,000

120,000

140,000

UNIT SIZE

(BTUH)

40,000

60,000

80,000

100,000

120,000

140,000

UNIT SIZE

(BTUH)

40,000


TERMINATION

TYPE

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 3-in

Concentric

2 Pipe or 3-in.

Concentric


TERMINATION

TYPE

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 2-in

Concentric

2 Pipe or 3-in

Concentric

2 Pipe or 3-in.

Concentric


TERMINATION

TYPE

2 Pipe or 2-in

Concentric

PIPE DIA

(IN.)*

1-1/2

2

1-1/2

2

2

2-1/2

2-1/2

3

3† no disk

NA

4† no disk

PIPE DIA

(IN.)*

1-1/2

2

1-1/2

2

2

2-1/2

2-1/2

3

3† no disk

NA

4† no disk

PIPE DIA

(IN.)*

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.)*

1-1/2

2

1

49

66

12

53

36

66

25

63

20

46

61

1

46

62

11

49

33

62

23

59

10

43

35

1

42

57


2

44

65

7

48

31

65

17

58

13

44

56

3

39

63

NA

46

19

63

8

53

7

43

51

4

34

62

NA

41

14

62

7

48

NA

41

46

5

33

60

NA NA

40 38

12 NA

60 59

NA NA

43

NA NA

40

41


2

41

60

6

44

28

60

15

54

NA

41

30

2

37

55

3

36

58

NA

42

17

58

7

49

NA

39

25

3

32

53

4

31

56

NA

37

12

56

5

44

NA

37

20

4

27

51

5

29

55

NA

35


5

25

49

6

28

59

38

38

36

6

24

53

NA

34

10 NA

55 53

NA NA

39 34

NA NA

35

15

34

10

6

20

47

60,000

2 Pipe or 2-in

Concentric

2 2 45 40 38 33 31 29

9001 to 10,000‡

80,000

100,000

120,000

2 Pipe or 2-in

Concentric

2 Pipe or 3-in

Concentric

2 Pipe or 3-in.

Concentric

2

2-1/2

2-1/2

3

NA

4† no disk

2

2-1/2

2-1/2

3

3†

4† no disk

NA

30

57

21

54

39

10

25

55

13

49

37

5

14

53

5

44

35

NA

9

51

NA

39

33

NA

7

49

34

31

NA

47

NA NA

29

29

NA NA

140,000

*Disk usage-Unless otherwise specified, use perforated disk assembly (factory-supplied in loose parts bag). If one disk is stated, separate 2 halves of perforated disk assembly and use shouldered disk half. When using shouldered disk half, install screen side toward inlet box.

†Wide radius elbow.

‡Vent sizing for Canadian installations over 4500 ft (1370 m) above sea level are subject to acceptance by the local authorities having jurisdiction.

NA-Not Allowed; pressure switch will not make.

NOTES:

1. Do not use pipe size greater than those specified in table or incomplete combustion, flame disturbance, or flame sense lockout may occur.

2. Size both the combustion-air and vent pipe independently, then use the larger diameter for both pipes.

3. Assume two 45° elbows equal one 90° elbow. Long radius elbows are desirable and may be required in some cases.

4. Elbows and pipe sections within the furnace casing and at the vent termination should not be included in vent length or elbow count.

5. The minimum pipe length is 5 ft for all applications.

6. Use 3-in. diameter vent termination kit for installations requiring 4-in diameter pipe.

—42—

HOUSING

PLUG

3/8

″

ID TUBE

COMBUSTION–AIR

INTAKE HOUSING

BURNER

BOX

FURNACE

3/16

″

DRILL

TRAP

4

″

MIN

COMBUSTION–

AIR PIPE

NOT IN

HORIZONTAL

SECTION

PIPE DIAMETER

TRANSITION IN

VERTICAL SECTION

TO OPEN

DRAIN

Fig. 39—Intake Housing Plug Fitting Drain

A96190 Fig. 38—Vent Pipe Diameter Transition Location and Elbow Configuration

A93034

6. Install a field-supplied No. 6 or No. 8 sheet metal screw into combustion air pipe.

7. Install casing hole filler cap (factory-supplied in loose parts bag) in unused combustion air pipe casing hole.

NOTE: Do not attach combustion air intake pipe permanently to combustion air intake housing since it may be necessary to remove pipe for service of igniter or flame sensor.

ATTACHMENT OF COMBUSTION AIR INTAKE HOUSING PLUG FITTING

The combustion-air intake plug fitting must be installled in unused combustion air intake housing. This fitting must be attached by using RTV sealant, or by drilling a 1/8-in. hole in fitting, using hole in intake housing as a guide. Install a field-supplied No. 6 or No. 8 sheet metal screw.

NOTE: DO NOT OVERTIGHTEN SCREW. Breakage of intake housing or fitting may cause air leakage to occur.

A plugged drain connection has been provided on this fitting for use when moisture is found in combustion air intake pipe and combustion box.

If use of this drain connection is desired, drill out fitting’s tap plug with 3/16-in. drill and connect a field-supplied 3/8-in. tube. This tube should be routed to open condensate drain for furnace and A/C (if used), and should be trapped, as shown in Fig. 38.

NOTE: (Direct Vent/2-Pipe System ONLY). Moisture in combustion air intake may be a result of improper termination. Ensure combustion air pipe termination is similar to those as shown in Fig. 40 so that it will not be susceptible to area where light snow or others sources of moisture could be pulled in.

→

F.

Vent Pipe

GENERAL

Furnace vent connection must be attached as shown in Fig. 35.

WARNING: CARBON MONOXIDE POISONING AND PROPERTY DAMAGE HAZARD

Failure to follow this warning could result in property damage, personal injury, or death.

Vent pipes must be airtight.

NOTE: A 2-in. diameter pipe must be used within the furnace casing. Make all pipe diameter transitions outside furnace casing per Fig. 37.

The minimum vent pipe length for these furnaces is 5 ft. Short pipe lengths (5-8 ft) may discharge condensate droplets. These condensate droplets may be undesirable. A 12-in. minimum offset pipe section is recommended to reduce excessive condensate droplets from exiting vent pipe outlet.

(See Fig. 40)

ATTACHMENT OF VENT PIPE

1. Determine vent pipe diameter and maximum pipe lengths using Table 11.

NOTE: (Direct Vent/2-Pipe) vent pipe system has the same diameter and same length as combustion air pipe as mentioned in section ″Assembly of Combustion Air Pipe (Direct Vent/2-Pipe system ONLY).

″

NOTE: Do not count elbows or pipe sections in terminations or within furnace, as indicated as shaded areas in Fig. 40 for Direct Vent/2-Pipe system, and Fig. 41 for Non-Direct Vent/1-Pipe system.

2. Determine location of vent pipe connection to inducer housing as shown in Fig. 35 for application.

3. Reposition elastomeric (rubber) inducer housing outlet cap and clamp to appropriate unused inducer housing connection. Tighten clamp.



Inducer housing outlet cap must be installed and fully seated against inducer housing. Clamp must be tightened to prevent any condensate leakage.

4. Install pipe support (factory-supplied in loose parts bag) into selected furnace casing vent pipe hole. Pipe support should be positioned at bottom of casing hole.

—43—

COMBUSTION AIR

PIPE (NON-DIRECT

VENT/1-PIPE)

VENT PIPE

12

″

MIN

COMBUSTION AIR

PIPE (DIRECT VENT

/2-PIPE)

COMBUSTION AIR

PIPE (NON-DIRECT

VENT/1-PIPE)

VENT PIPE

12 ″ MIN

COMBUSTION AIR

PIPE (DIRECT

VENT/2-PIPE)

HORIZONTAL TO ROOF

COMBUSTION AIR

PIPE (NON-DIRECT

VENT/1-PIPE)

COMBUSTION AIR

PIPE (DIRECT VENT

/2-PIPE)

HORIZONTAL TO SIDEWALL

VENT PIPE

COMBUSTION AIR

PIPE (NON-DIRECT

VENT/1-PIPE)

COMBUSTION AIR

PIPE (DIRECT VENT

/2-PIPE)

12 ″ MIN

12

″

MIN

VENT PIPE

VERTICAL TO ROOF VERTICAL TO SIDEWALL

NOTE: A 12-In. minimum offset pipe section is recommended with short (5-ft. to 8-ft) vent systems. This recommendation is to reduce excessive condensate droplets from exiting the vent pipe.

