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Payne PG95 - User Manual

Payne PG95
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1
PG95SAS
Installation, Start-up, Operating and
Service and Maintenance Instructions
Single-Stage 4-Way Multipoise
Condensing Gas Furnace
Series A and B
NOTE: Read the entire instruction manual before starting the installation.
SECTIONS
SAFETY CONSIDERATIONS 3.........................
INTRODUCTION 4...................................
CODES AND STANDARDS 4...........................
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS 5...
ACCESSORIES 5.....................................
LOCATION 8........................................
AIR FOR COMBUSTION AND VENTILATION 9..........
CONDENSATE TRAP 12...............................
CONDENSATE DRAIN 16.............................
INSTALLATION 20...................................
AIR DUCTS 29.......................................
GAS PIPING 31......................................
ELECTRICAL CONNECTIONS 32.......................
VENTING 37........................................
STARTUP, ADJUSTMENT, AND SAFETY CHECK 62......
SERVICE AND MAINTENANCE PROCEDURES 74........
SEQUENCE OF OPERATION 82........................
PARTS REPLACEMENT GUIDE 86......................
CERTIFIED
Use of the AHRI Certified
TM
Mark indicates a
manufacturers participation in the program. For
verification of certification for individual products,
go to www.ahridirectory.org.
Portions of the text and tables are reprinted from current edition of
NFPA 54/ANSI Z223.1, 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.
TABLES
LOOSE PARTS BAG 5.................................
MIN. CLEARANCES TO COMBUSTIBLE MATERIALS 5...
MINIMUM FREE AREA REQUIRED 11..................
MINIMUM SPACE VOLUMES 11.......................
FILTER SIZE INFORMATION 23........................
OPENING DIMENSIONS 25............................
AIR DELIVERY CFM 30...............................
MAXIMUM CAPACITY OF PIPE 32.....................
ELECTRICAL DATA 34...............................
VENT TERM. KIT FOR DIRECT VENT (2PIPE) SYSTEMS 39
CombustionAir Vent Pipe, Fitting & Cement Material.. 45.....
Maximum Allowable Exposed Vent Lengths Insulation 46......
Maximum Equivalent Vent Length 48......................
Deductions from Maximum Equivalent Vent Length 48........
Blower Off Delay Setup Switch 65........................
Altitude Derate Multiplier for U.S.A. 66....................
Gas Rate 69..........................................
Orifice Size and Manifold Pressure 69.....................
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Summary

Safety Considerations

Fire, Explosion, Electrical Shock, and Carbon Monoxide Poisoning Hazard

Warning about potential hazards from improper operation, installation, or service.

Fire Hazard

Warning regarding combustible materials and flammable vapors.

Furnace Reliability Hazard

Caution regarding potential damage to furnace components from improper application.

Cut Hazard

Caution about sharp edges or burrs on sheet metal parts.

Introduction

Direct Vent (2-pipe) Applications

Describes furnaces installed as direct vent, taking combustion air from outdoors.

Non-Direct Vent (1-pipe) Applications

Describes furnaces using indoor air for combustion, requiring adequate air supply.

Ventilated Combustion Air Applications

Describes furnaces using ventilated combustion air from an attic or crawl space.

Codes and Standards

Safety

Lists safety codes and standards applicable in the US and Canada.

General Installation

Specifies compliance with national and local codes for installation.

Combustion and Ventilation Air

References standards for air supply for combustion and ventilation.

Duct Systems

References standards for designing and sizing duct systems.

Acoustical Lining and Fibrous Glass Duct

References standards for acoustical treatment of ducts.

Gas Piping and Gas Pipe Pressure Testing

References standards for gas piping installation and testing.

Electrostatic Discharge (ESD) Precautions Procedure

Furnace Reliability Hazard

Caution on potential damage to electronic components from ESD.

Accessories

Location

Personal Injury and;or Property Damage Hazard

Caution regarding furnace failure due to improper installation during construction.

General

General guidelines for furnace placement and installation.

Carbon Monoxide Poisoning; Component Damage Hazard

Warning about corrosive air contaminants affecting heat exchangers.

Fire, Injury or Death Hazard

Warning for furnace installation in garages or hazardous atmospheres.

Air for Combustion and Ventilation

Direct Vent (2-pipe) Applications

Describes requirements for combustion and ventilation air.

Non-Direct Vent (1-pipe) Applications

Describes requirements for combustion and ventilation air.

Ventilated Combustion Air Applications

Describes requirements for combustion and ventilation air.

Carbon Monoxide Poisoning Hazard

Warning about negative pressure conditions affecting combustion air.

Indoor Combustion Air NFPA & AGA Standard and Known-Air-Infiltration Rate Methods

Carbon Monoxide Poisoning Hazard

Warning about outdoor air supply requirements for combustion.

Standard Method

Describes requirements for indoor combustion air using volume calculations.

The Known Air Infiltration Rate Method

Describes requirements for indoor combustion air based on infiltration rates.

Combination of Indoor and Outdoor Air

Describes requirements for combined indoor and outdoor air supply.

Condensate Trap

Condensate Trap - Upflow Orientation

Instructions for condensate trap in upflow installation.

