Payne PG9MAB Service And Maintenance Instructions

Brand: Payne

Model: PG9MAB

Type: Service And Maintenance Instructions

This manual is also suitable for

PG9MAB Series A

PG9MAB

Service and Maintenance Instructions

For Sizes 040--120, Series B

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

Multipoise Fixed Capacity

Condensing Gas Furnace

NOTE: Read the entire instruction manual before starting the

installation.

TABLE OF CONTENTS

PAGE

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

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

ELECTROSTATIC DISCHARGE (ESD) P RECAUTIONS 2...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

ELECTRICAL SHOCK, FIRE, OR EXPLOSION

HAZARD

Failure to follow safety warnings exactly could result in

dangerous operation, personal injury, death, or property

damage.

-- Before servicing, disconnect all electrical power to furnace.

--When servicing controls, label all wires prior to

disconnecting. Reconnect wires correctly.

-- Verify proper operation after servicing.

WARNING

SAFETY CONSIDERATIONS

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

When you see this symbol on the furnace and in instructions or

manuals, be alert to the potential for personal injury.

Understand the signal words DANGER, WARNING, and

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

DANGER identifies the most serious hazards which will result in

severe personal injury or death. WARNING signifies a hazard

which could result in personal injury o r death. CAUTION is used

to identify unsafe practices which may result in minor personal

injury or product and property damage. NOTE is used to highlight

suggestions which will result in enhanced installation, reliability, or

operation.

ELECTRICAL SHOCK, FIRE, OR EXPLOSION

HAZARD

Failure to follow this warning could result in possible

damage to this equipment, personal injury, or death.

The ability to properly perform maintenance on this

equipment requires certain expertise, mechanical skills,

tools, and equipment. If you do not possess these, do not

attempt to perform any maintenance on this equipment

other than those procedures recommended in the User’s

Manual.

WARNING

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could property damage,

personal injury, or death.

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

such as:

1. Spray or aerosol cans, rags, brooms, dust mops, vacuum

cleaners, or other cleaning tools.

2. Soap powders, bleaches, waxes or other cleaning

compounds, plastic or plastic containers, gasoline, kerosene,

cigarette lighter fluid, dry cleaning fluids, or other volatile

fluids.

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

or other paper products.

WARNING

A05086

Fig. 1 -- Furnace in Upflow Orientation

ama

REGISTERED

ISO 9001:2000

CERTIFIED

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 o ther

operations must be performed by trained service personnel. When

working on heating equipment, observe precautions in the

literature, on tags, and on labels attached to or shipped with the

unit and other safety precautions that may apply.

Follow all safety codes including the National Fuel Gas Code

(NFGC) NFPA 54 -- 2006/ANSI Z223.1-- 2006 in the USA, CSA

B149.1--05 National Standard of Canada, Natural Gas and Propane

Installation Codes (NSCNGPIC) in Canada, and the Installation

Standards, Warm Air Heating and Air Conditioning Systems

(NFPA 90B) ANSI/NFPA 90B. Wear safety glasses and work

gloves. Have a fire extinguisher available during start--up and

adjustment procedures and service calls.

UNIT DAMAGE HAZARD

Failure to follow this caution may result in damage to

furnace.

Label all wires prior to disconnection when servicing

controls. Wiring errors can cause improper and dangerous

operation.

CAUTION

GENERAL

This furnace can be installed as a direct vent (2--pipe) or non-- direct

vent (1--pipe) condensing gas furnace. These instructions are

written as if the furnace is installed in an upflow application. An

upflow furnace application is where the blower is located below

the combustion and controls section of the furnace, and

conditioned air is discharged upward. Since this furnace can be

installed in any of the 4 positions shown in Fig. 2, you may need to

revise your orientation to component location accordingly.

UPFLOW

DOWNFLOW

HORIZONTAL

LEFT

AIRFLOW

HORIZONTAL

RIGHT

A93041

Fig. 2 -- Multipoise Orientation

ELECTROSTATIC DISCHARGE (ESD)

PRECAUTIONS

UNIT DAMAGE HAZARD

Failure to follow this caution may damage furnace

components.

Electrostatic discharge can affect electronic components.

Take precautions during furnace installation and servicing

to protect the furnace electronic control. Precautions will

prevent electrostatic discharges from personnel and hand

tools which are held during the procedure. These

precautions will help to avoid exposing the control to

electrostatic discharge by putting the furnace, the control,

and the person at the same electrostatic potential.

CAUTION

1. Disconnect all power to the furnace. 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 fur-

nace chassis which is close to the control. Tools held in a

PG9MAB

person’s hand during grounding will be satisfactorily dis-

charged.

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 ungroun-

ded objects, etc.).

4. If you touch ungrounded objects (recharge your body with

static electricity), firmly touch furnace again before touch-

ing control or wires.

5. Use this procedure for installed and uninstalled (ungroun-

ded) 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 con-

trol or yourself into contact with the furnace. Put all used

AND new controls into containers before touching un-

grounded objects.

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

mayalsobeusedtopreventESDdamage.

CARE AND MAINTENANCE

For continuing high performance and to minimize possible furnace

failure, it is essential that maintenance be performed annually.

Consult your local dealer for maintenance and maintenance

contract availability.

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury

or death.

Turn off the gas and electrical supplies to the unit before

performing any maintenance or service. Follow the operating

instructions on the label attached to the furnace.

WARNING

The minimum maintenance that should be performed on this

equipment is as follows:

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

2. Check blower motor and wheel for cleanliness annually.

3. Check electrical connections for tightness and controls for

proper operation each heating season. Service as necessary.

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

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

nually.

6. Check burners for cleanliness annually.

CUT HAZARD

Failure to follow this caution may result in personal injury.

Be careful of sharp metal edges, etc. Use care and wear

protective clothing, gloves, and safety glasses when

removing parts.

CAUTION

Step 1 — Cleaning and/or Replacing Air Filter

The air filter arrangement may vary depending on the application

or orientation. See T able 1 for filter size and type.

FILTER

SUPPORT

FILTER

RETAINER

A08586

Fig. 3 -- Bottom Filter Arrangement

FILTER

RETAINER

FILTER

A08587

Fig. 4 -- Filter Installed for Side Inlet

FIRE, CARBON MONOXIDE POISONING

HAZARD

Failure to follow this warning could result in personal injury,

death or property damage.

Never operate unit without a filter or with the blower access

panel removed. Operating a unit without a filter or with the

blower access door removed could cause damage to the

furnace blower motor. Dust and lint on internal parts of

furnace can cause a loss of efficiency .

WARNING

NOTE: If the filter has an airflow direction arrow, the arrow must

point toward the blower.

