Payne PG8MVA, PG8JVA Installation Instructions Manual

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VA R I A B L E --- S P E E D

PG8MVA PG8JVA

Installation Instructions

SAFETY CONSIDERATIONS 2........................

INTRODUCTION 4..................................

CODES AND STANDARDS 4..........................

Safety 4...........................................

General Installation 4................................

Combustion and Ventilation Air 4......................

Duct Systems 4.....................................

Acoustical Lining and Fibrous Glass Duct 4...............

Gas Piping and Gas Pipe Pressure Testing 4...............

Electrical Connections 4..............................

Venting 4.........................................

ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS

PROCEDURE 4.....................................

LOCATION 5.......................................

AIR FOR COMBUSTION AND VENTILATION 8.........

Outdoor Combustion Air Method 9....................

The Standard Method: 9............................

Combination of Indoor and Outdoor Air 10.............

INSTALLATION 10..................................

Bottom Return Air Inlet 10..........................

Side Return Air Inlet 10.............................

Leveling Legs (If Desired) 11........................

Bottom Return Air Inlet 11..........................

Suspended Furnace Support 11.......................

Platform Furnace Support 11.........................

Roll--Out Protection 12.............................

Bottom Return Air Inlet 12..........................

Side Return Air Inlet 12.............................

Filter Arrangement 13..............................

AIR DUCTS 13......................................

General Requirements 13............................

Ductwork Acoustical Treatment 13....................

Supply Air Connections 14..........................

Upflow and Horizontal Furnaces 14...................

Downflow Furnaces 15.............................

Return Air Connections 18..........................

Downflow Furnaces 18.............................

Upflow and Horizontal Furnaces 18...................

INDUCED ---COMBUSTION

4---WAY MULTIPOISE GAS FURNACE

SERIES A

GAS PIPING 19.....................................

ELECTRICAL CONNECTION 20.......................

ACCESSORIES 22...................................

VENTING 22.......................................

START--UP, ADJUSTMENT, AND SAFETY CHECK 34.....

General 34........................................

Start--Up Procedures 37..............................

Adjustments 37.....................................

Check Safety Controls 45.............................

Checklist 46.......................................

SERVICE AND MAINTENANCE PROCEDURES 46.......

General 46........................................

Care and Maintenance 47.............................

Sequenceof Operation 52.............................

Wiring Diagram 56..................................

Troubleshooting 56..................................

PARTS REPLACEMENT INFORMATION GUIDE 59.......

Always Ask For

CERTIFIED

Use of the AHRI Certified manufacturer’s participation in the program. For verification of certification for individual products, go to www.ahridirectory.org.

NOTE: Read the entire instruction manual before starting the installation.

Portions of the text and tables are reprinted from NFPA 54/ANSI Z223.1--2012E, with permission of National Fire Protection Association, Quincy, MA 02269 and American Gas Association, Washington DC 20001. This reprinted material is not the complete and official position of the NFPA or ANSI on the referenced subject, which is represented only by the standard in its entirety.

Mark indicates a

SAFETY CONSIDERATIONS

WARNING

FIRE, EXPLOSION, ELECTRICAL SHOCK, AND CARBON MONOXIDE POISONING HAZARD

Failure to follow this warning could result in dangerous operation, 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 service agency, local gas supplier, or your distributor or branch for information or assistance. The qualified service agency must use only factory--authorized and listed kits or accessories when modifying this product.

PG8MVA

FURNACE RELIABILITY HAZARD

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

Application of this furnace should be indoors with special attention given to vent sizing and material, gas input rate, air temperature rise, unit leveling, and unit sizing.

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 furnace and other safety precautions that may apply.

These instructions cover 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.

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, safety glasses and gloves when handling parts, and servicing furnaces.

Wear safety glasses, protective clothing and work gloves. Have fire extinguisher available during start--up and adjustment procedures and service calls.

This is the safety--alert symbol 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

CAUTION

. When you see this symbol on

to identify 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.

1. Use only with type of gas approved for this furnace. Refer to the furnace rating plate.

2. Install this furnace only in a location and position as specified in the “Location” section of these instructions.

3. Provide adequate combustion and ventilation air to the furnace space as specified in “Air for Combustion and Ventilation” section.

4. Combustion products must be discharged outdoors. Connect this furnace to an approved vent system only, as specified in the “Venting” section of these instructions.

5. Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections, as specified in the “Gas Piping” section.

6. 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 the “Start--Up, Adjustments, and Safety Check” section. See furnace rating plate.

7. When a furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by duct(s) sealed to the furnace casing and terminating outside the space containing the furnace. See “Air Ducts” section.

8. A gas--fired furnace for installation in a residential garage must be installed as specified in the warning box in the “Location” section.

9. The furnace may be used for construction heat provided that the furnace installation and operation complies with the first CAUTION in the LOCATION section of these instructions.

10. These Multipoise Gas--Fired Furnaces are CSA (formerly A.G.A. and C.G.A.) design--certified for use with natural and propane gases (see furnace rating plate) and for installation in alcoves, attics, basements, closets, utility rooms, crawlspaces, and garages. The furnace is factory--shipped for use with natural gas. A CSA (A.G.A. and C.G.A.) listed accessory gas conversion kit is required to convert furnace for use with propane gas.

11. See Fig. 1 for required clearances to combustible construction.

12. Maintain a 1--in. (25 mm) clearance from combustible materials to supply air ductwork for a distance of 36 in. (914 mm) horizontally from the furnace. See NFPA 90B or local code for further requirements.

13. These furnaces SHALL NOT be installed directly on carpeting, tile, or any other combustible material other than wood flooring. In downflow installations, factory accessory floor base MUST be used when installed on combustible materials and wood flooring. Special base is not required when this furnace is installed on manufacturer’s Coil Assembly Part No. CNRV, CNPV, CAP, or CAR or when Coil Box Part No. KCAKC is used. See Fig. 1 for clearance to combustible construction information.

Fig. 1 -- Clearances to Combustibles

PG8MVA

A10269

INTRODUCTION

The Series 150/F 4--way multipoise Category I fan--assisted furnace is CSA (formerly A.G.A. and C.G.A.) design--certified. A Category I fan--assisted furnace is an appliance equipped with an integral mechanical means to either draw or force products of combustion through the combustion chamber and/or heat exchanger. The furnace is factory--shipped for use with natural gas. This furnace is not approved for installation in mobile homes, recreational vehicles, or outdoors.

PG8MVA

80 / 27 C

/ 16 C

only the NFGC, contact the American Gas Association, 400 N. Capitol Street, N.W., Washington, DC 20001 (www.AGA.org.) .

Combustion and Ventilation

Section 9.3 NFPA 54/ANSI Z223.1--2012, Air for Combustion and Ventilation .

Systems

Duct

Air Conditioning Contractors Association (ACCA) Manual D, Sheet Metal and Air Conditioning Contractors National Association (SMACNA), or American Society of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE) 2001 Fundamentals Handbook Chapter 34 or 2000 HVAC Systems and Equipment Handbook Chapters 9 and 16.

Acoustical Lining and Fibrous Glass

Current edition of SMACNA and NFPA 90B as tested by UL Standard 181 for Class I Rigid Air Ducts

Gas Piping and Gas Pipe Pressure T

NFPA 54/ANSI Z223.1--2012 ; chapters 5, 6, and 7 and National Plumbing Codes .

Electrical

National Electrical Code (NEC) ANSI/NFPA70--2011 .

enting

NFPA 54/ANSI Z223.1--2012; chapters 12 and 13.

Connections

Air

Duct

esting

A06745

Fig. 2 -- Return Air Temperature

This furnace is designed for minimum continuous return--air temperature of 60_F(15_C) db or intermittent operation down to 55_F(13_C)db such as when used with a night setback thermostat. Return--air temperature must not exceed 80_F(27_C) db. Failure to follow these return--air temperature limits may affect reliability of heat exchangers, motors, and controls. (See Fig. 2.)

For accessory installation details, refer to the applicable instruction literature.

NOTE: Remove all shipping brackets and materials before operating the furnace.

CODES AND STANDARDS

Follow all national and local codes and standards in addition to these instructions. The installation must comply with

regulations of the serving gas supplier, local building, heating, plumbing, and other codes. In absence of local codes, the installation must comply with the national codes listed below and all authorities having jurisdiction.

In the United States, follow all codes and standards for the following:

Safety

NFPA 54/ANSI Z223.1--2012 and the Installation Standards, Warm Air Heating and Air Conditioning Systems ANSI/NFPA 90B .

General

Current edition of the NFGC and the NFPA 90B. For copies, contact the National Fire Protection Association Inc., Batterymarch Park, Quincy, MA 02269; (www.NFPA.org) or for

Installation

ELECTROSTATIC DISCHARGE (ESD)

PRECAUTIONS PROCEDURE

CAUTION

FURNACE RELIABILITY HAZARD

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

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. Multiple disconnects may be required. DO NOT TOUCH THE CONTROL OR ANY WIRE CONNECTED TO THE CONTROL PRIOR TO DISCHARGING YOUR BODY’S ELECTROSTATIC CHARGE TO GROUND.

2. Firmly touch the clean, unpainted, metal surface of the furnace chassis which is close to the control. Tools held in a person’s hand during grounding will be satisfactorily discharged.

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

WEIGHT

SHIPPING

FLUE COLLAR

inches mm LBS KG

115 52.1

(BOTTOM INLET WIDTH)

4 102

[582.6]

22 15/16

22 3/4

[577.8]

[573.1]

22 9/16

21 5/8

[549.3]

19 3/4

[501.6]

[481.7]

OUTLET

AIR FLOW

1/2

7 13/16

[12.7]

[290.7]

11 7/16

[245.4]

9 11/16

[197.8]

1 3/4

[44.5]

GAS ENTRY

THERMOSTAT WIRE ENTRY

14 7/8

[337.3]

7/8

(BOTH SIDES)

[22.2]

ACCESSORY

[25.4]

[560]

22 1/16

1 1/4

[31.8]

26 1/16

SIDE INLET

(BOTH SIDES)

[662.0]

[671.5]

26 7/16

REV

SHT

SD4973-4

PART NUMBER

NONE

NEXT SHEET

TOP AND BOTTOM

(VENT KNOCKOUT LOCATION)

(OUTLET WIDTH)

(CABINET WIDTH)

(MODELS)

FURNACE SIZE

26 1/8

[663.6]

inches mm inches mm inches mm inches mm

036-070 14 3/16 360 12 9/16 319 9 5/16 237 12 11/16 322

048-090 17 1/2 445 15 7/8 403 11 9/16 294 16 406 130 59.0

060-110 21 533 19 3/8 495 13 5/16 338 19 1/2 495 155 70.3

(PG8JVA/PG8MVA)

066-135 24 1/2 622 22 7/8 584 15 1/16 383 23 584 166 75.3

5 1/8

Z-Z

SECTION

61:3 ELACS

[130.5]

2 1/16

[51.6]

1 11/16

[43.5]

7/8

[22.2]

ACCESSORY

7/8

2 5/16

[22.2]

[59]

ACCESSORY

KNOCK OUTS FOR

VENTING (5 PLACES)

3/4

[19.1]

WIDTH

BOTTOM RETURN

6 1/8

[155.7]

28 3/8

[721.2]

21 5/8

[549.5]

BOTTOM INLET

PG8MVA

[736.9]

7/8

[22.2]

[122.2]

4 13/16

9 9/16

[243.3]

AIR FLOW

7/8

[22.2]

JUNCTION BOX

LOCATION

7/8

[22.2]

ACCESSORY (2)

[49.2]

1 15/16

3 7/16

[86.8]

5 7/8

AIR FLOW

[148.5]

7/8

[22.2]

ACCESSORY

LOCATION

ALTERNATE

JUNCTION BOX

27 3/4

[704.7]

[750.7]

29 9/16

1 3/4

[44.5]

GAS ENTRY

1/2

[12.7]

THERMOSTAT WIRE ENTRY

*135 size furnaces requires a 5 or 6 ---in. (127 or 152 mm) ven t. Use a vent adapter between furnace and vent stack. See Installation Instructions for complete install ation requirements.

5 1/2

[140.3]

5 15/16

[150.7]

8 7/16

[213.5]

Fig. 3 -- Dimensional Drawing

9 7/8

[250.7]

27 3/4

[704.7]

33 1/4

[843.9]

A12051

4. If you touch ungrounded objects (and recharge your body with static electricity), firmly touch a clean, unpainted metal surface of the furnace again before touching control or wires.

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

6. Before removing a new control from its container, discharge your body’s electrostatic charge to ground to protect the control from damage. If the control is to be installed in a furnace, follow items 1 through 4 before bringing the control or yourself in contact with the furnace. Put all used and new controls into containers before touching ungrounded objects.

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

LOCATION

GENERAL This multipoise furnace is shipped in packaged configuration.

Some assembly and modifications are required when used in any of the four applications shown in Fig. 5.

PG8MVA

NOTE: For high--altitude installations, the high--altitude conversion kit MUST be installed at or above 5500 ft. (1676 M) above sea level. Obtain high--altitude conversion kit from your area authorized distributor.

This furnace must:

S be installed so the electrical components are protected

from water.

S not be installed directly on any combustible material

other than wood flooring (refer to SAFETY CONSIDERATIONS).

S be located close to the chimney or vent and attached to

an air distribution system. Refer to Air Ducts section.

S be provided ample space for servicing and cleaning.

Always comply with minimum fire protection clearances shown on the furnace clearance to combustible construction label.

WARNING

CARBON MONOXIDE POISONING / COMPONENT DAMAGE HAZARD

Failure to follow this warning could result in personal injury or death and unit component damage.

Corrosive or contaminated air may cause failure of parts containing flue gas, which could leak into the living space. Air for combustion must not be contaminated by halogen compounds, which include fluoride, chloride, bromide, and iodide. These elements can corrode heat exchangers and shorten furnace life. Air contaminants are found in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air fresheners, and other household products. Do not install furnace in a corrosive or contaminated atmosphere. Make sure all combustion and circulating air requirements are met, in addition to all local codes and ordinances.

The following types of furnace installations may require OUTDOOR AIR for combustion due to chemical exposures:

S Commercial buildings S Buildings with indoor pools S Laundry rooms S Hobby or craft rooms, and S Chemical storage areas

If air is exposed to the following substances, it should not be used for combustion air, and outdoor air may be required for combustion:

S Permanent wave solutions S Chlorinated waxes and cleaners S Chlorine based swimming pool chemicals S Water softening chemicals S De--icing salts or chemicals S Carbon tetrachloride S Halogen type refrigerants S Cleaning solvents (such as perchloroethylene) S Printing inks, paint removers, varnishes, etc. S Hydrochloric acid S Cements and glues S Antistatic fabric softeners for clothes dryers S Masonry acid washing materials

All fuel--burning equipment must be supplied with air for fuel combustion. Sufficient air must be provided to avoid negative pressure in the equipment room or space. A positive seal must be made between the furnace cabinet and the return--air duct to prevent pulling air from the burner area and from draft safeguard opening.

WARNING

FIRE, INJURY OR DEATH HAZARD

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

When the furnace is installed in a residential garage, the burners and ignition sources must be located at least 18 in. (457 mm) above the floor. The furnace must be located or protected to avoid damage by vehicles. When the furnace is installed in a public garage, airplane hangar, or other building having a hazardous atmosphere, the furnace must be installed in accordance with the NFPA 54/ANSI Z223.1--2012 . (See Fig. 4.)

18-IN. (457.2 mm)

MINIMUM TO BURNERS

A93044

Fig. 4 -- Installation in a Garage

THE BLOWER IS LOCATED

TO THE RIGHT OF THE

BURNER SECTION, AND

AIR CONDITIONED AIR IS

DISCHARGED TO THE LEFT.

THE BLOWER IS

LOCATED BELOW THE

BURNER SECTION, AND

CONDITIONED AIR IS

DISCHARGED UPWARD.

THE BLOWER IS

LOCATED ABOVE THE

BURNER SECTION, AND

CONDITIONED AIR IS

DISCHARGED DOWNWARD

Fig. 5 -- Multipoise Orientations

WARNING

FIRE HAZARD

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

Do not install the furnace on its back or hang furnace with control compartment facing downward. Safety control operation will be adversely affected. Never connect return--air ducts to the back of the furnace. (See Fig. 6.)

LOCATION RELATIVE TO COOLING EQUIPMENT

The cooling coil must be installed parallel with, or on the downstream side of the unit to avoid condensation in the heat exchangers. When installed parallel with the furnace, dampers or other flow control must prevent chilled air from entering the furnace. If the dampers are manually operated, they must be equipped with means to prevent operation of either unit unless the damper is in the full--heat or full--cool position.

A02054

Fig. 6 -- Prohibit Installation on Back

THE BLOWER IS

LOCATED TO THE LEFT

OF THE BURNER SECTION,

AND CONDITIONED AIR IS

DISCHARGED TO THE RIGHT.

CAUTION

PERSONAL INJURY AND/OR PROPERTY DAMAGE HAZARD

Improper use or installation of this furnace may result in premature furnace component failure. This gas furnace may be used for heating buildings under construction provided that:

--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 gas input rate has been set to the nameplate 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.

--Verify proper furnace operating conditions including ignition, gas input rate, air temperature rise, and venting according to these installation instructions.

PG8MVA

A02097

Table 1 – Minimum Free Area Required for Each Combustion Air opening of Duct to Outdoors

FURNACE

INPUT

(BTUH)

44,000 22 (14194) 6 (152) 14.7 (9484) 5 (127) 11 (7096) 4 (102) 66,000 33 (21290) 7 (178) 22 (14193) 6 ( 152) 16.5 (10645) 5 (127)

88,000 44 (28387) 8 (203) 29.3 ( 18903) 7 (178) 22 (14193) 6 (152) 110,000 55 (35484) 9 (229) 36.7 (23677) 7 (178) 27.5 ( 17742) 6 (152) 132,000 66 (42580) 10 (254) 44 (28387) 8 (203) 33 (21290) 7 (178) 154,000 77 (49677) 10 (254) 51.3 (33096) 9 (229) 38.5 (24839) 8 (203)

TWO HORIZONTAL DUCTS SINGLE DUCT OR OPENING TWO OPENINGS OR VERTICAL DUCTS

(1 SQ. IN./2,000 BTUH) (1,100 SQ. MM/KW) (1 SQ. IN./3,000 BTUH) (734 SQ. MM/KW) (1 SQ. IN./4,000 BTUH) (550 SQ. MM/KW)

Free Area of Opening

and Duct

Sq. In. (Sq. mm)

Round Duct

Dia.

In. (mm)

Free Area of Opening

and Duct

Sq. In. (Sq. mm)

Round Duct

Dia.

In. (mm)

Free Area of Opening

and Duct

Sq. In. (Sq. mm)

EXAMPLES: Determining Free Area

FURNACE WATER HEATER TOTAL INPUT

110,000 + 30,000 = (140,000 divided by 4,000) = 35.0 Sq. In. for each two Vertical Ducts or Openings

66,000 + 40,000 = (106,000 divided by 3,000) = 35.3 Sq. In. for a Single Duct or Opening

88,000

+ 30,000 = (118,000 divided by 2,000) = 59.0 Sq. In. for each of two Horizontal Ducts

PG8MVA

Table 2 – Minimum Space Volumes for 100% Combustion, Ventilation, and Dilution from Indoors

OTHER THAN FAN-ASSISTED TOTAL

(1,000’S BTUH GAS INPUT RATE)

ACH

0.60

0.50

0.40

0.30

0.20

0.10

0.00 NP NP NP NP NP NP NP NP NP

NP = Not Permitted

30 40 50 44 66 88 110 132 154

Space Volume Ft3(M3)

1,050

(29.7)

1,260

(35.6)

1,575

(44.5)

2,100

(59.4)

3,150

(89.1)

6,300

(178.3)

1,400

(39.6)

1,680

(47.5)

2,100

(59.4)

2,800

(79.2)

4,200

(118.9)

8,400

(237.8)

1,750 (49.5)

2,100 (59.4)

2,625 (74.3)

3,500 (99.1)

5,250 (148.6)

10,500 (297.3)

1,100

(31.1)

1,320

(37.3)

1,650

(46.7)

2,200

(62.2)

3,300

(93.4)

6,600

(186.8)

1,650

(46.7)

1,980

(56.0)

2,475

(70.0)

3,300

(93.4)

4,950

(140.1)

9,900

(280.3)

FAN-ASSISTED TOTAL

(1,000’S BTUH GAS INPUT RATE)

2,200 (62.2)

2,640 (74.7)

3,300 (93.4)

4,400

(124.5)

6,600

(186.8) 13,200

(373.7)

2,750

(77.8)

3,300

(93.4)

4,125

(116.8)

5,500

(155.7)

8,250

(233.6)

16,500

(467.2)

3,300

(93.4)

3,960

(112.1)

4,950

(140.1)

6,600

(186.8)

9,900

(280.3) 19,800

(560.6)

Round Duct

Dia.

In. (mm)

3,850

(109.0)

4,620

(130.8)

5,775

(163.5)

7,700

(218.0) 11,550

(327.0) 23,100

(654.1)

AIR FOR COMBUSTION AND

VENTILATION

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

S U.S. Installations: Section 9.3 of the NFPA 54/ANSI

Z223.1--2012 , Air for Combustion and Ventilation and applicable provisions of the local building codes.

CAUTION

FURNACE CORROSION HAZARD

Failure to follow this caution may result in furnace damage. Air for combustion must not be contaminated by halogen

compounds, which include fluoride, chloride, bromide, and iodide. These elements can corrode heat exchangers and shorten furnace life. Air contaminants are found in aerosol sprays, detergents, bleaches, cleaning solvents, salts, air fresheners, and other household products.

WARNING

CARBON MONOXIDE POISONING HAZARD

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

The operation of exhaust fans, kitchen ventilation fans, clothes dryers, attic exhaust fans or fireplaces could create a NEGATIVE PRESSURE CONDITION at the furnace. Make--up air MUST be provided for the ventilation devices, in addition to that required by the furnace. Refer to the Carbon Monoxide Poisoning Hazard warning in the venting section of these instructions to determine if an adequate amount ofmake--up air isavailable.

The requirements for combustion and ventilation air depend upon whether or not the furnace is located in a space having a volume of at least 50 cubic feet per 1,000 Btuh input rating for all gas appliances installed in the space.

S Spaces having less than 50 cubic feet per 1,000 Btuh

require the OUTDOOR COMBUSTION AIR METHOD.

1 SQ IN.

12 ″ MAX

(305mm)

1 SQ IN. PER 4000 BTUH*

PER 4000 BTUH*

1 SQ IN .

BTUH*

1 SQ IN .

BTUH*

12 ″ MAX

PER

4000

OUTDOORS

PER 4000

12 ″ MAX

DUCTS

O UTDOORS

(305mm)

12 ″ MAX

1 SQ IN. PER 2000 BTUH*

DUCT S

OUTDOORS

1 SQ IN. PER 2000 BTUH*

(305mm)

12 ″ MAX

CIRCULA TING AIR DUCT S

*Minimum dimensions of 3 --- in. (76 mm).

NOTE: Use any of the following combinations of openings:

A&BC&DD&EF&G

AIR DUCTS

C IRCULA TING

OF COMB USTION AIR

CLEARANCE IN FRONT

VENT THR OUGH R OOF

(76mm)

AT LEAST 3 IN .

OPENINGS SHALL BE

DUCT

OUTDOORS

Fig. 7 -- Air for Combustion, Ventilation, and Dilution for

Outdoors

(305mm)

A03174

CIRCULATING AIR

DUCTS

INTERIOR

HEATED

SPACE

CIRCULATING AIR DUCTS

* Minimum opening size is 100 sq in. (64516 sq. mm)with minimum dimensions of3in.(76mm) †Minimumof3in.(76mm)whentype-B1ventisused.

VENT THROUGH ROOF

12" MAX

1 SQ IN. PER 1000 BTUH* IN DOOR OR WALL

UNCONFINED SPACE

(152mm)

6" MIN (FRONT)

1 SQ IN. PER 1000 BTUH* IN DOOR

OPENINGS SHALL BE AT LEAST 3 IN.

