PAYNE Furnace/Heater, Gas Manual L0907498

User Manual: PAYNE PAYNE Furnace/Heater, Gas Manual PAYNE Furnace/Heater, Gas Owner's Manual, PAYNE Furnace/Heater, Gas installation guides

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Installation Instructions

Special Venting Requirements for Installations in Canada

Installation in Canada must conform to the requirements of CSA

B149 code. Vent systems must be composed of pipe, fittings,

cements, and primers listed to ULC $636. The special vent

fittings and accessory concentric vent termination kits and

accessory external drain trap have been certified to ULC $636 for

use with those IPEX PVC vent components which have been

certified to this standard. In Canada, the primer and cement must

be of the same manufacturer as the vent system - IPEX System

636, PVC/CPVC Primer, Purple Violet for Flue Gas Venting and

IPEX System 636, PVC Cement for Flue Gas Venting, rated

Class IIA, 65 deg C. must be used with this venting system - do

not mix primers and cements from one manufacturer with a vent

system from a different manufacturer. Follow the manufacturer's

instructions in the use of primer and cement and never use primer

or cement beyond its expiration date.

The safe operation, as defined by ULC $636, of the vent system

is based on following these installation instructions, the vent

system manufacturer's installation instructions, and proper use of

primer and cement. All fire stop and roof flashing used with this

system must be UL listed material. Acceptability under Canadian

standard CSA B149 is dependent upon full compliance with all

installation instructions. Under this standard, it is recommended

that the vent system be checked once a year by qualified service

personnel.

The authority having jurisdiction (gas inspection authority,

municipal building department, fire department, etc) should be

consulted before installation to determine the need to obtain a

permit.

Consignes sp_ciales pour l'installation de ventillation au Canada

Uinstallation faite au Canada doit se conformer aux exigences du

code CSA B149. Ce syst_me de ventillation dolt se composer de

tuyaux, raccords, ciments et appr_ts conformes au ULC $636. La

tuyauterie de ventillation des gaz, ses accessoires, le terminal

concentrique mural ainsi que l'ensemble du drain de condensat

ext_rieur ont _t_ certifies ULCS 636 pour l'application des

composantes IPEX PVC qui sont certifi_es fi ce standard. Au

Canada l'appr_t et le ciment doivent _tre du m_me manufacturier

que le syst_me de ventillation - IPEX Syst_me 636, Appr_t

PVC/CPVC. Mauve Violette pour conduit en _vacuation des gaz

et IPEX Syst_me 636, ciment pour PVC pour conduit en

_vacuation des gaz, _valu_ CLASSE IIA, 65 deg. C. doit _tre

utilis_ avec ce syst_eme d'_vacuation - ne pas m_langer l'appr_t

et le ciment d'un manufacturier avec le syst_me de ventillation

d'un autre manufacturier. Bien suivre les indications du

manufacturier lors de l'utilisation de l'appr_t et du ciment et ne

pas utiliser ceux-ci si la date d'expiration est atteinte.

Uop_ration s_curitaire, tel que d_finit par ULC $636, du syst_me

de ventilation est bass sur les instructions d'installation suivantes,

ainsi que l'usage appropri_ de l'appr_t et ciment. Tout arret feu et

solin de toit utilis_s avec ce syst_me doivent _tre des mat_riaux

list,s UL. Uacceptation du standard Canadien CSA B419 est

directement reli_ fi l'installation conforme aux instructions ci-

haut mentionn_es. Le standard Canadien recommande 1'

inspection par un personel qualifi_ et ce, une fois par annie.

Les autorit_es ayant juridiction (inspecteurs de gas, inspecteurs

en bfitiments, d@artement des incendies, etc) devraient _tre

consult_es avant l'installation afin de d_terminer si un permis est

requis.

Required Notice for Massachusetts Installations

IMPORTANT

The Commonwealth of Massachusetts requires compliance with regulation 248 CMR as follows:

5.08: Modifications to NFPA-54, Chapter 10

2) Revise 10.8.3 by adding the following additional requirements:

a. For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used

in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where

the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting,

including but not limited to decks and porches, the following requirements shall be satisfied:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented

gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an

alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the

installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is

installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled

equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for

the installation of hard wired carbon monoxide detectors

a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard

wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.

b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner

shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty

(30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the

above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.

3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a

minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas

fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, "(}AS

VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS".

4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve

the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in

accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4.

5. EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:

(1.) The equipment listed in Chapter 10 entitled "Equipment Not Required To Be Vented" in the most current edition of

NFPA 54 as adopted by the Board; and

(2.) Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from

the dwelling, building or structure used in whole or in part for residential purposes.

c. MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the

manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design

or venting system components with the equipment, the instructions provided by the manufacturer for installation

of the equipment and the venting system shall include:

1. Detailed instructions for the installation of the venting system design or the venting system components; and

2. A complete parts list for the venting system design or venting system.

d. MANUFACTURER REQUIREMENTS - (}AS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When

the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the

parts for venting the flue gases, but identifies "special venting systems", the following requirements shall be

satisfied by the manufacturer:

1. The referenced "special venting system" instructions shall be included with the appliance or equipment installation

instructions; and

2. The "special venting systems" shall be Product Approved by the Board, and the instructions for that system shall include a

parts list and detailed installation instructions.

e. A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled

equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions

shall remain with the appliance or equipment at the completion of the installation.

START-UP CHECK SHEET

For 95% Furnace

(This sheet is optional. Keep this page for future reference.)

Date of Start-Up:

Dealer Name:

Address:

City, State(Province), Zip or Postal Code:

Phone:

Owner Name:

Address:

City, State(Province), Zip or Postal Code:

Model Number:

Serial Number:

Setup Checks

Check the box when task is complete

All Electrical Connections Tight?

Have hoses been relocated for furnace application

(upflow/horizontal)?

Condensate Drain Connected?

Condensate Drain Trapped?

Manual Gas Shut-Off Upstream of

Furnace/Drip- Leg?

Gas Valve turned ON?

Type of Gas: Natural: Lj Propane: Lj

Filter Type and Size:

Calculated Firing Rate:(See Checks and Adjustments

Section).

Heating Check

Measured Line Pressure when Firing Unit:

Measured Manifold Gas Pressure:

Temperature of Supply Air:

Temperature of Return Air:

(°)m

Temperature Rise (supply-return temperature):(°)__

In Rise (see furnace rating plate)? (o)__

Static Pressure (Ducts): Supply Air Return __

Which blower speed tap is used? (Heating)

Optional Check: CO ? CO2 ?

Cooling Check

Temperature of Supply Air: (o)__

Temperature of Return Air: (o)__

Temperature Difference: (o)__

Static Pressure (Ducts) cooling: Supply Air Return

Blower Speed Tap used for cooling:

Dealer Comments:

NOTE: Read the entire instruction manual before starting the

installation.

NOTE: Please retain these instructions with the furnace after

installation for future reference.

SAFETYCONSIDERATIONS

FURNACE RELIABILITY HAZARD

Improper installation or misapplication of furnace may

require excessive servicing or cause premature component

failure.

Application of this furnace should be indoors with special

attention given to vent sizing and material combustion air

requirements, gas input rate, air temperature rise, unit

leveling, and unit sizing.

FIRE, EXPLOSION, ELECTRICAL SHOCK AND

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal

injury, death, or property damage.

Improper installation, adjustment, alteration, service,

maintenance, or use can cause carbon monoxide poisoning,

explosion, fire, electrical shock, or other conditions which

may cause personal injury or property damage. Consult a

qualified installer, service agency, local gas supplier, or your

distributor or branch for information or assistance. The

qualified installer or agency must use only

factory-authorized and listed kits or accessories when

modifying this product.

Installing and servicing heating equipment can be hazardous due

to gas and electrical components. Only trained and qualified

personnel should install, repair, or service heating equipment.

Untrained personnel can perform basic maintenance functions

such as cleaning and replacing air filters. All other operations

must be performed by trained service personnel. When working

on heating equipment, observe precautions in literature, on tags,

and on labels attached to or shipped with unit and other safety

precautions that may apply.

These instructions cover the minimum requirements and conform

to existing national standards and safety codes. In some instances,

these instructions exceed certain local codes and ordinances,

especially those that may not have kept up with changing

residential construction practices. We require these instructions as

a minimum for a safe installation.

Wear safety glasses and work gloves. Have a fire extinguisher

available during start-up and adjustment procedures and service

calls.

Recognize safety information. This is the safety-alert symbol

z_. When you see this symbol on the furnace and in instructions

or manuals, be alert to the potential for personal injury.

Understand the signal words DANGER, WARNING, and

CAUTION. These words are used with the safety-alert symbol.

DANGER identifies the most serious hazards which will result in

severe personal injury or death. WARNING signifies a hazard

which could result in personal injury or death. CAUTION is used

to identify unsafe practices which may result in minor personal

injury or product and property damage. NOTE is used to

highlight suggestions which will result in enhanced installation,

reliability, or operation.

CUT HAZARD

Failure to follow this caution may result in personal injury.

Sheet metal parts may have sharp edges or burrs. Use care

and wear appropriate protective clothing and gloves when

handling parts.

TABLEOF CONTENTS

PAGE

IMPORTANT INFORMATION ......................... 2

SAFE INSTALLATION REQUIREMENTS ............... 5

COMBUSTION & VENTILATION AIR ................. 10

CONCENTRIC TERMINATION ....................... 30

GAS SUPPLY & PIPING ............................. 32

ELECTRICAL WIRING .............................. 35

DUCTWORK & FILTER ............................. 36

CHECKS & ADJUSTMENTS ......................... 38

FURNACE MAINTENANCE ......................... 40

SEQUENCE OF OPERATION & DIAGNOSTICS ......... 40

SAFEINSTALLATION

REQUIREMENTS

FIRE, EXPLOSION, AND ASPHYXIATION HAZARD

Failure to follow this warning could result in personal injury or

death.

Improper adjustment, alteration, service, maintenance or

installation could cause personal injury, death and/or

property damage.

Installation or repairs made by unqualified persons could

result in hazards to you and others. Installation MUST

cont_rm to local codes or, in the absence of local codes,

with codes of all governmental authorities having

jurisdiction.

The infi_rmation contained in this manual is intended tbr

use by a qualified service agency that is experienced in

such work, is familiar with all precautions and safety

procedures required in such work, and is equipped with

the proper tools and test instruments.

NOTE: This furnace is design-certified by the CSA

International (formerly AGA and CGA) for installation in the

United States and Canada. Refer to the appropriate codes, along

with this manual, for proper installation.

• Use only the type of gas approved for this furnace (see Rating

Plate on unit). Overfiring will result in failure of heat

exchanger and cause dangerous operation. (Furnaces can be

converted to Propane gas with approved kit.)

• Install this furnace only in a location and position as specified

in "Installation" of these instructions.

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or

death.

Do NOT install this furnace in DOWNFLOW applications.

• Provide adequate combustion and ventilation air to the furnace

as specified in" Combustion and Ventilation Air" of these

instructions.

• Combustion products must be discharged outdoors. Connect

this furnace to an approved vent system only, as specified in

"Vent and Combustion Air P@ing" of these instructions.

• Never test for gas leaks with an open flame. Use a

commercially available soap solution made specifically for the

detection of leaks to check all connections, as specified in

"Gas Supply and Piping, Final Check" of these instructions.

• Always install 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 "Technical Support Manual" of these instructions. See

furnace rating plate.

• 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 a duct(s)

sealed to the furnace casing and terminating outside the space

containing the furnace.

• A gas-fired furnace for installation in a residential garage must

be installed as specified in "Installation" of these instructions.

• This furnace is not to be used for temporary heating of

buildings or structures under construction.

• This furnace is NOT approved for installation in mobile

homes, trailers or recreation vehicles.

• Seal around supply and return air ducts.

• Install correct filter type and size.

• Unit MUST be installed so electrical components are protected

from direct contact with water.

SafetyRules

Your unit is built to provide many years of safe and dependable

service providing it is properly installed and maintained.

However, abuse and/or improper use can shorten the life of the

unit and create hazards for you, the owner.

The U.S. Consumer Product Safety Commission encourages

installation of carbon monoxide alarms. There can be various

sources of carbon monoxide in a building or dwelling. The

sources could be gas-fired clothes dryers, gas cooking stoves,

water heaters, furnaces, gas-fired fireplaces, wood fireplaces.

Carbon monoxide can cause bodily injury and/or death. Carbon

monoxide or "CO" is a colorless and odorless gas produced when

fuel is not burned completely or when the flame does not receive

sufficient oxygen.

Therefore, to help alert people of potentially dangerous carbon

monoxide levels, you should have a commercially available

carbon monoxide alarm that is listed by a nationally recognized

testing agency in accordance with Underwriters Laboratories Inc.

Standard for Single and Multiple Station Carbon Monoxide

Alarms, ANSI/UL 2034 or the CSA 6.19-01 Residential Carbon

Alarming Devices installed and maintained in the building or

dwelling concurrently with the gas-fired furnace installation (see

Note below). The alarm should be installed as recommended by

the alarm manufacturer's installation instructions.

There can be numerous sources of fire or smoke in a building or

dwelling. Fire or smoke can cause bodily injury, death, and/or

property damage. Therefore, in order to alert people of potentially

dangerous fire or smoke, you should have fire extinguisher and

smoke alarms listed by Underwriters Laboratories installed and

maintained in the building or dwelling (see Note below).

NOTE: The manufacturer of your furnace does not test any

alarms and makes no representations regarding any brand or type

of alarms.

To ensure safe and efficient operation of your unit, you should do

the following:

1. Thoroughly read this manual and labels on the unit.

This will help you understand how your unit operates and

the hazards involved with gas and electricity.

2. Do not use this unit if any part has been under water

Immediately call a qualified service technician to inspect

the unit and to replace any part of the control system and

any gas control which has been under water.

3. Never obstruct the vent grilles, or any ducts that

provide air to the unit. Air must be provided for proper

combustion and ventilation of flue gases.

FrozenWaterPipe Hazard Installation

WATER DAMAGE TO PROPERTY HAZARD

Failure to follow this caution may result in property damage.

Do not leave your home unattended for long periods during

freezing weather without turning off water supply and

draining water pipes or otherwise protecting against the risk

of frozen pipes and resultant damage.

Your furnace is designed solely to provide a safe and comfortable

living environment. The furnace is NOT designed to ensure that

water pipes will not freeze. It is equipped with several safety

devices that are designed to turn the furnace off and prevent it

from restarting in the event of various potentially unsafe

conditions.

If your furnace remains off for an extended time, the pipes in

your home could freeze and burst, resulting in water damage.

If the structure will be unattended during cold weather you should

take these precautions.

1. Turn off the water supply to the structure and drain the wa-

ter lines if possible and add an antifreeze for potable water

to drain traps and toilet tanks. Open faucets in appropriate

areas.

-or-

2. Have someone check the structure frequently during cold

weather to make sure it is warm enough to prevent pipes

from freezing. Instruct them on a service agency to call to

provide service, if required.

-or-

3. Install a reliable remote sensing device that will notify

somebody of freezing conditions within the home.

Winter Shutdown

If you go away during the winter months and do not leave the

heat on in your home, the plastic transition box and the

condensate trap on the furnace must be protected from freeze

damage. (See Fig. 10 through Fig. 17)

1. Disconnect the 5/8" OD rubber hose from the vent drain

fitting that is located downstream of the combustion

blower. Insert a funnel into the hose and pour four(4)

ounces of sanitary type (RV) antifreeze into the condensate

trap. Reconnect the 5/8" OD rubber hose to the stub on the

vent drain fitting. Secure with the hose clamp.

2. Disconnect the 3/4" OD rubber hose from the condensate

trap. Insert a funnel into the hose and and pour four(4)

ounces of sanitary type (RV) antifreeze into the plastic

Transition box. Squeeze the hose together near the end and

quickly reconnect the 3/4" OD rubber hose to the stub on

the condensate trap. Secure with the hose clamp.

When you return home, your furnace will be ready to start, as it is

not necessary to drain the antifreeze from the furnace.

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or

death.

This furnace can NOT be common vented or connected

to any type B, BW or L vent or vent connector, nor to

any portion of a factory-built or masonry chimney. If

this furnace is replacing a previously common-vented

turnace, it may be necessary to resize the existing vent

and chimney to prevent oversizing problems for the

other

remaining appliance(s). See Venting and Combustion Air

C_ec'k in Gas Vent Installation section. This furnace

MUST be vented to the outside.

LocationandClearances

1. Refer to Fig. 1 for typical installation and basic connecting

parts required. Refer to Fig. 4 for typical horizontal direct

vent installation and basic connecting parts required. Sup-

ply and return air plenums and duct are also required.

