Service Guide - HVACpartners
Contents
1. dn peiemod SI JI spuooes 06 10 suni ASLL Hd3MOd H314V NO Ulejs s 0 10 Buneeu uiejs s uny peydnuequi si 10 AS L paseo Osje sepoo 5 poJojs ZZ Jaye poseJe Sepoo GOO SfIOIA3Hd ON 18 19 2002 Payne Heating amp Cooling 7310 W Morris St Indianapolis IN 46231 20 sgpg9m06 Catalog No 53PG 9M212. e Q HAS d nn Qu PRINTED CIRCIUT BOARE zoas 105 194 NIML IS3L OVASLL Hd Ma M1 avnouo 1Nanaino3 n SVO A z 3ION Nv4H9v1Q 9LLVIN3HOS LOANNOOSIG OL 4191413934 30195 01315 LNAWdINOA 013154 TIVNIAH3 L M3H9S ONIHIM 01314 99 IOHLNOO NO OWAr2 ONIHIM 07314 OVASLI ONIHIM ONIHIM OWASEL ONIHIM IWNIIAH3 L IOH LNOO 89d IWNIIAH3LL GAHEVINNN NOILONNT OVATO OVAG LL H3INHOJSNVH L TIVNIINH3 L NIML 9 1541 LN3NOdAOO CO N LSdS HOLIMS SHNSSAYd HOLOANNOO LINDHID HOLO3NNOO ISH LINDYIO 2 YOLOANNOO YOLOANNOO d OH1NO9 HOLIMS QVOTH3AO HOLOW TVNH3LNI 19534 lt Y 2 NVuL NIML 1S31 Sud ld 99 1545 11S3H OLNV HOLIMS LITT O N LSdS HOLIMS 3HnSS3Hd SVO 3009 SNIWLS 30010 SNLLLIN3 LHOI1 NOLLONAP 440 YOLOSTSS Hadr 440 H3M018 O N LSdS HOLIMS
3. uoniuDi 10 eui Josues pue JO uo eis y oq amp HUB eu oq Mo 01 seb pue uedo seb seoq NYZ 9N9901 seoq suonoeuuoo seD ssoioe JOJ LU JOA JOOUUOD Y JO e9 o1 Je SOLIEU 198 pue peaj 1 5 eui 1euuooeH ponad puooes GL 10 jueseJd AGL SEM 1 eu ZT IWH_LNAN AG 10 eouenbes 159 jueuoduioo Jeuyoue ejeniui pue sseuJeu yub Andun ponad puooes eu pue eui ejym eBueio y seoq eouenbes 159 jueuodujoo eu ejeniur pue eu je1souueui eui e ouJeJ 1514 eui oeuo 0 159 eu eq uiejs s eu Josues eue se6 eu ui Si eu OL pepunoJD jou 5 10SU8S 4 19995 peioeuuoo M JJO INUS paun sey deis 1xeu eu 6uipeeooud e102q 151 Sue eui YOOYD Jewo g eui 10j uo M poled Aejap uo eu 190 si
4. jeisouueu eui JO eui 0 ApZWOD eui jeuuoo 1se eq EISUI JOU eoeuunj eu jou s 941 uaym yeadas au seoq 1011009 eoeuunj eu JOBUUODSIG eui uo 10 ZA A LA M Te uased S ejgeo JO 10 50 1 49949 LUVLS 0 eq pue 1exeeJq 95015 eoeuin 1 YN JO 499uo pesojo LHVLS pue uoiiws eso 2 eoeuun eoe deu peidnuejul st Az 10 AGLL 18A9U9UM eq osje UBD sepoo snjels 5 437 54 Jeye peseJe sepoo snes xoeuo 0 1949 Bujooo 10 e yno 5 uny sjeuBbls pue ZA A 11 uey 19410 QueseJd LA M 01 puodsei eu seoq sns snoad e SEM uo peuuni JOU IM pue Sec spuooes GL 01 10 peeds 1009 pue peeds v3H ISH eu 89 eJnue y 10 UNI pue HEIS 469npul
5. spuooes 081 Jo 06 081 06 suonoejes pL spuooes 2 y 10 spuooes 09 seb uo iewo g EL SInou 3914 Jaye 1esej ojne 10 5 njsseoonsun Jaye IM 21 pesn jou 1847 LL 4030 uo jou PES MOTT3A OL uonoejes pseds UO SIrejep 10 uone reisui ees suomipuoo JO TYHLNIN suomeuuoo SIMS 1959 urejuoo 5 4 pue AGI esn e e eoejde ur papnjoul Jou pue pejuud god SU pijos juo uogejuesoudaj eoupeje ere sioqui S eurej e oJd jo 1uoo 10 1eeus pejoeuuoo SIUL uonounf eoeuunj eui pue 19euuoosip eu ueewjeq Jeddoo esf 70901 10 esn s eum jueuudinbe jo Aue y 5 o SALON Sit ALON pus 929 3S4 6 Le 4 1
6. 54 2002 ANSI Z223 1 2002 in the USA National Standard of Canada Natural Gas and Propane Installation Code CSA B149 1 00 NSCNGPIC in Canada and the Installation Standards Warm Air Heating and Air Conditioning Systems NFPA 90B ANSI NFPA 90B Wear safety glasses and work gloves Have a fire extinguisher available during start up and adjustment procedures and service calls N CAUTION 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 2 you may need to revise your orientation to component location accordingly ELECTROSTATIC DISCHARGE ESD PRECAUTIONS N CAUTION 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
7. idee Peu eae TR ER EXER LIE ERE ERROR eee SAFETY CONSIDERATIONS Recognize safety information This is the safety alert symbol N When you see this symbol on the furnace and in instructions or manuals be alert to the potential for personal injury Understand the signal words DANGER WARNING CAUTION and NOTE 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 hazards which could result in personal injury or death CAUTION is used to identify unsafe practices which would 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 Installing and servicing heating equipment can be hazardous due to gas and electrical components Only trained and qualified service agency personnel should install repair or service heating equipment Untrained personnel can perform basic maintenance functions described in User s Information Manual such as cleaning and replacing air filters All other operations must be performed by trained and qualified service agency personnel When working on heating equipment observe precautions in the literature on tags and on labels attached to or shipped with the unit and other safety precautions that may apply Follow all safety codes including the National Fuel Gas Code NFGC
8. NOTE Heat tape when used should be wrapped around the condensate drain trap and drain line There is no need to use heat tape within the furnace casing Most heat tapes are temperature activated and it is not practical to verify the actual heating of the tape Check the following 32 F MINIMUM INSTALLED AMBIENT OR FREEZE PROTECTION REQUIRED AES TX Fig 13 Winterizing the Furnace P9096 1 Check for signs of physical damage to heat tape such as nicks cuts abrasions gnawing by animals etc 2 Check for discolored heat tape insulation If any damage or discolored insulation is evident replace heat tape 3 Check that heat tape power supply circuit is on PROCEDURE 9 WINTERIZING Z CAUTION Freezing condensate left in the furnace will damage the furnace If the furnace will be off for an extended period of time in a structure where the temperature will drop to 32 F or below winterize as follows 1 Turn off electrical supply to furnace 2 Remove main furnace door 3 Disconnect drain cap from unused drain tap on inducer housing See Fig 14 4 Connect field supplied 1 2 in I D tube to upper inducer housing drain connection A CAUTION Do not use ethylene glycol Prestone Il antifreeze coolant or equivalent automotive type Failure of plastic components will occur 5 Insert funnel in tube and pour up to one quart of antifreeze propylene glycol RV swimming pool antifreeze or equivalent int