OR WALL

CLEARANCE IN FRONT OF COMBUSTION AIR

12" MA X

(305mm)

A03175

Fig. 8 -- Air for Combustion, Ventilation, and Dilution from

Indoors

PG8MVA

S Spaces having at least 50 cubic feet per 1,000 Btuh

may use the INDOOR COMBUSTION AIR, STANDARD or KNOWN AIR INFILTRATION

METHOD.

Outdoor Combustion Air Method

1. Provide the space with sufficient air for proper combustion, ventilation, and dilution of flue gases using permanent horizontal or vertical duct(s) or opening(s) directly communicating with the outdoors or spaces that freely communicate with the outdoors.

2. Fig. 7 illustrates how to provide TWO OUTDOOR OPENINGS, one inlet and one outlet combustion and ventilation air opening, to the outdoors.

a. One opening MUST commence within 12 in. (300

mm) of the ceiling and the second opening MUST commence within 12 in. (300 mm) of the floor.

b. Size openings and ducts per Fig. 7 and Table 1.

c. TWO HORIZONTAL DUCTS require 1 sq. in. (645

sq. mm) of free area per 2,000 Btuh (1,100 mm of combined input for all gas appliances in the space per Fig. 7 and Table 1.

d. TWO OPENINGS OR VERTICAL DUCTS require 1

sq. in. (645 sq. mm) of free area per 4,000 Btuh (550

/kW) for combined input of all gas appliances in

mm the space per Fig. 7 and Table 1.

3. ONE OUTDOOR OPENING requires:

a. 1 sq. in. (645 sq. mm) of free area per 3,000 Btuh

(734 mm ances in the space per Table 1 and

b. Not less than the sum of the areas of all vent connect-

ors in the space.

/kW) for combined input of all gas appli-

/kW)

The opening shall commence within 12 in. (300 mm) of the ceiling. Appliances in the space shall have clearances of at least 1 in. (25 mm) from the sides and back and 6 in. (150 mm) from the front. The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces (crawl or attic) that freely communicate with the outdoors.

Indoor Combustion AirE NFPA & AGA Standard and Known--Air--Infiltration Rate Methods Indoor air is permitted for combustion, ventilation, and dilution,

if the Standard or Known--Air--Infiltration Method is used.

WARNING

CARBON MONOXIDE POISONING HAZARD

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

Many homes require air to be supplied from outdoors for furnace combustion, ventilation, and dilution of flue gases.

The furnace combustion air supply must be provided in accordance with this instruction manual.

The Standard Method:

1. The space has no less volume than 50 cubic feet per 1,000 Btuh of the maximum input ratings for all gas appliances installed in the space and

2. The air infiltration rate is not known to be less than 0.40 air changes per hour (ACH).

The Known Air Infiltration Rate Method shall be used, if the infiltration rate is known to be:

1. Less than 0.40 ACH and

2. 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 1 and 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.

Table 2 -- Minimum Space Volumes were determined by using the following equations from the National Fuel Gas Code ANSI

Z223.1--2012/NFPA 54--2012, 9.3.2.2:

1. For other than fan--assisted appliances, such as a draft hood--equipped water heater:

Volume

PG8MVA

If: Iother = combined input of all other than fan--assisted appliances in Btuh/hr

Ifan = combined input of all fan--assisted appliances in Btuh/hr ACH = air changes per hour (ACH shall not exceed 0.60.) The following requirements apply to the Standard Method and

to the Known Air Infiltration Rate Method.

Other

2. For fan--assisted appliances such as this furnace:

Fan

1. Adjoining rooms can be considered part of a space if:

a. There are no closeable doors between rooms.

b. Combining spaces on same floor level. Each opening

shall have free area of at least 1 in. mm in the space, but not less than 100 in. opening shall commence within 12 in. (300 mm) of the ceiling and the second opening shall commence within 12 in. (300 mm) of the floor. The minimum dimension of air openings shall be at least 3 in. (80 mm).(SeeFig.8.)

c. Combining space on different floor levels. The

volumes of spaces on different floor levels shall be considered as communicating spaces if connected by one or more permanent openings in doors or floors having free area of at least 2 in. mm

2. An attic or crawlspace may be considered a space that freely communicates with the outdoors provided there are adequate permanent ventilation openings directly to outdoors having free area of at least 1--in. input rating for all gas appliances in the space.

3. In spaces that use the Indoor Combustion Air Method, infiltration should be adequate to provide air for combustion, permanent ventilation and dilution of flue gases. However, in buildings with unusually tight construction, additional air MUST be provided using the methods describedintheOutdoor Combustion Air Method section.

4. Unusually tight construction is defined as Construction with:

a. Walls and ceilings exposed to the outdoors have a con-

tinuous, sealed vapor barrier. Openings are gasketed or sealed and

b. Doors and openable windows are weatherstripped and

c. Other openings are caulked or sealed. These include

joints around window and door frames, between sole

21ft

ACH

15ft

ACH

/kW) of the total input rating of all gas appliances

/kW) of total input rating of all gas appliances.

other

1000 Btu/hr

fan

1000 Btu/hr

/1,000 Btuh (2,000

/1,000 Btuh (4,400

/4,000 Btuh of total

(0.06 m2). One

A04002

A04003

plates and floors, between wall--ceiling joints, between wall panels, at penetrations for plumbing, electrical and gas lines, etc.

Combination of Indoor and Outdoor

1. Indoor openings shall comply with the Indoor Combustion Air Method below and,

2. Outdoor openings shall be located as required in the Outdoor Combustion Air Method mentioned previously and,

3. Outdoor openings shall be sized as follows:

a. Calculate the Ratio of all Indoor Space volume divided

by required volume for Indoor Combustion Air Method below.

b. Outdoor opening size reduction Factor is 1 minus the

Ratio in a. above.

c. Minimum size of Outdoor openings shall be the size

required in Outdoor Combustion Air Method above multiplied by reduction Factor in b. above. The minimum dimension of air openings shall be not less than 3in.(80mm).

Air

INSTALLATION

UPFLOW INSTALLATION Bottom Return Air

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

1. Tilt or raise furnace and remove 2 screws holding bottom filler panel. (See Fig. 9.)

2. Rotate bottom filler panel downward to release holding tabs.

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

Side Return Air

These furnaces are shipped with bottom closure panel installed in bottom return--air opening. This panel MUST be in place when only side return air is used.

Fig. 9 -- Removing Bottom Closure Panel

NOTE: Side return--air openings can be used in UPFLOW and

most HORIZONTAL configurations. Do not use side return--air openings in DOWNFLOW configuration.

Leveling Legs (If Desir

In upflow position with side return inlet(s), leveling legs may be used. (See Fig. 10.) Install field--supplied, 5/16 X 1--1/2 in. (8 X 38 mm) (max) corrosion--resistant machine bolts, washers and nuts.

Inlet

Bottom Closure Panel

Bottom Filler Panel

A10273

ed)

16 

(8mm)

16 

1 3 / 4 

(44mm)

/ 4 

(44mm)

(8mm)

/ 16 

(8mm)

16 

(44mm)

4 

A89014

(44mm)

Fig. 10 -- Leveling Legs

NOTE: Bottom closure must be used when leveling legs are

used. It may be necessary to remove and reinstall bottom closure panel to install leveling legs. To remove bottom closure panel, see Item 1 in Bottom Return Air Inlet section in Step 1 above.

To install leveling legs:

1. Position furnace on its back. Locate and drill a hole in each bottom corner of furnace. (See Fig. 10.)

2. For each leg, install nut on bolt and then install bolt with nut in hole. (Install flat washer if desired.)

3. Install another nut on other side of furnace base. (Install flat washer if desired.)

4. Adjust outside nut to provide desired height, and tighten inside nut to secure arrangement.

5. Reinstall bottom closure panel if removed.

DOWNFLOW INSTALLA

TION

NOTE: For downflow applications, this furnace is approved for

use on combustible flooring when any one of the following 3 accessories are used:

S Special Base, KGASB S Cased Coil Assembly Part No. CNPV, CNRV, CAP, or

CAR

S Coil Box Part No. KCAKC

1. Determine application being installed from Table 3.

2. Construct hole in floor per Table 3 and Fig. 11.

3. Construct plenum to dimensions specified in Table 3 and Fig. 11.

4. If downflow subbase, KGASB is used, install as shown in Fig. 12. If Coil Assembly Part No. CPVP, CAPMP or CNPVP Coil Box Part No. KCAKC is used, install as shown in Fig. 13.

NOTE: It is recommended that the perforated supply--air duct flanges be completely folded over or removed from furnace when installing the furnace on a factory--supplied cased coil or coil box. To remove the supply--air duct flange, use wide duct pliers or hand seamers to bend flange back and forth until it breaks off. Be careful of sharp edges. (See Fig. 14.)

Bottom Return Air

Inlet

1. Tilt or raise furnace and remove 2 screws holding bottom filler panel. (See Fig. 9.)

2. Rotate bottom filler panel downward to release holding tabs.

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

HORIZONTAL INSTALLA

WARNING

TION

FIRE, EXPLOSION, AND CARBON MONOXIDE POISONING HAZARD

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

The furnace can be installed horizontally in an attic or crawlspace on either the left--hand (LH) or right--hand (RH) side. The furnace can be hung from floor joists, rafters or trusses or installed on a non--combustible platform, blocks, bricks or pad.

Suspended Furnace

Support

The furnace may be supported under each end with threaded rod, angle iron or metal plumber’s strap as shown. (See Fig. 15 and

16.) Secure angle iron to bottom of furnace as shown. Heavy--gauge sheet metal straps (plumber’s straps) may be used to suspend the furnace from each bottom corner. To prevent screws from pulling out, use 2 #8 x in. screws into the side and 2 #8 x in. screws in the bottom of the furnace casing for each strap. (See Fig. 15 and 16.)

If the screws are attached to ONLY the furnace sides and not the bottom, the straps must be vertical against the furnace sides and not pull away from the furnace sides, so that the strap attachment screws are not in tension (are loaded in shear) for reliable support.

Platform Furnace

Support

Construct working platform at location where all required furnace clearances are met. (See Fig. 2 and 17.) For furnaces with 1--in. (25 mm) clearance requirement on side, set furnace on non--combustible blocks, bricks or angle iron. For crawlspace installations, if the furnace is not suspended from the floor joists, the ground underneath furnace must be level and the furnace set on blocks or bricks.

PG8MVA

FURNACE

(OR COIL CASING

WHEN USED)

PLENUM

OPENING

FLOOR

PG8MVA

Fig. 11 -- Floor and Plenum Opening Dimensions

Roll--Out Pr

Provide a minimum 17--3/4--in. X 22--in. (451 X 559 mm) piece of sheet metal for flame roll--out protection in front of burner area for furnaces closer than 12--in. (305 mm) above the combustible deck or suspended furnaces closer than 12--in. (305 mm) to joists. The sheet metal MUST extend underneath the furnace casing by 1--in. (25 mm)with the door removed.

The bottom closure panel on furnaces of widths 17--1/2--in. (445 mm) and larger may be used for flame roll--out protection when bottom of furnace is used for return air connection. See Fig. 17 for proper orientation of roll--out shield.

Bottom Return Air

1. Tilt or raise furnace and remove two screws holding bot-

2. Rotate bottom filler panel downward to release holding

3. Remove bottom closure panel.

4. Reinstall bottom filler panel and screws.

Side Return Air

These furnaces are shipped with bottom closure panel installed in bottom return--air opening. This panel MUST be in place when side return air inlet(s) are used without a bottom return air inlet.

otection

Inlet

tom filler panel. (See Fig. 9.)

tabs.

Inlet

A96283

COMBUSTIBLE

FLOORING

DOWNFLOW

SUBBASE

SHEET METAL

PLENUM

FLOOR

OPENING

A96285

Fig. 12 -- Furnace, Plenum, and Subbase Installed on a

Combustible Floor

FURNACE

APPROVED

COIL ASSEMBLY

COIL BOX

COMBUSTIBLE

FLOORING

SHEET METAL

PLENUM

FLOOR

OPENING

A08556

Fig. 13 -- Furnace, Plenum, and Coil Assembly or Coil Box

Installed on a Combustible Floor

Not all horizontal furnaces are approved for side return air connections (See Fig. 20.)

Table 3 – Opening Dimensions -- In. (mm)

FURNACE

CASING

WIDTH

IN. (mm)

14–3/16

(360)

17–1/2

(445)

(533)

24--- 1/2

(622)

APPLICATION

Upflow Applications on Combustible or Noncombustible Floor-

ing (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring (KGASB

subbase not required)

Downflow applications on combustible flooring (KGASB sub-

base required)

Downflow Applications on Combustible Flooring with CNPV,

CNRV, CAR or CAP Coil Assembly or KCAKC coil box (KGASB

subbase not required)

Upflow Applications on Combustible or Noncombustible Floor-

ing (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring (KGASB

subbase not required)

Downflow applications on combustible flooring (KGASB sub-

base required)

Downflow Applications on Combustible Flooring with CNPV,

CNRV, CAR or CAP Coil Assembly or KCAKC coil box (KGASB

subbase not required)

Upflow Applications on Combustible or Noncombustible Floor-

ing (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring (KGASB

subbase not required)

Downflow applications on combustible flooring (KGASB sub-

base required)

Downflow Applications on Combustible Flooring with CNPV,

CNRV, CAR or CAP Coil Assembly or KCAKC coil box (KGASB

subbase not required)

Upflow Applications on Combustible or Noncombustible Floor-

ing (KGASB subbase not required)

Downflow Applications on Noncombustible Flooring (KGASB

subbase not required)

Downflow applications on Combustible flooring (KGASB sub-

base required)

Downflow Applications on Combustible Flooring with CNPV,

CNRV, CAR or CAP Coil Assembly or KCAKC coil box (KGASB

subbase not required)

PLENUM OPENING FLOOR OPENING

A B C D

12--- 11/16

(322)

12--- 9/16

(319)

11--- 13/16

(284)

12--- 5/16

(319)

(406)

15--- 7/8

(403)

15--- 1/8

(384)

15--- 1/2

(394)

19--- 1/2

(495)

19--- 3/8

(492)

18--- 5/8

(473)

(483)

(584)

22--- 7/8

(581)

22--- 1/8

(562)

22--- 1/2

(572)

21--- 5/8

(549)

(483)

21--- 5/8

(549)

(483)

21--- 5/8

(549)

(483)

21--- 1/8

(537)

(483)

13--- 5/16

(338)

13--- 3/16

(335)

13--- 7/16

(341)

13--- 5/16

(338)

16--- 5/8

(422)

16--- 1/2

(419)

16--- 3/4

(425)

16--- 1/2

(419)

20--- 1/8

(511)

(508)

20--- 1/4

(514)

(508)

23--- 5/8

(600)

23--- 1/2

(597)

23--- 3/4

(603)

23--- 1/2

(597)

22--- 1/4

(565)

19--- 5/8

(498)

20--- 5/8

(600)

(508)

22--- 1/4

(565)

19--- 5/8

(498)

20--- 5/8

(600)

(508)

22--- 1/4

(565)

19--- 5/8

(498)

20--- 5/8

(600)

(508)

22--- 1/4

(565)

19--- 5/8

(498)

20--- 5/8

(600)

(508)

PG8MVA

Filter Arrangement

WARNING

CARBON MONOXIDE POISONING HAZARD

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

Never operate a furnace without a filter or with filter access door removed.

There are no provisions for an internal filter rack in these furnaces. A field--supplied accessory external filter rack is required.

Refer to the instructions supplied with the external filter rack for assembly and installation options.

DUCTS

AIR General Requir

ements

The duct system should be designed and sized according to accepted national standards such as those published by: Air Conditioning Contractors Association (ACCA), Sheet Metal and Air Conditioning Contractors National Association (SMACNA) or American Society of Heating, Refrigerating and Air Conditioning Engineers (ASHRAE) or consult The Air Systems Design Guidelines reference tables available from your local distributor. The duct system should be sized to handle the required system design CFM at the design external static pressure. The furnace airflow rates are provided in Table 4--Air Delivery--CFM (With Filter). When a furnace is installed so that

the supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air shall also be handled by duct(s) sealed to the furnace casing and terminating outside the space containing the furnace.

Secure ductwork with proper fasteners for type of ductwork used. Seal supply-- and return--duct connections to furnace with code approved tape or duct sealer.

NOTE: Flexible connections should be used between ductwork and furnace to prevent transmission of vibration.

Ductwork passing through unconditioned space should be insulated to enhance system performance. When air conditioning is used, a vapor barrier is recommended.

Maintain a 1--in. (25 mm) clearance from combustible materials to supply air ductwork for a distance of 36--in. (914 mm) horizontally from the furnace. See NFPA 90B or local code for further requirements.

Ductwork Acoustical Tr

eatment

NOTE: Metal duct systems that do not have a 90 degree elbow

and 10 ft. (3 M) of main duct to the first branch take--off may require internal acoustical lining. As an alternative, fibrous ductwork may be used if constructed and installed in accordance with the latest edition of SMACNA construction standard on fibrous glass ducts. Both acoustical lining and fibrous ductwork shall comply with NFPA 90B as tested by UL Standard 181 for Class 1 Rigid air ducts.

Supply Air

Connections

For a furnace not equipped with a cooling coil, the outlet duct shall be provided with a removable access panel. This opening shall be accessible when the furnace is installed and shall be of such a size that the heat exchanger can be viewed for possible openings using light assistance or a probe can be inserted for sampling the air stream. The cover attachment shall prevent leaks.

Upflow and Horizontal

Furnaces

Connect supply--air duct to flanges on furnace supply--air outlet. Bend flange upward to 90_ with wide duct pliers. (See Fig. 14.) The supply--air duct must be connected to ONLY the furnace supply--outlet--air duct flanges or air conditioning coil casing (when used). DO NOT cut main furnace casing side to attach supply air duct, humidifier, or other accessories. All accessories MUST be connected to duct external to furnace main casing.

UPFLOW DOWNFLOW HORIZONTAL

PG8MVA

90

NOTE: For horizontal applications, the top most flange may be bent past 90_ to allow the evaporator coil to hang on the flange temporarily while the remaining attachment and sealing of the coil are performed.

Downflow

Furnaces

Connect supply--air duct to supply--air outlet on furnace. Bend flange inward past 90_ with wide duct pliers (See Fig. 14.) The supply--air duct must be connected to ONLY the furnace supply outlet or air conditioning coil casing (when used). When installed on combustible material, supply--air duct must be connected to ONLY the factory--approved accessory subbase, or a factory--approved air conditioning coil casing. DO NOT cut main furnace casing to attach supply side air duct, humidifier, or other accessories. All accessories MUST be connected to duct external to furnace casing.

90

120

MIN

YES

120

MIN

YES

Fig. 14 -- Duct Flanges

120 MIN

YES

A02020

OUTER DOOR A S SEMBLY

8" (203mm) FOR DOOR REMOVAL

MIN

4 " (6mm) THREADED ROD

4 REQ.

SECURE ANGLE IRON TO BOTTOM OF FURNACE WITH

/4" (19mm) SCREWS

3 #8 x TYPICAL FOR 2 SUPPORTS

1” (25mm) SQUARE, 1-1/4”x1-1/4”x1/8” (32x32x3mm) ANGLE IRON OR UNI-STRUT MAY BE USED

PG8MVA

(2) HEX NUTS, (2) WASHERS & (2) LOCK WASHERS REQ. PER ROD

Fig. 15 -- Horizontal Unit Suspension

METHOD 2 USE (4) #8 x 3/4 (19 mm) SHEET METAL SCREWS FOR EACH STRAP. THE STRAPS SHOULD BE VERTICAL AGAINST THE FURNACE SIDES AND NOT PULL AWAY FROM THE FURNACE SIDES.

A10130

METHOD 1 FOLD ALL STRAPS UNDER FURNACE AND SECURE WTH (4) #8 x 3/4 (19 mm) SHEET METAL SCREWS (2 SCREWS IN SIDE AND 2 SCREWS IN BOTTOM).

Fig. 16 -- Horizontal Suspension with Straps

A10131

LINE CONT A CT ONL Y PERMISSIBLE BETWEEN LINES FORMED BY INTERSECTIONS OF THE T OP AND TW O SIDES OF THE FURNA CE JA CKET AND BUILDING JOISTS , STUDS , OR FRAMING.

GAS ENTR Y

6 ″

M IN

TYPE-B VENT

(152mm)

30-IN . (762mm) MIN WORK AREA

17 3 / 4 ″

(451mm)

4 3 / 4 ″

(121mm)

1 ″

(25mm)

EXTEND OUT 12 ″

OVERALL

UNDER DOOR

UNDER FURNACE

(305mm)

FR OM FA CE OF DOOR

* WHEN USED W ITH SINGLE W ALL VEN T CONNECTIONS

(451mm)

SHEET MET AL

17 3 / 4 ″

″

(559mm)

EQUIPMENT MANU AL

SHUT -OFF GAS VA LV E

PG8MVA

SEDIMENT

TRAP

UNION

A10164

Fig. 17 -- Typical Attic Installation

Fig. 18 -- Upflow Return Air Configurations and Restrictions

A02075

Fig. 19 -- Downflow Return Air Configurations and Restrictions

A02163

PG8MVA

Fig. 20 -- Horizontal Return Air Configurations and Restrictions

A02162

Unit Size Operating Mode

036070 AIRFLOW (CFM)

†† Low Heat 735 (615)† 0 ---0.50 735 735 735 735 725

†† 1 --- 1 / 2 --- Ton C o o l i n g 525 0--- 0.50‡ 515 500 500 490 485 †† 2 --- To n A / C C o o l i n g 700 0--- 0.50‡ 690 680 675 680 675

2 --- 1 / 2 --- Ton A / C C o o l i n g 875 0 ---1.0‡ 875 875 875 870 865 855 850 835 825 820

3 --- To n A / C C o o l i n g 1050 0--- 1.0‡ 1050 1050 1050 1050 1050 1050 1045 1035 1020 1000

3 --- 1 / 2 --- Ton A / C C o o l i n g 1225 0 --- 1 . 0 1220 1225 1225 1225 1225 1220 1205 1190 1185 1170

048090

PG8MVA

†† 1 --- 1 / 2 --- To n A / C C o o l ing 525 0--- 0.50‡ 525 520 525 495 475 †† 2 --- To n A / C C o o l i n g 700 0--- 0.50‡ 680 680 680 675 670

2 --- 1 / 2 --- Ton A / C C o o l i n g 875 0 ---1.0‡ 815 845 845 855 850 850 845 835 820 805

3 --- To n A / C C o o l i n g 1050 0--- 1.0‡ 1005 1005 1015 1035 1040 1040 1035 1030 1025 1010

3 --- 1 / 2 --- Ton A / C C o o l i n g 1225 0 --- 1 . 0 1190 1200 1200 1205 1205 1215 1205 1200 1185 1170

4 --- To n A / C C o o l i n g 1400 0 --- 1 . 0 1350 1370 1390 1390 1400 1390 1380 1380 1360 1340

060110***

†† 2 --- To n A / C C o o l i n g 700 0--- 0.50‡ 700 700 700 700 700 †† 2 --- 1 / 2 --- To n A / C C o o l ing 875 0--- 0.50‡ 875 875 875 875 875 †† 3 --- To n A / C C o o l i n g 1050 0 --- 0.50‡ 1050 1050 1050 1050 1050

3 --- 1 / 2 --- Ton A / C C o o l i n g 1225 0 ---1.0‡ 1225 1225 1225 1225 1225 1225 1225 1225 1225 1225

4 --- To n A / C C o o l i n g 1400 0--- 1.0‡ 1400 1400 1400 1400 1400 1400 1400 1400 1400 1400 5 --- To n A / C C o o l i n g 1750 0--- 1.0‡ 1750 1750 1750 1750 1750 1750 1750 1750 1740 1725 6 --- To n A / C C o o l i n g 2100 0 --- 1 . 0 2100 2100 2100 2100 2090 2075 2055 2040 2005 1970

066135

†† 2 --- To n A / C C o o l i n g 700 0--- 0.50‡ 700 700 700 700 665 †† 2 --- 1 / 2 --- To n A / C C o o l ing 875 0--- 0.50‡ 870 870 865 865 865 †† 3 --- To n A / C C o o l i n g 1050 0 --- 0.50‡ 1010 1030 1050 1050 1050

3 --- 1 / 2 --- Ton A / C C o o l i n g 1225 0 ---1.0‡ 1155 1180 1200 1210 1220 1225 1225 1225 1225 1225

4 --- To n A / C C o o l i n g 1400 0--- 1.0‡ 1395 1400 1400 1400 1400 1400 1400 1390 1375 1355 5 --- To n A / C C o o l i n g 1750 0--- 1.0‡ 1740 1750 1750 1750 1735 1740 1735 1730 1715 1700 6 --- To n A / C C o o l i n g 2100 0 --- 1 . 0 2075 2085 2090 2100 2100 2100 2090 2080 2055 2025

Table 4 – Air Delivery -- CFM (With Filter)*

External

Static

Pressure

Range*

(In. W.C.)

