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Gas Furnace Heating & Cooling NOTE TO INSTALLER : USER : Please read all manuals and retain manuals for future reference . This manual must be left with the equipment user . WARNING : o FIRE OR EXPLOSION HAZARD _ © _ © © © © 8 © 8 © Failure to follow safety warnings exactly could _ @ _ _ _ 8 © 8 @ result in serious injury , death , or property _ © © _ damage . 8 © 8 © - - Do not store or use gasoline or other flammable 8 © 8 © © 8 © 8 vapors and liquids in the vicinity of this or any 8 © 8 © other appliance . - - WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance . @ • Do not touch any electrical switch ; do not use any phone in your building . • Leave the building immediately . • Immediately call your gas supplier from a neighbor's phone . Follow the gas supplier's instructions . • If you cannot reach your gas supplier , call the fire department . - - Installation and service must be performed by a qualified installer , service agency or the gas J supplier . WARNING : Carbon Monoxide is invisible , odorless , and toxic ! Do not use this furnace if any part has been Payne Heating and Cooling recommends a carbon under water . A flood - damaged furnace is monoxide alarm in your home , even if you do not own extremely dangerous . Attempts to use the fur - a gas appliance . Locate the carbon monoxide alarm in nace can result in fire or explosion . A qualified the living area of your home and away from gas appli - service agency should be contacted to inspect the ances and doorways to attached garages . Follow the furnace and to replace all gas controls , control alarm manufacturer's instruction included with the system parts , electrical parts that have been wet alarm . or the furnace if deemed necessary .
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TABLE OF CONTENTS WELCOME TO TODAY'S GENERATION OF COMFORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 FURNACE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL FURNACE SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 IMPORTANT FACTS ( DO'S AND DON'TS ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 BEFORE STARTING YOUR FURNACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 STARTING YOUR FURNACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steps for Starting Your Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHUTTING DOWN YOUR FURNACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PERFORMING ROUTINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filtering Out Trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMBUSTION AREA AND VENT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEFORE YOU REQUEST A SERVICE CALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REGULAR DEALER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WELCOME TO TODAY'S GENERATION OF COMFORT Congratulations ! Your new , higher efficiency gas furnace is a sotmd investment which will reward you and your family with years of warm memories winter after winter . Not only is your new furnace energy efficient , it is also extremely reliable . Spend just a few minutes with this booklet to learn about the operation of your new furnace - - and the small amount of maintenance it takes to keep it operating at peak efficiency . Years went into the development of your new furnace . Take a little time now to assure its most efficient operation for years to come . FURNACE COMPONENTS INDUCER MOTOR VENT ELBOW ASSEMBLY ( BEHIND GAS VALVE ) PRESSURE / SWITCH DRAFT SAFEGUARD FLUE SWITCH COLLECTOR FLAME SENSOR BOX GAS VALVE MANUAL RESET GAS BURNER LIMIT SWITCHES @ HOT SURFACE _ DOOR IGNITER SAFETY SWITCH CONTROL _ " BLOWERAND MOTOR CAPACITOR * Elbow may be turned to a different position , RATING PLATE NOTSHOWN depending on type of installation ( LOCATED ON A02259 BLOWER DOOR ) ( Furnace shown in upflow position ; may be used in downflow or horizontal orientation or applications ) 7 . Flood Damage Wurning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l GENERAL FURNACE SAFETY 8 . Fire or Explosion Hazard Warning . . . . . . . . . . . . . . . . . . . . . . . 1 1 . Combnstible Materiuls , Gasoline Warning . . . . . . . . . . . . . . . . . 1 9 . Carbon Monoxide Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 . Furnace Must be Kept Free and Clear of Insulating 10 . Service and Maintenance Electrical Hazard . . . . . . . . . . . . . . . . 6 Material Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3 . Furnace Needs Air for Combustion and 11 . Improper Vent Wurning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Ventilation Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 12 . Sharp Edges Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 4 . Starting ( Lighting ) and Shutting Down the 13 . No Filter Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Furnace Wurning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,5 14 . Filter Rod Modification Caution . . . . . . . . . . . . . . . . . . . . . . . . 7 5 . Draft Safeguard Switch Caution . . . . . . . . . . . . . . . . . . . . . . . . . 8 15 . Dirt , Rust , orAccnmnlation Caution . . . . . . . . . . . . . . . . . . . . . 8 6 . Proper Furnace Shutdown Procedures . . . . . . . . . . . . . . . . . . . . 5