A05094

Fig. 40—Short Vent (5 to 8 Ft) System

5. Be certain that mating surfaces of inducer housing connection elastomeric (rubber) coupling, and 2-in. diameter vent pipe are clean and dry.

Assemble the elastomeric (rubber) vent coupling (with 2 loose clamps) onto inducer housing connection. Insert the 2-in. diameter vent pipe through the elastomeric (rubber) coupling and fully into inducer housing connection until it touches a stop inside the inducer housing outlet.

Tighten the screws on both clamps to 15-in-lb. of torque. pipe to inducer housing. Tighten the clamp screws to 15 in.-lb. of torque.

NOTE: Starting at furnace, slope vent pipe a minimum of 1/4-in. per linear ft with no sags between hangers.



Vent pipe must be installed and fully seated against inducer housing internal stop. Clamp must be tightened to prevent any condensate leakage.

6. Install casing hole filler cap (factory-supplied in loose parts bag) in unused vent pipe casing hole.

ATTACHMENT OF VENT EXTENSION PIPE

Furnaces with 100,00 Btuh and larger input are supplied with a PVC vent extension pipe (2-in. diameter by 12-in. long). This pipe has a built-in channel to assist vent condensate disposal. When this vent extension pipe is supplied, it MUST be used to connect the field vent pipe to furnace inducer housing on ALL upflow and downflow applications.

NOTE: See label on vent extension pipe for proper installation. This pipe may be shortened if an elbow is used to connect vent extension tube to field-installed vent pipe.

INSTALLATION GUIDELINES FOR COMBUSTION AIR PIPE AND VENT PIPE

It is recommended that all pipes be cut, prepared, and pre-assembled before permanently cementing any joint.

1. Attach combustion air pipe and vent pipe per instructions in sections ″Combustion Air Pipe″ and ″Vent Pipe.″

2. Working from furnace to outside, cut pipe to required length(s).

3. Deburr inside and outside of pipe.

4. Chamfer outside edge of pipe for better distribution of primer and cement.

5. Clean and dry all surfaces to be joined.

6. Check dry fit of pipe and mark insertion depth on pipe.

—44—

Roof Termination (Preferred)

At least 36 in.

Vertical separation between combustion air and vent

8 3/4 in. for 3 in. kit

6 3/4 in. for 2 in. kit 18 in. maximum

Maintain 12 in. min.

clearance above highest anticipated snow level

Maximum of 24 in.

above roof

Note: "A" denotes 0 to < 2 in.

A

Concentric Vent and Combustion Air

Roof Termination (preferred)

A

At least

36 in.

Maintain 12 in.

min. clearance above highest anticipated snow level, maximum of

24 in. above roof

12 in.

min from overhang or roof

Abandoned masonry used as raceway

(per code)

1 in.

maximum (type)

12 in. minimum from overhang or roof

At lea

36

in.

st A

Maintain 12 in.

min. clearance above highest anticipated snow level or grade whichever is greater

Concentric Vent and Combustion - Air

Side Termination

90

°

At least 36 in

.

A

A

12 in.

separation between bottom of combustion air and bottom of vent

Maintain 12 in.

min. clearance above highest anticipated snow level or grade whichever is greater

At least 36 in.

Side wall termination of less than 12 in.

A05090

→

Fig. 41—Combustion Air and Vent Pipe Termination for Direct Vent (2-Pipe) System (All Sizes)

Roof Termination (Preferred)

Vent

Maintain 12 in.

minimum clearance above highest anticipated

snow level maximum of

24 in. above roof.

Abandoned masonry used as raceway

(per code)

6 in. minimum clearance between wall and end of vent pipe.

10 in. maximum pipe length

12 in. min. from overhang or roof

→

90

°

12 in. min. from overhang or roof

Sidewall Termination with Straight Pipe (preferred)

Maintain 12 in.

minimum clearance above highest anticipated snow level or grade whichever is greater

Maintain 12 in.

minimum clearance above highest anticipated snow level or grade whichever is greater.

Side wall termination with 2 elbows (preferred)

A05091

Fig. 42—Vent Pipe Termination for Non-Direct

Vent (1-pipe) System (Sizes 040 Through 120 Only)

7. After pipes have been cut and preassembled, apply generous layer of cement primer to pipe fitting socket and end of pipe to insertion mark.

Quickly apply approved cement to end of pipe and fitting socket (over primer). Apply cement in a light, uniform coat on inside of socket to prevent buildup of excess cement. Apply second coat.

8. While cement is still wet, twist pipe into socket with 1/4 turn. Be sure pipe is fully inserted into fitting socket.

9. Wipe excess cement from joint. A continuous bead of cement will be visible around perimeter of a properly made joint.

—45—

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.

→

EXAMPLE:

An 080-12 size furnace located in Indianapolis, elevation 650 ft above sea level, could be installed as either a direct vent/2-pipe system that requires 3 elbows and 32 ft of vent pipe, along with 5 elbows and 34 ft of combustion-air pipe OR a non-direct vent/1-pipe system that requires 3 elbows and 32 ft vent pipe. For a direct vent/2-pipe system, Table 11 indicates this application would allow a 2-in. diameter vent pipe, but require a 2-1/2 in. diameter combustion air pipe. According to Table 11, 2-in. diameter pipe is good for 35 ft with 3 elbows, but only 30 ft with 5 elbows. Therefore, 2-1/2 in. diameter pipe must be used for both vent and combustion-air pipes since larger required diameter must always be used for both pipes. For a non-direct vent/1-pipe system, Table 11 indicates that this application would allow a

2-in. diameter vent pipe.

If same installations were in Albuquerque, elevation 5250 ft above sea level:

For a direct vent/2-pipe system, Table 11 indicates that 2-1/2 in. diameter vent pipe and combustion-air pipe are required. For a non-direct vent/1-pipe system, Table 11 indicates that 2-1/2-in. diameter vent pipe is required.

If same applications are to be installed at 5001- to 6000 ft elevation:

For a direct vent/2-pipe system, 2-in. pipe is only good for 23 ft (with 3 elbows) and 17 ft (with 5 elbows). Therefore, 2-1/2 in. diameter combustion air and vent pipe must be used.

For a non-direct vent/1-pipe system, a 2-in. diameter pipe is only good for 23 ft with 3 elbows. A 2-1/2-in. diameter vent pipe must be used.

→

G.

Vent Termination

GENERAL

Combustion-air (direct vent/2-pipe system only) and vent pipe must terminate outside structure, either through sidewall or roof. For vent termination clearance, refer to Table 8 for Direct Vent/2-Pipe system and Table 9 for Non-direct Vent/1-Pipe system. For exterior piping arrangements, refer to Fig. 40 for Direct Vent/2-Pipe system and Fig. 41 for Non-Direct/1-Pipe system.

Roof termination is preferred since it is less susceptible to damage or contamination, and it has less visible vent vapors. Sidewall termination require sealing or shielding of building surfaces with a corrosive resistance material due to corrosive combustion products of vent system.

NOTE: (Direct Vent/2-Pipe system ONLY). A factory accessory termination kit MUST be used. See section

″Vent Termination Kit (Direct

Vent/2-Pipe System Only)

″ in this instruction.

When determining appropriate location for termination, consider the following guidelines:

1. Comply with all clearance requirements stated in Table 8 or Table 9 per application.

2. Termination or termination kit should be positioned where vent vapors will not damage plants/shrubs or air conditioning equipment.

3. Termination or termination kit should be positioned so that it will not be affected by wind eddy, such as inside building corners, nor by recirculation of flue gases, airborne leaves, or light snow.

4. Termination or termination kit should be positioned where it will not be damaged by or subjected to foreign objects such as stones, balls, etc.

5. Termination or termination kit should be positioned where vent vapors are not objectionable.

EXTENDED EXPOSED SIDEWALL PIPES

Sidewall combustion air pipe termination (direct vent/2-pipe system only) and vent pipe termination may be extended beyond area shown in Fig.

40 or in Fig. 41 per application in outside ambient by insulating pipe as indicated in Table 10.