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

0 --- 1 . 0 1160 1165 1175 1180 1180 1180 1180 1180 1180 1175

High Heat

CFM Airflow Setting

1180 (1060)†

Maximum 1400 0 --- 1 . 0 1395 1400 1400 1400 1395 1385 1370 1340 1300 1245

Low Heat 985 (825)† 0 --- 1 . 0 950 970 985 985 985 985 985 985 985 980

High Heat

1210 (1090)†

0 --- 1 . 0 1190 1205 1210 1210 1210 1210 1210 1210 1210 1200

Maximum 1600 0 --- 1 . 0 1595 1600 1600 1600 1595 1555 1505 1465 1430 1390

Low Heat

High Heat

1320 (1110)†

1475 (1330)†

0 --- 1 . 0 1275 1295 1315 1320 1320 1320 1320 1320 1320 1315

0 --- 1 . 0 1460 1465 1475 1475 1475 1475 1475 1475 1465 1465

Maximum 2200 0 --- 1 . 0 2200 2190 2190 2180 2155 2145 2125 2100 2080 2020

Low Heat

High Heat

1700 (1430)†

1915 (1725)†

0 --- 1 . 0 1700 1700 1700 1700 1700 1695 1700 1695 1685 1670

0 --- 1 . 0 1900 1905 1915 1915 1915 1915 1915 1915 1915 1915

Maximum 2200 0 --- 1 . 0 2180 2195 2200 2200 2200 2200 2185 2165 2140 2095

External Static Pressure (ESP) (IN. W.C.)

*Actual external static pressure (ESP) can be determined by using the fan laws (CFM 2 proportional to ESP); such as, a system with 1180 CFM

at 0.5 ESP would operate at cooling airflow of 1050 CFM at 0.4 ESP and low--- heating airflow of 735 CFM at 0.19 ESP.

{Comfort airflow values are shown in parenthesis. Comfort airflow is selected when the low--- heat rise adjustment switch (SW1--- 3) is OFF and

the comfort/efficiency switch (SW1 --- 4) is ON.

}Ductwork must be sized for high --- heating CFM within the operational range of ESP. {{Operation within the blank areas of the chart is not recommended because high--- heat operation will be above 1.0 ESP.

***All airflow on 110 size furnace are 5% less on side return only installations.

Return Air

FIRE HAZARD

A failure to follow this warning could cause personal injury, death and/or property damage.

Never connect return--air ducts to the back of the furnace. Follow instructions below.

Downflow Furnaces

The return--air duct must be connected to return--air opening (bottom inlet) as shown in Fig. 3. DO NOT cut into casing sides (left or right). Side opening is permitted for only upflow and certain horizontal furnaces. Bypass humidifier connections should be made at ductwork or coil casing sides exterior to furnace. (See Fig. 19.)

Upflow and Horizontal

The return--air duct must be connected to bottom, sides (left or right), or a combination of bottom and side(s) of main furnace casing as shown in Fig. 3. Bypass humidifier may be attached into unused return air side of the furnace casing. (See Fig. 18 and

20.) Not all horizontal furnace models are approved for side return air connections. (See Fig. 20.)

GAS

FIRE OR EXPLOSION HAZARD

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

Never purge a gas line into a combustion chamber. 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 may result causing property damage, personal injury or loss of life.

FIRE OR EXPLOSION HAZARD

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

Use proper length of pipe to avoid stress on gas control manifold and a gas leak.

Connections

PIPING

WARNING

Furnaces

WARNING

Installations must be made in accordance with all authorities having jurisdiction. If possible, the gas supply line should be a separate line running directly from meter to furnace.

NOTE: In the state of Massachusetts:

1. Gas supply connections MUST be performed by a licensed plumber or gas fitter.

2. When flexible connectors are used, the maximum length shall not exceed 36 in. (915 mm).

3. When lever handle type manual equipment shutoff valves are used, they shall be T--handle valves.

4. The use of copper tubing for gas piping is NOT approved by the state of Massachusetts.

Refer to Table 5 for recommended gas pipe sizing. Risers must be used to connect to furnace and to meter. Support all gas piping with appropriate straps, hangers, etc. Use a minimum of 1 hanger every 6 ft. (1.8 M). Joint compound (pipe dope) should be applied sparingly and only to male threads of joints. Pipe dope must be resistant to the action of propane gas.

Table 5 – Maximum Capacity of Pipe

NOMINAL

IRON PIPE

SIZE

IN. (MM)

1/2 (12.7) 0.622(158) 175 120 97 82 73

3/4 (19.0) 0.824 (20.9) 360 250 200 170 151

1 ( 25.4) 1.049 (26.6) 680 465 375 320 285

1-1/4

(31.8)

1-1/2

(38.1)

* Cubic ft of gas per hr for gas pressures of 0.5 psig (14 --- In. W.C.) or less and a pressure dro p of 0.5 --- In. W.C. (based on a 0.60 specific gravity gas). Ref: Ta bl e 6 a nd 9 .2 N F GC .

FIRE OR EXPLOSION HAZARD

A failure to follow this warning could result in personal injury, death, and/or property damage.

If local codes allow the use of a flexible gas appliance connector, always use a new listed connector. Do not use a connector which has previously served another gas appliance. Black iron pipe shall be installed at the furnace gas control valve and extend a minimum of 2--in. (51 mm) outside the furnace.

FURNACE DAMAGE HAZARD

Failure to follow this caution may result in furnace damage. Connect gas pipe to furnace using a backup wrench to

avoid damaging gas controls and burner misalignment.

INTERNAL

DIA.

IN. (MM)

1.380 (35.0) 1400 950 770 660 580

1.610 (40.9) 2100 1460 1180 990 900

WARNING

CAUTION

LENGTH OF PIPE --- FT (M)

(3.0)20(6.0)30(9.1)40(12.1)50(15.2)

PG8MVA

FIRE OR EXPLOSION HAZARD

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

Gas valve inlet and/or inlet pipe must remain capped until gas supply line is permanently installed to protect the valve from moisture and debris. Also, install a sediment trap in the gas supply piping at the inlet to the gas valve.

Gas piping must be installed in accordance with national and local codes. Refer to current edition of NFGC in the U.S.

An accessible manual equipment shutoff valve MUST be installed external to furnace casing and within 6 ft. (1.8 M) of furnace. A 1/8--in. (3 mm) NPT plugged tapping, accessible for test gauge connection, MUST be installed immediately upstream of gas supply connection to furnace and downstream of manual equipment shutoff valve.

NOTE: The furnace gas control valve inlet pressure tap connection is suitable to use as test gauge connection providing test pressure DOES NOT exceed maximum 0.5 psig (14--In. W.C.) stated on gas control valve. (See Fig. 50.)

Some installations require gas entry on right side of furnace (as viewed in upflow). (See Fig. 21.)

Install a sediment trap in riser leading to furnace as shown in Fig.

22. Connect acapped nipple into lower end of tee. Capped nipple should extend below level of furnace gas controls. Place a ground joint union between furnace gas control valve and exterior manual equipment gas shutoff valve.

A 1/8--in. (3 mm) NPT plugged tapping, accessible for test gauge connection, MUST be installed immediately upstream of gas supply connection to furnace and downstream of manual equipment shutoff valve.

Piping should be pressure and leak tested in accordance with the current addition of the NFGC in the United States, local, and national plumbing and gas codes before the furnace has been connected. After all connections have been made, purge lines and check for leakage at furnace prior to operating furnace.

If pressure exceeds 0.5 psig (14--In. W.C.), gas supply pipe must be disconnected from furnace and capped before and during supply pipe pressure test. If test pressure is equal to or less than

0.5 psig (14--In. W.C.), turn off electric shutoff switch located on furnace gas control valve and accessible manual equipment shutoff valve before and during supply pipe pressure test. After all connections have been made, purge lines and check for

PG8MVA

leakage at furnace prior to operating furnace. The gas supply pressure shall be within the maximum and

minimum inlet supply pressures marked on the rating plate with the furnace burners ON and OFF.

ELECTRICAL

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 control. No component operation can occur. Do not bypass or close switch with panel removed.

See Fig. 25 for field wiring diagram showing typical field 115--v wiring. Check all factory and field electrical connections for tightness.

Field--supplied wiring shall conform with the limitations of 63_F (33_C) rise.

ELECTRICAL SHOCK AND FIRE HAZARD

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

The cabinet MUST have an uninterrupted or unbroken ground according to NEC ANSI/NFPA 70--2011 or local codes to minimize personal injury if an electrical fault should occur. This may consist of electrical wire, conduit approved for electrical ground or a listed, grounded power cord (where permitted by local code) when installed in accordance with existing electrical codes. Refer to the power cord manufacturer’s ratings for proper wire gauge. Do not use gas piping as an electrical ground.

CONNECTIONS

WARNING

2” (51mm)

Street Elbow

Fig. 21 -- Burner and Manifold

GAS SUPPLY

MANUAL SHUTOFF VALV E (REQUIRED)

SEDIMENT TRAP

UNION

Fig. 22 -- Typical Gas Pipe Arrangement

A08551

A02035

CAUTION

FURNACE MAY NOT OPERATE HAZARD

Failure to follow this caution may result in intermittent furnace operation.

Furnace control must be grounded for proper operation or else control will lock out. Control must remain grounded through green/yellow wire routed to gas valve and manifold bracket screw.

115 -- V Wiring

Verify that the voltage, frequency, and phase correspond to that specified on unit rating plate. Also, check to be sure that service provided by utility is sufficient to handle load imposed by this equipment. Refer to rating plate or Table 6 for equipment electrical specifications.

U.S. Installations: Make all electrical connections in accordance with National Electrical Code (NEC) ANSI/NFPA 70--2011 and any local codes or ordinances that might apply.

Table 6 – Electrical Data

Factory Installed

Alternate Location

FURNACE

SIZE

070---12/036070 1 1 5 --- 6 0 --- 1 127 104 9.0 11.99 30 (9.0) 15 14 090---16/048090 1 1 5 --- 6 0 --- 1 127 104 9.6 12.56 29 (8.8) 15 14 110---20/060110 1 1 5 --- 6 0 --- 1 127 104 15.1 19.33 29 (8.8) 20 12

135---22/066135 1 1 5 --- 6 0 --- 1 127 104 14.9 19.13 30 (9.0) 20 12

* Permissible limits of the voltage range at which the unit operates satisfactorily. # Unit ampacity = 125 percent of largest operating component’s full load amps plus 100 percent of all other potential operating components’ (EAC, humidifier,

etc.) full load amps.

{Time---delay type is recommended. }Length shown is as measured 1 way along wire path between furnace and service panel for maximum 2 percent voltage drop.

V O L T S ---

H E R T Z ---

PHASE

WARNING

OPERATING

VOLTAGE RANGE

Max. Min.

MAX. UNIT

AMPS

UNIT

AMPACITY

MAX. WIRE

L E N G T H --- F T ( M ) }

Factory Installed

MAX. FUSE OR

CKT BKR AMPS {

MIN.

WIRE

GAUGE

FIRE HAZARD

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

Alternate Location

Do not connect aluminum wire between disconnect switch and furnace. Use only copper wire.

Use a separate, fused branch electrical circuit with a properly sized fuse or circuit breaker for this furnace. See Table 6 for wire size and fuse specifications. A readily accessible means of electrical disconnect must be located within sight of the furnace.

NOTE: Proper polarity must be maintained for 115--v wiring. If polarity is incorrect, control LED status indicator light will flash rapidly and furnace will NOT operate.

Relocation

J--Box NOTE: If factory location of J--Box is acceptable, go to next

section (ELECTRICAL CONNECTION to J--Box). NOTE: On 14--in. (356 mm) wide casing models, the J--Box

shall not be relocated to other side of furnace casing when the vent pipe is routed within the casing.

1. Remove and save two screws holding J--Box. (See Fig.

23.)

NOTE: The J--Box cover need not be removed from the J--Box in order to move the J--Box. Do NOT remove green ground screw inside J--Box. (See Fig. 23.)

2. Cut wire tie on loop in furnace wires attached to J--Box.

3. Move J--Box to desired location.

4. Fasten J--Box to casing with the two screws removed in Step 1.

5. Route J--Box wires within furnace away from sharp edges, rotating parts and hot surfaces.

Electrical Connection to Electrical Box on Furnace Casing Side (See Fig.

J--Box

24.)

Fig. 23 -- Relocating J--Box

1. Select and remove a hole knockout in the casing where the electrical box is to be installed.

NOTE: Check that duct on side of furnace will not interfere with installed electrical box.

2. Remove the desired electrical box hole knockout and position the hole in the electrical box over the hole in the furnace casing.

3. Fasten the electrical box to casing by driving two field-supplied screws from inside electrical box into casing steel.

4. Remove and save two screws holding J--Box. (See Fig.

23.)

5. Pull furnace power wires out of 1/2--in. (12 mm) diameter hole in J--Box. Do not loosen wires from strain--relief wire--tie on outside of J--Box.

6. Route furnace power wires through holes in casing and electrical box and into electrical box.

7. Pull field power wires into electrical box.

A10291

8. Remove cover from furnace J--Box.

WARNING

FIRE OR ELECTRICAL SHOCK HAZARD

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

If field--supplied manual disconnect switch is to be mounted on furnace casing side, select a location where a drill or fastener cannot damage electrical or gas components.

9. Route field ground wire through holes in electrical box and casing, and into furnace J--Box.

10. Reattach furnace J--Box to furnace casing with screws removedinStep4.

11. Secure field ground wire to J--Box green ground screw.

12. Complete electrical box wiring and installation. Connect line voltage leads as shown in Fig. 24. Use best practices (NEC in U.S. for wire bushings, strain relief, etc.

13. Reinstall cover to J--Box. Do not pinch wires between cover and bracket.

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Fig. 24 -- Field--Supplied Electrical Box on Furnace Casing

Power Cord Installation in Furnace NOTE: Power cords must be able to handle the electrical

requirements listed in Table 5. Refer to power cord manufacturer’s listings.

1. Remove cover from J--Box.

2. Route listed power cord through 7/8--in. (22 mm) diameter hole in J--Box.

3. Secure power cord to J--Box bracket with a strain relief bushing or a connector approved for the type of cord used.

4. Secure field ground wire to green ground screw on J--Box bracket.

5. Connect line voltage leads as shown in Fig. 25.

6. Reinstall cover to J--Box. Do not pinch wires between cover and bracket.

BX Cable Installation in Furnace

1. Remove cover from J--Box.

J--Box

A10141

2. Route BX cable into 7/8--in. (22 mm) diameter hole in J--Box.

3. Secure BX cable to J--Box bracket with connectors approved for the type of cable used.

4. Secure field ground wire to green ground screw on J--Box bracket.

5. Connect line voltage leads as shown in Fig. 25.

6. Reinstall cover to J--Box. Do not pinch wires between cover and bracket.

24--V W

iring

Make field 24--v connections at the 24--v terminal strip. (See Fig. 25 -- 34.) Connect terminal Y/Y2 as shown in Fig. 27--34 for proper cooling operation. Use only AWG No. 18, color--coded, copper thermostat wire.

The 24--v circuit contains an automotive--type, 3--amp. fuse located on the control. Any direct shorts during installation, service, or maintenance could cause this fuse to blow. If fuse replacement is required, use ONLY a 3--amp. fuse of identical size.

ACCESSORIES

1. Electronic Air Cleaner (EAC) Connect an accessory Electronic Air Cleaner (if used) using 1/4--in female quick connect terminals to the two male 1/4--in quick--connect terminals on the control board marked EAC--1 and EAC--2. The terminals are rated for 115VAC, 1.0 amps maximum and are energized during blower motor operation. (See Fig. 26.)

2. Humidifier (HUM) Connect an accessory 24 VAC, 0.5 amp. maximum humidifier (if used) to the 1/4--in male quick--connect HUM terminal and COM--24V screw terminal on the control board thermostat strip. The HUM terminal is energized when blower is energized in heating. (See Fig. 26.)

NOTE: DO NOT connect furnace control HUM terminal to HUM (humidifier) terminal on thermostat, zone controller or similar device. See thermostat or zone controller manufacturer’s instructions for proper connection.

VENTING

The furnace shall be connected to a listed factory built chimney or vent, or a clay--tile lined masonry or concrete chimney. Venting into an unlined masonry chimney or concrete chimney is prohibited.

When an existing Category I furnace is removed or replaced, the original venting system, may no longer be sized to properly vent the attached appliances. An improperly sized Category I venting system could cause the formation of condensate in the furnace and vent, leakage of condensate and combustion products, and spillage of combustion products into the living space.

BLK

WHT

GND

115-VOLT FIELD-

SUPPLIED

FUSED

DISCONNECT

BLK

WHT

JUNCTION BOX

FIVE

WIRE

THREE-WIRE

HEATING-

ONLY

CONTROL

BOX

FURNACE

COM

W/W1

Y/Y2

24-VOLT

TERMINAL

BLOCK

NOTE 2

WCY RG

1-STAGE THERMOSTAT TERMINALS

NOTE 1

NOTES: 1.

Connect Y/Y2-terminal as shown for proper operation. 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. 25 -- Field Wiring Diagram

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

FIELD-SUPPLIED

FUSED DISCONNECT

208/230- OR 460-VOLT THREE PHASE

208/230VOLT SINGLE PHASE

CONDENSING

UNIT

GND

PG8MVA

A95236

MODEL PLUG CONNECTOR

SW1 SETUP

SWITCHES AND

BLOWER OFF-

DELAY

AIR CONDITIONING

(A/C) AIRFLOW

SETUP SWITCHES

24-V THERMOSTAT

TERMINALS

STATUS AND COMM

LED LIGHTS

3-AMP FUSE

RANSFORMER 24-VAC

CONNECTIONS

CONTINUOUS FAN

(CF) AIRFLOW

SETUP SWITCHES

SW4 SETUP

SWITC HES

HUMIDIFIER

TERMINAL (24-VAC

0.5 AMP MAX.

ACRDJ – AIR

CONDITIONING

RELAY DISABLE

JUMPER

FLASH

UPGRADE

CONNECTOR

(FACTORY

ONLY)

PL3 – ECM BLOWER

HARNESS

CONNECTOR

BOARD SERIAL

NUMBER

115-VAC (L2) NEUTRAL

CONNECTIONS

PL1 – LOW VOLTAGE MAIN

HARNESS CONNECTOR

Fig. 26 -- Variable Speed Furnace Control for ECM Blower Motor

(115 -VAC 1.0 AMP MAX.)

V20 HK42FZ050 0912

SOFTWARE

VERSION

EAC-1 TERMINAL

EXAMPLE:

PA RT

NUMBER

VOLTAGE CONNECTIONS

DATE CODE

115-VAC (L1) LINE

PL2 – HOT SURFACE

IGNITER INDUCER

MOTOR CONNECTOR

A12056

WARNING

CARBON MONOXIDE POISONING HAZARD

Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death.

The following steps shall be followed for 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 venting system.

2. Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas Code, NFPA 54/ANSI Z223.1--2012 and these instructions. Determine that there is no blockage or restriction, leakage, corrosion and other deficiencies, which could cause an unsafe condition.

PG8MVA

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.

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, NFPA 54/ANSI Z223.1--2012.

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.

Vent system or vent connectors may need to be resized. Vent systems or vent connectors must be sized to approach minimum size as determined using appropriate table found in the current edition of NFGC.

General Venting Requir

Follow all safety codes for proper vent sizing and installation requirements, including local building codes, the National Fuel Gas Code NFPA 54/ANSI Z223.1--2012 (NFGC), Parts 12 and 13 in the United States, the local building codes, and furnace and vent manufacturers’ instructions.

The following information and warning must be considered in addition to the requirements defined in the NFGC.

ements

A00275

Fig. 27 -- Two--Stage Furnace with Single--Speed

Air Conditioner

WARNING

CARBON MONOXIDE POISONING HAZARD

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

Do not bypass the draft safeguard switch, as an unsafe condition could exist which must be corrected.

1. If a vent (common or dedicated) becomes blocked, the furnace will be shut off by the draft safeguard switch located on the vent elbow.

2. Two--stage furnaces require Type B vent connectors outside the casing in all configurations. Single wall vent connector may be used inside the furnace casing with the transition to Type B vent outside the furnace casing. Size the connector so that the FAN--Min vent connector capacity is equal to or lower than the low fire rate of the furnace and the FAN--Max vent connector capacity is equal to or higher than the furnace high fire rate.

3. Do not vent this Category I furnace into a single wall dedicated or common vent. The dedicated or common vent is considered to be the vertical portion of the vent system that terminates outdoors.

4. Vent connectors serving Category I furnaces shall not be connected into any portion of a mechanical draft system operating under positive pressure.

5. Do not vent this appliance with any solid fuel burning appliance.

6. Category I furnaces must be vented vertically or nearly vertically unless equipped with a listed mechanical venter. See SIDEWALL VENTING section.

7. Do not vent this appliance into an unlined masonry chimney. Refer to Chimney Inspection Chart, Fig. 35.

See notes 2, 5, 8, 10, 11 and 12 on the page following these figures

See notes 1, 2, 3, 4, 6, 8, 9, 10, 12, 13 and 15 on the page following these figures

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A03179

Fig. 28 -- Two--Stage Furnace with Two--Speed Air Condi-

tioner

See notes 1, 2, 4, 6, 7, 9, 10, 11, and 15 on the page following these figures

A03178

Fig. 30 -- Two--Stage Furnace with Two--Speed Heat Pump

(Dual Fuel)

See notes 1, 2, 4, 11, 14, 15, and 16 on the page following these figures

Fig. 29 -- Two--Stage Furnace with Single--Speed Heat Pump

(Dual Fuel)

A03180

A03181

Fig. 31 -- Dual--Fuel Thermostat with Two--Stage Furnace

and Single--Speed Heat Pump

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See notes 1, 2, 3, 4, 12, 13, 14, 15, and 17 on the page following these figures

A03182

Fig. 32 -- Dual--Fuel Thermostat with Two--Stage Furnace

and Two--Speed Heat Pump

See notes 2, 11, and 12 on the page following these figures

A03183

Fig. 33 -- Two--Stage Thermostat with Two--Stage Furnace

and Two--Speed Air Conditioner

Fig. 34 -- Single--Stage Thermostat with Two--Stage Furnace and Two--Speed Air Conditioner

See notes 1 and 2 on the page following these figures

A03184

NOTES FOR FIGURES 27 -- 34

1. Heat pump MUST have a high pressure switch for dual fuel applications.

2. Refer to outdoor equipment Installation Instructions for additional information and setup procedure.

3. If the heat pump date code is 1501E or earlier, select the “ZONE” position on the two--speed heat pump control. Heat pumps having date codes 1601E and later do not have or require a “ZONE” selection.

4. Outdoor Air Temperature Sensor must be attached in all dual fuel applications.

5. Does not apply for this model.

6. Does not apply for this model.

7. Does not apply for this model.

8. Does not apply for this model.

9. Does not apply for this model.

10. Does not apply for this model.

11. Optional connection: If wire is connected, dip switch SW1--2 on furnace control should be set in ON position to allow thermostat to control furnace staging.

12. Optional connection: If wire is connected, ACRDJ jumper on furnace control should be removed to allow thermostat to control outdoor unit staging.

13. Furnace must control its own high--stage heating operation via furnace control algorithm.

14. The RVS Sensing terminal “L” should not be connected. This is internally used to sense defrost operation.

15. DO NOT SELECT the “FURNACE INTERFACE” or “BALANCE POINT” option on the two--speed heat pump control board. This is controlled internally by the Dual Fuel Thermostat.

16. Dip switch D on Dual Fuel Thermostat should be set in OFF position for single--speed compressor operation. This is factory default.