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IMPORTANT FACTS ( DO'S AND DON'TS ) • DO : READ AND UNDERSTAND THIS MANUAL . * DO : Have your furnace and vent system inspected ammally by a qualified service technician . • DO : Inspect your filter monthly and clean or replace when needed . • DO : Provide adequate airflow m the furnace or efficient combustion and sale ventilation . • DO : Keep your furnace flee and clear of insulating material . Some materials may beon combustible . Examine the furnace area when the furnace is installed or when insulati is added . • DO NOT : Enclose your furnace in an airtight room or seal it behind solid doors . • DO NOT : Keep combustible materials , gasoline , and other flammable liquids or vapors 3 around your furnace . • DO NOT : Cover your furnace in any manner . * DO NOT : Store anything ( including trash or debris ) near your furnace . * DO NOT : In any way block or restrict airflow around your furnace . * DO NOT : In any way block or restrict airflow to your supply air and return air grills . * DO NOT : Use your furnace room as a broom closet or a place to store any kind of chemical or cleaner . • DO NOT : Contaminate the air used for combustion of your furnace with any kind of chemical or fumes . This could also cause heat exchangers , metal vent systems or components to deteriorate . NOTE : These chemicals or fumes are present in many products around the home , such as : water softener salts , any type of household cleaning product , any type of laundry product , adhesives , paints , varnishes , paint strippers , waxes and plastics , etc . During remodeling be sure the combustion air is fresh and uncontaminated . If these compounds are burned in your furnace , the heat exchangers and metal vent system may deteriorate . NOTE : The qualified installer or agency must use only factory - authorized replacement parts , kits , and accessories when mod - ifying this product . This furnace contains safety devices which must be manually reset . If the furnace is left unattended for an extended period of time , have it checked periodically for proper operation . This precaution will prevent problems associated with no heat , such as frozen water pipes , etc . See " Before You Request a Service Call " section in this manual . SAFETY CONSIDERATIONS Installing and servicing heating equipment can be hazardous due to gas and electrical components . Only trained and qualified personnel should install , repair , or service heating equipment . Untrained personnel can perform basic maintenance functions such as cleaning or replacing air filters . All other operations must be performed by trained service personnel . Observe safety precautions in this manual , on tags , and on labels attached to the furnace , and other safety precautions that may apply . Recognize safety information . This is the safety - alert symbol z _ . When you see this symbol on the furnace and in instructions or manuals , be alert to the potential for personal injury . Understand the signal words DANGER , WARNING , and CAUTION . These words are used with the safety - alert symbol . DANGER identifies the most serious hazards which will result in severe personal injury or death . WARNING signifies hazards which could result in personal injury or death . CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage . NOTE is used to highlight suggestions which will result in enhanced instal - lafion , reliability or operation . WARNING : Do not keep combustible materials , gasoline , and other flammable liquids or vapors around your furnace . WARNING : Fire Hazard ! Failure to keep insulation clear of furnace could result in fire , personal injury , or death . BEFORE STARTING YOUR FURNACE Examine the furnace installation to determine that : 1 . All flue gas carrying areas external to the furnace ( i . e . chimney , vent connector ) are clear and free of obstructions . 2 . The vent connector is in place , slopes upward and is physically sound without holes or excessive corrosion .