9. y eouenbes 1581 jueuodujoo e eu y epoo eui use Buoj pue 11005 epoo sniels Ysey JIM Jno 5906 APZWOD eujus NIML 1S21 9U Buoys 12081 epoo 5 jaued sseooe 10 AOW JOU OP GAY uo snieis ejdsip 0 YMS 1nojog 10 YAMS WI eu GAY euo 1 pue epoo snieis OL 10 peuulm Sun j Auejod eui 1981109 10 YOUMS 100p eoeuunj euoyms 0 3494 S 22 098 pue 1 09518 01991 S SHA SHA amp pesop YAMS Joop S ZT 118 ASL S ON 3din 9NILOOHS3 8fnIOu L peuse j SEM Jeu sniels y 10 uonoes 0 o5 seyse y Buoj 1equunu y Aq puooes au pue uoys jo Aq peuiuuejep 1 Dip 1514 eu 2 S opoo 5 By epoo 5 euiuuejeqg gsoysey Buoj pue 11005 jo JIM A mo s 33O NO 1961 snes 037 SI amp esned e ynoyym Ajpides 1461 smeis 0317 SI SHA
10. 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 a 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 that recharges your body with static electricity for example DO NOT move or shuffle your feet DO NOT touch ungrounded objects etc 4 If you touch ungrounded objects recharge your body with static electricity firmly touch furnace again before touching control or wires 5 Use this procedure for installed and uninstalled ungrounded furnaces 6 Before removing a new control from its container discharge your body s electrostatic charge to ground to protect the control from damage If the control is to be installed in a furnace follow items 1 through 5 before bringing the control or yourself into contact with the furnace Put all used AND new controls into containers before touching ungrounded objects EX AIRFLOW e UPFLOW HORIZONTAL HORIZONTAL RIGHT DOWNFLOW AIRFLOW AIRFLOW Vv AIRFLOW 93041 Fig 2 Multipoise Orientations 7 An ESD service kit available from commercial sources may also be used to prevent ESD damage CARE AND MAINTENANCE For continuing high performance and to mi
11. j sinoo0 p Li noy90 e eouenbes uous y eui poued uous 40 ay pesues jou 1 eurey j 3HfY TI vd 9NIAOHd NOILINOI 4614 001 195 ayes 1ndu dei peeds 981109UI uo 1 PUIM Buizis Juan pejouiseu ayenbapeu Jo0joedeo 10 Suonoeuuoo JO YMS 85007 Ulejs s 5 Jo ALG YOOYD ese jenuew 4 YO sinus ysel senunuoo egest epoo 5 ull ugy sse uedo j eit 110420 epoo sejnuiui 2 uey uedo j si uoyAs uedo JO g 10 UN Jewojg uedo si YMS 1noj oJ 40 eu sejyeoipu ANYA LINOHIO pejouiseu SAISS99X2 YOUMS einsseid Jeonpul Buiqm ainsseid 10 pejoeuuoosiq Ajddns uonsnquioo eyenbepeu 54901 eunsseid seb AGL L Burzis juea Y99049 ejep Jo peioejes QU JO uo
12. PROVING FAILURE Control will try three more times before lockout 3114 occurs If flame signal lost during blower on delay period blower will come on for the selected blower off delay Check for Control ground continuity Flame sensor must not be grounded Oxide buildup on flame sensor clean with fine steel wool Proper flame sense microamps 5 microamps D C min 4 0 6 0 nominal Gas valve defective or gas valve turned off Manual valve shut off Defective Hot Surface Ignitor Low inlet gas pressure Inadequate flame carryover or rough ignition Green Yellow wire MUST be connected to furnace sheet metal CONTROL CIRCUITRY LOCKOUT Auto reset after one hour lockout due to Gas valve relay stuck open Flame sense circuit failure Software check error Reset power to clear lockout Replace control if status code repeats COMPONENT TEST To initiate the component test sequence shut OFF the room thermostat or disconnect the R thermostat lead Briefly short the TEST TWIN terminal to the Com 24V ter minal Status LED will flash code and then turn ON the inducer motor The inducer motor will run for the entire component test The hot surface ignitor blower motor FAN speed AMBER LED boards only blower motor HEAT speed and blower motor COOL speed will be turned ON for 10 15 seconds each Gas Valve and Humidifier will not be turned on 327884 101 REV B 02270 Fig 17 Service Label 5
13. WIRING NOTE 2 THERMOSTAT FIVE WIRE Q 0 TERMINALS FIELD SUPPLIED HEATING ONLY PIE Hat p E B 208 230 OR BLOWER DOOR SWITCH ere e 460 V el ee j el Tie e THREE PHASE BLK eT pot 5 H M w E Ww an 16 O uds cop N e e 208 230 V m T adh SINGLE ZOND GND R HE L rt ed a gt PHASE 115 V FIELD AUXILIARY Se e SUPPLIED _ J BOX L O GND DISCONNECT ____ 1____ CONDENSING OF y UNIT 24 V TWO TERMINAL WIRE BLOCK FURNACE NOTES 1 Connect Y terminal in furnace as shown for proper blower operation 2 Some thermostats require terminal connection as shown 3 If any of the original wire as supplied must be replaced use same type or equivalent wire A02174 Fig 11 Field Wiring TWINNING AND OR BLOWER OFF DELAY COMPONENT TEST TERMINAL J2 JUMPER HUMIDIFIER TERMINAL 24 VAC 0 5 AMP MAX 24 V THERMOSTAT TERMINALS TRANSFORMER 24 VAC CONNECTIONS 3 AMP FUSE LED OPERATION amp DIAGNOSTIC LIGHT PL1 LOW VOLTAGE MAIN 115 VAC L2 NEUTRAL HARNESS CONNECTOR CONNECTIONS 115 VAC L1 LINE PL2 HOT SURFACE VOLTAGE CONNECTION IGNITER amp INDUCER BLOWER SPEED MOTOR CONNECTOR SELECTION TERMINA