To clean or replace filters, proceed as follows:

If filter is installed in filter cabinet adjacent to furnace:

PG9MAB

Ta ble 1 – Furnace Air Filter Table

FURNACE CASING WIDTH

IN (MM)

FILTER QUANTITY AND SIZE *

FILTER TYPE*SIDE RETURN*

IN (MM)

BOTTOM RETURN*

IN (MM)

17---1/2 (445)

(1) 16 x 25 x 3/4

(406 x 635 x 19)

(1) 16 x 25 x 3/4

(406 x 635 x 19)

3/4” (19 mm) thick washable

21 (533 )

(1) 16 x 25 x 3/4

(406 x 635 x 19)

(1) 20 x 25 x 3/4

(508 x 635 x 19)

3/4” (19 mm) thick washable

24---1/2 (610)

(1) 16 x 25 x 3/4

(406 x 635 x 19)

(1) 24 x 25 x 3/4

(610 x 635 x 19)

3/4” (19 mm) thick washable

COLLECTOR BOX

TUBE (PINK)

COLLECTOR BOX

TUBE (GREEN)

INDUCER HOUSING

(MOLDED) DRAIN

TUBE (BEHIND

COLLECTOR BOX

DRAIN TUBE)

COLLECTOR BOX

DRAIN TUBE (BLUE)

FIELD-INSTALLED

FACTORY-SUPPLIED

DRAIN TUBE

COUPLING (LEFT

DRAIN OPTION)

FIELD-INSTALLED

FACTORY-SUPPLIED

DRAIN TUBE

FIELD-INSTALLED

FACTORY-SUPPLIED

⁄

-IN. CPVC STREET

ELBOWS (2) FOR

LEFT DRAIN OPTION

FIELD-INSTALLED

FACTORY-SUPPLIED

DRAIN TUBE

COUPLING (RIGHT

DRAIN OPTION)

CAP

COLLECTOR BOX

DRAIN TUBE (BLUE

& WHITE STRIPED)

PLUG

CONDENSATE

TRAP

A05110

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

(Shown with Blower Access Panel Removed)

1. Turn off electrical supply to furnace.

2. Remove filter cabinet door.

3. Slide filter out of cabinet.

4. If equipped with permanent, washable filter, clean filter by

spraying cold tap water through filter in opposite direction

of airflow. Rinse filter and let dry . Oiling or coating of the

filter is not recommended.

5. If equipped with factory specified disposable media filter,

replace only with a factory specified media filter of the same

size.

6. Slide filter into cabinet.

7. Replace filter cabinet door.

8. Turn on electrical supply to furnace.

If filter is installed in furnace blower compartment:

1. Turn off electrical supply to furnace.

2. Remove main furnace door and blower access panel.

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

NOTE: Filters shown in Fig. 3 and 4 can be in furnace blower

compartment or in filter cabinet, but not in both.

4. Slide filter out of furnace.

5. If equipped with permanent, washable filter(s), clean filter

by spraying cold tap water through filter in opposite direc-

tion of airflow.

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

mended.

7. Slide filter into furnace.

8. Recapture filter retaining wire.

9. Replace blower access panel and main furnace door.

10. Turn on electrical supply to furnace.

Step 2 — Blower Motor and Wheel Maintenance

To ensure long life, economy, and high efficiency, clean

accumulated dirt and grease from blower wheel and motor

annually.

The inducer and blower motors are pre-- lubricated and require no

additional lubrication. These motors can be identified by the

absence of oil ports on each end of the motor.

The following items should be performed by a qualified service

technician.

Clean blower motor and wheel as follows:

1. Turn off electrical supply to furnace.

2. Remove main furnace door and blower access panel.

3. Disconnect wires

All factory wires can be left connected, but field thermostat

connections may need to be disconnected depending on

their length and routing.

4. Remove control box mounting screws, and position control

box, transformer, and door switch assembly to right side of

furnace casing.

5. If condensate trap is located in left-- or right-- hand side of

furnace casing, proceed to item 6. Otherwise remove trap

and tubing as described below (See Fig. 5.):

a. Disconnect field drain connection from condensate trap.

b. Disconnect drain and relief port tubes from condensate

trap.

c. Remove condensate trap from blower shelf.

6. Remove screws securing blower assembly to blower shelf

and slide blower assembly out of furnace. Detach ground

wire and disconnect blower motor harness plugs from

blower motor.

NOTE: Blower wheel is fragile. Use care.

7. Clean blower wheel and motor by using a vacuum with soft

brush attachment. Be careful not to disturb balance weights

(clips) on blower wheel vanes. Do not bend wheel or blades

as balance will be af fected.

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:

PG9MAB

a. Mark blower wheel location on shaft before disassembly

to ensure proper reassembly.

b. Loosen setscrew holding blower wheel on motor shaft.

NOTE: Mark blower mounting arms and blower housing so each

arm is positioned at the same hole location during reassembly.

c. Mark blower wheel orientation and cutoff plate location

to ensure proper reassembly.

d. Remove screws securing cutoff plate and remove cutoff

plate from housing.

e. Remove bolts holding motor mounts to blower housing

and slide motor and mounts out of housing. Disconnect

capacitor and ground wire attached to blower housing

before removing motor. Motor mounts need not be

removed from motor.

f. Remove blower wheel from housing.

UNIT DAMAGE HAZARD

Failure to follow this caution may result in noise or furnace

component failure.

The blower wheel should not be dropped or bent as balance

will be affected.

CAUTION

g. Clean wheel per instructions on degreaser cleaner. Do

not get degreaser in motor.

9. Reassemble motor and blower wheel by reversing items 8b

through 8f. Ensure wheel is positioned for proper rotation.

Be sure to reattach ground wire. Tighten setscrew to 140 to

160 in--lb torque.

NOTE: Be sure to attach ground wire and reconnect blower

harness plugs to blower motor.

10. Reinstall blower assembly in furnace.

11. Reinstall control box, transformer, and door switch as-

sembly on blower shelf.

12. Reinstall condensate trap and tubing if previously removed.

a. Reinstall condensate trap in hole in blower shelf.

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

tubing diagram on main furnace door for proper tube

location.

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

operation.

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

from collector box.

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

ducer housing.

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

collector box.

c. Connect field drain to condensate trap.

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

operation.

13. Reinstall control box, transformer, and door switch as-

sembly on blower shelf.

14. Reconnect wires.

Refer to furnace wiring diagram and connect thermostat

leads if previously disconnected. (See Fig. 21.)

NOTE: Refer to Table one for motor speed lead reconnection if

leads were not identified before disconnection.

UNIT DAMAGE HAZARD

Failure to adjust the heating speed may shorten heat

exchanger life.

Heating speed selection MUST be adjusted to provide

proper temperature rise as specified on the rating plate.

CAUTION

Ta ble 2 – Speed Selection

COLOR SPEED

FACTORY

ATTACHED TO

Black High Cool

Yellow (When Present) Medium High Spare

Blue Medium Low Heat

Red Low Fan

White Common Com

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal

injury or death.

Blower access panel door switch opens 115--v power to

furnace control. No component operation can occur.

Caution must be taken when manually closing this

switch for service purposes.

WARNING

15. Turn on electrical supply. Manually close blower access

panel door switch. Use a piece of tape to hold switch closed.