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3 . Thereturn - adiructconnection ( iss ) physicallsyoundis , sealedtothefunlacecasinga , ndterlni - uatesoutsidethespacceontainintghefurnace . 4 . Thephysicaslupporotfthetunlaceissoundwithoutsaggincgracks , gaps , etc . around the base . 5 . There are no obvious signs of deterioration of the funlace . 6 . The pilot and burner flames are in good adjustment ( by comparison with pictorial sketches or drawings of the main burner flame and , if applicable , the pilot burner flame ) . STARTING YOUR FURNACE Your furnace uses an automatic hot surface ignition system to light the burners each time the thermostat signals the furnace m start . Follow these important safeguards : • Never attempt to manually light the burners with a match or other source of flame . • Read and follow the operating instructions on the inside of main furnace door , especially the item that reads as follows : " Wait 5 minutes to clear out any gas . Then smell for gas , including near the floor . If you smell gas , STOP ! Follow " B " in the safety information above on this label . If you don't smell gas , go to the next step . " • Ifa suspected malfunction occurs with your gas control system , such as the burners do not light when they should , refer to the shutdown procedures on the furnace , or in the next section , m turn off your system , then call your dealer as soon as possible . WARNING : Should the gas supply fail to shut off or if overheating occurs , shut off the gas valve to the furnace before shutting off the electrical supply , A failure to follow this warning could result in a fire or explo - sion , and personal injury or death , • CHECK AIR FILTER : Before attempting to start your furnace , be sure the furnace filter is clean and in place . ( See the maintenance section of this manual . ) Do not run the furnace without a filter in place . Then proceed as follows : STEPS FOR STARTING YOUR FURNACE 1 . Set your room thermostat to the lowest temperature setting . ( See Fig . 5 . ) 2 . Close the external manual gas valve . ( See Fig . 6 . ) 5 6 3 . Turn OFF electrical supply to the furnace . ( See Fig . 7 . ) 4 . Remove the outer door by loosing the thumbscrew and pulling the door forward . ( See Fig . 8 . ) 5 . Turn the control switch to OFF and wait 5 minutes to clear out any gas . ( See Fig . 9 ) Then smell for gas , including near the floor . If you smell gas , STOP ! Follow " B " on furnace label . If you don't smell gas , go to next step . 6 . After waiting 5 minutes if you still smell gas , STOP ! Follow the safety information on the cover of this manual . If you do not smell gas , go to the next step . 7 . Turn the control switch m ON ( See Fig . 10 . ) OR 8 9
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8 . Replace the outer door and tighten the thumbscrew . ( See Fig . 11 . ) J OR 10 11 L - - - - oFF I 12 13 9 . Turn ON the electrical supply to the furnace . ( See Fig . 12 . ) 10 . Open the external manual gas valve . ( See Fig . 13 . ) 11 . Set the room thermostat to a temperature slightly above the room temperature . This will automatically signal the furnace to start . The inducer motor will start , and the hot surface ignitor will energize . When hot , the ignitor will have an orange glow . 12 . Alter about 32 seconds , the gas valve permits gas to flow to the main burners where it is ignited . Hot flames begin m warm the furnace's heat exchanger . Alter a time delay of approximately 25 - 45 sec the furnace blower is switched on . NOTE : If the main burners fail to ignite , the furnace control system will go through 3 more ignition cycles . Then , if burners fail to ignite , the system will lockout . If lockout occurs , or the blower does not come on - - shut down your furnace and call your dealer for service . 13 . Set your thermostat to the temperature that satisfies your comfort requirements . SUGGESTION : Setting the thermostat back a few degrees - - and compensating for the difference with warmer clothing - - can make a big difference in your fuel consulnp - tion on extremely cold days . The few degrees at the top of your thermostat " comfort level " are the most costly degrees to obtain . When the room temperature drops below the temperature selected on the thermostat , the furnace will switch on automatically . When the room temperature reaches the setting selected on the thermostat , the furnace will be autolnatically switched off . Continuous Fan Operation - Some thermostats have a " FAN " switch with 2 selections : AUTO and ON . When thermostat is set on AUTO , the furnace blower cycles on and oft . controlled by the thermostat . In ON position , the furnace blower runs continuously except for a 42 - 62 sec delay at the " call for heat . " Continuous fan keeps the temperature level in your home more evenly balanced . It also continuously filters the indoor air . SHUTTING DOWN YOUR FURNACE Should you ever suspect a malfunction in your furnace , you will need to turn the furnace off . The following procedures must be followed : 1 . Set your room thermostat to the lowest temperature setting . ( See Fig . 14 . ) 2 . Close the external manual gas valve ( See Fig . 6 on page 4 . ) 3 . Turn OFF electrical power to your furnace . ( See Fig . 15 . )