17. Dip switch D on Dual Fuel Thermostat should be set in ON position for two--speed compressor operation.

PG8MVA

CHIMNEY INSPECTION CHART

For additional requirements refer to the National Fuel Gas Code NFPA 54/ANSI Z223.1 and ANSI/NFPA 211

Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances

Crown

condition:

Missing mortar

or brick?

Is chimney

property lined with

clay tile liner?

PG8MVA

Mortar, tile, metal vent,

fuel oil residue?

Ye s

liner and top

seal in good

condition?

Ye s

Debris

in cleanout?

Ye s

Rebuild

crown.

Repair

liner or top seal

or reline chimney as

necessary.

Repair

Mortar

or tile

debris?

Reline

Ye s

Remove mortar

and tile debris

Clay tile misalignment, missing sections,

gaps?

Condensate

drainage at bottom

of chimney?

Chimney

exposed to

outdoors below

roof line?

Chimney is

acceptable for use.

Remove metal vent

or liner.

Ye s

lined with properly

sized, listed liner or

Ye s

Is chimney

Type-B vent?

Ye s

Is chimney

to be dedicated to

a single

furnace?

Consult

Part B of

chimney adapter venting

instructions for

application

suitability.

Suitable

Ye s

Install chimney

adapter per

instructions.

chimney adapter venting

Not Suitable

Consult

Part C of

instructions for

application

suitability

Line chimney with property

sized, listed flexible metal

liner or Type-B vent per

Sizing Tables and liner or

vent manufacturer’s

Installation instructions.

Suitable

Install chimney

adapter per

instructions.

NFGC

Ven t

A10133

Fig. 35 -- Chimney Inspection Chart

Masonry Chimney Requir

ement

NOTE: These furnaces are CSA design--certified for use in

exterior tile--lined masonry chimneys with a factory accessory Chimney Adapter Kit. Refer to the furnace rating plate for correct kit usage. The Chimney Adapter Kits are for use with ONLY furnaces having a Chimney Adapter Kit number marked on the furnace rating plate.

If a clay tile--lined masonry chimney is being used and it is exposed to the outdoors below the roof line, relining might be required. Chimneys shall conform to the Standard for Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances ANSI/NFPA 211--2012 in the United States and must be in good condition.

U.S.A.--Refer to Sections 13.1.8 and 13.2.20 of the NFPA 54/ANSI Z223.1--2012 or the authority having jurisdiction to determine whether relining is required. If relining is required, use a properly sized listed metal liner, Type--B vent, or a listed alternative venting design.

NOTE: See the NFPA 54/ANSI Z223.1--2012 13.1.9 and

13.2.20 regarding alternative venting design and the exception, which cover installations such as our Chimney Adapter Kits which are listed for use with these furnaces. See Product Data Sheet for accessory listing.

The Chimney Adapter Kit is a listed alternative venting system for these furnaces. See the kit instructions for complete details.

This furnace is permitted to be vented into a clay tile--lined masonry chimney that is exposed to the outdoors below the roof line, provided:

1. Vent connector is Type--B double--wall, and

2. This furnace is common vented with at least 1 draft hood equipped appliance, and

3. The combined appliance input rating is less than the maximum capacity given in Table 7, and

4. The input rating of each space heating appliance is greater than the minimum input rating given in Table 8 for the local 99% Winter Design Temperature. Chimneys having internal areas greater than 38 sq. in. (24516 sq. mm) require furnace input ratings greater than the input ratingsof these furnaces. See footnote at bottom of Table 8, and

5. The authority having jurisdiction approves.

If all of these conditions cannot be met, an alternative venting design shall be used, such as the listed chimney adapter kit with a furnace listed for use with the kit, a listed chimney--lining system, or a Type--B common vent.

Inspections before the sale and at the time of installation will determine the acceptability of the chimney or the need for repair and/or (re)lining. Refer to the Fig. 33 to perform a chimney inspection. If the inspection of a previously used tile--lined chimney:

a. Shows signs of vent gas condensation, the chimney

should be relined in accordance with local codes and the authority having jurisdiction. The chimney should be relined with a listed metal liner, Type--B vent, or a listed chimney adapter kit shall be used to reduce condensation. If a condensate drain is required by local code, refer to the NFPA 54/ANSI Z223.1--2012, Section 12.10 for additional information on condensate drains.

b. Indicates the chimney exceeds the maximum permiss-

ible size in the tables, the chimney should be rebuilt or relined to conform to the requirements of the equipment being installed and the authority having jurisdiction.

A chimney without a clay tile liner, which is otherwise in good condition, shall be rebuilt to conform to ANSI/NFPA 211 or be lined with a UL listed metal liner or UL listed Type--B vent.

Relining with a listed metal liner or Type--B vent is considered to be a vent--in--a--chase.

If a metal liner or Type--B vent is used to line a chimney, no other appliance shall be vented into the annular space between the chimney and the metal liner.

Exterior Masonry Chimney FAN + NAT

Installations with Type--B Double--Wall Vent

Connectors ENFPA & AGA

Table 7 – Combined Appliance Maximum Input

Rating in Thousands of Btuh per Hour

INTERNAL AREA OF CHIMNEY

VENT HEIGHT

FT (M)

6 (1.8) 74 119 178 257

8 (2.4) 80 130 193 279 10 (3.0) 84 138 207 299 15 (4.5) NR 152 233 334 20 (6.0) NR NR 250 368 30 (9.1) NR NR NR 404

(7741)19(12258)28(18064)38(24516)

SQ. IN. (SQ. MM)

Appliance Application Requirements

Appliance operation has a significant impact on the performance of the venting system. If the appliances are sized, installed, adjusted, and operated properly, the venting system and/or the appliances should not suffer from condensation and corrosion. The venting system and all appliances shall be installed in accordance with applicable listings, standards, and codes.

The furnace should be sized to provide 100 percent of the design heating load requirement plus any margin that occurs because of furnace model size capacity increments. Heating load estimates can be made using approved methods available from Air Conditioning Contractors of America (Manual J); American Society of Heating, Refrigerating, and Air--Conditioning Engineers; or other approved engineering methods. Excessive oversizing of the furnace could cause the furnace and/or vent to fail prematurely.

When a metal vent or metal liner is used, the vent must be in good condition and be installed in accordance with the vent manufacturer’s instructions.

To prevent condensation in the furnace and vent system, the following precautions must be observed:

1. The return--air temperature must be at least 60_F db except for brief periods of time during warm--up from setback at no lower than 55_F(13_C) db or during initial start--up from a standby condition.

2. Adjust the gas input rate per the installation instructions. Low gas input rate causes low vent gas temperatures, causing condensation and corrosion in the furnace and/or venting system. Derating is permitted only for altitudes above 2000 Ft. (610 M).

3. Adjust the air temperature rise to the midpoint of the rise range or slightly above. Low air temperature rise can cause low vent gas temperature and potential for condensation problems.

4. Set the thermostat heat anticipator or cycle rate to reduce short cycling.

CAUTION

BURN HAZARD

Failure to follow this caution may result in personal injury. Hot vent pipe is within reach of small children when

installed in downflow position. See the following instruction.

PG8MVA

Table 8 – Minimum Allowable Input Rating of

Space--Heating Appliance in Thousands of Btuh per Hour

INTERNAL AREA OF CHIMNEY

VENT HEIGHT

FT. (M)

Local 99% Winter Design Temperature: 17 to 26 degrees F

6 0 55 99 141

8 52 74 111 154 10 NR 90 125 169 15 NR NR 167 212 20 NR NR 212 258 30 NR NR NR 362

Local 99% Winter Design Temperature: 5 to 16 degrees F*

6 NR 78 121 166

8 NR 94 135 182 10 NR 111 149 198 15 NR NR 193 247 20 NR NR NR 293

PG8MVA

*The 99.6% heating (db) temperatures found in the 1997 or 2001 ASHRAE Fundamentals Handbook, Climatic Design Information chapter, Tabl e 1A (United States) and 2A (Canada) or the 2005 ASHRAE Fundamentals handbook, Climatic Design Information chapter, and the CD --ROM included with th e 2005 ASHRAE Fundamentals Handbook.

30 NR NR NR 377

Local 99% Winter Design Temperature: ---10 to 4 degrees F*

6 NR NR 145 196

8 NR NR 159 213 10 NR NR 175 231 15 NR NR NR 283 20 NR NR NR 333 30 NR NR NR NR

Local 99% Winter Design Temperature: ---11 degrees F or

Not recommended for any vent configuration.

(7741)19(12258)2818064)38(24516)

SQ. IN. (SQ. MM)

lower

Air for combustion must not be contaminated by halogen compounds which include chlorides, fluorides, bromides, and iodides. These compounds are found in many common home products such as detergent, paint, glue, aerosol spray, bleach, cleaning solvent, salt, and air freshener, and can cause corrosion of furnaces and vents. Avoid using such products in the combustion--air supply. Furnace use during construction of the building could cause the furnace to be exposed to halogen compounds, causing premature failure of the furnace or venting system due to corrosion.

Vent dampers on any appliance connected to the common vent can cause condensation and corrosion in the venting system. Do not use vent dampers on appliances common vented with this furnace.

Additional Venting Requir

ements

A 4--in. (102 mm) round vent elbow is supplied with the furnace. A 5--in. (127 mm) or 6-- in. (152 mm) vent connector may be required for some model furnaces. A field--supplied 4--in. (102 mm) to 5--in. (127 mm) or 4--in. (102 mm) to 6--in. (152 mm) sheet metal increaser fitting is required when 5--in. (127 mm) or 6--in. (152 mm) vent connector is used. See Fig. 36 -- 48, Venting Orientation for approved vent configurations.

NOTE: Vent connector length for connector sizing starts at furnace vent elbow. The 4--in. (102 mm) vent elbow is shipped for upflow configuration and may be rotated for other positions. Remove the three screws that secure vent elbow to furnace, rotate furnace vent elbow to position desired, reinstall screws. The factory--supplied vent elbow does NOT count as part of the number of vent connector elbows.

The vent connector can exit the furnace through one of five locations on the casing.

CAUTION

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, safety glasses and gloves when handling parts, and servicing furnaces.

1. Attach the single wall vent connector to the furnace vent elbow, and fasten the vent connector to the vent elbow with at least two field--supplied, corrosion--resistant, sheet metal screws located 180_ apart.

NOTE: An accessory flue extension is available to extend from the furnace elbow to outside the furnace casing. See Product Data Sheet for accessory listing. If flue extension is used, fasten the flue extension to the vent elbow with at least two field--supplied, corrosion--resistant, sheet metal screws located 180_ apart. Fasten the vent connector to the flue extension with at least two field--supplied, corrosion resistant sheet metal screws located 180_ apart.

2. Vent the furnace with the appropriate connector as shown in Fig. 36 -- 48.

3. Determine the correct location of the knockout to be removed.

4. Use a hammer and screwdriver to strike a sharp blow between the tie points and work the slug back and forth until the slug breaks free.

An accessory Vent Guard Kit is REQUIRED for downflow applications for use where the vent exits through the lower portion of the furnace casing. Refer to the Vent Guard Kit Instructions for complete details. See Product Data Sheet for accessory listing.

SEE NOTES: 1,2,4,7,8,9 on the page following these figures

SEE NOTES:1,2,3,4,5,7,8,9 on the page following these figures

PG8MVA

Fig. 36 -- Upflow Application -- Vent Elbow Up

SEE NOTES: 1,2,3,4,7,8,9 on the pages following these figures

Fig. 37 -- Upflow Application -- Vent Elbow Right

A03208

A03209

A03210

Fig. 38 -- Downflow Application -- Vent Elbow Up then Left

SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures

A03211

Fig. 39 -- Downflow Application -- Vent Elbow Up

SEE NOTES: 1,2,4,7,8,9 on the page following these figures

A03213

Fig. 42 -- Horizontal Left Application -- Vent Elbow Left

PG8MVA

SEE NOTES: 1,2,4,5,6,7,8,9,10 on the page following these figures

Fig. 40 -- Downflow Application -- Vent Elbow Left then Up

A03207

SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures

A03214

Fig. 43 -- Horizontal Left Application -- Vent Elbow Right

then Up

SEE NOTES:1,2,3,4,5,7,8,9 on the page following these figures.

Fig. 41 -- Downflow Application -- Vent Elbow Up then Right

A03212

SEE NOTES: 1,2,4,7,8,9 on the page following these figures

Fig. 44 -- Horizontal Right Application -- Vent Elbow Right

A03218

SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures

A03215

Fig. 45 -- Horizontal Left Application -- Vent Elbow Up

Fig. 47 -- Horizontal Right Application -- Vent Elbow Left

then Up

SEE NOTES: 1,2,4,5,7,8,9 on the page following these figures

Fig. 46 -- Horizontal Left Application -- Vent Elbow Right

A03216

Fig. 48 -- Horizontal Right Application--Vent Elbow Left

SEE NOTES: 1,2,4,5,7,8,9

VENTING NOTES FOR FIG. 36 -- 48

1. For common vent, vent connector sizing and vent material: United States----use the NFGC.

2. Immediately increase to 5--in. (102 mm) or 6--in. (152 mm) vent connector outside furnace casing when 5--in. (127 mm) vent connector is required, refer to Note 1 above.

3. Side outlet vent for upflow and downflow installations must use Type B vent immediately after exiting the furnace, except when factory--approved Downflow Vent Guard Kit is used in the downflow position. See Product Data Sheet for accessory listing.

4. Type--B vent where required, refer to Note 1 above.

5. A 4--in.(102 mm) single--wall (26 ga. min.) vent must be used inside furnace casing and when the factory--approved Downflow Vent Guard Kit is used external to the furnace. See Product Data Sheet for accessory listing.

6. Accessory Downflow Vent Guard Kit required in downflow installations with lower vent configuration. See Product Data Sheet for accessory listing.

7. Chimney Adapter Kit may be required for exterior masonry chimney applications. Refer to Chimney Adapter Kit for sizing and complete application details. See Product Data Sheet for accessory listing.

8. Secure vent connector to furnace elbow with (2) corrosion--resistant sheet metal screws, spaced approximately 180_ apart.

9. Secure all other single wall vent connector joints with (3) corrosion resistant screws spaced approximately 120_ apart. Secure Type--B vent connectors per vent connector manufacturer’s recommendations.

10. The total height of the vent and connector shall be at least seven feet for the 154,000 Btuh gas input rate model when installed in a downflow application with furnace elbow turned to left side with the connector elbow outside furnace casing pointing upward. (See Fig. 38.)

A03219

PG8MVA

A02068

Caution!! For the following applications, use the minimum vertical heights as specified below.

For all other applications, follow exclusively the National Fuel Gas Code.

FURNACE

ORIENTATION

Downflow

Horizontal Left

Downflow

NOTE: All vent configurations must also meet National Fuel Gas Code venting requirements NFGC. *4 -- -in. (102 mm) inside casing or vent guard

PG8MVA

**Including 4 in. (102 mm) vent section(s)

VENT ORIENTATION FURNACE INPUT

Vent elbow left, then up

Fig. 36

Vent elbow right, then up

Fig.

Vent Elbow up

Fig. 40

Vent elbow right

Fig. 41

Vent elbow up then left

Fig. 34

Vent elbow up, then right

Fig. 37

(BTUH/HR)

154,000 132,000 110,000 5 (127) 12 (3.6)

154,000 132,000 5 (127) 7 (2.1)

154,000 5 (127) 7 (2.1)

110,000 5 (127) 10 (3.0)

The horizontal portion of the venting system shall slope upwards not less than 1/4--in. per linear ft. (21 mm/m) from the furnace to the vent and shall be rigidly supported every 5 ft. (1.5 M) or less with metal hangers or straps to ensure there is no movement after installation.

Sidewall V

enting

This furnace is not approved for direct sidewall horizontal venting.

Per section 12.4.3 of the NFPA 54/ANSI Z223.1--2012, any listed mechanical venter may be used, when approved by the authority having jurisdiction.

Select the listed mechanical venter to match the Btuh input of the furnace being vented. Follow all manufacturer’s installation requirements for venting and termination included with the listed mechanical venter.

START--UP, ADJUSTMENT, AND SAFETY

CHECK

General

MIN. VENT

DIAMETER

IN. (mm)*

MIN. VERTICAL VENT

HEIGHT

FT. (M)**

3. Gas supply pressure to the furnace must be greater than

4.5--In. W.C. (0.16 psig ) but not exceed 14--In. W.C. (0.5 psig).

4. Check all manual--reset switches for continuity.

5. Replace blower compartment door. Door must be in place to operate furnace.

6. Setup switch descriptions The variable speed furnace control has DIP switches to select thermostat staging, blower off delay timings, air flow selection and other operational or service related functions. (See Fig. 26, 52, and 54. )

CAUTION

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, safety glasses and gloves when handling parts, and servicing furnaces.

WARNING

FIRE HAZARD

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

This furnace is equipped with manual reset limit switches in the gas control area. The switches open and shut off power to the gas valve, if a flame rollout or overheating condition occurs in the gas control area. DO NOT bypass the switches. Correct problem before resetting the switches.

1. Maintain 115--v wiring and ground. Improper polarity will result in rapid flashing LED and no furnace operation.

2. Make thermostat wire connections at the 24--v terminal block on the furnace control. Failure to make proper connections will result in improper operation. (See Fig. 25 --

34.)

REGULATOR COVER SCREW

ON/OFF SWITCH

1/2˝ NPT INLET

INLET PRESSURE TAP

1/2˝ NPT OUTLET

PLASTIC ADJUST SCREW

REGULATOR SPRING

HIGH STAGE GAS PRESSURE REGULATOR ADJUSTMENT

MANIFOLD PRESSURE TAP

Fig. 49 -- Redundant Automatic Gas Control Valve

LOW STAGE GAS PRESSURE REGULATOR ADJUSTMENT

A04167

Fig. 50 -- Orifice Hole

BURNER

ORIFICE

A93059

Start--Up Procedur

FIRE AND EXPLOSION HAZARD

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

Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury or loss of life.

ELECTRICAL SHOCK HAZARD

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

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

WARNING

PG8MVA

EXAMPLE:

THERMOSTAT SUBBASE TERMINALS WITH THERMOSTAT REMOVED (ANITICIPATOR, CLOCK, ETC., MUST BE OUT OF CIRCUIT.)

HOOK-AROUND AMMETER

R Y W G

10 TURNS

FROM UNIT 24-V CONTROL TERMINALS

5.0 AMPS ON AMMETER 10 TURNS AROUND JAWS

Fig. 51 -- Amp. Draw Check with Ammeter

0.5 AMPS FOR THERMOSTAT

ANTICIPATOR SETTING

A96316

1. Purge gas lines after all connections have been made.

2. Check gas lines for leaks.

3. To Begin Component Self--Test: Remove Blower Access Door. Disconnect the thermostat R lead from furnace control board. Manually close blower door switch. Turn Setup DIP switch SW1--6 ON. (See Fig. 26, 52 and 54.)

NOTE: The furnace control allows all components, except the gas valve, to be run for short period of time. This feature helps diagnose a system problem in case of a component failure. Component test feature will not operate if any thermostat signal is present at the control.

Refer to service label attached to furnace or See Fig. 53. Component test sequence is as follows:

a. Inducer motor starts on high--speed and continues to

run until Step d. of component test sequence.

b. Hot surface igniter is energized for 15 sec., then off.

c. Blower motor operates for 15 sec.

d. Inducer motor goes to low--speed for 10 sec., then

stops.

e. After component test is completed, one or more status

codes (11, 25, or 41) will flash. See component test section of service label (Fig. 53) in furnace for explanation of status codes.

NOTE: To repeat component test, turn setup switch SW1--6 OFF, then back ON.

4. Turn setup DIP switch SW1--6 OFF. Reconnect R lead to furnace control board, release blower door switch and reinstall blower access door.

5. Operate furnace per instruction on inner door.

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

7. Verify furnace restarts by raising thermostat setting above room temperature.

Furnace Setup Switch Description

400 CFM

,( g )

The CF switch position is the low cooling airflow selection for two stage cooling units.

SETUP SWITCH SWITCH NAME NORMAL POSITION DESCRIPTION OF USE

urn ON to retrieve up to 7 stored status codes for

SW1-1 Status Code Recovery OFF

SW1-2

SW1-3 Low Heat Rise Adjustment OFF

SW1-4 Comfort/Efficiency Adjustment ON

SW1-5 CFM per ton adjust OFF

SW1-6 Component Self Test OFF

Low Heat Only

(Adaptive Heat Mode when SW1

2 is OFF)

OFF

PG8MVA

SW1-7 & SW1-8 Blower OFF delay ON or OFF

troubleshooting assistance when R thermostat lead is disconnected. When SW1-2 is OFF allows low heat operation with a single stage thermostat. Turn ON when using twostage thermostat to allow Low Heat operation when R to W/W1 closes and High Heat operation when R to W/W1 and W2 close. Turn ON to increase Low Heat airflow by 18 percent. This compensates for increased return air temperature caused with bypass humidifier. This also increases the low heat inducer speed 15 percent.

Turn ON to decrease low heat airflow by 7 percent, and high heat airflow 10 percent for maximum comfort. Turn ON for 400 CFM per ton, Turn OFF for 350 CFM per ton. See also SW4. Turn ON to initiate Component Self Test for troubleshooting assistance when R thermostat lead is disconnected. Turn OFF when Self Test is completed.

Blower Off Delay time – adjustable 90 seconds to 180 seconds. See table in Adjustments section or refer to

diagram.

unit wirin Allows additional CFM per ton selections when used

with SW 1-5

325 CFM per ton (nominal) when SW 4-3 ON and SW 1-5 OFF

350 CFM per ton (nominal) when SW 4-3 OFF and SW 1-5 OFF

SW4-3

1 2

AC (Cooling Airflow) SETUP SWITCHES

SW 2

The AC setup switch selects desired cooling or high stage cooling (two stage units) airflow.

See Cooling Air Delivery Tables for specific switch settings.

SW 3, CF (Continuous Fan) SETUP SWITCHES

The CF setup switch selects desired Continuous Fan Airflow

CFM per ton Adjust

AIR CONDITIONING (A/C) SETUP SWITCHES

CONTINUOUS FAN (CF) SETUP SWITCHES

OFF

370 CFM per ton (nominal) when SW4-3 ON and SW 1-5 ON

per ton (nominal) when SW 1-5 ON and SW

4-3 OFF

See Air Delivery Tables for model specific CFM vs. static pressure

SW3

The CFM values are shown in the Air Delivery Tables below for SW 3 settings. SW 3 cannot be set for airflow higher than SW 2.

See Continuous Fan Air Flow Table for specific switch settings.

Fig. 52 -- Furnace Setup Switch Description

A12092

LED CODE

CONTINUOUS OFF - Check for 115VAC at L1 and L2, and 24VAC at SEC-1 and SEC-2. CONTINUOUS ON - Control has 24VAC power. RAPID FLA SHING - Line voltage (115V AC) polarity reversed.

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

11 NO PREVIOUS CODE - Stored status codes are erase d automatic ally after 72

hours or as specified above.

12 BL OWER ON A FTER POWER UP (115 VA C or 24 VA C) -Blower runs for 90

seconds, if unit is powered up during a cal l for heat (R-W/W1 closed) or (R-W/W1 opens) during blower on-delay period.

13 L IMIT CIRCUIT LOCKOUT - Lockout occurs if a limit, draft safeguard, flame

rollout, or blocked vent switch (if used) is open longer than 3 minutes or 10 successive limit trips occurred during high-heat. Control will auto r eset after three hours. Refer to status code #33.

14 IGNITION LOCK OUT - Control will auto-reset after three hours. Refer to status

code #34.

15 BL OWER MOTOR LOCKOUT - Indicates the blower failed to reach 250 RPM or

the blower failed to communicate within 30 seco nds after being turned ON in two successive heating cycles. Control will auto reset aft er 3 hours. Refer to status code #41.

21 GAS HEAT ING LOCKOUT - Control will NOT auto reset. Check for:

- Mis-wired gas valve -Defective control (valve relay)

22 ABNO RMAL FLA ME-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 va lve

23 PRESSURE SWIT CH DID NOT OPEN Check for:

- Obstructed pressure tubing - Pressure switch stuck closed

24 SECONDARY VOLTAGE FUSE IS OPEN Check for: - Sh ort circuit in secondary

voltage (24VAC) wiring.