1. Determine combustion air pipe diameter (direct vent/2-pipe system only) and vent pipe diameter, as stated above, using total pipe length and number of elbows.

2. Using winter design temperature (used in load calculations), find appropriate temperature for your application and furnace model.

3. Determine required insulation thickness for exposed pipe length(s).

NOTE: Pipe length(ft) specified for maximum pipe lengths located in unconditioned spaces cannot exceed total allowable pipe length as specified in Table 8.

VENT TERMINATION KIT (DIRECT VENT/2-PIPE SYSTEM ONLY)

NOTE: Always refer to the instructions in termination kit for the latest version.

Combustion air and vent pipes MUST terminate outside structure. A factory accessory termination kit must be installed as shown in Table 12.

There are four options of vent/combustion air termination kits available as shown in Table 12.

NOTE: Combustion air pipe must have the same diameter as vent pipe.

CONCENTRIC VENT/COMBUSTION AIR TERMINATION KIT

Determine an appropriate location for termination kit using the guidelines provided in section

″Vent Termination: General″ in this instruction.

1. Cut one 4-in. diameter hole for 2-in. kit, or one 5-in. diameter hole for 3-in. kit.

2. Loosely assemble concentric vent/combustion air termination components together using instructions in kit.

—46—

→

DIRECT VENT (2-PIPE) TERMINATION KIT

2-in. Concentric Vent Kit

3-in. Concentric Vent Kit

2-in. Termination Bracket Kit

3-in. Termination Bracket Kit

Table 12—Vent Termination Kit for Direct Vent/2-Pipe System

TERMINATION SYSTEM

Single Penetration of Wall or Roof

Single Penetration of Wall or Roof

2-Pipe Termination System

2-Pipe Termination System

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. Slide assembled kit with rain shield REMOVED through hole.

NOTE: Do not allow insulation or other materials to accumulate inside of pipe assembly when installing it through hole.

Roof terminations—Locate assembly through roof to appropriate height as shown in Fig. 40.

Sidewall terminations—Locate assembly through sidewall with rain shield positioned no more than 1-in. from wall as shown in Fig. 40.

4. Disassemble loose pipe fittings. Clean and cement using same procedures as used for system piping.

5. Check required dimensions as shown in Fig. 40.

TWO-PIPE TERMINATION KIT

Determine an appropriate location for termination kit using the guidelines provided in section

″Vent Termination: General″ in this instruction.

1. Cut 2 holes, 1 for each pipe, of appropriate size for pipe size being used.

2. Loosely install elbow in bracket and place assembly on combustion-air pipe.

Roof terminations—Loosely install pipe coupling on properly cut vent pipe. Coupling must be positioned so bracket will mount as shown in Fig. 40.

For applications using combustion-air pipe option, indicated by dashed lines in Fig. 40, install 90° street elbow into 90° elbow, making a

U-fitting. A 180° U-fitting may be used.

Sidewall terminations—Install bracket as shown in Fig. 40.

For applications using vent pipe option indicated by dashed lines in Fig. 40, rotate vent elbow 90° from position shown in Fig. 40.

3. Disassemble loose pipe fittings. Clean and cement using same procedures as used for system piping.

4. Check required dimensions as shown in Fig. 40.

MULTIVENTING AND VENT TERMINATIONS

When 2 or more PG9MAB Furnaces are vented near each other, each furnace must be individually vented. NEVER common vent or breach vent

PG9MAB furnaces.

(Direct Vent/2-Pipe System ONLY)-When 2 or more PG9MAB furnaces are vented near each other, 2 vent terminations may be installed as shown in Fig. 40, but next vent termination must be at least 36 in. away from first 2 terminations. It is important that vent terminations be made as shown in Fig. 40 to avoid recirculation of flue gases.

PROCEDURE 8—CONDENSATE DRAIN

A.

General

Condensate trap is shipped installed in the blower shelf and factory connected for UPFLOW applications. Condensate trap must be RELOCATED for use in DOWNFLOW and HORIZONTAL applications.

Condensate trap MUST be used for all applications.

An external trap is not required when connecting the field drain to this condensate trap.

The field drain connection (condensate trap or drain tube coupling) is sized for 1/2-in. CPVC, 1/2-in. PVC, or 5/8-in. ID tube connection.

Drain pipe and fittings must conform to ANSI standards and ASTM D1785, D2466 or D2846. CPVC or PVC cement must conform to ASTM

D2564 or F493. Primer must conform to ASTM F656. In Canada, use CSA or ULC listed schedule 40 CPVC or PVC drain pipe, fittings, and cement.

When a condensate pump is required, select a pump which is approved for condensing furnace applications. To avoid condensate spillage, select a pump with an overflow switch.



Unit must not be installed, operated, and then turned off and left in an unconditioned structure during cold weather when temperature drops to 32°F and below unless drain trap and drain line have adequate freeze protection. See Service and Maintenance Instructions for winterizing procedures. (See Fig. 16.)

Furnace condensate is mildly acidic, typically in the pH range of 3.2 to 4.5. Due to corrosive nature of this condensate, a condensate pH neutralizing filter may be desired. Check with local authorities to determine if a pH neutralizer is required.

B.

Application

The furnace, A/C, and humidifier drains may be combined and drained together. The A/C drain must have an external, field-supplied trap prior to the furnace drain connection. All drain connections (furnace, A/C, or humidifier) must be terminated into an open or vented drain as close to the respective equipment as possible to prevent siphoning of the equipment’s drain.

—47—

CONDENSATE TRAP

OPEN STAND

PIPE FOR

A/C OR

HUMIDIFIER

DRAIN

TEE

TO OPEN

DRAIN

WIRE TIE(S)

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. Caution should be taken when freezing ambient may freeze drain pipe and prohibit draining.

WARNING: PERSONAL INJURY HAZARD

Caution should be taken to prevent draining where slippery conditions could cause personal injuries.

Excessive condensate draining may cause saturated soil conditions which could result in damage to plants.

C.

Condensate Drain Protection

Freezing condensate left in condensate trap and drain line may cause cracks, and possible water damage may occur. If freeze protection is required, use condensate freeze protection accessory or equivalent 3 to 6 watt per ft at 120v and 40°F self-regulating, shielded, and waterproof heat tape.

See Installation Instructions supplied with accessory or heat tape manufacturer’s recommendations.

1. Fold heat tape in half and wrap on itself 3 times.

2. Locate heat tape between sides of condensate trap back. (See Fig. 44.)

3. Use wire ties to secure heat tape in place. Wire ties can be positioned in notches of condensate trap sides. (See Fig. 44.)

4. Wrap field drain pipe with remaining heat tape, approximately 1 wrap per ft.

5. When using field-supplied heat tape, follow heat tape manufacturer’s instructions for all other installation guidelines.

START-UP, ADJUSTMENTS AND SAFETY CHECK


1. Furnace must have a 115-v power supply properly connected and grounded. Proper polarity must be maintained for correct operation.

NOTE: Proper polarity must be maintained for 115-v wiring. If polarity is incorrect, control center LED status light will flash rapidly and furnace will not operate.

2. Thermostat wire connections at terminals R, W, G, and Y must be made at 24-v terminal block on furnace control.

3. Natural gas service pressure must not exceed 0.5 psig (14-in. wc), but must be no less than 0.16 psig (4.5-in. wc).

4. Blower access panel must be in place to complete 115-v electrical circuit to furnace.



These furnaces are equipped with a manual reset limit switch in burner box. This switch will open and shut off power to gas control valve if an overheat condition (flame rollout) occurs in burner enclosure. Correct inadequate combustion-air supply or improper venting condition and reset switch. DO NOT jumper this switch.

Before operating furnace, check flame rollout manual reset switch for continuity. If necessary, press button to reset switch.

PROCEDURE 2—PRIME CONDENSATE TRAP WITH WATER



Condensate trap must be PRIMED or proper draining may not occur. The condensate trap has 2 internal chambers which can ONLY be primed by pouring water into the inducer drain side of condensate trap.

—48—

A94208 A94209

Fig. 45—Inducer Housing Drain Cap 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. Remove funnel and tube from inducer housing and replace drain connection cap and clamp.