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© v . _ 14 15 4 . Remove the outer door on your furnace . ( See Fig . 8 . ) 5 . Turn the switch on the gas valve to the OFF positiom ( See Fig . 16 . ) 6 . Replace the outer door . ( See Fig 11 . ) 7 . If the furnace is being shut down because of a malfunction , call your dealer as soon as possible . OR 16 PERFORMING ROUTINE MAINTENANCE With proper maintenance and care , your furnace will operate economically and dependably . Basic maintenance , which can easily be accomplished by someone who follows the directions , is found on this and the following pages . However , before beginning maintenance , follow these safety precautions : WARNING : Turn off electrical power supply to your furnace before removing the access doors to service or perform maintenance . A failure to follow this warning could result in personal injury or death . CAUTION : Although special care has been taken to minimize sharp edges , be extremely careful when handling parts or reaching into the furnace . FILTERING OUT TROUBLE CAUTION : Never operate your furnace without a filter in place . Doing so may damage the furnace blower motor . An accumulation of dust and lint on internal parts of your furnace can cause a loss of efficiency . A dirty filter will cause excessive stress on the furnace , heat exchanger , and blower motor and can cause it to overheat and aummafically shut down . The furnace filter should be checked every 4 weeks or so and cleaned or replaced if necessary . If installed with factory specified disposable media filter , check or replace filter before each heating and cooling season . Replace disposable media filter at least twice a year . If your furnace filter needs replacing , be sure to use the same size and type of filter that was originally specified . The air filter for the furnace may be located in a filter cabinet attached to the side or bottom of the furnace . If air filter has been installed in another location , contact your dealer for instructions . To inspect , clean aud / or replace the air filter ( s ) , follow these steps :
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1 . Turn off the electrical supply to the furnace . ( See Fig . 7 . ) 2 . Remove filter cabinet door . NOTE : It may be necessary to remove 1 thumbscrew . 3 . Slide air filter out of filter cabinet . Keep dirty side up ( if dirty ) to avoid spilling dirt . 4 . Inspect the filter . If torn , replace it . NOTE : Ifa washable filter has been replaced with : a ) Factory specified disposable media filter - Do not cleam If dirty , replace only with media filter having the same part number and size . Install with airflow direction arrow pointing towards blower . b ) Elecmmic air cleaner ( EAC ) - Refer to EAC Owner's Manual for maintenance information . 5 . Wash filter ( if dirty ) in sink , bathtub , or outside with a garden hose . Always use cold tap water . A mild liquid detergent may be used if necessary . Spray water through filter in the opposite direction of airflow . Allow filter to dry . 6 . Reinstall clean air filter . 7 . Replace filter cabinet door . 8 . Turn on electrical supply to furnace ( See Fig 12 ) . NOTE : If side return ducts are used , 2 filters may be required in some models . The procedure listed above may be used to remove side filters . FILTER QUANTITY AND SIZE : * " : ' FURNACE CAS - SIDE ING WIDTH RETURN BOTTOM RETURN FILTER TYPE * 14 - 1 / 2 ( 1 ) 16 x 25 ( I ) 14 x 25 1 " thick deanable or lhick media - type 17 - 1 / 2 ( 1 ) 16x25 ( I ) 16x25 I " tl _ ick cleanable orlhick media - type 21 ( 1 ) 16x25 ( I ) 20x 25 1 " thick cleanable or lhick media - type 24 ( 1 ) 16x25 ( I ) 24 x 25 1 " lhick cleanable or thick mcdia - tyI * : Recommended Some ihrnaces may have 2 fihcrs Filters may be fiekl modified by , cutting filter material and support rods ( 3 ) in fillers . Alternate sizes and additional fillers may be ordered lrom your dealer . CAUTION : Use care when cutting support rods in filters to protect against flying pieces and sharp rod ends . Wear safety glasses , gloves , and appropriate protective clothing . Failure to follow this caution could result in personal injury . COMBUSTION AREA AND VENT SYSTEM WARNING : If holes are found or if the vent pipe is obstructed or is not connected , toxic fumes can escape into your home . DO NOT OPERATE YOUR FURNACE . Call your dealer for service . A failure to follow this warning could result in personal injury or death . WARNING : For proper and safe operation the furnace needs air for combustion and ventilation . Do not block or obstruct air openings on the furnace , air opening to the area in which the furnace is installed , and the space around the furnace . Inspect the Colnbustion area and vent system before each heating season . An accumulation of dirt , soot , or rust can mean a loss of efficiency and improper performance . Buildups on the main burners can cause faulty firing . This " delayed ignition " is characterized by an alarmingly loud sound . NOTE : If your furnace makes a loud noise when the main burners are ignited , shut down the furnace and call your servicing dealer . Use your flashlight and follow these steps for inspecting the combustion area and vent system of your furnace : 1 . Turn off electrical supply to the furnace and remove the access door . ( See Fig . 7 and 8 . ) 2 . Carefully inspect the gas burner for dirt , rust , or scale ( See Fig . 17 . ) Inspect the elbow , flue connection area , and the vent pipe for rest .