Check for proper rotation and speed changes between heat-

ing and cooling by jumpering R to G and R to Y/Y2 on

furnace control thermostat terminals. (See Fig. 15.)

16. If furnace is operating properly, release blower access panel

door switch, replace blower access panel, and replace main

furnace door.

MANIFOLD

MOUNTING

SCREWS

MANIFOLD

GAS VALVE

REGULATOR

FITTING

GAS

CONTROL

VALVE

CELL

PANEL

GASKET

A02312

Fig. 6 -- Burner Box Assembly

PG9MAB

Step3—CleaningBurners

The following items should be performed by a qualified service

technician. If the burners develop an accumulation of light dirt or

dust, they may be cleaned by using the following procedure:

1. Turn off gas and electrical supplies to furnace.

2. Remove main furnace door.

3. Remove burner box cover.

4. Using backup wrench, disconnect gas supply pipe from fur-

nace gas control valve.

UNIT DAMAGE HAZARD

Failure to follow this caution may result in furnace

component damage.

Label all wires prior to disconnection when servicing

controls. Wiring errors can cause improper and dangerous

operation.

CAUTION

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

6. Remove burner box pressu re tube from gas valve regulator

fitting.

7. Unplug igniter from harness.

8. Remove igniter leads from slot in manifold grommet.

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

Fig. 6.)

NOTE: Do not remove burner box from cell panel.

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

11. Remove screws attaching burner assembly in burner box.

NOTE: Use care when removing and reinstalling burners not to

strike the hot surface igniter.

IGNIT ER WIRES MUST

BE PLACED IN THIS SLOT

A05074

Fig. 7 -- Igniter Wir e Placement

12. Remove burner assembly from burner box.

NOTE: All burners are attached to burner bracket and can be

removed as one assembly.

13. Clean burners with soft brush and vacuum.

14. Reinstall manifold, orifice, and gas valve assembly in burn-

er box. Ensure manifold seal grommet is installed properly

and burners fit over orifices.

15. Reinsert the igniter wires in the slot in the manifold grom-

met, dressing the wires to ensure there is no tension on the

igniter itself. (See Fig. 7.)

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal

injury or death.

Igniter wires must be securely placed in slot in manifold

grommet or else they could become pinched or severed

and electrically shorted.

WARNING

16. Reconnect wires to gas valve and igniter. Refer to furnace

wiring diagram for proper wire location.

17. Reinstall burner box pressure tube to gas valve regulator fit-

ting.

18. Reinstall gas supply p ipe to furnace gas control valve using

backup wrench on gas valve to prevent rotation and im-

proper orientation.

NOTE: Use propane gas resistant pipe dope to prevent gas leaks.

DO NOT use Teflon tape.

FIRE, EXPLOSION, UNIT DAMAGE HAZARD

Failure to follow this warning could result in personal

injury, death, or property damage.

Gas valve switch MUST be facing forward or tilted

slightly .

WARNING

19. Replace burner box cover.

20. Turn on gas and electrical supplies to furnace.

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal

injury , death or property damage.

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

commercially available soap solution made specifically

for the detection of leaks to check all connections.

WARNING

21. Check for gas leaks.

22. Replace main furnace door.

Step 4 — Cleaning Heat Exchangers

The following items should be performed by a qualified service

technician.

Prim ary Heat Exchangers

If the heat exchangers get an accumulation of light dirt or dust on

the inside, they may be cleaned by the following procedure:

NOTE: If the heat exchangers get a heavy accumulation of soot

and carbon, both the primary and secondary heat exchangers

should be replaced rather than trying to clean them thoroughly due

to their intricate design. A build--up of soot and carbon indicates

that a problem exists which needs to be corrected, such as improper

adjustment of manifold pressure, insufficient or poor quality

combustion air, improper vent termination, incorrect size or

damaged manifold orifice(s), improper gas, or a restricted heat

exchanger (primary or secondary). Action must be taken to correct

the problem.

1. Turn off gas and electrical supplies to furnace.

2. Remove main furnace door.

PG9MAB

UNIT DAMAGE HAZARD

Failure to follow this caution may result in furnace

component damage.

Label all wires prior to disconnection when servicing

controls. Wiring errors can cause improper and hazardous

operation.

CAUTION

3. Disconnect wires or connectors to flame rollout switch, gas

valve, igniter, and flame sensor.

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

ing.

5. Remove the pressure switch tube from intake housing.

6. Remove screws attaching intake housing to burner box, and

rotate intake housing away from burner box for removal.

7. Using backup wrench, disconnect gas supply pipe from fur-

nace gas control valve.

8. Disconnect pressure tubing from gas valve.

9. Remove two screws attaching top filler panel and rotate up-

wards to gain access to screws attaching burner box to cell

panel.

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

6.)

NOTE: Burner box, cover, manifold, gas valve, and burner

assembly should be removed as one assembly.

11. Clean heat exchanger openings with a vacuum and a soft

brush. (See Fig. 8.)

NOTE: After cleaning, inspect the heat exchangers to ensure they

are free of all foreign objects that may restrict flow of combustion

products.

PRIMARY HX

INLET OPENINGS

A96305

Fig. 8 -- Cleaning Inlet Openings of Primary

Heat Exchangers

UNIT MAY NOT OPERATE

Failure to follow this caution may result in improper or

intermittent unit operation.

The ground wire from the gas valve MUST be attached to

the burner box attachment screw.

CAUTION

12. Reverse items 3 through 10 for reassembly.

NOTE: Be sure burner box gasket is installed between burner box

and cell panel. (See Fig. 6.) If gasket is damaged, replace it.

NOTE: Inspect combustion--air intake housing. If foamed gasket

was removed, check for any damage. If gasket is damaged in any

way, it must be repaired. To repair, remove damaged gasket

section, apply sealant releasing agent such as PAM cooking spray

or equivalent (must not contain corn nor canola oil, halogenated

hydrocarbons nor aromatic content, to prevent inadequate seal

from occurring) to burner box and apply a small bead of G.E. RTV

162, G.E. RTV 6702, or Dow-- Corning RTV 738 sealant to edge

of combustion--air intake housing. (See Fig. 9.)

PAM

RTV

A93087

Fig. 9 -- Combustion--Air Intake Housing

Gasket Repair

13. Refer to furnace wiring diagram and reconnect wires to

flame rollout switch, gas valve, igniter, and flame sensor.

14. Reconnect pressure switch tubes to gas valve and intake

housing. Refer to tube routing label on main furnace door

for proper tube location. (See Fig. 10.) Be sure tubes are not

kinked.

15. Turn on gas and electrical supplies to furnace.

16. Check furnace operation through two complete heat operat-

ing cycles. Look through sight glass in burner enclosure to

check burners. Burner flames should be clear blue, almost

transparent. (See Fig. 11.)

17. Check for gas leaks.

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal

injury , death or property damage.

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

commercially available soap solution made specifically

for the detection of leaks to check all connections.

WARNING

18. Replace main furnace door.

Secondary Heat Exchangers

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

exchangers CANNOT be serviced or inspected. A small number of

bottom outlet openings can be inspected by removing the inducer

assembly. See Flushing Collector Box and Drainage System

section for details on removing inducer assembly.