14. YOOTHSLNI TANVd SS399v H3MO 18 O N LSdS Av HH HOLON 14YHQ OSd HOLON 1 XW 0 NOLLO3NNOO HAIAIGIANH OvAvZ O N 1SdS AVTSH HALINOI SOVSHNS LOH OWA 911 SOVSUNS LOH 15 AVTSY SVD INVONAQ3H 3AVA SYD aariddns GATIVLSNI 91315 JOINS LdNHHALNI LINOHIO HO ISNA GATIVISNI AdAL 30V18 SALLOWOLNY dy ISNA 300419713 ONIAOHd ANVT14 01589 13534 TYNNVA MS LNOTION NOWINOO NOLLO3NNOO HANV319 HIV OINOHL93713 CXVIN 071 OWA 911 NOLLO3NNOO DINOHLO313 HOSS300HdOHOIN WOLIOVdVO Ll IdS LN3NVINH3d HOLOW O N 1SdS HOLON 1085 JONVHO 03345 HOLOW H3MO T8 Lf 554 584 Ymg 419 1H8 HOLIMS LO3NNOOSIG LINDHIO HO dasn4 cuuvds L3uvds 1009 10168199 1 095 935 7 NIMU LSAL Ost Sd91 5 N3HM oct 109135 Had AN T3Q 440 H3MO T8 9 3ION Cm NL PRINTED CIRCIUT BOARB 14 SERVICE If stat
15. a unit without a filter or with the blower access door removed could cause damage to the furnace blower motor Dust and lint on internal parts of furnace can cause a loss of efficiency NOTE If filter has cross mesh binding binding must face blower If filter has an air direction arrow arrow must point toward blower To clean or replace the filters proceed as follows Turn off electrical supply to furnace Remove main furnace door and blower access panel 2 3 Release filter retainer wire See Fig 3 or 4 4 Slide filter out of furnace 5 Furnaces are equipped with permanent washable filter s Clean filter by spraying cold tap water through filter in opposite direction of airflow 6 Rinse filter and let dry Oiling or coating of filter is not recommended MAC caa WASHABLE FILTER FILTER WASHABLE RETAINER FILTER FILTER SUPPORT RETAINER A93046 A93045 Fig 3 Bottom Filter Arrangement Fig 4 Filter Installed for Side Inlet 7 Slide filter into furnace 8 Recapture filter retainer wire 9 Replace blower access panel and main furnace door 10 Turn on electrical supply to furnace PROCEDURE 2 BLOWER MOTOR AND WHEEL MAINTENANCE To ensure long life economy and high efficiency clean accumulated dirt and grease from blower wheel and motor annually The inducer and blower motors are pre lubricated and require no additional lubrication These motors can be i
16. design A build up of soot and carbon indicates that a problem exists which needs to be corrected such as improper adjustment of manifold pressure insufficient or poor quality combustion air improper vent termination incorrect size or damaged manifold orifice s improper gas or a restricted heat exchanger primary or secondary Action must be taken to correct the problem 1 Turn off gas and electrical supplies to furnace 2 Remove main furnace door N CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation 3 Disconnect wires or connectors to flame rollout switch gas valve igniter and flame sensor 6 Fig 6 Cleaning Inlet Openings of Primary Heat PRIMARY HX INLET OPENINGS A96305 Exchangers TUBE ROUTING Furnace is shipped from factory in upflow configuration Pressure tube and drain tube routing MUST match the diagrams below Tube location when used in UPFLOW application Condensate Trap on LEFT Side Optional Condensate Trap Factory Installed in Blower Shelf BURNER ENCLOSURE pa Blower access panel removed PRESSURE REFERENCE ENCLOSURE TUBE ASSEMBLY TUBE ASSEMBLY COLLECTOR BOX TUBE o i 1 COLLECTOR BOX TUBE N CPUS ECTOR EO TUBE COLLECT
17. on furnace control board will flash rapidly and prevent furnace from operating The control system also requires an earth ground for proper operation of furnace control and flame sensor The 24 v circuit contains an automotive type 3 amp fuse located on the control See Fig 12 Any direct shorts of the 24 v wiring during installation service or maintenance will cause this fuse to blow If fuse replacement is required use ONLY a 3 amp fuse of identical size The control LED will flash status code 24 when fuse needs to be replaced With power to unit disconnected check all electrical connections for tightness Tighten all screws on electrical connections If any smoky or burned connections are found disassemble connection clean all parts strip wire and reassemble properly and securely Reconnect electrical supply to unit and observe unit through 1 complete operating cycle for proper operation PROCEDURE 8 CHECKING HEAT TAPE OPERATION IF APPLICABLE In applications where the ambient temperature around the furnace is 32 F or lower freeze protection measures are required If heat tape has been applied check to ensure it will operate when low temperatures are present Z CAUTION If this furnace is to be operated in an unconditioned space where the ambient temperatures may be 32 F or lower freeze protection measures must be taken See Fig 13 See CONDENSATE DRAIN PROTECTION section of Installation Start Up and Operating Instructions
18. the secondary heat exchanger will occur Flush with water only gt 10 Reassemble inducer assembly by reversing items 5 through 7 Tighten the vent coupling screw s to 15 in Ib of torque 8 BURNER FLAME a BURNER MANIFOLD F Fig 9 Burner Flame Fig 10 Gasket on Collector Box A89020 A93081 NOTE If seal between inducer housing and collector box is damaged in any way it must be repaired To repair apply sealant releasing agent such as PAM cooking spray or equivalent must not contain corn or canola oil aromatic or halogenated hydrocarbons which could cause an inadequate seal to occur to inducer housing See Fig 10 Apply a small bead of G E RTV 162 G E RTV 6702 or Dow Corning RTV 738 sealant to groove in collector box 11 Refer to furnace wiring diagram and connect wires to inducer motor and pressure switch or connectors 12 Reconnect pressure tubes to pressure switch See diagram on main furnace door for proper location of tubes Be sure tubes are not kinked See Fig 8 13 Turn on gas and electrical supplies to furnace 14 Check furnace operation through 2 complete heat operating cycles Check area below inducer housing vent pipe and condensate trap to ensure no condensate leaks occur If leaks are found correct problem A WARNING FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings exactly could result in serious injury death or property damage Never test for gas l