2. If furnace is a replacement, it is usually best to install the

furnace where the old one was. Choose the location or

evaluate the existing location based upon the minimum

clearance and furnace dimensions (Fig. 2).

Aluminum or non-rusting shield recommended. (See

VentTerminationShieldingfordimensions).

8" Min.... '1=,,I _ ..... /_ Couplingonendsof

20' Max. 1_ #._ InletPipe(not /_exhaustpipe.Total

in same _ _ =_ usedon Single /pipe& couplingout-

atmospheric I[ Ill" Pipe model) sidestructure=8"

zone _L_ _ _)

Vent Pipes MUST be

supported Horizontally

and Vertically atmospheric

*Increaseminimumfrom 8" to 18"forcold climates(sustainedtemperatures0 ° F

andbelowfor24 or moreconsecutivehours).

A07700

Fig. 1 -Typical Upflow Installation

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or

death.

Do NOT operate furnace in a corrosive atmosphere containing

chlorine, fluorine or any other damaging chemicals, which

could shorten filrnace life.

Refer to Combustion &Ventilation Air section, Contaminated

Combustion Air for combustion air evaluation and remedy.

FROZEN AND BURST PIPE HAZARD

Failure to follow this caution may result in property damage.

Special precautions MUST be made is installing furnace in

an area which may drop below freezing. This can cause

improper operation or damage to equipment. If furnace

environment has the potential of freezing, the drain trap and

drain line must be protected. The use of electric heat tape or

RV antifreeze is recommended for these installations. (See

"Condensate Trap Freeze Protection Section")

Do NOT operate furnace in acorrosive atmosphere

containing chlorine, fluorine or any other damaging

chemicals. Refer to Combustion & Ventilation Air section,

Contaminated Combustion Air.

InstallationRequirements

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or

death.

Do NOT install this furnace in DOWNFLOW applications.

1. Install furnace level.

2. This furnace is NOT to be used for temporary heat of

buildings or structures under construction.

3. Install the vent pipes as short as practical. (See Gas Vent

Installation section).

4. Do NOT install furnace directly on carpeting, tile or other

combustible material other than wood flooring.

5. Maintain clearance for fire safety and servicing. A front

clearance of 24" (609.6 mm) required and 30" (762.0

mm)recommended for access to the burner, controls and

filter. See clearance requirements in Fig. 2.

6. Use a raised base if the floor is damp or wet at times.

7. Residential garage installations require:

• Burners and ignition sources installed at least 18" above the

floor.

• Furnace must be located or physically protected from possible

damage by a vehicle.

8. If the furnace is to be suspended from the floor joists in a

basement or a crawl space or the rafters in an attic, it is

necessary to use steel pipe straps or an angle iron frame to

attach the furnace. These straps should be attached to the

furnace with sheet metal screws and to the rafters or joists

with bolts. The preferred method is to use an angle iron

frame bolted to the rafters or joists.

9. Local codes may require a drain pan under the entire fur-

nace and condensate trap when the furnace is installed in

attic application.

This furnace may be used for construction heat provided that all

the following conditions are met:

• The furnace is permanently installed with all electrical wiring,

piping, venting and ducting installed according to these

installation instructions. A return air duct is provided, sealed

to the furnace casing, and terminated outside the space

containing the furnace. This prevents a negative pressure

condition as created by the circulating air blower, causing a

flame rollout and/or drawing combustion products into the

structure.

• The furnace is controlled by a thermostat. It may not be "hot

wired" to provide heat continuously to the structure without

thermostatic control.

• Clean outside air is provided for combustion. This is to

minimize the corrosive effects of adhesives, sealers and other

construction materials. It also prevents the entrainment of

drywall dust into combustion air, which can cause fouling and

plugging of furnace components.

• The temperature of the return air to the furnace is maintained

between 55 ° F (13 ° C) and 80 ° F (27 ° C), with no evening

setback or shutdown. The use of the furnace while the

structure is under construction is deemed to be intermittent

operation per our installation instructions.

• The air temperature rise is within the rated rise range on the

furnace rating plate, and the firing rate has been set to the

rating plate value.

• The filters used to clean the circulating air during the

construction process must be either changed or thoroughly

cleaned prior to occupancy.

• The furnace, ductwork and filters are cleaned as necessary to

remove drywall dust and construction debris from all HVAC

system components after construction is completed.

• After construction is complete, verify furnace operating

conditions including ignition, input rate, temperature rise and

venting according to these instructions.

Knockouts

CUT HAZARD

Failure to follow this caution may result in personal injury.

Sheet metal parts may have sharp edges or burrs. Use care

and wear appropriate clothing, safety glasses and gloves

when handling parts and servicing furnaces.

Use a hammer and screwdriver to strike a sharp blow (See Fig. 3)

directly to the knockout tie points or use a hammer in the upper

left corner of the desired knockout. Remove any burrs and sharp

edges.

....1F _°--

TOP

S ¸

E"_

LEFT SIDE _-=_

TRAP(KO)(COUNTERFLOW) _ _-

GAS..... _-/_

VENT .....;_I/

AIRINTAKE(KO) Fl-\

(ALTERNATE) ........./\_/)

TRAP(KO) 413/16:'-I

• UPFLOW/HORIZONTAL ........ __

THERMOSTAT_Jt _ 7_ ....

(KO)

215/8 _

BOTTOM

/j AIR INTAKE

._1Z _VENT

o_ 1114

/ELECTRICAL

t i 1311/1_

11/16

283/4

/241/1d I

6 1 /16

i 7 r

Unit

Ca p acity

PG9YAA036060

PG9YAA036080

PG9YAA048080

PGRYAA0601 O0

FRONT

MINIMUM CLEARANCES TO

COMBUSTIBLE MATERIALS FOR ALL UNITS

REAR 0

FRONT (combustion air openings in 3"

furnace and in structure)

Required For Service *24"

ALL SIDES Of SUPPLY PLENUM 1"

SIDES 0

VENT 0

TOP OF FURNACE 1"

"30" clearance recommended for furnace remq_val.

Horizontal position: Linecontact is permissible only between

lines formed by intersections of top and two sides of furnace

jacket, and building joists, studs or framing.

NOTE: Evaporator "A" coil drain pan dimensions

may vary from furnace duct opening size. Always

consult evaporator specifications for duct size

requirements.

Furnace is designed for bottom return or side

return.

Return air through back of furnace is NOT allowed,

Cabinet Bottom

A B C D

191/8 17_ 8 21/8 143/4

223/4 211/4 11_16 183/4

241/2 23 _16 23

Drawing is representative,

but some models may vary

_ 37/8 ALL DIMENSIONS IN INCHES

1IN=25.4MM

Top

E F G H

43/8 41/2 21/2 91/2

43/8 41/2 25/8 113/8

43/8 41/2 21/4 121/4

T ..........

li/6

297/8

281/2

_-- 181/2 _-

913/16

3311116 191/4

(KO)

_- 5/16

23/8--

11/16---_J ,,, ,

GAS\ RIGHT SIDE

/TRAP(COUNTERFLOW)

ELECTRICAL(KO)

\AIR INTAKE(KO)

_:.......... (ALTERNATE)

413/1 _ _> VENT(KO)

/-- _j, ......

....... _'\ /TRAP(KO)

111116-- F_ ...... UPFLOW/HORIZONTAL

....7 ......... _\\

\ 21/4

273/16 THERMOSTAT

15/8

175/16

11]116

I -- t 47/8 - 215/8

/-'_ 24

3/,

17/8

KO = Knockout

Specifications are subject to change without notice

Fig. 2 -Dimensions and Clearances

A07701

"\ .//

A07702

Fig. 3 -Hammer and Screwdriver used for Knockout

NOTE: If a knockout does not come out after two sharp blows,

pull and snip as needed to remove the knockout.

InstallationPositions

This furnace can be installed in an upflow or horizontal (either

left or right) airflow position. DO NOT install this furnace in the

downflow position or on its back. For the upflow position, the

return air ductwork can be attached to either the left or right side

panel and/or the bottom. For horizontal positions, the return air

ductwork must be attached to the bottom:

ULC-$636. ULC-$636 certified plastic vent system material or

the components of ULC-$636 certified vent systems must not be

interchanged with other vent systems or unlisted pipe/fittings.

Vent components supplied with the furnace and components in

factory authorized vent kits may be used with ULC-$636

certified vent systems.

The ULC-$636 certified plastic components, and specified

primers and glues of the certified system must be from a single

system manufacturer and not intermixed with other system

manufacturer's vent system parts.

The first 3 ft. (900 mm) of the venting system must be readily

accessible for inspection.

In some provinces the combustion air system may also be

required to be ULC-$636 certified.

The vent and combustion air pipes attach to the furnace through

the top panel or to the alternate locations on the furnace side

panels.

Note: Repositioning of the combustion blower is required for the

vent pipe connection to the furnace through the "right side"

panel. See "Vent and Combustion Air Piping" section for further

details.

HorizontalFurnaceInstallation

Inlet Pipe(not used onSingle Pipe model)

Vent

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or

death.

Do NOT install this furnace in DOWNFLOW applications.

Condensate

Trap

FurnaceInstallationConsiderations

The installation of the furnace for a given application will dictate

the position of the furnace, the airflow, ductwork connections,

vent and combustion air piping. Consideration must be given to

the following:

CondensateTrapand DrainLines

The supplied condensate trap must be attached to the furnace side

panel on either the left or right side. For horizontal installations,

the drain trap is vertically attached to the side panel below the

furnace. A minimum clearance of 6" below the furnace is

required for the condensate trap. Downward slope of the

condensate drain line from the condensate trap to the drain

location must be provided. Adequate freeze protection of the

drain trap and the drain line must be provided. See "Condensate

Drain Trap" section for further details.

Leveling

Proper leveling of the furnace must be provided to insure proper

drainage of the condensate from the furnace. The furnace must be

level to within 1/4" (6.35 mm) from front to back and from side to

side for upflow installations or top to bottom for horizontal

installations.

Ventand CombustionAir Connections

For venting information literature, contact www.cac-bdp.com

with the complete model and serial number of the furnace.

NOTE: Furnaces installed in Canada must use vent systems that

are certified to the standard for Type BH Gas Venting Systems,

NOTE:6"bottomclearancerequiredfor condensatetrap.

Fig. 4 - Typical Horizontal Installation

A07703

This furnace can be installed horizontally in an attic, basement,

crawl space, alcove, or suspended from a ceiling in a basement or

utility room. See Fig. 4. Do not install furnace on its back or in

the reverse airflow positions as safety control operation will be

adversely affected.

If the furnace is to be installed in a crawl space, consult local

codes. A suitable concrete pad or blocks are recommended for

crawl space installation on the ground.

NOTE: 6" bottom clearance required for condensate trap.

Twenty four (24) inches between the front of the furnace and

adjacent construction or other appliances MUST be maintained

for service clearance.

Keep all insulating materials clear from louvered door. Insulating

materials may be combustible.

The horizontal furnaces may be installed directly on combustible

wood flooring or supports as long as all required furnace

clearances are met. See Fig. 4.

GasVent

ThisinstallationNOTapprovedinCanada GasVent

GableVent

,_'.'_Atern_a ,etAir(1, _ j Gab,eVent ,__1L_'_

_ _" GasVent _Outlet__J II II I] II-- Outlet

I_:-- _II J_VentilatedAttic_ Air(l) _I II _ _;_Air(_)

OutletAir (1) I I SoffitVent I11"11 _"_- I II _| I I I I

I I _lr II TopAbovelnsulation"_ I J-_ _I I I I

n II I-IFII OutletAir(1) _fltVent I.nleL _F ...... I b,I _ _J_ Inlet

I I _ _ I I I F"l Minimum One Inlet and One Outlet Air Supply is Required

_ m= I I I I I Inlet May beinanyCombinationShown

_m E Inlet J I........I I.÷°°1 A,r(2) Inlet AirOpeningMustbe Within12"of floor

VentilatedCrawlSpace i..J I I_T_3 --

Air(1) _._ I 1'_'1 [_ -- OutletAirOpening MustbeWithin12"ofceiling

(1)1SquareInchper4000BTUH

(2)1SquareInchper2000BTUH

A07704

Fig. 5 -Outside Air

(This is ONLY a guide. Subject to codes of country having jurisdiction).

This furnace MUST NOT be installed directly on carpeting or

tile or other combustible material other than wood flooring or

supports.

COMBUSTION& VENTILATIONAIR

For SinglePipeInstallation

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or

death.

Use methods described here to provide combustion and

ventilation air.

Furnaces require ventilation openings to provide sufficient air for

proper combustion and ventilation of flue gases. All duct or

openings for supplying combustion and ventilation air must

comply with the gas codes, or in the absence of local codes, the

applicable national codes.

Combustion and ventilation air must be supplied in accordance

with one of the following:

NOTE: The Combustion & Ventilation Air Section in this

document, uses tables and information from the ANSI

Z223.1/NFPA 54. For use in Canada, use CSA B149.1 for this

information.

1. Section 9.3, Air for Combustion and Ventilation, of the

National Fuel Gas Code, (NFGC), ANSI

Z223.1-2006/NFPA 54-2006 in the U.S.,

2. Sections 8.2, 8.3, 8.5, 8.6, 8.7, and 8.8 of National Stand-

ard of Canada, Natural Gas and Propane Installation Code

(NSCNGPIC), CSA B149.1-05 in Canada,

3. Applicable provisions of the local building code.

This furnace can NOT be common vented or connected to any

type B, BW or L vent or vent connector, nor to any portion of a

factory-built or masonry chimney. Multistory venting is NOT

permitted. If this furnace is replacing a previously

common-vented furnace, it may be necessary to resize the

existing vent and chimney to prevent oversizing problems for the

other remaining appliance(s). See "Venting and Combustion Air

For horizontal installation over a finished living space. A field

fabricated auxiliary drain pan with drain pipe is required to

prevent damage by overflow due to blocked condensate drain.

Check" in this section. This furnace MUST be vented to the

outside.

When the installation is complete, check that all appliances have

adequate combustion air and are venting properly. See Venting

And Combustion Air Check in "Gas Vent Installation" Section in

this manual.

OutdoorCombustionAir Method

A space having less than 50 cubic feet per 1,000 BTUH input

rating for all gas appliances installed in the space requires

outdoor air for combustion and ventilation.

Air Openingsand ConnectingDucts

1. Total input rating for all gas appliances in the space

MUST be considered when determining free area of open-

ings.

2. Connect ducts or openings directly to the outdoors.

3. When screens are used to cover openings, the openings

MUST be no smaller than 1/4" (6.35 mm) mesh.

4. The minimum dimension of air ducts MUST NOT be less

than 3".

5. When sizing a grille, louver, or screen use the free area of

opening. If free area is NOT stamped or marked on grill or

louver, assume a 20% free area for wood and 60% for met-

al. Screens shall have a mesh size not smaller than 1/4"

(6.35 mm) .

ConfinedSpaceInstallation

NOTE: A confined space is defined as an area with less than 50

cubic feet per 1,000 BTUH input rating for all gas appliances

installed in the area.

Requirements

1. Provide the space with sufficient air for proper combustion

and ventilation of flue gases using horizontal or vertical

ducts or openings.

2.Fig.5illustrateshowtoprovidecombustionandventila-

tionairwhentwopermanentopenings,oneinletandone

outlet,areused.

f. OneopeningMUSTcommencewithin12"ofthefloor

andthesecondopeningMUSTcommencewithin12"

oftheceiling.

g.SizeopeningsandductsperTable1.

h.Horizontalductopeningsrequire1squareinchoffree

areaper2,000BTUH(1,100mmZ/kW)ofcombined

inputforallgasappliancesinthespace(seeTable1).

i. Verticalductopeningsoropeningsdirectlycommunic-

atingwiththeoutdoorsrequire1squareinchoffree

areaper4,000BTUH(550mm2/kW)forcombined

inputofallgasappliancesinthespace(seeTable1).

3.Whenonepermanentoutdooropeningisused,theopening

requires:

a.1sq.inoffreeareaper3,000BTUH(700mmZ/kW)

forcombinedinputofallgasappliancesinthespace

(seeTable1) and

b.notlessthanthesumoftheareasofallventconnect-

orsinthespace.

Theopeningshallcommencewithin12"of thetopof the

enclosure.Appliancesshallhaveclearancesof atleast1"from

thesidesandbackand6" fromthefront.Theopeningshall

directlycommunicatewiththeoutdoorsorshallcommunicate

throughaverticalorhorizontalducttotheoutdoorsorspaces

(crawlorattic)thatfreelycommunicatewiththeoutdoors.