PROCEDURE 3—PURGE GAS LINES

WARNING: FIRE AND EXPLOSION HAZARD

Failure to follow this warning could result in a fire, explosion, personal injury, or death.

Never purge a gas line into a combustion chamber. 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.

If not previously done, purge lines after all connections have been made and check for leaks.

PROCEDURE 4—SEQUENCE OF OPERATION

CAUTION: FURNACE MAY NOT OPERATE

Failure to follow this caution may result in furnace operation stopping and water pipes freezing during cold weather.

Furnace control must be grounded for proper operation, or control will lock out. Control is grounded through green/yellow wire routed to gas valve and burner box screw.

Using schematic diagram, follow sequence of operation through different modes. (See Fig. 34.) Read and follow wiring diagram carefully.

NOTE: If 115-v power supply to furnace or blower access panel switch is interrupted during a call for heat, blower operates for 90 sec when power is restored before heating cycle is resumed.

A.

Heating Mode

(See Fig. 31 for thermostat connections.)

The wall thermostat ″calls for heat″, closing the R to W circuit. The furnace control performs a self-check, verifies the pressure switch contacts PRS are open, and starts the inducer motor IDM.

a. Inducer Prepurge Period- As the inducer motor IDM comes up to speed, the pressure switch contacts PRS close, 24 vac power is supplied for a field installed humidifier at the HUM terminal and the control begins a 15-second prepurge period.

—49—

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. The HSI igniter will remain energized until the flame is sensed or until the 2-second flame proving period begins.

d. Flame-Proving- When the burner flame is proved at the flame-proving sensor electrode FSE, the furnace control CPU begins the blower-ON delay period and continues to hold the gas valve GV open. If the burner flame is not proved within two seconds, the control

CPU will close the gas valve GV, and the control CPU will repeat the ignition sequence for up to three more Trials-For-Ignition before going to Ignition-Lockout. Lockout will be reset automatically after three hours, by momentarily interrupting 115 vac power to the furnace, or by interrupting 24 vac power at SEC1 or SEC2 to the furnace control CPU (not at W, G, R, etc.)

If flame is proved when flame should not be present, the furnace control CPU will lock out of Gas-Heating mode and operate the inducer motor IDM until flame is no longer proved.

e. Blower-On Delay- If the burner flame is proven, the blower motor is energized on HEAT speed 66 seconds (040 through 120 sizes) or

45 seconds (140 size) after the gas valve GV is energized.

Simultaneously, the electronic air cleaner terminal EAC-1 is energized and remains energized as long as the blower motor BLWM is energized.

f. Blower-Off Delay- When the thermostat is satisfied, the R-to-W circuit is opened, de-energizing the gas valve GV, stopping gas flow to the burners, and de-energizing the humidifier terminal HUM. The inducer motor IDM will remain energized for a 15-second (040 through 120 sizes) or 5-second (140 size) post-purge period. The blower motor BLWM and air cleaner terminal EAC-1 will remain energized for 90, 120, 150, or 180 seconds (depending on the blower-OFF delay selection). The furnace control CPU is factory-set for a 120-second blower-OFF delay.

B.

Cooling Mode

(See Fig. 31 for thermostat connections)

The thermostat closes the R-to-G-and-Y circuits. The R-to-Y circuit starts the outdoor unit, and the R-to-G and-Y circuits start the furnace blower motor BLWM on COOL speed.

The electronic air cleaner terminal EAC-1 is energized with 115 vac when the blower motor BLWM is operating.

When the thermostat is satisfied, the R-to-G-and-Y circuits are opened. The outdoor unit will stop, and the furnace blower motor BLWM will continue operating on the COOL speed for an additional 90 seconds. Cut jumper J2 to reduce the cooling off-delay to 5 seconds. (See Fig. 35.)

C.

Continuous Blower Mode

When the R-to-G circuit is closed by the thermostat, the blower motor BLWM will operate on continuous-blower speed (same as HEAT speed).

Terminal EAC-1 is energized as long as the blower motor BLWM is energized.

During a ″call for heat,″ the blower BLWM will stop during igniter warm-up (17 seconds), ignition (7 seconds), and blower-ON delay (66 or 45 seconds for 040 through 120 sizes or for 140 size), allowing the furnace heat exchangers to heat up more quickly, then restarts at the end of the blower-ON delay period at HEAT speed.

In heating, the furnace control CPU will continue running the blower motor BLWM at HEAT speed after the selected blower-OFF delay period is completed.

When the thermostat

″calls for cooling″, the blower motor BLWM will operate at COOL speed. When the thermostat is satisfied, the blower motor

BLWM will operate an additional 90 seconds on COOL speed before reverting back to HEAT speed. Jumper J2 can be cut to reduce the cooling off-delay to 5 seconds. (See Fig. 35.)

6. Insert 2-in. diameter pipe into inducer housing through neoprene coupling and clamp in inducer housing. Tighten clamp.

When the R-to-G circuit is opened, the blower motor BLWM will continue operating for an additional 5 seconds, if no other function requires blower motor BLWM operation.

D.

Heat Pump Mode

When installed with a heat pump, the furnace control automatically changes the timing sequence to avoid long blower off times during demand defrost cycles. When the R-to-W-and-Y or R-to-W-and-Y-and-G circuits are energized the furnace control CPU will continue to turn on the blower motor BLWM at HEAT speed, and begin a heating cycle. The blower motor BLWM will remain on until the end of the prepurge period, then shut off for 24 seconds then come back on at HEAT speed. When the W input signal disappears, the furnace control begins a normal inducer post-purge period and the blower switches to COOL speed after a 3 second delay. If the R-to-W-and-Y-and-G signals disappear at the same time, the blower motor BLWM will remain on for the selected blower-OFF delay period. If the R-to-W-and-Y signals disappear, leaving the G signal, the blower motor BLWM will continue running the blower motor BLWM at HEAT speed after the selected blower-OFF delay period is completed.

Control initiates a 90-sec blower only on period before starting another heat pump cycle if there is a power interruption. Anytime control senses false flame, control locks out of heating mode. This reaction occurs because control ignores W input due to false flame signal and, as a result, sees only Y input and goes into cooling mode blower off delay. All other control functions remain in standard format.

E.

Component Test

NOTE: The furnace control component test allows all components to run for a short time; except the gas valve and humidifier terminal HUM are not energized for safety reasons. The EAC-1 terminal is energized when the blower is energized. This feature helps diagnose a system problem in case of a component failure. The component test feature will not operate if any thermostat signal is present ant the control and not until all time delays are completed.

NOTE: Record the status code BEFORE opening the blower access door and before shutting off power to the furnace. Opening the blower access door will open the blower door switch and shut off power within the furnace. When power to the furnace is shut off by either method, the status code will be lost because the code is not stored while power is removed for any reason.

—50—

To Begin Component Self-Test:


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. For approximately 2 sec, short (jumper) the C

OM

-24v terminal on control to the TEST/TWIN 3/16-inch quick-connect terminal on control until the LED goes out. Remover jumper from terminals. (See Fig. 35.)

NOTE: If TEST/TWIN and C

OM

-24v terminals are jumpered longer than 2 sec, LED will flash rapidly and ignore component test status code retrieval request.

Component test sequence is as follows: a. LED will display previous status code 4 times.

b. Inducer motor starts and continues to run until Step f of component test sequence.

c. After 7 seconds the hot surface igniter is energized for 15 sec, then off.

d. Blower motor operates on HEAT speed for 10 sec.

e. Blower motor operates on COOL speed for 10 sec.

f. Inducer motor stops.

5. Reconnect R lead to furnace control, remove tape from blower door switch, and re-install blower door.

6. Operate furnace per instruction on outer door.

7. Verify furnace shut down by lowering thermostat setting below room temperature.

8. Verify that furnace restarts by raising thermostat setting above room temperature.

PROCEDURE 5—ADJUSTMENTS

A.

Set Gas Input Rate

Furnace gas input rate on rating plate is for installations at altitudes up to 2000 ft.

In the U.S.A., the input ratings for altitudes above 2000 ft must be reduced by 2 percent for each 1000 ft above sea level.

In Canada, the input ratings must be derated by 5 percent for altitudes of 2000 ft to 4500 ft above sea level.

