Payne Deluxe PG9MAB, PG9MAB Service And Maintenance Instructions

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PG9MAB

D e l u x e 4 --- W a y

Multipoise Fixed Capacity

Condensing Gas Furnace

Service and Maintenance Instructions

For Sizes 040--120, Series B

NOTE: Read the entire instruction manual before starting the

installation.

TABLE OF CONTENTS

PAGE

SAFETY CONSIDERATIONS 1.........................

GENERAL 2.........................................

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS 2...

CARE AND MAINTENANCE 3.........................

Cleaning and/or Replacing Air Filter 3....................

Blower Motor and Wheel Maintenance 4..................

Cleaning Burners 6...................................

Cleaning Heat Exchangers 6............................

Primary Heat Exchangers 6............................

Secondary Heat Exchangers 7..........................

Flushing Collector Box and Drainage System 7.............

Servicing Hot Surface Igniter 9..........................

Electrical Controls and Wiring 10........................

Checking Heat Tape Operation (If Applicable) 10...........

Winterizing 12......................................

WIRING DIAGRAM 12................................

TROUBLESHOOTING 12..............................

Status Codes 12.....................................

Component Tests 13..................................

SAFETY CONSIDERATIONS

Recognize safety information. This is the safety--alert symbol . 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.

WARNING

ELECTRICAL SHOCK, FIRE, OR EXPLOSION HAZARD

Failure to follow this warning could result in possible damage to this equipment, personal injury, or death.

The ability to properly perform maintenance on this equipment requires certain expertise, mechanical skills, tools, and equipment. If you do not possess these, do not attempt to perform any maintenance on this equipment other than those procedures recommended in the User’s Manual.

WARNING

ELECTRICAL SHOCK, FIRE, OR EXPLOSION HAZARD

Failure to follow safety warnings exactly could result in dangerous operation, personal injury, death, 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.

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could property damage, personal injury, or death.

Never store anything on, near, or in contact with the furnace, such as:

1. Spray or aerosol cans, rags, brooms, dust mops, vacuum cleaners, or other cleaning tools.

2. Soap powders, bleaches, waxes or other cleaning compounds, plastic or plastic containers, gasoline, kerosene, cigarette lighter fluid, dry cleaning fluids, or other volatile fluids.

3. Paint thinners and other painting compounds, paper bags, or other paper products.

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PG9MAB

CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in damage to furnace.

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

GENERAL

This furnace can be installed as a direct vent (2--pipe) or non--direct vent (1--pipe) condensing gas furnace. These instructions are written as if the furnace is installed in an upflow application. An upflow furnace application is where the blower is located below the combustion and controls section of the furnace, and conditioned air is discharged upward. Since this furnace can be installed in any of the 4 positions shown in Fig. 2, you may need to revise your orientation to component location accordingly.

AIRFLOW

UPFLOW

A05086

Fig. 1 -- Furnace in Upflow Orientation

ama

ISO 9001:2000

CERTIFIED

REGISTERED

Installing and servicing heating equipment can be hazardous due to gas and electrical components. Only trained and qualified

service agency personnel should install, repair, or service heating equipment. Untrained personnel can perform basic maintenance functions described in User’s Information Manual 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 the literature, on tags, and on labels attached to or shipped with the unit and other safety precautions that may apply.

Follow all safety codes including the National Fuel Gas Code (NFGC) NFPA 54 -- 2006/ANSI Z223.1--2006 in the USA, CSA B149.1--05 National Standard of Canada, Natural Gas and Propane Installation Codes (NSCNGPIC) in Canada, and the Installation Standards, Warm Air Heating and Air Conditioning Systems (NFPA 90B) ANSI/NFPA 90B. Wear safety glasses and work gloves. Have a fire extinguisher available during start--up and adjustment procedures and service calls.

AIRFLOW

HORIZONTAL

LEFT

Fig. 2 -- Multipoise Orientation

DOWNFLOW

AIRFLOW

HORIZONTAL

RIGHT

AIRFLOW

ELECTROSTATIC DISCHARGE (ESD)

PRECAUTIONS

CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may damage furnace components.

Electrostatic discharge can affect electronic components. Take precautions during furnace installation and servicing to protect the furnace electronic control. Precautions will prevent electrostatic discharges from personnel and hand tools which are held during the procedure. These precautions will help to avoid exposing the control to electrostatic discharge by putting the furnace, the control, and the person at the same electrostatic potential.

1. Disconnect all power to the furnace. DO NOT TOUCH THE CONTROL OR ANY WIRE CONNECTED TO THE CONTROL P RIOR TO DISCHARGING YOUR BODY’S ELECTROSTATIC CHARGE TO GROUND.

2. Firmly touch a clean, unpainted, metal surface of the furnace chassis which is close to the control. Tools held in a

A93041

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person’s hand during grounding will be satisfactorily discharged.

3. After touching the chassis, you may proceed to service the control or connecting wires as long as you do nothing that recharges your body with static electricity (for example; DO NOT move or shuffle your feet, DO NOT touch ungrounded objects, etc.).

4. If you touch ungrounded objects (recharge your body with static electricity), firmly touch furnace again before touching control or wires.

5. Use this procedure for installed and uninstalled (ungrounded) furnaces.

6. Before removing a new control from its container, discharge your body’s electrostatic charge to ground to protect the control from damage. If the control is to be installed in a furnace, follow items 1 through 5 before bringing the control or yourself into contact with the furnace. Put all used AND new controls into containers before touching ungrounded objects.

7. An ESD service kit (available from commercial sources) mayalsobeusedtopreventESDdamage.

CARE AND MAINTENANCE

For continuing high performance and to minimize possible furnace failure, it is essential that maintenance be performed annually. Consult your local dealer for maintenance and maintenance contract availability.

WARNING

FILTER SUPPORT

Fig. 3 -- Bottom Filter Arrangement

FILTER

FILTER RETAINER

FILTER

FILTER RETAINER

A08586

PG9MAB

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death.

Turn off the gas and electrical supplies to the unit before performing any maintenance or service. Follow the operating instructions on the label attached to the furnace.

The minimum maintenance that should be performed on this equipment is as follows:

1. Check and clean or replace air filter each month as needed.

2. Check blower motor and wheel for cleanliness annually.

3. Check electrical connections for tightness and controls for proper operation each heating season. Service as necessary.

4. Check for proper condensate drainage. Clean as necessary.

5. Check for blockages in combustion--air and vent pipes annually.

6. Check burners for cleanliness annually.

CAUTION

CUT HAZARD

Failure to follow this caution may result in personal injury.

Be careful of sharp metal edges, etc. Use care and wear protective clothing, gloves, and safety glasses when removing parts.

Step 1 — Cleaning and/or Replacing Air Filter

The air filter arrangement may vary depending on the application or orientation. See Table 1 for filter size and type.

A08587

Fig. 4 -- Filter Installed for Side Inlet

WARNING

FIRE, CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in personal injury, death or property damage.

Never operate unit without a filter or with the blower access panel removed. Operating a unit without a filter or with the blower access door removed could cause damage to the furnace blower motor. Dust and lint on internal parts of furnace can cause a loss of efficiency.

NOTE: If the filter has an airflow direction arrow, the arrow must point toward the blower.

To clean or replace filters, proceed as follows: If filter is installed in filter cabinet adjacent to furnace:

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FURNACE CASING WIDTH

DRAIN TUBE (BLUE

PG9MAB

& WHITE STRIPED)

COLLECTOR BOX

INDUCER HOUSING

COLLECTOR BOX

DRAIN TUBE (BLUE)

FACTORY-SUPPLIED

FIELD-INSTALLED

FACTORY-SUPPLIED

IN (MM)

17--- 1/2 (445)

21 (533 )

24--- 1/2 (610)

PLUG

CAP

COLLECTOR BOX

TUBE (PINK)

TUBE (GREEN)

(MOLDED) DRAIN

TUBE (BEHIND

COLLECTOR BOX

DRAIN TUBE)

FIELD-INSTALLED

DRAIN TUBE

COUPLING (LEFT

DRAIN OPTION)

DRAIN TUBE

FIELD-INSTALLED

FACTORY-SUPPLIED

⁄2-IN. CPVC STREET

ELBOWS (2) FOR

LEFT DRAIN OPTION

IN (MM)

(1) 16 x 25 x 3/4 (406 x 635 x 19)

CONDENSATE TRAP

FIELD-INSTALLED

FACTORY-SUPPLIED

DRAIN TUBE

COUPLING (RIGHT

DRAIN OPTION)

Fig. 5 -- Factory--Shipped Upflow Tube Configuration

(Shown with Blower Access Panel Removed)

1. Turn off electrical supply to furnace.

2. Remove filter cabinet door.

3. Slide filter out of cabinet.

4. If equipped with permanent, washable filter, clean filter by spraying cold tap water through filter in opposite direction of airflow. Rinse filter and let dry. Oiling or coating of the filter is not recommended.

5. If equipped with factory specified disposable media filter, replace only with a factory specified media filter of the same size.

6. Slide filter into cabinet.

7. Replace filter cabinet door.

8. Turn on electrical supply to furnace.

If filter is installed in furnace blower compartment:

Table 1 – Furnace Air Filter Table

FILTER QUANTITY AND SIZE *

BOTTOM RETURN*

IN (MM)

(1) 16 x 25 x 3/4 (406 x 635 x 19)

(1) 20 x 25 x 3/4 (508 x 635 x 19)

(1) 24 x 25 x 3/4 (610 x 635 x 19)

1. Turn off electrical supply to furnace.

2. Remove main furnace door and blower access panel.

3. Release filter retainer wire. (See Fig. 3 or 4.)

NOTE: Filters shown in Fig. 3 and 4 can be in furnace blower compartment or in filter cabinet, but not in both.

4. Slide filter out of furnace.

5. If equipped with permanent, washable filter(s), clean filter by spraying cold tap water through filter in opposite direction of airflow.

6. Rinse filter and let dry. Oiling or coating filter is not recommended.

7. Slide filter into furnace.

8. Recapture filter retaining wire.

9. Replace blower access panel and main furnace door.

10. Turn on electrical supply to furnace.

Step 2 — Blower Motor and Wheel Maintenance

To ensure long life, economy, and high efficiency, clean accumulated dirt and grease from blower wheel and motor annually.

The inducer and blower motors are pre--lubricated and require no additional lubrication. These motors can be identified by the absence of oil ports on each end of the motor.

The following items should be performed by a qualified service technician.

Clean blower motor and wheel as follows:

1. Turn off electrical supply to furnace.

2. Remove main furnace door and blower access panel.

3. Disconnect wires All factory wires can be left connected, but field thermostat connections may need to be disconnected depending on their length and routing.

4. Remove control box mounting screws, and position control box, transformer, and door switch assembly to right side of furnace casing.

A05110

5. If condensate trap is located in left-- or right--hand side of furnace casing, proceed to item 6. Otherwise remove trap and tubing as described below (See Fig. 5.):

a. Disconnect field drain connection from condensate trap.

b. Disconnect drain and relief port tubes from condensate

trap.

c. Remove condensate trap from blower shelf.

6. Remove screws securing blower assembly to blower shelf and slide blower assembly out of furnace. Detach ground wire and disconnect blower motor harness plugs from blower motor.

NOTE: Blower wheel is fragile. Use care.

7. Clean blower wheel and motor by using a vacuum with soft brush attachment. Be careful not to disturb balance weights (clips) on blower wheel vanes. Do not bend wheel or blades as balance will be affected.

8. If greasy residue is present on blower wheel, remove wheel from the blower housing and wash it with an appropriate degreaser. To remove wheel:

FILTER TYPE*SIDE RETURN*

3/4” (19 mm) thick washable

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a. Mark blower wheel location on shaft before disassembly

to ensure proper reassembly.

b. Loosen setscrew holding blower wheel on motor shaft.

NOTE: Mark blower mounting arms and blower housing so each arm is positioned at the same hole location during reassembly.

c. Mark blower wheel orientation and cutoff plate location

to ensure proper reassembly.

d. Remove screws securing cutoff plate and remove cutoff

plate from housing.

e. Remove bolts holding motor mounts to blower housing

and slide motor and mounts out of housing. Disconnect capacitor and ground wire attached to blower housing before removing motor. Motor mounts need not be removed from motor.

f. Remove blower wheel from housing.

CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in noise or furnace component failure.

The blower wheel should not be dropped or bent as balance will be affected.

g. Clean wheel per instructions on degreaser cleaner. Do

not get degreaser in motor.

9. Reassemble motor and blower wheel by reversing items 8b through 8f. Ensure wheel is positioned for proper rotation. Be sure to reattach ground wire. Tighten setscrew to 140 to 160 in--lb torque.

NOTE: Be sure to attach ground wire and reconnect blower harness plugs to blower motor.

10. Reinstall blower assembly in furnace.

11. Reinstall control box, transformer, and door switch assembly on blower shelf.

12. Reinstall condensate trap and tubing if previously removed.

a. Reinstall condensate trap in hole in blower shelf.

b. Connect condensate trap drain tubes. See Fig. 5 or

tubing diagram on main furnace door for proper tube location.

NOTE: Ensure tubes are not kinked or pinched, as this will affect operation.

(1.) Connect one tube (blue or blue and white striped)

from collector box.

(2.) Connect one tube (violet or unmarked) from in-

ducer housing.

(3.) Connect one tube (relief port, green or pink) from

collector box.

c. Connect field drain to condensate trap.

NOTE: Ensure tubes are not kinked or pinched, as this will affect operation.

13. Reinstall control box, transformer, and door switch assembly on blower shelf.

14. Reconnect wires. Refer to furnace wiring diagram and connect thermostat leads if previously disconnected. (See Fig. 21.)

NOTE: Refer to Table one for motor speed lead reconnection if leads were not identified before disconnection.

CAUTION

UNIT DAMAGE HAZARD

Failure to adjust the heating speed may shorten heat exchanger life.

Heating speed selection MUST be adjusted to provide proper temperature rise as specified on the rating plate.

Table 2 – Speed Selection

COLOR SPEED

Black High Cool

Yellow (When Present) Medium High Spare

Blue Medium Low Heat

Red Low Fan

White Common Com

WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death.

Blower access panel door switch opens 115--v power to furnace control. No component operation can occur. Caution must be taken when manually closing this switch for service purposes.

15. Turn on electrical supply. Manually close blower access panel door switch. Use a piece of tape to hold switch closed. Check for proper rotation and speed changes between heating and cooling by jumpering R to G and R to Y/Y2 on furnace control thermostat terminals. (See Fig. 15.)

16. If furnace is operating properly, release blower access panel door switch, replace blower access panel, and replace main furnace door.

CELL

PANEL

MANIFOLD MOUNTING SCREWS

GAS VALVE REGULATOR FITTING

GAS CONTROL VALV E

Fig. 6 -- Burner Box Assembly

FACTORY

ATTACHED TO

GASKET

MANIFOLD

A02312

PG9MAB

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Step3—CleaningBurners

The following items should be performed by a qualified service technician. If the burners develop an accumulation of light dirt or dust, they may be cleaned by using the following procedure:

1. Turn off gas and electrical supplies to furnace.

2. Remove main furnace door.

3. Remove burner box cover.

4. Using backup wrench, disconnect gas supply pipe from furnace gas control valve.

CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in furnace component damage.

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

PG9MAB

5. Remove wires from gas valve. Note location for reassembly.

6. Remove burner box pressure tube from gas valve regulator fitting.

7. Unplug igniter from harness.

8. Remove igniter leads from slot in manifold grommet.

9. Remove screws that secure manifold to burner box. (See Fig. 6.)

NOTE: Do not remove burner box from cell panel.

10. Remove manifold, orifices, and gas valve as one assembly.

11. Remove screws attaching burner assembly in burner box.

NOTE: Use care when removing and reinstalling burners not to strike the hot surface igniter.

15. Reinsert the igniter wires in the slot in the manifold grommet, dressing the wires to ensure there is no tension on the igniter itself. (See Fig. 7.)

WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death.

Igniter wires must be securely placed in slot in manifold grommet or else they could become pinched or severed and electrically shorted.

16. Reconnect wires to gas valve and igniter. Refer to furnace wiring diagram for proper wire location.

17. Reinstall burner box pressure tube to gas valve regulator fitting.

18. Reinstall gas supply pipe to furnace gas control valve using backup wrench on gas valve to prevent rotation and improper orientation.

NOTE: Use propane gas resistant pipe dope to prevent gas leaks. DO NOT use T eflon tape.

WARNING

FIRE, EXPLOSION, UNIT DAMAGE HAZARD

Failure to follow this warning could result in personal injury, death, or property damage.

Gas valve switch MUST be facing forward or tilted slightly.

19. Replace burner box cover.

20. Turn on gas and electrical supplies to furnace.

IGNIT ER WIRES MUST BE PLACED IN THIS SLOT

A05074

Fig. 7 -- Igniter Wire Placement

12. Remove burner assembly from burner box.

NOTE: All burners are attached to burner bracket and can be removed as one assembly.

13. Clean burners with soft brush and vacuum.

14. Reinstall manifold, orifice, and gas valve assembly in burner box. Ensure manifold seal grommet is installed properly and burners fit over orifices.

WARNING

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal injury, death 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.

21. Check for gas leaks.

22. Replace main furnace door.

Step 4 — Cleaning Heat Exchangers

The following items should be performed by a qualified service technician.

Primary Heat Exchangers

If the heat exchangers get an accumulation of light dirt or dust on the inside, they may be cleaned by the following procedure:

NOTE: If the heat exchangers get a heavy accumulation of soot and carbon, both the primary and secondary heat exchangers should be replaced rather than trying to clean them thoroughly due to their intricate design. A build--up of soot and carbon indicates that a problem exists which needs to be corrected, such as improper adjustment of manifold pressure, insufficient or poor quality combustion air, improper vent termination, incorrect size or damaged manifold orifice(s), improper gas, or a restricted heat exchanger (primary or secondary). Action must be taken to correct the problem.

1. Turn off gas and electrical supplies to furnace.

2. Remove main furnace door.

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CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in furnace component damage.

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and hazardous operation.

3. Disconnect wires or connectors to flame rollout switch, gas valve, igniter, and flame sensor.

4. Disconnect combustion--air intake pipe from intake housing.

5. Remove the pressure switch tube from intake housing.

6. Remove screws attaching intake housing to burner box, and rotate intake housing away from burner box for removal.

7. Using backup wrench, disconnect gas supply pipe from furnace gas control valve.

8. Disconnect pressure tubing from gas valve.

9. Remove two screws attaching top filler panel and rotate upwards to gain access to screws attaching burner box to cell panel.

10. Remove screws attaching burner box to cell panel. (See Fig.

6.)

NOTE: Burner box, cover, manifold, gas valve, and burner assembly should be removed as one assembly.

11. Clean heat exchanger openings with a vacuum and a soft brush. (See Fig. 8.)

NOTE: After cleaning, inspect the heat exchangers to ensure they are free of all foreign objects that may restrict flow of combustion products.

PRIMARY HX INLET OPENINGS

12. Reverse items 3 through 10 for reassembly.

NOTE: Be sure burner box gasket is installed between burner box and cell panel. (See Fig. 6.) If gasket is damaged, replace it.

NOTE: Inspect combustion--air intake housing. If foamed gasket was removed, check for any damage. If gasket is damaged in any way, it must be repaired. To repair, remove damaged gasket section, apply sealant releasing agent such as PAM cooking spray or equivalent (must not contain corn nor canola oil, halogenated hydrocarbons nor aromatic content, to prevent inadequate seal from occurring) to burner box and apply a small bead of G.E. RTV 162, G.E. RTV 6702, or Dow--Corning RTV 738 sealant to edge of combustion--air intake housing. (See Fig. 9.)

RTV

PG9MAB

PAM

A93087

Fig. 9 -- Combustion--Air Intake Housing

Gasket Repair

13. Refer to furnace wiring diagram and reconnect wires to flame rollout switch, gas valve, igniter, and flame sensor.

14. Reconnect pressure switch tubes to gas valve and intake housing. Refer to tube routing label on main furnace door for proper tube location. (See Fig. 10.) Be sure tubes are not kinked.

15. Turn on gas and electrical supplies to furnace.

16. Check furnace operation through two complete heat operating cycles. Look through sight glass in burner enclosure to check burners. Burner flames should be clear blue, almost transparent. (See Fig. 11.)

17. Check for gas leaks.

Fig. 8 -- Cleaning Inlet Openings of Primary

Heat Exchangers

CAUTION

UNIT MAY NOT OPERATE

Failure to follow this caution may result in improper or intermittent unit operation.

The ground wire from the gas valve MUST be attached to the burner box attachment screw.

A96305

WARNING

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal injury, death 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.

18. Replace main furnace door.

Secondary Heat Exchangers

NOTE: The condensing side (inside) of the secondary heat

exchangers CANNOT be serviced or inspected. A small numb er of bottom outlet openings can be inspected by removing the inducer assembly. See Flushing Collector Box and Drainage System section for details on removing inducer assembly.

Step 5 — Flushing Collector Box and Drainage System

1. Turn off gas and electrical supplies to furnace.

2. Remove main furnace door.

3. Disconnect inducer motor and pressure switch wires or connectors.

Page 8

PG9MAB

Condensate Trap; Facto ry Installed

(Blower access panel removed)

INDUCER HOUSING (MOLDED) DRAIN TUBE

(BEHIND COLLECTOR BOX DRAI N TUBE)

COLLECTOR BOX DRAIN TUBE

FIELD-INSTALL ED FACTORY-SUPPLIED

Condensate Trap on

BURNER ENCLOSURE PRESSURE

REFERENCE TUBE ASSEMBLY

INDUCER HOUSING DRAIN T UBE (VIOLET)

BURNER ENCLOSURE

PRESSURE REFERENCE

TUBE ASSEMBLY

COLLECTOR BOX EXTENSION DRAIN TUBE

NOTE:

1. All tubing must be connected securely and rout ed to avoid kinks and t raps.

2. Pressure tubing must always slope away from pressure switch to coll ector box connection as shown.

3. HORIZONTAL-LEFT installati ons requir e the collector box pressure tube to be rel ocated between the inducer housing and the blower shelf to prevent a trap.Refer to the Installation Instructions for further details.

Furnace is shipped from factory in upflow configuration. Pressur e tube and drain tube routing MUST match the diagrams below.

in Blower Shelf

COLLECTOR BOX TUBE

(PINK)

COLLECTOR BOX TUBE

(GREEN)

(BLUE)

FIELD-INSTALL ED FACTORY-SUPPLIED DRAIN TUBE COUPLING (LEFT DRAI N OPTION)

DRAIN TUBE

LEFT Side

CAP

COLLECTOR BOX

TUBE (GREEN)

COLLECTOR BOX DRAIN TUBE

(BLUE & WHITE STRIPED)

COLLECTOR BOX EXTENSION TUBE

CONDENSATE TRAP

Tube location when used on

HORIZONTAL - LEFT application

PLUG

CAP

COLLECTOR BOX EXTENSION TUBE

CONDENSATE TRAP

Tube location when used in UPFLOW application

BURNER ENCLOSURE

PRESSURE REFERENCE

TUBE ASSEMBLY

CAP

PLUG

COLLECTOR BOX DRAIN

TUBE

(BLUE & WHITE STRIPED)

CONDENSATE TRAP

FIELD-INSTALL ED

FACTORY-SUPPLIED

DRAIN TUBE COUPLI NG

(RIGHT DRAIN OPT ION)

FIELD-INSTALL ED FACTORY-SUPPLI ED 1/2-IN. CPVC STREET ELBOWS (2)

FOR LEFT DRAIN OPTION

COLLECTOR BOX TUBE

(PINK)

COLLECTOR BOX TUBE (GREEN)

COLLECTOR BOX DRAIN TUBE

(BLUE)

CONDENSATE TRAP

Tube location when used in DOWNFLOW application

COLLECTOR BOX

DRAIN TUBE (BLUE)

DRAIN TUBE

COUPLING

PLUGGED END

PLUG

COLLECTOR BOX EXTENSION TUBE

COLLECTOR BOX

TUBE (PINK)

COLLECTOR BOX DRAIN TUBE

(BLUE & WHITE STRI PED)

COLLECTOR BOX

TUBE (GREEN)

INDUCER HOUSING

COLLECTOR BOX

DRAIN TUBE (BLUE)

COLLECTOR BOX TUBE (PINK)

RELOCATE TUBE BETWEEN BLOWER

SHELF AND INDUCER HOUSING FOR

040,060, AND 080 HEATING INPUT

FURNACES

DRAIN TUBE

(VIOLET)

COLLECTOR BOX DRAIN

TUBE

(BLUE & WHITE STRIPED)

INDUCER HOUSING DRAIN

TUBE (VIOLET)

DRAIN TUBE COUPLING

DRAIN TUBES ROUTED IN

FRONT OF GAS VALVE

COLLECTOR BOX DRAIN TUBE

(BLUE)

PLUG

CAP

COLLECTOR BOX

TUBE (GREEN)

COLLECTOR BOX DRAIN TUBE

(BLUE AND WHITE STRIPED)

Tube location when used on

HORIZONTAL - RIGHT application

TUBE ROUTING

Condensate Trap on LEFT

Side Option al

BURNER ENCLOSURE

PRESSURE REFERENCE

TUBE ASSEMBLY

CAP

PLUG

COLLECTOR BOX DRAIN TUBE

(BLUE & WHITE STRIPED)

INDUCER HOUSING DRAI N TUBE

Condensate Trap on

PLUG

CAP

COLLECTOR BOX DRAIN TUBE

(BLUE)

COLLECTOR BOX TUBE

(PINK)

COLLECTOR BOX TUBE

(GREEN)

COLLECTOR BOX EXTENSION TUBE

BURNER ENCLOSURE PRESSURE

REFERENCE TUBE ASSEMBLY

CONDENSATE TRAP

COLLECTOR BOX

EXTENSION DRAI N TUBE

GAS VALVE

COLLECTOR BOX EXTENSION TUBE

COLLECTOR BOX TUBE (PINK)

INDUCER HOUSING DRAIN T UBE (VIOLET)

AUXILIARY "J" BOX RELOCATED HERE

BURNER ENCLOSURE

PRESSURE REFERENCE

TUBE ASSEMBLY

COLLECTOR BOX

EXTENSION TUBE

CONDENSATE TRAP

324999-201 REV. C

(VIOLET)

RIGHT Side

Fig. 10 -- Furnace Pressure and Drain Tubing Diagram

4. Disconnect pressure switch tubes.

5. Disconnect vent pipe from inducer housing outlet by loosening coupling clamp on inducer outlet.

6. Disconnect drain tube from inducer housing. (See Fig. 10.)

NOTE: Ensure the drain tube disconnected from the inducer housing is higher than the collector box opening or water will flow out of tube.

7. Remove inducer housing assembly by removing 4 bolts attaching assembly to cell panel.

8. Flush inside of collector box with water until discharge from condensate trap is clean and runs freely.

9. Inspect inside area of collector box for any pieces of foreign materials and remove them if present.

CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in furnace component damage.

DO NOT use wire brush or other sharp object to inspect or dislodge materials in secondary heat exchangers as cutting of the secondary heat exchanger protective coating may occur. Flush with water only.

A00308

10. Reassemble inducer assembly by reversing items 3--7. Tighten the vent coupling clamp screw(s) to 15 in.--lb of torque.

NOTE: If seal between the inducer housing and the collector box is damaged in any way, it must be repaired. To repair, apply sealant releasing agent such as PAM cooking spray or equivalent (must not contain corn nor canola oil, halogenated hydrocarbons nor aromatic content, to prevent inadequate seal from occurring) to inducer housing. (See Fig. 12.) Apply a small bead of G.E. RTV 162, G.E. RTV 6702, or Dow--Corning RTV 738 sealant to groove in collector box.

11. Refer to furnace wiring diagram and reconnect wires to inducer motor and pressure switches or connectors.

12. Reconnect pressure tubes to pressure switches. See diagram on main furnace door for proper location of tubes. Be sure tubes are not kinked. (See Fig. 10.)

13. Turn on gas and electrical supplies to furnace.

14. Check furnace operation through two complete heat operating cycles. Check area below inducer housing, vent pipe, and condensate trap to ensure no condensate leaks occur. If leaks are found, correct the problem.

15. Check for gas leaks.

Page 9

WARNING

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal injury, death 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.

16. Replace main furnace door.

Step 6 — Servicing Hot Surface Igniter

The igniter does NOT require annual inspection. Check igniter resistance before removal.

1. Turn off gas and electrical supplies to furnace.

CAUTION

BURN HAZARD

Failure to follow this caution may result in personal injury.

Allow igniter to cool before removal. Normal operating temperatures exceed 2000_F (1093_C).

2. Remove main furnace door.

3. Disconnect igniter wire connection.

4. Check igniter resistance. Igniter resistance is affected by temperature. Only check resistance when the igniter is at room temperature.

a. Using an ohm meter, check resistance across both ig-

niter leads in connector.

b. Cold reading should be between 40 ohms and 70 ohms.

5. Remove igniter assembly.

a. Remove burner box cover.

b. Remove igniter wires from slot in manifold grommet.

(See Fig. 7.)

c. Using a 1/4--in. driver, remove the single screw securing

the igniter bracket to the burner box bracket (See Fig.

13.) and carefully withdraw the igniter and bracket assembly through the front of the burner box without striking the igniter on surrounding parts. Note that the igniter bracket has a handle that extends to the front of the burner box to aid in handling. (See Fig. 13.)

d. Inspect igniter for signs of damage or failure.

e. If replacement is required, replace igniter on igniter

bracket and then install assembly into burner box to avoid damage to the igniter.

6. To replace igniter and bracket assembly, reverse items 5a through 5c.

7. Reconnect igniter wire connection and insert the igniter wires in the slot in the manifold grommet, dressing the igniter wires to ensure there is no tension on the igniter itself. (See Fig.7.)

8. Reinstall burner box cover.

9. Turn on gas and electrical supplies to furnace.

10. Verify igniter operation by initiating control board self--test feature or by cycling thermostat.

11. Replace main furnace door.

BURNER FLAME

BURNER

PG9MAB

MANIFOLD

A89020

Fig. 11 -- Burner Flame

PAM

RTV

CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in premature failure of the igniter.

The igniter is fragile. DO NOT allow it to hit burner box parts while removing or replacing it.

A93081

Fig. 12 -- Gasket on Collector Box

Page 10

EXTENDED IGNITER BRACKET HANDLE

IGNITER BRACKET MOUNTING SCREW

Fig. 13 -- Igniter Bracket

IGNITER

BRACKET

PG9MAB

2-5/32˝

(55 mm)

Fig. 14 -- Igniter

WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death.

Igniter wires must be securely placed in slot in manifold grommet or else they could become pinched or severed and electrically shorted.

9/16˝

11/16˝

A05075

A04181

Step 7 — Electrical Controls and Wiring

WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death.

There may be more than one electrical supply to the unit. Check accessories and cooling unit for additional electrical supplies.

The electrical ground and polarity for 115--v wiring must be maintained properly. Refer to Fig. 15 for field wiring information and to Fig. 21 for unit wiring information.

NOTE: If the polarity is not correct or furnace is not properly grounded, the STATUS LED on the furnace control will flash rapidly and prevent the furnace from operating. The control system also requires an earth ground for proper operation of the furnace control and flame sensor.

The 24--v circuit contains an automotive--type, 3--amp fuse located on the furnace control. (See Fig. 16.) Any direct shorts of the 24 --v wiring during installation, service, or maintenance will cause this fuse to blow. If fuse replacement is required, use ONLY a fuse of identical size. The furnace control LED will flash status code 24 when fuse needs to be replaced.

With power to the unit disconnected, check all electrical connections for tightness. Tighten all screws on electrical connections. If any smoky or burned connections are found, disassemble the connection, clean all parts, strip wire, and reassemble properly and securely.

Reconnect electrical supply to unit and observe unit through one complete operating cycle and check for proper operation.

Step 8 — Checking Heat Tape Operation (If Applicable)

In applications where the ambient temperature around the furnace is 32_F(0_C) or lower, freeze protection measures are required. If this application is where heat tape has been applied, check to ensure it will operate when low temperatures are present.

NOTE: Heat tape, when used, should be wrapped around the condensate drain trap and drain line. There is no need to use heat tape within the furnace casing. Most heat tapes are temperature activated, and it is not practical to verify the actual heating of the tape. Check the following:

1. Check for signs of physical damage to heat tape such as nicks, cuts, abrasions, gnawing by animals, etc.

2. Check for discolored heat tape insulation. If any damage or discolored insulation is evident, replace heat tape.

3. Check that heat tape power supply circuit is on.

Page 11

FIVE WIRE

THREE-WIRE

HEATING-ONLY

BLOWER DOOR SWITCH

BLK

WHT

115-V FIELD-

SUPPLIED

BLK

WHT

GND

AUXILIARY J-BOX

DISCONNECT

GND

FURNACE

NOTE 2

O N T

R O

COM

24-V

TERMINAL

BLOCK

FIELD 24-V WIRING FIELD 115-, 208/230-, 460-V WIRING FACTORY 24-V WIRING FACTORY 115-V WIRING

WCR GY

THERMOSTAT TERMINALS

FIELD-SUPPLIED DISCONNECT

208/230- OR 460-V THREE PHASE

208/230-V SINGLE PHASE

NOTE 1

CONDENSING

GND

UNIT

TWO WIRE

NOTES: Connect Y-terminal in furnace as shown for proper blower operation.

1. Some thermostats require a "C" terminal connection as shown.

2. If any of the original wire, as supplied, must be replaced, use

3. same type or equivalent wire.

Fig. 15 -- Field Wiring

PG9MAB

A02174

BLOWER OFF-DELAY

J2 JUMPER

24-V THERMOSTAT

TERMINALS

3-AMP FUSE

LED OPERATION &

DIAGNOSTIC LIGHT

115-VAC(L2)NEUTRAL

CONNECTIONS

COOL

HEAT

BLOWER SPEED

SELECTION TERMINALS

G Com W Y R

24V

STATUS CODE LED

COOL HEAT

SPARE-1

SPARE-2

TEST/TWIN

0.5 AMP@24VAC

FUSE 3-AMP

SEC-2 SEC-1

EAC-2 L2

NUETRAL

BLW

SPARE-1 SPARE-2

BLOWER OFF-DELAY

90 150

120 180

PLT

HUM

PLT 1

EAC-1

(115-VAC 1.0 AMP MAX.)

TWINNING AND/OR COMPONENT TEST

TERMINAL

1-AMP@

115VAC

PR-1

PL2 1

115 VAC (L1) LINE

VOLTAGE CONNECTION

EAC-1 TERMINAL

Fig. 16 -- Control Center

HUMIDIFIER TERMINAL

(24-VAC 0.5 AMP MAX.)

TRANSFORMER 24-VAC

CONNECTIONS

PL1-LOW VOLTAGE MAIN HARNESS CONNECTOR

PL2-HOT SURFACE

IGNITER & INDUCER

MOTOR CONNECTOR

A02100

Page 12

CAUTION

UNIT AND PROPERTY DAMAGE

Failure to follow this caution may result in furnace component failures or water property damage.

Operating a unit without a filter or with the blower access door removed could cause damage to the furnace blower motor. Dust and lint on internal parts of furnace can cause a loss of efficiency. If this furnace is to be operated in an unconditioned space where the ambient temperatures may be 32_F(0_C)or lower, freeze protection measures must be taken. See CONDENSATE DRAIN PROTECTION section of Installation, Start-- up, and Operating Instructions. (See Fig. 17.)

Step 9 — Winterizing

PG9MAB

UNIT DAMAGE HAZARD

Failure to follow this caution may result in furnace component damage.

Freezing condensate left in the furnace may damage the furnace.

If the furnace will be off for an extended period of time in a structure where the temperature will drop to 32_F(0_C)or below, winterize as follows:

1. Turn off electrical supply to furnace.

2. Remove main furnace door.

3. Disconnect upper inducer housing drain connection cap

4. Connect field--supplied 1/2--in. I.D. inducer housing tube to

5. Insert funnel in tube and pour one quart of antifreeze, pro-

UNIT DAMAGE HAZARD

Failure to follow this caution may result in unit component damage.

Do not use ethylene glycol (Prestone II antifreeze/coolant or equivalent automotive type).

6. Replace drain connection cap and clamp to inducer housing.

7. Replace main furnace door.

8. Propylene glycol need not be removed before restarting fur-

CAUTION

from inducer housing. (See Fig. 18.)

upper inducer housing drain connection.

pylene glycol (RV, swimming pool antifreeze, or equivalent) into funnel/tube until it is visible at point where condensate enters open drain. (See Fig. 19.)

CAUTION

nace.

A07911

Fig. 17 -- Freeze Protection

WIRING DIAGRAMS

See Fig. 21 for wiring diagram.

TROUBLESHOOTING

Use the troubleshooting guide, the status code LED on the furnace control and the component test to isolate furnace operation problems.

Status Codes

For an explanation of status codes, refer to service label located on back of main furnace door or Fig. 20.

NOTE: Removing the blower access door will open the blower access door switch and terminate 115--v power to the control.

To read current status code, remove main furnace door. The status code LED can be viewed through the sight glass on the blower access door.

NOTE: NO thermostat signals may be present at control and all blower off delays must be completed to view previous codes.

CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in damage to unit components.

Make sure limit switch or flame rollout switch wire does not contact any metal component, such as gas valve. If wire is shorted, 3-- amp fuse on furnace control board will open and unit will not operate.

To retrieve previous codes, remove one of the red main limit or flame rollout switch wires for 1 to 4 sec until the LED light goes out, then reconnect it. (Do not leave red wire disconnected for longer periods of time as the control will assume an overtemperature condition exists and will respond with blower operation.) This places the control in the status recall mode and displays the last code stored in memory.