Step 5 — Flush ing Collector B ox and Drainage

System

1. Turn off gas and electrical supplies to furnace.

2. Remove main furnace door.

3. Disconnect inducer motor and pressure switch wires or con-

nectors.

PG9MAB

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

Tube location when used in DOWNFLOW application

Tube location when used on

HORIZONTAL - RIGHT application

PLUG

CAP

COLLECTOR BOX DRAIN TUBE

(BLUE & WHITE STRIPED)

COLLECTOR BOX TUBE

(PINK)

COLLECTOR BOX DRAIN TUBE

(BLUE)

INDUCER HOUSING DRAIN TUBE

(VIOLET)

COLLECTOR BOX TUBE

(PINK)

COLLECTOR BOX DRAIN

TUBE

(BLUE & WHITE STRIPED)

COLLECTOR BOX DRAIN TUBE

(BLUE)

INDUCER HOUSING (MOLDED) DRAIN TUBE

(BEHIND COLLECTOR BOX DRAIN TUBE)

FIELD-INSTALLED

FACTORY-SUPPLIED DRAIN TUBE

COUPLING (LEFT DRAIN OPTION)

FIELD-INSTALLED FACTORY-SUPPLIED

DRAIN TUBE

FIELD-INSTALLED

FACTORY- SUPPLIED 1/2-IN.

CPVC STREET ELBOWS (2)

FOR LEFT DRAIN OPTION

COLLECTOR BOX TUBE

(GREEN)

CONDENSATE TRAP

CAP

Condensate Trap; Factory Installed

in Blower Shelf

CONDENSATE TRAP

COLLECTOR BOX TUBE (GREEN)

Condensate Trap on LEFT

Side Optional

CAP

PLUG

COLLECTOR BOX

DRAIN TUBE (BLUE)

PLUGGED END

COLLECTOR BOX DRAIN TUBE

(BLUE & WHITE STRIPED)

COLLECTOR BOX

TUBE (GREEN)

COLLECTOR BOX

TUBE (PINK)

COLLECTOR BOX

EXTENSION TUBE

CONDENSATE TRAP

INDUCER HOUSING DRAIN TUBE (VIOLET)

COLLECTOR BOX

EXTENSION TUBE

COLLECTOR BOX TUBE

(PINK)

COLLECTOR BOX DRAIN TUBE

(BLUE)

COLLECTOR BOX TUBE

(GREEN)

CONDENSATE TRAP

INDUCER HOUSING DRAIN

TUBE (VIOLET)

COLLECTOR BOX EXTENSION TUBE

COLLECTOR BOX DRAIN

TUBE

(BLUE & WHITE STRIPED)

Condensate Trap on

RIGHT Side

COLLECTOR BOX

EXTENSION DRAIN TUBE

DRAIN TUBE COUPLING

GAS VALVE

DRAIN TUBES ROUTED IN

FRONT OF GAS VALVE

PLUG

CAP

COLLECTOR BOX DRAIN TUBE

(BLUE & WHITE STRIPED)

CONDENSATE TRAP

COLLECTOR BOX

EXTENSION TUBE

COLLECTOR BOX

TUBE (GREEN)

INDUCER HOUSING

DRAIN TUBE

(VIOLET)

COLLECTOR BOX TUBE (PINK)

RELOCATE TUBE BETWEEN BLOWER

SHELF AND INDUCER HOUSING FOR

040,060, AND 080 HEATING INPUT

FURNACES

CAP

PLUG

COLLECTOR BOX DRAIN TUBE

(BLUE)

COLLECTOR BOX EXTENSION TUBE

COLLECTOR BOX TUBE (PINK)

COLLECTOR BOX

TUBE (GREEN)

COLLECTOR BOX DRAIN TUBE

(BLUE AND WHITE STRIPED)

INDUCER HOUSING DRAIN TUBE (VIOLET)

CONDENSATE TRAP

Condensate Trap on

LEFT Side

COLLECTOR BOX

DRAIN TUBE (BLUE)

PLUG

Tube location when used in UPFLOW application

Tube location when used on

HORIZONTAL - LEFT application

CAP

PLUG

COLLECTOR BOX

EXTENSION TUBE

DRAIN TUBE

COUPLING

COLLECTOR BOX EXTENSION DRAIN TUBE

(Blower access panel removed)

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 collector box pressure tube to be relocated between the inducer housing and the blower shelf to

prevent a trap. Refer to the Installation Instructions for further details.

NOTE:

324999-201 REV. C

FIELD-INSTALLED

FACTORY-SUPPLIED

DRAIN TUBE COUPLING

(RIGHT DRAIN OPTION)

BURNER ENCLOSURE

PRESSURE REFERENCE

TUBE ASSEMBLY

BURNER ENCLOSURE

PRESSURE REFERENCE

TUBE ASSEMBLY

BURNER ENCLOSURE PRESSURE

REFERENCE TUBE ASSEMBLY

BURNER ENCLOSURE

PRESSURE REFERENCE

TUBE ASSEMBLY

BURNER ENCLOSURE

PRESSURE REFERENCE

TUBE ASSEMBLY

BURNER ENCLOSURE PRESSURE

REFERENCE TUBE ASSEMBLY

TUBE ROUTING

AUXILIARY "J" BOX RELOCATED HERE

A00308

Fig. 10 -- Furnace Pressure and Drain Tubing Diagram

4. Disconnect pressure switch tubes.

5. Disconnect vent pipe from inducer housing outlet by

loosening coupling clamp on inducer outlet.

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

NOTE: Ensure the drain tube disconnected from the inducer

housing is higher than the collector box opening or water will flow

out of tube.

7. Remove inducer housing assembly by removing 4 bolts at-

taching assembly to cell panel.

8. Flush inside of collector box with water until discharge

from condensate trap is clean and runs freely.

9. Inspect inside area of collector box for any pieces of foreign

materials and remove them if present.

UNIT DAMAGE HAZARD

Failure to follow this caution may result in furnace

component damage.

DO NOT use wire brush or other sharp object to inspect or

dislodge materials in secondary heat exchangers as cutting

of the secondary heat exchanger protective coating may

occur. Flush with water only.

CAUTION

10. Reassemble inducer assembly by reversing items 3 --7.

Tighten the vent coupling clamp screw(s) to 15 in.--lb of

torque.

NOTE: If seal between the inducer housing and the collector box

is damaged in any way, it must be repaired. To repair, apply sealant

releasing agent such as PAM cooking spray or equivalent (must not

contain corn nor canola oil, halogenated hydrocarbons nor

aromatic content, to prevent inadequate seal from occurring) to

inducer housing. (See Fig. 12.) Apply a small bead of G.E. RTV

162, G.E. RTV 6702, or Dow--Corning RTV 738 sealant to groove

in collector box.

11. Refer to furnace wiring diagram and reconnect wires to in-

ducer motor and pressure switches or connectors.

