Payne OG-PG9M-07, PG9MAB User's Information Manual
USER’S INFORMATION MANUAL
Condensing
Gas Furnace
USER’S INFORMATION MANUAL FOR THE OPERATION AND
MAINTENANCE OF YOUR NEW GAS-FIRED FURNACE
NOTE TO INSTALLER:
This manual must be left with the equipment user.
!
WARNING:
FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings exactly could
result in serious injury, death, or property damage.
— Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any
other appliance.
— WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use
any phone in your building.
• Leave the building immediately.
• Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s
instructions.
USER: Please read all instructions in the manual
and retain all manuals for future reference.
• If you cannot reach your gas supplier, call the
fire department.
— Installation and service must be performed by a
qualified installer, service agency or the gas
supplier.
Do not use this furnace if any part has been under
water. A flood-damaged furnace is extremely dan-
gerous. Attempts to use the furnace can result in
fire or explosion. A qualified service agency should
be contacted to inspect the furnace and to replace
all gas controls, control system parts, electrical
parts that have been wet or the furnace if deemed
necessary.
!
WARNING:
CARBON MONOXIDE POISONING HAZARD
Carbon Monoxide is invisible, odorless, and
toxic! Payne Heating & Cooling Systems recommends a carbon monoxide alarm in your
home, even if you do not own a gas appliance.
Locate the carbon monoxide alarm in the living area of your home and away from gas appliances and doorways to attached garages.
Follow the alarm manufacturer’s instruction
included with the alarm.
CERTIFIED
®
As an ENERGY STAR® Partner,
Payne Heating & Cooling Systems Company has determined
that this product meets the
ENERGY STAR® guidelines for
energy efficiency.
TABLE OF CONTENTS
WELCOME TO A NEW GENERATION OF COMFORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
FURNACE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
STARTING AND SHUTTING DOWN YOUR FURNACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Steps for Starting Your Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Shutting Down Your Furnace. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PERFORMING ROUTINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Filtering Out Trouble. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
COMBUSTION AREA AND VENT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Heading South for the Winter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
A CHECK-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
BEFORE YOU REQUEST A SERVICE CALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
WELCOME TO A NEW GENERATION OF COMFORT
Congratulations! In light of rising energy costs, the PG9MAB Multipoise, Fixed-Capacity, Direct/Non-Direct Vent, Condensing Gas
Furnaces are among the soundest investments today’s homeowner can make.
Your new furnace is truly a triumph of technology in home heating. A revolutionary design employs 2 heat exchangers to “squeeze”
out the maximum amount of heat from the fuel consumed. In fact, your new furnace is so efficient, over 90%* of the heat generated
during combustion is captured and delivered inside your home. That is more than a 30%* increase in heating efficiency over conventional furnaces.
This furnace is among the most energy-efficient furnaces you can buy today. The PG9MAB is also among the safest and most
dependable. We are proud of the technological advances incorporated into the design of this furnace. With only minimal care, your
new furnace will deliver many years of money-saving home comfort and enjoyment. Spend just a few minutes with this manual to
learn the operation of your new furnace and the small amount of maintenance it takes to help keep it operating at peak efficiency
year after year.
* The output capacity and any representations of efficiency for this furnace are based on standard U.S. Department of Energy test procedures.
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FURNACE COMPONENTS
1
Burner sight glass for viewing burner flame.
2
Burner assembly (inside), operates with energysaving, inshot burners and hot surface igniter for safe,
dependable heating.
3
Combustion-air intake connection (right or left side).
4
Redundant gas valve. Safe and efficient. Features 1 gas
control with 2 internal shutoff valves.
5
Junction box for 115-v electrical power supply.
6
Vent outlet, uses PVC pipe to carry flue gas from the furnace’s combustion system (right or left side).
7
Secondary condensing heat exchanger (inside). Wrings
out more heat through condensation.
Constructed with polypropylene-laminated steel to ensure durability.
8
Pressure switch ensures adequate flow of flue gas
through furnace and out vent system.
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3
4
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5
6
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6
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16
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9
Inducer motor. Pulls hot flue gases through the heat exchangers, maintaining negative pressure for added safety.
MODEL PG9MAB FURNACE
10
Condensate drain connection, collects moisture
condensed from burned gases for disposal into home
drain system. (location in furnace varies)
11
Heavy-duty blower, circulates air across the heat
exchangers to transfer heat into the home.
12
Air filter and retainer. (Location in furnace may vary.)
13
Rollout switch (manual reset) to prevent
overtemperature.
14
Primary serpentine heat exchanger (inside),
stretches fuel dollars with the S-shaped heat-flow
design. Solid construction of corrosion-resistant
aluminized steel means reliability.
(SHOWN IN UPFLOW POSITION) 1
15
3-amp fuse provides electrical and component
protection.
16
Status code light emitting diode (LED) on furnace control
board. Status code light is for diagnosing furnace operation and service requirements.
17
Furnace control board.
18
Blower access panel safety interlock switch.