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17 A CAUTION : If dirt , rust , soot , or scale accumulations are found , call your servicing dealer . DO NOT OPERATE THE FURNACE . 3 . Inspect the vent pipe for a sag , holes , or a disconnection . A horizontal vent pipe must slope upward away from furnace . If rusty joints or seams , or signs of water leakages are found , call your dealer for service . 4 . Restore electrical power to the furnace . ( See Fig . 12 . ) 5 . Start the furnace and observe its operatiom If possible , watch the burner flames . Are they burning bright blue ? If not or if you suspect some other malfunction , call your servicing dealer . 6 . Replace the access door . ( See Fig . 11 . ) BEFORE YOU REQUEST A " SERVICE CALL " Before you call for service , check for several easily solved problems : • Check for sufficient airflow . Check the air tilter for dirt . Check for blocked return - air or supply - air grilles . Be sure they are open and unobstructed . If this isn't the cause of the problem , call your servicing dealer . If your furnace isn't operating at all , check the following list for easily solved problems : • Is your thermostat set above room temperature ' ? Is the HEAT mode selected ' ? • Is the electrical power supply switch on ? Is the blower access door firmly in place ' ? Are any fuses blown ? ( There is a fuse on the furnace control . ) Has a circuit breaker tripped ? • Is the manual shut - off valve in the gas supply pipe leading to the furnace open ? Does the lever point in the same direction that the pipe runs ( open ) ? Or is it at a right angle to the pipe ( closed ) ' ? NOTE : Before proceeding with the next checks , turn off the electrical power supply m the furnace . Remove access door . • Is the switch on the gas valve turned to the ON position ? If this or the preceding check shows an interruption in the gas supply , make sure the gas has not been shut off for safety reasons . If nothing else seems m be wrong , follow the startup procedures found on pages 4 and 5 of this booklet . CAUTION : If for some reason the vent is blocked , the draft safeguard switch will shut off the furnace . ( See page 2 or 3 for switch location . ) The switch will automatically reset after the furnace cools off . If the furnace fails to operate , contact a qualified service agency . • Check the lnauual resetlimit switches located on the ends of the burner enclosures ( SeeFig . 2 ) . If the _ ruace has experienced a high - temperature condition due to inadequate combustion air , these switches will shut off the furnace . Reset the switches by pushing the button on the switch . If the switch trips a second time , turn off the furnace and call for service . • If your furnace still fails to operate , call your servicing dealer for troubleshooting and repairs . Tell your dealer the model and serial numbers for your furnace . ( You should have them recorded on page 8 of this booklet . ) By knowing exactly which furnace you have , the dealer may be able to offer suggestions over the phone or save valuable time through knowledgeable preparation for the service call . REGULAR DEALER MAINTENANCE In addition to the type of routine maintenance you might be willing to do , your furnace should be inspected regularly by a properly trained service technician . A semiannual inspection ( or annual inspection , at least ) should include the following : 1 . Inspection of all flue gas passages including the burners , heat exchanger , inducer , elbow , and vent pipe . 2 . Inspection of all combustion and ventilation air passages and openings . 3 . Close check of all gas pipes leading to and inside of your furnace .
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AIR CONDITIONER OR HEAT PUMP INSTALLATION DATA OUTDOOR UNIT : Date Installed Product No . Dealer Name Model No . Address Serial No . City State / Province Zip / Postal Code INDOOR COIL : Telephone Product No . Model No . FURNACE Serial No . Product No . Model No . Serial No . Heating & Cooling Cancels : OG - PG8M02 OG - PG8M03 ¢ c32002 Payne Heating & Cooling , P . O . Box 70 , Indianapolis , IN 46206 12 Printed in U . S . A . 11 - 02 Catalog No . 53PG - 6M3