12. Reconnect pressure tubes to pressure switches. See diagram

on main furnace door for proper location of tubes. Be sure

tubes are not kinked. (See Fig. 10.)

13. Turn on gas and electrical supplies to furnace.

14. Check furnace operation through two complete heat operat-

ing cycles. Check area below inducer housing, vent pipe,

and condensate trap to ensure no condensate leaks occur. If

leaks are found, correct the problem.

15. Check for gas leaks.

PG9MAB

FIRE OR EXPLOSION HAZARD

Failure to follow this warning could result in personal

injury , death or property damage.

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

commercially available soap solution made specifically for

the detection of leaks to check all connections.

WARNING

16. Replace main furnace door.

Step 6 — Servicing Hot Surface Igniter

The igniter does NOT require annual inspection. Check igniter

resistance before removal.

1. Turn off gas and electrical supplies to furnace.

BURN HAZARD

Failure to follow this caution may result in personal injury.

Allow igniter to cool before removal. Normal operating

temperatures exceed 2000_F (1093_C).

CAUTION

2. Remove main furnace door.

3. Disconnect igniter wire connection.

4. Check igniter resistance. Igniter resistance is affected by

temperature. Only check resistance when the igniter is at

room temperature.

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

niter leads in connector.

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

5. Remove igniter assembly.

a. Remove burner box cover.

b. Remove igniter wires from slot in manifold grommet.

(See Fig. 7.)

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

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

13.) and carefully withdraw the igniter and bracket as-

sembly through the front of the burner box without

striking the igniter on surrounding parts. Note that the

igniter bracket has a handle that extends to the front of

the burner box to aid in handling. (See Fig. 13.)

d. Inspect igniter for signs of damage or failure.

UNIT DAMAGE HAZARD

Failure to follow this caution may result in premature

failure of the igniter.

The igniter is fragile. DO NOT allow it to hit burner box

parts while removing or replacing it.

CAUTION

e. If replacement is required, replace igniter on igniter

bracket and then install assembly into burner box to

avoid damage to the igniter.

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

through 5c.

7. Reconnect igniter wire connection and insert the igniter

wires in the slot in the manifold grommet, dressing the ig-

niter wires to ensure there is no tension on the igniter itself.

(See Fig.7.)

8. Reinstall burner box cover.

9. Turn on gas and electrical supplies to furnace.

10. Verify igniter operation by initiating control board self--test

feature or by cycling thermostat.

11. Replace main furnace door.

BURNER FLAME

BURNER

MANIFOLD

A89020

Fig. 11 -- Burner Flame

RTV

PAM

A93081

Fig. 12 -- Gasket on Collector Box

PG9MAB

BRACKET

IGNITER

9/16˝

11/16˝

EXTENDED IGNITER

BRACKET HANDLE

IGNITER BRACKET

MOUNTING SCREW

A05075

Fig. 13 -- Igniter Bracket

2-5/32˝

(55 mm)

A04181

Fig. 14 -- Igniter

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal

injury or death.

Igniter wires must be securely placed in slot in manifold

grommet or else they could become pinched or severed and

electrically shorted.

WARNING

Step 7 — Electrical Controls and Wiring

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal

injury or death.

There may be more than one electrical supply to the unit.

Check accessories and cooling unit for additional electrical

supplies.

WARNING

The electrical ground and polarity for 115--v wiring must be

maintained properly. Refer to Fig. 15 for field wiring information

and to Fig. 21 for unit wiring information.

NOTE: If the polarity is not correct or furnace is not properly

grounded, the STATUS LED on the furnace control will flash

rapidly and prevent the furnace from operating. The control system

also requires an earth ground for proper operation of the furnace

control and flame sensor.

The 24--v circuit contains an automotive--type, 3--amp fuse located

on the furnace control. (See Fig. 16.) Any direct shorts of the 24 --v

wiring during installation, service, or maintenance will cause this

fuse to blow. If fuse replacement is required, use ONLY a fuse of

identical size. The furnace control LED will flash status code 24

when fuse needs to be replaced.

With power to the unit disconnected, check all electrical

connections for tightness. Tighten all screws on electrical

connections. If any smoky or burned connections are found,

disassemble the connection, clean all parts, strip wire, and

reassemble properly and securely.

Reconnect electrical supply to unit and observe unit through one

complete operating cycle and check for proper operation.

Step 8 — Checking Heat Tape Operation

(If Applicable)

In applications where the ambient temperature around the furnace

is 32_F(0_C) or lower, freeze protection measures are required. If

this application is where heat tape has been applied, check to

ensure it will operate when low temperatures are present.

NOTE: Heat tape, when used, should be wrapped around the

condensate drain trap and drain line. There is no need to use heat

tape within the furnace casing. Most heat tapes are temperature

activated, and it is not practical to verify the actual heating of the

tape. Check the following:

1. Check for signs of physical damage to heat tape such as

nicks, cuts, abrasions, gnawing by animals, etc.

2. Check for discolored heat tape insulation. If any damage or

discolored insulation is evident, replace heat tape.

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

PG9MAB

115-V FIELD-

SUPPLIED

DISCONNECT

AUXILIARY

J-BOX

24-V

TERMINAL

BLOCK

THREE-WIRE

HEATING-ONLY

FIVE WIRE

NOTE 1

NOTE 2

FIELD-SUPPLIED

DISCONNECT

CONDENSING

UNIT

TWO

WIRE

FURNACE

COM

WCR GY

GND

FIELD 24-V WIRING

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

FACTORY 24-V WIRING

FACTORY 115-V WIRING

208/230- OR

460-V

THREE

PHASE

208/230-V

SINGLE

PHASE

BLOWER DOOR SWITCH

WHT

BLK

WHT

BLK

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

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

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

same type or equivalent wire.

GND

THERMOSTAT

TERMINALS

A02174

Fig. 15 -- Field Wiring

BLW

NUETRAL

STATUS CODE LED

SEC-2 SEC-1

EAC-2 L2

FUSE 3-AMP

0.5 AMP@24VAC

HUM

TEST/TWIN

G Com W Y R

24V

120 180

90 150

BLOWER OFF-DELAY

PLT 1

COOL HEAT

SPARE-1 SPARE-2

EAC-1

1-AMP@

115VAC

PR-1

PL2 1

24-V THERMOSTAT

TERMINALS

3-AMP FUSE

LED OPERATION &

DIAGNOSTIC LIGHT

115-VAC(L2)NEUTRAL

CONNECTIONS

COOL

HEAT

SPARE-1

SPARE-2

BLOWER SPEED

SELECTION TERMINALS

EAC-1 TERMINAL

(115-VAC 1.0 AMP MAX.)

115 VAC (L1) LINE

VOLTAGE CONNECTION

PL2-HOT SURFACE

IGNITER & INDUCER

MOTOR CONNECTOR

PL1-LOW VOLTAGE MAIN

HARNESS CONNECTOR

TRANSFORMER 24-VAC

CONNECTIONS

HUMIDIFIER TERMINAL

(24-VAC 0.5 AMP MAX.)