19. BOD poled Aejap uo suedo j 1101 G 10 jo Sinus g uey uedo j qQ3N3dO3H HO 25070 LON GIG HOLIMS 3Hf1SS3ud Jinour 11045 5 0 spee JOSUUODSIG Spea Bum Atz eBeyon uoug 110 Y00949 NadO SI 3505 39VETOA 0 35 HONJS YMS egni ensseJd 110 YOBUD N3dO LON GIG HOLIMS SYNSS3Yd yeo uedo xong YOOYD SI UNL SI Se po o d si 4 IVNSIS ONIAOHd 3IAV 14 M 526 0 11045 JO 9JIMSIIA uo seb 110 40049 G pue 1 10104901 ONILVIH SVO YE epoo 5 ees SINOY JOYE 19591 01 IM sadueye e o4d pue seb 01 payrey 5 107007 NOLLINSI EE sinou e Jaye 950 M g uey uedo SI YOUMS JO Y ji 51000 1103001 LNOMOOT LINDYIO poued eu suedo M H ueym 10 ee 10 e
20. LS EAC 1 TERMINAL 115 VAC 1 0 AMP MAX A02100 Fig 12 Control Center 10 A CAUTION The igniter is fragile DO NOT allow it to hit the side of the burner box opening while removing or replacing it b Inspect igniter for a white area indicating a crack may be present If found replace igniter NOTE A small crack cannot be seen on a new igniter After a period of operation a white area will be visible around the crack c If replacement is required replace igniter on igniter bracket external to furnace to avoid damage as the silicon portion is very brittle and will easily crack or shatter d To remove igniter from igniter bracket remove screw holding igniter ceramic block to bracket and pull ceramic block out of bracket To replace igniter igniter assembly reverse items 5a through 5d 6 7 Reconnect igniter wire connection 8 Turn on gas and electrical supplies to furnace 9 Verify igniter operation by initiating furnace control self test feature or by cycling thermostat 10 Replace main furnace door PROCEDURE 7 ELECTRICAL CONTROLS AND WIRING Z CAUTION There may be more than 1 electrical supply to the furnace Check accessories and cooling unit for additional electrical supplies The electrical ground and polarity for 115 v wiring must be maintained properly Refer to Fig 11 for field wiring information and to Fig 16 for furnace wiring information NOTE If polarity is not correct STATUS LED
21. N TUBE BURNER ENCLOSURE PRESSURE COLLECTOR BOX REFERENCE TUBE ASSEMBLY CONDENSATE TRAP EXTENSION TUBE m DRAIN TUBE COUPLING 4 CONDENSATE TRAP COLLECTOR BOX o BURNER ENCLOSURE PRESSURE TUBE PINK DRAIN TUBES ROUTED IN COLLECTOR BOX REFERENCE TUBE ASSEMBLY FRONT GAS VALVE y EXTENSION DRAIN TUBE INDUCER HOUSING DRAIN TUBE VIOLET GAS VALVE Tube location when used on Tube location when used on HORIZONTAL LEFT application HORIZONTAL RIGHT application COLLECTOR BOX DRAIN TUBE COLLECTOR BOX DRAIN TUBE COLLECTOR BOX EXTENSION TUBE n BLUE amp WHITE STRIPED BLUE SECTE ACTU PNG _ RE ri COITEGTOR BOR PLUG 4 AUXILIARY J RELOCATED HERE TUBE GREEN BURNER ENCLOSURE d a o COLLECTOR BO E INDUCER HOUSING cap ANS EXTENSION TUBE DRAIN TUBE BURNER ENCLOSURE VIOLET PRESSURE REFERENCE 1 ASSEMBLY COLLECTOR BOX d CONDENSATE TRAP DRAIN TUBE BLUE COLLECTOR BOX CE EO PE EXTENSION TUBE QUE mon en COUPLING COLLECTOR BOX EXTENSION DRAIN TUBE RELOCATE TUBE BETWEEN BLOWER COLLECTOR BOX DRAIN TUBE CONDENSATE TRAP 040 060 AND 80 HEATING INPUT INDUCER HOUSING DRAIN TUBE VIOLET NOTE 1 All tubing must be connected securely and routed to avoid kinks and traps 2 Pressure tubing must always slope away from pressure switch to collector box connection as shown 3 HORIZONTAL LEFT installations require the collect
22. NG SIGNAL Flame is proved while gas valve is de energized Inducer will run until fault is cleared Check for Leaky gas valve Stuck open gas valve 23 PRESSURE SWITCH DID NOT OPEN Check for Obstructed pressure tubing Pressure switch stuck closed 24 SECONDARY VOLTAGE FUSE IS OPEN Check for Short circuit in secondary voltage 24VAC wiring 31 PRESSURE SWITCH DID NOT CLOSE OR REOPENED If open longer than five minutes inducer shuts off for 15 minutes before retry Check for Excessive wind Proper vent sizing Defective inducer motor Low inducer voltage 115VAC Defective pressure switch Inadequate combustion air supply Restricted vent Disconnected or obstructed pressure tubing Low inlet gas pressure if LGPS used If it opens during blower on delay period blower will come on for the selected blower off delay LIMIT CIRCUIT FAULT Indicates a limit or flame rollout is open Blower will run for 4 minutes or until open switch remakes whichever is longer If open longer than 3 minutes code changes to lockout 13 If open less than 3 minutes status code 33 continues to flash until blower shuts off Flame rollout switch requires manual reset Check for Restricted vent Proper vent sizing Loose blower wheel Excessive wind Dirty filter or restricted duct system Defective blower motor or capacitor Defective switch or connections Inadequate combustion air supply Flame Roll out Switch open IGNITION
23. OR BOX DRAIN PINK e GREEN ae BLUE amp WHITE STRIPED COLLECTOR BOX TUBE GREEN COLLECTOR BOX DRAIN TUBE INDUCER HOUSING MOLDED DRAIN TUBE BEHIND COLLECTOR BOX DRAIN TUBE G BLUE amp WHITE STRIPED CONDENSATE TRAP COLLECTOR BOX DRAIN TUBE COLLECTOR BOX DRAIN TUBE BLUE BLUE gt i FACTORVSUPRLIED f S 2 DRAIN TUBE COUPLING CONDENSATE TRAP LD RIGHT DRAIN OPTION m FACTORY SUPPLIED DRAIN TUBE Ad PORN ORAN TUBE COUPLING LEFT DRAIN OPTION H DINSTATES VIOLET FACTORY SUPPLIED 1 2 IN I CPVC STREET ELBOWS 2 FIELD INSTALLED FACTORY SUPPLIED DRA FOR LEFT DRAIN OPTIO Condensate Trap on LEFT Side Condensate Trap on Tube location when used in DOWNFLOW application vus COLLECTOR BOX PER CAP 4 DRAIN TUBE BLUE PLUGGED BND COLLECTOR BOX DRAIN TUBE HUS BLUE COLLECTOR BOX TUBE GREEN A5 BLUE amp WHITE STRIPED TUBE COLLECTOR BOX DRAIN TUBE PLUG BLUE amp WHITE STRIPED INOUCER HOUSING DRAN I Ped TUBE COLLECTOR BOX TUBE VIOLET EXTENSION TUBE S COLLECTOR BOX EXTENSIO
