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Payne PG95ESA - User Manual

Payne PG95ESA
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Installation, Start--up, Operating and
Service and Maintenance Instructions
PG95ESA
SINGLE--STAGE 4--WAY MULTIPOISE, 35--IN. (889 MM)
CONDENSING GAS FURNACE
NOTE: Read the entire instruction manual before starting the installation.
SECTIONS
SAFETY CONSIDERATIONS 3.........................
INTRODUCTION 4...................................
CODES AND STANDARDS 5...........................
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS 5...
ACCESSORIES 5.....................................
LOCATION 7........................................
AIR FOR COMBUSTION AND VENTILATION 9..........
CONDENSATE TRAP 12...............................
CONDENSATE DRAIN 17.............................
INSTALLATION 21...................................
AIR DUCTS 29.......................................
GAS PIPING 31......................................
ELECTRICAL CONNECTIONS 32.......................
VENTING 3 7........................................
START -- UP, ADJUSTMENT, AND SAFETY CHECK 62......
SERVICE AND MAINTENANCE PROCEDURES 74........
WINTERIZATION 81..................................
SEQUENCE OF OPERATION 82........................
PARTS REPLACEMENT GUIDE 86......................
TABLES
Loose Parts Bag 4.....................................
Minimum Clearances to Combustible Materials 4.............
Minimum Free Area Required 11.........................
Minimum Space Vo lumes 11.............................
Filter Size Information 26...............................
Opening Dimensions 29................................
Air Delivery CFM 30...................................
Maximum Capacity of Pipe 32...........................
Electrical Data 36......................................
Vent Termination Kit for Direct Vent (2--Pipe) System 39.......
Hangar Spacing 46.....................................
Combustion--Air Vent Pipe, Fitting & Cement Material.. 49.....
Maximum Allowable Exposed Vent Lengths Insulation 50......
Maximum Equivalent Vent Length 51......................
Deductions from Maximum Equivalent Vent Length 51........
Blower Off Delay Setup Switch 70........................
Altitude Derate Multiplier for U.S.A. 71....................
Gas Rate 65..........................................
Orifice Size and Manifold Pressure 65.....................
Use of the AHRI Certified TM Mark indicates a
manufacturer’s 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 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.

Table of Contents

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Summary

Required Notice for Massachusetts Installations

Safety Considerations

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

Critical safety warnings regarding fire, explosion, electrical shock, and CO poisoning.

Furnace Reliability Hazard

Potential for unit component damage due to improper installation or operation.

Cut Hazard

Warning about sharp edges on sheet metal parts during handling.

Introduction

Codes and Standards

Safety Standards

Compliance with national safety regulations for HVAC systems.

General Installation Standards

General compliance requirements for HVAC installations.

Combustion and Ventilation Air Standards

Requirements for air supply for combustion and ventilation.

Duct Systems Standards

Standards and guidelines for HVAC ductwork design.

Gas Piping and Gas Pipe Pressure Testing Standards

Compliance for gas piping installation and testing.

Electrical Connections Standards

Compliance requirements for electrical wiring.

Condensate Drain Connection Standards

Compliance for condensate drain line installation.

Electrostatic Discharge (ESD) Precautions

Accessories

Location

General Location Requirements

Basic placement rules for the furnace, including clearances.

Location Relative to Cooling Equipment

Guidance on positioning the furnace relative to cooling coils.

Air for Combustion and Ventilation

Introduction to Air Requirements

Overview of air supply needs for combustion and ventilation.

Ventilated Combustion Air Applications

Procedures for using ventilated air for combustion.

Outdoor Combustion Air Method

Detailed method for supplying outdoor air for combustion.

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

Standard Method for Air Intake

Specifies standard air intake requirements based on space volume.

Combination of Indoor and Outdoor Air

Guidelines for combining indoor and outdoor air for combustion.

Condensate Trap

Condensate Trap - Upflow Orientation

Instructions for condensate trap in upflow configuration.

Condensate Trap - Downflow Orientation

Instructions for relocating the condensate trap in downflow.

Condensate Trap - Horizontal Orientation

Instructions for relocating the condensate trap in horizontal.

Condensate Drain Connection

Upflow;Downflow Orientation for Drain

Drain routing for upflow and downflow furnace orientations.

Right Side Condensate Drain Procedure

Step-by-step guide for connecting the right-side condensate drain.

Left Side Condensate Drain Connection

Step-by-step guide for connecting the left-side condensate drain.

Installation

Supply Air Connections

Instructions for connecting the supply air duct to the furnace.

Return Air Connections

Bottom Return Air Inlet

Procedure for connecting the return air duct to the bottom inlet.

Side Return Air Inlet

Procedure for connecting the return air duct to the side inlet.