TWINNING AND/OR

COMPONENT TEST

TERMINAL

BLOWER OFF-DELAY

J2 JUMPER

PLT

A02100

Fig. 16 -- Control Center

PG9MAB

UNIT AND PROPERTY DAMAGE

Failure to follow this caution may result in furnace

component failures or water property damage.

Operating a unit without a filter or with the blower access

door removed could cause damage to the furnace blower

motor . Dust and lint on internal parts of furnace can cause a

loss of efficiency. If this furnace is to be operated in an

unconditioned space where the ambient temperatures may

be 32_F(0_C)or lower, freeze protection measures must be

taken. See CONDENSATE DRAIN PROTECTION section

of Installation, Start-- up, and Operating Instructions. (See

Fig. 17.)

CAUTION

Step 9 — Winterizing

UNIT DAMAGE HAZARD

Failure to follow this caution may result in furnace

component damage.

Freezing condensate left in the furnace may damage the

furnace.

CAUTION

If the furnace will be off for an extended period of time in a

structure where the temperature will drop to 32_F(0_C)or below,

winterize as follows:

1. Turn off electrical supply to furnace.

2. Remove main furnace door.

3. Disconnect upper inducer housing drain connection cap

from inducer housing. (See Fig. 18.)

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

upper inducer housing drain connection.

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

pylene glycol (RV, swimming pool antifreeze, or equival-

ent) into funnel/tube until it is visible at point where con-

densate enters open drain. (See Fig. 19.)

UNIT DAMAGE HAZARD

Failure to follow this caution may result in unit component

damage.

Do not use ethylene glycol (Prestone II antifreeze/coolant or

equivalent automotive type).

CAUTION

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

7. Replace main furnace door.

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

nace.

A07911

Fig. 17 -- Freeze Protection

WIRING DIAGRAMS

See Fig. 21 for wiring diagram.

TROUBLESHOOTING

Use the troubleshooting guide, the status code LED on the furnace

control and the component test to isolate furnace operation

problems.

Status Codes

For an explanation of status codes, refer to service label located on

back of main furnace door or Fig. 20.

NOTE: Removing the blower access door will open the blower

access door switch and terminate 115--v power to the control.

To read current status code, remove main furnace door. The status

code LED can be viewed through the sight glass on the blower

access door.

NOTE: NO thermostat signals may be present at control and all

blower off delays must be completed to view previous codes.

UNIT DAMAGE HAZARD

Failure to follow this caution may result in damage to unit

components.

Make sure limit switch or flame rollout switch wire does

not contact any metal component, such as gas valve. If wire

is shorted, 3--amp fuse on furnace control board will open

and unit will not operate.

CAUTION

To retrieve previous codes, remove one of the red main limit or

flame rollout switch wires for 1 to 4 sec until the LED light goes

out, then reconnect it. (Do not leave red wire disconnected for

longer periods of time as the control will assume an

overtemperature condition exists and will respond with blower

operation.) This places the control in the status recall mode and

displays the last code stored in memory.

Reco rd the code. After the last code is displayed the control will

perform the component test, and then return to normal standby

mode.

PG9MAB

A99118

Fig. 18 -- Inducer Housing Drain Tube

Component Test

NOTE: The furnace control component test allows all

components to run for a short time; except the gas valve and

humidifier terminal HUM are not energized for safety reasons. The

EAC--1 terminal is energized when the blower is energized. This

feature helps diagnose a system problem in case of a component

failure. The component test feature will not operate if any

thermostat signal is present at the control and not until all time

delays are completed.

NOTE: Record the status code BEFORE opening the blower

access door and before shutting of f 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:

ELECTRICAL SHOCK AND UNIT MAY NOT

OPERATE HAZARD

Failure to follow this warning could result in electrical shock,

personal injury, or death.

Blower access panel door switch opens 115-- v power to

control board. No component operation can occur. Caution

must be taken when manually closing this switch for service

purposes.

WARNING

1. Remove blower access door.

2. Disconnect the thermostat R lead from furnace control

board.

3. Manually close blower door switch.

4. For approximately 2 sec, short (jumper) the COM-- 24v ter-

minal on control to the TEST/TWIN 3/16--in. quick--con-

nect terminal on control until LED turns off. Remove jump-

er from terminals. (See Fig. 16.)

NOTE: If TEST/TWIN and COM--24v terminals are jumpered

longer than 2 sec, LED will flash rapidly and ignore component

test request.

A99119

Fig. 19 -- Funnel in Drain Tube and Antifreeze

Running Through Trap

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

a. LED will display status code 11 four times.

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

component test sequence.

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

sec, then of f.

d. Blower motor operates o n HEAT speed for 10 sec.

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

f. Inducer motor stops.

5. Reconnect R lead to furnace contro l board, remove tape

from blower door switch, and reinstall blower door.

6. Operate furnace per instruction on outer door.

7. Verify furnace shut down by lowering thermostat setting be-

low room temperature.

8. Verify that furnace restarts by raising thermostat setting

above room temperature.

Use the Component Test to check furnace components for proper

operation. To initiate the component self--test sequence, shut off the

room thermostat or disconnect the “R” thermostat lead. Briefly

(approximately 2 sec) short the TWIN/TEST terminal to the COM

24V terminal. The status LED will turn off. The test sequence will

be as follows:

1. LED flashes last status code, or code 11, 4 times. Record

this status code for further troubleshooting.

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

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

energized.

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

turns off.

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

then turns off.

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

then turns off.

7. Inducer turns off.

8. The gas valve and humidifier terminal HUM are not ener-

gized for safety reasons.

PG9MAB

SERVICE

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.

CONTINUOUS OFF - Check for 115VAC at L1 & L2, & 24VAC at SEC-1 & SEC-2.

CONTINUOUS ON - Control has 24VAC power.

RAPID FLASHING - Line voltage (115VAC) polarity reversed. If twinned,

refer to twinning kit instructions.

LED CODE

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.

STATUS

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

hours. On RED LED boards stored status codes can also be erased when power

(115 VAC or 24 VAC) to control is interrupted.

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

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

during blower on-delay.

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

open longer than 3 minutes.

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

14 IGNITION LOCKOUT - Control will auto-reset after three hours. Refer to #34.

21 GAS HEATING LOCKOUT - Control will NOT auto reset.

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

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

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

- Leaky gas valve - Stuck-open gas valve

23 PRESSURE SWITCH DID NOT OPEN Check for:

- Obstructed pressure tubing. - Pressure switch stuck closed.

24 SECONDARY VOLTAGE FUSE IS OPEN Check for:

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

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

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

- Excessive wind - Proper vent sizing - Defective inducer motor

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

- Inadequate combustion air supply - Restricted vent

- Disconnected or obstructed pressure tubing

- Low inlet gas pressure (if LGPS used)

If it opens during blower on-delay period, blower will come on for the selected

blower off-delay.

