Payne PG8MAA - User Manual

Installation, Start-Up Operating and
Service and Maintenance Instructions
Series 140/E
SAFETY CONSIDERATIONS ........................ 2
INTRODUCTION .................................. 3
CODES AND STANDARDS .......................... 4
Safety ......................................... 4
General Installation ............................... 4
Combustion and Ventilation Air ..................... 4
Duct Systems ................................... 5
Acoustical Lining and Fibrous Glass Duct ............. 5
Gas Piping and Gas Pipe Pressure Testing ............. 5
Electrical Connections ............................ 5
Venting ........................................ 5
LOCATION ....................................... 5
AIR FOR COMBUSTION AND VENTILATION ......... 7
INSTALLATION .................................. 10
Bottom Return Air Inlet .......................... 10
Side Return Air Inlet ............................. 10
Leveling Legs (If Desired) ........................ 11
Bottom Return Air Inlet .......................... 12
Suspended Furnace Support ....................... 12
Platform Furnace Support ......................... 12
Roll-Out Protection ............................. 12
Bottom Return Air Inlet .......................... 12
Side Return Air Inlet ............................. 12
General Requirements ............................ 13
Ductwork Acoustical Treatment .................... 13
Supply Air Connections .......................... 13
Return Air Connections .......................... 19
115-V Wiring .................................. 21
J-box Relocation ............................... 21
Electrical Connection to J-Box ..................... 21
Power Cord Installation in Furnace J-Box ............ 22
BX Cable Installation in Furnace J-Box .............. 22
24-V Wiring ................................... 24
Accessories .................................... 24
General Venting Requirements ..................... 24
Masonry Chimney Requirements ................... 25
Appliance Application Requirements ................ 27
Sidewall Venting ................................ 27
START-UP, ADJUSTMENT, AND SAFETY CHECK ..... 32
General ....................................... 32
Start-Up Procedures ............................. 32
Adjustments ................................... 37
Check Safety Controls ........................... 37
Checklist ...................................... 38
SERVICE AND MAINTENANCE PROCEDURES ....... 43
Introduction ................................... 43
Care and Maintenance ........................... 44
Sequence of Operation ........................... 47
Wiring Diagrams ............................... 48
Troubleshooting ................................ 48
Accessory listing ................................ 51
PARTS REPLACEMENT INFORMATION GUIDE ....... 52
ISO 9001:2000
Always Ask For
Use of the AI IRI Cerfit_ed TM Mark indicates a
manuthcturer's parlicipation in the program. For
\,erit_cation of certification tbr individual products,
go to www.ahridirectory.org.
NOTE: Read the entire instruction manual before starting the
installation.
Portions of the text and tables are reprinted from NFPA 54/ANSI
Z223.1-2009©, with permission of Nation 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 entirely.

Summary

SAFETY CONSIDERATIONS

Fire, Explosion, and CO Poisoning Hazards

Hazards associated with installation, adjustment, alteration, service, and maintenance.

Furnace Reliability and Cut Hazards

INSTALLATION

Minimum Clearances to Combustible Construction

Upflow Installation

Side Return Air Inlet Handling

Downflow Installation

Horizontal Installation

COMBUSTION AND VENTILATION AIR

Location Considerations

Carbon Monoxide and Unit Damage Hazard

Hazards from corrosive air and importance of proper combustion air.

LOCATION RELATIVE TO COOLING EQUIPMENT

Air for Combustion and Ventilation

Requirements for adequate combustion, ventilation, and dilution air.

COMBUSTION AIR METHODS

Outdoor Combustion Air Method

Method for providing outdoor air for combustion, ventilation, and dilution.

Indoor Combustion Air Methods

Methods for using indoor air for combustion, ventilation, and dilution.

GAS PIPING

Fire and Explosion Hazard (Gas Piping)

Warnings related to gas piping installation and leak testing.

Furnace Overheat Hazard (Gas Piping)

ELECTRICAL CONNECTIONS

Electrical Shock Hazard Warning

Warning about electrical shock hazards during installation.

Power Cord Installation

BX Cable Installation

ELECTRICAL SHOCK AND FIRE HAZARD

Furnace Control Grounding

115-V Wiring and Connections

Guidelines for connecting 115-V wiring and ensuring proper polarity.

J-Box Relocation and Electrical Box Installation

VENTING

General Venting Requirements

START-UP, ADJUSTMENT, AND SAFETY CHECK

General Start-Up Procedures

Furnace Start-Up Procedures

Step-by-step procedures for safely starting the furnace.

Adjustments and Settings

Procedures for adjusting gas pressure and temperature rise.

SAFETY CONTROLS CHECK

Main Limit Switch Test

Procedure to test the main limit switch functionality.

Draft Safeguard Switch Test

Procedure to test the draft safeguard switch for proper operation.

Pressure Switch Test

Procedure to test the pressure switch for inducer blower operation.

FINAL CHECKLIST

Pre-Operation Checklist

Steps to ensure proper installation and readiness before operation.

SERVICE AND DIAGNOSTICS

Service Diagnostics using LED Codes

Using LED codes and component tests for diagnosing furnace issues.

CARE AND MAINTENANCE

Troubleshooting with LED Codes

Air Filter Cleaning;Replacement

BLOWER MOTOR AND WHEEL MAINTENANCE

Media Cabinet Filter Procedures

Blower Motor and Wheel Cleaning

Annual cleaning of blower motor and wheel for efficiency.

HEAT EXCHANGER CLEANING

Heat Exchanger Cleaning Procedures

Step-by-step guide for cleaning heat exchangers if necessary.

SEQUENCE OF OPERATION

Heating Mode Operation

Detailed sequence for furnace operation during heating.

Cooling Mode Operation

Detailed sequence for furnace operation during cooling.

Continuous Blower Mode

Heat Pump Operation

WIRING DIAGRAMS

Wiring Diagram Reference

Reference to diagrams for furnace electrical connections.

TROUBLESHOOTING

Using the Troubleshooting Guide

Guide for diagnosing and resolving furnace operation problems using provided resources.

Payne PG8MAA Specifications

General

Fuel Type	Natural Gas
AFUE	80%
Blower Motor	Multi-Speed
Ignition	Hot Surface Ignition
Heating Capacity	40, 000-120, 000 BTU/h
Ignition Type	Hot Surface Ignition
Heat Exchanger Material	Aluminized Steel
Stages	Single Stage
Warranty	10-Year Parts Limited Warranty