Condensate Trap - Downflow Orientation.

Instructions for relocating condensate trap in downflow installation.

Condensate Trap - Horizontal Orientation.

Instructions for relocating condensate trap in horizontal installation.

Condensate Drain Connection

Frozen and Burst Water Pipe Hazard

Caution regarding protecting drain lines from freezing.

Property Damage Hazard

Caution regarding burst pipes and property damage from drain issues.

Upflow;Downflow Orientation

Describes condensate drain routing for upflow/downflow installations.

For Right Side Condensate Drain:

Instructions for routing the condensate drain to the right side.

For Left Side Condensate Drain Connection:

Instructions for routing the condensate drain to the left side.

Installation

Upflow Installation

Specific instructions for upflow furnace installation.

Supply Air Connections

Instructions for connecting supply-air ductwork to the furnace.

Return Air Connections

Fire Hazard

Warning about connecting return air ducts to the furnace back.

Bottom Return Air Inlet

Instructions for using the bottom opening for return air.

Horizontal Installation

Notes for horizontal furnace installation pitch.

Fire, Explosion, and Carbon Monoxide Poisoning Hazard

Warning regarding furnace installation on its back or hanging.

Filter Arrangement

Fire, Carbon Monoxide and Poisoning Hazard

Warning about operating furnace without a filter or with access doors removed.

Filter and Return Duct Sizing

Guidance on sizing filters and associated ductwork for optimal performance.

Air Ducts

General Requirements

Guidelines for duct system design, sizing, and installation.

Return Duct Sizing

Guidance on selecting filter sizes and associated ductwork.

Ductwork Acoustical Treatment

Information on acoustical lining and fibrous ductwork requirements.

Gas Piping

Fire or Explosion Hazard

Warning about purging gas lines and testing for leaks.

Furnace Damage Hazard

Caution regarding damage to gas controls from improper connection.

Gas Pipe Grommet

Instructions for installing the gas pipe grommet for direct vent systems.

Electrical Connections

Electrical Shock, Fire or Explosion Hazard

Warning about dangerous operation from improper servicing.

Electrical Shock Hazard

Warning about personal injury or death from blower door switch bypass.

Electrical Shock and Fire Hazard

Warning about electrical fault and grounding requirements.

Furnace May Not Operate Hazard

Caution regarding intermittent operation if furnace control is not grounded.

115-V Wiring

U.S.A. Installations:

Electrical connection compliance for US installations.

Canada Installations:

Electrical connection compliance for Canadian installations.

Fire Hazard

Warning against using aluminum wire and improper circuit protection.

J-Box Installation

Instructions for installing the J-Box for field line voltage connections.

Fire or Electrical Shock Hazard

Warning about drilling into furnace casing for switch mounting.

External Electrical Box on Furnace Casing

Instructions for mounting an external electrical box on the furnace casing.

BX Cable Installation in Furnace J-Box

24-V Wiring

Fire, Explosion, Electrical Shock, and Carbon Monoxide Poisoning Hazard

Warning about routing control wiring improperly.

Accessories (See Fig. 37 and 39.)

Instructions for connecting accessories like EAC and Humidifier.

Alternate Power Supplies

Information on using alternate power supplies with the furnace.

Venting

Special Venting Requirements for Installations in Canada

Specific venting requirements for installations in Canada per CSA B149 code.

Carbon Monoxide Poisoning Hazard

General

Venting Systems

Carbon Monoxide Poisoning Hazard

Warning about adequate air supply for venting configurations.

Direct Vent; 2-Pipe System

Optional Configuration for Combustion Air Inlet Pipe

Optional method to add moisture trap to combustion air inlet pipe.

Recommended Combustion Air Inlet Moisture Trap

Details on constructing or using a trap for combustion air inlet moisture.

Additional Information for Polypropylene Venting Systems

Notes on using polypropylene venting systems and equivalent lengths.

Ventilated Combustion Air Systems

Non-Direct Vent (1-pipe) System

Termination Requirements for the Provinces of Alberta and Saskatchewan

Size the Vent and Combustion Air Pipes

Recommended Combustion Air Inlet Moisture Trap

Installing the Vent Pipe Adapter and Combustion Air Pipe Adapter

Carbon Monoxide Poisoning Hazard

Warning about using manufacturer-supplied kits for routing pipes.

Carbon Monoxide Poisoning Hazard

Warning not to use cement for polypropylene venting systems.

Near Furnace Vent Connections

Install the Vent and Combustion Air Pipes

Optional Installation of the Vent Pipe

Installing the Vent Termination

Roof Terminations

Instructions for installing roof vent terminations.

Concentric Vent

Instructions for installing concentric vent terminations.

Two-Pipe and Single-Pipe Terminations

Instructions for installing two-pipe and single-pipe vent terminations.

Sidewall Terminations

Instructions for installing sidewall vent terminations.

Venting System Length Calculations

Example 1

Calculation example for direct-vent system length.

Example 2

Calculation example for polypropylene vent system length.

Inside Corner Terminations

Start-Up, Adjustment, and Safety Check

General

General procedures for furnace start-up and checks.

Unit Operation Hazard

Caution regarding intermittent operation due to limit switch.

Prime Condensate Trap with Water

Procedure for priming the condensate trap with water.

Carbon Monoxide Poisoning Hazard

Warning about using a non-primed trap allowing vent gases into structure.

Purge Gas Lines

Instructions for purging gas lines and checking for leaks.

Fire or Explosion Hazard

Warning about purging gas lines and testing for leaks.

Adjustments

Fire Hazard

Warning about improper adjustment of gas valve regulator.

Furnace Damage Hazard

Caution regarding damage to furnace from improper adjustment.

Check Inlet Gas Pressure

Procedure for checking and adjusting inlet gas pressure.

Adjust Temperature Rise

Furnace Damage Hazard

Caution regarding overheating heat exchangers or shortening furnace life.

Electrical Operation Hazard

Warning about disconnecting power before changing speed tap.

Unit Damage Hazard

Caution to avoid operating outside rise range or damaging components.

Adjust Blower Off Delay (Heat Mode)

Instructions for adjusting blower off delay settings for heating.

Adjust Cooling Airflow

Instructions for setting cooling airflow from blower speed taps.

Furnace Overheating Hazard

Caution to recheck temperature rise and operate at midpoint.

Adjust Thermostat Heat Anticipator

Instructions for setting thermostat heat anticipator based on amp draw.

Check Safety Controls

Procedure for checking main limit switch and pressure switches.

Service and Maintenance Procedures

Fire, Injury or Death Hazard

Warning about performing maintenance without required knowledge or tools.

Environmental Hazard

Caution regarding environmental pollution from improper disposal.

Electrical Shock, Fire or Explosion Hazard

Warning about electrical hazards during installation or servicing.

Electrical Operation Hazard

Caution regarding improper operation due to wiring errors.

General

General notes on furnace orientation and component location.

Electrical Controls and Wiring

Information on pressure switch operation and control system.

Electrical Shock Hazard

Warning about electrical safety during servicing.

Troubleshooting

Guidance on using the troubleshooting guide and status codes.

Retrieving Stored Fault Codes

Procedure for retrieving stored fault codes from the control memory.

Component Self-Test

Electrical Shock Hazard

Warning about electrical shock when manually closing blower door switch.

Checklist

List of items to verify before and after furnace operation.

Care and Maintenance

General guidance on periodic maintenance for furnace performance.

Fire or Explosion Hazard

Warning about storing flammable materials near the furnace.

Electrical Shock and Fire Hazard

Warning to turn off gas and electrical supplies before service.

Carbon Monoxide Poisoning and Fire Hazard

Warning about operating furnace without a filter or with access doors removed.

Cleaning and;or Replacing Air Filter

Carbon Monoxide Poisoning and Fire Hazard

Warning about operating without a filter or with access doors removed.

Electrical Shock, Fire or Explosion Hazard

Warning to turn off power before filter maintenance.

Blower Motor and Wheel Maintenance

Servicing Hot Surface Igniter

Flushing Collector Box and Drainage System

Electrical Shock and Fire Hazard

Warning to turn off gas and electrical supplies before service.

Cleaning Condensate Drain and Trap

Procedure for cleaning the condensate drain and trap.

Checking Heat Pad Operation (If Applicable)

Cleaning Heat Exchangers

Primary Heat Exchangers

Procedure for cleaning primary heat exchangers.

Electrical Shock, Fire or Explosion Hazard

Warning to turn off gas and electrical supplies before cleaning.

Electrical Shock and Fire Hazard

Warning to turn off gas and electrical supplies before service.

Secondary Heat Exchangers

Winterization

Unit and Property Damage Hazard

Caution to take freeze protection measures in unconditioned spaces.

Unit Component Damage Hazard

Caution against using ethylene glycol for plastic components.

Sequence of Operation

1. Heating

Describes the sequence of operation during heating mode.

2. Cooling Mode

Describes the sequence of operation during cooling mode.

3. Continuous Blower Mode

Describes the sequence for continuous blower operation.

4. Heat Pump Mode

Describes the sequence of operation for heat pump applications.

Component Self-Test

Procedure for initiating the component self-test sequence.

Parts Replacement Information Guide

Casing Group

Lists replacement parts for the furnace casing.

Electrical Group

Lists replacement parts for electrical components.

Blower Group

Lists replacement parts for the blower assembly.

Filter Group

Lists replacement parts for the filter system.

Gas Control Group

Lists replacement parts for gas control components.

Heat Exchanger Group

Lists replacement parts for heat exchanger components.

Inducer Group

Lists replacement parts for the inducer assembly.

Model Nomenclature

Explains the model designation and its components.

Fire, Explosion, Electrical Shock and Carbon Monoxide Poisoning Hazard

Warning about improper service and the use of authorized parts.

Payne PG95 Specifications

General IconGeneral
Fuel TypeNatural Gas
AFUE95%
StagesTwo-Stage
Ignition TypeHot Surface Ignition
Heat Exchanger MaterialStainless Steel
Blower MotorVariable Speed
Warranty10-Year Limited

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