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

run for 4 minutes or until open switch remakes whichever is longer. If open

longer than 3 minutes, code changes to lockout #13. If open less than 3 minutes

status code #33 continues to flash until blower shuts off. Flame rollout switch

requires manual reset. Check for: - Restricted vent

- Proper vent sizing - Loose blower wheel - Excessive wind

- Dirty filter or restricted duct system.

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

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

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

#14 occurs. If flame signal lost during blower on-delay period, blower will come

on for the selected blower off-delay. Check for: - Control ground continuity

- Flame sensor must not be grounded

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

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

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

- Defective Hot Surface Ignitor

- Low inlet gas pressure

- Inadequate flame carryover or rough ignition

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

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

- Gas valve relay stuck open - Flame sense circuit failure

- Software check error

Reset power to clear lockout. Replace control if status code repeats.

If status code recall is needed, briefly remove then reconnect one main limit wire to display

stored status code. On RED LED boards do not remove power or blower door before initiat-

ing status code recall. After one status code recall is completed component test will occur.

COMPONENT TEST

327884-101 REV. B

A02270

Fig. 20 -- Service Label

PG9MAB

PCB

TRAN

FRS

NOTE #11

PRS

(WHEN USED)

LGPS

FUSED OR CIRCUIT BREAKER

DISCONNECT SWITCH (WHEN REQ’D)

NOTE #2

BLWR

TO 115VAC FIELD DISCONNECT

NOTE #2

EQUIPMENT GROUND

SPARE-1

HEAT

COOL

HSIR

EAC-1

START

MED HI

MED LO

BLWM

SCHEMATIC DIAGRAM

(NATURAL GAS & PROPANE)

HSI

PL3

PL2

115VAC

PR1

TRAN

24VAC

IDR

TEST/TWIN

F U 1

NOTE #6

IDM

AUX

CAP - 2

CAP-1

FRS

LGPS

(WHEN USED)

NOTE #11

PRS

FSE

CPU

PCB

SEC-1

GVR-1

NOTES:

328150-101 REV. A

PL4

NEUTRAL

ILK

FU2

ILK

GND

RED

BLU

ORN

WHT

RED

ORN

RED

GRN/YEL

YEL

BLU

RED

WHT

BLK

LED 1

12345678910

BLOWER OFF DELAY

JUMPER SELECT

YEL

START

BLK

WHT

BRN

IDM

BRN

CAP -2

AUX

HSI

WHT

BLK

WHT

WHT (COM)

BLK

WHT

PL2

WHT

BLK

BLWM

CAP -1

SPARE 1

SPARE 2

EAC-1

PR1

SEC-2

SEC-1

EAC-2

SEC-2

PL1

PL3

PL4

BRN

RED (LO)

WHT

(COM)

YEL

BLU

(MED LO)

COM

HUM

(MED HI)

HI/LO

WHT

PL1

GRN/YEL

GND

NOTE #3

GRN/YEL

FSE

NOTE #10

WHT

HUM

TEST/TWIN

24V

FU1

180

150

120

NOTE #6

EAC-2

NEUTRAL

NOTE #8

BLW

BHT/CLR BLWR

COOL

HEAT

BLK (HI)

BHT/CLR BLOWER MOTOR SPEED CHANGE RELAY, SPDT

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

BLWM BLOWER MOTOR, PERMANENT-SPLIT-CAPACITOR

CAP 1,2 CAPACITOR

CPU MICROPROCESSOR AND CIRCUITRY

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

EAC-2 ELECTRONIC AIR CLEANER CONNECTION (COMMON)

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

FSE FLAME-PROVING ELECTRODE

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

FU 2 FUSE OR CIRCUIT BREAKER CURRENT INTERRUPT DEVICE

(FIELD INSTALLED & SUPPLIED)

GND EQUIPMENT GROUND

GV GAS VALVE-REDUNDANT

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

HSI HOT SURFACE IGNITER (115 VAC)

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

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

IDM INDUCED DRAFT MOTOR, PSC

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

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

J1 BLOWER - OFF DELAY JUMPER SELECTOR

J2 COOLING - OFF DELAY JUMPER

JB JUNCTION BOX

LED LIGHT-EMITTING DIODE FOR STATUS CODES - RED

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

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

OL AUTO-RESET INTERNAL MOTOR OVERLOAD

TEMPERATURE SWITCH (N.C.)

PCB PRINTED CIRCUIT BOARD CONTROL

PL1 11-CIRCUIT PCB CONNECTOR

PL2 2-CIRCUIT CONNECTOR

PL3 2-CIRCUIT HSI, CONNECTOR

PL4 3-CIRCUIT IDM EXTENSION CONNECTOR

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

TEST/TWIN COMPONENT TEST & TWIN TERMINAL

TRAN TRANSFORMER-115VAC/24VAC

JUNCTION

UNMARKED TERMINAL

PCB CONTROL TERMINAL

FACTORY WIRING (115VAC)

FACTORY WIRING (24VAC)

FIELD WIRING (115VAC)

FIELD WIRING (24VAC)

CONDUCTOR ON CONTROL PCB

FIELD WIRING SCREW TERMINAL

FIELD EARTH GROUND

EQUIPMENT GROUND

FIELD SPLICE

PLUG RECEPTACLE

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

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

3. This wire must be connected to furnace sheet metal for control to prove flame.

4. Symbols are electrical representation only.

5. Solid lines inside PCB are printed circuit board conductors and are not included in legend.

6. Replace only with a 3 amp fuse.

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

8. Neutral connections are interchangeable within the NEUTRAL connector block.

9. Blower motor speed selections are for average conditions, see installation instructions for details on

optimum speed selection.

10. YELLOW lead not on all motors.

11. Factory connected when LGPS is not used.

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

auto-reset after three hours.

13. Blower-on delay: gas heating 60 seconds, cooling or heat pump 2 seconds.

14. Blower-off delay: gas heating selections are 90, 120, 150 or 180 seconds, cooling or heat pump

90 seconds or 5 seconds when J2 is cut.

NOTE #10

PRINTED CIRCIUT BOARD

NOTE #5

SPARE-2

24V

A02271

Fig. 21 -- Wiring Diagram

PG9MAB

Is LED status light on?

Is LED status light blinking rapidly without a

pause?

Is LED status light blinking ON/OFF slowly

with a combination of short and long flashes?

Determine status code.

The status code is a

2 digit number with the first digit determined

by the number of shor

t flashes

and the second

digit by the number of long flashes?

Go to section below for the status code that

was flashed.

Is there 115V at L1 and L2?

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

Replace furnace control.

Check for correct line voltage polarity and ground-

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

voltage (24V) transformer phasing.

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

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

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

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

the

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

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

there was no pre

vious code.

After the control repeats the code 4 times, the

control will go through

a brief component test sequence.

The inducer will start

and r

un for the entire component test.

The HSI, b

lower motor F

AN speed

(AMBER LED boards only) HEA

T speed, and COOL speed will run f

or 10 – 15

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

Was there a previous status code

other than #11?

Is door switch closed?

Is there 115V going to switch?

Replace door s

witch.

Replace transformer.

Does the control

respond to

W, Y1 (if present),

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

un system

through

heating

cooling

cycle

to chec

k operation.

Status codes are erased

after 72 hours

On RED LED boards stored

status codes can also be erased whene

ver

(115V or 24V) is interr

upted.

Replace furnace control.

Close door switch and go back to START.

Is circuit breaker closed?

Check for continuity in wire from circuit breaker

to furnace.

Close circuit breaker and go back to START.

Check room ther

mostat or

interconnecting cab

Is 24V present at

1 (if present), Y/Y2 or

G thermostat terminals on

the

furnace

control?

Disconnect all the thermostat wires from the

fur

nace control.

Does the prob

lem repeat when using

a jumper wire?

The thermostat is not compatible with the

fur

nace

control.

Either i

nstall a

ballast resistor

connect the Com24V ther

mostat terminal to

the thermostat, or replace the thermostat.

YES

START

TROUBLESHOOTING GUIDE

A05107

PG9MAB

NO PREVIOUS CODE – Stored codes

are erased after 72 hours. On RED LED

boards stored status codes can also be

erased whenever power (115V or 24V)

is interr

upted. Run system through a

heating or cooling cycle to

check system.

12 BLO

WER ON AFTER PO

WER UP –

(115V OR 24V) – Normal operation.

er r

uns for 90 seconds, if unit is

powered up during a call for heat (R-W

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

blower on-delay period.

13 LIMIT CIRCUIT LOCKOUT – Lockout

occurs if the limit or flame rollout switch is

open longer than 3 minutes. Control will

auto-r

eset after 3 hours.

See code 33

14 IGNITION LOCKOUT – System failed to

ignite gas and prove flame in 4

attempts.

Control will auto-reset after 3 hours.

See status code 34.

21 GAS HEATING LOCKOUT – Tur

n off

power and wait 5 minutes to retry.

Chec

k for:

- Stuck closed gas valve relay

on control.

- Miswire or short to gas valve wire.

22 ABNORMAL FLAME-PRO

VING SIGNAL

Flame is proved while gas valve is de-

energiz

ed.

Inducer will run until fault is

cleared. Chec

k for:

- Stuck open or leaky gas valve.

23 PRESSURE SWITCH DID NOT OPEN

Check for:

- Obstructed pressure tube.

- Pressure switch stuck closed.

SECONDARY VOLTAGE FUSE IS OPEN

Check for:

-Shor

t circuit in secondary

ltage (24V)

wiring including thermostat leads.

isconnect thermostat leads to isolate

short circuit.

31 PRESSURE SWITCH DID 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:

- Proper vent sizing.

- Low inducer voltage (115V).

- Low inlet

gas pressure

(if LGPS used).

- Inadequate comb

ustion air supply.

-D

isconnected or obstr

ucted pressure

tubing.

-D

efective inducer motor.

-D

efective pressure switch.

- Excessive wind.

-R

estr

icted vent.

33 LIMIT CIRCUIT FAU

LT – Indicates the

limit or flame rollout switch

open.

Blower

will run for 4 minutes or until open sw

itc

remakes whiche

ver is longer. If open

longer than 3 minutes, code changes to

lockout #13. If open less than 3 min.

status code #33 continues to flash until

blower shuts off. Flame rollout switch

requires manual reset. Check for:

- Dirty filter or restricted duct system.

- Loose b

lower wheel.

- Defective switch or connections.

-D

efectiv

e blower motor or capacitor.

Inadequate combustion air supply

(flame rollout s

witch open).

-R

estricted vent.

- Proper vent sizing.

- Excessive wind.

- Blower motor on incorrect speed tap.

- Input rate to fur

nace set too high.

34 I

GNITION PROVING FAILURE – If

flame

is not sensed during the trial f

or ignition

per

iod,

the control will repeat the ignition

sequence 3 more times before lo

out

#14 occurs. If flame signal is lost during

the blower on-delay period, blower wil

come on for the selected blower off-delay.

Check the following items first before

proceeding to the next step.

- Gas valve turned off.

- Manual shut-off valve.

-G

reen/Yellow

wire

MUST be connected

to furnace sheet metal.

- Flame sensor must not be grounded.

To determine whether the problem is in

the gas valve,

igniter, or flame sensor the

system can be operated in the component

test mode to chec

k the igniter. First

remove the R thermostat connection from

the control and initiate the component

test sequence. Does the igniter glow

orange/white by the end of the 15 second

warm-up period?

Unplug igniter harness from control and initiate

another component test sequence. Check

for 115V between pin 1 and NEUTRAL-L2 on

the control. Was 115V present for the 15

second per

iod?

Reconnect the R thermostat lead and set

ther

mostat to call for heat. Connect voltmeter

across gas va

lve

connections. Does gas valve

receiv

e 24V?

Does gas valv

e open and allow gas to flow?

Do the main burners ignite?

Do the main b

urners stay on?

Repeat call f

or heat and check flame sensor

current dur

ing trial for ignition period. Is the

DC microamps bel

ow 0.5?

Is current near typical value?

Will main b

urners ignite and stay on?

Fix

ed.

Clean flame sensor with fine steel wool and

recheck current. Nominal current is 4.0 to 6.0

microamps.

45 CONTROL CIRCUITRY LOCKOUT

Auto-reset after 1 hour lockout due to:

- Flame circuit failure.

- Gas valve relay stuck open.

- Software check error.

Reset power to clear lockout. Replace

control if code repeats.

Replace furnace control.

Check for continuity in the harness and

igniter.

Replace defective component.

Check connections. If OK, replace control.

Check that all gas valves are turned on.

Replace v

ve.

Check for:

Inadequate flame carr

yov

er or rough

ignition.

- Low inlet gas pressure.

- Proper firing rate.

Allow blow

er to come on and repeat test to

check for intermittent operation.

Chec

k connections and retry. If current is

near typical

value (4.0-6.0 nominal) and

burners will not stay on, replace control.

Replace electrode.

Replace furnace control.

YES

A05096

PG9MAB

SERVICE TRAINING

Packaged Service Training programs are an excellent way to increase your

knowledge of the equipment discussed in this manual, including:

• Unit Familiarization • Maintenance

• Installation Overview • Operating Sequence

A large selection of product, theory, and skills programs is available, using popular

video-based formats and materials. All include video and/or slides, plus companion

book.

Classroom Service Training plus "hands-on" the products in our labs can mean

increased confidence that really pays dividends in faster troubleshooting, fewer

callbacks. Course descriptions and schedules are in our catalog.

CALL FOR FREE CATALOG 1-800-644-5544

[ ] Packaged Service Training [ ] Classroom Service Training

A94328

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

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

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

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

PG9MAB

Payne PG9MAB Service And Maintenance Instructions

Brand: Payne

Model: PG9MAB

Type: Service And Maintenance Instructions

This manual is also suitable for

PG9MAB Series A

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Payne PG9MAB Service And Maintenance Instructions

This manual is also suitable for

Payne PG9MAB Service And Maintenance Instructions

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