24. Service Guide 4 Way Multipoise PG9MAA Fixed Capacity Dual Vent Series E Condensing Gas Furnace EFFICIENCY CERTIFIED DESIGN REGISTERED QUALITY SYSTEM A98187 Fig 1 Multipoise Furnace in Upflow Orientation Z WARNING ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in dangerous operation serious injury death or property damage Improper servicing could result in dangerous operation serious injury death or property damage Before servicing disconnect all electrical power to furnace When servicing controls label all wires prior to disconnecting Reconnect wires correctly Verify proper operation after servicing Z WARNING The ability to properly perform maintenance on this equipment requires certain expertise mechanical skills tools and equipment If you do not possess these do not attempt to perform any maintenance on this equipment other than those procedures recommended in the User s Manual FAILURE TO FOLLOW THIS WARNING COULD RESULT IN POSSIBLE DAMAGE TO THIS EQUIPMENT SERIOUS PERSONAL INJURY OR DEATH Z WARNING Never store anything on near or in contact with the furnace such as 1 Spray or aerosol cans rags brooms dust mops vacuum cleaners or other cleaning tools 2 Soap powders bleaches waxes or other cleaning compounds plastic or plastic containers gasoline kerosene cigarette lighter fluid dry cleaning fluids or other volatile
25. cifically for the detection of leaks to check all connections A fire or explosion may result causing property damage personal injury or loss of life 17 Check for gas leaks 18 Replace main furnace door B Secondary Heat Exchangers NOTE The condensing side inside of secondary heat exchangers CANNOT be serviced or inspected A small number of bottom outlet openings can be inspected by removing inducer assembly See Flushing Collector Box and Drainage System section for details on removing inducer assembly PROCEDURE 5 FLUSHING COLLECTOR BOX AND DRAINAGE SYSTEM 1 Turn off gas and electrical supplies to furnace Remove main furnace door Disconnect inducer motor and pressure switch wires or connectors 2 3 4 Disconnect pressure switch tubes 5 Disconnect vent pipe from inducer housing outlet by loosening clamp 6 Disconnect drain tube from inducer housing See Fig 8 7 Remove inducer housing assembly by removing 4 bolts attaching assembly to cell panel 8 Flush inside of collector box with water until discharge from condensate trap is clean and runs freely NOTE Ensure that drain tube disconnected from inducer housing is higher than collector box opening or water will flow out tube 9 Inspect inside area of collector box for any pieces of foreign materials and remove if present A CAUTION DO NOT use wire brush or other sharp object to inspect or dislodge materials in secondary heat exchangers as failure of
26. dentified by the absence of oil ports on each end of the motor The following items should be performed by a qualified service technician Clean blower motor and wheel as follows 1 Turn off electrical supply to furnace 2 Remove main furnace door and blower access panel 3 Disconnect blower motor wires from furnace control board Field thermostat connections may need to be disconnected depending on their length and routing 4 Remove control box mounting screws and position control box transformer and door switch assembly to right side of furnace casing 5 If condensate trap is located in left or right hand side of furnace casing proceed to item 6 otherwise remove trap and tubing as described below See top left of Fig 8 a Disconnect field drain connection from condensate trap b Disconnect drain and relief port tubes from condensate trap c Remove condensate trap from blower shelf 6 Remove screws securing blower assembly to blower shelf and slide blower assembly out of furnace 7 Clean blower wheel and motor by using a vacuum with soft brush attachment Be careful not to disturb balance weights clips on blower wheel vanes Do not bend wheel or blades as balance will be affected 8 If greasy residue is present on blower wheel remove wheel from the blower housing and wash it with an appropriate degreaser To remove wheel a Mark blower wheel location on shaft before disassembly to ensure proper reassembly b Lo
27. eaks 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 15 Check for gas leaks 16 Replace main furnace door PROCEDURE 6 SERVICING HOT SURFACE IGNITER The igniter does NOT require annual inspection Check igniter resistance before removal 1 Turn off gas and electrical supplies to furnace 2 Remove main furnace door 3 Disconnect igniter wire connection 4 Check igniter resistance a Using an ohm meter check resistance across both igniter leads in connector b Cold reading should be between 45 ohms and 90 ohms c If ohm reading is higher than 110 ohms igniter is cracked and must be replaced 5 Remove igniter A CAUTION Allow igniter to cool before removal Normal operating temperatures exceed 2000 F a Do not remove igniter from bracket while assembly is in furnace Using a 1 4 in nutdriver remove screw securing bracket and igniter assembly to bottom of burner box The screw in the bracket is always located toward outside of burner box The screw may be hidden by inlet box or inlet pipe but can be removed without removing either After removing screw slide igniter and bracket toward outside of burner box and pull straight out FIELD 24 WIRING FIELD 115 208 230 460 V WIRING FACTORY 24 V WIRING FACTORY 115 V