4.CombinationofIndoorandOutdoorAirshallhave:

a.IndooropeningsthatcomplywiththeIndoorCom-

bustionAirMethodbelowand

b.OutdooropeningslocatedasrequiredintheOutdoor

CombustionAirMethodaboveand

c.Outdooropeningssizedasfollows.

(3.)CalculatetheRatioofallIndoorSpacevolume

dividedbyrequiredvolumeforIndoorCombus-

tion Air Method.

(4.) Outdoor opening size reduction Factor is 1 minus

the Ratio in 1) above.

(5.) Minimum size of Outdoor openings shall be the

size required in Outdoor Combustion Air Meth-

od above multiplied by reduction Factor.

BTUH MinimumFree AreaRequiredfor EachOpeningor Ductto Outdoors

Input TwoHorizontalDucts SingleOpening TwoVerticalDuctsor Openings RoundDuct

Rating (sq.in./2,000BTUH) (sq.in./3,000BTUH) (sq.in./4,000BTUH) (sq.in./4,000 BTUH)

60,000 30 sq.in. 20 sq.in. 15 sq.in. 5"

80,000 40sq. in. 26.7sq.in. 20.0 sq.in. 5"

100,000 50 sq. in. 33.3sq.in. 25 sq.in. 6"

EXAMPLE: Determining Free Area

Furnace Water Heater Total Input

100,000 + 30,000 = (130,000 + 4,000) = 32.5 Sq. In. Vertical

Furnace Water Heater Total Input

100,000 + 30,000 = (130,000 ÷ 2,000) = 65 Sq. In. Horizontal

Table 1-Free Area

IndoorCombustionAir (UnconfinedSpace)

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or

death.

Most homes will require additional air from outdoors for

combustion and ventilation. A space with at least 50 cubic

feet per 1,000 Btuh Input rating or homes with tight

construction may need outdoor air, supplied through ducts, to

supplement air infiltration for proper combustion and

ventilation of flue gasses.

Standard and Known-Air-Infiltration Rate Methods

Indoor air is permitted for combustion and ventilation, if the

Standard or Known-Air-Infiltration Rate Method is used.

The Standard Method may be used, if the space has no less

volume than 50 cubic feet per 1,000 BTUH input rating for all

gas appliances installed in the space. The standard method

permits indoor air to be used for combustion and ventilation air.

The Known Air Infiltration Rate Method shall be used if the

infiltration rate is known to be less than 0.40 air changes per hour

(ACH) and equal to or greater than 0.10 ACH. Infiltration rates

greater than 0.60 ACH shall not be used. The minimum required

volume of the space varies with the number of ACH and shall be

determined per Table 2 or Equations 1and 2. Determine the

minimum required volume for each appliance in the space, and

add the volumes together to get the total minimum required

volume for the space.

CARBON MONOXIDE POISONING HAZARD

Failure to supply additional air by means of ventilation grilles

or ducts could result in personal injury or death.

An unconfined space or homes with tight construction may not

have adequate air infiltration for proper combustion and

ventilation of flue gasses. Most homes will require additional

air.

OtherThan Fan-AssistedTotal Fan-assistedTotal (1,000'sBtuh)

(1,000Btuh)

ACH 30 40 50 50 75 100 125

0,60 1,050 1,400 1,750 1,250 1,875 2,500 3,125

0,50 1,260 1,680 2,100 1,500 2,250 3,000 3,750

0,40 1,575 2,100 2,625 1,875 2,813 3,750 4,688

0,30 2,100 2,800 3,500 2,500 3,750 5,000 6,250

0,20 3,150 4,200 5,250 3,750 5,625 7,500 9,375

0,10 6,300 8,400 10,500 7,500 11,250 15,000 18,750

0,00 NP NP NP NP NP NP NP

Table 2-Minimum Space Volume for 100% Combustion and Ventilation Air from Indoors (ft 3)

HNP =Not Permitted

NO TAG Minimum Space Volumes were determined by using

the following equations from the National Fuel Gas (?ode ANSI

Z223.1/NFPA 54-2006, 9.3.2.2:

1. For appliances other than fan-assisted appliances (such

as a draft hood-equipped water heater), calculate using the

following equation:

-- ACH 1000 Btu /hr

2. For fan-assisted appliances (such as this furnace), calcu-

late using the following equation:

Required Volume fan> 15ft3 (- If an )

ACH 1000 Btu /hr

where:

Iother = all appliances other than fan-assisted input in Btu

per hour

Ifan = fan-assisted appliance input in Btu per hour

ACH = air change per hour (percent of volume of space

exchanged per hour, expressed as a decimal)

3. For purposes of this calculation, an infiltration rate greater

than 0.60 ACH shall not be used in the equations above.

The following requirements apply to the Standard Method and to

the Known Air Infiltration Rate Method.

• Adjoining rooms can be considered part of a space, if there are

no closeable doors between rooms.

• Combining spaces on the same story. Each opening shall have

a minimum free area of at least 1 in.2/1,000 BTUH (2,200

mm2/kW) of the total input rating of all appliances in the space

but not less than 100 in. 2 (0.06 m2). One opening shall

commence within 12 in. (304.8 mm) of the top, and one

opening shall commence within 12 in. (304.8 mm) of the

bottom, of the enclosure. The minimum dimension of air

openings shall not be less than 3 in. (76.2 mm).

• Combining spaces in different stories. The volumes of spaces

on different stories shall be considered as communicating

spaces where such spaces are connected by one or more

openings in doors or floors having a total minimum free area of

2 in.2/1,000 BTUH (4,400 mm2/kW) of total input rating of all

appliances.

• An attic or crawl space may be considered a space that freely

communicates with the outdoors provided there are adequate

ventilation openings directly to outdoors. Openings MUST

remain open and NOT have any means of being closed off.

Ventilation openings to outdoors MUST be at least 1 square

inch of free area per 4,000 BTUH (550 mm2/kW) of total input

rating for all gas appliances in the space.

• In spaces that use the Indoor Combustion Air Method,

infiltration should be adequate to provide air for combustion,

ventilation and dilution of flue gases. However, in buildings

with unusually tight construction, additional air MUST be

provided using the methods described in section titled Outdoor

Combustion Air Method:

• Unusually tight construction is defined as Construction with:

1. Walls and ceilings exposed to the outdoors have a continu-

ous, sealed vapor barrier. Openings are gasketed or sealed

and

2. Doors and openable windows are weather stripped and

3. Other openings are caulked or sealed. These include joints

around window and door frames, between sole plates and

floors, between wall-ceiling joints, between wall panels, at

penetrations for plumbing, electrical and gas lines, etc.

VentilationAir

Some provincial codes and local municipalities require

ventilation or make-up air be brought into the conditioned space

as replacement air. Whichever method is used, the mixed return

air temperature across the heat exchanger MUST not fall below

60 ° so that flue gases will not condense excessively in the heat

exchanger. Excessive condensation will shorten the life of the

heat exchanger and possibly void your warranty.

Ventingand CombustionAir Check

NOTE: If this installation replaces an existing furnace from a

commonly vented system, the original venting system may no

longer be sized to properly vent the attached appliances. An

improperly sized venting system may cause the formation of

condensate in the vent and the leakage or spillage of vent gases.

To make sure there is adequate combustion air for all appliances,

MAKE THE FOLLOWING CHECK.

Vent Pipe ._ DraftHood

/P%

TYaPieCa/G:tSer_ ]1! \ _...._

I""_ IMatch

Fig. 6 - Vent Check

A07688

The following information is supplied to allow the installer to

make adjustments to the setup of existing appliances, IF

REQUIRED, based on good trade practices, local codes, and

good judgement of the installer. Manufacturer does NOT take

responsibility for modifications made to existing equipment.

the existing vent and chimney to prevent oversizing problems for

the other remaining appliance(s). See "Venting and Combustion

Air Check" in this section. This furnace MUST be vented to the

outside.

VENTAND COMBUSTIONAIRPIPING

CARBON MONOXIDE POISONING HAZARD

Failure to tbllow the steps outlined below tbr each

appliance connected to the venting system being placed

into operation, could result in carbon monoxide

poisoning or death:

The tbllowing steps shall be followed t_r each appliance

connected to the venting system being placed into

operation, while all other appliances connected to the

venting system are not in operation:

1. Seal any unused openings in the venting system.

2. Inspect the venting system for proper size and

horizontal pitch, as required in the National Fuel Gas

Code, ANSI Z223.1/NFPA 54 or CSA B149.1, Natural

Gas and Propane Installation Code and these

instructions. Determine that there is no blockage or

restriction, leakage, corrosion and other deficiencies

which could cause an unsafe condition.

3. As far as practical, close all building doors and

windows and all doors between the space in which the

appliance(s) connected to the venting system are

located and other spaces of the building.

4. Close fireplace dampers.

5. Turn on clothes dryers and any appliance not

connected to the venting system. Turn on any exhaust

fans, such as range hoods and bathroom exhausts, so

they are operating at maximum speed. Do not operate

a summer exhaust fan.

6. Follow the lighting instructions. Place the appliance

being inspected into operation. Adjust the thermostat

so appliance is operating continuously.

7. Test for spillage from draft hood equipped appliances

at the draft hood relief opening after 5 minutes of

main burner operation. Use the flame of a match or

candle. (Fig. 6)

8. If improper venting is observed, during any of the

above tests, the venting system must be corrected in

accordance with the National Fuel Gas Code, ANSI

Z223.1/NFPA 54 and/or CSA B149.1, Natural Gas and

Propane Installation Code.

9. After it has been determined that each appliance

connected to the venting system properly vents when

tested as outlined above, return doors, windows,

exhaust fans, fireplace dampers and any other

gas-fired burning appliance to their previous

conditions of use.

ForTwo PipeInstallation(DirectVent)

This furnace can NOT be common vented or connected to any

type B, BW or L vent or vent connector, nor to any portion of a

factory-built or masonry chimney. If this furnace is replacing a

previously common-vented furnace, it may be necessary to resize

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or

death.

Use methods described here to provide combustion and

ventilation air.

Dual Certified(PG9YAAModels)

This furnace is certified as a category IV appliance. This furnace

can be installed as a direct vent furnace using outside air for

combustion or the furnace can use air from inside the structure

for combustion. The INLET air pipe is optional. If combustion

air comes from inside the structure, adequate make up air MUST

be provided to compensate for oxygen burned. See Confined

Space Installation in the Combustion and Ventilation Air

chapter. If combustion air is drawn from outside the structure, it

MUST be taken from the same atmospheric pressure zone as the

vent pipe.

ContaminatedCombustionAir

Installations in certain areas or types of structures will increase

the exposure to chemicals or halogens that may harm the furnace.

The following areas or types of structures may contain or have

exposure to the substances listed below. The installation must be

evaluated carefully as it may be necessary to provide outside air

for combustion.

• Commercial buildings.

• Buildings with indoor pools.

• Furnaces installed in laundry rooms.

• Furnaces installed in hobby or craft rooms.

• Furnaces installed near chemical storage areas.

• Permanent wave solutions for hair.

• Chlorinated waxes and cleaners.

• Chlorine based swimming pool chemicals.

• Water softening chemicals.

• De-icing salts or chemicals.

• Carbon tetrachloride.

• Halogen type refrigerants.

• Cleaning solvents (such as perchloroethylene).

• Printing inks, paint removers, varnishes, etc.

• Hydrochloric acid.

• Sulfuric Acid.

• Solvent cements and glues.

• Antistatic fabric softeners for clothes dryers.

• Masonry acid washing materials.

Vent and CombustionAir PipingGuidelines

This furnace is approved for venting with Schedule 40 PVC,

CPVC, ABS fittings, and Cellular Core and SDR-26 PVC pipe.

Applicable ASTM Standards for Vent Materials

Cell

Materi- Sch.40 SDR Solvent

als Pipe Pipe Core Fittings Primer Cement

Pipe

D2468

ABS D1527 F628 & -- D2235

D2661

D2466

PVC D1785 D224t F891 & F656 D2564

D2665

CPVC F44t F442 -- F438 -- F493

ABS

to .......... D3138

PVC

NOTE:

1. In Canada, all pipe, fittings &cements must conform to

applicable CSA standards or to local codes having juris-

diction.

2. Only use solvent cements that are marked for use with the

specific venting material.

3. ABS to PVC transition joints REQUIRE a special solvent

cement that meets the requirements of ASTM D3138.

4. Refer to ASTM D2855 for general procedure to use for

cementing plastic pipe and fittings.

NOTE: In order to create a seal that allows future removal of

pipe, RTV sealant MUST be used on the inlet pipe where it

joins to the furnace.

NOTE: All vent piping MUST be installed in compliance with

local codes or ordinances, these instructions, good trade practices,

and codes of country having jurisdiction.

1. Determine the best routing and termination for the vent

pipe and air inlet pipe by referring to all of the instructions

and guidelines in this Section.

2. Determine the size required for the vent pipe and air inlet

pipe.

3. Loosely assemble all venting parts without adhesive (pipe

joint cement) for correct fit before final assembly.

4. Furnace shall be installed so as to prevent the accumula-

tion of condensate.

5. Use of vertical piping is preferred because there will be

some moisture in the flue gases that may condense as it

leaves the vent pipe (See Instructions For Horizontal

Vents).

6. The vertical vent pipe MUST be supported so that no

weight is allowed to rest on the combustion blower.

7. Exhaust vent piping or air inlet piping diameter MUST

NOT be reduced.

8. All exhaust vent piping from the furnace to termination

MUST slope upwards. A minimum of 1/4" (6.35 mm) per

foot of run is required to properly return condensate to the

furnace drain system.

9. Use DWV type long radius elbows whenever possible, as

they provide for the minimum slope on horizontal runs and

they provide less resistance in the vent system. If DWV

elbows cannot be used, use two, 45 ° elbows when pos-

sible. On horizontal runs the elbows can be slightly mis-

aligned to provide the correct slope.

10. All horizontal pipe runs MUST be supported at least every

five feet with galvanized strap or other rust resistant ma-

terial. NO sags or dips are permitted.

11. All vertical pipe runs MUST be supported every six feet

where accessible.

12. The minimum pipe run length is 2' (.6 M).

13. The piping can be run in the same chase or adjacent to

supply or vent pipe for water supply or waste plumbing. It

can also be run in the same chase with a vent from another

90+ furnace.

NOTE: In NO case can the piping be run in a chase where

temperatures can exceed 140 ° F (60 ° C). or where radiated heat

from adjacent surfaces would exceed 140 ° F (60 ° C).

14. The vent outlet MUST be installed to terminate in the

same atmospheric pressure zone as the combustion air in-

let.

15. The vent system can be installed in an existing unused

chimney provided that:

• Both the exhaust vent and air intake run the length of the

chimney.

• No other gas fired appliance or fireplace (solid fuel) is vented

into the chimney.

• The top of the chimney MUST be sealed flush or crowned up

to seal against rain or melting snow so ONLY the piping

protrudes.

• The termination clearances shown in Fig. 7 and 8 are

maintained.

16. Furnace applications with vertical vents requiring vent dia-

meter increaser fittings must have increaser fittings in-

stalled in vertical portion of the vent. Condensate will be

trapped in the vent if the vent diameter is increased prior

to having an elbow turned upward. This could cause nuis-

ance tripping of the pressure switch.

CombustionAir andVent PipingInsulation

Guidelines

NOTE: Use closed cell, neoprene insulation or equivalent. If

Fiberglass or equivalent insulation is used it must have a vapor

barrier. Use R values of 7 up to 10', (2.1 - 3.0 M) R-11 if

exposure exceeds 10'. If Fiberglass insulation is used, exterior to

the structure, the pipe MUST be boxed in and sealed against

moisture.

1. When the vent or combustion air pipe height above the

roof exceeds 30"(762.0 mm), or if an exterior vertical riser

is used on a horizontal vent to get above snow levels, the

exterior portion MUST be insulated.

2. When combustion air inlet piping is installed above a sus-

pended ceiling, the pipe MUST be insulated with moisture

resistant insulation such as Armaflex or other equivalent

type of insulation.

3. Insulate combustion air inlet piping when run in warm, hu-

mid spaces.

SizingCombustionAir andVent Pipe

Consult Table 3 to select the proper diameter exhaust and

combustion air piping. Exhaust and combustion air piping is sized

for each furnace BTUH size based on total lineal vent length (on

inlet or outlet side), and number of 90 °elbows required. Two 45 °

elbows can be substituted for one 90 °elbow. The elbow or

elbows used for vent termination outside the structure ARE

counted, including elbows needed to bring termination above

expected snow levels. The elbow inside the furnace on the

PG9YAA IS NOT included in the count.

PIPE DIAMETER TABLE

PG9YAA MODEL

60,000 BTUH Furnaces

40' & (5) 90 ° elbows with 2" PVC pipe or

70' & (5) 90 ° elbows with 3" PVC pipe

80,000 BTUH Furnace

40' & (5) 90 ° elbows with 2" PVC pipe or

40' & (5) 90 ° elbows with 3" PVC pipe

100,000 BTUH Furnace

30' & (4) 90 ° elbows with 2" PVC pipe or

40' & (5) 90 ° elbows with 3" PVC pipe

Elbows are DWV Long Radius Type for 2" and 3" vents.

If morethan five elbows are required, reduce the length of both the

inlet and exhaust pipes 5' for each additional elbow used. If less than

five elbows are required, the length can be INCREASED by 5' for each

additional elbow NOT used.

Table 3-Pipe Diameter Table

NOTE: It is allowable to use larger diameter pipe and fitting

than shown in the tables but not smaller diameters than shown.

For "Concentric Termination Kit" Venting see Table 4 in

this manual.

Vent Termination Clearances

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or

death.

Inlet and outlet pipes may NOT be vented directly above each

other.

1. Determine termination locations based on clearances spe-

cified in following steps and as shown in Fig. 7, Fig. 8,

Fig. 19 through Fig. 27.

For "Concentric Termination Kit" clearances, see Fig. 28

through Fig. 33 in this manual. 1

2. For Single Pipe Installation refer to Fig. 8 for vent termin-

ation clearances.

3. For Direct Vent Installation refer to Fig. 7 for vent termin-

ation clearances.

V_ VENT TERMINAL

\ ..........: ...........

................. gS_24_JS-2

_WHERE _RMI_JOL _ NOT PE_D

C_earance to an o,_ts_ _

Oe_ra_ to _ taste

e_ m_,sr o__ser_ _u_ _m_

C_ to _os _ator _nt _

Ct_n_e _ nor_m_a_ _r S_y ini_to_jI1@ng 12 inches (30 cm) for applieances > 10,000 Btu h(3 kW) 9[rtc_-_ (_ cm) for _p]@_ >10,_ B_h (3_%_) and

and <._100,000 Btuh(3OkW), 36 inches (91 cm) for s 50,_ @u_h(15kW), i2 ir_es _._l_m_ for _m'_

_ppliances > 100,000 Btuh(3OkW) _"_000 _h (15_/V)

Fig. 7-Direct Vent Termination Clearance

A06675

[_ VENTTERMINAL _X_AIR SUPPLY INLET E_ AREAWHERE TERMINAL IS NOT PERMITED

Item Clearance Descriptions

A Clearance above grade, veranda, porch, deck, balcony, or

anticipated snow level

B Clearance to a window or door that may be opened

Clearance to a permanently closed window

Vertical clearance to a ventilated soffit located above the

terminal within a horizontal distance of 2'(61cm) from the

centerline of the terminal

Clearance to an unventilated soffit

Clearance to an outside corner

Clearance to an inside corner

Clearance to each side of the centerline extended above

electrical meter or gas service regulator assembly

Clearance to service regulator vent outlet

Clearance to non-mechanical air supply inlet to building or

the combustion air inlet to any other appliance

Clearance to a mechanical air supply inlet

Clearance under a veranda, porch, deck, or balcony

Canadian Installation (1)

12 inches (30cm) #

6 inches (15 cm) for appliances -< 10,000 Btuh (3 kW)

12 inches ( 30 cm) for appliances > 10,000 Btuh (3 kW0)

and -< 100,000 Btuh (30 kW), 36 inches (91 cm) for

appliances > 100,000 Btuh (30 kW)

3 feet (91 cm) within 15 feet(4.5 m) above the meter/regulator

assembly

3 feet (91 cm)

6 inches (15 cm) for appliances -<10,000 Btuh (3 kW)

12 inches ( 30 cm) for appliances > 10,000 Btuh (3 kW0)

and -<100,000 Btuh (30 kW)

36 inches (91 cm) for appliances > 100,000 Btuh (30 kW)

6 feet (1.83 m)

12 inches (30 cm) +

Clearance to each side of the centerline extended above or

below vent terminal of the furnace to a dryer or water heater

vent, or other appliance's direct vent intake or exhaust.

N Clearance to the vent terminal of a dryer vent, water heater

vent, or other appliances direct vent intake or exhaust.

O Clearance from a plumbing vent stack

p Clearance above paved sidewalk or paved 7 feet (2.13m)**

driveway located on public property

(1.) In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code

(2.) In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code

# 18" (46 cm) above roof surface

U.S. Installation (2)

12 inches (30 cm)

4 feet(1.2 m) below or to the side of the opening. 1 foot(30 cm',

above the opening.

3 feet (91 cm) within 15 feet (4.5 m) above the meter/regulator

assembly

4 feet (1.2 m) below or to the side of opening: 1 foot (30 cm)

above opening.

3 feet(91 cm) above if within 10 feet (3 m horizontally)

7 feet (2.13m)

+ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the floor.

For clearances not specified in ANSI Z223.1/NFPA 54 or CSA B 149.1, clearances shall be in accordance with local installation codes and the requirements of the gas supplier and the

Manufacturer's installation instructions.

** A vent shall not terminate above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings.

Notes:

1. The vent for this appliance shall not terminate

a. Over public walkways; or

b. Near soffit vents or crawl space vents or other areas where condensate or vapor could create a nusiance or hazard or property damage; or

c. Where condensate vapor could cause damage or could be detrimental to the operation of regulators, relief valves, or other equipment.

2. When locating vent terminations, consideration must be given to prevailing winds, location, and other conditions which may cause recirculation of the combustiob products of adjacent vents.

Recirculation can cause poor combustion, inlet condensate problems, and accelerated corrosion of the heat exchangers.

3 Avoid venting under a deck or large overhang. Recimulation could occur and cause performance or system problems.

Fig. 8 - Other than Direct Vent Termination Clearance

CondensateDrainTrap

This furnace removes both sensible and latent heat from the

products of combustion. Removal of the latent heat results in

condensation of the water vapor. The condensate is removed from

the furnace through the drains in the plastic transition and the

vent fitting. The drains connect to the externally mounted

condensate drain trap on the left or right side of the furnace.

The startup of a new furnace will involve a cycle or two of the

furnace to properly prime the condensate trap with water. Until

the trap is fully primed, some condensate will be pulled into the

combustion blower. The furnace may cycle on the pressure switch

connected to the plastic transition box due to condensate buildup.

After the trap is primed, the condensate will start draining from

the furnace. The combustion blower will clear out any remaining

condensate in the blower housing through the vent fitting

downstream of the blower. Note that the condensate trap can also

be primed by pouring water into the 1/2" drain hose. Remove

the1/2" ID drain hose from either the gutter or the white PVC tee

trap. Using a funnel pour eight (8) ounces of water into 1/2" ID

drain hose. Water will flow through the drain hose and into the

condensate drain trap. This will prime both the vent and the

transition sides of the trap. Reconnect the 1/2" ID drain hose to

the original component, either the gutter or the PVC tee trap.

The condensate drain trap supplied with the furnace MUST be

used. The drain connection on the condensate drain trap is sized

for 3/4" PVC or CPVC pipe, however alternate 1/2" CPVC

(nominal 5/8" O.D.) or vinyl tubing with a minimum inner

diameter (I.D.) of 5/8" may also be used, as allowed by local

codes. Alternate drain pipes and hoses may be used as allowed by

local codes.

The drain line must maintain a 1/4" (6.4 mm) per foot downward

slope toward the drain. 1/4" (6.4 mm) per foot is recommended.

Installation of an overflow line is recommended when the 1/4"

(6.4 mm) per foot slope to the condensate drain cannot be

maintained. A drain tube clip is included in the furnace to prevent

kinking/buckling of the drain tube. The clip should remain in the

furnace (between the door switch plate and the blower shelf, Fig.

9) during operation. See Fig. 17 for proper routing and

installation of the overflow.

DO NOT trap the drain line in any other location than at the

condensate drain trap supplied with the furnace.

FROZEN AND BURST WATER PIPE HAZARD

Failure to follow this caution may result in property damage.

If a condensate pump is installed, a plugged condensate drain

or a failed pump may cause the furnace to shut down. Do

not leave the home unattended during freezing weather

without turning off water supply and draining water pipes or

otherwise protecting against the risk of frozen pipes.

If possible, DO NOT route the drain line where it may freeze.

The drain line must terminate at an inside drain to prevent

freezing of the condensate and possible property damage.

1. A condensate sump pump MUST be used if required by

local codes, or if no indoor floor drain is available. The

condensate pump must be approved for use with acidic

condensate.

2. A plugged condensate drain line or a failed condensate

pump will allow condensate to spill. If the furnace is in-

stalled where a condensate spill could cause damage, it is

recommended that an auxiliary safety switch be installed

to prevent operation of the equipment in the event of pump

failure or plugged drain line. If used, an auxiliary safety

switch should be installed in the R circuit (low voltage)

ONLY.

3. If the auxiliary switch in the condensate pump is used, the

furnace may shut down due to a blocked condensate line

or failed pump. To prevent frozen water pipes see the

"Frozen Water Pipe Hazard" Installation Section of this

manual.

Drain Tube

Blower

Shelf Door

Switch

Representativedrawing only, some models mayvary in appearance.

A07705

Fig. 9 - Drain Tube Clip Location

CondensateDrainTrap Freeze Protection

Special precautions MUST be made if installing furnace in an

area which may drop below freezing. This can cause improper

operation or damage to the equipment. If the the furnace

environment has the potential of freezing, the drain trap and drain

line must be protected. Use 3 to 6 watt per foot at 115 volt, 40 ° F

(4.4 ° C) self-regulating shielded and waterproof heat tape. Wrap

the drain trap and drain line with the heat tape and secure with the

ties. Follow the heat tape manufacturer's recommendations.

Plastic Caps (2)

Yellowor black

VentDrain

&Clamps

Dual Pressure Switch Detail

Coupling&Clamps

(Optional)

DrainTee-.

DrainTube

Black Rubber ....

1/2" ID &Clamps

DrainTube

Corrugated5/8"ID.

& Clamps

DrainConnectorBlackPVC

3/4" PVCX 1/2" CPVC

(Loose parts bag)

CasingGrommet /

Black Rubber__/

5/8"ID i

(Loosepartsbag)

I-

,x,

_ _--On SomeModels

r- .........

m - ...... ONLY

ReliefTube

BlackRubber

i i 3/16"IO

i i

Single Pressure

i i Switc h

iStreetElbow

_i........1/2"cPvc

...... (Loosepartsbag)

\\ ) © o

\\\ , ,

DrainLineVentTee3/4" PVCor ",

1/2" CPVC(Fieldsupplied) DrainTubeBlackRubber5/8"ID &Clamps,

Cut length to fit (Loose parts bag)

Representative drawing only, some models may vary in appearance.

Fig. 10 -Upflow Installations Top Vent

25-24-80

A07706

Upflow Installations Top Vent (See Fig.

10)

•Remove knockout from the side of the furnace casing where

drain tube will exit.

• Install casing grommet (black rubber 5/8" ID grommet - in

loose parts bag)

• Install the 1/2" CPVC street elbow on discharge of trap

• Install the black PVC tube connector (3/4" PVC x 1/2" CPVC

from loose parts bag) as shown in the illustration above.

• Cut the black drain tube (5/8" ID - in loose parts bag) to length

to fit between trap and tube connector through grommet.

• Clamp both ends of the drain tube using clamps provided.

•Glue the CPVC street elbow to the trap using appropriate

cleaner and solvent cement.

• The field supplied 3/4" PVC or 1/2" CPVC drain line vent tee

must vent outside the furnace cabinet (see exploded view

above).

NOTE: It is recommended that all PVC piping and fitting

connections be fit up and inspected before final cementing. Trap

must be primed before operation. Verify all condensate drain

connections are securely clamped. A coupling and clamps (in

loose part bag) may be installed as shown for future servicing of

the vent system.

NOTE: "PVC" is used as a generic term. Pipe and fitting

materials used must be acceptable to the local code officials

having jurisdiction.

Plastic Cap

Yellow or black

Coupling& Clamps

(Optional)..... .

VentDrain Either:The PVC

&Clamps DrainTeeora field

supplied2"PVCTee ,,x,

DrainConnectorBlackPVC

3/4" PVCX 1/2" CPVC

(Loosepartsbag),

J \

CasingGrommet /\\

BlackRubber \

518"ID _ _ /

(Loosepartsbag)

DrainTube

Corrugated

518"ID &Clamps

2"PVCCoupling

f-- \_J

...................On SomeModels

ONLY

i{......

--- ....... _--- \

DrainLineVentTee3/4"PVCor1/2"CPVC(Fieldsupplied)

Representative drawing only, some models may vary in appearance.

i i

)i i

Switch

Fig. 11 -Upflow Installations Vent through Left Side

;: i be angled5°to 10° also.

25-24-81

A07707

Upflow Installations Vent through Left

Side (See Fig. 11)

•Remove drain tee from inducer discharge and remove black

drain tube (1/2" 1D) from bottom of drain tee.

•Install Vent Pipe grommet in side of casing.

• Cut an appropriate length of 2" PVC pipe long enough to exit

the cabinet and connect the vent drain to either:

-- A standard field supplied 2" PVC tee, or

-- A 2" PVC coupling fastened onto the drain tee.

• Install tee trap into bottom of tee.

• Remove knockout from the side of the furnace casing where

drain tube will exit.

• Install the 1/2" CPVC street elbow on discharge of trap

• Install the black PVC drain connector (3/4" PVC x 1/2" CPVC

from loose parts bag) as shown in the illustration above.

• Cut the black drain tube (5/8" ID - in loose parts bag) to length

to fit between trap and tube connector through grommet.

• Clamp both ends of the drain tube using clamps provided.

•Glue the CPVC street elbow to the trap using appropriate

cleaner and solvent cement.

• Connect the tee trap and the main drain line exiting the casing

as shown in Fig. 17.

NOTE: It is recommended that all PVC piping and fitting

connections be fit up and inspected before final cementing. Both

the internal trap and the external tee trap must be primed

before operation. Verify all condensate drain connections are

securely clamped. A coupling and clamps (in loose part bag) may

be installed as shown for future servicing of the vent system.

Plastic Cap _'_

Yellow or black

VentDrain

&Clamps

Dual

Pressure Switch

DrainTube

Corrugated

5/8"ID& Clamps.

SIDE VIEW

5° to10°

be angled 5° to 10° also.

A07708

Fig. 12 -All Models Vent Through Right Side

All Models Vent through Right Side (See

Fig. 12)

•Disconnect the black drain tube between the drain vent and the

trap.

• Rotate the inducer 180 ° for a right side vent after loosening the

4 inducer attachment screws. Reinstall and retighten the

inducer screws to 20" pounds torque.

• Using the _/2" OD barbed coupling in the loose parts bag

connect together with the 2 short 1/2" ID elbow tubes and

connect the lower discharge port of the vent drain to the trap.

Secure all connections with clamps.

• Install the vent pipe grommet into the casing

• Cut an appropriate length of 2" PVC pipe long enough to exit

the cabinet and connect the vent drain to either:

-- A standard field supplied 2" PVC tee, or

-- A 2" PVC coupling fastened onto the drain tee.

• Install tee trap into bottom section of tee.

• Remove knockout from the side of the furnace casing where

drain tube will exit.

•Install casing grommet (black rubber 5/8" ID grommet - in

loose parts bag)

• Install the _/2" CPVC street elbow on discharge of trap

• Install the black PVC tube connector (3/4" PVC x _/2" CPVC

from loose parts bag) as shown in the illustration above

• Cut the black drain tube (5/s" ID - in loose parts bag) to length

to fit between trap and tube connector through grommet.

• Clamp both ends of the drain tube using clamps provided.

• Glue the CPVC street elbow to the trap using appropriate

cleaner and solvent cement.

• Connect the tee trap and the main drain line exiting the casing

as shown in Fig. 17.

• Note: It is recommended that all PVC piping and fitting

connections be fit up and inspected before final cementing.

Both the internal trap and the external tee trap must be primed

before operation. Verify all condensate drain connections are

securely clamped. A coupling and clamps (in loose part bag)

may be installed as shown for future servicing of the vent

system.

Vent Drain

&Clamps Plastic Caps

Alternate Orientation

Single Pressure Switch Detail

TrapConnection

Preassemble&

insertinto furnace

Dual Pressure Switch

ReliefTube

BlackRubber

3/ ,,

....... 16 ID

Field

SuppliedTee

jFlexibleTubingConnector

3/16"OD (LoosePartsBag)

ReliefTube Extension

i ..J BlackRubber3/16" ID

,_ ....... Cut to Fit (LoosePartsBag)

TeeTrapWhitePVC

(loosepartsbag)

Coupling& Clamps /

(Optional) /

CapandClamp

OpenEnd

RemoveKO before

mountingTrap

DrainTube

Black Rubber

1/2" ID &Clamps

DrainTubeCorrugated5/8"ID &Clamps

Cut at straightsection

\ i

'\\

_'_ _ Cut Here

...... Leaveroomfor clamp

Representative drawing only, some models may vary in appearance.