Furnace input rate must be within

±2 percent of input on furnace rating plate adjusted for altitude.

1. Determine natural gas orifice size and manifold pressure for correct input.

a. Obtain average gas heat value (at installed altitude) from local gas supplier.

b. Obtain average gas specific gravity from local gas supplier.

c. Verify furnace model and size. Table 13 can only be used for model PG9MAB furnaces with heating sizes of 040 through 120. Table

14 can only be used for model PG9MAB furnaces with heating size of 140.

d. Find installation altitude in Table 13 or 14.

NOTE: For Canada altitudes of 2001 to 4500 ft, use U.S.A. altitudes of 2001 to 3000 ft in Table 13 or 14.

e. Find closest natural gas heat value and specific gravity in Table 13 or 14.

f. Follow heat value and specific gravity lines to point of intersection to find orifice size and manifold pressure settings for proper operation.

EXAMPLE: (0—2000 ft altitude using Table 13)

Heating value = 1050 Btu/cu ft

Specific gravity = 0.62

Therefore: Orifice No. 45

Manifold pressure 3.6-in. wc

* Furnace is shipped with No. 45 orifices. In this example all main burner orifices are the correct size and do not need to be changed to obtain the proper input rate.

Check and verify burner orifice size in furnace. NEVER ASSUME ORIFICE SIZE; ALWAYS CHECK AND VERIFY.

2. Adjust manifold pressure to obtain input rate.

NOTE: Manifold pressure must always be measured with burner enclosure front REMOVED. Gas meter must always be clocked with burner enclosure front INSTALLED.

a. Remove burner enclosure front.

b. Remove cap that conceals adjustment screw for gas valve regulator. (See Fig. 48.) c. Jumper R and W thermostat connections on control to start furnace operation.

—51—

ALTITUDE

RANGE

(FT)

0 to

2000

0% derate

ALTITUDE

RANGE

(FT)

U.S.A.

Altitudes

2001 to

3000 or

Canada

Altitudes

2001 to

4500

5% derate

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)*

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

1000

1025

1050

1075

1100

850

875

900

925

950

975

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

775

800

825

850

875

900

925

950

975

1000

1025

Orifice

No.

0.58

Manifold

Pressure

43

43

44

44

44

44

3.7

3.5

3.7

3.5

3.4

3.2

45

45

45

45

47

3.7

3.5

3.3

3.2

3.6

Orifice

No.

43

0.58

Manifold

Pressure

3.8

43

44

44

44

44

45

3.5

3.8

3.6

3.4

3.2

3.7

45

45

45

45

3.5

3.3

3.1

3.0

ALTITUDE

RANGE

(FT)

3001 to

4000

7% derate

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

750

775

800

825

850

875

900

925

950

975

1000

Orifice

No.

0.58

Manifold

Pressure

43

43

44

44

44

45

45

45

45

45

45

3.7

3.5

3.7

3.5

3.3

3.8

3.6

3.4

3.2

3.0

2.9

* Orifice numbers shown in BOLD are factory installed.

Percents of derate are based on midpoints of U.S. altitude ranges.

45

45

45

45

47

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

0.60

0.62

0.64

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

43

43

43

44

44

44

3.8

3.6

3.4

3.7

3.5

3.3

42

43

43

44

44

44

3.2

3.7

3.5

3.8

3.6

3.4

42

43

43

43

44

44

3.3

3.8

3.6

3.4

3.7

3.5

3.8

3.6

3.4

3.3

3.7

44

45

45

45

45

3.2

3.7

3.6

3.4

3.2

44

44

45

45

45

3.4

3.2

3.7

3.5

3.4

Orifice

No.

42


0.60

0.62

0.64

Manifold

Pressure

3.2

Orifice

No.

42

Manifold

Pressure

3.3

Orifice

No.

42

Manifold

Pressure

3.4

43

43

44

44

44

45

3.7

3.4

3.7

3.5

3.3

3.8

43

43

44

44

44

44

3.8

3.6

3.8

3.6

3.4

3.2

42

43

43

44

44

44

3.2

3.7

3.5

3.7

3.5

3.3

45

45

45

45

3.6

3.4

3.2

3.1

45

45

45

45

3.7

3.5

3.4

3.2

45

45

45

45

3.8

3.6

3.5

3.3

44

44

45

45

45

45

45

Orifice

No.


0.60

0.62

0.64

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

43

43

43

44

3.8

3.6

3.4

3.6

42

43

43

44

3.3

3.7

3.5

3.8

42

43

43

43

3.4

3.8

3.6

3.4

3.4

3.2

3.7

3.5

3.3

3.2

3.0

44

44

45

45

45

45

45

3.5

3.3

3.8

3.6

3.4

3.3

3.1

44

44

44

45

45

45

45

3.7

3.5

3.3

3.7

3.5

3.4

3.2

Orifice

No.

0.66

Manifold

Pressure

42

42

43

43

44

44

3.4

3.2

3.7

3.5

3.8

3.6

44

44

45

45

45

3.5

3.3

3.8

3.6

3.5

Orifice

No.

42

0.66

Manifold

Pressure

3.5

42

43

43

43

44

44

3.3

3.8

3.6

3.4

3.6

3.4

44

45

45

45

3.3

3.8

3.6

3.4

44

44

44

44

45

45

45

Orifice

No.

0.66

Manifold

Pressure

42

42

43

43

3.5

3.2

3.7

3.5

3.8

3.6

3.4

3.2

3.7

3.5

3.3

—52—

ALTITUDE

RANGE

(FT)

4001 to

5000

9% derate

ALTITUDE

RANGE

(FT)

5001 to

6000

11% derate

Table 13—Model PG9MAB Orifice Size and Manifold Pressure for Correct Input (Continued)


(Tabulated Data Based on 20,000 Btuh per Burner, Derated 2% for Each 1000 Ft Above Sea Level)

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

725

750

775

800

825

850

875

900

925

950

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

900

925

950

975

1000

700

725

750

775

800

825

850

875

Orifice

No.

0.58

Manifold

Pressure

43

43

44

44

44

45

3.7

3.4

3.7

3.5

3.2

3.7

45

45

45

45

3.5

3.3

3.1

3.0

45

45

45

45

45

44

45

45

45

Orifice

No.

0.58

Manifold

Pressure

43

43

44

44

3.6

3.4

3.6

3.4

3.0

2.9

2.7

2.6

2.5

3.2

3.6

3.4

3.2

ALTITUDE

RANGE

(FT)

6001 to

7000

13% derate

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

650

675

700

725

750

775

800

825

850

875

Orifice

No.

42

0.58

Manifold

Pressure

3.2

43

44

44

44

45

45

45

45

45

3.6

3.8

3.6

3.3

3.8

3.5

3.3

3.1

3.0



Orifice

No.


0.60

0.62

0.64

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

43

43

44

44

44

45

3.8

3.5

3.8

3.6

3.4

3.8

42

43

43

44

44

44

3.2

3.7

3.4

3.7

3.5

3.3

42

43

43

44

44

44

3.3

3.8

3.5

3.8

3.6

3.4

45

45

45

45

3.6

3.4

3.2

3.1

45

45

45

45

3.7

3.5

3.3

3.2

44

45

45

45

3.2

3.6

3.4

3.3

45

45

45

45

45

44

45

45

45

Orifice

No.


0.60

0.62

0.64

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

43

43

44

44

3.7

3.5

3.7

3.5

42

43

43

44

3.2

3.6

3.4

3.6

42

43

43

44

3.3

3.7

3.5

3.7

3.3

3.7

3.5

3.3

3.1

3.0

2.8

2.7

2.5

44

44

45

45

45

45

45

45

45

3.4

3.2

3.6

3.4

3.3

3.1

2.9

2.8

2.6

44

44

45

45

45

45

45

45

45

3.4

3.2

3.0

2.9

2.7

3.5

3.3

3.8

3.6

44

45

45

45

45

Orifice

No.

42


0.60

0.62

0.64

Manifold

Pressure

3.3

Orifice

No.

42

Manifold

Pressure

3.4

Orifice

No.

