Payne PG8MAA Installation Instructions Manual

Payne PG8MAA

1. Use only with type of gas approved for this furnace. Refer to the furnace rating plate.
2. Install this furnace only in a location and position as specified in the “Location” section of these instructions.
3. Provide adequate combustion and ventilation air to the furnace space as specified in “Air for Combustion and Ventilation” section.
4. Combustion products must be discharged outdoors. Connect this furnace to an approved vent system only, as specified in the “Venting” section of these instructions.
5. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the of leaks to check all connections, as specified in the “Gas Piping” section.
6. Always install the furnace to operate within the furnace’s intended temperature-rise range with a duct system which has an external static pressure within the allowable range, as specified in the “Start-Up, Adjustments, and Safety Check” section. See furnace rating plate.
7. 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 the furnace casing and terminating outside the space containing the furnace. See “Air Ducts” section.
8. A gas-fired furnace for installation in a residential garage must be installed as specified in the warning box in the “Location” section.
9. The furnace may be used for construction heat provided that the furnace installation and operation complies with the first CAUTION in the LOCATION section of these instructions.

NOTES:

1. 1. Two additional 7/8-in. (22 mm) diameter holes are located in the top plate.
   2. Minimum return-air openings at furnace, based on metal duct. If flex duct is used, see flex duct manufacturer’s recommendations for equivalent diameters.
   (a,) For 800 CFM-16-in. (406 mm) round or 14 1/2 x 12-in. (368 x 305 mm) rectangle.
   (b.) For 1200 CFM-20-in. (508 mm) round or 14 1/2 x 19 1/2-in. (368 x 495 mm) rectangle,
   (c.) For 1600 CFM-22-in. (559 mm) round or 14 1/2 x 22 1/16-in. (368 x 560mm) rectangle.
   (d.) 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.

INSTALLATION

MINIMUM INCHES CLEARANCE TO COMBUSTIBLE CONSTRUCTION

• This forced air furnace is equipped for use with natural gas at altitudes 0 – 10,000 ft (0 – 3,050m). 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 on combustible flooring in alcove
  or closet at minimum clearance as indicated by the diagram from combustible material.
• This furnace may be used with a Type B-1 Vent and may be vented in common with other gas fired appliances.
• Vent Clearance to combustibles:
• For SingleWall vents 6 inches(6 po).
• ForType B-1 vent type I inch (1 po)

INTRODUCTION

• Series 140/E 4-way multipoise Category I fan-assisted furnace is CSA design-certified. A Category I fan-assisted furnace is anappliance equipped with an integral mechanical means to either draw or force products of combustion through the combustion chamber and/or heat exchanger. The furnace is factory-shipped for use with natural gas.
• This furnace is not approved for installation in mobile homes, recreational vehicles, or outdoors. This furnace is designed for minimum continuous return-air temperature of 60 °F (16 ° C) db or intermittent operation down to 55°F (13°C) db such as when used with a night setback thermostat. Return-air temperature must not exceed 80 ° F (27 ° C) db.
• Failure to follow these return-air temperature limits may affect reliability of heat exchangers, motors, and controls. (See Fig. 3.) For accessory installation details, refer to the applicable instruction literature.
• NOTE: Remove all shipping brackets and materials before operating the furnace.

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS PROCEDURE

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.
2. Firmly touch the 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 to recharge 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 (and 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 4 before bringing the control or yourself in 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.

GENERAL

This multipoise furnace is shipped in packaged configuration. Some assembly and modifications are required when used in any of the four applications shown in Fig. 4. 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 for upflow applications. Downflow installations require use of a factory-approved floor base or coil assembly when installed on combustible materials or wood flooring. (Refer to SAFETY CONSIDERATIONS).
• be located as close to the chimney or vent and attached to an air distribution system. Refer to Air Ducts section.
• be provided ample space for servicing and cleaning. Always comply with minimum fire protection clearances shown on the furnace clearance to combustible label.
• 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

AIR FOR COMBUSTION AND VENTILATION

Provisions for adequate combustion, ventilation, and dilution air must be provided in accordance with:

• Section 9.3 of the NFPA 54 / ANSI Z223.1-2009, Air for Combustion and Ventilation, and applicable provisionsof the local building codes.