25 INVAL ID MODEL SELECTIO N OR SETUP ERROR - Indicates either the model

plug is missing or incorrect or, setup switch "SW1-1" or "SW1-6" is positi oned improperly. If code flashes 4 times on power-up control is defaulting to model selection stored in memory.Check for: -Thermos tat call with SW1-1, SW1-6 or both SW1-1 & SW1-6 ON. - Board date code 2103 or later required to recognize model plug 007. - Proper model plug number and resist ance val ues per wiri ng dia gram

31 HIGH-HEA T PRESSURE SWITCH OR RELAY DID NOT CLOSE OR

REOPENED - Control relay may be defective. Refer to status code #32.

32 L OW-HEAT PRESSURE SWITCH DID NOT CLOSE OR REOPENED - If open

longer than five minutes, inducer shuts off for 15 minutes before retry. If opens during blower on-delay period, blower will come on for the selected blower off-delay. Check for: - Exc essive wind - Restri cted vent - Proper vent sizing

STATUS

SERVICE

If sta tus code recall is needed disconnect the "R" thermostat lead, reset power, and put setup switch "SW1-1" in the ON positi on. To cl ear t he status code histor y put setup switc h "SW1-1" in the ON positi on and jumper thermostat terminals "R", "W/W1", and "Y/Y2" simultaneously unt il statu s code #11 is fl ashed.

32 Cont inued: Check for: - Low inducer voltage (115 VAC)

- Defective inducer motor - Inadequate combustion air suppl y

- Defective pressure switch - Low inlet gas pressure (if LGP S used)

- Low inducer voltage (115 VAC)

- Disconnected or obstructed pressure tubing

33 LIMIT CIRCUIT FAUL T - Indicates a limit, draft safeguard, flame rollout, or

blocked vent switch (if used) is open or the furnace is operating in high-heat only mode due to 2 successive low heat limit trips. Blower will run for 4 minutes or until open switch remakes whichever is l onger. If open longer than 3 minutes, code changes to lockout #13. If open less than 3 minutes status code #33 continues to flash unti l blower shuts off. Flame rollout switch and BVSS require manual reset. Check for: - Loose blower wheel

- Restricted vent - Pr oper vent sizing - Excessive wind

- Dirty filter or restricted duct system - Defective switch or connections

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

34 IGNITION PROVING FA ILURE - 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:

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

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

- Manual valve shut-off - Low inlet gas pressure - Control ground continuity

- Gas valve defective or turned off - Flame sensor must not be grounded

- Inadequate flame carryover or rough ignition

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

41 BL OWER MOTOR FAULT - Indicates the blower failed to reach 250 RPM

or the blower failed to communicate within the prescribed times limits. Thirty seconds after being turned ON or ten seconds during steady-state operation.

43 L OW-HE AT PRESSURE SWITCH OPEN WHILE HIGH-HEAT PRESSURE

SWITCH IS CLOSED - Check f or: - Mis-wired pressure switches

- Low-heat pressure switch stuck open - Low inlet gas pressure (if LGPS used)

- Disconnected or obstructed pressure tubing

45 CONTROL CIRCUI TRY L OCKOUT Auto-reset after one hour lockout due to;

- Gas valve relay stuck open - Fl ame sense circuit failure - Software check error Reset power to clear lockout. Replace control if status code repeats.

COMPONENT TEST

To initiate the component test sequence, shut OFF the room thermostat or disconnect the "R" thermostat lead. Reset power and then put setup switch "SW1-6" in the ON position to start the component test sequence. Once initiat ed the furnace control will turn the inducer ON at highheat speed. The inducer motor will run for the entire test. The hot surface igniter and bl ower motor will be turned ON for 15 seconds each. When the blower is turned OFF the inducer will be switched to low-speed for 10 seconds. When the component test is completed one or more of the following codes will flash.

CODE

11 Indicates the blower motor tested

OK. Visual check of inducer motor and hot surface igniter required.

25 SETUP ERROR - Same as code 25 above.

41 BL OWER MOTOR FAULT - Indicates

blower motor failed test. Check blower, wiring, and furnace control.

To repeat component test turn setup switch "SW1-6" OFF and then back ON. After component test is completed put setup switch " SW1-6" in the OFF position and reconnect the "R" thermostat lead.

DESCRIPTION

328787-101 REV. A

Adjustments

WARNING

FIRE HAZARD

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

DO NOT bottom out gas valve regulator adjusting screw. This can result in unregulated manifold pressure and result in excess overfire and heat exchanger failures.

CAUTION

FURNACE DAMAGE HAZARD

Failure to follow this caution may result in reduced furnace life.

DO NOT redrill orifices. Improper drilling (burrs, out--of--round holes, etc.) can cause excessive burner noise and misdirection of burner flames. This can result in flame impingement of heat exchangers, causing failures. (See Fig.

50.)

Fig. 53 -- Service Label

NOTE: If orifice hole appears damaged or it is suspected to have

been redrilled, check orifice hole with a numbered drill bit of correct size. Never redrill an orifice. A burr--free and squarely aligned orifice hole is essential for proper flame characteristics.

A04015

a. Obtain average yearly gas heat value (at installed alti-

tude) from local gas supplier.

b. Obtain average yearly gas specific gravity from local

gas supplier.

c. Find installation altitude in Table 12 or 13.

d. Find closest natural gas heat value and specific gravity

in Table 12 or 13.

e. Follow heat value and specific gravity lines to point of

intersection to find orifice size and low--and high--heat manifold pressure settings for proper operation.

f. Check and verify burner orifice size in furnace.

NEVER ASSUME ORIFICE SIZE. ALWAYS CHECK AND VERIFY.

g. Replace orifice with correct size, if required by Table

12 or 13. Use only factory--supplied orifices. See EXAMPLE 1.

Table 9 – Altitude Derate Multiplier for U.S.A.

PG8MVA

Furnace gas input rate on rating plate is for installations at altitudes up to 2000 Ft. (610 M). Furnace input rate must be within +/--2 percent of furnace rating plate input. For altitudes above 5500 Ft. (1676 M), a field--supplied high altitude pressure switch is required.

1. Determine the correct gas input rate. The input rating for altitudes above 2,000 ft. (610 M) must be reduced by 4 percent for each 1,000 ft. (305 M) above sea level. For installations below 2000 Ft. (610 M), refer to the unit rating plate. For installations above 2000 Ft. (610 M), multiply the input on the rating plate by the de--rate multiplier in Table 9 for the correct input rate.

2. Determine the correct orifice and manifold pressure adjustment. All models in all positions except Low NOx models in downflow and horizontal positions use Table 12 (22,000 Btuh per burner.) Low NOx models in downflow or horizontal positions must use Table 13 (21,000 Btuh per burner.) See input listed on rating plate.

(914--- 1219)

(1219--- 1524)

1524--- 1829)

(1829--- 2134)

(2134--- 2438)

(2438--- 2743)

9001–10,000

(2743--- 3048)

ALTITUDE

FT. (M)

0–2000

(0--- 610)

2001–3000 (610--- 914)

3001–4000

4001–5000

5001–6000

6001–7000

7001–8000

8001–9000

PERCENT

DERATE MULTIPLIER

OF DERATE

0 1.00

8–12 0.90

12–16 0.86

16–20 0.82

20–24 0.78

24–28 0.74

28–32 0.70

32–36 0.66

36–40 0.62

FACTOR*

Table 10 – Blower Off Delay Setup Switch

SETUP SWITCH

DESIRED HEATING MODE

BLOWER OFF DELAY (SEC.)

90 OFF OFF 120 ON OFF 150 OFF ON 180 ON ON

EXAMPLE 1: 0–2000 ft. (0--610 M) altitude

For 22,000 Btuh per burner application use Table 12. Heating value = 1000 Btuh/cu ft. Specific gravity = 0.62 Therefore: Orifice No. 43* Manifold pressure: 3.7--In. W.C. for high--heat

1.6--In. W.C. for low--heat * Furnace is shipped with No. 43 orifices. In this example all main burner orifices are the correct size and do not need to be changed to obtain proper input rate.

( S W --- 7 A N D --- 8 )

POSITION

S W 1 --- 7 SW1--- 8

PG8MVA

3. Adjust manifold pressure to obtain low fire input rate. (See Fig. 49.)

a. Turn gas valve ON/OFF switch to OFF.

b. Remove manifold pressure tap plug from gas valve.

c. Connect a water column manometer or similar device

to manifold pressure tap.

d. Turn gas valve ON/OFF switch to ON.

e. Move setup SW1—2 on furnace control to ON posi-

tion to lock furnace in low--heat operation. (See Fig. 24and52.)

f. Manually close blower door switch.

g. Jumper R and W/W1 thermostat connections on con-

trol to start furnace. (See Fig. 24.)

h. Remove regulator adjustment cap from low heat gas

valve pressure regulator (See Fig. 49.) and turn low-heat adjusting screw (3/16 or smaller flat--tipped screwdriver) counterclockwise (out) to decrease input rate or clockwise (in) to increase input rate.

NOTE: DO NOT set low--heat manifold pressure less than

1.4--In. W.C. or more than 1.7--In. W.C. for natural gas. If manifold pressure is outside this range, change main burner orifices.

i. Install low--heat regulator adjustment cap. j. Move setup switch SW1--2 to off position after com-

pleting low--heat adjustment.

k. Leave manometer or similar device connected and

proceed to Step 4.

4. Adjust manifold pressure to obtain high fire input rate. (See Fig. 49.)

a. Jumper R to W/W1 and W2 thermostat connections on

furnace control. This keeps furnace locked in high-heat operation.

b. Remove regulator adjustment cap from high--heat gas

valve pressure regulator (See Fig. 49) and turn high heat adjusting screw (3/16--in. or smaller flat--tipped screwdriver) counterclockwise (out) to decrease input rate or clockwise (in) to increase input rate.

NOTE: DO NOT set high--heat manifold pressure less than

3.2--In. W.C. or more than 3.8 In. W.C. for natural gas. If manifold pressure is outside this range, change main burner orifices to obtain manifold pressure in this range.

c. When correct input is obtained, replace caps that con-

ceal gas valve regulator adjustment screws. Main

burner flame should be clear blue, almost transparent (See Fig. 56.)

d. Remove jumpers R to W/W1 and R to W2.

5. Verify natural gas input rate by clocking meter.

NOTE: Gas valve regulator adjustment caps must be in place for proper input to be clocked.

a. Turn off all other gas appliances and pilots served by

the meter.

b. Move setup switch SW1--2 to ON position. This

keeps furnace locked in low--heat operation.

c. Jumper R to W/W1.

d. Run furnace for 3 minutes in low--heat operation.

e. Measure time (in sec) for gas meter to complete 1

revolution and note reading. The 2 or 5 cubic feet dial provides a more accurate measurement of gas flow.

f. Refer to Table 11 for cubic ft. of gas per hr.

g. Multiply gas rate cu ft./hr by heating value (Btuh/cu

ft.) to obtain input. If clocked rate does not match required input from Step 1, increase manifold pressure to increase input or decrease manifold pressure to decrease input. Repeat steps b through e until correct low--heat input is achieved. Re--install low heat regulator seal cap on gas valve.

h. Move setup switch SW1--2 to OFF position and jump-

er R to W/W1, and W2. This keeps furnace locked in high--heat operation. Repeat items d through g for high--heat operation.

6. Set Temperature Rise

NOTE: Blower access door must be installed when taking temperature rise reading. Leaving blower access door off will result in incorrect temperature measurements.

CAUTION

FURNACE DAMAGE HAZARD

Failure to follow this caution may result in shorten furnace life.

Set air temperature rise within limits specified on the rating plate to prevent reduced life of furnace components. Operation is within a few degrees of the mid--point of rise rangewhensetupswitchSW1--4isOFF.

CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in overheating the heat exchangers or condensing flue gases in heat exchanger areas not designed for condensate.

Temperature rise must be within limits specified on unit rating plate. Operation is within a few degrees of midpoint ofriserangewhensetupswitchSW1--4isOFF.

When setup switch SW1--4 is ON, operation will be near the high end of the rise range for improved comfort.

Furnace must operate within ranges of temperature rise specified on the furnace rating plate. Determine air temperature rise as follows:

a. Place thermometers in return and supply ducts as near

furnace as possible. Be sure thermometers do not see heat exchanger so that radiant heat does not affect readings. This practice is particularly important with straight--run ducts.

b. When thermometer readings stabilize, subtract return--

air temperature from supply--air temperature to determine air temperature rise.

NOTE: Temperature rise can be determined for low--heat operation by placing setup switch SW1--2 on furnace control in ON position. For high--heat operation, place setup switch SW1--2 in OFF position and jumper R--W2 on furnace control. DO NOT forget to return setup switch to OFF position and remove R--W2 jumper upon completion of testing.

c. This furnace is capable of automatically providing

proper airflow to maintain the temperature rise within the range specified on furnace rating plate. If temperature rise is outside this range, proceed as follows:

(1.) Check gas input for low-- and high--heat opera-

tion. (2.) Check derate for altitude if applicable. (3.) Check all return and supply ducts for excessive

restrictions causing static pressure greater than

0.5--In. W.C..

(4.) Ensure Low Heat Rise Adjust switch SW1--3 on

furnace control is in ON position when a bypass

humidifier is used. (See Fig. 26 for switch loca-

tion.) (5.) Make sure proper model plug is installed.

d. Remove thermostat jumpers and release blower access

door switch.

e. Repeat Steps a through c as required to adjust for high

heat temperature rise.

f. When correct high heat input rate and temperature rise

is achieved, turn gas valve ON/OFF switch to OFF. g. Release blower access door switch. h. Remove manometer or similar device from gas valve.

i. Re--install manifold pressure tap plug in gas valve.

(See Fig. 49.)

WARNING

FIRE HAZARD

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

Reinstall manifold pressure tap plug in gas valve to prevent gas leak.

j. Remove thermostat jumper wire from furnace control

board. k. Turn gas valve ON/OFF switch to ON.

CAUTION

FURNACE OVERHEATING HAZARD

Failure to follow this caution may result in reduced furnace life.

Recheck temperature rise. It must be within limits specified on the rating plate. Recommended operation is at the mid--point of rise range or slightly above.

l. Proceed to Step 6, “Set Blower Off Delay” before in-

stalling blower access door.

7. Set Blower Off Delay a. Remove blower access door if installed.

b. TurnDipswitchSW--7orSW--8ONorOFFforde-

sired blower off delay. (See Fig. 26, 52 and 54.)

8. Set thermostat heat anticipator. a. Mechanical thermostat. Set thermostat heat anticipator

to match the amp. draw of the electrical components in the R--W/W1 circuit. Accurate amp. draw readings can be obtained at the wires normally connected to thermostat subbase terminals, R and W. The thermostat anticipator should NOT be in the circuit while measuring current.

(1.) Set SW1--2 switch on furnace control board to

ON. (2.) Remove thermostat from subbase or from wall. (3.) Connect an amp. meter as shown in Fig. 51.

across the R and W subbase terminals or R and

W wires at wall. (4.) Record amp. draw across terminals when furnace

is in low heat and after blower starts. (5.) Set heat anticipator on thermostat per thermostat

instructions and install on subbase or wall. (6.) Turn SW1--2 switch OFF. (7.) Install blower access door.

b. Electronic thermostat: Set cycle rate for 3 cycles per

hr.

9. Set Airflow for Air Conditioning --Single Stage and High Stage Cooling The ECM blower can be adjusted for a range of airflow for Low Speed or High Speed cooling. See Table 4--Air Delivery -- CFM (With Filter ). Depending on the model size, the cooling airflow can be adjusted from 1. tons nominal cooling to 3 ., to 4 or to 6 tons of nominal cooling based on 350 cfm ton. The cooling airflow is adjusted by turning Setup switches SW2--1, SW2--2 and SW2--3 either ON or OFF. Select the required airflow from Fig. 58. Fig. 58 is based on 350 CFM per ton. For airflow at 400 CFM per ton, turn Setup SW1--5 ON (See Fig. 26 and 52.)

NOTE: 6 ton airflow will truncate at 2200 cfm on applicable models. For a complete explanation of cooling airflow, refer to the section titled “Sequence of Operation.”

10. Set Airflow For Continuous Fan/Low Speed Cooling Airflow The ECM blower motor can be adjusted for continuous fan speeds different than heating or cooling fan speed. See Table 4 -- Air Delivery -- CFM (With Filter). Select the required continuous fan airflow from Fig. 58. The continuous fan speed is also the fan speed for low speed cooling when furnace is used with a 2--speed cooling unit. Adjust the Continuous Fan CFM to match the airflow required for low speed cooling. Select the required airflow from Fig. 56. For airflow at 400 CFM per ton, turn Setup SW1--5 ON (See Fig. 58.) The airflow selected for low speed cooling will also be the airflow used for continuous fan. The continuous fan speed can be further adjusted at the thermostat using the “Comfort Fan” select function. Changing the continuous fan speed at the thermostat DOES NOT change the low speed cooling airflow selected at the control board.

PG8MVA

A12057

Fig. 54 -- Wiring Diagram

Table 11 – Gas Rate (CU ft./hr)

SECONDS G

FOR 1 REVOLUTION

10 360 720 1800 50 72 144 360 11 327 655 1636 51 71 141 355 12 300 600 1500 52 69 138 346 13 277 555 1385 53 68 136 340 14 257 514 1286 54 67 133 333 15 240 480 1200 55 65 131 327 16 225 450 1125 56 64 129 321 17 212 424 1059 57 63 126 316 18 200 400 1000 58 62 124 310 19 189 379 947 59 61 122 305 20 180 360 900 60 60 120 300 21 171 343 857 62 58 116 290 22 164 327 818 64 56 112 281 23 157 313 783 66 54 109 273 24 150 300 750 68 53 106 265 25 144 288 720 70 51 103 257 26 138 277 692 72 50 100 250 27 133 267 667 74 48 97 243 28 129 257 643 76 47 95 237 29 124 248 621 78 46 92 231 30 120 240 600 80 45 90 225 31 116 232 581 82 44 88 220 32 113 225 563 84 43 86 214 33 109 218 545 86 42 84 209 34 106 212 529 88 41 82 205 35 103 206 514 90 40 80 200 36 100 200 500 92 39 78 196 37 97 195 486 94 38 76 192 38 95 189 474 96 38 75 188 39 92 185 462 98 37 74 184 40 90 180 450 100 36 72 180 41 88 176 439 102 35 71 178 42 86 172 429 104 35 69 173 43 84 167 419 106 34 68 170 44 82 164 409 108 33 67 167 45 80 160 400 110 33 65 164 46 78 157 391 112 32 64 161 47 76 153 383 116 31 62 155 48 75 150 375 120 30 60 150 49 73 147 367

1CuFt. 2CuFt. 5CuFt. 1CuFt. 2CuFt. 5CuFt.

SIZE OF TEST DIAL

SECONDS

FOR 1 REVOLUTION

SIZE OF TEST DIAL

PG8MVA

Table 12 – Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate

(Tabulated Data Based on 22,000 Btuh High--Heat/14,500 Btuh for Low--Heat per Burner, Derated 4 Percent for Each 1000 Ft.

(305 M) Above Sea Level)

ALTITUDE RANGE

FT. (M)

USA

ALTITUDE RANGE

(0 to 610)

FT. (M)

0to

2000

PG8MVA

2001 to

USA

ALTITUDE RANGE

USA

ALTITUDE RANGE

USA

* Orifice numbers 43 are factory installed

3000 (610

FT. (M)

3001 to

FT. (M)

4001 to

(1219 to

to 914)

4000

(914 to

1219)

5000

1524)

AVG. GAS

HEAT VALUE

(BTUH/CU FT.)

900 42 3.5/1.5 42 3.6/1.6 42 3.7/1.6 41 3.5/1.5 925 42 3.3/1.4 42 3.4/1.5 42 3.5/1.5 42 3.7/1.6 950 43 3.8/1.7 42 3.3/1.4 42 3.4/1.5 42 3.5/1.5

975 43 3.6/1.6 43 3.8/1.6 42 3.2/1.4 42 3.3/1.4 1000 43 3.5/1.5 43 3.6/1.6 43 3.7/1.6 43 3.8/1.7 1025 43 3.3/1.4 43 3.4/1.5 43 3.5/1.5 43 3.6/1.6 1050 44 3.6/1.6 43 3.2/1.4 43 3.4/1.5 43 3.5/1.5 1075 44 3.4/1.5 44 3.5/1.5 43 3.2/1.4 43 3.3/1.4 1100 44 3.3/1.4 44 3.4/1.5 44 3.5/1.5 43 3.2/1.4

AVG. GAS

HEAT VALUE

(BTUH/CU FT.)

800 42 3.4/1.5 42 3.5/1.5 42 3.6/1.6 42 3.7/1.6

825 42 3.2/1.4 42 3.3/1.4 42 3.4/1.5 42 3.5/1.5

850 43 3.7/1.6 43 3.8/1.6 42 3.2/1.4 42 3.3/1.4

875 43 3.5/1.5 43 3.6/1.6 43 3.7/1.6 43 3.8/1.7

900 43 3.3/1.4 43 3.4/1.5 43 3.5/1.5 43 3.6/1.6

925 44 3.5/1.5 43 3.2/1.4 43 3.3/1.4 43 3.4/1.5

950 44 3.4/1.5 44 3.5/1.5 44 3.6/1.6 43 3.2/1.4

975 44 3.2/1.4 44 3.3/1.4 44 3.4/1.5 44 3.5/1.5 1000 45 3.7/1.6 45 3.8/1.7 44 3.2/1.4 44 3.4/1.5

AVG. GAS

HEAT VALUE

(BTUH/CU FT.)

775 42 3.2/1.4 42 3.3/1.4 42 3.4/1.5 42 3.5/1.5

800 43 3.6/1.6 43 3.8/1.6 42 3.2/1.4 42 3.3/1.4

825 43 3.4/1.5 43 3.5/1.5 43 3.7/1.6 43 3.8/1.6

850 43 3.2/1.4 43 3.3/1.4 43 3.4/1.5 43 3.6/1.5

875 44 3.5/1.5 44 3.6/1.6 43 3.3/1.4 43 3.4/1.5

900 44 3.3/1.4 44 3.4/1.5 44 3.5/1.5 43 3.2/1.4

925 45 3.8/1.6 44 3.2/1.4 44 3.3/1.5 44 3.4/1.5

950 46 3.8/1.6 45 3.7/1.6 45 3.8/1.7 44 3.3/1.4

AVG. GAS

HEAT VALUE

(BTUH/CU FT.)

750 43 3.6/1.6 43 3.8/1.6 42 3.2/1.4 42 3.3/1.4

775 43 3.4/1.5 43 3.5/1.5 43 3.6/1.6 43 3.8/1.6

800 43 3.2/1.4 43 3.3/1.4 43 3.4/1.5 43 3.5/1.5

825 44 3.4/1.5 44 3.6/1.5 43 3.2/1.4 43 3.3/1.4

850 44 3.2/1.4 44 3.4/1.5 44 3.5/1.5 44 3.6/1.6

875 45 3.7/1.6 45 3.8/1.7 44 3.3/1.4 44 3.4/1.5

900 46 3.7/1.6 46 3.8/1.7 45 3.7/1.6 44 3.2/1.4

925 46 3.5/1.5 46 3.6/1.6 46 3.7/1.6 46 3.8/1.7

0.58 0.60 0.62 0.64

Orifice

No.

Orifice

No.

Orifice

No.

Orifice

No.

Manifold Pressure

High/Low

0.58 0.60 0.62 0.64

Manifold Pressure

High/Low

0.58 0.60 0.62 0.64

Manifold Pressure

High/Low

0.58 0.60 0.62 0.64

Manifold Pressure

High/Low

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

Manifold Pressure

High/Low

Manifold Pressure

High/Low

Manifold Pressure

High/Low

Manifold Pressure

High/Low

Orifice

No.

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

High/Low

Manifold

Pressure

High/Low

Manifold

Pressure

High/Low

Manifold

Pressure

High/Low

Orifice

No.

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

High/Low

Manifold Pressure

High/Low

Manifold Pressure

High/Low

Manifold Pressure

High/Low

Table 12 -- Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate (Con’t.)

