Payne PG80ESAA - User Manual

Installation, Start--up, Operating and
Service and Maintenance Instructions
PG80ESAA/PG80ESLA
SINGLE-- STAGE, 4--WAY MULTIPOISE
33--1/3 IN. NON--CONDENSING GAS FURNACE
INPUT CAP ACI TIES 45,000 THRU 155,000 BTUH
SAFETY CONSIDERATIONS 2.......................
INTRODUCTION
2.................................
CODES AND STANDARDS
4.........................
S
AFETY 4.......................................
G
ENERAL INSTALLATION 4...........................
C
OMBUSTION AND VENTILATION AIR 4.................
D
UCT SYSTEMS 5.................................
A
COUSTICAL LINING AND FIBROUS GLASS DUCT 5........
G
AS PIPING AND GAS PIPE PRESSURE TESTING 5..........
E
LECTRICAL CONNECTIONS 5........................
V
ENTING 5......................................
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS
PROCEDURE
5....................................
LOCATION
6......................................
AIR FOR COMBUSTION AND VENTILATION
7.........
O
UTDOOR COMBUSTION AIR METHOD 8................
C
OMBINATION OF INDOOR AND OUTDOOR AIR 8...........
INSTALLATION
9..................................
UPFLOW INSTALLATION 10............................
DOWNFLOW INSTALLATION 10.........................
HORIZONTAL INSTALLATION 12.........................
FURNACE SUPPORT 12...............................
AIR DUCTS 12.....................................
GAS PIPING 15.....................................
ELECTRICAL CONNECTIONS 19.........................
115--V WIRING 19...................................
J--BOX RELOCATION 19...............................
24--V WIRING 20....................................
ACCESSORIES 20...................................
VENTING
23.......................................
GENERAL VENTING REQUIREMENTS 23...................
MASONRY CHIMNEY REQUIREMENTS 23..................
APPLIANCE APPLICATION REQUIREMENTS 24...............
ADDITIONAL VENTING REQUIREMENTS 26.................
SIDEWALL VENTING 26...............................
START--UP, ADJUSTMENT, AND SAFETY CHECK
30.....
START -- UP PROCEDURES 30............................
ADJUSTMENTS 31..................................
CHECK SAFETY CONTROLS 33..........................
CHECKLIST 33.....................................
SERVICE AND MAINTENANCE PROCEDURES
38.......
INTRODUCTION 38..................................
GENERAL 38......................................
ELECTRICAL CONTROLS AND WIRING 38..................
CARE AND MAINTENANCE 39..........................
CLEANING AND/OR REPLACING AIR FILTER 40..............
BLOWER MOTOR AND WHEEL 40........................
CLEANING HEAT EXCHANGER 41........................
SEQUENCE OF OPERATION 43..........................
WIRING DIAGRAMS 44...............................
TROUBLESHOOTING 45...............................
PARTS REPLACEMENT INFORMATION GUIDE
47.......
NOTE: Read the entire instruction manual before starting the
installation.
Portions of the text and tables are reprinted from current edition
of NFPA 54/ANSI Z223.1E, with permission of National Fire
Protection Association, Quincy, MA 02269 and American Gas
Association, Washington DC 20001. This reprinted material is
not the complete and official position of the NFPA or ANSI on
the referenced subject, which is represented only by the standard
in its entirety.
SAFETY CONSIDERATIONS
FIRE, EXPLOSION, ELECTRICAL SHOCK, AND
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in dangerous
operation, serious injury, death, or property damage.
Improper installation, adjustment, alteration, service,
maintenance, or use could cause carbon monoxide
poisoning, explosion, fire, electrical shock, or other
conditions which may cause personal injury or property
damage. Consult a qualified service agency, local gas
supplier, or your distributor or branch for information or
assistance. The qualified service agency must use only
factory--authorized and listed kits or accessories when
modifying this product.
!
WARNING

Summary

INTRODUCTION

CODES AND STANDARDS

INSTALLATION

GENERAL INSTALLATION

General guidelines for furnace installation.

COMBUSTION AND VENTILATION AIR

Requirements for air needed for combustion and ventilation.

LOCATION

Guidelines for selecting an appropriate installation location for the furnace.

DUCT SYSTEMS

Procedures and standards for connecting ductwork to the furnace.

UPFLOW INSTALLATION

Specific instructions for installing the furnace in an upflow configuration.

DOWNFLOW INSTALLATION

Specific instructions for installing the furnace in a downflow configuration.

HORIZONTAL INSTALLATION

Procedures for installing the furnace in a horizontal orientation.

GAS PIPING

Instructions for connecting the gas supply line to the furnace.

ELECTRICAL CONNECTIONS

Guidelines for making electrical wiring connections to the furnace.

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS PROCEDURE

VENTING

GENERAL VENTING REQUIREMENTS

Standards and codes for proper furnace venting systems.

MASONRY CHIMNEY REQUIREMENTS

Specific requirements for venting into masonry chimneys.

START-UP, ADJUSTMENT, AND SAFETY CHECK

General

General procedures for furnace start-up and safety checks.

Start-Up Procedures

Step-by-step guide for initiating furnace operation after installation.

Adjustments

Procedures for adjusting furnace settings like gas input and temperature rise.

Check Safety Controls

Verification steps for critical furnace safety controls.

Checklist

A list of final checks to be completed before leaving the installation site.

SERVICE AND MAINTENANCE PROCEDURES

INTRODUCTION

Overview of service and maintenance tasks for trained personnel.

GENERAL

General notes on furnace orientation and service considerations.

ELECTRICAL CONTROLS AND WIRING

Maintenance and safety checks for furnace electrical components.

CARE AND MAINTENANCE

Routine care tasks to ensure furnace longevity and performance.

CLEANING AND;OR REPLACING AIR FILTER

Instructions for maintaining the furnace air filter.

BLOWER MOTOR AND WHEEL

Procedures for cleaning the blower motor and wheel for optimal performance.

CLEANING HEAT EXCHANGER

Steps for cleaning the furnace heat exchanger, performed by qualified personnel.

SEQUENCE OF OPERATION

Wiring Diagrams

Troubleshooting

PARTS REPLACEMENT INFORMATION GUIDE

CASING GROUP

List of replacement parts for the furnace casing components.

ELECTRICAL GROUP

List of replacement parts for the furnace electrical system.

BLOWER GROUP

List of replacement parts for the blower motor and assembly.

GAS CONTROL GROUP

List of replacement parts for the furnace gas control system.

HEAT EXCHANGER GROUP

List of replacement parts for the furnace heat exchanger assembly.

INDUCER GROUP

List of replacement parts for the furnace inducer assembly.

Payne PG80ESAA Specifications

General

Model	PG80ESAA
Type	Gas Furnace
Efficiency Rating	80% AFUE
Heating Capacity	40, 000-120, 000 BTU/h
Fuel Type	Natural Gas
Stages	Single-stage
Heat Exchanger	Aluminized Steel
Ignition Type	Hot Surface Ignition
Dimensions	Varies by model
Thermostat Compatibility	Standard Thermostats
Warranty	10-year limited parts warranty