42

Manifold

Pressure

3.5

43

43

44

44

3.7

3.4

3.7

3.4

43

43

44

44

3.8

3.6

3.8

3.6

42

43

43

44

3.2

3.7

3.4

3.7

3.2

3.7

3.4

3.2

3.1

44

45

45

45

45

3.3

3.8

3.6

3.4

3.2

44

44

45

45

45

3.4

3.2

3.7

3.5

3.3

Orifice

No.

0.66

Manifold

Pressure

42

42

43

43

44

44

3.4

3.2

3.7

3.4

3.7

3.5

44

45

45

45

3.3

3.8

3.6

3.4

45

45

45

45

45

44

44

44

45

Orifice

No.

0.66

Manifold

Pressure

42

43

43

43

3.4

3.8

3.6

3.4

3.5

3.3

3.1

2.9

2.8

3.6

3.4

3.2

3.7

Orifice

No.

42

0.66

Manifold

Pressure

3.6

42

43

43

44

3.3

3.8

3.5

3.8

44

44

45

45

45

3.5

3.3

3.8

3.6

3.4

—53—

ALTITUDE

RANGE

(FT)

7001 to

8000

15% derate

ALTITUDE

RANGE

(FT)

8001 to

9000

17% derate




AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

625

650

675

700

725

750

775

800

825

850

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

600

625

650

675

700

725

750

775

800

Orifice

No.

0.58

Manifold

Pressure

43

43

44

44

44

45

3.8

3.5

3.8

3.5

3.3

3.7

45

45

45

45

3.5

3.3

3.1

2.9

Orifice

No.

0.58

Manifold

Pressure

43

43

44

44

3.8

3.5

3.7

3.5

44

45

45

45

45

3.2

3.6

3.4

3.2

3.0

ALTITUDE

RANGE

(FT)

9001 to

10,000

19% derate

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

575

600

625

650

675

700

725

750

775

Orifice

No.

0.58

Manifold

Pressure

43

43

44

44

45

45

45

45

45

3.8

3.5

3.7

3.4

3.8

3.6

3.3

3.1

2.9



Orifice

No.


0.60

0.62

0.64

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

42

43

43

44

44

45

3.3

3.7

3.4

3.6

3.4

3.8

42

43

43

44

44

44

3.4

3.8

3.5

3.8

3.5

3.3

42

42

43

43

44

44

3.5

3.2

3.6

3.4

3.6

3.4

45

45

45

45

3.6

3.4

3.2

3.0

45

45

45

45

3.7

3.5

3.3

3.1

45

45

45

45

3.8

3.6

3.4

3.2

44

45

45

45

45

Orifice

No.


0.60

0.62

0.64

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

42

43

43

44

3.3

3.6

3.4

3.6

42

43

43

44

3.4

3.8

3.5

3.7

42

42

43

44

3.5

3.2

3.6

3.8

3.3

3.8

3.5

3.3

3.1

44

44

45

45

45

3.4

3.2

3.6

3.4

3.2

44

44

45

45

45

3.6

3.3

3.8

3.5

3.3

Orifice

No.


0.60

0.62

0.64

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

42

43

44

44

44

45

45

45

45

3.2

3.6

3.8

3.5

3.3

3.7

3.4

3.2

3.0

42

43

43

44

44

45

45

45

45

3.3

3.7

3.5

3.7

3.4

3.8

3.6

3.3

3.1

42

42

43

44

44

44

45

45

45

3.5

3.2

3.6

3.8

3.5

3.3

3.7

3.4

3.2

Orifice

No.

0.66

Manifold

Pressure

42

42

43

43

44

44

3.6

3.3

3.7

3.5

3.7

3.5

44

45

45

45

3.3

3.7

3.5

3.3

Orifice

No.

0.66

Manifold

Pressure

42

42

43

43

3.6

3.3

3.7

3.4

44

44

44

45

45

3.7

3.4

3.2

3.6

3.4

Orifice

No.

0.66

Manifold

Pressure

42

42

3.6

3.3

44

45

45

45

43

43

44

3.7

3.4

3.6

3.4

3.8

3.5

3.3

—54—

ALTITUDE

RANGE

(FT)

0 to

2000

0% derate

ALTITUDE

RANGE

(FT)

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.

Altitudes

2001 to

3000 or

Canade

Altitudes

2001 to

4500

5% derate

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

1000

1025

1050

1075

1100

850

875

900

925

950

975

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

775

800

825

850

875

900

925

950

975

1000

1025

Orifice

No.

0.58

Manifold

Pressure

41

42

42

42

42

43

3.6

3.8

3.5

3.4

3.2

3.7

43

43

43

44

44

3.5

3.3

3.2

3.5

3.3

Orifice

No.

41

0.58

Manifold

Pressure

3.7

42

42

42

42

43

43

3.8

3.6

3.4

3.2

3.7

3.5

43

43

43

43

3.3

3.1

3.0

2.8

ALTITUDE

RANGE

(FT)

3001 to

4000

7% derate

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

750

775

800

825

850

875

900

925

950

975

1000

Orifice

No.

0.58

Manifold

Pressure

41

42

42

42

43

43

43

43

43

43

43

3.6

3.8

3.5

3.3

3.8

3.6

3.4

3.2

3.1

2.9

2.8



43

43

43

44

44

Orifice

No.


0.60

0.62

0.64

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

41

41

42

42

42

43

3.7

3.5

3.7

3.5

3.3

3.8

41

41

42

42

42

42

3.8

3.6

3.8

3.6

3.4

3.2

40

41

41

42

42

42

3.6

3.7

3.5

3.7

3.5

3.3

3.6

3.4

3.3

3.6

3.4

43

43

43

43

44

3.7

3.6

3.4

3.2

3.5

42

43

43

43

43

3.2

3.7

3.5

3.3

3.2

Orifice

No.

41


0.60

0.62

0.64

Manifold

Pressure

3.8

Orifice

No.

40

Manifold

Pressure

3.6

Orifice

No.

40

Manifold

Pressure

3.7

41

42

42

42

43

43

3.6

3.7

3.5

3.3

3.8

3.6

41

41

42

42

42

43

3.7

3.5

3.6

3.4

3.2

3.7

41

41

42

42

42

42

3.8

3.6

3.7

3.5

3.3

3.2

43

43

43

43

3.4

3.3

3.1

2.9

43

43

43

43

3.5

3.4

3.2

3.0

43

43

43

43

3.7

3.5

3.3

3.1

42

43

43

43

43

43

43

Orifice

No.


0.60

0.62

0.64

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

41

41

42

42

3.8

3.5

3.7

3.4

40

41

42

42

3.6

3.6

3.8

3.6

40

41

41

42

3.7

3.7

3.5

3.7

3.2

3.7

3.5

3.3

3.2

3.0

2.9

42

42

43

43

43

43

43

3.4

3.2

3.6

3.5

3.3

3.1

3.0

42

42

43

43

43

43

43

3.5

3.3

3.8

3.6

3.4

3.2

3.0

Orifice

No.

0.66

Manifold

Pressure

40

41

41

42

42

42

3.8

3.8

3.6

3.8

3.6

3.4

42

43

43

43

43

3.3

3.8

3.6

3.4

3.3

Orifice

No.

39

0.66

Manifold

Pressure

3.6

40

41

41

42

42

42

3.6

3.7

3.5

3.6

3.4

3.3

43

43

43

43

3.8

3.6

3.4

3.2

42

42

42

43

43

43

43

Orifice

No.

0.66

Manifold

Pressure

40

40

41

42

3.8

3.6

3.6

3.8

3.6

3.4

3.2

3.7

3.5

3.3

3.1

—55—

ALTITUDE

RANGE

(FT)

4001 to

5000

9% derate

ALTITUDE

RANGE

(FT)

5001 to

6000

11% derate


For Use with 140 Size Furnaces Only


AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

725

750

775

800

825

850

875

900

925

950

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

900

925

950

975

1000

700

725

750

775

800

825

850

875

Orifice

No.

0.58

Manifold

Pressure

41

42

42

42

43

43

3.6

3.7

3.5

3.3

3.7

3.5

43

43

43

43

3.3

3.1

3.0

2.8

43

43

43

43

43

43

43

43

43

Orifice

No.