19
Transformer (24v) behind furnace control board provides
low-voltage power to furnace control board and
thermostat.
SAFETY CONSIDERATIONS
Installing and servicing of 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. Observe safety precautions in this manual, on tags, and on labels attached to the furnace
and other safety precautions that may apply.
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, CAUTION, and NOTE. DANGER, WARNING, and CAUTION are used
with the safety-alert symbol. DANGER identifies the most serious hazards which
WARNING signifies hazards 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.
To minimize the possibility of serious personal injury, fire, damage to your furnace, or improper operation,
safety rules
Your new gas furnace may have been installed in 1 of 2 ways, as a direct-vent (2-pipe) application or as a non-direct vent (1-pipe)
application.
which apply to both direct-vent and non-direct vent applications:
could result in personal injury or death. CAUTION is used to identify unsafe practices which
!
will result in severe personal injury or death.
carefully follow these
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In a direct-vent (2-pipe) application, your furnace uses air from outside the home for combustion and vents flue gas to the outdoors.
This type of application will have 2 pipes running from the furnace to the outdoors. (See Fig. 2.) In this application, the vent and airintake pipes must terminate outside the structure and must not be obstructed in any way. Do not block or obstruct air openings on
furnace or spaces around furnace.
In a non-direct vent (1-pipe) application, your furnace uses air from adjacent to the furnace for combustion and vents flue gas to the
outdoors. This type of application will have only 1 pipe running from the furnace to the outdoors. (See Fig. 3.) The other pipe will
terminate in the same space as the furnace and is the source of combustion air for your furnace. Therefore, the furnace must not be
enclosed in an airtight room or be sealed behind solid doors. It must have adequate airflow for efficient combustion and safe ventilation. Do not obstruct the combustion-air pipe in any way. The vent pipe must terminate outside the structure and must not be
obstructed in any way. Do not block or obstruct air openings or space around furnace.
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• Keep the area around your furnace clear and free of combustible materials, gasoline, and other flammable liquids and vapors.
4
• Do not cover the furnace, store trash or debris near it, or in any way block the flow of fresh air to the unit.
In addition to the safety rules above, make sure that the following combustion-air requirements are met for non-direct vent applica-
tions:
• Combustion air must be clean and uncontaminated with chlorine or fluorine. These compounds are present in many products
around the home, such as: water softener salts, laundry bleaches, detergents, adhesives, paints, varnishes, paint strippers, waxes,
and plastics.
• Make sure the combustion air for your furnace does not contain any of these compounds. During remodeling be sure the combustion
air is fresh and uncontaminated. If these compounds are burned in your furnace, the heat exchangers may deteriorate.
• A furnace installed in an attic or other insulated space must be kept free and clear of insulating material. Examine the furnace area
when the furnace is installed or when insulation is added. Some insulation materials may be combustible.
• Should the gas supply fail to shut off or if overheating occurs, shut off the gas valve to the furnace before shutting off electrical
supply.
This furnace contains SAFETY DEVICES which must be MANUALLY RESET. If the furnace is left unattended for an extended
period of time, have it checked periodically for proper operation. This precaution will prevent problems associated with no heat, such
as frozen water pipes, etc. See “Before You Request a Service Call” section in this manual
!
WARNING:
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in fire, personal injury/death or property damage.
Do not keep combustible materials, gasoline, and other flammable liquids or vapors around your furnace.
.
4
.
!
WARNING:
FIRE AND UNIT OPERATION HAZARD
Failure to follow this warning could result in fire, personal injury/death or property damage.
For proper and safe operation the furnace needs air for combustion and ventilation. Do not block or obstruct
the openings on the furnace, air openings to the area in which the furnace is installed, and the space around
the furnace.
Examine the furnace installation monthly to determine that:
1. All flue gas carrying areas external to the furnace (i.e. chimney, vent connector) are clear and free of obstructions.
2. The vent connector is in place, slopes upward and is physically sound without holes or excessive corrosion.
3. The return-air duct connection(s) is physically sound, is sealed to the furnace casing, and terminates outside the space
containing the furnace.
4. The physical support of the furnace is sound without sagging cracks, gaps, etc. around the base.
5. There are no obvious signs of deterioration of the furnace.
6. The burner flames are in good adjustment. (See Fig. 5.)
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STARTING AND SHUTTING DOWN YOUR FURNACE
Instead of a continuously burning pilot flame which wastes valuable energy, your furnace uses an automatic, hot surface ignition
system to light the burners each time the thermostat starts your furnace.
Follow these important safeguards:
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• Never attempt to light the burners manually with a match or other source of flame.
• Read and follow the operating instructions on the inside of main furnace door, especially the item that reads as follows:
Wait 5 minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas,
information above on this furnace label. If you don’t smell gas, go to the next step.
STOP! Follow “B” in the safety
• If a suspected malfunction occurs with your gas control system, such as the burners not lighting when they should, refer to the
shutdown procedures on the inside of main furnace door, or in the “Shutting Down Your Furnace” section, and call your dealer as
soon as possible.
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