28. fluids 3 Paint thinners and other painting compounds paper bags or other paper products Failure to follow this warning can cause corrosion of the heat exchanger fire personal injury or death Form SG PG9M 06 Cancels SG PG9M 05 Printed in U S A 11 02 Catalog No 53PG 9M21 NOTE Read the entire instruction manual before starting the installation INDEX SAFETY CONSIDERATIONS um ee RO ERU HEB CE erri enr men re CEOs GENERAT ED Ye tak E OT ree ren i ad rds ELECTROSTATIC DISCHARGE ESD PRECAUTION E CARE AND MANT NA OE tru unt e gn on ertet ad Cleaning Replacing Air Pilter s oo e on pe REO irure d o p ERR ete EORR RSS Blower Motor Wheel Maintenance eet ee He exe estate Cleaning Burners oet p oo eet coe i rc oO fes ER UD HERREN Pen Oe OAL OY osea ee re Cleaning Heat Exchangers Primary Heat Exchangers Secondary Heat Exchangers Flushing Collector Box and Drainage System sise Servicing Hot Surface Igmter s ano cs dp depre ERU Renee ir ORO SOBRE Electrical Controls and Wiring Checking Heat Tape Operation If Applicable Zin Ossie eerte eH eerte WIRING DIAGRAM eee ir er ele m e aeree Ur re e E CHEER Rat ERE UR En I n meme EE Eam TROUBLESHOOTING GUIDE
29. k out NOTE Be sure burner box gasket is installed between burner box and cell panel See Fig 5 If gasket is damaged replace it NOTE Inspect combustion air intake housing If foamed gasket was removed check for any damage If gasket is damaged in any way it must be repaired To repair remove damaged gasket section apply sealant releasing agent such as PAM cooking spray or equivalent must not contain corn or canola oil aromatic or halogenated hydrocarbons which could cause an inadequate seal to occur to burner box and apply a small bead of G E RTV 162 G E RTV 6702 or Dow Corning RTV 738 sealant to edge of combustion air intake housing See Fig 7 13 Refer to furnace wiring diagram and connect wires to flame rollout switch gas valve igniter and flame sensor 14 Reconnect pressure switch tubes to gas valve and intake housing Refer to tube routing label on main furnace door for proper tube location Be sure tubes are not kinked See Fig 8 15 Turn on gas and electrical supplies to furnace 16 Check furnace operation through 2 complete heat operating cycles Look through sight glass in burner enclosure to check burners Burner flames should be clear blue almost transparent See Fig 9 A WARNING FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings exactly could result in serious injury death or property damage Never test for gas leaks with an open flame Use a commercially available soap solution made spe
30. nimize possible equipment failure it is essential that maintenance be performed annually on this equipment Consult your local dealer about proper maintenance and maintenance contract availability A WARNING Turn off the gas and electrical supplies to the unit before performing any maintenance or service Follow the operating instructions on the label attached to the furnace Failure to follow this warning could result in personal injury or death The minimum maintenance that should be performed on this equipment is as follows Check and clean or replace air filter each month as needed Check blower motor and wheel for cleanliness annually Check electrical connections for tightness and controls for proper operation each heating season Service as necessary Check for proper condensate drainage Clean as necessary Check for blockages in combustion air and vent pipes annually Check burners for cleanliness annually N CAUTION Be careful of sharp metal edges etc Use care and wear protective clothing safety glasses and gloves when removing parts Failure to follow this caution could result in personal injury PROCEDURE 1 CLEANING AND OR REPLACING AIR FILTER The air filter arrangement may vary depending on the application or orientation N WARNING Never operate unit without a filter or with the blower access panel removed Failure to follow this warning could result in a fire or personal injury A CAUTION Operating
31. o funnel until it is visible at point where condensate enters open drain See Fig 15 6 Reconnect drain cap to inducer housing 7 Replace main furnace door 8 Propylene glycol need not be removed before restarting furnace 94209 A94208 Fig 15 Funnel in Drain and Antifreeze Running Fig 14 Inducer Housing Drain Cap Through Trap WIRING DIAGRAM See Fig 16 for Wiring Diagram TROUBLESHOOTING Use the Troubleshooting Guide the status code LED on the cotntrol and the Component Test to isolate furnace operation problems A Status Codes For an explanation of status codes refer to service label located on back of main furnace door or Fig 17 NOTE Removing the blower access door will open the blower access door switch and terminate 115 v power to the control This will erase all stored status codes To read current status code remove main furnace door The status code LED can be viewed through the sight glass in the blower access door NOTE NO thermostat signals should be present at control and all blower off delays must be completed to view previous codes A CAUTION Make sure limit switch wire does not contact any metallic component such as the gas valve If wire is shorted 3 amp fuse on furnace control board will blow To retrieve previous codes remove of the red main limit wires for 1 to 4 sec until the LED light goes out then