(Tabulated Data Based on 22,000 Btuh High--Heat/14,500 Btuh for Low--Heat per Burner, Derated 4 Percent for Each 1000 Ft.

Above Sea Level)

ALTITUDE

RANGE FT. (M)

5001 to

6000

USA

* Orifice numbers 43 are factory installed

(1524

1829)

ALTITUDE

RANGE

FT. (M)

6001 to

7000

(1829

2134)

ALTITUDE

RANGE

FT. (M)

7001 to

8000

(2134

2438)

ALTITUDE

RANGE

FT. (M)

8001 to

9000

(2438

2743)

9001 to

10,000

2743 to

3048)

AVG. GAS

HEAT VALUE

AT ALTITUDE

(BTUH/CU FT.)

725 43 3.4/1.5 43 3.5/1.5 43 3.6/1.6 43 3.7/1.6 750 43 3.2/1.4 43 3.3/1.4 43 3.4/1.5 43 3.5/1.5 775 44 3.4/1.5 44 3.5/1.5 43 3.2/1.4 43 3.3/1.4 800 44 3.2/1.4 44 3.3/1.4 44 3.4/1.5 44 3.5/1.5 825 46 3.8/1.7 45 3.8/1.6 44 3.2/1.4 44 3.3/1.4 850 46 3.6/1.6 46 3.7/1.6 46 3.8/1.7 45 3.8/1.6 875 47 3.8/1.7 46 3.5/1.5 46 3.6/1.6 46 3.7/1.6 900 47 3.6/1.6 47 3.8/1.6 46 3.4/1.5 46 3.5/1.5

AVG. GAS HEAT VALUE AT ALTITUDE

(BTUH/CU FT.)

675 43 3.4/1.5 43 3.5/1.5 43 3.6/1.6 43 3.7/1.6 700 44 3.6/1.6 43 3.3/1.4 43 3.4/1.5 43 3.5/1.5 725 44 3.4/1.5 44 3.5/1.5 44 3.6/1.6 43 3.2/1.4 750 45 3.8/1.7 44 3.3/1.4 44 3.4/1.5 44 3.5/1.5 775 46 3.7/1.6 45 3.7/1.6 45 3.8/1.7 44 3.2/1.4 800 46 3.5/1.5 46 3.6/1.6 46 3.8/1.6 45 3.7/1.6 825 47 3.7/1.6 46 3.4/1.5 46 3.5/1.5 46 3.6/1.6 850 47 3.5/1.5 47 3.6/1.6 47 3.8/1.6 46 3.4/1.5

AVG. GAS HEAT VALUE AT ALTITUDE

(BTUH/CU FT.)

650 44 3.6/1.6 43 3.2/1.4 43 3.4/1.5 43 3.5/1.5 675 44 3.3/1.5 44 3.5/1.5 44 3.6/1.6 43 3.2/1.4 700 45 3.8/1.6 44 3.2/1.4 44 3.3/1.4 44 3.4/1.5 725 46 3.7/1.6 46 3.8/1.7 45 3.7/1.6 44 3.2/1.4 750 46 3.4/1.5 46 3.6/1.5 46 3.7/1.6 46 3.8/1.6 775 47 3.6/1.6 47 3.8/1.6 46 3.4/1.5 46 3.6/1.5 800 47 3.4/1.5 47 3.5/1.5 47 3.7/1.6 47 3.8/1.6 825 48 3.7/1.6 48 3.8/1.6 47 3.4/1.5 47 3.6/1.5

AVG. GAS HEAT VALUE AT ALTITUDE

(BTUH/CU FT.)

625 44 3.3/1.5 44 3.5/1.5 44 3.6/1.6 43 3.2/1.4 650 45 3.7/1.6 44 3.2/1.4 44 3.3/1.4 44 3.4/1.5 675 46 3.6/1.6 46 3.8/1.6 45 3.7/1.6 45 3.8/1.7 700 47 3.8/1.7 46 3.5/1.5 46 3.6/1.6 46 3.7/1.6 725 47 3.6/1.6 47 3.7/1.6 47 3.8/1.7 46 3.5/1.5 750 48 3.8/1.7 47 3.5/1.5 47 3.6/1.6 47 3.7/1.6 775 48 3.6/1.5 48 3.7/1.6 48 3.8/1.7 47 3.5/1.5 600 45 3.7/1.6 45 3.8/1.7 44 3.3/1.4 44 3.4/1.5 625 46 3.6/1.6 46 3.7/1.6 46 3.8/1.7 45 3.8/1.6 650 47 3.8/1.6 46 3.4/1.5 46 3.6/1.5 46 3.7/1.6 675 47 3.5/1.5 47 3.6/1.6 47 3.7/1.6 46 3.4/1.5 700 48 3.7/1.6 48 3.8/1.7 47 3.5/1.5 47 3.6/1.6 725 48 3.5/1.5 48 3.6/1.6 48 3.7/1.6 48 3.8/1.7

0.58 0.60 0.62 0.64

Orifice

No.

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

High/Low

0.58 0.60 0.62 0.64

Manifold

Pressure

High/Low

0.58 0.60 0.62 0.64

Manifold

Pressure

High/Low

0.58 0.60 0.62 0.64

Manifold

Pressure

High/Low

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

Orifice

No.

Orifice

No.

Orifice

No.

Manifold Pressure

High/Low

SPECIFIC GRAVITY OF NATURAL GAS

Manifold Pressure

High/Low

SPECIFIC GRAVITY OF NATURAL GAS

Manifold Pressure

High/Low

SPECIFIC GRAVITY OF NATURAL GAS

Manifold Pressure

High/Low

Orifice

No.

Orifice

No.

Orifice

No.

Orifice

No.

High/Low

Manifold Pressure

Orifice

No.

Orifice

No.

Orifice

No.

Orifice

No.

Manifold Pressure

High/Low

Manifold Pressure

High/Low

PG8MVA

Manifold Pressure

High/Low

Manifold Pressure

High/Low

Table 13 – Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate

(Tabulated Data Based on 21,000 Btuh High--Heat/14,500 Btuh for Low--Heat Per Burner, Derated 4 Percent for Each 1000 Ft.

(305 M) Above Sea level)

ALTITUDE RANGE

FT. (M)

0to

USA

ALTITUDE RANGE

PG8MVA

USA

ALTITUDE RANGE

USA

ALTITUDE RANGE

USA

* Orifice numbers 43 are factory installed

2000

(0 to 610)

FT. (M)

2001 to

3000 (610

to 914)

FT. (M)

3001 to

4000 (914

to 1219)

FT. (M)

4001 to

5000

(1219 to

1524)

AVG. GAS

HEAT VALUE

(BTUH/CU

FT.)

900 42 3.2/1.5 42 3.3/1.6 42 3.4/1.6 42 3.5/1.7 925 43 3.7/1.8 43 3.8/1.8 42 3.2/1.5 42 3.3/1.6 950 43 3.5/1.7 43 3.6/1.7 43 3.7/1.8 43 3.8/1.8

975 43 3.3/1.6 43 3.4/1.6 43 3.5/1.7 43 3.7/1.7 1000 44 3.6/1.7 43 3.3/1.6 43 3.4/1.6 43 3.5/1.7 1025 44 3.4/1.6 44 3.6/1.7 43 3.2/1.5 43 3.3/1.6 1050 44 3.3/1.6 44 3.4/1.6 44 3.5/1.7 43 3.2/1.5 1075 45 3.8/1.8 44 3.2/1.5 44 3.3/1.6 44 3.4/1.6 1100 46 3.8/1.8 45 3.7/1.8 44 3.2/1.5 44 3.3/1.6

AVG. GAS

HEAT VALUE

(BTUH/CU FT.)

800 43 3.8/1.8 42 3.2/1.5 42 3.3/1.6 42 3.4/1.6

825 43 3.5/1.7 43 3.7/1.7 43 3.8/1.8 42 3.2/1.5

850 43 3.3/1.6 43 3.5/1.6 43 3.6/1.7 43 3.7/1.8

875 43 3.2/1.5 43 3.3/1.6 43 3.4/1.6 43 3.5/1.7

900 44 3.4/1.6 44 3.5/1.7 43 3.2/1.5 43 3.3/1.6

925 44 3.2/1.5 44 3.3/1.6 44 3.5/1.6 44 3.6/1.7

950 45 3.7/1.8 45 3.8/1.8 44 3.3/1.6 44 3.4/1.6

975 46 3.7/1.8 46 3.8/1.8 45 3.8/1.8 44 3.2/1.5 1000 46 3.5/1.7 46 3.6/1.7 46 3.8/1.8 45 3.7/1.8

AVG. GAS

HEAT VALUE

(BTUH/CU FT.)

775 43 3.5/1.7 43 3.7/1.7 43 3.8/1.8 42 3.2/1.5

800 43 3.3/1.6 43 3.4/1.6 43 3.5/1.7 43 3.7/1.7

825 44 3.6/1.7 43 3.2/1.5 43 3.3/1.6 43 3.4/1.6

850 44 3.4/1.6 44 3.5/1.7 44 3.6/1.7 43 3.2/1.5

875 45 3.8/1.8 44 3.3/1.6 44 3.4/1.6 44 3.5/1.7

900 46 3.8/1.8 45 3.8/1.8 44 3.2/1.5 44 3.3/1.6

925 46 3.6/1.7 46 3.7/1.8 45 3.7/1.8 45 3.8/1.8

950 46 3.4/1.6 46 3.5/1.7 46 3.7/1.7 46 3.8/1.8

AVG. GAS

HEAT VALUE

(BTUH/CU FT.)

750 43 3.3/1.6 43 3.4/1.6 43 3.5/1.7 43 3.6/1.7

775 44 3.6/1.7 43 3.2/1.5 43 3.3/1.6 43 3.4/1.6

800 44 3.3/1.6 44 3.4/1.6 44 3.6/1.7 43 3.2/1.5

825 45 3.8/1.8 44 3.2/1.5 44 3.4/1.6 44 3.5/1.6

850 46 3.8/1.8 45 3.7/1.8 45 3.8/1.8 44 3.3/1.6

875 46 3.5/1.7 46 3.7/1.7 46 3.8/1.8 45 3.7/1.8

900 47 3.8/1.8 46 3.5/1.7 46 3.6/1.7 46 3.7/1.8

925 47 3.6/1.7 47 3.7/1.8 47 3.8/1.8 46 3.5/1.7

0.58 0.60 0.62 0.64

Orifice

No.

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

High/Low

0.58 0.60 0.62 0.64

Manifold

Pressure

High/Low

0.58 0.60 0.62 0.64

Manifold

Pressure

High/Low

0.58 0.60 0.62 0.64

Manifold

Pressure

High/Low

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

Manifold

Pressure

High/Low

Manifold Pressure

High/Low

Manifold Pressure

High/Low

Manifold Pressure

High/Low

Orifice

No.

Orifice

No.

Orifice

No.

Orifice

No.

Manifold Pressure

High/Low

Manifold Pressure

High/Low

Manifold Pressure

High/Low

Manifold Pressure

High/Low

Orifice

No.

Orifice

No.

Orifice

No.

Orifice

No.

Manifold Pressure

High/Low

Manifold Pressure

High/Low

Manifold Pressure

High/Low

Manifold Pressure

High/Low

Table 13 -- Orifice Size and Manifold Pressure (In. W.C.) for Gas Input Rate (Con’t.)

(Tabulated Data Based on 21,000 Btuh High--Heat/14,500 Btuh for Low--Heat Per Burner, Derated 4 Percent for Each 1000 Ft.

(305 M) Above Sea level)

AVG. GAS

ALTITUDE RANGE

FT. (M)

5001 to

USA

ALTITUDE RANGE

USA

ALTITUDE RANGE

USA

ALTITUDE RANGE

USA

* Orifice numbers 43 are factory installed

6000

(1524 to

1829)

FT. (M)

6001 to

7000

(1829 to

2134)

FT. (M)

7001 to

8000

(2134 to

2438)

FT. (M)

8001 to

9000

(2438 to

2743)

9001 to

10,000

(2743 to

3048)

HEAT VALUE AT ALTITUDE

(BTUH/CU

FT.)

725 44 3.5/1.7 43 3.2/1.5 43 3.3/1.6 43 3.4/1.6 750 44 3.3/1.6 44 3.4/1.6 44 3.5/1.7 43 3.2/1.5 775 45 3.7/1.8 44 3.2/1.5 44 3.3/1.6 44 3.4/1.6 800 46 3.7/1.8 46 3.8/1.8 45 3.8/1.8 44 3.2/1.5 825 46 3.5/1.7 46 3.6/1.7 46 3.7/1.8 46 3.8/1.8 850 47 3.7/1.8 47 3.8/1.8 46 3.5/1.7 46 3.6/1.7 875 47 3.5/1.7 47 3.6/1.7 47 3.7/1.8 46 3.4/1.6 900 48 3.8/1.8 47 3.4/1.6 47 3.5/1.7 47 3.7/1.7

AVG. GAS

HEAT VALUE

AT ALTITUDE

(BTUH/CU FT.)

675 44 3.5/1.7 43 3.2/1.5 43 3.3/1.6 43 3.4/1.6 700 44 3.3/1.6 44 3.4/1.6 44 3.5/1.7 43 3.2/1.5 725 45 3.7/1.8 45 3.8/1.8 44 3.3/1.6 44 3.4/1.6 750 46 3.6/1.7 46 3.8/1.8 45 3.7/1.8 45 3.8/1.8 775 46 3.4/1.6 46 3.5/1.7 46 3.6/1.7 46 3.8/1.8 800 47 3.6/1.7 47 3.8/1.8 46 3.4/1.6 46 3.5/1.7 825 47 3.4/1.6 47 3.5/1.7 47 3.6/1.7 47 3.8/1.8 850 48 3.7/1.7 48 3.8/1.8 47 3.4/1.6 47 3.5/1.7

AVG. GAS

HEAT VALUE

AT ALTITUDE

(BTUH/CU FT.)

650 44 3.3/1.6 44 3.4/1.6 44 3.5/1.7 43 3.2/1.5 675 45 3.7/1.8 45 3.8/1.8 44 3.3/1.6 44 3.4/1.6 700 46 3.6/1.7 46 3.7/1.8 46 3.8/1.8 45 3.8/1.8 725 47 3.8/1.8 46 3.5/1.7 46 3.6/1.7 46 3.7/1.8 750 47 3.5/1.7 47 3.7/1.8 47 3.8/1.8 46 3.5/1.6 775 48 3.8/1.8 47 3.4/1.6 47 3.6/1.7 47 3.7/1.7 800 48 3.6/1.7 48 3.7/1.8 48 3.8/1.8 47 3.4/1.6 825 48 3.3/1.6 48 3.5/1.6 48 3.6/1.7 48 3.7/1.8

AVG. GAS

HEAT VALUE

AT ALTITUDE

(BTUH/CU FT.)

625 45 3.7/1.8 45 3.8/1.8 44 3.3/1.6 44 3.4/1.6 650 46 3.6/1.7 46 3.7/1.8 46 3.8/1.8 45 3.8/1.8 675 47 3.8/1.8 46 3.4/1.6 46 3.5/1.7 46 3.7/1.7 700 47 3.5/1.7 47 3.6/1.7 47 3.7/1.8 46 3.4/1.6 725 48 3.7/1.8 48 3.8/1.8 47 3.5/1.7 47 3.6/1.7 750 48 3.5/1.7 48 3.6/1.7 48 3.7/1.8 48 3.8/1.8 775 49 3.8/1.8 48 3.4/1.6 48 3.5/1.7 48 3.6/1.7 600 46 3.6/1.7 46 3.7/1.8 46 3.8/1.8 45 3.7/1.8 625 47 3.7/1.8 47 3.8/1.8 46 3.5/1.7 46 3.6/1.7 650 47 3.4/1.6 47 3.6/1.7 47 3.7/1.8 47 3.8/1.8 675 48 3.6/1.7 48 3.8/1.8 47 3.4/1.6 47 3.5/1.7 700 48 3.4/1.6 48 3.5/1.7 48 3.6/1.7 48 3.7/1.8 725 49 3.7/1.8 49 3.8/1.8 48 3.4/1.6 48 3.5/1.7

0.58 0.60 0.62 0.64

Orifice

No.

Orifice

No.

Orifice

No.

Orifice

No.

Manifold Pressure

High/Low

0.58 0.60 0.62 0.64

Manifold Pressure

High/Low

0.58 0.60 0.62 0.64

Manifold Pressure

High/Low

0.58 0.60 0.62 0.64

Manifold Pressure

High/Low

SPECIFIC GRAVITY OF NATURAL GAS

Orifice

No.

Orifice

No.

Orifice

No.

Orifice

No.

Manifold Pressure

High/Low

SPECIFIC GRAVITY OF NATURAL GAS

Manifold Pressure

High/Low

SPECIFIC GRAVITY OF NATURAL GAS

Manifold Pressure

High/Low

SPECIFIC GRAVITY OF NATURAL GAS

Manifold Pressure

High/Low

Orifice

No.

Orifice

No.

Orifice

No.

Orifice

No.

Manifold

Pressure

High/Low

Manifold

Pressure

High/Low

Manifold

Pressure

High/Low

Manifold

Pressure

High/Low

Orifice

No.

Orifice

No.

Orifice

No.

Orifice

No.

Manifold Pressure

High/Low

Manifold Pressure

High/Low

PG8MVA

Manifold Pressure

High/Low

Manifold Pressure

High/Low

Check Safety Contr

The flame sensor, gas valve, and pressure switch were all checked in the Start--up procedure section as part of normal operation.

1. Check Main Limit Switch This control shuts off combustion system and energizes air--circulating blower motor, if furnace overheats. By using this method to check limit control, it can be established that limit is functioning properly and will operate if there is a restricted return--air supply or motor failure. If limit control does not function during this test, cause must be determined and corrected.

a. Run furnace for at least 5 minutes.

b. Gradually block off return air with a piece of card-

board or sheet metal until the limit trips.

c. Unblock return air to permit normal circulation.

d. Burners will re--light when furnace cools down.

2. Check draft safeguard switch. The purpose of this control is to cause the safe shutdown of the furnace during certain blocked vent conditions.

PG8MVA

a. Verify vent pipe is cool to the touch.

b. Disconnect power to furnace and remove vent con-

nector from furnace vent elbow.

c. Restore power to furnace and set room thermostat

above room temperature.

d. After normal start--up, allow furnace to operate for 2

minutes, then block vent elbow in furnace 80 percent of vent area with a piece of flat sheet metal.

e. Furnace should cycle off within 2 minutes. If gas does

not shut off within 2 minutes, determine reason draft safeguard switch did not function properly and correct condition.

f. Remove blockage from furnace vent elbow. g. Switch will auto--reset when it cools. h. Re--install vent connector.

NOTE: Should switch remain open longer than 3 minutes, furnace control board will lockout the furnace for 3 hours. To reset furnace control board, turn thermostat below room temperature or from HEAT to OFF and turn 115--v power OFF, then back ON.

3. Check Pressure Switch(es) This control proves operation of the draft inducer blower.

a. Turn off 115--v power to furnace.

b. Disconnect inducer motor lead wires from wire har-

ness.

c. Turn on 115--v power to furnace.

d. Set thermostat to “call for heat” and wait 1 minute.

When pressure switch is functioning properly, hot surface igniter should NOT glow and control diagnostic light flashes a status code 32. If hot surface igniter glows when inducer motor is disconnected, shut down furnace immediately.

e. Determine reason pressure switch did not function

properly and correct condition.

f. Turn off 115--v power to furnace.

g. Reconnect inducer motor wires, replace outer door,

andturnon115--vpower.

h. Blower will run for 90 seconds before beginning the

call for heat again.

i. Furnace should ignite normally.

Checklist

1. Put away tools and instruments. Clean up debris.

2. Verify that switches SW1--1 and SW1--6 are OFF and other setup switches are set as desired. Verify that switches

ols

SW1--7andSW1--8fortheblowerOFFDELAYaresetas desired per Fig. 52.

3. Verify that blower and burner access doors are properly installed.

4. Cycle test furnace with room thermostat.

5. Check operation of accessories per manufacturer’s instructions.

6. Review User’s Guide with owner.

7. Attach literature packet to furnace.

SERVICE AND MAINTENANCE

PROCEDURES

WARNING

FIRE, INJURY OR DEATH HAZARD

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

The ability to properly perform maintenance on this equipment requires certain knowledge, 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.

CAUTION

ENVIRONMENTAL HAZARD

Failure to follow this caution may result in environmental pollution.

Remove and recycle all components or materials (i.e. oil, refrigerant, control board, etc.) before unit final disposal.

WARNING

ELECTRICAL SHOCK, FIRE OR EXPLOSION HAZARD

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

Before installing, modifying, or servicing system, main electrical disconnect switch must be in the OFF position and install a lockout tag. There may be more than one disconnect switch. Lock out and tag switch with a suitable warning label. Verify proper operation after servicing.

CAUTION

ELECTRICAL OPERATION HAZARD

Failure to follow this caution may result in improper furnace operation or failure of furnace.

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

General

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. 5, you must revise your orientation to component location accordingly.

Electrical Controls and W

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 furnace. Check accessories and cooling unit for additional electrical supplies that must be shut off during furnace servicing. Lock out and tag switch with a suitable warning label.

The electrical ground and polarity for 115--v wiring must be properly maintained. Refer to Fig. 25 for field wiring information and to Fig. 54 for furnace wiring information.

NOTE: If the polarity is not correct, the STATUS LED on the control will flash rapidly and prevent the furnace from heating. The control system also requires an earth ground for proper operation of the control and flame--sensing electrode.

The 24--v circuit contains an automotive--type, 3--amp. fuse located on the control. (See Fig. 26.) Any 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 3--amp. fuse. The control LED will display status code 24 when fuse needs to be replaced.

Proper instrumentation is required to service electrical controls. The control in this furnace is equipped with a Status Code LED (Light--Emitting Diode) to aid in installation, servicing, and troubleshooting. Status codes can be viewed at the sight glass in blower access door. The amber furnace control LED is either ON continuously, rapid flashing, or a code composed of 2 digits. The first digit is the number of short flashes, the second digit is the number of long flashes.

For an explanation of status codes, refer to service label located on blower access door or Fig. 53, and the troubleshooting guide which can be obtained from your distributor.

See Fig. 59, a brief Troubleshooting Guide. For 2--Stage Variable Speed ECM Controls the stored status

codes will NOT be erased from the control memory, when 115-or 24--v power is interrupted. The control will store up to the last 7 Status Codes in order of occurrence.

1. To retrieve status codes, proceed with the following:

NOTE: NO thermostat signal may be present at control, and all blower--OFF delays must be completed.

a. Leave 115--v power to furnace turned on.

b. Remove outer access door.

c. Look into blower access door sight glass for current

LED status.

d. Remove blower access door.

iring

WARNING

NOTE: The Status Codes cannot be retrieved by disconnecting

the limit switch or draft safeguard switch. To retrieve Status Codes, follow the procedure below.

2. Turn Setup Switch, SW1--1 “ON.”

3. Manually close blower access door switch.

4. Control will flash up to 7 Status Codes.

5. The last Status Code, or 8th Code, will be Code 11.

6. Turn SW1--1 “OFF.”

7. A continuously--lit Amber LED will appear and indicates proper operation.

8. Release blower access door switch, install blower access door and replace outer door or refer to the SERVICE label on the front of the blower access door for more information.

Component Self--T

Component Test can ONLY be initiated by performing the following:

1. Remove outer access door.

2. Remove blower access door.

3. Remove the wire from the “R” terminal of the control board.

4. Turn Setup Switch, SW--1--6 “ON.”

5. Manually close blower access door switch.

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

ELECTRICAL SHOCK HAZARD

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

Blower access door switch opens 115--v power to furnace control. No component operation can occur unless switch is closed. Exercise caution to avoid electrical shock from exposed electrical components when manually closing this switch for service purposes.

6. Component Test sequence will function as follows:

a. Inducer motor starts on high--speed and continues to

run until Step (d.) of component test sequence.

b. Hot surface igniter is energized for 15 sec, then deen-

ergized.

c. Blower operates for 10 sec, then turns off.

d. Inducer motor goes to low--speed for 10 seconds, then

turns off.

e. After component test is completed, one or more status

codes (11, 25, or 41) will flash. See component test section of service label for explanation of status codes.