Fig. 13 -Horizontal Left through Top

A07709

Horizontal Left through Top (See Fig. 13)

•Disconnect the hoses from the trap assembly, and remove trap

and trap mounting bracket from the blower compartment.

Using cover plate and gasket provided in the loose parts bag,

cover the hole from the burner compartment to the blower

compartment and secure with screws.

• Remove knockout from the side of the furnace casing where

drain tube will exit.

• Mount the trap externally to the bottom side of the unit using

the 2 screws provided in the location shown.

• Cut the corrugated tube as shown in the illustration above.

Connect the corrugated hose from the transition to the trap.

Secure connections with clamps.

• Remove the black 1/2" ID drain tube from the drain tee. Install

a yellow cap and clamp over the open drain port of the drain

tee.

• Connect the black 1/2" ID drain tube from the Vent Drain to the

trap. Secure connections with clamps.

• Connect the 3/16" ID relief tube to the middle port on the trap.

If an extension is required, use the 3/16" OD flexible tubing

connector and the black 3/16" ID relief tube in the loose parts

bag. Cut tube to length. Secure all connections with clamps.

• Cut an appropriate length of 2" PVC pipe, long enough to exit

the cabinet and connect the vent drain to either:

-- A standard field supplied 2" PVC tee, or

-- A 2" PVC coupling fastened onto the drain tee.

• Install tee trap into bottom section of tee.

• Connect the tee trap and the main drain line exiting the casing

as shown in Fig. 17.

NOTE: It is recommended that all PVC piping and fitting

connections be fit up and inspected before final cementing. Both

the external trap and the external tee trap must be primed

before operation. Verify all condensate drain connections are

securely clamped. A coupling and clamps (in loose part bag) may

be installed as shown for future servicing of the vent system.

Alternate Orientation

Field

Single Pressure Switch Detail

Yellowor black

Plasticcap

Vent Drain

TeeTrapWhite PVC/_/

(loosepartsbag) _ :'

On e sm;.

ElbowTube BlackRubber

&Clamps

(LoosePartsBag)

BarbedCoupling

1/2" OD (LooseParts Bag)

DrainTubeBlackRubber

1/2" ID& Clamps

FlexibleTubingt_onnector

3/16" OD (LoosePartsBag)

ReliefTubeExtension

BlackRubber3/16" ID Cutto Fit

(LoosePartsBag)

WARNING

zMove Capsto top of trap

DrainTubeBlack,5/a"IDCorrugated

Cut at stralghtsection

Leaveroomfor clamp "Cut Here

Representativedrawingonly,somemodelsmayvary inappearance.

Fig. 14 -Horizontal Left-Side Vent

25-24-88

A07710

Horizontal Left-Side Vent (See Fig. 14)

• Remove the drain tee from the Vent Drain if installed.

• Rotate the inducer 180 ° for a side vent after loosening the 4

inducer attachment screws. Reinstall and retighten the inducer

screws to 20" pounds torque.

• Disconnect the hoses from the trap assembly, and remove trap

and trap mounting bracket from the blower compartment.

Using cover plate and gasket provided in the loose parts bag,

cover the hole from the burner compartment to the blower

compartment and secure with screws.

• Remove knockout from the side of the furnace casing where

drain tube will exit.

• Mount the trap externally to the bottom side of the unit using

the 2 screws provided in the location shown.

• Cut the corrugated tube as shown in the illustration above.

Connect the corrugated hose from the transition to the trap.

Secure connections with clamps.

• Connect the black 1/2" ID drain tube from the Vent Drain to the

trap. If an extension is required, use the black 1/2" OD flexible

tubing connector and the black 1/2" ID drain tube in the loose

parts bag. Cut tube to length. Secure connections with clamps.

• Connect the 3/16" ID relief tube to the middle port on the trap.

If an extension is required, use the 3/16"OD flexible tubing

connector and the black 3/16" ID relief tube in the loose parts

bag. Cut tube to length.

• Cut an appropriate length of 2" PVC pipe, fittings and

extension pipe long enough to exit the cabinet and connect the

vent drain to either:

-- A standard field supplied 2" PVC tee, or

-- A 2" PVC coupling fastened onto the drain tee.

• Install tee trap into bottom section of tee.

• Important: The pipe to the tee trap must be level or sloping

towards the tee trap

• Connect the tee trap and the main drain line exiting the casing

as shown in Fig. 17.

NOTE: It is recommended that all PVC piping and fitting

connections be fit up and inspected before final cementing. Both

the external trap and the external tee trap must be primed before

operation. Verify all condensate drain connections are securely

clamped. A coupling and clamps (in loose part bag) may be

installed as shown for future servicing of the vent system.

TrapConnection

"Clampears"

PointedOUT

Preassemble

insertintofurnace

Single Pressure Switch Detail

ReliefTubeRubberTube \ i

3/16"ID _

FlexibleTubingConnector

3/16"OD (LoosePartsBag) i

ReliefTube Extension

BlackRubber3/16" ID i_

Cut to Fit (LoosePartsBag)

Coupling& Clamps

(Optional),

\\\\\\

WARNING \,

Add Capand \,

Clamp "

Dual Pressure Switch

DrainTubeCorrugated5/8"ID&Clamps/

Plastic Cap

Yellow or black

Alternate Orienta-

I--i

_i Field

VentDrain <:Cj SuppliedTee

&Clamps ,,I,- i /

Xiii_TeeTrap

'J White PVC

\ i

ElbowTubeBlackRubber 1/2"

ID& Clamps(LoosePartsBag)

On SomeModels

ONLY

BarbedCoupling1/2"OD

_-.. (LoosePartsBag)

DrainTubeBlackRubber

1/2"ID &Clamps

Leaveroomfor clamp "Cut Here

Representativedrawingonly,somemodelsmayvaryinappearance.

Fig. 15 -Horizontal Right through Top

A07711

Horizontal Right through Top (See Fig.

15)

•Disconnect the hoses from the trap assembly, and remove trap

and trap mounting bracket from the blower compartment.

Using cover plate and gasket provided in the loose parts bag,

cover the hole from the burner compartment to the blower

compartment and secure with screws.

•Remove knockout from the side of the furnace casing where

drain tube will exit.

• Mount the trap externally to the bottom side of the unit using

the 2 screws provided in the location shown.

• Cut the corrugated tube as shown in the illustration above.

Connect the corrugated hose from the transition to the trap.

Secure connections with clamps.

• Connect the black 1/2" ID drain tube from the Vent Drain to

the trap. If an extension is required, use the black 1/2" OD

barbed coupling and the black 1/2" ID drain tube in the loose

parts bag. Cut tube to length. Secure connections with clamps.

• Connect the 3/16" ID relief tube to the middle port on the trap.

If an extension is required, use the clear 3/16" OD flexible

tubing connector and the black 3/16" ID relief tube in the loose

parts bag. Cut tube to length.

• Cut an appropriate length of 2" PVC pipe, fittings and

extension pipe long enough to exit the cabinet and connect the

vent drain to a standard field supplied 2" PVC tee

• Install tee trap into bottom section of tee.

• Connect the tee trap and the main drain line exiting the casing

as shown in Fig. 17.

NOTE: It is recommended that all PVC piping and fitting

connections be fit up and inspected before final cementing. Both

the external trap and the external tee trap must be primed before

operation. Verify all condensate drain connections are securely

clamped. A coupling and clamps (in loose part bag) may be

installed as shown for future servicing of the vent system.

Plastic Cap

Yellowor black

_'i -- _'

'i,_ ...... ;ingle Press:ureSwitch Detail

Vent Drain

& Clamps

Level or Sloped

towards Tee

ReliefTube BlackRubbt

3/16"ID _ _

FlexibleTubingConnector ..........

3/16" OD (LoosePartsBag)

ReliefTubeExtension.... -J---

BlackRubber3/16" ID

Cutto Fit(LoosePartsBag)

Dual Pressure Switch

DrainTubeCorrugated,5/8"ID& Clamps

Cut at straightsection

Leaveroomfor clamp Cut Here

DrainTube

BlackRubber

1/2"ID& Clamps

Representativedrawingonly,somemodelsmayvary inappearance.

Fig. 16 -Horizontal Right Side Vent

_Coupling& Clamps

ptional)

<:: Field

/Supplied Tee

/TeeTrap

:::::::::::__ WhitePVC

_-(loosepartsbag)

-Elbow Tube

BlackRubber

1/2"ID &Clamps

(LoosePartsBag)

On SomeModels

/ONLY

INLET _

Alternate Orientation

\'BarbedCoupling1/2" OD

(LoosePartsBag)

A07712

Horizontal Right Side Vent (See Fig. 16)

•Disconnect drain tee if installed

• Disconnect the hoses from the trap assembly, and remove trap

and trap mounting bracket from the blower compartment.

Using cover plate and gasket provided in the loose parts bag,

cover the hole from the burner compartment to the blower

compartment and secure with screws.

• Remove knockout from the side of the furnace casing where

drain tube will exit.

• Mount the trap externally to the bottom side of the unit using

the 2 screws provided in the location shown.

• Cut the corrugated tube as shown in the illustration above.

Connect the corrugated hose from the transition to the trap.

Secure connections with clamps.

• Connect the black 1/2" ID drain tube from the Vent Drain to the

trap. If an extension is required, use the 1/2" OD barbed

coupling and the black 1/2" ID drain tube in the loose parts bag.

Cut tube to length. Secure connections with clamps.

• Connect the 3/16" ID relief tube to the middle port on the trap.

If an extension is required, use the clear 3/16"OD splice

connector and the black 3/16" ID relief tube in the loose parts

bag. Cut tube to length.

• Cut an appropriate length of 2" PVC pipe, fittings and

extension pipe long enough to exit the cabinet and connect the

vent drain to either:

-- A standard field supplied 2" PVC tee, or

-- A 2" PVC coupling fastened onto the drain tee.

• Install tee trap into bottom section of tee.

• Important: The pipe to the tee trap must be level or sloping

towards the tee trap.

• Connect the tee trap and the main drain line exiting the casing

as shown in Fig. 17.

NOTE: It is recommended that all PVC piping and fitting

connections be fit up and inspected before final cementing. Both

the external trap and the external tee trap must be primed

beforeoperation.Verifyallcondensatedrainconnectionsare

securelyclamped.Acouplingandclamps(inloosepartbag)may

beinstalledasshownforfutureservicingof the vent system.

4/,,

ConnectingVent and Combustion Air Piping

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or

death.

Cement or mechanically seal all joints, fittings, etc. to prevent

leakage of flue gasses.

[

Tee Trap

Evaporator

Coil

Drain Line

(Optional)

/) " J

Condensate

Trap

Representativedrawingonly,somemodelsmayvaryin appearance,

A07713

Fig. 17 -Connecting Tee Trap to Condensate Trap and Main

Drain Line

The tee trap must be connected to the main condensate drain line

as conceptually shown above. Different installations may require

slightly different orientations. The following steps apply to all

installations.

1. The tee trap should be installed as close to the side or top

of the furnace as practical. Minimize the distance between

the inducer and the tee trap as much as possible.

2. An open tee is to be used at the tee trap discharge. The top

end of the tee should be open to the atmosphere to elimin-

ate potential air lock problems.

3. The drain line from the tee trap is to be connected to the

furnace condensate trap drain line as shown above.

4. Condensate drain lines from a cooling coil may be connec-

ted downstream of the connection point of the tee trap and

furnace condensate trap.

IMPORTANT: Prime both traps with water before operation.

Failure to prime the traps may result in discharge of flue gases

from the condensate drain line and open tee for aperiod of time,

and may result in temporary lockout of the furnace upon start up.

Main drain line construction is left to the discretion of the

installer. It may be made of either rigid pipe or flexible tube.

Tube ID should NOT be less than 1/2,,.

Refer to Fig. 10 through Fig. 16 that corresponds to the

installation position of the furnace for the application.

Preassemble the vent and combustion air piping from the furnace

to the vent termination. Do not cement the pipe joints until the

pipe preassembly process is complete.

Combustion Air Pipe Connection (Dual Certified or

Direct Vent)

Install the air intake coupling and gasket to the furnace with the

four(4) screws:

NOTE: The air intake coupling and gasket can be installed to the

top panel, or to the alternate air intake locations on either the left

or right side panels of the furnace.

For installation in the alternate air intake location on either the

left or right side panels, remove the 3" knockout from the side

panel and relocate to the air intake hole in the top panel. Use four

(4) screws to seal the four (4) mounting holes in the top panel

next to the hole plug. Drill four (4) 7/64" diameter holes in the

casing using the air intake coupling as the template.

The air intake coupling is sized for 2" PVC pipe.

Install the combustion air pipe to the air intake coupling using

RTV sealant to provide for future serviceability.

Vent Pipe Connection

Install the vent pipe grommet to the furnace panel. Locate the

grommet in the furnace panel at a location directly away from the

vent fitting on the combustion blower. The grommet snaps into

the 3" hole on the furnace panel. NOTE: Depending on the

installation position, the vent pipe grommet will be installed to

the top panel or to the alternate location on the side panels. If

needed, remove the 3" hole plug from the loose parts bag and

relocate to the open hole in the furnace panel. (See Fig. 10 or Fig.

17)

Install the vent pipe to the rubber coupling, the vent fitting or the

PVC vent extension pipe. Securely attach using the clamp or

PVC cement as required.

NOTE: The vent fitting MUST be installed with the air flow

marking arrow pointed toward the vent pipe. (See Fig. 18

Some installations require the vent fitting to be installed with

a 5 ° to 10 ° downward slope. (See Fig. 10 through Fig. 17)

RubberCoupling J ._ VentPipe

&Clamps - _ (Top PanelExit)

.. _,_,-_ NOTE: The 90 ° elbow is approved

v_P_pe ....."_ for use inside the furnace ONLY.

_l_Vent Fitting

& Clamps

Combustion

Blower

Tee

Exit) _b/-_L_ IPipe(SidePanel _'y_

Vent i

SIDE VIEW (

_ i-'qr R-otatedownward '/\

:>, 5° to 10°

.!iv )

NOTE:Built-inchannelwillbeangled5° to 10° als0.

A07714

Fig. 18 - Proper Sealing Procedure for Combustion Blower

Joining Pipe and Fittings

SEE VENT AND COMBUSTION AIR PIPING, vent and

Combustion Air Piping Guidelines in this manual for applicable

ASTM Standards for vent materials.

primer to inside surface of socket and outside of pipe. Do

NOT allow primer to dry before applying cement.

3. Apply a thin coat of cement evenly in the socket. Quickly

apply a heavy coat of cement to the pipe end and insert

pipe into fittings with a slight twisting movement until it

bottoms out.

NOTE: Cement MUST be fluid while inserting pipe. If NOT,

recoat pipe.

4. Hold the pipe in the fitting for 30 seconds to prevent the

tapered socket from pushing the pipe out of the fitting.

5. Wipe all excess cement from the joint with a rag. Allow 15

minutes before handling. Cure time varies according to fit,

temperature and humidity.

ConnectingVent Pipesand Termination

(Direct Vent)

NOTE: For direct vent applications, combustion air intake and

vent MUST terminate in the same atmospheric pressure zone. If

installation is in a cold climate (sustained temperatures 0°F

(-17.8°C)and below for 24 or more consecutive hours), increase

the minimum distance between vent pipe and air intake from 8"

to 18" (203.2 to 457.2 mm).

6. Install all couplings, nipples and elbows using proper pro-

cedures for Joining Pipe and Fittings and maintain spa-

cing between vent and combustion air piping as indicated

in Fig. 19 through Fig. 27.

MIN. "18"Minimumfor coldclimates

(sustainedtemperatures0° F

andbelowfor 24ormorecon-

secutivehours)

FIRE HAZARD

Failure to follow this warning could result in personal injury,

death, and/or property damage.

Obselve all cautions and warnings printed on material

containers.

Provide adequate ventilation and do NOT assemble near heat

source or open flame. Do NOT smoke while using solvent

cements and avoid contact with skin or eyes.

_:::_INLET

iiiiiiiiif M_N.

FF GRADE LEVEL

SNOW LEVEL

25-00-05F

A07715

Fig. 19 - Sidewall Termination 12" (304.8 mm) or More

Above Snow Level or Grade Level

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or

death.

Do NOT use solvent cement that has become curdled, lumpy

or thickened and do NOT thin. Observe precautions printed

on containers. For applications below 32°F (0°C), use only

low temperature type solvent cement. Poor joints may lead to

disconnected or leaking vent pipe joints allowing carbon

monoxide to enter the living space.