32. ocation 14 Reinstall burner box pressure tube to gas valve regulator fitting 15 Reinstall gas supply pipe to furnace gas control valve using backup wrench on gas valve to prevent rotation and improper orientation NOTE Use propane gas resistant pipe dope to prevent gas leaks DO NOT use Teflon tape Z WARNING Gas valve switch MUST be facing forward or tilted upward Failure to follow this warning could result in property damage personal injury or death 16 Replace burner box cover 17 Turn on gas and electrical supplies to furnace Z WARNING FIRE OR EXPLOSION HAZARD Failure to follow the safety warnings exactly could result in serious injury death or property damage Never test for gas leaks with an open flame Use a commercially available soap solution made specifically for the detection of leaks to check all connections A fire or explosion may result causing property damage personal injury or loss of life 18 Check for gas leaks 19 Replace main furnace door PROCEDURE 4 CLEANING HEAT EXCHANGERS The following items should be performed by a qualified service technician A Primary Heat Exchangers If heat exchangers get an accumulation of light dirt or dust on the inside they may be cleaned by the following procedure NOTE If heat exchangers get a heavy accumulation of soot and carbon both the primary and secondary heat exchangers should be replaced rather than trying to clean them thoroughly due to their intricate
33. or PROCEDURE 3 CLEANING BURNERS The following items should be performed by a qualified service technician If burners develop an accumulation of light dirt or dust they may be cleaned by using the following procedure Turn off gas and electrical supplies to furnace 2 Remove main furnace door 3 Remove burner box cover 4 Using backup wrench disconnect gas supply pipe from furnace gas control valve N CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation 5 Remove wires from gas valve Note location for reassembly 6 Remove burner box pressure tube from gas valve regulator fitting 7 Remove screws that secure manifold to burner box See Fig 5 NOTE Do not remove burner box from cell panel 8 Remove manifold orifices and gas valve as 1 assembly 9 Remove screws attaching burner assembly in burner box 10 Remove burner assembly from burner box 75 MANIFOLD MOUNTING LS MANIFOLD GAS VALVE REGULATOR FITTING GAS VALVE Fig 5 Burner Box Assembly A96304 NOTE All burners are attached to burner bracket and can be removed as 1 assembly 11 Clean burners with soft brush and vacuum 12 Reinstall manifold orifice and gas valve assembly in burner box Ensure manifold seal grommet is installed properly and burners fit over orifices 13 Reconnect wires to gas valve Refer to furnace wiring diagram for proper wire l
34. or box pressure tube to be relocated between the inducer housing and the blower shelf to 324999 201 prevent trap Refer to the Installation Instructions for further details Fig 8 Furnace Pressure and Drain Tubing Diagram 93087 Fig 7 Combustion Air Intake Housing Gasket Repair 00308 Disconnect combustion air intake pipe from intake housing Remove pressure switch tube from intake housing Remove screws attaching intake housing to burner box and rotate intake housing away from burner box for removal Using backup wrench disconnect gas supply pipe from gas valve Disconnect pressure tubing from gas valve N AO t R Remove 2 screws attaching top filler panel and rotate upwards to gain access to screws attaching burner box to cell panel 10 Remove screws attaching burner box to cell panel See Fig 5 NOTE Burner box cover manifold gas valve and burner assembly should be removed as 1 assembly 11 Clean heat exchanger openings with a vacuum and a soft brush See Fig 6 NOTE After cleaning inspect heat exchangers to ensure they are free of all foreign objects that may restrict flow of combustion products 12 Reverse items 4 through 10 for reassembly N CAUTION The ground wire from the gas valve MUST be attached to the burner box attachment screw Failure to attach this ground wire to an adequate casing ground will cause the furnace control to loc
35. osen setscrew holding blower wheel on motor shaft NOTE Mark blower mounting arms and blower housing so each arm is positioned at the same hole location during reassembly c Mark blower wheel orientation and cutoff plate location to ensure proper reassembly d Remove screws securing cutoff plate and remove cutoff plate from housing e Remove bolts holding motor mounts to blower housing and slide motor and mounts out of housing Disconnect capacitor and ground wire attached to blower housing before removing motor Motor mounts need not be removed from motor f Remove blower wheel from housing A CAUTION The blower wheel should not be dropped or bent as balance will be affected 2 Clean wheel per instructions on degreaser cleaner Do not get degreaser cleaner in motor 4 9 Reassemble motor and blower wheel by reversing items 8b through 8f Ensure wheel is positioned for proper rotation Be sure to reattach ground wire Tighten setscrew to 140 to 160 in Ib torque 10 Reinstall blower assembly in furnace 11 Reinstall control box transformer and door switch assembly on blower shelf 12 Reinstall condensate trap and tubing if previously removed a Reinstall condensate trap in hole in blower shelf b Connect condensate trap drain tubes See Fig 8 or tubing diagram on main furnace door for proper tube location NOTE Ensure tubes are not kinked or pinched as this will affect operation 1 Connect 1 tube blue or blue and whi