0.58

Manifold

Pressure

41

42

42

42

3.5

3.7

3.4

3.2

2.9

2.7

2.6

2.5

2.3

3.7

3.5

3.3

3.1

ALTITUDE

RANGE

(FT)

6001 to

7000

13% derate

AVG GAS

HEAT VALUE

AT ALTITUDE

(BTU/CU FT)

650

675

700

725

750

775

800

825

850

875

Orifice

No.

41

0.58

Manifold

Pressure

3.8

41

42

42

43

43

43

43

43

43

3.5

3.6

3.4

3.8

3.6

3.4

3.2

3.0

2.8



Orifice

No.


0.60

0.62

0.64

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

41

42

42

42

42

43

3.7

3.8

3.6

3.4

3.2

3.6

41

41

42

42

42

43

3.8

3.6

3.7

3.5

3.3

3.8

40

41

42

42

42

42

3.6

3.7

3.8

3.6

3.4

3.2

43

43

43

43

3.4

3.3

3.1

2.9

43

43

43

43

3.6

3.4

3.2

3.0

43

43

43

43

3.7

3.5

3.3

3.1

43

43

43

43

43

43

43

43

43

Orifice

No.


0.60

0.62

0.64

Manifold

Pressure

Orifice

No.

Manifold

Pressure

Orifice

No.

Manifold

Pressure

41

42

42

42

3.7

3.8

3.5

3.3

41

41

42

42

3.8

3.5

3.7

3.4

40

41

42

42

3.6

3.6

3.8

3.5

3.8

3.6

3.4

3.2

3.0

2.8

2.7

2.6

2.4

42

43

43

43

43

43

43

43

43

3.2

3.7

3.5

3.3

3.1

2.9

2.8

2.6

2.5

42

43

43

43

43

43

43

43

43

3.2

3.0

2.9

2.7

2.6

3.3

3.8

3.6

3.4

43

43

43

43

43

Orifice

No.

40


0.60

0.62

0.64

Manifold

Pressure

3.6

Orifice

No.

40

Manifold

Pressure

3.7

Orifice

No.

40

Manifold

Pressure

3.8

41

42

42

42

3.6

3.7

3.5

3.3

41

41

42

42

3.7

3.5

3.6

3.4

40

41

42

42

3.6

3.6

3.7

3.5

3.7

3.5

3.3

3.1

2.9

43

43

43

43

43

3.8

3.6

3.4

3.2

3.0

42

43

43

43

43

3.3

3.7

3.5

3.3

3.1

Orifice

No.

0.66

Manifold

Pressure

40

41

41

42

42

42

3.8

3.8

3.6

3.7

3.5

3.3

43

43

43

43

3.8

3.6

3.4

3.2

43

43

43

43

43

42

42

43

43

Orifice

No.

0.66

Manifold

Pressure

40

41

41

42

3.7

3.8

3.5

3.7

3.3

3.1

3.0

2.8

2.7

3.4

3.2

3.7

3.5

Orifice

No.

39

0.66

Manifold

Pressure

3.7

40

41

42

42

3.7

3.7

3.8

3.6

42

43

43

43

43

3.4

3.8

3.6

3.4

3.2

—56—

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.


Failure to follow this caution may result in reduced furnace life.

DO NOT bottom out gas valve regulator adjusting screw. This can result in unregulated manifold pressure and result in excess overfire and heat exchanger failures.

NOTE: If orifice hole appears damaged or it is suspected to have been redrilled, check orifice hole with a numbered drill bit of correct size. Never redrill an orifice. A burr-free and squarely aligned orifice hole is essential for proper flame characteristics.


Failure to follow this caution may result in component damage due to flame impingement of burners and heat exchangers.

DO NOT redrill orifices. Improper drilling (burrs, out-of-round holes, etc.) can cause excessive burner noise and misdirection of burner flames. (See Fig. 47.) e. Replace gas valve regulator adjustment screw cap.

f. Replace burner enclosure front and verify adjusted gas input rate using method outlined in item 3.

g. Look through sight glass in burner enclosure and check burner flame. Burner flame should be clear blue, almost transparent. (See Fig.

49.) h. Remove jumper from R and W.

3. Verify natural gas input rate by clocking gas meter.

NOTE: Be sure all pressure tubing, combustion-air and vent pipes, and burner enclosure front are in place when checking input by clocking gas meter.

a. Calculate high-altitude adjustment (if required).

UNITED STATES

At altitudes above 2000 ft, this furnace has been approved for a 2% derate for each 1000 ft above sea level. See Table 15 for derate multiplier factor.

EXAMPLE:

100,000 Btuh input furnace installed at 4300 ft.

FURNACE INPUT RATE

AT SEA LEVEL

X DERATE MULTIPLIER FACTOR =

FURNACE INPUT RATE

AT INSTALLATION ALTITUDE

100,000 X 0.91

= 91,000

CANADA

At installation altitudes from 2001 to 4500 ft, this furnace must be derated 5% by an authorized Gas Conversion Station or Dealer. To determine correct input rate for altitude, see example above and use 0.95 as derate multiplier factor.

b. Reinstall burner box cover.

c. Gas valve regulator seal cap MUST be installed.

d. Turn off all other gas appliances and pilots.

e. Start furnace and let operate for 3 minutes.

f. Measure time (in sec) for gas meter test dial to complete 1 revolution.

—57—

ON/OFF SWITCH

REGULATOR

SEAL CAP

REGULATOR

ADJUSTMENT

SCREW

REGULATOR SPRING

(PROPANE - WHITE, 6 TURNS

NATURAL - SILVER, 10 TURNS)

GAS PRESSURE

REGULATOR

ADJUSTMENT

BURNER FLAME

BURNER

INLET

PRESSURE TAP

MANIFOLD

PRESSURE TAP

MANIFOLD

A03142

Fig. 48—Redundant Automatic Gas Valve Fig. 49—Burner Flame

Table 15—Altitude Derate Multiplier for U.S.A.

ALTITUDE (FT)

0—2000

2001—3000

3001—4000

4001—5000

5001—6000

6001—7000

7001—8000

8001—9000

9001—10,000

* Derate multiplier factor is based on midpoint altitude for altitude range.

% OF DERATE

0

4—6

6—8

8—10

10—12

12—14

14—16

16—18

18—20

DERATE MULTIPLIER FACTOR*

1.00

0.95

0.93

0.91

0.89

0.87

0.85

0.83

0.81

A89020 g. Refer to Table 16 for cu ft of gas per hr.

h. Multiply gas rate (cu ft/hr) X heating value (Btu/cu ft) using natural gas heating value from local gas utility/supplier.

EXAMPLE: (0—2000 ft altitude)

Furnace input from rating plate is 100,000 Btuh.

Btu heating input = Btu/cu ft X cu ft/hr

Heating value of gas = 975 Btu/cu ft

Time for 1 revolution of 2-cu ft dial = 70 sec

Gas rate = 103 cu ft/hr (from Table 15)

Btu heating input = 103 X 975 = 100,425 Btuh

In this example, the orifice size and manifold pressure adjustment is within

±2 percent of the furnace input rate.

B.

Set Temperature Rise


Failure to follow this caution may result in overheating the heat exchangers or condensing flue gases in heat exchanger areas not designed for condensate.

Temperature rise must be within limits specified on unit rating plate. Recommended operation is at midpoint of rise range or above.

Determine and adjust air temperature rise as follows:

1. Place thermometers in return and supply ducts as close to furnace as possible. Be sure thermometers do not see heat exchanger so that radiant heat does not affect readings. This practice is particularly important with straight-run ducts.

2. When thermometer readings stabilize, subtract return-air temperature from supply-air temperature to determine air temperature rise.