1. Cut pipe end square, remove ragged edges and burrs.

Chamfer end of pipe, then clean fitting, socket and pipe

joint of all dirt, grease, or moisture.

NOTE: Stir the solvent cement frequently while using. Use a

natural bristle brush or the dauber supplied with the cement. The

proper brush size is one inch.

2. After checking pipe and socket for proper fit, wipe socket

and pipe with cleaner-primer. Apply a liberal coat of

HorizontalTermination

1. Cut two holes. 21/2" for 2" pipe, 3" for 21/2" pipe, or 31/2"

for 3" pipe. Do NOT make the holes oversized, or it will

be necessary to add a sheet metal or plywood plate on the

outside with the correct size hole in it.

2. Check hole sizes by making sure it is smaller than the

couplings or elbows that will be installed on the outside.

The couplings or elbows MUST prevent the pipe from be-

ing pushed back through the wall.

3. Extend vent pipe and combustion air pipe through the wall

3/4" to 1" and seal area between pipe and wall.

4. Install the couplings, nipple and termination elbows as

shown and maintain spacing between vent and combustion

air piping as indicated in Fig. 19 and Fig. 20.

A metal shield is recommended 18" x 18" min. or 18" (457.2

mm) min. diameter around the vent termination at the exterior

wall to protect the house exterior materials from flue product or

condensation (freezing) damage.

'18" Minimum for cold climates

(sustained temperatures 0° F and be-

low for 24 or more consecutive hours}

A07716

Fig. 20 -Sidewall Termination with Exterior Risers to Get

Above Snow Level or Grade Level

VerticalTermination

1. Fig. 21 shows the proper installation and clearances for

vertical vent termination. The vertical roof termination

should be sealed with a plumbing roof boot or equivalent

flashing. The inlet of the intake pipe and end of the ex-

haust vent must be terminated no less than 12" (304.8 mm)

above the roof or snow accumulation level, and 12" (304.8

mm) away from a vertical wall or other protrusion.

2. If the vent system is installed in an existing chimney make

sure clearances shown in Fig. 21 are maintained. Horizont-

al section before the termination elbow can be extended on

the inlet air to provide necessary clearance.

MultiVent TerminationClearances

When two (2) or more furnaces are vented near each other, each

furnace must be individually vented.

Two (2) vent terminations may be installed as shown in Fig. 22,

23, 24, 25, 26 and 27, but the next vent termination must be at

least 36" away from first 2 terminations. It is important that vent

terminations be made as shown to avoid recirculation of flue

gases.

Using ExteriorRisers

1. Install elbows and pipe to form riser as shown in Fig. 20.

2. Secure vent pipe to wall with galvanized strap or other rust

resistant material to restrain pipe from moving.

3. Insulate pipe with Armaflex or equivalent moisture resist-

ant closed cell foam insulation or fiberglass insulation if

boxed in and sealed against moisture.

VentTerminationShielding

Under certain wind conditions some building materials may be

affected by flue products expelled in close proximity to

unprotected surfaces. Sealing or shielding of the exposed surfaces

with a corrosion resistant material (such as aluminum sheeting)

may be required to prevent staining or deterioration. The

protective material should be attached and sealed (if necessary) to

the building before attaching the vent terminal.

A= 12" Above roof or snow accumulation level

B= 8" Min., 20' Maximum, except in areas with extreme cold temperatures (sustained

temperatures 0°F and below for 24 or more consecutive hours), then 18" Min.

A07717

Fig. 21 -Rooftop Termination

12" Min. Grade )

or Snow Level ' .............

Combustion

Air

A07718

Fig. 22 -Concentric Vent and Combustion-Air

Roof Termination

"A"

.............. Exhaust

Vent 25-22-02d

Dimension "A" is touching or 2" maximum separation.

A07695

Fig. 23 -Concentric Vent and Combustion Air

Sidewall Termination

.--J" j ....

20'Max._................ "................

.... .-o

! 18" Min.for

_ColdClimates

(Sustainedtemperatures0° F

.J andbelowfor 24 or morecon-

12" Min.Gradeor J

SnowLevel J -j" secutivehours)

..... "Dimension "A" is touching or 2" maximum separation.

A07696

Fig. 24 - Sidewall Inlet Vent and Exhaust-Air Termination

18"Min. for Cold Climates

(SustainedtemperaturesO° F

andbelowfor 24or morecon-

secutivehours) 8" Min.

12" Min.

Gradeor

Snow Level

/'A" j/

"A"

Dimension "A" is touching or 2" maximum separation.

A07697

Fig. 25 - Sidewall Inlet Vent and Exhaust-Air Termination

with Exterior Risers

18" Min. for Cold Climates

J(Sustained temperatures

0° F and below for 24 or

more consecutive hours)

'\ \ '_

12" Min.

Level

Inlet

A07698

Fig. 26 - Rooftop Inlet Vent and Exhaust-Air Termination

X: ............. zz:::: : ..........

OVERHANG

EXHAUST 12" MIN.

.......... _ ......... _ --l_,, MiN: Gt0und Level

..................... ......... _--.. _ OR Snow Level

FRONT VIEW

SameJoist

Space

SIDE VIEW

Fig. 27 -Recommended Alternate Installation

for Sustained Cold Weather

(0°F &below for 24 or more consecutive hours)

A07699

CONCENTRICTERMINATION

VentTerminationClearances

CARBON MONOXIDE POISONING, FIRE AND

EXPLOSION HAZARD

Failure to follow this warning could result in personal injury,

death, or property damage.

Inlet and outlet pipes may NOT be vented directly above each

other (standard vent terminals).

1. Determine termination locations based on clearances spe-

cified in following steps and as shown in Fig• 7, Fig• 28

through Fig• 33.

2. The vent termination must be located at least 12" (304.8

mm) above ground or normally expected snow accumula-

tion levels.

3. Do NOT terminate over public walkways. Avoid areas

where condensate may cause problems such as above

planters, patios, or adjacent to windows where steam may

cause fogging.

4. The vent termination shall be located at least 4' (1.2 M)ho-

rizontally from any electric meter, gas meter, gas regulator,

and any relief equipment. These distances apply ONLY to

U.S. installations.

5. The vent termination is to be located at least 3' (•91 M)

above any forced air inlet located within 10' (3.1 M); (3.1

M) and at least 10' (3.1 M) from a combustion air intake of

another appliance, except another direct vent furnace in-

take.

6. In Canada, the Canadian Fuel Gas Code takes precedence

over the preceding termination instructions.

ConcentricVentTermination- Kit#

KGAVT0601CVT& KGAVT051CVT

These kits are for vertical or horizontal termination of the

combustion air inlet and the exhaust vent pipes on Category IV

gas-fired condensing furnaces. The KGAVT0601CVT kit can be

used for 3" diameter pipe systems. The KGAVT0501CVT kit can

be used for 2" diameter pipe system. Refer to Table 4 for the

correct pipe size for the furnace. Both the combustion air inlet

and the exhaust vent pipes must attach to the termination kit. The

termination kit must terminate outside the structure and must be

installed per the instructions outlined below for vertical or

horizontal termination. Vertical termination is preferred. Field

supplied pipe and fittings are required to complete the

installation.

Vertical& HorizontalTermination

Determine the pipe diameters required for the installation

from Table 4 and Fig. 30.

Determine the best location for the termination kit. See

Fig. 29 for vertical termination or Fig. 33 for horizontal

termination. Roof termination is preferred since it is less

susceptible to damage, has reduced intake contaminants

and less visible vent vapor. For side wall termination, con-

sideration should be given to: 1) possible damage from the

vapors to plants/shrubs, other equipment and building ma-

terials, 2) possible damage to the terminal from foreign ob-

jects, 3) wind effects that may cause recirculation of flue

products, debris or light snow and 4) visible vent vapor.

3. Cut one 5" diameter hole through the structure for the

KGAVT0601CVT Kit or one 4" diameter hole for the

KGAVT0501CVT Kit.

Kit Contents:

3" Rain Cap or 2" Rain Cap

3" Diameter SDR-26 Pipe, 191/2" Long or

4" Diameter SDR-26 Pipe, 24" Long,

2" Diameter SDR-26 Pipe, 315/8 " Long or

21/2'' Diameter SDR-26 Pipe, 371/8 '' Long,

3" Y Concentric Fitting or 2" Y Concentric Fitting

Nominal3"or4" Dia.

,_ SDR-26Pipe

•2or 2112" Dia.

Y ConcentricFitting SDR-26Pipe

Fig. 28 - Kit Components

2"or3"Dia.

RainCap

A07719

Vent _

Combustion

Air ,,

Roof Boot/

Flashing

(Field Supplied)'

i Maintain 12" min. clearance above

///_ ofhighest24"aboveanticipatedroof,snow level• Max.

45° Elbow

,Ak/(Field Supplied)

Vent, i_Combustion

,_J Air

Note:

Support must be field installed to secure termination kit to structure•

Fig. 29 - Concentric Vent Roof Installation

A07720

4. Dimension D may be lengthened to 60" (1524 mm) max•

or shortened by cutting the pipes to 12" (304.8 mm) min•

Dimension A will change according to D dimension. (See

Fig. 30).

5. Partially assemble the concentric vent termination kit.

Clean and cement the parts using the procedures for Join-

ing Pipe and Fittings section of the manual. A) Cement the

Y Concentric fitting to the longest of the two straight kit

pipes. (See Fig. 28) B) Cement the rain cap to the shortest

of the straight kit parts. (See Fig. 28).

NOTE: A field supplied stainless steel screw may be used to

secure the rain cap to the pipe instead of cementing when field

disassembly is desired for cleaning (See Fig. 31).

11/2"

., i- V0,ntake,@s

Model A* B C D**

KGAVTO601CVT 387/8 3 41/2 211/8

KGAVTO5Ol CVT 333/8 2 31/2 165/8

* = Dimension will change accordingly as dimension D is lengthened

or shortened.

**= Dimension D may be lengthened to 60" may also be shortened by

cutting the pipes provided in the kit to 12" minimum.

A07721

Fig. 30 - Concentric Vent Dimensional Drawing

Concentric Termination Kit KGAVT0801CVT &

KGAVT0701CVT Venting Table for

PG9YAA Models

60,000 Btuh Furnaces

KGAVT0701CVT -35' & (4) 90 ° elbows with 2" PVC pipe or

KGAVT0801OVT - 65' & (4) 90 ° elbows with 3" PVC pipe

80,000 Btuh Furnace

KGAVT0701QVT - 35' & (4) 90 ° elbows with 2" PVC pipe or

KGAVT0801OVT - 35' & (4) 90 ° elbows with 3" PVC pipe

100,000 Btuh Furnace

KGAVT0701CVT -25' & (3) 90 ° elbows with 2" PVC pipe or

KGAVT0801OVT - 35' & (4) 90 ° elbows with 3" PVC pipe

1. Do not include the field supplied 45 ° elbow in the total el-

bow count,

2. If more elbows are required, reduce the length of both the

inlet and the exhaust pipes five feet for each additional elbow

used,

3, Elbows are DWV long radius type for 2" and 3" vents,

NOTE: Feet of pipe is whichever pipe run is the longest,

either inlet or outlet side,

Table 4-Concentric Termination Kit

If assembly needs to be extended to meet height or side wall

thickness requirement, the two pipes supplied in the kit may be

replaced by using the same diameter solid, single (no coupling

connections) field supplied SDR-26 PVC (ASTM D2241) pipes.

Do not extend dimension D more than 60". (See Fig. 30).

Do not use field supplied couplings to extend the pipes.

Airflow restriction will occur and the furnace pressure switch

may cause intermittent operation.

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or

death.

When using the alternate screw assembly method, drill a

clearance hole in the rain cap and a pilot hole in the vent pipe

for the screw size being used. Failure to drill adequate holes

may cause cracking of the PVC components, allowing flue

gasses to be recirculated.

Drill clearance hole in rain

cap and pilot hole in vent pipe.

_oel screw

(Field supplied)

Fig. 31 - Rain Cap to Vent Pipe Assembly

A07722

6. Install the Y concentric fitting and the pipe assembly

through the structure's hole. For vertical termination, in-

stall the parts through the field supplied roof boot/flashing.

NOTE: Do not allow insulation or other materials to accumulate

inside the pipe assembly when installing through the structure's

hole.

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or

death.

Do not operate the furnace with the rain cap removed as

recirculating of the flue gasses may occur. Water may also

collect inside the larger combustion air pipe and flow to the

burner enclosure.

7. Secure the assembly to the structure as shown in Fig. 29 or

Fig. 33 using field supplied metal strapping or equivalent

material.

NOTE: Ensure the termination height is above the roof surface

or anticipated snow level as shown in Fig. 29 for vertical

termination. Ensure the termination location clearance

dimensions are as shown in Fig. 32 and Fig. 33 for horizontal

termination.

8. Install the rain cap and the small diameter pipe assembly

in the Y concentric fitting and the large pipe assembly.

Ensure that the small diameter pipe is bottomed out and

securely cemented in the Y concentric fitting.

_\ Roof Overhang

Maintain12" clearanceabove highestantici-

pated snowlevel or grade whicheveris greater.

A07736

Fig. 32 -Concentric Vent and Combustion-Air

Side Termination

9. Cement the furnace combustion air and vent pipes to the

concentric vent termination assembly. See Fig. 32 or Fig.

33 for proper pipe attachment.

10.Operatethe furnace through one heat cycle to ensure com-

bustion air and vent pipes are properly connected to the

concentric termination connections.

GASSUPPLYANDPIPING

FIRE AND EXPLOSION HAZARD

Failure to follow this warning could result in personal injury,

death, and/or property damage.

Models designated for Natural Gas are to be used with Natural

Gas ONLY, unless properly converted to use with Propane gas.

NOTE: The rating plate is stamped with the model number, gas

type and gas input rating. In addition, models manufactured for

sale in Canada have orifice size information stamped on the

rating plate.

Gas Supply Requirements

Gas supply pressure should be within minimum and maximum

values listed on rating plate. Pressures are usually set by gas

suppliers.

(See Propane Gas Conversion Kit instruction manual for furnaces

converted to Propane gas)

•Use only the Type of gas approved for this furnace. See rating

plate for approved gas type.

• A 1/8" NPT plugged tapping, accessible for a test gauge

connection,must be installed immediately upstream of the gas

supply connection to furnace.

•Gas supply pressure should be within minimum and maximum

values listed on rating plate. Pressures are usually set by gas

suppliers.

•Gas input must not exceed the rated input shown on the rating

plate. Overfiring will result in failure of heat exchanger and

cause dangerous operation.

• Do not allow minimum supply pressure to vary downward.

Doing so will decrease input to furnace. Refer to Table 5 for

Gas supply. Refer to Table 6 or Table 7 for manifold pressures.

Vent

Strap

(FieldSuppli_) AirC°mbusti°n

Vent

1" max,

Air 45°Elbow

(FieldSupplied)

Note:

Securingstrapmustbefieldinstalledto preventmovementofterminationkitinsidewall.

A07723

Fig. 33 -Concentric Vent Sidewall Attachment

Supply Pressure

Gas Type

Natural

Propane

Recommended Max.

7" 14"

11" 14"

Min.

4.5"

11"

Table 5 - Gas Pressures

Gas PipingRequirements

NOTE: The gas supply line must be installed by a qualified

service technician in accordance with all building codes.

NOTE: In the state of Massachusetts.

a. Gas supply connections MUST be performed by a li-

censed plumber or gas fitter.

b. When flexible connectors are used, the maximum

length shall not exceed 36"(914.4 mm).

c. When lever handle type manual equipment shutoff

valves are used, they shall be T-handle valves.

d. The use of copper tubing for gas piping is NOT ap-

proved by the state of Massachusetts.

1. Install gas piping in accordance with local codes, or in the

absence of local codes, the applicable national codes. Re-

fer to the current edition of NFPA 54/ANSI Z223.1 for

proper gas pipe size.

2. It is recommended that a manual equipment shutoff valve

be installed in the gas supply line outside the furnace.

Locate valve as close to the furnace as possible where it is

readily accessible. Refer to Fig. 34.

3. Use black iron or steel pipe and fittings or other pipe ap-

proved by local code.

4. Use pipe thread compound which is resistant to natural

and Propane gases.

5. Use ground joint unions and install a drip leg no less than

3" long to trap dirt and moisture before it can enter gas

control valve inside furnace.

NOTE: Refer to Fig. 34 for the general layout at the furnace.

The rules listed apply to natural and Propane gas pipe

installations.