NOTE: To repeat component test, turn setup switch SW1--6 OFF then back ON.

f. TurnsetupswitchSW1--6OFF.

est

WARNING

PG8MVA

7. RELEASE BLOWER ACCESS DOOR SWITCH, reattach wire to “R” terminal on furnace control board, replace blower access door, and replace outer access door.

CARE AND

FIRE OR EXPLOSION HAZARD

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

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

PG8MVA

For continuing high performance and to minimize possible furnace failure, periodic maintenance must be performed on this furnace. Consult your local dealer about proper frequency of maintenance and the availability of a maintenance contract.

MAINTENANCE

WARNING

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. Exposure to these materials could lead to corrosion of the heat exchangers.

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

4. Inspect burner compartment before each heating season for rust, corrosion, soot or excessive dust. If necessary, have furnace and burner serviced by a qualified service agency.

5. Inspect the vent pipe/vent system before each heating season for rust, corrosion, water leakage, sagging pipes or broken fittings. Have vent pipes/vent system serviced by a qualified service agency.

6. Inspect any accessories attached to the furnace such as a humidifier or electronic air cleaner. Perform any service or maintenance to the accessories as recommended in the accessory instructions.

Cleaning and/or Replacing Air

The air filter arrangement will vary depending on the application. NOTE: If the filter has an airflow direction arrow, the arrow

must point towards the blower.

CAUTION

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, safety glasses and gloves when handling parts, and servicing furnaces.

Filter

WARNING

ELECTRICAL SHOCK AND FIRE HAZARD

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

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

WARNING

CARBON MONOXIDE POISONING AND FIRE HAZARD

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

Never operate furnace without a filter or with filter access door removed.

CAUTION

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, safety glasses and gloves when handling parts, and servicing furnaces.

The minimum maintenance on this furnace is as follows:

1. Check and clean air filter each month or more frequently if required. Replace if torn.

2. Check blower motor and wheel for cleanliness each heating and cooling season. Clean as necessary.

Media cabinet filter procedures:

1. Turn off electrical supply to furnace before removing filter access door.

2. Remove filter cabinet door.

3. Slide filter out of cabinet.

4. If equipped with permanent, washable 3/4--in. (19 mm) 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. See Table 13 for size information.

5. If equipped with factory--specified disposable media filter, replace only with media filter having the same part number and size. For expandable replacement media, refer to the instructions included with the replacement media.

6. Slide filter into cabinet.

7. Replace filter cabinet door.

8. Turn on electrical supply to furnace.

Blower Motor and

ELECTRICAL SHOCK HAZARD

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

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

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

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

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

Wheel

WARNING

Table 14 – Filter Size Information -- In. (mm)

FURNACE CASING WIDTH

14---1/2 (368)

17---1/2 (445)

21 (533)

24 (610)

* Recommended

RETURN

16 X 25 X 3/4

(406 X 635 X 19)

16 X 25 X 3/4

(406 X 635 X 19)

16 X 25 X 3/4

(406 X 635 X 19)

16 X 25 X 3/4

(406 X 635 X 19)

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.

Clean blower motor and wheel as follows:

1. Turn off electrical supply to furnace.

2. Remove outer door.

3. For downflow or horizontal furnaces having vent pipes within the furnace that pass in front of the blower access door:

a. Disconnect vent connector from furnace vent elbow.

b. Disconnect and remove short piece of vent pipe from

within furnace.

4. Remove 2 screws from blower access door and remove blower access door.

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

6. Remove 2 screws holding blower assembly to blower deck and slide blower assembly out of furnace.

7. Clean blower wheel and motor using a vacuum with soft brush attachment. Blower wheel blades may be cleaned with a small paint or flux brush. Do not remove or disturb balance weights (clips) on blower wheel blades.

8. Vacuum any loose dust from blower housing, wheel and motor.

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

NOTE: Before disassembly, mark blower mounting arms, motor, and blower housing so motor and each arm is positioned at the same location during reassembly.

a. Disconnect ground wire attached to blower housing.

b. Remove screws securing cutoff plate and remove

cutoff plate from housing.

c. Loosen set screw holding blower wheel on motor shaft

(160+/--20 in.--lb. when assembling).

d. Remove bolts holding motor to blower housing and

slide motor out of wheel (40+/--10 in.--lb. when reassembling).

e. Remove blower wheel from housing.

f. Clean wheel and housing.

10. Reassemble motor and blower by reversing steps 9a, through 9e. Be sure to reattach ground wire to the blower housing.

11. Verify that blower wheel is centered in blower housing and set screw contacts the flat portion of the motor shaft. Loosen set screw on blower wheel and reposition if necessary.

12. Spin the blower wheel by hand to verify that the wheel does not rub on the housing.

13. Reinstall blower assembly in furnace.

14. Reinstall 2 screws securing blower assembly to blower deck.

FILTER SIZE

BOTTOM

RETURN

14 X 25 X 3/4

(356 X 635 X 19)

16 X 25 X 3/4

(406 X 635 X 19)

20 X 25 X 3/4

(508 X 635 X 19)

24 X 25 X 3/4

(610 X 635 X 19)

FILTER TYPESIDE

Wash able *

15. Reconnect blower leads to furnace control. Refer to furnace wiring diagram, and connect thermostat leads if previously disconnected.

16. To check blower for proper rotation:

a. Turn on electrical supply.

WARNING

ELECTRICAL SHOCK HAZARD

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

b. Manually close blower access door switch.

NOTE: If R--W/W1 thermostat terminals are jumpered at the time blower access door switch is closed, blower will run for 90 sec before beginning a heating cycle.

c. Perform component self--test as shown at the bottom

of the SERVICE label, located on the front of blower access door.

d. Verify blower is rotating in the correct direction

17. If furnace is operating properly, RELEASE BLOWER ACCESS DOOR SWITCH. Remove any jumpers or reconnect any disconnected thermostat leads. Replace blower access door.

18. Downflow or horizontal furnaces with vent pipe through furnace only:

a. Install and connect short piece of vent pipe inside fur-

nace to existing vent.

b. Connect vent connector to vent elbow.

19. Reinstall outer door.

20. Turn on gas supply and cycle furnace through one complete heating and cooling cycle. Verify the furnace temperature rise as shown in Adjustments Section. Adjust temperature rise as shown in Adjustments Section. If outdoor temperature is below 70_F, turn off circuit breaker to outdoor unit before running furnace in the cooling cycle. Turn outdoor circuit breaker on after completing cooling cycle.

Cleaning Heat

Exchanger

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

NOTE: If the heat exchangers get a heavy accumulation of soot

and carbon, they should be replaced rather than trying to clean them thoroughly. 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, incorrect size or damaged manifold orifice(s), improper gas, or a restricted heat exchanger. Action must be taken to correct the problem.

PG8MVA

9. Using field--provided 25--caliber rifle cleaning brush, 36--in. (914 mm) long, 1/4--in. (6 mm) diameter steel spring cable, a variable speed, follows:

a. Remove metal screw fitting from wire brush to allow

insertion into cable.

b. Insert the twisted wire end of brush into end of spring

cable, and crimp tight with crimping tool or crimp by striking with ball--peen hammer. TIGHTNESS IS VERY IMPORTANT.

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

(1.) Attach variable--speed, reversible drill to the end

of spring cable (end opposite brush).

(2.) Insert brush end of cable into the outlet opening

of cell and slowly rotate with drill. DO NOT force cable. Gradually insert cable into upper pass of cell. (See Fig. 58.)

A05025

Fig. 55 -- Igniter Position -- Side View

PG8MVA

(3.) Work cable in and out of cell 3 or 4 times to ob-

tain sufficient cleaning. DO NOT pull cable with great force. Reverse drill and gradually work cable out.

(4.) Insert brush end of cable in burner inlet opening

1-7/8

(47.6 mm)

of cell, and proceed to clean 2 lower passes of cell in same manner as upper pass.

(5.) Repeat foregoing procedures until each cell in

furnace has been cleaned.

(6.) Using vacuum cleaner, remove residue from each

cell.

(7.) Using vacuum cleaner with soft brush attachment,

clean burner assembly.

A05026

Fig. 56 -- Igniter Position -- Top View

(8.) Clean flame sensor with fine steel wool. (9.) Install NOx baffles (if removed).

If it becomes necessary to clean the heat exchangers because of dust or corrosion, proceed as follows:

1. Turn OFF gas and electrical power to furnace.

2. Remove outer access door.

3. Disconnect vent connector from furnace vent elbow.

4. For downflow or horizontal furnace having an internal vent pipe, remove internal vent pipe within the casing.

5. Disconnect wires to the following components. Mark wires to aid in reconnection (be careful when disconnecting wires from switches because damage may occur):

a. Draft safeguard switch.

b. Inducer motor.

c. Pressure switches.

d. Limit overtemperature switch.

e. Gas valve.

f. Hot surface igniter. g. Flame--sensing electrode. h. Flame rollout switches.

6. Remove screws that fasten the collector box assembly to the cell panel. Be careful not to damage the collector box. Inducer assembly and elbow need not be removed from collector box.

7. Disconnect gas line from gas manifold.

8. Remove the four screws that attach the burner assembly to the cell panel. The gas valve and individual burners need not be removed from support assembly. Remove NOx baffles, if installed.

NOTE: Be very careful when removing burner assembly to avoid breaking igniter. See Fig. 55--56 for correct igniter location.

A91252

Fig. 57 -- Cleaning Heat Exchanger Cell

(10.) Reinstall burner assembly. Center burners in cell

openings.

10. Remove old sealant from cell panel and collector box flange.

11. Spray releasing agent on the heat exchanger cell panel where collector box assembly contacts cell panel.

NOTE: A releasing agent such as cooking spray or equivalent (must not contain corn or canola oil, aromatic or halogenated hydrocarbons or inadequate seal may occur) and RTV sealant (G.E. 162, 6702, or Dow--Corning 738) are needed before starting installation. DO NOT substitute any other type of RTV sealant. G.E. 162 (P771--9003) is available through RCD in 3--oz tubes.

12. Apply new sealant to flange of collector box and attach to cell panel using existing screws, making sure all screws are secure.

13. Reconnect wires to the following components (Use connection diagram on wiring label, if wires were not marked for reconnection locations.):

a. Draft safeguard switch.

b. Inducer motor.

c. Pressure switches.

d. Limit overtemperature switch.

e. Gas valve.

f. Hot surface igniter. g. Flame--sensing electrode. h. Flame rollout switches.

14. Reinstall internal vent pipe, if applicable.

15. Reinstall vent connector on furnace vent elbow. Securely fasten vent connector to vent elbow with 2 field--supplied, corrosion--resistant, sheet metal screws located 180_ apart.

16. Replace blower access door only if it was removed.

17. Set thermostat above room temperature and check furnace for proper operation.

18. Verify blower airflow and speed changes between heating and cooling.

WARNING

FIRE OR EXPLOSION HAZARD

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

Sequence of NOTE: Furnace control must be grounded for proper operation

or else control will lock out. Control is grounded through green/yellow wire routed to gas valve and burner box screw. Using the schematic diagram in Fig. 54, follow the sequence of operation through the different modes. Read and follow the wiring diagram very carefully.

NOTE: If a power interruption occurs during a call for heat (W/W1 or W/W1--and--W2), the control will start a 90--second blower--only ON period two seconds after power is restored, if the thermostat is still calling for gas heating. The amber LED light will flash code 12 during the 90--second period, after which the LED will be ON continuous, as long as no faults are detected. After the 90--second period, the furnace will respond to the thermostat normally.

The blower door must be installed for power to be conducted through the blower door interlock switch ILK to the furnace control CPU, transformer TRAN, inducer motor IDM, blower motor BLWM, hot--surface igniter HSI, and gas valve GV.

1. Two--Stage Heating (Adaptive Mode) with Single--Stage

NOTE: The low--heat only switch SW1--2 selects either the low--heat only operation mode when ON, (See Item 2. below) or the adaptive heating mode when OFF in response to a call for heat. (See Fig. 52.) When the W2 thermostat terminal is energized it will always cause high--heat operation when the R--to--W circuit is closed, regardless of the setting of the low--heat only switch. This furnace can operate as a two--stage furnace with a single--stage thermostat because the furnace control CPU includes a programmed adaptive sequence of controlled operation, which selects low--heat or high--heat operation. This selection is based upon the stored history of the length of previous gas--heating periods of the single--stage thermostat.

Operation

Thermostat See Fig. 27 -- 34 for thermostat connections

PG8MVA

19. Check for gas leaks.

COOLING TONNAGE VS. AIRFLOW (CFM)

AIR CONDITIONING AIRFLOW 070 MODEL 090 MODEL 110 and 135

TONS (12,000 BTU/HR) (CFM) MODELS

1-1/2 525 X X

2 700 X X X

2-1/2 875 X X X

3 1050 X X X

3-1/2 1225 X X X

4 1400 X X

5 1750 X

6 2100 X

X-INDICATES AN ALLOWABLE SELECTION.

BASED ON 350 CFM/TON (SETUP SWITCH SW1-5 OFF, SW4-3 OFF)

SETUP SWITCH SW2 OR SW3 POSITIONS

MODEL

SIZE

PG8MVA

070

090

110, 135

525

DEF.

5252 700 875 1050 1225 14001 1400

700

BASED ON 400 CFM/TON (SETUP SWITCH SW1-5 ON, SW4-3 OFF)

SETUP SWITCH SW2 OR SW3 POSITIONS

MODEL

SIZE

070

090

110, 135

6002 800 1000 12001 1400 1400 1400 DEF.

6002 800 1000 1200 1400 16001 1600

DEF.

800 10002 1200 1400 1600 20001 2200 DEF.

700

875 1050

8752 1050

1225

1750

1225

2100

1400

BASED ON 325 CFM/TON (SETUP SWITCH SW1-5 OFF, SW4-3 ON)

SETUP SWITCH SW2 OR SW3 POSITIONS

MODEL

SIZE

488

070

110, 135

DEF.

DEF. 090

DEF.

651

4882 651 814 976

651

8142 976

BASED ON 370 CFM/TON (SETUP SWITCH SW1-5 ON, SW4-3 ON)

SETUP SWITCH SW2 OR SW3 POSITIONS

MODEL

SIZE

558

070

DEF.

DEF. 090

110, 135

1. DEFAULT A/C AIRFLOW WHEN A/C SWITCHES ARE IN OFF POSITION

2. DEFAULT CONT. FAN AIRFLOW WHEN CF SWITCHES ARE IN OFF POSITION

3. SWITCH POSITIONS ARE ALSO SHOWN ON FURNACE WIRING DIAGRAM

DEF.

744

5582 744 930 1116 1302 14881 1488

744

9302 1116

Fig. 58 -- Cooling (A/C) or Continuous--Fan (CF) Airflow Selection Chart

The furnace will start up in either low-- or high--heat. If the furnace starts up in low--heat, the control CPU determines the low--heat on--time (from 0 to 16 minutes) which is permitted before switching to high--heat.

If the power is interrupted, the stored history is erased and the control CPU will select low--heat for up to 16 minutes and then switch to high--heat, as long as the thermostat continues to call for heat. Subsequent selection is based on stored history of the thermostat cycle times.

The wall thermostat “calls for heat”, closing the R--to--W circuit. The furnace control performs a self--check, verifies the low--heat

814 976

1139

930 1116

1302

1139

1302

1488

1139

13021 1302

1627

1950

1302

1860

2200

A12091

and high--heat pressure switch contacts LPS and HPS are open, and starts the inducer motor IDM in high--speed.

a. Inducer Prepurge Period

(1.) If the furnace control CPU selects low--heat oper-

ation the inducer motor IDM comes up to speed, the low--heat pressure switch LPS closes, and the furnace control CPU begins a 15--second prepurge period. If the low--heat pressure switch LPS fails to remain closed the inducer motor IDM will remain running at high--speed. After the low--heat pressure switch re--closes the furnace control CPU

will begin a 15--second prepurge period, and continue to run the inducer motor IDM at high-speed.

(2.) If the furnace control CPU selects high--heat op-

eration, the inducer motor IDM remains running at high--speed, and the high--heat pressure switch relay HPSR is de--energized to close the NC contact. When sufficient pressure is available the high--heat pressure switch HPS closes, and the high--heat gas valve solenoid GV--HI is energized. The furnace control CPU begins a 15--second prepurge period after the low--heat pressure switch LPS closes. If the high--heat pressure switch HPS fails to close and the low--heat pressure switch LPS closes, the furnace will operate at low--heat gas flow rate until the high--heat pressure switch closes for a maximum of 2 minutes after ignition.

b. Igniter Warm--Up --At the end of the prepurge period,

the Hot--Surface Igniter HSI is energized for a 17--second igniter warm--up period.

c. Trial--For--Ignition Sequence --When the igniter

warm--up period is completed the main gas valve relay contact GVR closes to energize the gas valve solenoid GV--M. The gas valve solenoid GV--M permits gas flow to the burners where it is ignited by the HSI. Five seconds after the GVR closes, a 2--second flame proving period begins. The HSI igniter will remain energized until the flame is sensed or until the 2--second flame proving period begins. If the furnace control CPU selects high--heat operation, the high--heat gas valve solenoid GV--HI is also energized.

d. Flame--Proving -- When the burner flame is proved at

the flame--proving sensor electrode FSE, the inducer motor IDM switches to low--speed unless the furnace is operating in high--heat, and the furnace control CPU begins the blower--ON delay period and continues to hold the gas valve GV--M open. If the burner flame is not proved within two seconds, the control CPU will close the gas valve GV--M, and the control CPU will repeat the ignition sequence for up to three more Trials--For--Ignition before going to Ignition--Lockout. Lockout will be reset automatically after three hours, or by momentarily interrupting 115 vac power to the furnace, or by interrupting 24 vac power at SEC1 or SEC2 to the furnace control CPU (not at W/W1, G, R, etc.). If flame is proved when flame should not be present, the furnace control CPU will lock out of Gas-Heating mode and operate the inducer motor IDM on high speed until flame is no longer proved.

e. Blower--On delay -- If the burner flame is proven the

blower--ON delays for low--heat and high--heat are as follows: Low--heat -- 45 seconds after the gas valve GV--M is opened the blower motor BLWM is turned ON at low--heat airflow. High--heat -- 25 seconds after the gas valve GV--M is opened the BLWM is turned ON at high--heat airflow. Simultaneously, the humidifier terminal HUM and electronic air cleaner terminal EAC--1 are energized and remain energized throughout the heating cycle.

f. Switching from Low-- to High--Heat -- If the furnace

control CPU switches from low--heat to high--heat, the furnace control CPU will switch the inducer motor IDM speed from low to high. The high--heat pressure switch relay HPSR is de--energized to close the NC contact. When sufficient pressure is available the high-heat pressure switch HPS closes, and the high--heat gas

valve solenoid GV--HI is energized. The blower motor BLWM will transition to high--heat airflow five seconds after the furnace control CPU switches from low--heat to high--heat.

g. Switching from High-- to Low--Heat --The furnace

control CPU will not switch from high--heat to low-heat while the thermostat R--to--W circuit is closed when using a single--stage thermostat.

h. Blower--Off Delay --When the thermostat is satisfied,

the R to W circuit is opened, de--energizing the gas valve GV--M, stopping gas flow to the burners, and de--energizing the humidifier terminal HUM. The inducer motor IDM will remain energized for a 5--second post--purge period. The blower motor BLWM and air cleaner terminal EAC--1 will remain energized at low--heat airflow or transition to low--heat airflow for 90, 120, 150, or 180 seconds (depending on selection at blower--OFF delay switches). The furnace control CPU is factory--set for a 120--second blower--OFF delay.

2. Two--Stage Thermostat and Two--Stage Heating

See Fig. 27--34 for thermostat connections. : In this mode the low--heat only switch SW1--2 must be

NOTE

ON to select the low--heat only operation mode in response to closing the thermostat R--to--W1 circuit. Closing the thermostat R--to-- W1--and--W2 circuits always causes high--heat operation, regardless of the setting of the low--heat only switch.

The wall thermostat “calls for heat”, closing the R--to--W1 circuit for low--heat or closing the R--to--W1--and--W2 circuits for high--heat. The furnace control performs a self--check, verifies the low--heat and high--heat pressure switch contacts LPS and HPS are open, and starts the inducer motor IDM in high--speed.

The start up and shut down functions and delays described in item 1. above apply to the 2--stage heating mode as well, except for switching from low-- to high--Heat and vice versa.

a. Switching from Low-- to High--Heat -- If the thermo-

stat R--to--W1 circuit is closed and the R--to--W2 circuit closes, the furnace control CPU will switch the inducer motor IDM speed from low to high. The high--heat pressure switch relay HPSR is de--energized to close the NC contact. When sufficient pressure is available the high--heat pressure switch HPS closes, and the high--heat gas valve solenoid GV--HI is energized. The blower motor BLWM will transition to high--heat airflow five seconds after the R--to--W2 circuit closes.

b. Switching from High-- to Low--Heat --If the thermo-

stat R--to-- W2 circuit opens, and the R--to--W1 circuit remains closed, the furnace control CPU will switch the inducer motor IDM speed from high to low. The high--heat pressure switch relay HPSR is energized to open the NC contact and de--energize the high--heat gas valve solenoid GV--HI. When the inducer motor IDM reduces pressure sufficiently, the high--heat pressure switch HPS will open. The gas valve solenoid GV--M will remain energized as long as the low--heat pressure switch LPS remains closed. The blower motor BLWM will transition to low--heat airflow five seconds after the R--to--W2 circuit opens.

3. Cooling mode

The thermostat “calls for cooling”.

a. Single--Speed Cooling--

See Fig. 27 for thermostat connections The thermostat closes the R--to--G--and--Y circuits. The R--to-- Y circuit starts the outdoor unit, and the R--to-G--and--Y/Y2 circuits start the furnace blower motor BLWM on cooling airflow. Cooling airflow is based

PG8MVA

on the A/C selection shown in Fig. 58. The electronic air cleaner terminal EAC--1 is energized with 115 vac when the blower motor BLWM is operating. When the thermostat is satisfied, the R--to--G--and--Y circuits are opened. The outdoor unit will stop, and the furnace blower motor BLWM will continue operating at cooling airflow for an additional 90 seconds. Jumper Y/Y2 to DHUM to reduce the cooling off--delay to 5 seconds. (See Fig. 26.)

b. Single--Stage Thermostat and Two--Speed Cooling

(Adaptive Mode) -See Fig. 34 for thermostat connections. This furnace can operate a two--speed cooling unit with a single--stage thermostat because the furnace control CPU includes a programmed adaptive sequence of controlled operation, which selects low-cooling or high--cooling operation. This selection is based upon the stored history of the length of previous cooling period of the single--stage thermostat.

NOTE: The air conditioning relay disable jumper ACRDJ must be connected to enable the adaptive cooling mode in response to

PG8MVA

a call for cooling. (See Fig. 26.) When ACRDJ is in place the furnace control CPU can turn on the air conditioning relay ACR to energize the Y/Y2 terminal and switch the outdoor unit to high--cooling. The furnace control CPU can start up the cooling unit in either low-- or high--cooling. If starting up in low--cooling, the furnace control CPU determines the low--cooling on--time (from 0 to 20 minutes) which is permitted before switching to high--cooling. If the power is interrupted, the stored history is erased and the furnace control CPU will select low--cooling for up to 20 minutes and then energize the air conditioning relay ACR to energize the Y/Y2 terminal and switch the outdoor unit to high--cooling, as long as the thermostat continues to call for cooling. Subsequent selection is based on stored history of the thermostat cycle times. The wall thermostat “calls for cooling”, closing the R--to--G--and--Y circuits. The R--to--Y1 circuit starts the outdoor unit on low--cooling speed, and the R--to--G--and--Y1 circuits starts the furnace blower motor BLWM at low--cooling airflow which is the true on--board CF selection as shown in Fig. 58. If the furnace control CPU switches from low--cooling to high--cooling, the furnace control CPU will energize the air conditioning relay ACR. When the air conditioning relay ACR is energized the R--to--Y1--and--Y2 circuits switch the outdoor unit to high--cooling speed, and the R--to--G--and--Y1--and--Y/Y2 circuits transition the furnace blower motor BLWM to high--cooling airflow. High--cooling airflow is based on the A/C selectionshowninFig.58.