Filter Arrangement

Platform Furnace Support

Suspended Furnace Support

Roll-Out Protection

Filter and Return Duct Sizing

Air Ducts

General Ductwork Requirements

General guidelines for designing and installing ductwork.

Return Duct Sizing

Information on selecting and sizing return air ducts.

Ductwork Acoustical Treatment

Methods for reducing noise in ductwork systems.

Gas Piping

Gas Pipe Grommet

Instructions for installing the gas pipe grommet.

Electrical Connections

115-V Wiring

Requirements and precautions for 115-volt wiring.

J-Box Installation

Procedures for installing the wiring junction box.

External Electrical Box on Furnace Casing

Mounting an external electrical box to the furnace.

Power Cord Installation in Furnace J-Box

Instructions for installing power cords in the junction box.

BX Cable Installation in Furnace J-Box

Instructions for installing BX cable in the junction box.

24-V Wiring

Low voltage wiring connections for the thermostat and controls.

Accessories Wiring

Wiring instructions for optional accessories like EAC and humidifier.

Alternate Power Supplies

Considerations for using generators or other power supplies.

Venting

Special Venting Requirements for Installations in Canada

Canadian codes and specific requirements for venting.

General Venting Information

Venting Systems

Materials for Venting

Approved materials for combustion air and vent pipes.

Direct Vent; 2-Pipe System

Description of the direct vent system configuration.

Ventilated Combustion Air Systems

Description of the ventilated combustion air system.

Non-Direct Vent (1-pipe) System

Description of the non-direct vent (single-pipe) system.

Locating the Vent Termination

General Vent Termination Location

General guidelines for choosing vent termination locations.

Direct Vent; 2-Pipe System Termination

Specific termination requirements for direct-vent systems.

Ventilated Combustion Air Termination

Specific termination requirements for ventilated air systems.

Size the Vent and Combustion Air Pipes

General Pipe Sizing

General guidelines for sizing vent and combustion air pipes.

Combustion Air and Vent Piping Insulation Guidelines

Guidelines for insulating combustion air and vent pipes.

Install the Vent and Combustion Air Pipes

Installing the Vent Pipe Adapter and Combustion Air Pipe Adapter

Optional Installation of the Vent Pipe

Optional method for installing the vent pipe adapter.

Installing the Vent Termination

Roof Terminations

Guidelines for vent termination on a roof.

Concentric Vent

Installation instructions for concentric vent terminations.

Two-Pipe and Single-Pipe Terminations

Installation for two-pipe and single-pipe vent terminations.

Inducer Outlet Restrictor

Venting System Length Calculations

Inside Corner Terminations

Start-Up, Adjustment, and Safety Check

Prime Condensate Trap with Water

Procedure to prime the condensate trap for proper drainage.

Adjustments

Adjust Manifold Pressure

Procedure for setting the manifold gas pressure.

Adjust Temperature Rise

Procedure for adjusting blower speed for proper temperature rise.

Check Safety Controls

Check Main Limit Switch

Testing the furnace's main limit switch functionality.

Check Pressure Switch(es)

Testing the operation of the pressure switches.

Checklists

List of items to verify after installation and start-up.

Service and Maintenance Procedures

General Service Information

General guidelines for servicing the furnace.

Electrical Controls and Wiring

Servicing electrical controls and wiring connections.

Troubleshooting

Retrieving Stored Fault Codes

How to access and interpret stored fault codes.

Care and Maintenance

Cleaning and;or Replacing Air Filter

Procedures for cleaning or replacing the air filter.

Blower Motor and Wheel Maintenance

Maintenance procedures for the blower motor and wheel.

Cleaning Burners and Flame Sensor

Servicing Hot Surface Igniter

Flushing Collector Box and Drainage System

Cleaning Condensate Drain and Trap

Procedure for cleaning the condensate drain and trap.

Cleaning Heat Exchangers

Primary Heat Exchangers

Cleaning procedures for the primary heat exchangers.

Secondary Heat Exchangers

Information on servicing secondary heat exchangers.

Winterization

Sequence of Operation

1. Heating Operation

Detailed sequence for heating mode operation.

2. Cooling Mode

Detailed sequence for cooling mode operation.

3. Continuous Blower Mode

Operation of the blower in continuous fan mode.

4. Heat Pump Operation

Sequence for heat pump operation with the furnace.

Component Self-Test

Procedure for testing furnace components.

Troubleshooting Guide

Parts Replacement Information Guide

Model Nomenclature

Explanation of model naming conventions and variations.

Payne PG95ESA Specifications

General IconGeneral
BrandPayne
ModelPG95ESA
CategoryFurnace
LanguageEnglish

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