NOTE: Install the gas pipe grommet to the furnace side panel

with the gas pipe entry. If needed, remove the 2" hole plug from

the plastic accessory bag and relocate to the open hole in the

furnace side panel.

6. Use two pipe wrenches when making connections to pre-

vent gas valve from turning.

7. Install a manual shut-off valve external to furnace casing

and tighten all joints securely.

8. If local codes allow the use of flexible gas appliance con-

nectors, always use a new listed connector.

Do not use a connector which has previously serviced an-

other gas appliance.

9. Flexible corrugated metal gas connector may NOT be

used inside the furnace or be secured or supported by the

furnace or ductwork.

10. Properly size gas pipe to handle combined appliance load

or run gas pipe directly from gas meter or Propane gas reg-

ulator.

11. Install correct pipe size for run length and furnace rating.

12. Measure pipe length from gas meter or Propane second

stage regulator to determine gas pipe size.

AdditionalPropaneConnection

Requirements

1. Have a licensed Propane gas dealer make all connections

at storage tank and check all connections from tank to fur-

nace.

2. If copper tubing is used, it MUST comply with limitation

set in National Fuel Gas Code or CGA codes.

3. Two-stage regulation of Propane gas is recommended.

PropaneConversion

FIRE, EXPLOSION HAZARD

Failure to follow this warning could result in personal injury or

death.

A Propane conversion accessory kit is required when

operating the furnace with Propane gas.

An accessory kit shall be used to convert to propane gas use, see

the furnace rating plate for the Propane conversion accessory kit

part number.

Supply Pressure

FIRE HAZARD

Failure to follow this warning could result in personal injury or

death.

Do NOT set input rating above that shown on rating plate.

1. A 1/8" NPT plugged tapping, accessible for a test gauge

connection, must be installed immediately upstream of the

gas supply connection to the furnace.

2. Gas input to burners MUST NOT exceed the rated input

shown on rating plate.

3. Do NOT allow minimum gas supply pressure to vary

downward. Doing so will decrease input to furnace. Refer

to Table 6 and Table 7 for normal gas supply and manifold

pressures.

ManifoldGas PressureAdjustment

SEE CHECKS AND ADJUSTMENTS, Manifold Gas

Pressure Adjustment in this manual.

DripLegand Union,Union*shouldbeoutsidethe

cabinet.Manualshut-off valveMUST beupstreamof

dripleg,union,andfurnace.

Manualshut-off

valve

VentPipe Grommet(SinglePipe)

Use elbowsand3" pipe nippleto connectvalveto

pipingwhenusingright sidegas pipeentry.

jl .......... .

PropaneLow_,,_-_ /

sureswitch "_. _

REQUIRED.

* Union may be installed inside the cabinet when necessary

because of clearances.

Representativedrawingonly,somemodelsmayvary inappearance.

Model s may

have 1|or 2

:: pressur e

switch|es

Fig. 34 - Typical Gas Piping for Upflow

•Alternative

installation

A07724

HEATING

VALUE

at ALTITUDE

BTU/CU, FT.

700

725

750

775

8OO

825

85O

875

9OO

925

95O

975

1000

1050

1100

MEAN ELEVATION FEET ABOVE SEA LEVEL

0 to 2001 to 3001 to 4001 to 5001 to 6001 to 7001 to

2000 3000 4000 5000 6000 7000 8000

Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold Orifice Manifold

No, Pressure No, Pressure No, Pressure No, Pressure No, Pressure No, Pressure No, Pressure

42 3.6

42 3.5 42 3.4

42 3.3 42 3.2

41 2.9 43 3.7 43 3.6

....42 3.1 43 3.6 43 3.5 43 3.4

......... 43 3.7 43 3.6 43 3.4 43 3.3 44 3.6

.......... 43 3.5 43 3.4 44 3.7 44 3.6 44 3.4

43 3.4 43 3.3 44 3.6 44 3.5 44 3.4 44 3.2

44 3.7 44 3.6 44 3.4 44 3.3 44 3.2 44 3.1

44 3.7 44 3.5 44 3.4 44 3.2 44 3.1 45 3.6 45 3.5

44 3.5 44 3.3 44 3.2 44 3.1 45 3.6 45 3.5 45 3.3

44 3.3 44 3.1 45 3.7 45 3.5 45 3.4 45 3.3 45 3.2

44 3.2 45 3.6 45 3.5 45 3.4 45 3.2 45 3.1 46 3.1

48 3.6 45 3.3 45 3.2 45 3.1 48 3.1

46 3.3 45 3.0 46 3.0 46 2.9

Conversion: 1 inwc = .25 kPa

NOTE: Natural gas data is based on 0.60 specificgravity. For fuels with different specific gravity consult the National Fuel Gas Code ANSI

Z223.1-2006/NFPA 54-2006 or National Standard of Canada, Natural Gas And Propane Installation Code CSA B149.1-05.

Table 6 - Natural Gas Manifold Pressure

HEATING VALUE MEAN ELEVATION FEET ABOVE SEA LEVEL

at ALTITUDE 0 to 2001 to 3001 to 4001 to 5001 to 6001 to 7001 to

BTU/CU. FT. 2000 3000 4000 5000 6000 7000 8000

2500 10.0 8.9 8.4 10.0 10.0 10.0 10.0

Orifice Size #55 #55 #55 i#561 i#561 i#561 i#561

Conversion: 1 inwc = 25 kPa

NOTE: Propane data is based on 1.53 specific gravity. For fuels with different specific gravity consult the National Fuel Gas Code ANSI

Z223.1-2006/NFPA 54-2006 or National Standard Of Canada, Natural Gas And Propane Installation Code CSA B149.1-05.

NOTE: The derating of these furnaces at 2% (Natural Gas) and 4% (Propane Gas) has been tested and design-certified by CSA.

In Canada, the input rating must be derated 5% (Natural Gas) and 10% (Propane Gas) for altitudes of 2,000 to 4,500 above sea level. Use the 2001 to

3000 column in Table 6 and Table 7.

Table 7 -Propane Gas Manifold Pressure

The burner orifice part nos. are as follows:

Orifice #41 333730-701

Orifice #42 333730-702

Orifice #43 333730-703

Orifice #44 333730-704

Orifice #45 333730-705

Orifice #46 333730-709

Orifice #54 333730-706

Orifice #55 333730-707

Orifice #56 333730-708

GeneralDeratingRules

1. These furnaces may be used at full input rating when in-

stalled at altitudes up to 2,000'. When installed above

2,000', the input must be decreased 2% (natural) or 4%

(Propane) for each 1000' above sea level in the USA. In

Canada, the input rating must be derated 5% (natural) or

10% (Propane) for each 1000' above sea level. See Table 6

or Table 7 for required high altitude input rate.

2. For operation with natural gas at altitudes above 2,000',

orifice change and/or manifold pressure adjustments may

be required for the gas supplied. First consult your local

gas supplier, then refer to Table 6 for required pressure

change and/or orifice change for high altitudes.

3. For operation with Propane gas, gas orifices MUST be

changed and manifold pressure MUST be maintained as

per Table 7. Orifices can be ordered through our distribut-

or. (See Fig. 35).

High Altitude Input Rate =

Nameplate Sea Level Input Rate x (Multiplier)

[USA]

High Altitude Multiplier

Elevation

2001'-3000'

3001'-4000'

4001'-5000'

5001'-6000'

6001'-7000'

7001'-8000'

Natural Gas

0.95

0.93

0.91

0.89

0.87

0.85

Propane Gas

0.90

0.86

0.82

0.78

0.74

0.70

Based on mid-range of elevation.

HighAltitudeAir PressureSwitch

Altitudes over 4,000' may require a different air pressure switch

than the one installed at the factory. Check parts list for pressure

switch and consult your distributor for part number and

availability. In Canada, provincial codes may govern installation

of switch. Check with governing authorities.

ChangingOrificesfor HighAltitude

ELECTRICAL SHOCK, FIRE OR EXPLOSION

HAZARD

Failure to follow this warning could result in personal injury,

death, and/or property damage.

Turn OFF electric power (at disconnect) and gas supply (at

manual valve in gas line) when installing orifices. Installation

of orifices requires a qualified service technician.

NOTE: Main burner orifices can be changed for high altitudes.

1. Disconnect gas line from gas valve.

2. Remove manifold from furnace.

3. Remove the orifices from the manifold and replace them

with properly sized orifices.

4. Tighten orifices so it is seated and gas tight. (See Fig. 35)

5. Reinstall manifold. Ensure burners do NOT bind on new

orifices.

NaturalGas InputRatingCheck

SEE CHECKS AND ADJUSTMENTS, Natural Gas Input

Rating Check in this manual.

Measure from face of orifice

to the back side of the

manifold.

1.11" (28.2mm)

1.21" (30.8ram)

Fig. 35 - Changing Orifices

Final Gas PipingCheck

A07725

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal injury,

death, and/or property damage.

Never test for gas leaks with an open flame. Use a

commercially available soap solution made specifically for the

detection of leaks to check all connections. A fire or

explosion could result causing property damage, personal

injury and/or loss of life.

1. The furnace and the equipment shut off valve must be dis-

connected from the gas supply piping system during any

pressure testing of that system at test pressures in excess of

1/2" PSIG. Close the manual shut-off valve before testing

at such pressures.

2. When installation is complete, test all pipe connections for

leaks with the gas pressure less than 1/2" PSIG to the gas

valve.

3. The furnace must be isolated from the gas supply system

by closing the equipment shut off valve during any pres-

sure testing of the gas supply system at test pressure equal

to or less than 1/2" PSI (3.5 kPa).

4. Apply a commercial soap solution to all joints to test for

leaks. Correct any leaks indicated by bubbles.

5. Correct even the smallest leak at once.

6. Check for leaks at gas valve and orifice connections to the

burner manifold while the furnace is operating.

ELECTRICALWIRING

PowerSupply Wiring

The furnace MUST be electrically wired and grounded in

accordance with local codes, or in the absence of local codes with

the latest edition of The National Electric Code, ANSI NFPA 70

and/or The Canadian Electric Code CSA C22.1.

The power supply to the furnace connections must be between

104 VAC and 127 VAC during furnace operation for acceptable

performance.

Field wiring connections must be made inside the furnace

connection box. A suitable strain relief should be used at the

point the wires exit the furnace casing.

Copper conductors shall be used. Line voltage wires should

conform to temperature limitation of 63 ° F (35 ° C) rise and be

sized for the unit maximum amps stated on the rating plate. Add

the full load amps for potential field-installed accessories such as

electronic air cleaners and humidifiers that would receive power

from the furnace control. The furnace control is rated for a

maximum of 1.0 amp combined for EAC and HUM. Consult

NEC or local codes for proper wire and circuit sizing.

NOTE: Furnace will not have normal operation if line polarity is

reversed. Check ALL field and control connections prior to

operation.

Junction Box (J-Box) Relocation

The J-box is installed on left side of casing. An alternate j-box

location on right side can be used.

1. Remove bag containing two hole plugs and two self tap-

ping screws from loose parts bag in blower compartment.

2. Remove two screws holding J-Box to casing.

3. Move large hole plug from right to left J-Box location.

4. Clip wire tie holding J-Box wires.

5. Move J-Box to alternate location and attach using two self

tapping screws from bag.

6. Apply two hole plugs from bag at left J-Box location.

Thermostat

Thermostat location has an important effect on the operation of

the unit. Follow instructions included with thermostat for correct

mounting and wiring.

Low voltage connections to furnace must be made on terminal

board of furnace control.

Heat anticipator setting will need to be measured if 24VAC

humidifier is installed. Measure current in series from R to W at

the thermostat. Be sure 24VAC humidifier is wired up to control.

Allow furnace to operate for 2 minutes before recording the AC

amperage reading. Set anticipator on thermostat to recorded

value.

OptionalEquipment

All wiring from furnace to optional equipment MUST conform to

local codes or, in the absence of local codes with the latest edition

of The National Electric Code, ANSI NFPA 70 and/or The

Canadian Electric Code CSA C22.1. Install wiring in accordance

with manufacturer's instructions. The wiring MUST have a

minimum temperature rating of 105 ° C.

Humidifier/ElectronicAir Cleaner

The furnace is wired for humidifier and/or electronic air cleaner

connection.

REDUCED FURNACE LIFE HAZARD

Failure to follow this caution may result in reduced furnace

life.

Do NOT exceed 115V/1.0 amp. maximum current load for

both the EAC terminal and the HUM terminal combined.

HUMIDIFIER - The HUM (115) is energized when the pressure

switch closes on a call for heat. The HUM is energized when the

inducer is energized.

ELECTRONIC AIR CLEANER - EAC is energized when there

is a blower speed call, except is NOT energized when blower

operates in the hard-wired continuous fan mode.

FurnaceControl

The furnace control is preset at the factory with a fixed blower

ON delay of 30 seconds in the heating mode. The blower OFF

timing is preset at 140 seconds. If desired, the fan OFF delay can

be reset to obtain the longest delay times while still maintaining

comfort levels. See "Furnace Wiring Diagram" .

NOTE: Junction Box can be

mounted to either the left or right r-,/

side.

115_60 Hz

Box

Gr_nd

Low Voltage

Terminal Board

NOTE: 115 VAC/60Hz/single-phase

Operating voltage range*: 127 VAC max, 104 VAC min.

* Permissible limits of voltage at which unit will operate satisfactorily

Representativedrawing only,some models mayvary in appearance.

A07726

Fig. 36 - Electrical Connections

FurnaceControl Fuse

The 24V circuit contains a 5-amp, automotive-type fuse located

on furnace control. (See Fig. 37) Any electrical shorts of 24V

wiring during installation, service, or maintenance may cause

fuse to blow. If fuse replacement is required, use only a fuse of

identical size (5 amp.)

BlowerOff

DelayJumper

HUM

jDiagnosticLight

115VAC

FUSE

EAC

Fig. 37 - Control Board

DUCTWORKAND FILTER

A07727

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or

death.

Do NOT draw return air from inside a closet or utility room

where furnace is located. Return air duct MUST be sealed to

furnace casing.

Installation

NOTE: Design and install the air distribution system to comply

with Air Conditioning Contractors of America manuals and/or

NFPA pamphlets 90A and 90B or other approved methods that

conform to local codes and good trade practices.

1. When furnace supply ducts carry air outside furnace area,

seal return air duct to furnace casing and terminate duct

outside furnace space.

2. Install air conditioning cooling coil (evaporator) on outlet

side of furnace.

3. For furnaces installed without a cooling coil it is recom-

mended that the outlet duct be provided with a removable

access panel. This panel should be accessible when the

furnace is installed so the exterior of the heat exchanger

can be viewed for inspections. The access panel MUST be

sealed to prevent leaks.

4. If separate evaporator and blower units are used, install

good sealing dampers for air flow control. Chilled air go-

ing through the furnace could cause condensation and

shorten the furnace life.

NOTE: Dampers (field supplied) can be either automatic or

manual. Manually operated dampers MUST be equipped with a

means to prevent furnace or air conditioning operation unless

damper is in the full heat or cool position.

CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury or

death.

Cool air passing over heat exchanger can cause condensate to

form resulting in heat exchanger failure.

Connections

NOTE: On upflow installations, return air can enter through

either side, both sides, or the bottom. On horizontal installations

the return air must enter through the knockout opening in the

lower panel of the furnace. Return air can not enter through rear

of the furnace. When the furnace is located in an area near or

adjacent to the living area, the system should be carefully

designed with returns to minimize noise transmission through the

return grille. Any blower moving a high volume of air will

produce audible noise which could be objectionable to when the

unit is located very close to living areas. It is advisable to route

the return air ducts under the floor or through the attic.

1. For side connections using a 16" x 25" (406.4 x 635.0

mm) filter, cut out the embossed area shown in Fig. 38.

This will provide a 141/2 '' x 221/2 '' (368.3 x 571.5 mm)

approximate opening.

NOTE: Furnaces with 5 ton cooling rating may require both

(left and right) side return or one side and bottom return.

Side return air duct(s) is not permitted with horizontal

furnace installation.

A = 141/2" Height of Cutout for 16" x 25" Filter

B = 221/2" Width of Cutout for 16" x 25" Filter

Embossed Area

on Side of Furnace

Fig. 38 - Side Return Air Cutout

Bottom

A07728

2. Bottom returns can be made by removing the knockout

panel in the furnace base. Do NOT remove knock-out ex-

cept for a bottom return.

3. Installation of locking-type dampers are recommended in

all branches, or in individual ducts to balance system's air

flOW.

4. Non-combustible, flexible duct connectors are recommen-

ded for return and supply connections to furnace.

5. If air return grille is located close to the fan inlet, install at

least one, 90 ° air turn between fan and inlet grille to re-

duce noise.

NOTE: To further reduce noise, install acoustical air turning

vanes and/or line the inside of duct with acoustical material.

Sizing

Existing or new ductwork MUST be sized to handle the correct

amount of airflow for either heating only or heating and air

conditioning.

Insulation

1. Insulate ductwork installed in attics or other areas exposed

to outside temperatures with a minimum of 2" (50.8 mm)

insulation and vapor barrier.

2. Insulate ductwork in indoor unconditioned areas with a

minimum of 1" (25.4 mm) insulation with indoor type va-

por barrier.

Filters

A Filter must be used:

Filters are not supplied with these furnaces, but can be purchased

from the distributor.

Use either filter type:

• Washable, high velocity filters are based on a maximum

air flow rating of 600 FPM.

• Disposable, low velocity filters are based on a maxim-

um air flow of 300 FPM when used with filter grille.

• See Circulating Air Blower Data for additional data.

NOTE: Disposable, low velocity filters may be replaced with

washable, high velocity filter providing they meet the minimum

size areas. Washable, high velocity filters can be replaced ONLY

with same type and size.

Fig. 39 - Side Mounted Filter Rack

A07729

FilterInstallationusing OptionalFilter Rack

When installing or removing a bottom mounted filter, slide the

two side filter clips to the back of the furnace BEFORE installing

or removing. This will allow the filter to clear the front raised

edge of the furnace. Insert filter into side clips first and push filter

back until it is fully engaged into back clip. When filter is in

place, slide clips back into place midway on filter as shown in

Fig. 40 and Fig. 41.

Center Clip

side-to-side ",,

Fig. 40 -Bottom Mounted Filter Rack

A07691

application. The coil installation instructions must be consulted

for proper coil location and installation procedures. With a

parallel flow arrangement, dampers must be installed to prevent

chilled air from entering the furnace. If manually operated

dampers are used, they must be equipped with a means to prevent

operation of either unit unless the damper is in full heat or full

cool position.

A 3" (76.2 mm) clearance is required on the right side of the

furnace in order to run the copper or plastic tubing for the

condensate drain line.

UNIT OPERATIONAL HAZARD

Failure to follow this caution may result in improper unit

operation.

This furnace is not approved for use with "N" style

evaporator coils. If installed with an "N" style evaporator

coil, improper limit operation may occur.

CHECKSANDADJUSTMENTS

NOTE: Verity the input rate of the furnace.

26 Ga. Galvanized Steel

FAST part number 1008482

11/4"

\-_" 11116,,

A07730

Fig. 41 -Filter Clip Construction

Refer to Fig. 42 and for guidelines to install filters. Furnaces

which require larger filter media and have limited clearances on

one side of furnace, require a standoff filter rack, see Fig. 42,

available from your distributor.

Using Optional

StandoffFilter

Rack

Fig. 42 - Standoff Filter Rack

A07731

AdditionOfAir Conditioning

When a refrigeration coil is used in conjunction with this unit, it

must be installed parallel with or on the discharge side of the unit

to avoid condensation on the heat exchanger. All furnaces are

designed with a break-away duct flange on the supply air side of

the furnace. This allows for installation in the horizontal right

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal injury,

death and/or property damage.

Turn OFF gas at shut off before connecting manometer.

Startup

NOTE: Refer to the start-up procedures in the "User k

Information Manuar' or to the "Operating Instructions Label" on

the furnace.

ELECTRICAL OPERATION HAZARD

Failure to follow this warning could result in personal injury,

death, and/or property damage.

If any sparks, odors or unusual noises occur, immediately shut

OFF power to the furnace. Check for wiring errors or

obstruction to blower.

GasSupply Pressure

Gas supply pressure should be within minimum and maximum

values listed on rating plate (minimum and maximum pressures,

refer to Table 5). Pressures are usually set by gas suppliers.

ManifoldGas PressureAdjustment

NOTE: Make adjustment to manifold pressure with burners

operating.

1. Remove the burner compartment door.

2. Remove the blower compartment door. Place a jumper

across furnace controls R to W. Replace blower compart-

ment door.

3. With gas OFF, connect manometer to tapped opening on

gas valve. Use manometer with a 0 to 15 inches of water

column range.

4.TurngasONandremoveadjustmentscrewcoverongas

valve.Turnadjustingscrewcounterclockwisetodecrease

manifoldpressureandclockwisetoincreasepressure.

NOTE:AdjustmentscrewcoverMUSTbe replacedongas

controlvalvebeforereadingmanifoldpressureandoperating

furnace.

5.SetmanifoldpressuretovalueasshowninTable6 or

Table7 underGASSUPPLYANDPIPINGsectionin

thismanual.

6.Whenthemanifoldpressureisproperlyset,replacethead-

justmentscrewcoveronthegascontrolvalve.

Regulator Adjustment

UnderCap

INLET

..lj .....

Inlet

Pressure

Tap1/8NPT o

Fig. 43 - Typical Gas Valve

"_ OI Outlet

Pressure

Tap

1/8NPT

OUTLET

A07732

Face

Fig. 44 - Main Burner

NOTE: For Ignite location see Fig. 45

21/16{52.4)

Fig. 45 - Igniter Location

A07734

A07735

7. Remove blower compartment door. Remove jumper wire

from thermostat connection on furnace control board. Re-

move manometer connection from manifold pressure tap,

and replace plug in manifold.

8. Check for leaks at plug.

9. Replace the burner and blower compartment doors.

NaturalGas InputRatingCheck

NOTE: The gas meter can be used to measure input to furnace.

Rating is based on a natural gas BTU content of 1,000 BTU's per

cubic meter. Check with gas supplier for actual BTU content.

1. Turn OFF gas supply to all appliances and start furnace.

Use jumper wire on R to W for Heat.

2. Time how many seconds it takes the smallest dial on the

gas meter to make one complete revolution. Refer to

Example.

NOTE: If meter uses a2 cubic foot dial, divide results

(seconds) by two.

Natural Gas

BTU Content

1,000

Example

No. of Time Per

Seconds Cubic Foot

Per Hour in Seconds

3,600 48

BTU Per

Hour

75,000

1,000 x 3,600 +48 = 75,000 BTUH

3. Remove jumper wire from R to W.

4. Relight all appliances and ensure all pilots are operating.

MainBurnerFlameCheck

Allow the furnace to run approximately 10 minutes then inspect

the main burner. See Fig. 44.

Check for the following (Fig. 44):

• Stable and blue flames. Dust may cause orange tips or wisps of

yellow, but flames MUST NOT have solid, yellow tips.

• Flames extending directly from burner into heat exchanger.

• Flames do NOT touch sides of heat exchanger.

If any problems with main burner flames are noted, it may be

necessary to adjust gas pressures, or check for drafts.

TemperatureRiseCheck

The blower speed MUST be set to give the correct air

temperature rise through the furnace as marked on the rating

plate. Temperature rise is the difference between supply and

return air temperatures.

To check temperature rise,use the following procedure:

1.Place thermometers in supply and return air registers as close to

furnace as possible, avoiding direct radiant heat from heat

exchangers.

2.Operate furnace continuously for 15 minutes with all registers

and duct dampers open.

3.Take reading and compare with range specified on rating plate.

4.If the correct amount of temperature rise is NOT obtained, it

may be necessary to change blower speed. A higher blower speed

will lower the temperature rise. A lower blower speed will

increase the temperature rise.

ChangingBlowerSpeed

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or

death.

Turn OFF power to furnace before changing speed taps.

NOTE: The speed taps that the manufacturer sets from the

factory for this product are based on a nominal 400 CFM per ton

cooling and the basic mid range on the temperature rise for

heating.

Since the manufacturer cannot establish the static pressure

that will be applied to the unit, it is the responsibility of the

installer dealer/contractor to select the proper speed taps for

the application when the unit is installed.

If it is necessary to change speeds, refer to steps below.

REDUCEDFURNACELIFE HAZARD

Failure to follow this caution may result in reduced furnace

life.

Use ONLY the blower motor speed taps insert indicated in

the Circulation Air Blower Data for setting air temperature

rise.

Wire Color

Black

Orange*

Blue

Red

Motor Speed

High

Med-High

Medium

Low

* Med-High speed may not be provided on all models.

Table 8-Blower Speed Chart

1. Refer to Furnace Wiring Diagram for location of the heat-

ing and cooling speed taps located on the furnace control

as well as location of unused blower motor speed leads.

Use the chart (Table 8) to determine the blower motor

speed settings.

2. Change the heat or cool blower motor speed by removing

the motor lead from the "Heat" or "Cool" terminal and

replace it with the desired motor speed lead from the

"Unused Motor Lead" location. Connect the wire previ-

ously removed from the "Heat" or "Cool" terminal to the

vacated "Unused Motor Lead" terminal.

3. If the same speed must be used for both heating and cool-

ing, remove the undesired motor speed lead from the

"Heat" or "Cool" terminal and connect that lead to the

open terminal at "Unused Motor Lead" location. Attach a

jumper between the "Heat" and "Cool" terminals and the

remaining motor speed lead.

NOTE: For motors with (4) speed leads, it will be necessary to

tape off the terminal of the motor speed lead removed from the

"Heat" or "Cool" terminal with electrical tape since an open

terminal will not be available at the "Unused Motor Lead"

location.

Continuous-Fan Operation using "G"

Energizing the "G" terminal on the furnace control provides

continuous fan operation. This is done by connecting the G

terminal of the thermostat to the Gterminal on the furnace

control. When the FAN switch is turned from auto to ON the fan

will operate continuously at "HEAT" speed. EAC will be

energized in this mode.

NOTE: In heating, the fan will turn off during furnace ignition

and warm up then restart at heating speed.

HardWiredContinuousFanOperation

A terminal is provided on the furnace control board located in the

circulating blower compartment for operation of the continuous

fan option. This connection is intended for the low speed motor

tap, and has a lower contact rating (8 amps) than the heat and

cool taps. When the low speed blower lead is connected to this

terminal, this will provide low speed blower operation whenever

the other two speeds (Heat or Cool) are not energized.

Thoroughly check the system after modification to ensure the

proper operation of the circulating air blower in all modes of

operation.

SeparateSpeed Selectionsfor Heat,Cool,

andContinuousFan

Connect low speed lead from circulating motor to the "Cont."

terminal at the furnace control. The appropriate motor leads

should already be connected to the "Heat" and "Cool" terminals.

Heatingand ContinuousBlowerSpeed the

Same

If it is necessary to operate the heating speed and continuous

blower speed using the same blower speed, connect a jumper

between the "Heat" and "Cont." terminals on the furnace

control.

NOTE: There should be only ONE motor lead going to the

"Heat" and "Cont." terminals.

FURNACEMAINTENANCE

FIRE, EXPLOSION, OR CARBON MONOXIDE

HAZARDS

Failure to follow this warning could result in personal injury,

death and/or property damage.

It is recommended that the furnace be inspected and serviced

on an annual basis (before the heating season) by a qualified

service technician.

ELECTRICAL SHOCK, FIRE OR EXPLOSION

HAZARD

Failure to follow this warning could result in personal injury,

death, and/or property damage.

Before servicing, disconnect all electrical power to furnace.

When servicing controls, label all wires prior to disconnecting.

Reconnect wires correctly.

Verify proper operation after servicing.

See "User's Information Manual" and the "Service

Manual".

SEQUENCEOF OPERATION

& DIAGNOSTICS

Following is the normal operating sequence:

Cooling (Y) Request:

24VAC signals applied to Y & Gterminals of FCB (furnace

control board)

• Cool motor speed is energized after 5second Cool Fan On

Delay time.

Y & G signals removed from FCB

• Cool motor speed is de-energized after 90 second Cool Fan

Off Delay time.

ContinuousCirculatingFan (G) Request:

• 24 VAC signal is applied to Gterminal of the FCB.

• Heat motor speed is energized without delay.

•Gsignal removed from FCB.

• Heat motor speed is de-energized after 5 second delay.

NOTE:

(1.) Furnace de-energizes the fan during the heat ex-

changer warm-up period on a call for Heating

that occurs during a G request unless a blower

motor lead is connected to the Cont terminal on

the FCB, in which case see NOTE 2).

(2.) Heating or Cooling requests received during a Fan

request cause the fan speed to change to the ap-

propriate heat or cool speed after the Fan on

Delay time expires. The fan returns to continuous

circulating speed after the selected Fan Off Delay

time expires following loss of the Heating or

Cooling request.

ContinuousCirculatingFanHard-Wired

(Cont) Request

Field selected low speed motor tap installed on "CONT"

terminal.

• Low speed is energized when power applied to furnace.

Operates at this speed continuously while there are no other

blower demands from furnace control. Fan demands from

furnace control for heat, cool or "G" will override hard-wired

speed tap.

NOTE: EAC is NOT active for hard-wired mode but IS active

for fan demands from furnace control for heat, cool and "G".

Heating (W)Request:

Heating (W) Request:

• 24 VAC signal applied to W terminal of FCB.

• Inducer motor turns on and the pressure switch(es) close(s)

• Following a 15 second prepurge delay, after the pressure

switches closes, the igniter begins a 17 second warm-up.

• The gas valve is energized, the main burners light and flame is

sensed.

• The igniter is de-energized after the main burners ignite.

• FCB will delay blower operation for the 30 seconds timed from

the opening of the gas valve.

• W signal removed from FCB.

• The gas valve de-energizes and the main burners go out.

• The inducer runs for a 15 second postpurge period.

• The fan stays at Heat speed.

• The fan de-energizes after the selected Heat Fan Off Delay

time expires, timed from the gas valve de-energizing.

HUMIDIFIER - The 24V HUM is energized when the pressure

switch closes on a call for heat. The 115V HUM (called HUM on

Control) is energized when the inducer is energized.

ELECTRONIC AIR CLEANER - EAC is energized when there

is a blower speed call. It is NOT energized when blower operates

in the hard-wired continuous fan mode.

NOTE: If a new Heating request arrives while the control is

waiting in the Heat Fan Off Delay time, the FCB will wait for the

selected Heat Fan Off Delay then start a new heating cycle as

long as the heat call remains.

HeatingRequestwith GasShut Off:

24 VAC signal applied to W terminal of FCB.

The FCB will attempt 4 cycles for ignition then go to soft lockout

for 3 hours then try for ignition again as long as the heat call

remains. Power reset will clear lockout.

• Inducer motor turns on

• Following a 15 second prepurge delay, the igniter begins warm

up.

• The igniter glows red-hot for 22 seconds, then turns off. The

FCB flashes error code 6.

• The igniter stays off for 17 seconds, then begins to warm up

again.

• The igniter glows red hot for 22 seconds then turns off. The

FCB continues flashing error code 6.

• The igniter stays off for 17 seconds, then begins to warm up

again.

• The igniter glows red hot for 22 seconds then turns off. The

FCB continues flashing error code 6.

• The igniter stays off for 17 seconds, then begins to warm up

again.

• The igniter glows red hot for 22 seconds then turns off. The

FCB proceeds to soft lockout and stops flashing error code 6

and begins flashing error code 6 + 1.

• The inducer motor de-energizes after a 15 second post purge.

BlowerOff

DelayJumper

24 VAC _

HUM .........._

DiagnosticLight

FUSE

A07733

Fig. 46 - Control Board

ControlBoard DiagnosticCodes

OFF =24VAC or 115VAC is off, fuse is open

Heartbeat -- Normal operation or no previous Diagnostic Code

ON SOLID -- Soft Lockout - Furnace Control Error (1 hr. delay) If code repeats immediately following power reset

then replace control

1 Flash = Not used

2 Flashes -- Pressure switch(es) closed when should be open

3 Flashes -- Pressure switch open when should be closed

4 Flashes -- Limit or roll-out switch open (less than 2 minutes)

5 Flashes -- Flame sensed out of sequence

6 Flashes -- Failure to ignite or flame sense lost while running

6 + 1 Flashes -- Soft Lockout - Max trials for ignition reached (3 hr delay)

7 Flashes -- Soft Lockout - Limit or roll-out switch open longer than two minutes (1 hr delay) (roll-out switch

requires manual reset)

8 Flashes -- Permanent Lockout - Gas valve relay contact stuck closed or miswired gas valve (power reset only)

10 Flashes -- Line voltage (115VAC) polarity reversed. If twinned, refer to twinning kit instructions

If status code recall is needed, briefly (2-3 seconds) remove then reconnect one limit switch wire (main or rollout) to display last stored status code. Do not

remove power or blower door before initiating status code recall or code will be lost. Code is automatically cleared after 72 hours or upon power reset.

* Proper flame sense microamps: 0.7 microamps D.C. minimum, 2.0 - 4.0 microamps nominal

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations,

Catalog No: IM-PG9YAA-03

Replaces: IM- PGOYAA-02

PAYNE Furnace/Heater, Gas Manual L0907498

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