Record the code. After the last code is displayed the control will perform the component test, and then return to normal standby mode.

Page 13

PG9MAB

A99118

Fig. 18 -- Inducer Housing Drain Tube

Component Test

NOTE: The furnace control component test allows all

components to run for a short time; except the gas valve and humidifier terminal HUM are not energized for safety reasons. The EAC--1 terminal is energized when the blower is energized. This feature helps diagnose a system problem in case of a component failure. The component test feature will not operate if any thermostat signal is present at the control and not until all time delays are completed.

NOTE: Record the status code BEFORE opening the blower access door and before shutting off power to furnace. Opening the blower access door will open the blower door switch and shut off power within the furnace. When power to the furnace is shut off by either method, the status code will be lost because the code is not stored while power is removed for any reason.

To Begin Component Self--Test:

WARNING

ELECTRICAL SHOCK AND UNIT MAY NOT OPERATE HAZARD

Failure to follow this warning could result in electrical shock, personal injury, or death.

Blower access panel door switch opens 115--v power to control board. No component operation can occur. Caution must be taken when manually closing this switch for service purposes.

1. Remove blower access door.

2. Disconnect the thermostat R lead from furnace control board.

3. Manually close blower door switch.

4. For approximately 2 sec, short (jumper) the COM--24v terminal on control to the TEST/TWIN 3/16 -- in. quick--connect terminal on control until LED turns off. Remove jumper from terminals. (See Fig. 16.)

NOTE: If TEST/TWIN and COM-- 24v terminals are jumpered longer than 2 sec, LED will flash rapidly and ignore component test request.

A99119

Fig. 19 -- Funnel in Drain Tube and Antifreeze

Running Through Trap

Component test sequence for single--stage furnace is as follows:

a. LED will display status code 11 four times.

b. Inducer motor starts and continues to run until Step f. of

component test sequence.

c. After 7 sec the hot surface igniter is energized for 15

sec, then off.

d. Blower motor operates on HEAT speed for 10 sec.

e. Blower motor operates on COOL speed for 10 sec.

f. Inducer motor stops.

5. Reconnect R lead to furnace control board, remove tape from blower door switch, and reinstall blower door.

6. Operate furnace per instruction on outer door.

7. Verify furnace shut down by lowering thermostat setting below room temperature.

8. Verify that furnace restarts by raising thermostat setting above room temperature.

Use the Component Test to check furnace components for proper operation. To initiate the component self--test sequence, shut off the room thermostat or disconnect the “R” thermostat lead. Briefly (approximately 2 sec) short the TWIN/TEST terminal to the COM 24V terminal. The status LED will turn off. The test sequence will be as follows:

1. LED flashes last status code, or code 11, 4 times. Record this status code for further troubleshooting.

2. The inducer will start and continue to run until test is over.

3. Hot surface igniter (HSI) is energized for 15 sec, then de-energized.

4. Blower operates on continuous FAN speed for 10 sec, then turns off.

5. The blower motor operates on HEATING speed for 10 sec, then turns off.

6. The blower motor operates on COOLING speed for 10 sec, then turns off.

7. Inducer turns off.

8. The gas valve and humidifier terminal HUM are not energized for safety reasons.

Page 14

PG9MAB

SERVICE

If status code recall is needed, briefly remove then reconnect one main limit wire to display stored status code. On RED LED boards do not remove power or blower door before initiating status code recall. After one status code recall is completed component test will occur.

LED CODE

CONTINUOUS OFF - Check for 115VAC at L1 & L2, & 24VAC at SEC-1 & SEC-2. CONTINUOUS ON - Control has 24VAC power. RAPID FLASHING - Line voltage (115VAC) polarity reversed. If twinned,

refer to twinning kit instructions.

EACH OF THE FOLLOWING STATUS CODES IS A TWO DIGIT NUMBER WITH THE FIRST DIGIT DETERMINED BY THE NUMBER OF SHORT FLASHES AND THE SECOND DIGIT BY THE NUMBER OF LONG FLASHES.

11 NO PREVIOUS CODE - Stored status code is erased automatically after 72

hours. On RED LED boards stored status codes can also be erased when power (115 VAC or 24 VAC) to control is interrupted.

12 BLOWER ON AFTER POWER UP (115 VAC or 24 VAC) -Blower runs for 90

seconds, if unit is powered up during a call for heat (R-W closed) or R-W opens during blower on-delay.

13 LIMIT CIRCUIT LOCKOUT - Lockout occurs if the limit or flame rollout switch is

open longer than 3 minutes.

- Control will auto reset after three hours. - Refer to #33.

14 IGNITION LOCKOUT - Control will auto-reset after three hours. Refer to #34. 21 GAS HEATING LOCKOUT - Control will NOT auto reset.

Check for: - Mis-wired gas valve -Defective control (valve relay)

22 ABNORMAL FLAME-PROVING SIGNAL - Flame is proved while gas valve is

de-energized. Inducer will run until fault is cleared. Check for:

- Leaky gas valve - Stuck-open gas valve

23 PRESSURE SWITCH DID NOT OPEN Check for:

- Obstructed pressure tubing. - Pressure switch stuck closed.

24 SECONDARY VOLTAGE FUSE IS OPEN Check for:

- Short circuit in secondary voltage (24VAC) wiring.

31 PRESSURE SWITCH DID NOT CLOSE OR REOPENED - If open longer than

five minutes, inducer shuts off for 15 minutes before retry. Check for:

- Excessive wind - Proper vent sizing - Defective inducer motor

- Low inducer voltage (115VAC) - Defective pressure switch

- Inadequate combustion air supply - Restricted vent

- Disconnected or obstructed pressure tubing

- Low inlet gas pressure (if LGPS used) If it opens during blower on-delay period, blower will come on for the selected blower off-delay.

33 LIMIT CIRCUIT FAULT - Indicates a limit, or flame rollout is open. Blower will

run for 4 minutes or until open switch remakes whichever is longer. If open longer than 3 minutes, code changes to lockout #13. If open less than 3 minutes status code #33 continues to flash until blower shuts off. Flame rollout switch requires manual reset. Check for: - Restricted vent

- Proper vent sizing - Loose blower wheel - Excessive wind

- Dirty filter or restricted duct system.

- Defective blower motor or capacitor. - Defective switch or connections.

- Inadequate combustion air supply (Flame Roll-out Switch open).

34 IGNITION PROVING FAILURE - Control will try three more times before lockout

#14 occurs. If flame signal lost during blower on-delay period, blower will come on for the selected blower off-delay. Check for: - Control ground continuity

- Flame sensor must not be grounded

- Oxide buildup on flame sensor (clean with fine steel wool).

- Proper flame sense microamps (.5 microamps D.C. min., 4.0 - 6.0 nominal).

- Gas valve defective or gas valve turned off - Manual valve shut-off

- Defective Hot Surface Ignitor

- Low inlet gas pressure

- Inadequate flame carryover or rough ignition

- Green/Yellow wire MUST be connected to furnace sheet metal

45 CONTROL CIRCUITRY LOCKOUT Auto-reset after one hour lockout due to;

- Gas valve relay stuck open - Flame sense circuit failure

- Software check error Reset power to clear lockout. Replace control if status code repeats.

STATUS

COMPONENT TEST

To initiate the component test sequence, shut OFF the room thermostat or disconnect the "R" thermostat lead. Briefly short the TEST/TWIN terminal to the "Com 24V" terminal. Status LED will flash code and then turn ON the inducer motor. The inducer motor will run for the entire component test. The hot surface ignitor, blower motor FAN speed (AMBER LED boards only) blower motor HEAT speed, and blower motor COOL speed will be turned ON for 10-15 seconds each. Gas Valve and Humidifier will not be turned on.

Fig. 20 -- Service Label

327884-101 REV. B

A02270

Page 15

SCHEMATIC DIAGRAM

(NATURAL GAS & PROPANE)

NOTE #2

TO 115VAC FIELD DISCONNECT

EQUIPMENT GROUND

GND

CAP-1

SPARE-2

ILK

EAC-2

IDM

BLWM

START

COM

MED LO

MED HI

NOTE #10

COOL

HEAT

SPARE-1

HI/L O

HSIR

EAC-1

BLWR

AUX

HSI

PL3

PL2

115VAC

PR1

IDR

PL4

24VAC

TRAN

TEST/TWI N

FRS

CAP - 2

SEC-2

SEC-1

NOTE #6

F U 1

PRINTED CIRCIUT BOARD

NOTE #3

(WHEN USED)

NOTE #11

PRS

LGPS

PL1

328150-101 REV. A

GVR-1

CPU

FSE

PG9MAB

NOTE #5

PCB

HUM

24V

1. If any of the ori ginal equipment wire is replaced use wire rated for 105°C.

2. Use only copper wire between the disconnect switch and the furnace junction box (JB).

3. This wire must be co nnected to furnace sheet metal f or control to prove flame.

4. Symbols are electrical representation only.

NOTES:

optimum speed select ion.

auto-reset after three hours.

5. Solid lines inside PCB are printed circuit b oard conductors and are not included i n legend.

6. Replace only wit h a 3 amp fuse.

7. Inducer (IDM) and blower (BLWM) motors contain internal auto-reset thermal overload switches (OL).

8. Neutral connect ions are i nterchangeable withi n the NEUTRAL connecto r block.

9. Blower motor speed s electio ns are for average condit ions, see installation instructi ons for details on

10. YELLOW lead not on all motors.

90 seconds or 5 seconds when J2 i s cut.

11. Factory connected when LGPS is not used.

12. Ignition-lockout will occur after four consecutive unsuccessful trials-for-ignition. Control will

13. Bl ower-on delay: gas heating 60 seconds , coolin g or heat pump 2 seconds.

14. Bl ower-off delay: gas heati ng selections are 90, 120, 150 or 180 s econds, cool ing or heat pump

LGPS

(WHEN USED)

NOTE #11

PRS

ORN

PCB

120

BLOWER OFF DELAY

150

JUMPER SELECT

PRINTED CIRCIUT BOARD

YEL

GRN/YEL

NOTE #3

BLU

FRS

RED

ORN

BLU

180

HUM

TEST/TWIN

24V

FU1

NOTE #6

GRN/YEL

WHT

BLK

CAP -2

TRAN

WHT

BLU

RED

GRN/ YEL

WHT

SEC-1

LED 1

EAC-2

SEC-2

BRN

GRN/YEL

NOTE #8

WHT

321

PL4

YEL

WHT

12345678910

NEUTRAL

IDM

AUX

GRN/YEL

FSE

PL1

BLW

HSI

WHT

PL3

BLK

WHT

BLK

PL2

EAC-1

SPARE 2

BHT/CLR BLWR

COOL

HEAT

SPARE 1

FUSED OR CIRCUIT BREAKER

WHT

BLK

WHT (COM)

PR1

BLWM

BLK (HI)

WHT

(COM)

NEUTRAL

NOTE #2

FU2

BLK

WHT

DISCONNECT SWITCH (WHEN REQ’D)

GRN/YEL

BRN

YEL

(MED HI)

GND

TEMPERATURE SWITCH (N.C.)

OL AUTO-RESET INTERNAL MOTOR OVERLOAD

PCB PRINTED CIRCUIT BO ARD CONTROL

PL1 11-CIRCUIT PCB CONNEC TOR

PL2 2-CIRCUIT CONNECTOR

PL3 2-CIRCUIT HSI, CONNECTOR

ILK

BLK

WHT

CAP -1

BRN

START

RED (LO)

NOTE #10

BLU

(MED LO)

BHT/CLR BLOWER MOTOR SPEED CHANGE RELAY, SPDT

BLWR BLOWER MOTOR RELAY, SPST-(N.O.)

BLWM BLOWER MOTOR, PERMANENT-SPLIT-CAPACITOR

CAP 1,2 CAPACITOR

CPU MICROPROCESSOR AND CIRCUITRY

EAC-1 ELECTRONIC AIR CLEANER CONNECTION (115 VAC 1.0 AMP MAX.)

LEGEN

PL4 3-CIRCUIT IDM EXTEN SION CONNECTOR

EAC-2 ELECTRONIC AIR CLEANER CONNECTION (COMMON)

JUNCTION

UNMARKED TERMINAL

PCB CONTROL TERMINAL

FACTORY WIRING (11 5VAC)

FACTORY WIRING (24 VAC)

FIELD WIRING (115VAC)

FIELD WIRING (24VAC)

CONDUCTOR ON CONTROL PCB

FIELD WIRING SCREW TERMINAL

FIELD EARTH GROUND

EQUIPMENT GROUND

FIELD SPLICE

PLUG RECEPTACLE

PRS PRESSURE SWITCH, SPST-(N.O.)

TEST/TWIN COMPONENT TEST & TWIN TERMINAL

TRAN TRANSFORMER-115VAC/24VAC

(FIELD INSTALLED & SUPPLIED)

FRS FLAME ROLLOUT SW. -MANUAL RESET, SPST-(N.C.)

FSE FLAME-PROVING ELECTRODE

FU 1 FUSE, 3 AMP, AUTOMOTIVE BLADE TYPE, FACTORY INSTALLED

FU 2 FUSE OR CIRCUIT BREAKER CURRENT INTERRUPT DEVICE

GND EQUIPMENT GROUND

GV GAS VALVE-REDUNDANT

GVR 1, 2 GAS VALVE RELAY, DPST-(N.O.)

HSI HOT SURFACE IGNITER (115 VAC)

HSIR HOT SURFACE IGNITER RELAY, SPST-(N.O.)

HUM 24VAC HUMIDIFIER CONNECTION (0.5 AMP . MAX.)

IDM INDUCED DRAFT MOTOR, PSC

IDR INDUCED DRAFT MOTOR RELAY, SPST-(N.O.)

ILK BLOWER ACCESS PANEL INTERLOCK SWITCH, SPST-(N.O.)

J1 BLOWER - OFF DELAY JUMPER SELECTOR

J2 COOLING - OFF DELAY JUMPER

JB JUNCTION BOX

LED LIGHT-EMITTING DIODE FOR STATUS CODES - RED

LGPS LOW GAS PRESSURE SWITCH, SPST- (N.O.)

LS LIMIT SWITCH, AUTO-RESET, SPST (N.C.)

Fig. 21 -- Wiring Diagram

A02271

Page 16

control?

PG9MAB

Close door switch and go back to STA RT.

Is door switch closed?

YES

Is circuit breaker closed?

Is there 115V going to switch?

YES

to furnace.

Check for continuity in wire from circuit breaker

witch.

Replace door s

furnace

YES

the

1 (if present), Y/Y2 or

mostat or

Close circuit breaker and go back to STA RT.

Replace transformer.

Check room ther

or 10 – 15

AN speed

The inducer will start

lower motor F

interconnecting cab

G thermostat terminals on

Is 24V present at

W, Y1 (if present),

respond to

Y/Y2, and G (24V) thermostat signals?

Does the control

nace control. fur

Disconnect all the thermostat wires from the

ver

cycle

cooling or

YES

upted.

heating a

Status codes are erased

On RED LED boards stored

through

k operation.

un system

(115V or 24V) is interr

status codes can also be erased whene

after 72 hours

to chec

lem repeat when using

a jumper wire?

Does the prob

YES

Replace furnace control.

ballast resistor

mostat terminal to

nstall a

Either i

control.

nace

the thermostat, or replace the thermostat.

connect the Com24V ther

fur

The thermostat is not compatible with the

TROUBLESHOOTING GUIDE

YES

Is there 115V at L1 and L2?

YES

START

Is LED status light on?

Is there 24V at SEC-1 and SEC-2?

YES

Replace furnace control.

TEST/TWIN terminal to Com24V terminal until the LED goes out. LED will

the

code recall. You can also recall the previous status code by momentarily shorting

control do not remove power or blower access panel before initiating status

Switch or Flame Rollout switch to display stored status code. On RED LED

To recall status code briefly remove and reconnect one RED wire from the Limit

voltage (24V) transformer phasing.

ing. If units are twinned, check for proper low-

Check for correct line voltage polarity and ground-

YES

pause?

Is LED status light blinking rapidly without a

Is LED status light blinking ON/OFF slowly

YES

with a combination of short and long flashes?

The HSI, b

T speed, and COOL speed will run f

After the control repeats the code 4 times, the

a brief component test sequence.

vious code.

un for the entire component test.

seconds each. Gas valve and humidifier will not be turned on.

(AMBER LED boards only) HEA

and r

control will go through

there was no pre

flash the previous status code or status code #11 (1 short and 1 long flash) if

and the second

The status code is a

t flashes

digit by the number of long flashes?

by the number of shor

2 digit number with the first digit determined

Determine status code.

other than #11?

Was there a previous status code

YES

was flashed.

Go to section below for the status code that

A05107

Page 17

igniter.

er or rough yov

Auto-reset after 1 hour lockout due to:

- Flame circuit failure.

45 CONTROL CIRCUITRY LOCKOUT

minutes, inducer shuts off for 15 minutes

OR REOPENED – If open longer than 5

31 PRESSURE SWITCH DID NOT CLOSE

- Gas valve relay stuck open.

- Software check error.

delay period, blower will come on for the

before retry. If opens during blower on-

Reset power to clear lockout. Replace

control if code repeats.

- Proper vent sizing.

selected blower off-delay. Check for:

- Low inducer voltage (115V).

Check for continuity in the harness and

Replace furnace control.

YES

iod?

second per

the control. Was 115V present for the 15

for 115V between pin 1 and NEUTRAL-L2 on

another component test sequence. Check

Unplug igniter harness from control and initiate

(if LGPS used).

ucted pressure

ustion air supply.

gas pressure

isconnected or obstr

efective pressure switch.

efective inducer motor.

tubing.

- Excessive wind.

-D

- Inadequate comb

- Low inlet

Check connections. If OK, replace control.

Replace defective component.

Reconnect the R thermostat lead and set

Blower

open. is

LT – Indicates the

icted vent.

estr

limit or flame rollout switch

-R

33 LIMIT CIRCUIT FAU

ve. al

Replace v

Check that all gas valves are turned on.

connections. Does gas valve lve

e 24V?

mostat to call for heat. Connect voltmeter

receiv

across gas va

ther

h itc

ver is longer. If open

longer than 3 minutes, code changes to

remakes whiche

will run for 4 minutes or until open sw

Inadequate flame carr

Check for:

YES

e open and allow gas to flow?

Does gas valv

requires manual reset. Check for:

blower shuts off. Flame rollout switch

status code #33 continues to flash until

lockout #13. If open less than 3 min.

ignition.

YES

lower wheel.

- Dirty filter or restricted duct system.

- Loose b

- Proper firing rate.

- Low inlet gas pressure.

Do the main burners ignite?

e blower motor or capacitor.

efectiv

-D

- Defective switch or connections.

er to come on and repeat test to

k connections and retry. If current is

Chec

check for intermittent operation.

Allow blow

YES

urners stay on?

Do the main b

estricted vent.

-R

- Blower motor on incorrect speed tap.

- Excessive wind.

- Proper vent sizing.

or heat and check flame sensor

Repeat call f

nace set too high.

- Input rate to fur

YES

witch open).

(flame rollout s

Inadequate combustion air supply

value (4.0-6.0 nominal) and

burners will not stay on, replace control.

near typical

YES

ow 0.5?

ing trial for ignition period. Is the

DC microamps bel

current dur

out

flame

or ignition

the control will repeat the ignition

iod,

GNITION PROVING FAILURE – If

sequence 3 more times before lo

per

is not sensed during the trial f

34 I

microamps.

recheck current. Nominal current is 4.0 to 6.0

Clean flame sensor with fine steel wool and

YES

MUST be connected

wire

reen/Yellow

to furnace sheet metal.

-G

- Gas valve turned off.

proceeding to the next step.

Check the following items first before

come on for the selected blower off-delay.

the blower on-delay period, blower wil

#14 occurs. If flame signal is lost during

- Manual shut-off valve.

Replace electrode.

Is current near typical value?

- Flame sensor must not be grounded.

Replace furnace control.

YES

urners ignite and stay on?

Will main b

k the igniter. First

igniter, or flame sensor the

the control and initiate the component

remove the R thermostat connection from

test mode to chec

system can be operated in the component

the gas valve,

To determine whether the problem is in

YES

ed. Fix

warm-up period?

orange/white by the end of the 15 second

test sequence. Does the igniter glow

PG9MAB

WER UP –

check system.

upted. Run system through a

heating or cooling cycle to

is interr

erased whenever power (115V or 24V)

boards stored status codes can also be

are erased after 72 hours. On RED LED

NO PREVIOUS CODE – Stored codes

uns for 90 seconds, if unit is er r

WER ON AFTER PO

blower on-delay period.

closed) or when (R-W opens) during th

powered up during a call for heat (R-W

(115V OR 24V) – Normal operation.

12 BLO

13 LIMIT CIRCUIT LOCKOUT – Lockout

occurs if the limit or flame rollout switch is

open longer than 3 minutes. Control will

See code 33

eset after 3 hours.

auto-r

attempts.

See status code 34.

Control will auto-reset after 3 hours.

ignite gas and prove flame in 4

14 IGNITION LOCKOUT – System failed to

n off

21 GAS HEATING LOCKOUT – Tur

Check for:

SECONDARY VOLTAGE FUSE IS OPEN

ltage (24V) vo

t circuit in secondary

wiring including thermostat leads.

-Shor

isconnect thermostat leads to isolate

short circuit.

A05096

on control.

k for:

Chec

power and wait 5 minutes to retry.

VING SIGNAL

k for:

Inducer will run until fault is ed.

- Pressure switch stuck closed.

- Obstructed pressure tube.

- Stuck open or leaky gas valve.

cleared. Chec

energiz

- Miswire or short to gas valve wire.

- Stuck closed gas valve relay

Flame is proved while gas valve is de-

22 ABNORMAL FLAME-PRO

Check for:

23 PRESSURE SWITCH DID NOT OPEN

Page 18

PG9MAB

SERVICE TRAINING

Packaged Service Training programs are an excellent way to increase your knowledge of the equipment discussed in this manual, including:

• Unit Familiarization • Maintenance

• Installation Overview • Operating Sequence A large selection of product, theory, and skills programs is available, using popular video-based formats and materials. All include video and/or slides, plus companion book.

Classroom Service Training plus "hands-on" the products in our labs can mean increased confidence that really pays dividends in faster troubleshooting, fewer callbacks. Course descriptions and schedules are in our catalog.

CALL FOR FREE CATALOG 1-800-644-5544

[ ] Packaged Service Training [ ] Classroom Service Training

A94328

E2008 Payne Heating & Cooling Systems D 7310 W. Morris St. D Indianapolis, IN 46231 Printed in U.S.A. Edition Date: 12/08

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

C a t a l o g N o : S G --- P G 9 M A B --- 0 3

R e p l a c e s : S G --- PG 9 M A B --- 0 2