36. reconnect it Do not leave red wire disconnected for longer periods of time as the control will assume an overtemperature condition exists and will respond with blower operation This places the control in the status recall mode and displays the first code stored in memory Record the code After the last code is displayed the control will perform the component test and then return to normal standby mode B Component Test NOTE The furnace control component test allows all components to run for a short time except the gas valve and humidifier terminal HUM are not energized for safety reasons The EAC 1 terminal is energized when the blower is energized This feature helps diagnose a system problem in case of a component failure The component test feature will not operate if any thermostat signal is present at the control and not until all time delays are completed NOTE Record the status code BEFORE opening the blower access door and before shutting off power to furnace Opening the blower access door will open the blower door switch and shut off power within the furnace When power to the furnace is shut off by either method the status code will be lost because the code is not stored while power is removed for any reason To Begin Component Self Test Z WARNING Blower access panel door switch opens 115 v power to control center No component operation can occur Caution must be taken when manually closing this switch for service purpose
37. s Failure to follow this warning could result in electrical shock personal injury or death 1 Remove blower access door Disconnect the thermostat R lead from furnace control board Manually close blower door switch A For approximately 2 sec short jumper the Cow 24v terminal on control to the TEST TWIN 3 16 in quick connect terminal on control until LED turns off Remove jumper from terminals See Fig 12 NOTE If TEST TWIN and Com 24v terminals are jumpered longer than 2 sec LED will flash rapidly and ignore component test request Component test sequence for single stage furnace is as follows a LED will display status code 11 four times b Inducer motor starts and continues to run until Step f of component test sequence c After 7 sec the hot surface igniter is energized for 15 sec then off d Blower motor operates on HEAT speed for 10 sec e Blower motor operates on COOL speed for 10 sec f Inducer motor stops Reconnect R lead to furnace control board remove tape from blower door switch and reinstall blower door Operate furnace per instruction on outer door Verify furnace shut down by lowering thermostat setting below room temperature D I ON tA Verify that furnace restarts by raising thermostat setting above room temperature 43 6 0 weibeig 9 514 lt C V 101 0S182e INO SI Zf spuooos G Jo spuooes 06 yeay 10
38. te striped from collector box 2 Connect 1 tube violet or unmarked from inducer housing 3 Connect 1 tube relief port green or pink from collector box c Connect field drain to condensate trap 13 Reconnect wires Refer to furnace wiring diagram and connect thermostat leads if previously disconnected See Fig 16 NOTE Refer to Table 1 for motor speed lead reconnection if leads were not identified before disconnection N CAUTION Heating speed selection MUST be adjusted to provide proper temperature rise as specified on the rating plate Failure to adjust the heating speed may shorten heat exchanger life Table 1 Selector FACTORY ATTACHED TO Black High Yellow When Present Medium High Blue Medium Low Red Low White Common 14 Turn on electrical supply Manually close blower access door switch Use a piece of tape to hold switch closed Check for proper rotation and speed changes by performing a component self test as shown at the bottom of SERVICE label See Fig 17 N WARNING Blower access door switch opens 115 v power to furnace control No component operation can occur Caution must be taken when manually closing this switch for service purposes Failure to follow this warning could result in electrical shock personal injury or death 15 If furnace is operating properly remove tape to release blower access door switch replace blower access door and replace main furnace do
39. uo snes q31 SI 1815 16 0 20 eoe dau Ae s jou s1euunq pue 0 9 0 eoid SI jueuno j pue suonoeuuoo 289 uone1edo 10 YOSYO 0 1S9 pue uo 10 0940 ayes aunsseid seb uoniubi eure j ejenbepeu Y08490 uo se jeu YOOUD HO J eoe deu pue y 10 Y98049 ji 01 19MOd 1eseu 10119 uedo yonjs Seo einjrej 4 10 enp Jaye 1959 1 AHLINOHIO TOHLNOO Sv uo fes pue sieuung IM anjen e9idA zuN S 0 9 010v 5 JUUNI 98 S Josues 490 MoJeq sdureojotu y s
40. us code recall is needed briefly remove then reconnect one main limit wire to display stored status code On RED LED boards do not remove power or blower door before initiat ing status code recall After one status code recall is completed component test will occur LED CODE STATUS CONTINUOUS OFF Check for 115VAC at L1 amp L2 amp 24VAC at SEC 1 amp SEC 2 CONTINUOUS ON Control has 24VAC power RAPID FLASHING Line voltage 115VAC polarity reversed If twinned refer to twinning kit instructions EACH OF THE FOLLOWING STATUS CODES IS A TWO DIGIT NUMBER WITH THE FIRST DIGIT DETERMINED BY THE NUMBER OF SHORT FLASHES AND THE SECOND DIGIT BY THE NUMBER OF LONG FLASHES 11 NO PREVIOUS CODE Stored status code is erased automatically after 72 hours On RED LED boards stored status codes can also be erased when power 115 VAC or 24 VAC to control is interrupted 12 BLOWER ON AFTER POWER UP 115 VAC or 24 VAC Blower runs for 90 seconds if unit is powered up during a call for heat R W closed or R W opens during blower on delay 13 LIMIT CIRCUIT LOCKOUT Lockout occurs if the limit or flame rollout switch is open longer than 3 minutes Control will auto reset after three hours Refer to 33 14 IGNITION LOCKOUT Control will auto reset after three hours Refer to 34 21 GAS HEATING LOCKOUT Control will NOT auto reset Check for Mis wired gas valve Defective control valve relay 22 ABNORMAL FLAME PROVI
Download Pdf Manuals
Related Search