Outdoor Combustion Air Method

1. Provide the space with sufficient air for proper combustion, ventilation, and dilution of flue gases using permanenthorizontal or vertical duct(s) or opening(s) directly communicating with the outdoors or spaces that freely communicate with the outdoors.
2. Fig. 7 illustrates how to provide TWO OUTDOOR OPENINGS, one inlet and one outlet combustion and ventilation air opening, to the outdoors.

Indoor Combustion Air NFPA & AGA

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

INSTALLATION

HORIZONTAL INSTALLATION

• Suspended Furnace Support
• The furnace may be supported under each end with threaded rod, angle iron or metal plumber’s strap as shown. (See Fig. 15 and 16.) Secure angle iron to bottom of furnace as shown. Heavy-gauge sheet metal straps (plumber’s straps) may be used to suspend the furnace from each bottom corner. To prevent screws from pulling out, use 2 #8 x 3/4-in. (19 ram) screws into the side and 2 #8 x 3/4-in. (19 ram) screws in the bottom of the furnace casing for each strap. (See Fig. 15 and 16.)

Bottom Return Air Inlet

These furnaces are shipped with bottom closure panel installed in bottom return-air opening, Remove and discard this panel when bottom return air is used, To remove bottom closure panel, perform the following:

1. Tilt or raise furnace and remove 2 screws holding bottom filler panel, (See Fig, 90
2. Rotate bottom filler panel downward to release holding tabs.
3. Remove bottom closure panel.
4. Reinstall bottom filler panel and screws.

Side Return Air Inlet

• These furnaces are shipped with bottom closure panel installed in bottom return-air opening. This panel MUST be in place when side return air inlet(s) is used without a bottom return air inlet. Not all horizontal furnaces are approved for side return air connections. (See Fig. 20.)

FILTER ARRANGEMENT

• There are no provisions for an internal filter rack in these furnaces. Refer to the instructions supplied with accessory Media Cabinet
  for assembly and installation options. This furnace requires a field-supplied external filter rack or a suitable field-supplied substitute, such as the media cabinet.
• See Table 17 for accessory list. Refer to the instructions supplied with external filter rack for assembly and installation options.

AIR DUCTS

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 external static pressure. The furnace airflow rates are provided in Table 5 – AIR DELIVERY-CFM (With Filter).

Supply Air Connections

• 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.

GAS PIPING

Gas piping must be installed in accordance with national and local codes. Refer to current edition of NFGC. Installations must be made in accordance with all authorities having jurisdiction. If possible, the gas supply line should be a separate line running directly from meter to furnace.
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.

• Piping should be pressure and leak tested in accordance with NFGC, 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. W.C.), gas supply pipe nmst be disconnected from furnace and capped before and during supply pipe pressure test. If test pressure is equal to or less than 0.5 psig (14-In. W.C.), turn off electric shutoff switch located on furnace gas control valve and accessible manual equipment shutoff valve before and during supply pipe pressure test.
• After all connections have been made, purge lines and check for leakage at furnace prior to operating furnace. 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.

POWER CORD INSTALLATION IN FURNACE J-BOX

NOTE: Power cords must be able to handle the electrical requirements listed in Table 7. Refer to power cord manufacturer’s listings.

1. Remove cover from J-Box.
2. Route listed power cord through 7/8-in. (22 mm) diameter hole in J-Box.
3. Secure power cord to J-Box bracket with a strain relief bushing or a connector approved for the type of cord used.
4. Secure field ground wire to green ground screw on J-Box bracket.
5. Connect line voltage leads as shown in Fig. 26.
6. Reinstall cover to J-Box. Do not pinch wires between cover and bracket.

BX CABLE INSTALLATION IN FURNACE J-BOX

1. Remove cover from J-Box.
2. Route BX cable into 7/8-inch (22 mm) diameter hole in J-Box.
3. Secure BX cable to J-Box bracket with connectors approved for the type of cable used.
4. Secure field ground wire to green ground screw on J-Box bracket.
5. Connect line voltage leads as shown in Fig. 26.
6. Reinstall cover to J-Box. Do not pinch wires between cover and bracket.

CHIMNEY INSPECTION CHART

• For additionalrequirementsreferto the National Fuel Gas Code NFPA 54/ANSI Z223.1 and ANSI/NFPA 211 Chimneys, Fireplaces,Vents,and Solid Fuel BurningAppliances

START-UP, ADJUSTMENT, AND SAFETY CHECK

Step 1 -General

1. Maintain 115-v wiring and ground. Improper polarity will result in rapid flashing LED and no furnace operation,
2. Make thermostat wire connections at the 24-v terminal block on the furnace control. Failure to make proper connections will result in improper operation, (See Fig. 26,)
3. Gas supply pressure to the furnace must be greater than 4.5-In, W,C, (0,16 psig ) but not exceed 14-In, W,C, (0,5 psig).
4. Check all manual-reset switches for continuity.
5. Install blower compartment door. Door must be in place to operate furnace.
6. Replace outer door.

Step 2 -Start-Up Procedures

1. Purge gas lines after all connections have been made.
2. Check gas lines for leaks
3. To Begin Component Self-Test: Remove blower access door. Disconnect the thermostat R lead from the furnace control board. Manually close the blower door switch. Short (jumper) the COM-24v terminal on control to the TEST/TWIN 3/16-inch quick connect terminal on control until LED goes out (approximately 2 sec). Gas valve and humidifier will not be turned on. (See Fig. 25.)
   • NOTE: The furnace control allows all components, except the gas valve, to be run for short period of time. This feature helps
     diagnose a system problem in case of a component failure. Component test feature will not operate if any thermostat signal is
     present at the control.

Step 3 -Adjustments

Furnace gas input rate on rating plate is for installations at altitudes up to 2000 ft. (610 M). Furnace input rate must be within +/-2 percent of furnace rating plate input.

1. Determine the correct gas input rate. The input rating for altitudes above 2,000 ft. (610 M) must be reduced by 4 percent for each 1,000 ft. (305 M) above sea level. For installations below 2000 ft., refer to the unitrating plate. For installations above 2000 ft. (610 M), multiply the input on the rating plate by the derate multiplier in Table 11 for the correct input rate.
2. Determine the correct orifice and manifold pressure adjustment. There are two different orifice and manifold adjustment tables. All models in all positions, except Low NOx models in downflow or horizontal positions, use Table 15 (22,000 Btuh/Burner). Low NOx models in the downflow or horizontal positions must use Table 16 (21,000 Btuh/Burner). See input listed on rating plate.
   • a. Obtain average yearly gas heat value (at installed altitude) from local gas supplier.
   • b. Obtain average yearly gas specific gravity from local gas supplier.
   • c. Find installation altitude in Table 15 or 16.
   • d. Find closest natural gas heat value and specific gravity in Table 15 or 16.
   • e. Follow heat value and specific gravity lines to point of intersection to find orifice size and manifold pressure settings for proper operation.
   • f. Check and verify burner orifice size in furnace. NEVER ASSUME ORIFICE SIZE. ALWAYS CHECK AND VERIFY.
   • g. Replace orifice with correct size if required by Table 15 or 16. Use only factory-supplied orifices. See EXAMPLE 2.
3. Adjust manifold pressure to obtain correct input rate.
   • a. Turn gas valve ON/OFF switch to OFF.
   • b. Remove manifold pressure tap plug from gas valve. (See Fig. 42.)
   • c. Connect a water column manometer or similar device to manifold pressure tap.
4. Verify natural gas input rate by clocking meter.
   • NOTE: Gas valve regulator adjustment cap must be in place for proper input to be clocked.
   • a. Turn off all other gas appliances and pilots served by the meter.
   • b. Run furnace for 3 minutes in heating operation.
   • c. Measure time (in sec) for gas meter to complete 1 revolution and note reading. The 2 or 5 cubic feet dial provides a more accurate measurement of gas fow.
   • d. Refer to Table 13 for cubic ft. of gas per hr.
   • e. Multiply gas rate (cu ft./hr) by heating value (Btu/cu ft.) to obtain input
5. Set temperature rise. The furnace must operate within the temperature rise ranges specified on the furnace rating plate. Do not exceed temperature rise range specified on unit rating plate. Determine the temperature rise as follows:
   • NOTE: Blower access door must be installed when taking temperature rise reading. Leaving blower access door off will result in incorrect temperature measurements.
   • a. Place thermometers in return and supply ducts as close to furnace as possible. Be sure thermometers do not see radiant heat from heat exchangers. Radiant heat affects temperature rise readings. This practice is particularly important with straight-run ducts.
   • b. When thermometer readings stabilize, subtract returnair temperature from supply-air temperature to determine air temperature rise.
6. Set thermostat heat anticipator.
   • a. Mechanical thermostat – Set thermostat heat anticipation to match the amp. draw of the electrical components in the R-W circuit. Accurate amp. draw readings can be obtained at the wires normally connected to thermostat subbase terminals, R and W. The thermostat anticipator should NOT be in the circuit while measuring current.
     • (1.) Remove the thermostat from the subbase or from wall.
     • (2.) Connect an amp. meter as shown in Fig. 44 across the R and W subbase terminals or R and W wires at wall.
     • (3.) Record amp. draw across terminals when furnace is in heating and after blower starts.
     • (4.) Set heat anticipator on thermostat per thermostat instructions and install on subbase or wall.
   • b. Electronic thermostat: Set cycle rate for 4 cycles per hr.
7. Adjust blower off delay The blower off delay has 4 adjustable settings from 90 sec to 180 sec. The blower off delay jumpers are located on the furnace control board. (See Fig. 25.) To change the blower-off delay setting, move the jumper from one set of pins on the control to the pins used for the selected blower-off delay. Factory off delay setting is 120 sec.
8. Set airflow CFM for cooling Select the desired blower motor speed lead for cooling airflow. See Table 5-Air Delivery- CFM (With Filter). See Table 12 for lead color identification.

CLEANING HEAT EXCHANGER

The following steps should be performed by a qualified service agency:

NOTE: The materials needed in item 9 can usually be purchased at local hardware stores.

• (1) Attach variaMe-speed, reversible drill to the end of spring caMe (end opposite brush).
• (2) Insert brush end of cable into the outlet opening of cell and slowly rotate with drill. DO NOT force cable. Gradually insert cable into upper pass of cell. (See Fig. 48.)
• (3) Work cable in and out of cell 3 or 4 times to obtain sufficient cleaning. DO NOT pull cable with great force. Reverse drill and gradually work caMe out.
• (4) Insert brush end of cable in burner inlet opening of cell, and proceed to clean 2 lower passes of cell in same manner as upper pass.
• (5) Repeat the foregoing procedures until each cell in the furnace has been cleaned.
• (6) Using a vacuum cleaner, remove residue from each cell.
• (7) Using vacuum cleaner with soft brush attachment, clean burner assembly.
• (8) Clean flame sensor with fine steel wool.
• (9) Install NOx baffles (if removed).
• (10) Reinstall burner assembly. Center burners in cell openings.

Step 5 Troubleshooting

• Refer to the service label. (See Fig. 45-Service Label.) The Troubleshooting Guide can be a useful tool in isolating furnace operation problems. Beginning with the word Start, answer each question and follow the @propriate arrow to the next item.
• The Guide will help to identify the problem or failed component. After replacing any component, verify correct operation sequence.

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Payne PG8MAA-FAQs