NOTE: When transitioning from low--cooling to high--cooling the outdoor unit compressor will shut down for 1 minute while the furnace blower motor BLWM transitions to run at high--cooling airflow. The electronic air cleaner terminal EAC--1 is energized with 115 vac whenever the blower motor BLWM is operating. When the thermostat is satisfied, the R--to--G--and--Y circuit are opened. The outdoor unit stops, and the furnace blower BLWM and electronic air cleaner terminal EAC--1 will remain energized for an additional 90 seconds. Jumper Y1 to DHUM to reduce the cooling off--delay to 5 seconds. (See Fig. 26.)

c. Two--Stage Thermostat and Two--Speed Cooling

See Fig. 33 for thermostat connections

NOTE: The air conditioning relay disable jumper ACRDJ must be disconnected to allow thermostat control of the outdoor unit staging. (See Fig. 26.)

The thermostat closes the R--to--G--and--Y1 circuits for low--cooling or closes the R--to--G--and--Y1--and--Y2 circuits for

high--cooling. The R--to--Y1 circuit starts the outdoor unit on low--cooling speed, and the R--to--G--and--Y1 circuit starts the furnace blower motor BLWM at low--cooling airflow which is the true on--board CF (continuous fan) selection as shown in Fig. 56. The R--to--Y1--and--Y2 circuits start the outdoor unit on high--cooling speed, and the R--to-- G--and--Y/Y2 circuits start the furnace blower motor BLWM at high--cooling airflow. High--cooling airflow is based on the A/C (air conditioning) selectionshowninFig.58. The electronic air cleaner terminal EAC--1 is energized with 115 vac whenever the blower motor BLWM is operating. When the thermostat is satisfied, the R--to--G--and--Y1 or R--to-G--and--Y1--and--Y2 circuits are opened. The outdoor unit stops, and the furnace blower BLWM and electronic air cleaner terminal EAC--1 will remain energized for an additional 90 seconds. Jumper Y1 to DHUM to reduce the cooling off--delay to 5 seconds. (See Fig. 26.)

4. Dehumidification Mode

See Fig. 27--29 for thermostat connections. The dehumidification output, DHUM on the humidity sensing thermostat should be connected to the furnace control thermostat terminal DHUM. When there is a dehumidify demand, the DHUM input is activated, which means 24 vac signal is removed from the DHUM input terminal. In other words, the DHUM input logic is reversed. The DHUM input is turned ON when no dehumidify demand exists. Once 24 vac is detected by the furnace control on the DHUM input, the furnace control operates in dehumidification mode. If the DHUM input is low for more than 48 hours, the furnace control reverts back to non--dehumidification mode. The cooling operation described in item 3. above also applies to operation with a humidity sensing thermostat. The exceptions are listed below:

a. Low cooling-- W h e n t h e R -- t o -- G -- a n d -- Y 1 c i r c u i t i s

closed and there is a demand for dehumidification, the furnace blower motor BLWM will drop the blower airflow to 86 percent of low--cooling airflow which is the true on--board CF (continuous fan) selection as shown in Fig. 56.

b. High cooling-- W h e n t h e R -- t o -- G -- a n d Y / Y 2 c i r c u i t i s

closed and there is a demand for dehumidification, the furnace blower motor BLWM will drop the blower airflow to 86 percent of high--cooling airflow. High-cooling airflow is based on the A/C (air conditioning) selectionshowninFig.56.

c. Cooling off--delay--When the “call for cooling” is

satisfied and there is a demand for dehumidification, the cooling blower--off delay is decreased from 90 seconds to 5 seconds.

5. Super--Dehumidify Mode

Super--Dehumidify mode can only be entered if the furnace control is in the dehumidification mode and there isa demand for dehumidification. The cooling operation described in item 3. above also applies to operation with a humidity sensing thermostat. The exceptions are listed below:

a. When the R--to--Y1 circuit is closed, R--to--G circuit is

open, and there is a demand for dehumidification, the furnace blower motor BLWM will drop the blower airflow to 65 percent of low--cooling airflow for a maximum of 10 minutes each cooling cycle or until the R--to--G circuit closes or the demand for dehumidification is satisfied. Low--cooling airflow is the true on--board CF (continuous fan) selection as shown in Fig. 58.

b. When the R--to--Y/Y2 circuit is closed, R--to--G circuit

is open, and there is a demand for dehumidification,

the furnace blower motor BLWM will drop the blower airflow to 65 percent of high--cooling airflow for a maximum of 10 minutes each cooling cycle or until the R--to--G circuit closes or the demand for dehumidification is satisfied. High--cooling airflow is based on the A/C (air conditioning) selection shown in Fig. 58.

c. When the “call for cooling” is satisfied and there is a

demand for dehumidification, the cooling blower--off delay is decreased from 90 seconds to 5 seconds.

6. Continuous Blower Mode

When the R--to--G circuit is closed by the thermostat, the blower motor BLWM will operate at continuous blower airflow. Continuous blower airflow selection is initially based on the CF (continuous fan) selection shown in Fig.

58. Factory default is shown in Fig. 58. Terminal EAC--1 is energized as long as the blower motor BLWM is energized. During a call for heat, the furnace control CPU will transition the blower motor BLWM to continuous blower airflow, low--heat airflow, or the mid--range airflow, whichever is lowest. The blower motor BLWM will remain ON until the main burners ignite then shut OFF and remain OFF for the blower--ON delay (45 seconds in low-heat, and 25 seconds in high--heat), allowing the furnace heat exchangers to heat up more quickly, then restarts at the end of the blower--ON delay period at low--heat or high--heat airflow, respectively. The blower motor BLWM will revert to continuous-blower airflow after the heating cycle is completed. In high--heat, the furnace control CPU will drop the blower motor BLWM to low--heat airflow during the selected blower--OFF delay period before transitioning to continuous--blower airflow. When the thermostat “calls for low--cooling”, the blower motor BLWM will switch to operate at low--cooling airflow. When the thermostat is satisfied, the blower motor BLWM will operate an additional 90 seconds at low--cooling airflow before transitioning back to continuous-blower airflow. When the thermostat “calls for high--cooling”, the blower motor BLWM will operate at high cooling airflow. When the thermostat is satisfied, the blower motor BLWM will operate an additional 90 seconds at high--cooling airflow before transitioning back to continuous--blower airflow. When the R--to--G circuit is opened, the blower motor BLWM will continue operating for an additional 5 seconds, if no other function requires blower motor BLWM operation.

Continuous Blower Speed Selection from Thermostat

To select different continuous--blower airflow from the room thermostat, momentarily turn off the FAN switch or push button on the room thermostat for 1--3 seconds after the blower motor BLWM is operating. The furnace control CPU will shift the continuous--blower airflow from the factory setting to the next highest CF selection airflow as shown in Fig. 58. Momentarily turning off the FAN switch again at the thermostat will shift the continuous--blower airflow up one more increment. If you repeat this procedure enough you will eventually shift the continuous-blower airflow to the lowest CF selection as shown in Fig.

58. The selection can be changed as many times as desired and is stored in the memory to be automatically used following a power interruption.

NOTE: If the blower--off delay is set to the maximum, the adjustable continuous--fan feature is locked (i.e., fan speed cannot be changed from its current setting).

7. Heat pump

See Fig. 29 -- 32 for thermostat connections.

When installed with a heat pump, the furnace control automatically changes the timing sequence to avoid long blower off times during demand defrost cycles. Whenever W/W1 is energized along with Y1 or Y/Y2, the furnace control CPU will transition to or bring on the blower motor BLWM at cooling airflow, low--heat airflow, or the mid--range airflow, whichever is lowest. The blower motor BLWM will remain on until the main burners ignite then shut OFF and remain OFF for 25 seconds before coming back on at heating airflow. When the W/W1 input signal disappears, the furnace control begins a normal inducer post--purge period while changing the blower airflow. If Y/Y2 input is still energized the furnace control CPU will transition the blower motor BLWM airflow to cooling airflow. If Y/Y2 input signal disappears and the Y1 input is still energized the furnace control CPU will transition the blower motor BLWM to low--cooling airflow. If both the Y1 and Y/Y2 signals disappear at the same time, the blower motor BLWM will remain on at low--heat airflow for the selected blower--OFF delay period. At the end of the blower-- OFF delay, the blower motor BLWM will shut OFF unless G is still energized, in which case the blower motor BLWM will operate at continuous blower airflow.

8. Component test

The furnace features a component test system to help diagnose a system problem in the case of a component failure. To initiate the component test procedure, ensure that there are no thermostat inputs to the control and all time delays have expired. Turn on setup switch SW1--6. (See Fig. 26.)

NOTE: The component test feature will not operate if thecontrol is receiving any thermostat signals or until all time delays have expired. The component test sequence is as follows:

a. The furnace control CPU turns the inducer motor ON

at high--heat speed and keeps it ON through step c.

b. After waiting 10 seconds the furnace control CPU

turns the hot surface igniter ON for 15 seconds, then OFF.

c. The furnace control CPU then turns the blower motor

BLWM on at mid--range airflow for 15 seconds, then OFF.

d. After shutting the blower motor OFF the furnace con-

trol CPU switches the inducer to low--heat speed for 10 seconds, then OFF.

NOTE: The EAC terminals are energized when the blower is operating. After the component test is completed, 1 or more status codes (11, 25, or 41) will flash. See component test section or Service Label (Fig. 53) for explanation of status codes.

NOTE: To repeat component test, turn setup switch SW1--6 to OFF and then back ON.

Wiring

Diagram

Refer to wiring diagram Fig. 54.

oubleshooting

Refer to the service label. (See Fig. 53—Service Label.) The Troubleshooting Guide (See Fig. 59.) can be a useful tool in

isolating furnace operation problems. Beginning with the word “Start,” answer each question and follow the appropriate arrow to the next item.

The Guide will help to identify the problem or failed component. After replacing any component, verify correct operation sequence.

A more detailed Troubleshooting Guide is available from your distributor.

PG8MVA

thermostat terminals on the furnace control?

Is 24V present at W/W1, W2, Y1, Y/Y2 or G

YES

furnace control.

Disconnect all the thermostat wires from the

a jumper wire?

Does the problem repeat when using

YES

The thermostat is not compatible with the

furnace control. Either install a ballast resistor,

the thermostat, or replace the thermostat.

connect the Com24V thermostat terminal to

YES

er closed?

Is door switch closed?

Is circuit break

Check for continuity in wire from circuit

breaker to furnace.

Close circuit breaker and go back to START.

ng cable.

interconnecti

Check room thermostat or

PG8MVA

W/W1, W2, Y1,

Is there 115V going to switch?

YES

Replace door switch.

k operation. Status

YES

low-heat, high-heat,

nace control.

Replace transformer.

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

Does the control respond to

SW1-1 in the ON position and jumpering R,

manually erased by putting setup switch

codes are erased after 72 hours or can be

or cooling cycle to chec

Run system through a

Replace fur

code #11 is flashed.

W/W1, and Y/Y2 simultaneously until status

YES

Is door switch closed?

START

YES

Is there 115V at L1 and L2?

Is AMBER LED status light on?

YES

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

Replace furnace control.

mer phasing.

w-voltage (24V) transfor lo

If units are twinned, check for proper

Check for correct line voltage polarity.

YES

rapidly without a pause?

Is AMBER LED status light blinking

To recall previous status codes disconnect

Is AMBER LED status light blinking ON/OFF

umpering R, W/W1, and Y/Y2 simultaneously

put setup switch SW1-1 in the OFF position.

until status code #11 is flashed. When done

switch SW1-1 in the ON position and

can be manually erased by putting setup

Status codes are erased after 72 hours or

code #11 flashes the status codes will repeat.

flashes (1 short and 1 long flash). After status

Record status codes until status code #11

status codes in the order of occurrence.

position. The AMBER LED will flash the

and put setup switch SW1-1 in the ON

the R thermostat connection, reset power,

determined

YES

long flashes?

slowly with a combination of short and

digit

e. The status code is

he first

the number of long flashes?

mine status cod

2 digit number with t

y the number of short flashes and the

second digit by

Deter

Fig. 59 -- Troubleshooting Guide

than #11?

Was there a previous status code other

YES

that was flashed.

Go to section below for the status code

A02108A

Auto-reset after 1 hour lockout due to:

45 CONTROL CIRCUITRY LOCKOUT

- Flame circuit failure.

- Gas valve relay stuck open.

- Software check error.

Reset power to clear lockout.

yover or rough

alves are turned on.

k connections. If OK, replace control.

k that all gas v

Chec

k for:

Replace valve.

Chec

- Inadequate flame carr

ow inlet gas pressure.

ignition.

-L

roper firing rate.

-P

locked or incorrect carry- over gap.

(.045” nominal)

-B

Replace control if code repeats.

Replace furnace control.

Check for continuity in the harness and

Chec

igniter. Replace defective component.

k connections and retry. If current is

Allow blower to come on and repeat test

to check for intermittent operation.

Chec

near typical value (4.0-6.0 nominal) and

burners will not stay on, repeat check in high-

heat. If burners will still not stay on replace

control. If burners operate in high-heat then

switch to low-heat,check manifold pressure.

If OK, check burner carryover and flame

sensor location.

Replace electrode.

Replace furnace control.

k for:

ning setup switch tur

ow inlet gas pressure (if LGPS used).

tube.

WHILE HIGH-HEAT PRESSURE

SWITCH IS CLOSED - Chec

- Low-heat pressure switch stuck open.

- Disconnected or obstructed pressure

- Miswired pressure switches.

-L

43 LOW-HEAT PRESSURE SWITCH OPEN

NOT CLOSE OR REOPENED – If open

longer than 5 minutes, inducer shuts off

for 15 minutes before retry. If opens

during blower on-delay period, blower will

come on for the selected blower off-delay.

Check for:

32 LOW-HEAT PRESSURE SWITCH DID

- Proper vent sizing.

- Low inlet gas pressure (if LGPS used).

- Disconnected or obstructed pressure

- Low inducer voltage (115V).

- Inadequate combustion air supply.

Unplug igniter harness from control and

repeat component test by

tubing.

- Defective inducer motor.

YES

k ON. Check for

SW1-6 OFF and then bac

115V between pin 3 and NEUTRAL-L2 on

- Defective pressure switch.

- Excessive wind.

- Restricted vent.

the control. Was 115V present for the 15

Reconnect the R thermostat lead and set

second period?

LT – Indicates the AU

limit, draft safeguard, flame rollout, or

blocked vent switch* (if used) is open or

33 LIMIT CIRCUIT F

ltmeter

to call for heat. Connect vo

hermostat

across gas valve connections. Does gas

valve receive 24V?

Blower will run for 4 min. or until

the furnace is operating in high-heat only

mode due to 2 successive low-heat limit

trips.

YES

Does gas valve open and allow gas to flow?

change

code

longer than 3 min.,

open switch remakes whichever is longer.

If open

to lockout #13. If open less than 3 min.

status code #33 continues to flash until

YES

Do the main burners ignite?

Check for:

lame rollout switch and

off. F

ty filter or restricted duct system.

er shuts

blow

BVSS requires manual reset.

-Dir

- Loose blower wheel.

- Defective switch or connections.

YES

(flame rollout switch open).

- Inadequate combustion air supply

Do the main burners stay on?

icted vent.

- Restr

Repeat call for heat and check flame sensor

- Proper vent sizing.

- Excessive wind.

YES

current during trial for ignition period. Is the

DC microamps below 0.5?

FAILURE – If flame

IGNITION PROVING

is not sensed during the trial for ignition

period, the control will repeat the ignition

sequence 3 more times before lockout

4.0 to

YES

Clean flame sensor with fine steel wool and

recheck current. Nominal current is

6.0 microamps.

Is current near typical value?

during

wer on-delay period, blower will

proceeding to the next step.

- Gas valve turned off.

to furnace sheet metal.

- Green/Yellow wire MUST be connected

- Flame sensor must not be grounded.

- Manual shut-off valve.

#14 occurs. If flame signal is lost

the blo

come on for the selected blower off-delay.

Check the following items first before

YES

Will main burners ignite and stay on?

Fixed.

YES

To determine whether the problem is in

the gas valve, igniter, or flame sensor the

system can be operated in component

test mode. To check the igniter remove

the R thermostat connection from the

PG8MVA

control, reset power, and put setup switch

SW1-6 in the ON position to start the

component test. Does the igniter glow

orange/white by the end of the 15 second

warm-up period?

* Blocked vent switch used in Chimney Adapter Kit

WER ON AFTER POWER UP –

BLO

(115V OR 24V) – Normal operation.

Blower runs for 90 seconds, if unit is

powered up during a call for heat (R-

W/W1 closed) or when (R-W/W1 opens)

are erased after 72 hours or can be

manually erased by putting setup switch

SW1-1 in the ON position and jumpering

R, W/W1, and Y/Y2 simultaneously until

status code #11 is flashed. Run system

through a low-heat, high-heat, or cooling

cycle to check system.

11 NO PREVIOUS CODE – Status codes

during the blower on-delay period.

ing

ips occurred dur

LIMIT CIRCUIT LOCKOUT – Lockout

occurs if the limit, draft safeguard, flame

rollout, or blocked vent switch* (if used)

is open longer than 3 minutes or 10

successive limit tr

high-heat. Control will auto-reset after

hours. See code 33.

IGNITION LOCKOUT – System failed to

ignite gas and prove flame in 4 attempts.

Control will auto-reset after 3 hours.

See status code 34.

Indicates

. Control will

wer failed to reach 250 RPM or

wer failed to communicate within

the b

30 seconds after being turned ON in two

successive heating cycles

auto-reset after 3 hours. See code 41.

15 BLOWER MOTOR LOCKOUT –

21 GAS HEATING LOCKOUT – Turn off

SIGNAL

ING

Inducer will run until fault is ed.

power and wait 5 minutes to retry.

Check for:

- Stuck closed gas valve relay on control.

- Miswire or short to gas valve wire.

Flame is proved while gas valve is de-

energiz

cleared. Check for :

- Stuck open or leaky gas valve.

Check for:

- Obstructed pressure tube.

- Pressure switch stuck closed.

22 ABNORMAL FLAME-PROV

23 PRESSURE SWITCH DID NOT OPEN

ing including thermostat

(24V) wir

leads. Disconnect thermostat leads

to isolate short circuit.

Check for:

- Short circuit in secondary voltage

24 SECONDARY VOLTAGE FUSE IS OPEN

A02108B

wer leads

WHITE po

between the furnace control and the blower

either the BLACK or

You have an open wire or bad terminal on

motor. If you have a power choke disconnect

nace control

lower motor.

furnace control and the b

either the RED or GREEN wire between the

it and check continuity.

You have an open wire or bad terminal on

YES

PL3-2 GREEN (-)?

Is there 5-VDC at PL3-3 YELLOW (+) and

bad terminal on the or

and the blower motor.

YELLOW wire between the fur

You have an open wire

YES

PG8MVA

YES

Is there 12-VDC at PL13-7 RED (+) and PL13-

PL14-5 and PL14-4?

Tu r n power back on. Is there 115VAC at

YES

hirty seconds . T

ned ON or ten seconds

1 GREEN (-)?

wer wheel.

k the following items first

2 GREEN (-)?

Is there 12-VDC at PL3-1 RED (+) and PL3-

mostat connection

Replace the furnace control.

ery

YES

oltage just measured should be v

PL13-1 GREEN (-)?

Is there 5-VDC at PL13-16 YELLOW (+) and

The v

make sure

proceeding.

this get a different voltmeter before

.02-VDC. If the voltage fluctuates more than

stable and should not fluctuate more than

minal on the

wer back on.

the blower motor, then turn po

Turn power off, reconnect PL13 and PL14 to

YES

nace control.

previous step?

the voltage fluctuate more than it did in the

YELLOW (+) and PL3-2 GREEN (-). Does

Connect a DC voltmeter across PL3-3

Turn power off, disconnect PL13 and PL14

briefly go high several times a second. If you

you have an analog voltmeter the needle will

fluctuate briefly several times a second. If

voltage should be near 0-VDC but it will

16 BLUE (+) and PL13-1 GREEN (-). The

on. Connect a DC voltmeter across PL13-

from the blower motor, then turn power back

oltage

back?

Does the v

oltmeter across PL3-4 BLUE

the bar graph several times a second. If you

will show a large change in magnitude on

have a digital voltmeter with a bar graph it

scribed in the

YES

a brief fluctuation in voltage and the

have a standard digital voltmeter it will show

voltmeter used.

magnitude may vary depending on the

. Follow the instructions

er failed to communicate within th

-Wiring from furnace control to blower

- Loose blower wheel.

-Rubbing blo

before proceeding to the next step.

off and chec

during steady-state operation. Tur n p ow er

after being tur

prescribed time limits

blow

blower failed to reach 250 RPM or the

41 BLOWER MOTOR FAULT – Indicates the

memory. This will happen if you forget

is no valid model stored in permanent

- Model plug PL4 is missing and there

following:

continuously it could indicate any of the

in memory. If status code 25 flashes

defaulting to the model selection stored

is missing its model plug PL4 and is

flashes 4 times on power-up the control

SETUP ERROR – If status code 25 only

25 INVALID MODEL SELECTION OR

motor.

to install the model plug PL4 on a

freely?

and PL14. Does the blower wheel turn

connectors from the blower motor PL13

from the furnace control, disconnect both

Remove the R ther

Replace the blower control module attached

mostat call with SW1-6 ON.

mostat call with SW1-1 ON.

her

service replacement control.

- SW1-1 and SW1-6 both ON.

-T

RELAY DID NOT CLOSE OR

31 HIGH-HEAT PRESSURE SWITCH OR

with the blower control module to

to the blower motor. Follow the instructions

k for:

- Control relay may be defective.

REOPENED - Chec

replaced.

the entire blower motor does not need to be

- See status code 32.

-Gas valve is miswired.

ave an open wire or bad ter

ou h Y

Replace the fur

the blower motor

BLUE wire between the furnace control and

fluctuate as described two steps

(+) and PL3-2 GREEN (-).

Connect a DC v

YES

to the blower motor

previous step?

Does the voltage fluctuate as de

Replace the blower control module attached

replaced.

the entire blower motor does not need to be

with the blower control module to make sure

A02108C

PARTS REPLACEMENT INFORMATION GUIDE

CASING GROUP

Outer door Blower door Top filler plate Bottom filler plate Bottom enclosure

ELECTRICAL

Control bracket Junction box Limit switch(es) Circuit board Door switch Transformer Wiring harness 115v Wiring harness 24v

BLOWER

Blower housing Blower cutoff Blower motor Blower wheel Capacitor (where used) Capacitor strap (where used) Grommet Power choke (where used)

GROUP

GAS CONTROL

Manifold Burner assembly Orifice Flame sensor Hot surface igniter Gas valve Manual reset limit switches Burner support assembly

HEAT EXCHANGER

Heat exchanger cell Cell panel Lox NOx baffle (California models only)

INDUCER

Housing assembly Pressure switch Inducer motor Inducer wheel Vent elbow assembly Draft safeguard switch

GROUP

PG8MVA

TO OBTAIN INFORMATION ON PARTS: Consult your installing dealer or classified section of your local telephone directory under “Heating Equipment” or “Air Conditioning Contractors and Systems” headings for dealer listing by brand name or contact:

PAYNE HEATING & COOLING

Consumer Relations Department

P.O. Box 4952

Syracuse, New York 13221--4952

1--800--417--2963

Have available the model number, series number, and serial number located on the unit rating plate to ensure correct replacement part.

Example of Model Number

MODEL

PG8M V A 036 070 A B JA

WARNING: Improper installation, adjustment, alteration, service, or maintenance can cause personal injury, property damage, or death. Consult a qualified installer, service agency, or your local gas supplier for information or assistance. The qualified installer or service agency must use only factory--authorized replacement parts, kits, or accessories when modifying this product.

ELECTRICAL

SUPPLY

MAJOR

SERIES

COOLING

SIZE

HEATING

SIZE

VARIATION

MINOR SERIES

VARIATION

PG8MVA

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

C a t a l o g N o . I M --- P G 8 M

R epl a ce s : I M --- P G 8M V A --- 0 1

--- 0 2

Payne PG8MVA, PG8JVA Installation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual