WARNING WARNING WARNING

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					     PG9MAB                                                                                                                       Deluxe 4---Way
                                                                                                                       Multipoise Fixed Capacity
                                                                                                                       Condensing Gas Furnace




                                      Service and Maintenance Instructions
                                                        -120, Series B
                                           For Sizes 040-

NOTE: Read the entire instruction manual before starting the                                                SAFETY CONSIDERATIONS
installation.
                                                                                               Recognize safety information. This is the safety-  -alert symbol      .
                                                                                               When you see this symbol on the furnace and in instructions or
                     TABLE OF CONTENTS                                                         manuals, be alert to the potential for personal injury.
                                                                                   PAGE        Understand the signal words DANGER, WARNING, and
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 1                      CAUTION. These words are used with the safety-          -alert symbol.
                                                                                               DANGER identifies the most serious hazards which will result in
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2    severe personal injury or death. WARNING signifies a hazard
ELECTROSTATIC DISCHARGE (ESD) PRECAUTIONS . . . 2                                              which could result in personal injury or death. CAUTION is used
CARE AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . 3                       to identify unsafe practices which may result in minor personal
                                                                                               injury or product and property damage. NOTE is used to highlight
  Cleaning and/or Replacing Air Filter . . . . . . . . . . . . . . . . . . . . 3               suggestions which will result in enhanced installation, reliability, or
  Blower Motor and Wheel Maintenance . . . . . . . . . . . . . . . . . . 4                     operation.
  Cleaning Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
  Cleaning Heat Exchangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
    Primary Heat Exchangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
                                                                                                             !       WARNING
    Secondary Heat Exchangers . . . . . . . . . . . . . . . . . . . . . . . . . . 7                ELECTRICAL SHOCK, FIRE, OR EXPLOSION
                                                                                                   HAZARD
  Flushing Collector Box and Drainage System . . . . . . . . . . . . . 7
                                                                                                   Failure to follow this warning could result in possible
  Servicing Hot Surface Igniter . . . . . . . . . . . . . . . . . . . . . . . . . . 9
                                                                                                   damage to this equipment, personal injury, or death.
  Electrical Controls and Wiring . . . . . . . . . . . . . . . . . . . . . . . . 10
                                                                                                   The ability to properly perform maintenance on this
  Checking Heat Tape Operation (If Applicable) . . . . . . . . . . . 10                            equipment requires certain expertise, mechanical skills,
  Winterizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12       tools, and equipment. If you do not possess these, do not
                                                                                                   attempt to perform any maintenance on this equipment
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12                  other than those procedures recommended in the User’s
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12                     Manual.
  Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
  Component Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
                                                                                                             !       WARNING
                                                                                                   FIRE OR EXPLOSION HAZARD
                 !          WARNING                                                                Failure to follow this warning could property damage,
                                                                                                   personal injury, or death.
  ELECTRICAL                 SHOCK,          FIRE,        OR       EXPLOSION                       Never store anything on, near, or in contact with the furnace,
  HAZARD                                                                                           such as:
  Failure to follow safety warnings exactly could result in                                        1. Spray or aerosol cans, rags, brooms, dust mops, vacuum
  dangerous operation, personal injury, death, or property                                         cleaners, or other cleaning tools.
  damage.                                                                                          2. Soap powders, bleaches, waxes or other cleaning
                                                                                                   compounds, plastic or plastic containers, gasoline, kerosene,
   -
   - Before servicing, disconnect all electrical power to furnace.                                 cigarette lighter fluid, dry cleaning fluids, or other volatile
   -When servicing controls, label all wires prior to
   -                                                                                               fluids.
     disconnecting. Reconnect wires correctly.                                                     3. Paint thinners and other painting compounds, paper bags,
   -
   - Verify proper operation after servicing.                                                      or other paper products.




                                                                                               1
                                                                                             !        CAUTION
                                                                                  UNIT DAMAGE HAZARD
                                                                                  Failure to follow this caution may result in damage to
                                                                                  furnace.
                                                                                  Label all wires prior to disconnection when servicing
                                                                                  controls. Wiring errors can cause improper and dangerous
                                                                                  operation.


                                                                                                        GENERAL
                                                                                                                               -pipe) or non-
                                                                              This furnace can be installed as a direct vent (2-            -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
PG9MAB




                                                                              the combustion and controls section of the furnace, and
                                                                              conditioned air is discharged upward. Since this furnace can be
                                                                              installed in any of the 4 positions shown in Fig. 2, you may need to
                                                                              revise your orientation to component location accordingly.
                                                                                                              AIRFLOW




                                                                                                            UPFLOW



                                                                     A05086
                            -
                     Fig. 1 - Furnace in Upflow Orientation
                                                                                        HORIZONTAL                            HORIZONTAL
                                                                                           LEFT                                 RIGHT
                                                                                                           DOWNFLOW
                                                                              AIRFLOW
                                     ama
                                                                                                                                       AIRFLOW




                                ISO 9001:2000                                                                 AIRFLOW
                                                                                                                                             A93041
                                                       CERTIFIED
                                                                                                        -
                                                                                                 Fig. 2 - Multipoise Orientation


                                 REGISTERED
                                                                                   ELECTROSTATIC DISCHARGE (ESD)
                                                                                           PRECAUTIONS

                                                                                             !        CAUTION
                                                                                  UNIT DAMAGE HAZARD
         Installing and servicing heating equipment can be hazardous due to       Failure to follow this caution may damage furnace
         gas and electrical components. Only trained and qualified                components.
         service agency personnel should install, repair, or service
         heating equipment. Untrained personnel can perform basic                 Electrostatic discharge can affect electronic components.
         maintenance functions described in User’s Information                    Take precautions during furnace installation and servicing
         Manual such as cleaning and replacing air filters. All other             to protect the furnace electronic control. Precautions will
         operations must be performed by trained service personnel. When          prevent electrostatic discharges from personnel and hand
                                                                                  tools which are held during the procedure. These
         working on heating equipment, observe precautions in the
                                                                                  precautions will help to avoid exposing the control to
         literature, on tags, and on labels attached to or shipped with the
                                                                                  electrostatic discharge by putting the furnace, the control,
         unit and other safety precautions that may apply.                        and the person at the same electrostatic potential.
         Follow all safety codes including the National Fuel Gas Code
         (NFGC) NFPA 54-      -2006/ANSI Z223.1-   -2006 in the USA, CSA
                  -05
         B149.1- National Standard of Canada, Natural Gas and Propane              1. Disconnect all power to the furnace. DO NOT TOUCH
         Installation Codes (NSCNGPIC) in Canada, and the Installation                THE CONTROL OR ANY WIRE CONNECTED TO THE
         Standards, Warm Air Heating and Air Conditioning Systems                     CONTROL PRIOR TO DISCHARGING YOUR BODY’S
         (NFPA 90B) ANSI/NFPA 90B. Wear safety glasses and work                       ELECTROSTATIC CHARGE TO GROUND.
         gloves. Have a fire extinguisher available during start-  -up and
         adjustment procedures and service calls.                                  2. Firmly touch a clean, unpainted, metal surface of the fur-
                                                                                      nace chassis which is close to the control. Tools held in a

                                                                              2
         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.).
                                                                                                                              FILTER
    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-




                                                                                                                                                  PG9MAB
                                                                                                                  FILTER
         trol or yourself into contact with the furnace. Put all used                                FILTER       RETAINER
         AND new controls into containers before touching un-                                        SUPPORT
         grounded objects.                                                                                                               A08586
    7.   An ESD service kit (available from commercial sources)                                   -
                                                                                           Fig. 3 - Bottom Filter Arrangement
         may also be used to prevent ESD damage.
             CARE AND MAINTENANCE
                                                                                            FILTER
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.                                                                                                             FILTER
                                                                                                                                   RETAINER
              !        WARNING
  ELECTRICAL SHOCK HAZARD
  Failure to follow this warning could result in personal injury
  or death.
  Turn off the gas and electrical supplies to the unit before
  performing any maintenance or service. Follow the operating
  instructions on the label attached to the furnace.


The minimum maintenance that should be performed on this                                                                                 A08587
equipment is as follows:                                                                       -
                                                                                        Fig. 4 - Filter Installed for Side Inlet
    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.
                                                                                       !        WARNING
    4. Check for proper condensate drainage. Clean as necessary.             FIRE, CARBON MONOXIDE POISONING
    5. Check for blockages in combustion-    -air and vent pipes an-         HAZARD
       nually.                                                               Failure to follow this warning could result in personal injury,
    6. Check burners for cleanliness annually.                               death or property damage.
                                                                             Never operate unit without a filter or with the blower access
                !       CAUTION                                              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
  CUT HAZARD                                                                 furnace can cause a loss of efficiency.
  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                   NOTE: If the filter has an airflow direction arrow, the arrow must
  removing parts.                                                        point toward the blower.
                                                                         To clean or replace filters, proceed as follows:
                                                                         If filter is installed in filter cabinet adjacent to furnace:
Step 1 — Cleaning and/or Replacing Air Filter
The air filter arrangement may vary depending on the application
or orientation. See Table 1 for filter size and type.




                                                                         3
                                                                Table 1 – Furnace Air Filter Table
                                                               FILTER QUANTITY AND SIZE *
          FURNACE CASING WIDTH
                                                     SIDE RETURN*                BOTTOM RETURN*                               FILTER TYPE*
                 IN (MM)
                                                         IN (MM)                       IN (MM)
                                                     (1) 16 x 25 x 3/4             (1) 16 x 25 x 3/4
                  17--- 1/2 (445)                                                                                      3/4” (19 mm) thick washable
                                                     (406 x 635 x 19)               (406 x 635 x 19)
                                                     (1) 16 x 25 x 3/4             (1) 20 x 25 x 3/4
                     21 (533 )                                                                                         3/4” (19 mm) thick washable
                                                     (406 x 635 x 19)               (508 x 635 x 19)
                                                     (1) 16 x 25 x 3/4             (1) 24 x 25 x 3/4
                  24--- 1/2 (610)                                                                                      3/4” (19 mm) thick washable
                                                     (406 x 635 x 19)               (610 x 635 x 19)

                                                                                       1. Turn off electrical supply to furnace.
                                                                                       2. Remove main furnace door and blower access panel.
                                                                                       3. Release filter retainer wire. (See Fig. 3 or 4.)
                                                                                    NOTE: Filters shown in Fig. 3 and 4 can be in furnace blower
                                                                                    compartment or in filter cabinet, but not in both.
PG9MAB




                        PLUG
                                                                                       4. Slide filter out of furnace.
                         CAP
                                                                                       5. If equipped with permanent, washable filter(s), clean filter
            COLLECTOR BOX                                                                 by spraying cold tap water through filter in opposite direc-
           DRAIN TUBE (BLUE
           & WHITE STRIPED)                                                               tion of airflow.
                                                                                       6. Rinse filter and let dry. Oiling or coating filter is not recom-
            COLLECTOR BOX
                TUBE (PINK)                                                               mended.
                                                                                       7. Slide filter into furnace.
                                                                                       8. Recapture filter retaining wire.
            COLLECTOR BOX
              TUBE (GREEN)
                                                                                       9. Replace blower access panel and main furnace door.
                                                                                      10. Turn on electrical supply to furnace.
           INDUCER HOUSING                                                          Step 2 — Blower Motor and Wheel Maintenance
             (MOLDED) DRAIN
               TUBE (BEHIND
                                                                                    To ensure long life, economy, and high efficiency, clean
             COLLECTOR BOX                                                          accumulated dirt and grease from blower wheel and motor
                DRAIN TUBE)                                                         annually.
            COLLECTOR BOX                                                           The inducer and blower motors are pre-    -lubricated and require no
          DRAIN TUBE (BLUE)                                 CONDENSATE              additional lubrication. These motors can be identified by the
                                                            TRAP                    absence of oil ports on each end of the motor.
                                                                                    The following items should be performed by a qualified service
                                                                                    technician.
            FIELD-INSTALLED
          FACTORY-SUPPLIED                                                          Clean blower motor and wheel as follows:
                 DRAIN TUBE
            COUPLING (LEFT
                                                                                        1. Turn off electrical supply to furnace.
              DRAIN OPTION)                                                             2. Remove main furnace door and blower access panel.
                                                                                        3. Disconnect wires
           FIELD-INSTALLED                                                                 All factory wires can be left connected, but field thermostat
         FACTORY-SUPPLIED
                DRAIN TUBE
                                                                                           connections may need to be disconnected depending on
                                                                                           their length and routing.
                       FIELD-INSTALLED           FIELD-INSTALLED
                   FACTORY-SUPPLIED            FACTORY-SUPPLIED                         4. Remove control box mounting screws, and position control
                   1⁄2-IN. CPVC STREET                DRAIN TUBE                           box, transformer, and door switch assembly to right side of
                        ELBOWS (2) FOR          COUPLING (RIGHT                            furnace casing.
                   LEFT DRAIN OPTION               DRAIN OPTION)
                                                                                                                                 -
                                                                                        5. If condensate trap is located in left- or right--hand side of
                                                                         A05110
                                                                                           furnace casing, proceed to item 6. Otherwise remove trap
                    -        -Shipped Upflow Tube Configuration
             Fig. 5 - Factory-
                                                                                           and tubing as described below (See Fig. 5.):
                  (Shown with Blower Access Panel Removed)
                                                                                           a. Disconnect field drain connection from condensate trap.
             1.   Turn off electrical supply to furnace.                                   b. Disconnect drain and relief port tubes from condensate
                                                                                               trap.
             2.   Remove filter cabinet door.
                                                                                           c. Remove condensate trap from blower shelf.
             3.   Slide filter out of cabinet.
                                                                                        6. Remove screws securing blower assembly to blower shelf
             4.   If equipped with permanent, washable filter, clean filter by
                                                                                           and slide blower assembly out of furnace. Detach ground
                  spraying cold tap water through filter in opposite direction
                                                                                           wire and disconnect blower motor harness plugs from
                  of airflow. Rinse filter and let dry. Oiling or coating of the
                                                                                           blower motor.
                  filter is not recommended.
                                                                                    NOTE: Blower wheel is fragile. Use care.
               5. If equipped with factory specified disposable media filter,
                  replace only with a factory specified media filter of the same        7. Clean blower wheel and motor by using a vacuum with soft
                  size.                                                                    brush attachment. Be careful not to disturb balance weights
               6. Slide filter into cabinet.                                               (clips) on blower wheel vanes. Do not bend wheel or blades
                                                                                           as balance will be affected.
               7. Replace filter cabinet door.
                                                                                        8. If greasy residue is present on blower wheel, remove wheel
               8. Turn on electrical supply to furnace.                                    from the blower housing and wash it with an appropriate
         If filter is installed in furnace blower compartment:                             degreaser. To remove wheel:

                                                                                    4
       a. Mark blower wheel location on shaft before disassembly
           to ensure proper reassembly.                                              !       CAUTION
       b. Loosen setscrew holding blower wheel on motor shaft.
NOTE: Mark blower mounting arms and blower housing so each                UNIT DAMAGE HAZARD
arm is positioned at the same hole location during reassembly.            Failure to adjust the heating speed may shorten heat
       c. Mark blower wheel orientation and cutoff plate location         exchanger life.
           to ensure proper reassembly.                                   Heating speed selection MUST be adjusted to provide
       d. Remove screws securing cutoff plate and remove cutoff           proper temperature rise as specified on the rating plate.
           plate from housing.
       e. Remove bolts holding motor mounts to blower housing
           and slide motor and mounts out of housing. Disconnect
                                                                                           Table 2 – Speed Selection
           capacitor and ground wire attached to blower housing
                                                                                                                         FACTORY
           before removing motor. Motor mounts need not be                      COLOR                  SPEED
                                                                                                                       ATTACHED TO
           removed from motor.
                                                                                  Black                High                Cool
        f. Remove blower wheel from housing.                              Yellow (When Present)     Medium High            Spare




                                                                                                                                              PG9MAB
                                                                                   Blue             Medium Low             Heat
             !        CAUTION                                                      Red
                                                                                  White
                                                                                                       Low
                                                                                                     Common
                                                                                                                            Fan
                                                                                                                           Com
  UNIT DAMAGE HAZARD
  Failure to follow this caution may result in noise or furnace
  component failure.                                                                !       WARNING
  The blower wheel should not be dropped or bent as balance
  will be affected.                                                       ELECTRICAL SHOCK HAZARD
                                                                          Failure to follow this warning could result in personal
                                                                          injury or death.
       g. Clean wheel per instructions on degreaser cleaner. Do
                                                                                                                   -v
                                                                          Blower access panel door switch opens 115- power to
           not get degreaser in motor.                                    furnace control. No component operation can occur.
    9. Reassemble motor and blower wheel by reversing items 8b            Caution must be taken when manually closing this
       through 8f. Ensure wheel is positioned for proper rotation.        switch for service purposes.
       Be sure to reattach ground wire. Tighten setscrew to 140 to
                -lb
       160 in- torque.
NOTE: Be sure to attach ground wire and reconnect blower                  15. Turn on electrical supply. Manually close blower access
harness plugs to blower motor.                                                panel door switch. Use a piece of tape to hold switch closed.
                                                                              Check for proper rotation and speed changes between heat-
   10. Reinstall blower assembly in furnace.                                  ing and cooling by jumpering R to G and R to Y/Y2 on
   11. Reinstall control box, transformer, and door switch as-                furnace control thermostat terminals. (See Fig. 15.)
       sembly on blower shelf.                                            16. If furnace is operating properly, release blower access panel
   12. Reinstall condensate trap and tubing if previously removed.            door switch, replace blower access panel, and replace main
       a. Reinstall condensate trap in hole in blower shelf.                  furnace door.
       b. Connect condensate trap drain tubes. See Fig. 5 or                                   CELL
           tubing diagram on main furnace door for proper tube                                PANEL
           location.                                                        MANIFOLD
NOTE: Ensure tubes are not kinked or pinched, as this will affect           MOUNTING
                                                                            SCREWS
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.                                                                                               GASKET

       c. Connect field drain to condensate trap.
NOTE: Ensure tubes are not kinked or pinched, as this will affect
operation.                                                                                                        MANIFOLD

   13. Reinstall control box, transformer, and door switch as-                                              GAS VALVE
       sembly on blower shelf.                                                                              REGULATOR
                                                                                                            FITTING
   14. Reconnect wires.
                                                                                                         GAS
       Refer to furnace wiring diagram and connect thermostat                                            CONTROL
       leads if previously disconnected. (See Fig. 21.)                                                  VALVE
NOTE: Refer to Table one for motor speed lead reconnection if                                                                        A02312
leads were not identified before disconnection.                                                 -
                                                                                         Fig. 6 - Burner Box Assembly




                                                                      5
         Step 3 — Cleaning Burners                                                 15. Reinsert the igniter wires in the slot in the manifold grom-
                                                                                       met, dressing the wires to ensure there is no tension on the
         The following items should be performed by a qualified service
                                                                                       igniter itself. (See Fig. 7.)
         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.                             !       WARNING
             2. Remove main furnace door.
                                                                                   ELECTRICAL SHOCK HAZARD
             3. Remove burner box cover.
             4. Using backup wrench, disconnect gas supply pipe from fur-          Failure to follow this warning could result in personal
                                                                                   injury or death.
                 nace gas control valve.
                                                                                   Igniter wires must be securely placed in slot in manifold
                      !        CAUTION                                             grommet or else they could become pinched or severed
                                                                                   and electrically shorted.

           UNIT DAMAGE HAZARD                                                    16. Reconnect wires to gas valve and igniter. Refer to furnace
                                                                                     wiring diagram for proper wire location.
           Failure to follow this caution may result in furnace
                                                                                 17. Reinstall burner box pressure tube to gas valve regulator fit-
PG9MAB




           component damage.
                                                                                     ting.
           Label all wires prior to disconnection when servicing                 18. Reinstall gas supply pipe to furnace gas control valve using
           controls. Wiring errors can cause improper and dangerous
                                                                                     backup wrench on gas valve to prevent rotation and im-
           operation.
                                                                                     proper orientation.
                                                                               NOTE: Use propane gas resistant pipe dope to prevent gas leaks.
              5. Remove wires from gas valve. Note location for reassembly.    DO NOT use Teflon tape.
              6. Remove burner box pressure tube from gas valve regulator
                 fitting.
              7. Unplug igniter from harness.
                                                                                             !       WARNING
              8. Remove igniter leads from slot in manifold grommet.               FIRE, EXPLOSION, UNIT DAMAGE HAZARD
              9. Remove screws that secure manifold to burner box. (See            Failure to follow this warning could result in personal
                 Fig. 6.)                                                          injury, death, or property damage.
         NOTE: Do not remove burner box from cell panel.                           Gas valve switch MUST be facing forward or tilted
             10. Remove manifold, orifices, and gas valve as one assembly.         slightly.
             11. Remove screws attaching burner assembly in burner box.
         NOTE: Use care when removing and reinstalling burners not to              19. Replace burner box cover.
         strike the hot surface igniter.                                           20. Turn on gas and electrical supplies to furnace.

                                                                                             !       WARNING
                                                                                   FIRE OR EXPLOSION HAZARD
                                                                                   Failure to follow this warning could result in personal
                                                                                   injury, death or property damage.
                                                                                   Never test for gas leaks with an open flame. Use a
                                                                                   commercially available soap solution made specifically
                                                                                   for the detection of leaks to check all connections.
                                                                                   21. Check for gas leaks.
                                                                                   22. Replace main furnace door.
                                                                               Step 4 — Cleaning Heat Exchangers
                                                                               The following items should be performed by a qualified service
                                                                               technician.
                                                                               Primary Heat Exchangers
                                                                               If the heat exchangers get an accumulation of light dirt or dust on
                                          IGNITER WIRES MUST
                                                                               the inside, they may be cleaned by the following procedure:
                                          BE PLACED IN THIS SLOT               NOTE: If the heat exchangers get a heavy accumulation of soot
                                                                      A05074   and carbon, both the primary and secondary heat exchangers
                                 -
                          Fig. 7 - Igniter Wire Placement                      should be replaced rather than trying to clean them thoroughly due
                                                                               to their intricate design. A build- -up of soot and carbon indicates
            12. Remove burner assembly from burner box.                        that a problem exists which needs to be corrected, such as improper
         NOTE: All burners are attached to burner bracket and can be           adjustment of manifold pressure, insufficient or poor quality
         removed as one assembly.                                              combustion air, improper vent termination, incorrect size or
            13. Clean burners with soft brush and vacuum.                      damaged manifold orifice(s), improper gas, or a restricted heat
                                                                               exchanger (primary or secondary). Action must be taken to correct
            14. Reinstall manifold, orifice, and gas valve assembly in burn-
                                                                               the problem.
                er box. Ensure manifold seal grommet is installed properly
                and burners fit over orifices.                                      1. Turn off gas and electrical supplies to furnace.
                                                                                    2. Remove main furnace door.

                                                                               6
                                                                          12. Reverse items 3 through 10 for reassembly.
              !       CAUTION                                          NOTE: Be sure burner box gasket is installed between burner box
                                                                       and cell panel. (See Fig. 6.) If gasket is damaged, replace it.
  UNIT DAMAGE HAZARD                                                   NOTE: Inspect combustion-      -air intake housing. If foamed gasket
  Failure to follow this caution may result in furnace                 was removed, check for any damage. If gasket is damaged in any
  component damage.                                                    way, it must be repaired. To repair, remove damaged gasket
  Label all wires prior to disconnection when servicing                section, apply sealant releasing agent such as PAM cooking spray
  controls. Wiring errors can cause improper and hazardous             or equivalent (must not contain corn nor canola oil, halogenated
  operation.                                                           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
    3. Disconnect wires or connectors to flame rollout switch, gas                    -air
                                                                       of combustion- intake housing. (See Fig. 9.)
        valve, igniter, and flame sensor.
    4. Disconnect combustion-    -air intake pipe from intake hous-
        ing.
    5. Remove the pressure switch tube from intake housing.




                                                                                                                                                PG9MAB
    6. Remove screws attaching intake housing to burner box, and
        rotate intake housing away from burner box for removal.        RTV
    7. Using backup wrench, disconnect gas supply pipe from fur-
        nace gas control valve.
    8. Disconnect pressure tubing from gas valve.                                                                              PAM
    9. Remove two screws attaching top filler panel and rotate up-
        wards to gain access to screws attaching burner box to cell
        panel.                                                                                                                         A93087
   10. Remove screws attaching burner box to cell panel. (See Fig.                        -           -Air Intake Housing
                                                                                   Fig. 9 - Combustion-
        6.)                                                                                    Gasket Repair
NOTE: Burner box, cover, manifold, gas valve, and burner
assembly should be removed as one assembly.                                13. Refer to furnace wiring diagram and reconnect wires to
   11. Clean heat exchanger openings with a vacuum and a soft                  flame rollout switch, gas valve, igniter, and flame sensor.
        brush. (See Fig. 8.)                                               14. Reconnect pressure switch tubes to gas valve and intake
NOTE: After cleaning, inspect the heat exchangers to ensure they               housing. Refer to tube routing label on main furnace door
are free of all foreign objects that may restrict flow of combustion           for proper tube location. (See Fig. 10.) Be sure tubes are not
products.                                                                      kinked.
                                                                           15. Turn on gas and electrical supplies to furnace.
                         PRIMARY HX
                         INLET OPENINGS                                    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.

                                                                                     !       WARNING
                                                                           FIRE OR EXPLOSION HAZARD
                                                                           Failure to follow this warning could result in personal
                                                                           injury, death or property damage.
                                                                           Never test for gas leaks with an open flame. Use a
                                                                           commercially available soap solution made specifically
                                                                           for the detection of leaks to check all connections.


                                                                           18. Replace main furnace door.
                                                                       Secondary Heat Exchangers
                                                              A96305
          Fig. 8 - Cleaning Inlet Openings of Primary
                 -                                                     NOTE: The condensing side (inside) of the secondary heat
                        Heat Exchangers                                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
              !       CAUTION                                          section for details on removing inducer assembly.
                                                                       Step 5 — Flushing Collector Box and Drainage
  UNIT MAY NOT OPERATE                                                 System
  Failure to follow this caution may result in improper or                  1. Turn off gas and electrical supplies to furnace.
  intermittent unit operation.                                              2. Remove main furnace door.
  The ground wire from the gas valve MUST be attached to                    3. Disconnect inducer motor and pressure switch wires or con-
  the burner box attachment screw.                                             nectors.

                                                                       7
                                                                                                                 TUBE ROUTING
                                              Furnace is shipped from factory in upflow configuration. Pressure tube and drain tube routing MUST match the diagrams below.
                           Condensate Trap; Factory Installed                       Tube location when used in UPFLOW application                                                      Condensate Trap on LEFT
                                                                                                                                                                                            Side Optional
                                   in Blower Shelf
                                                                                                       BURNER ENCLOSURE
                           (Blower access panel removed)                                              PRESSURE REFERENCE
                                                                                                                                                                                                 BURNER ENCLOSURE
                                                                                                                                                                                                PRESSURE REFERENCE
                                                                                                         TUBE ASSEMBLY                                                                             TUBE ASSEMBLY
                                                                                                        CAP                                                                               CAP
                                     COLLECTOR BOX TUBE
                                           (PINK)
                                                                                                         PLUG                                                                                PLUG
                                                                                                                                     COLLECTOR BOX TUBE
                                   COLLECTOR BOX TUBE                                                                                      (PINK)
                                        (GREEN)                                                     COLLECTOR BOX DRAIN
                                                                                                            TUBE
                                                                                                   (BLUE & WHITE STRIPED)    COLLECTOR BOX TUBE (GREEN)                                  COLLECTOR BOX DRAIN TUBE
                           INDUCER HOUSING (MOLDED) DRAIN TUBE
                             (BEHIND COLLECTOR BOX DRAIN TUBE)                                                                                                                             (BLUE & WHITE STRIPED)
                                                                                                 CONDENSATE TRAP               COLLECTOR BOX DRAIN TUBE
                               COLLECTOR BOX DRAIN TUBE                                                                                (BLUE)
                                       (BLUE)
                                                                                                           FIELD-INSTALLED
                                                                                                         FACTORY -SUPPLIED            CONDENSATE TRAP
                                                                                                      DRAIN TUBE COUPLING
                                        FIELD-INSTALLED                                               (RIGHT DRAIN OPTION)
                                  FACTORY-SUPPLIED DRAIN TUBE                                                                                                                             INDUCER HOUSING DRAIN TUBE
                                  COUPLING (LEFT DRAIN OPTION)                                                                                                                                     (VIOLET)
                                                                                                    FIELD-INSTALLED
                                                                                                FACTORY -SUPPLIED 1/2-IN.
                           FIELD-INSTALLED FACTORY-SUPPLIED                                     CPVC STREET ELBOWS (2)
                                       DRAIN TUBE                                                FOR LEFT DRAIN OPTION

                            Condensate Trap on
                                LEFT Side
                                                                              Tube location when used in DOWNFLOW application                                                                 Condensate Trap on
                                                                                                                                                                                                 RIGHT Side
PG9MAB




                                                                                                                                                                                PLUG
                                                                                            COLLECTOR BOX
                                                          CAP                              DRAIN TUBE (BLUE)                                                                           CAP
                                                                                             PLUGGED END
                                                                                                                                                                                  COLLECTOR BOX DRAIN TUBE
                                                                                                                              COLLECTOR BOX DRAIN                                         (BLUE)
                                           COLLECTOR BOX                                                                              TUBE
                                                                                                                             (BLUE & WHITE STRIPED)                                COLLECTOR BOX TUBE
                                            TUBE (GREEN)
                                                                                                                                                                                         (PINK)
                                    COLLECTOR BOX DRAIN TUBE                                   PLUG
                                      (BLUE & WHITE STRIPED)                                                                                                                        COLLECTOR BOX TUBE
                                                                                                                             INDUCER HOUSING DRAIN                                       (GREEN)
                                      COLLECTOR BOX                                                                              TUBE (VIOLET)
                                      EXTENSION TUBE                                                                                                                            COLLECTOR BOX EXTENSION TUBE
                                                                                                                                                                                       BURNER ENCLOSURE PRESSURE
                                                                                            COLLECTOR BOX                                                                               REFERENCE TUBE ASSEMBLY
                                   CONDENSATE TRAP                                          EXTENSION TUBE
                                                                                                                               DRAIN TUBE COUPLING                                  CONDENSATE TRAP
                           BURNER ENCLOSURE PRESSURE                                      COLLECTOR BOX
                            REFERENCE TUBE ASSEMBLY                                         TUBE (PINK)                        DRAIN TUBES ROUTED IN                                    COLLECTOR BOX
                                                                                                                                FRONT OF GAS VALVE                                   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
                                                                                      (BLUE & WHITE STRIPED)                         (BLUE)
                                           PLUG                                                                                                                       COLLECTOR BOX TUBE (PINK)

                                             CAP                                                                              PLUG                                                     AUXILIARY "J" BOX RELOCATED HERE
                                                                                                          COLLECTOR BOX
                                                                                                           TUBE (GREEN)
                            BURNER ENCLOSURE
                           PRESSURE REFERENCE
                              TUBE ASSEMBLY


                                       COLLECTOR BOX                                                     INDUCER HOUSING           CAP
                                       EXTENSION TUBE                                                       DRAIN TUBE                                                                           BURNER ENCLOSURE
                                                                                                             (VIOLET)                                                                           PRESSURE REFERENCE
                                                                                                                                                                                                   TUBE ASSEMBLY
                                                                                                         COLLECTOR BOX
                                       CONDENSATE TRAP                                                  DRAIN TUBE (BLUE)                                                               COLLECTOR BOX
                                                                                                                                COLLECTOR BOX
                                                                                                                                 TUBE (GREEN)                                           EXTENSION TUBE
                                                                       DRAIN TUBE          COLLECTOR BOX TUBE (PINK)
                            COLLECTOR BOX EXTENSION DRAIN TUBE          COUPLING        RELOCATE TUBE BETWEEN BLOWER                 COLLECTOR BOX DRAIN TUBE                     CONDENSATE TRAP
                                                                                        SHELF AND INDUCER HOUSING FOR
                                                                                         040,060, AND 080 HEATING INPUT               (BLUE AND WHITE STRIPED)
                                                                                                    FURNACES                                                       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 collector box pressure tube to be relocated between the inducer housing and the blower shelf to                    324999-201 REV. C
                                prevent a trap. Refer to the Installation Instructions for further details.



                                                                                                                                                                                                                          A00308
                                                                             -
                                                                     Fig. 10 - Furnace Pressure and Drain Tubing Diagram

             4. Disconnect pressure switch tubes.                                                                                 10. Reassemble inducer assembly by reversing items 3-          -7.
             5. Disconnect vent pipe from inducer housing outlet by                                                                    Tighten the vent coupling clamp screw(s) to 15 in.- of-lb
                 loosening coupling clamp on inducer outlet.                                                                           torque.
             6. Disconnect drain tube from inducer housing. (See Fig. 10.)                                                     NOTE: If seal between the inducer housing and the collector box
         NOTE: Ensure the drain tube disconnected from the inducer                                                             is damaged in any way, it must be repaired. To repair, apply sealant
         housing is higher than the collector box opening or water will flow                                                   releasing agent such as PAM cooking spray or equivalent (must not
         out of tube.                                                                                                          contain corn nor canola oil, halogenated hydrocarbons nor
                                                                                                                               aromatic content, to prevent inadequate seal from occurring) to
             7. Remove inducer housing assembly by removing 4 bolts at-
                                                                                                                               inducer housing. (See Fig. 12.) Apply a small bead of G.E. RTV
                 taching assembly to cell panel.
                                                                                                                               162, G.E. RTV 6702, or Dow-     -Corning RTV 738 sealant to groove
             8. Flush inside of collector box with water until discharge                                                       in collector box.
                 from condensate trap is clean and runs freely.
                                                                                                                                   11. Refer to furnace wiring diagram and reconnect wires to in-
             9. Inspect inside area of collector box for any pieces of foreign                                                         ducer motor and pressure switches or connectors.
                 materials and remove them if present.
                                                                                                                                  12. Reconnect pressure tubes to pressure switches. See diagram

                       !              CAUTION                                                                                          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.
           UNIT DAMAGE HAZARD
                                                                                                                                  14. Check furnace operation through two complete heat operat-
           Failure to follow this caution may result in furnace                                                                        ing cycles. Check area below inducer housing, vent pipe,
           component damage.                                                                                                           and condensate trap to ensure no condensate leaks occur. If
           DO NOT use wire brush or other sharp object to inspect or                                                                   leaks are found, correct the problem.
           dislodge materials in secondary heat exchangers as cutting                                                             15. Check for gas leaks.
           of the secondary heat exchanger protective coating may
           occur. Flush with water only.

                                                                                                                               8
                                                                                e. If replacement is required, replace igniter on igniter
            !       WARNING                                                        bracket and then install assembly into burner box to
                                                                                   avoid damage to the igniter.
  FIRE OR EXPLOSION HAZARD                                                 6.   To replace igniter and bracket assembly, reverse items 5a
  Failure to follow this warning could result in personal                       through 5c.
  injury, death or property damage.                                        7.   Reconnect igniter wire connection and insert the igniter
  Never test for gas leaks with an open flame. Use a                            wires in the slot in the manifold grommet, dressing the ig-
  commercially available soap solution made specifically for                    niter wires to ensure there is no tension on the igniter itself.
  the detection of leaks to check all connections.                              (See Fig.7.)
                                                                           8.   Reinstall burner box cover.
                                                                           9.   Turn on gas and electrical supplies to furnace.




                                                                             ;
                                                                            ;;;
  16. Replace main furnace door.
                                                                          10.   Verify igniter operation by initiating control board self- -test
Step 6 — Servicing Hot Surface Igniter                                          feature or by cycling thermostat.
The igniter does NOT require annual inspection. Check igniter             11.   Replace main furnace door.
resistance before removal.
                                                                                        BURNER FLAME




                                                                                                                                                   PG9MAB
     1. Turn off gas and electrical supplies to furnace.
                                                                                                                             BURNER

             !        CAUTION
  BURN HAZARD
  Failure to follow this caution may result in personal injury.
  Allow igniter to cool before removal. Normal operating
  temperatures exceed 2000_F (1093_C).


   2. Remove main furnace door.
   3. Disconnect igniter wire connection.
   4. Check igniter resistance. Igniter resistance is affected by                         MANIFOLD
      temperature. Only check resistance when the igniter is at
      room temperature.                                                                                                                  A89020
                                                                                                      -
                                                                                              Fig. 11 - Burner Flame
       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.)
                                                                                                  PAM
                       -in.
       c. Using a 1/4- driver, remove the single screw securing
          the igniter bracket to the burner box bracket (See Fig.               RTV
          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.

             !        CAUTION
  UNIT DAMAGE HAZARD
  Failure to follow this caution may result in premature
  failure of the igniter.
  The igniter is fragile. DO NOT allow it to hit burner box
  parts while removing or replacing it.
                                                                                                                                         A93081
                                                                                                -
                                                                                        Fig. 12 - Gasket on Collector Box




                                                                      9
               EXTENDED IGNITER
                                            IGNITER                        Step 7 — Electrical Controls and Wiring
               BRACKET HANDLE
                                     BRACKET                    9/16˝                     !       WARNING
                                                                                ELECTRICAL SHOCK HAZARD
                                                                                Failure to follow this warning could result in personal
         IGNITER BRACKET                                       11/16˝           injury or death.
         MOUNTING SCREW
                                                                                There may be more than one electrical supply to the unit.
                                                                                Check accessories and cooling unit for additional electrical
                                                                                supplies.


                                                                                                                          -v
                                                                           The electrical ground and polarity for 115- wiring must be
                                                                           maintained properly. Refer to Fig. 15 for field wiring information
                                                                           and to Fig. 21 for unit wiring information.
PG9MAB




                                                                  A05075   NOTE: If the polarity is not correct or furnace is not properly
                                   -
                           Fig. 13 - Igniter Bracket                       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.
                                                                                   -v
                                                                           The 24- circuit contains an automotive-  -type, 3--amp fuse located
                                                                                                                                             -v
                                                                           on the furnace control. (See Fig. 16.) Any direct shorts of the 24-
                                                                           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.
                                  2-5/32˝                                  Reconnect electrical supply to unit and observe unit through one
                                  (55 mm)                                  complete operating cycle and check for proper operation.
                                                                  A04181
                                                                           Step 8 — Checking Heat Tape Operation
                                       -
                               Fig. 14 - Igniter
                                                                           (If Applicable)
                                                                           In applications where the ambient temperature around the furnace
                    !      WARNING                                         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.
          ELECTRICAL SHOCK HAZARD
                                                                           NOTE: Heat tape, when used, should be wrapped around the
          Failure to follow this warning could result in personal          condensate drain trap and drain line. There is no need to use heat
          injury or death.                                                 tape within the furnace casing. Most heat tapes are temperature
          Igniter wires must be securely placed in slot in manifold        activated, and it is not practical to verify the actual heating of the
          grommet or else they could become pinched or severed and         tape. Check the following:
          electrically shorted.
                                                                                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.




                                                                           10
                                                                                                                                                          FIELD 24-V WIRING
                                                                                                                                                          FIELD 115-, 208/230-, 460-V WIRING
                                                                                                                                                          FACTORY 24-V WIRING
                                                                                                                                                          FACTORY 115-V WIRING

                                                                 NOTE 2
                                                                                            W               C     R           G        Y    THERMOSTAT
                       FIVE WIRE                                                                                                            TERMINALS              FIELD-SUPPLIED
                     THREE-WIRE                                                                                                                                    DISCONNECT
                    HEATING-ONLY
                                                                                                                                                                                   208/230- OR
BLOWER DOOR SWITCH                                                                                                                                                                 460-V
                                                                                                                                                                                   THREE
                                                                              W                                                                                                    PHASE
BLK               BLK
                                                                   C          R
WHT              WHT
                                                                   O
                                                                   N                                                                                                               208/230-V
           GND              GND                                    T                                                                                                               SINGLE
                                                                   R          G                                                                                                    PHASE
  115-V FIELD-          AUXILIARY                                  O
                        J-BOX




                                                                                                                                                                                                           PG9MAB
   SUPPLIED                                                        L         COM                                                                                        GND
  DISCONNECT                                                                                                    NOTE 1
                                                                               Y
                                                                                                                                                       CONDENSING
                                                                                                                                                       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 a "C" terminal connection as shown.
                                                                                                               3. If any of the original wire, as supplied, must be replaced, use
                                                                                                                  same type or equivalent wire.
                                                                                                                                                                                                  A02174
                                                                                                                        -
                                                                                                                Fig. 15 - Field Wiring

                                                                                                             TWINNING AND/OR
                 BLOWER OFF-DELAY                                                                            COMPONENT TEST
                                                                                                                TERMINAL

             J2 JUMPER


                                                                             BLOWER OFF-DELAY
                                                                                   90 150

                                                                                            120 180
                                                                        J2




                                                                                                                                                                          HUMIDIFIER TERMINAL
                                                                                                                                                                          (24-VAC 0.5 AMP MAX.)
                                             G




       24-V THERMOSTAT
          TERMINALS
                                    24V
                                    Com      W




                                                                                                                                                                        TRANSFORMER 24-VAC
                                                                                                                                                                           CONNECTIONS
                                                                                                      PLT
                                             Y




                                                                         TEST/TWIN

                                                                               HUM
                                             R




                                                                             0.5 AMP@24VAC
                                    STATUS CODE LED




         3-AMP FUSE                                    FUSE 3-AMP
                                                               SEC-2 SEC-1

      LED OPERATION &                                           EAC-2         L2
      DIAGNOSTIC LIGHT
                                                 NUETRAL BLW




                                                                                    PLT




                                                                                                                                                                       PL1-LOW VOLTAGE MAIN
                                                                                                                                                                       HARNESS CONNECTOR
      115-VAC(L2)NEUTRAL
         CONNECTIONS
                                                                                    1
                                    COOL




                        COOL
                                    HEAT




                        HEAT
                                                                                                                  1-AMP@
                                                                                                                                  L1




                                                               SPARE-1 SPARE-2                              EAC-1 115VAC   PR-1
                                                                                                                                             PL2   1


                               SPARE-1
                                                                                                                        115 VAC (L1) LINE                         PL2-HOT SURFACE
                                            SPARE-2                                                                   VOLTAGE CONNECTION                         IGNITER & INDUCER
     BLOWER SPEED
                                                                                                                                                                 MOTOR CONNECTOR
  SELECTION TERMINALS
                                                                                                         EAC-1 TERMINAL
                                                                                                      (115-VAC 1.0 AMP MAX.)
                                                                                                                                                                                                  A02100
                                                                                                                     -
                                                                                                             Fig. 16 - Control Center




                                                                                                                                       11
                       !       CAUTION
           UNIT AND PROPERTY DAMAGE
           Failure to follow this caution may result in furnace
           component failures or water property damage.
           Operating a unit without a filter or with the blower access
           door removed could cause damage to the furnace blower
           motor. Dust and lint on internal parts of furnace can cause a
           loss of efficiency. If this furnace is to be operated in an
           unconditioned space where the ambient temperatures may
           be 32_F (0_C)or lower, freeze protection measures must be
           taken. See CONDENSATE DRAIN PROTECTION section
                                 -up, and Operating Instructions. (See
           of Installation, Start-
           Fig. 17.)
PG9MAB




         Step 9 — Winterizing

                       !       CAUTION
                                                                                                                                                A07911
           UNIT DAMAGE HAZARD                                                                                 -
                                                                                                      Fig. 17 - Freeze Protection
           Failure to follow this caution may result in furnace
           component damage.                                                                         WIRING DIAGRAMS
           Freezing condensate left in the furnace may damage the                See Fig. 21 for wiring diagram.
           furnace.
                                                                                                     TROUBLESHOOTING
                                                                                 Use the troubleshooting guide, the status code LED on the furnace
         If the furnace will be off for an extended period of time in a          control and the component test to isolate furnace operation
         structure where the temperature will drop to 32_F (0_C)or below,        problems.
         winterize as follows:
                                                                                 Status Codes
              1. Turn off electrical supply to furnace.
                                                                                 For an explanation of status codes, refer to service label located on
              2. Remove main furnace door.                                       back of main furnace door or Fig. 20.
              3. Disconnect upper inducer housing drain connection cap           NOTE: Removing the blower access door will open the blower
                 from inducer housing. (See Fig. 18.)                                                                  -v
                                                                                 access door switch and terminate 115- power to the control.
              4. Connect field-               -in.
                               -supplied 1/2- I.D. inducer housing tube to       To read current status code, remove main furnace door. The status
                 upper inducer housing drain connection.                         code LED can be viewed through the sight glass on the blower
              5. Insert funnel in tube and pour one quart of antifreeze, pro-    access door.
                 pylene glycol (RV, swimming pool antifreeze, or equival-        NOTE: NO thermostat signals may be present at control and all
                 ent) into funnel/tube until it is visible at point where con-   blower off delays must be completed to view previous codes.
                 densate enters open drain. (See Fig. 19.)

                       !       CAUTION                                                           !       CAUTION
                                                                                      UNIT DAMAGE HAZARD
           UNIT DAMAGE HAZARD
                                                                                      Failure to follow this caution may result in damage to unit
           Failure to follow this caution may result in unit component                components.
           damage.
                                                                                      Make sure limit switch or flame rollout switch wire does
           Do not use ethylene glycol (Prestone II antifreeze/coolant or              not contact any metal component, such as gas valve. If wire
           equivalent automotive type).                                                            -amp fuse on furnace control board will open
                                                                                      is shorted, 3-
                                                                                      and unit will not operate.
             6. Replace drain connection cap and clamp to inducer housing.
             7. Replace main furnace door.                                       To retrieve previous codes, remove one of the red main limit or
             8. Propylene glycol need not be removed before restarting fur-      flame rollout switch wires for 1 to 4 sec until the LED light goes
                nace.                                                            out, then reconnect it. (Do not leave red wire disconnected for
                                                                                 longer periods of time as the control will assume an
                                                                                 overtemperature condition exists and will respond with blower
                                                                                 operation.) This places the control in the status recall mode and
                                                                                 displays the last code stored in memory.
                                                                                 Record the code. After the last code is displayed the control will
                                                                                 perform the component test, and then return to normal standby
                                                                                 mode.




                                                                                 12
                                                                                                                                                   PG9MAB
                                                               A99118                                                                    A99119
                     -
             Fig. 18 - Inducer Housing Drain Tube                                        -
                                                                                 Fig. 19 - Funnel in Drain Tube and Antifreeze
                                                                                            Running Through Trap
Component Test
NOTE:       The furnace control component test allows all               Component test sequence for single-    -stage furnace is as follows:
components to run for a short time; except the gas valve and                    a. LED will display status code 11 four times.
humidifier terminal HUM are not energized for safety reasons. The               b. Inducer motor starts and continues to run until Step f. of
EAC- terminal is energized when the blower is energized. This
      -1                                                                           component test sequence.
feature helps diagnose a system problem in case of a component                  c. After 7 sec the hot surface igniter is energized for 15
failure. The component test feature will not operate if any                        sec, then off.
thermostat signal is present at the control and not until all time              d. Blower motor operates on HEAT speed for 10 sec.
delays are completed.                                                           e. Blower motor operates on COOL speed for 10 sec.
NOTE: Record the status code BEFORE opening the blower                          f. Inducer motor stops.
access door and before shutting off power to furnace. Opening the
                                                                            5. Reconnect R lead to furnace control board, remove tape
blower access door will open the blower door switch and shut off
                                                                               from blower door switch, and reinstall blower door.
power within the furnace. When power to the furnace is shut off by
                                                                            6. Operate furnace per instruction on outer door.
either method, the status code will be lost because the code is not
stored while power is removed for any reason.                               7. Verify furnace shut down by lowering thermostat setting be-
                                                                               low room temperature.
To Begin Component Self-   -Test:
                                                                            8. Verify that furnace restarts by raising thermostat setting
                                                                               above room temperature.
             !       WARNING                                            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
  ELECTRICAL SHOCK AND UNIT MAY NOT                                     (approximately 2 sec) short the TWIN/TEST terminal to the COM
  OPERATE HAZARD
                                                                        24V terminal. The status LED will turn off. The test sequence will
  Failure to follow this warning could result in electrical shock,      be as follows:
  personal injury, or death.                                                1. LED flashes last status code, or code 11, 4 times. Record
                                               -v
  Blower access panel door switch opens 115- power to                          this status code for further troubleshooting.
  control board. No component operation can occur. Caution                  2. The inducer will start and continue to run until test is over.
  must be taken when manually closing this switch for service
  purposes.                                                                 3. Hot surface igniter (HSI) is energized for 15 sec, then de-     -
                                                                               energized.
     1. Remove blower access door.                                          4. Blower operates on continuous FAN speed for 10 sec, then
     2. Disconnect the thermostat R lead from furnace control                  turns off.
        board.                                                              5. The blower motor operates on HEATING speed for 10 sec,
     3. Manually close blower door switch.                                     then turns off.
     4. For approximately 2 sec, short (jumper) the COM-    -24v ter-       6. The blower motor operates on COOLING speed for 10 sec,
        minal on control to the TEST/TWIN 3/16-      -in. quick-
                                                               -con-           then turns off.
        nect terminal on control until LED turns off. Remove jump-          7. Inducer turns off.
        er from terminals. (See Fig. 16.)                                   8. The gas valve and humidifier terminal HUM are not ener-
NOTE: If TEST/TWIN and COM-             -24v terminals are jumpered            gized for safety reasons.
longer than 2 sec, LED will flash rapidly and ignore component
test request.

                                                                        13
                                              SERVICE
          If status code recall is needed, briefly remove then reconnect one main limit wire to display
          stored status code. On RED LED boards do not remove power or blower door before 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 & L2, & 24VAC at SEC-1 & SEC-2.
         CONTINUOUS ON - Control has 24VAC power.
         RAPID FLASHING - Line voltage (115VAC) polarity reversed. If twinned,
                              refer to twinning kit instructions.
         EACH OF THE FOLLOWING STATUS CODES IS A TWO DIGIT NUMBER WITH THE FIRST
         DIGIT DETERMINED BY THE NUMBER OF SHORT FLASHES AND THE SECOND DIGIT BY
         THE NUMBER OF LONG FLASHES.

         11 NO PREVIOUS CODE - Stored status code is erased automatically after 72
            hours. On RED LED boards stored status codes can also be erased when power
            (115 VAC or 24 VAC) to control is interrupted.
PG9MAB




         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.

                                      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

                                                                                                          A02270
                                                   -
                                           Fig. 20 - Service Label



                                                           14
                                                                                                                                                                                                            (WHEN USED)                                                    TO 115VAC FIELD DISCONNECT                                                                      SCHEMATIC DIAGRAM
                                                                                             BLOWER OFF DELAY                                                                                                  LGPS
                                                                                                                                                                                           PRS                                                                             NOTE #2                                                                                      (NATURAL GAS & PROPANE)
                                                                                              JUMPER SELECT                                         PCB                                                                                                                                                  L2
                                                                                                                                                                                                                                                                                           L1                              GND         EQUIPMENT GROUND
                                                                                        J2
                                                                                                    90                                                                     ORN
                                                                                                                              120                                                                                                                                                                  ILK                                                        LO                                      CAP-1
                                                                                                                                                                                                                                                                                                                                       SPARE-2
                                                                           G                                                                                                                                 NOTE #11                                                                                                                                      MED LO
                                                                                                   150                                                                                                                                        YEL                                                                                       HEAT               MED HI
                                                                          Com
                                                                          24V                                             180                                                                                                                                                                 L1                                                             HI
                                                                                                                                            BLU                                                               BLU                                                                                                                                                                  START
                                                                                                                                                                                                                                                                                                                 HI/LO                 SPARE-1                          OL                                    L2
                                                                           W                                              J1                                                                                                                        GV                                         BLWR                                            NOTE #10
                                                                                                                                                                                                                                  M                                                                                                      COOL
                                                                                                                                                                            RED               RED                                                                                                                                                                                                       EAC-2
                                                                             Y                     TEST/TWIN                                                                                                                                                                                                                                                                               BLWM
                                                                                                                                            ORN                                          LS                   FRS                                                                                                                                             COM




                                               PRINTED CIRCIUT BOARD
                                                                             R                                                                                                                                                                      C                                                      EAC-1
                                                                                                         HUM                                                                                                                                            GRN/YEL
                                                                                                                                                                                                                                                                                                             HSIR
                                                                    FU1                                                                                                                  RED                                                  NOTE #3
                                                                   NOTE #6                                                                                                                          GRN/YEL
                                                                                                                                                                                                                                                                                                                                   1                   1          HSI
                                                                                                                                                                                                                                                                                                   IDR
                                                                                                                                             WHT                                                                                                                                                                                                                                                  IDM
                                                                          SEC-2              SEC-1                                                                                                                                                                                                                   PL2           2             PL3   2                                   OL
                                                                                                                                                                                               BLU                                BLK
                                                                                                                                                                                                                                                                                                         PR1     115VAC                                                            M
                                                                                         LED 1                                                             RED                                                                                                                                                                                                                              AUX




                                                                                                                                                                                                             TRAN
                                                                                                                                                                                              RED                                 WHT
                                                                                     EAC-2                                                  WHT
                                                                                                   L2                                                                                                                                                                                                    TRAN
                                                                                                                                                     RED                                             WHT
                                                                                                                                              GRN/YEL                                                                         CAP -2                                                                             24VAC                                                       1




                                                                NOTE #8
                                                                                                                                                                                                                                                                                                                                                                             3
                                                                                                                                                    GRN/YEL                                                         BRN                  BRN                                              TEST/TWIN                                                            PL4




                                                                           NEUTRAL
                                                                                                                                                           YEL                             PL4                                                                                                                                                                               2          CAP - 2




                                                                                                          1 2 3 4 5 6 7 8 9 10 11
                                                                                                                                                    WHT                                       3       WHT
                                                                                                                                    PL1                                                                                       M
                                                                                                                                                                            FSE                                                                                                                            NOTE #6




                                                                          BLW
                                                                                                                                                                                                     GRN/YEL                       AUX                                                               FU1
                                                                                                                                                                                              2                                               IDM
                                                                                                                                                           PL2                                                                     OL
                                                                                                                                                                                                                                                                                                                           SEC-1        SEC-2                                             FRS             LS
                                                                       BHT/CLR               BLWR                                                                                             1       BLK                                                                                                                                                     6
                                                                                                                                                       2         1                                                                       WHT
                                                                       COOL                   L1                                                                                                                    PL3
                                                                                                                                                                            BLK                         WHT               2
                                                                       HEAT




                                                                                                                                                                                                                                        HSI
                                                                                                                                                                     BLK                                BLK               1                                                                                                                                   8
                                                                                                                                                                                                                                                                                          R
                                                                   SPARE 1                    SPARE 2                   EAC-1                                                                                                                                                                                                                                                    LGPS         (WHEN USED)
                                                                                                                                                      PR1                                                                                                                                                                                                     2




             -
                                                                                                                                                                                                                                                                                          W

                                                                                                                                                                     WHT (COM)
                                                                                                                                                                                                                                                                  PRINTED CIRCIUT BOARD


                                              WHT                                    BLK (HI)                                                                                                                                                                                                                                                                PL1
                                                                                                                                                                                                      WHT                                                                                                                                                                           NOTE #11
                                             (COM)                                                                                                                                        BLK                                                                                             HUM
                                                                                                              BLWM                                                                                                                                                                                                                                                                PRS
                                                                                                                                                                                                             FUSED OR CIRCUIT BREAKER
                                                             YEL                                                                                     GRN/YEL                                             DISCONNECT SWITCH (WHEN REQ’D)




15
                                                                                                                                                                                              JB                     NOTE #2
                                                           (MED HI)                                                                           BRN
                                                                                                         OL                                                                                                                                                                                                                                                   4
                                                                                                                                                                      WHT                                   WHT                                         NEUTRAL
                                                                                                                                                                                                                              FU2                                                                                                                                                                  GV
                                                                       NOTE #10                                                     START              CAP -1                                                                                                                                                                              GVR-1
                                                                                                                                                                      BLK                                   BLK                                         L1                                                                                                    10                   M
                                                                                       RED (LO)




     Fig. 21 - Wiring Diagram
                                                                                                                                                                                                                                                                                                                       CPU
                                                BLU                                                                                           BRN                             ILK                      GND                                                                                Y                                                                    5                                  C
                                              (MED LO)
                                                                                                                                                                                                                                                                                                                                                                                                      NOTE #3

                                                                                                                                                                                    OL              AUTO-RESET INTERNAL MOTOR OVERLOAD                                                    G
                                         L   BHT/CLR                                    BLOWER MOTOR SPEED CHANGE RELAY, SPDT                                                                                                                                                                                                                                  1
                                                                                                                                                                                                    TEMPERATURE SWITCH (N.C.)
                                         E   BLWR                                        BLOWER MOTOR RELAY, SPST-(N.O.)
                                             BLWM                                       BLOWER MOTOR, PERMANENT-SPLIT-CAPACITOR                                                     PCB             PRINTED CIRCUIT BOARD CONTROL                                                                                                                              9                 FSE
                                         G   CAP 1,2                                   CAPACITOR                                                                                    PL1             11-CIRCUIT PCB CONNECTOR
                                         E   CPU                                       MICROPROCESSOR AND CIRCUITRY                                                                 PL2             2-CIRCUIT CONNECTOR                                                                                                                                        7
                                             EAC-1                                     ELECTRONIC AIR CLEANER CONNECTION (115 VAC 1.0 AMP MAX.)                                     PL3             2-CIRCUIT HSI, CONNECTOR                                                              COM        PCB
                                         N                                                                                                                                                                                                                                                24V                                                                  3
                                             EAC-2                                     ELECTRONIC AIR CLEANER CONNECTION (COMMON)                                                   PL4             3-CIRCUIT IDM EXTENSION CONNECTOR                                                                  NOTE #5
                                         D   FRS                                         FLAME ROLLOUT SW. -MANUAL RESET, SPST-(N.C.)                                               PRS              PRESSURE SWITCH, SPST-(N.O.)                                                                                                                             11
                                             FSE                                         FLAME-PROVING ELECTRODE                                                                    TEST/TWIN         COMPONENT TEST & TWIN TERMINAL                              NOTES:
                                             FU 1                                       FUSE, 3 AMP, AUTOMOTIVE BLADE TYPE, FACTORY INSTALLED                                       TRAN            TRANSFORMER-115VAC/24VAC
                                             FU 2                                       FUSE OR CIRCUIT BREAKER CURRENT INTERRUPT DEVICE
                                                                                                                                                                                                                                                                          1.               If any of the original equipment wire is replaced use wire rated for 105°C.
                                                                                                                                                                                                     JUNCTION                                                             2.               Use only copper wire between the disconnect switch and the furnace junction box (JB).
                                                                                       (FIELD INSTALLED & SUPPLIED)
                                             GND                                       EQUIPMENT GROUND                                                                                             UNMARKED TERMINAL                                                     3.               This wire must be connected to furnace sheet metal for control to prove flame.
                                             GV                                        GAS VALVE-REDUNDANT
                                                                                                                                                                                                                                                                          4.               Symbols are electrical representation only.
                                                                                                                                                                                                    PCB CONTROL TERMINAL                                                  5.               Solid lines inside PCB are printed circuit board conductors and are not included in legend.
                                             GVR 1, 2                                   GAS VALVE RELAY, DPST-(N.O.)                                                                                FACTORY WIRING (115VAC)                                               6.               Replace only with a 3 amp fuse.
                                             HSI                                        HOT SURFACE IGNITER (115 VAC)
                                                                                                                                                                                                    FACTORY WIRING (24VAC)                                                7.               Inducer (IDM) and blower (BLWM) motors contain internal auto-reset thermal overload switches (OL).
                                             HSIR                                        HOT SURFACE IGNITER RELAY, SPST-(N.O.)
                                                                                                                                                                                                                                                                          8.               Neutral connections are interchangeable within the NEUTRAL connector block.
                                             HUM                                       24VAC HUMIDIFIER CONNECTION (0.5 AMP. MAX.)                                                                  FIELD WIRING (115VAC)                                                 9.               Blower motor speed selections are for average conditions, see installation instructions for details on
                                             IDM                                       INDUCED DRAFT MOTOR, PSC                                                                                     FIELD WIRING (24VAC)                                                                   optimum speed selection.
                                             IDR                                        INDUCED DRAFT MOTOR RELAY, SPST-(N.O.)                                                                                                                                            10.              YELLOW lead not on all motors.
                                             ILK                                        BLOWER ACCESS PANEL INTERLOCK SWITCH, SPST-(N.O.)                                                           CONDUCTOR ON CONTROL PCB
                                                                                                                                                                                                                                                                          11.              Factory connected when LGPS is not used.
                                             J1                                        BLOWER - OFF DELAY JUMPER SELECTOR                                                                           FIELD WIRING SCREW TERMINAL                                           12.              Ignition-lockout will occur after four consecutive unsuccessful trials-for-ignition. Control will
                                             J2                                        COOLING - OFF DELAY JUMPER                                                                                   FIELD EARTH GROUND                                                                     auto-reset after three hours.
                                             JB                                         JUNCTION BOX                                                                                                                                                                      13.              Blower-on delay: gas heating 60 seconds, cooling or heat pump 2 seconds.
                                             LED                                        LIGHT-EMITTING DIODE FOR STATUS CODES - RED                                                                 EQUIPMENT GROUND
                                                                                                                                                                                                                                                                          14.              Blower-off delay: gas heating selections are 90, 120, 150 or 180 seconds, cooling or heat pump
                                             LGPS                                       LOW GAS PRESSURE SWITCH, SPST-(N.O.)                                                                        FIELD SPLICE                                                                           90 seconds or 5 seconds when J2 is cut.
                                             LS                                         LIMIT SWITCH, AUTO-RESET, SPST (N.C.)                                                                       PLUG RECEPTACLE                                                                                                                                                                     328150-101 REV. A




                                A02271
                                                                                                                                                                                                                                                                                                                PG9MAB
                                                                                                                                                                                    PG9MAB

                                                                                                 TROUBLESHOOTING GUIDE
                                START
                                                               NO                                                     NO                                                            NO
              Is LED status light on?                                Is there 115V at L1 and L2?                                  Is door switch closed?                                   Close door switch and go back to START.

                                        YES
                                                                                                 YES                                                          YES


                                                                                                                      NO                                                            NO
                                                                     Is there 24V at SEC-1 and SEC-2?                             Is there 115V going to switch?                           Is circuit breaker closed?



                                                                                                 YES                                                          YES                                                       YES


                                                                                                                                                                                                                                                 NO
                                                                     Replace furnace control.                                     Replace door switch.                                     Check for continuity in wire from circuit breaker
                                                                                                                                                                                           to furnace.




                                                               YES   Check for correct line voltage polarity and ground-          Replace transformer.                                     Close circuit breaker and go back to START.
              Is LED status light blinking rapidly without a         ing. If units are twinned, check for proper low-
              pause?                                                 voltage (24V) transformer phasing.

                                        NO

              Is LED status light blinking ON/OFF slowly       NO     o
                                                                     T recall status code briefly remove and reconnect one RED wire from the Limit
              with a combination of short and long flashes?          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
                                        YES
                                                                     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
              Determine status code. The status code is a            there was no previous code. After the control repeats the code 4 times, the
              2 digit number with the first digit determined         control will go through a brief component test sequence. The inducer will start
                                                                     and run for the entire component test. The HSI, blower motor FAN speed




16
              by the number of short flashes and the second
              digit by the number of long flashes?                   (AMBER LED boards only) HEAT speed, and COOL speed will run for 10 – 15                                               Check room thermostat or
                                                                     seconds each. Gas valve and humidifier will not be turned on.                                                         interconnecting cable.

                                                                                                                                                                                                                        NO

                                                               YES                                                     NO         Does the control respond to W, Y1 (if present),   NO     Is 24V present at W, Y1 (if present), Y/Y2 or
              Go to section below for the status code that           Was there a previous status code
                                                                     other than #11?                                              Y/Y2, and G (24V) thermostat signals?                    G thermostat terminals on the furnace control?
              was flashed.
                                                                                                                                                              YES                                                       YES

                                                                                                                                  Run system through a heating or cooling cycle            Disconnect all the thermostat wires from the
                                                                                                                                  to check operation. Status codes are erased              furnace control.
                                                                                                                                  after 72 hours. On RED LED boards stored
                                                                                                                                  status codes can also be erased whenever
                                                                                                                                  (115V or 24V) is interrupted.




                                                                                                                                                                                     YES   Does the problem repeat when using
                                                                                                                                  Replace furnace control.                                 a jumper wire?

                                                                                                                                                                                                                        NO


                                                                                                                                                                                           The thermostat is not compatible with the
                                                                                                                                                                                           furnace control. Either install a ballast resistor,
                                                                                                                                                                                           connect the Com24V thermostat terminal to
                                                                                                                                                                                           the thermostat, or replace the thermostat.




     A05107
              11 NO PREVIOUS CODE – Stored codes                  31 PRESSURE SWITCH DID NOT CLOSE                                                                               45 CONTROL CIRCUITRY LOCKOUT
                 are erased after 72 hours. On RED LED               OR REOPENED – If open longer than 5                                                                            Auto-reset after 1 hour lockout due to:
                 boards stored status codes can also be              minutes, inducer shuts off for 15 minutes                                                                   - Flame circuit failure.
                 erased whenever power (115V or 24V)                 before retry. If opens during blower on-                                                                       - Gas valve relay stuck open.
                                                                     delay period, blower will come on for the                                                                   - Software check error.
                 is interrupted. Run system through a                selected blower off-delay. Check for:
                 heating or cooling cycle to check system.           - Proper vent sizing.                                                                                          Reset power to clear lockout. Replace
                                                                     - Low inducer voltage (115V).                                                                                  control if code repeats.
                                                                     - Low inlet gas pressure (if LGPS used).
              12 BLOWER ON AFTER POWER UP –                          - Inadequate combustion air supply.                                                                   NO
                 (115V OR 24V) – Normal operation.                   - Disconnected or obstructed pressure              Unplug igniter harness from control and initiate         Replace furnace control.
                 Blower runs for 90 seconds, if unit is                 tubing.                                         another component test sequence. Check
                 powered up during a call for heat (R-W              - Defective inducer motor.                         for 115V between pin 1 and NEUTRAL-L2 on
                 closed) or when (R-W opens) during the              - Defective pressure switch.                       the control. Was 115V present for the 15
                                                                     - Excessive wind.                                                                                     YES   Check for continuity in the harness and igniter.
                 blower on-delay period.                                                                                second period?                                           Replace defective component.
                                                                     - Restricted vent.

              13 LIMIT CIRCUIT LOCKOUT – Lockout                  33 LIMIT CIRCUIT FAULT – Indicates the                                                                   NO
                 occurs if the limit or flame rollout switch is                                                         Reconnect the R thermostat lead and set                  Check connections. If OK, replace control.
                                                                     limit or flame rollout switch is open. Blower      thermostat to call for heat. Connect voltmeter
                 open longer than 3 minutes. Control will            will run for 4 minutes or until open switch
                 auto-reset after 3 hours. See code 33.                                                                 across gas valve connections. Does gas valve
                                                                     remakes whichever is longer. If open               receive 24V?                                             Check that all gas valves are turned on.
                                                                     longer than 3 minutes, code changes to                                                                      Replace valve.
                                                                     lockout #13. If open less than 3 min.                                        YES
                                                                     status code #33 continues to flash until
              14 IGNITION LOCKOUT – System failed to                 blower shuts off. Flame rollout switch             Does gas valve open and allow gas to flow?
                 ignite gas and prove flame in 4 attempts.                                                                                                                 NO    Check for:
                                                                     requires manual reset. Check for:
                 Control will auto-reset after 3 hours.                                                                                                                          - Inadequate flame carryover or rough
                                                                     - Dirty filter or restricted duct system.                                    YES
                 See status code 34.                                                                                                                                                ignition.
                                                                     - Loose blower wheel.
                                                                                                                                                                           NO    - Low inlet gas pressure.
                                                                     - Defective switch or connections.                 Do the main burners ignite?                              - Proper firing rate.
                                                                     - Defective blower motor or capacitor.
              21 GAS HEATING LOCKOUT – Turn off                      - Inadequate combustion air supply
                 power and wait 5 minutes to retry.                     (flame rollout switch open).                                              YES




17
                 Check for:                                          - Restricted vent.
                 - Stuck closed gas valve relay on control.          - Proper vent sizing.                                                                                 YES   Allow blower to come on and repeat test to
                                                                                                                        Do the main burners stay on?
                 - Miswire or short to gas valve wire.               - Excessive wind.                                                                                           check for intermittent operation.
                                                                     - Blower motor on incorrect speed tap.
                                                                     - Input rate to furnace set too high.                                        NO
              22 ABNORMAL FLAME-PROVING SIGNAL
                 Flame is proved while gas valve is de-                                                                 Repeat call for heat and check flame sensor              Check connections and retry. If current is
                                                                                                                                                                           NO    near typical value (4.0-6.0 nominal) and
                 energized. Inducer will run until fault is       34 IGNITION PROVING FAILURE – If flame                current during trial for ignition period. Is the
                 cleared. Check for:                                                                                    DC microamps below 0.5?                                  burners will not stay on, replace control.
                                                                     is not sensed during the trial for ignition
                 - Stuck open or leaky gas valve.                    period, the control will repeat the ignition
                                                                                                                  NO
                                                                     sequence 3 more times before lockout
                                                                     #14 occurs. If flame signal is lost during                                   YES
              23 PRESSURE SWITCH DID NOT OPEN                        the blower on-delay period, blower will      YES
                 Check for:                                          come on for the selected blower off-delay.         Clean flame sensor with fine steel wool and
                 - Obstructed pressure tube.                          Check the following items first before            recheck current. Nominal current is 4.0 to 6.0
                 - Pressure switch stuck closed.                     proceeding to the next step.                       microamps.
                                                                     - Gas valve turned off.
                                                                     - Manual shut-off valve.
              24 SECONDARY VOLTAGE FUSE IS OPEN                      - Green/Yellow wire MUST be connected
                 Check for:                                             to furnace sheet metal.
                 - Short circuit in secondary voltage (24V)          - Flame sensor must not be grounded.                                                                  NO    Replace electrode.
                                                                                                                        Is current near typical value?
                   wiring including thermostat leads.                To determine whether the problem is in
                   Disconnect thermostat leads to isolate            the gas valve, igniter, or flame sensor the
                   short circuit.                                    system can be operated in the component                                      YES
                                                                     test mode to check the igniter. First
                                                                                                                                                                           NO    Replace furnace control.
                                                                     remove the R thermostat connection from            Will main burners ignite and stay on?
                                                                     the control and initiate the component
                                                                     test sequence. Does the igniter glow
                                                                                                                                                  YES
                                                                     orange/white by the end of the 15 second
                                                                     warm-up period?
                                                                                                                        Fixed.




     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.
PG9MAB




                           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   Catalog No: SG ---PG9MAB---03
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.                  Replaces: SG--- PG9MAB--- 02



                                                                                                    18

				
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