—58—

Table 16—Gas Rate (Cu Ft/Hr)

SECONDS

FOR 1

REVOLUTION

40

41

42

43

44

45

46

47

48

49

35

36

37

38

39

30

31

32

33

34

20

21

22

23

24

15

16

17

18

19

10

11

12

13

14

25

26

27

28

29

240

225

212

200

189

180

171

164

157

150

144

138

133

129

124

1 cu ft

360

327

300

277

257

90

88

86

84

82

80

78

76

75

73

120

116

113

109

106

103

100

97

95

92

SIZE OF TEST DIAL

2 cu ft

720

655

600

555

514

480

450

424

400

379

360

343

327

313

300

288

277

267

257

248

180

176

172

167

164

160

157

153

150

147

240

232

225

218

212

206

200

195

189

185

SECONDS

FOR 1

REVOLUTION

100

102

104

106

108

110

112

116

120

124

90

92

94

96

98

80

82

84

86

88

60

62

64

66

68

55

56

57

58

59

50

51

52

53

54

70

72

74

76

78

1200

1125

1059

1000

947

900

857

818

783

750

720

692

667

643

621

5 cu ft

1800

1636

1500

1385

1286

450

439

429

419

409

400

391

383

375

367

600

581

563

545

529

514

500

486

474

462

327

321

316

310

305

300

290

281

273

265

257

250

243

237

231

5 cu ft

360

355

346

340

333

180

178

173

170

167

164

161

155

150

145

225

220

214

209

205

200

196

192

188

184

SIZE OF TEST DIAL

2 cu ft

144

141

138

136

133

131

129

126

124

122

120

116

112

109

106

103

100

97

95

92

72

71

69

68

67

65

64

62

60

58

80

78

76

75

74

90

88

86

84

82

60

58

56

54

53

65

64

63

62

61

51

50

48

47

46

1 cu ft

72

71

69

68

67

36

35

35

34

33

33

32

31

30

29

40

39

38

38

37

45

44

43

42

41

3. Adjust temperature rise by adjusting blower speed. Increase blower speed to reduce temperature rise. Decrease blower speed to increase temperature rise.



Disconnect 115-v electrical power before changing speed tap.

4. To change blower motor speed selections for heating mode, remove blower motor lead from control center HEAT terminal. (See Fig. 35.)

Select desired blower motor speed lead from 1 of the other motor leads and relocate it to HEAT terminal. See Table 18 for lead color identification. Reconnect original lead on SPARE terminal.

Follow this same procedure for proper selection of COOL speed selection.

C.

Blower Off Delay (Heat Mode)

The blower off delay has 4 adjustable settings from 90 sec to 180 sec. (See Table 18.) The blower off delay jumpers are located on the furnace control board (See Fig. 35). To change the blower off delay setting, move the jumper from one set of pins on the control board to the pins used for the desired blower off delay. Factory blower off delay setting is 120 sec.

D.

Set Thermostat Heat Anticipator

When using a nonelectronic thermostat, the thermostat heat anticipator must be set to match amp draw of the electrical components in R-W circuit.

Accurate amp draw readings can be obtained at thermostat subbase terminals R and W. Fig. 50 illustrates an easy method of obtaining actual amp draw. The amp reading should be taken after blower motor has started and furnace is heating. Connect ammeter wires as shown in Fig. 50. The thermostat anticipator should NOT be in the circuit while measuring current. If thermometer has no subbase, the thermostat must be disconnected from R and W wires during current measurement. See thermostat manufacturer’s instructions for adjusting heat anticipator and for varying heating cycle length.

For an electronic thermostat, set cycle rate for 3 cycles per hour.

PROCEDURE 6—CHECK SAFETY CONTROLS

This section covers the safety controls that must be checked before installation is complete. The flame sensor, gas valve, and pressure switch were all checked in the Start-up procedure section as part of normal operation.

—59—

COLOR

Black

Yellow (When Present)

Blue

Red

White

PINS

Time (in sec)

Table 17—Speed Selector

SPEED

High

Medium High

Medium Low

Low

Common

Table 18—Blower Off Delay Setup Position

1 AND 2

90

2 AND 3

120

3 AND 4

150

THERMOSTAT SUBBASE

TERMINALS WITH

THERMOSTAT REMOVED

HOOK-AROUND

VOLT/AMMETER

FACTORY-SHIPPED

CONNECTION

Cool

Spare

Heat

Spare

Com

4 AND 5

180

R Y W G

10 TURNS

FROM UNIT 24-VOLT

TERMINAL BLOCK

EXAMPLE:

5.0 AMPS ON AMMETER

10 TURNS AROUND JAWS

= 0.5 AMPS FOR THERMOSTAT SETTING

A80201

Fig. 50—Amp Draw Check with Ammeter

A.

Check Primary Limit Control

This control shuts off gas control system and energizes air-circulating blower motor if furnace overheats. Recommended method of checking this limit control is to gradually block off return air after furnace has been operating for a period of at least 5 minutes. As soon as limit control has shut off burners, return-air opening should be unblocked to permit normal air circulation. By using this method to check limit control, it can be established that limit is functioning properly and operates if there is a restricted return-air duct or motor failure. If limit control does not function during this test, cause must be determined and corrected.

B.

Check Pressure Switch

This control proves operation of draft inducer. Check switch operation as follows:

1. Turn off 115-v power to furnace.

2. Remove main furnace door and disconnect inducer motor lead wires from wire harness.

3. Turn on 115-v power to furnace.

4. Set thermostat to call for heat and wait 1 minute. When pressure switch is functioning properly, hot surface igniter should NOT glow, and control status code LED light flashes a Status Code 31. If hot surface igniter glows when inducer motor is disconnected, shut furnace down immediately. Determine reason pressure switch did not function properly and correct condition.

5. Turn off 115-v power to furnace.

6. Reconnect inducer motor leads, reinstall main furnace door, and turn on 115-v power supply.

—60—

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.

—61—

LOAD CALCULATION

____________

____________

____________

COMBUSTION AIR AND VENT PIPING

Termination Location

________

________

________

________

________

________

________

________

Pipe Insulation

________

________

Condensate Drain

________

________

________

________

________

CHECKLIST—START-UP

________

________

Thermostat Anticipator

________

________

Safety Controls Check Operation

________

________

CHECKLIST—DIRECT VENT INSTALLATIONS

Heating Load (Btuh)

Cooling Load (Btuh)

Furnace Model Selection

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 Sloped To Furnace

Over Ceilings

Low-Ambient Exposed Pipes

Unit Level or Pitched Forward

Internal Tubing Connections Free of Kinks and Traps

External Drain Connection Leak Tight and Sloped

Condensate Trap Primed before Start-Up

Heat Tape Installed if Required

Gas Input Rate (Set Within 2 percent of Rating Plate)

Temperature Rise Adjusted

Anticipator Setting Adjusted or

Cycle Rate (3 Cycles per Hr) Selected

Primary Limit

Pressure Switch

—62—

LOAD CALCULATION

____________

____________

____________

VENT PIPING

Termination Location

________

________

________

________

________

Pipe Insulation

________

________

Condensate Drain

________

________

________

________

________

CHECKLIST—START-UP

________

________

Thermostat Anticipator

________

________

Safety Controls Check Operation

________

________

CHECKLIST—NON-DIRECT VENT INSTALLATIONS

Heating Load (Btuh)

Cooling Load (Btuh)

Furnace Model Selection

Roof or Sidewall

Vent Pipe Length

Vent Pipe Elbow Quantity

Pipe Diameter Determined from Sizing Table

Pipe Sloped To Furnace

Over Ceilings

Low-Ambient Exposed Pipes

Unit Level or Pitched Forward

Internal Tubing Connections Free of Kinks and Traps

External Drain Connection Leak Tight and Sloped

Condensate Trap Primed before Start-Up

Heat Tape Installed if Required

Gas Input Rate (Set Within 2 percent of Rating Plate)

Temperature Rise Adjusted

Anticipator Setting Adjusted or

Cycle Rate (3 Cycles per Hr) Selected

Primary Limit

Pressure Switch

—63—

© 2005 Payne Heating & Cooling 7310 W. Morris St., Indianapolis, IN 46231 —64— impg9mab01 Catalog No. IM-PG9MAB-01

Payne PG9MAB060140 Installation manual

Assistant Bot

Installation Manual

4-WAY MULTIPOISE

FIXED-CAPACITY DUAL-VENT

CONDENSING GAS FURNACE

SIZES 040 THRU 140

PG9MAB

Series A

INSTALLATION

MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION

§

§

Related manuals

Table of contents

Payne PG9MAB060140 Installation manual

Assistant Bot

Installation Manual

4-WAY MULTIPOISE

FIXED-CAPACITY DUAL-VENT

CONDENSING GAS FURNACE

SIZES 040 THRU 140

PG9MAB

Series A

INSTALLATION

MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION

§

§

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