Payne 480BAV Upflow Guide

®Model 480BAV
Upflow and
481BAV
Downflow/Horizontal
USER’S INFORMATION MANUAL FOR THE OPERATION AND
MAINTENANCE OF YOUR NEW GAS-FIRED FURNACE
NOTE TO
INSTALLER:
This manual must be left
with the equipment user.
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WARNING: If the information in this
manual is not followed exactly, a fire or
explosion may result causing property
damage, personal injury or loss of life.
— Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any 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.
• 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 supplier.
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UPFLOW FURNACE COMPONENTS
Relief Box
Rating Plate
Gas Valve Control Knob or Electric Switch (On/Off)
Gas Valve
Gas Burner
Flame Sensor
Filter Retainer
Air Filter
Blower and Blower Motor
Draft Safeguard Tube and Switch
Gas Manifold
Manual Reset Limit Switch
Hot Surface Ignitor
Blower Door Safety Switch
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2
3
4
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7
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WELCOME TO
TODAY’S
GENERATION OF
COMFORT
Congratulations!Your new, higher effi-
ciency gas furnace is a sound invest-
ment 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
amountofmaintenanceittakestokeep
it operating at peak efficiency.Years
wentintothedevelopmentof your new
furnace.Takealittletimenowtoassure
its most efficient operation for years to
come.
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MODEL 480BAV
Upflow Furnace
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MODEL 481BAV
Downflow/Horizontal
Furnace

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DOWNFLOW/HORIZONTAL
FURNACE COMPONENTS
Manual-Reset Auxiliary Limit Switch (When Used)
Blower and Blower Motor
Relief Box
Gas Valve Control Knob or Electric Switch (On/Off)
Gas Valve
Gas Burner
Rating Plate
Blower Door Safety Switch
Draft Safeguard Tube and Switch
Gas Manifold
Manual Reset Limit Switch (2)
Hot Surface Ignitor
Flame Sensor
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IMPORTANT FACTS
Your furnace must have adequate air-
flow for efficient combustion and safe
ventilation. Do not enclose it in an air-
tight room or “seal” it behind solid
doors. To minimize the possibility of
serious personal injury, fire, damage to
your furnace, or improper operation;
carefully follow these safety rules:
• Keep the area around your furnace
free of combustible materials, gaso-
line, and other flammable liquids and
vapors.
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• Do not cover the furnace, store trash
or debris near it, or in any way block
the flow of fresh air to the unit.
•Combustionair mustbecleanandnot
contaminatedwithchlorineorfluorine.
These compounds are present in many
products around the home, such as:
water softener salts, laundry bleaches,
detergents, adhesives, paints, var-
nishes, paint strippers, waxes, and
plastics.
Make sure the combustion air for your
furnace does not contain any of these
compounds. During remodeling be
sure the combustion air is fresh and un-
contaminated. If these compounds are
burned in your furnace, the heat ex-
changers and metal vent system may
deteriorate.
• A furnace installed in the attic or
other insulated space must be kept free
and clear of the insulating material.
Examine the furnace area when install-
ing the furnace or adding more insula-
tion. Some materials may be
combustible.
NOTE: Do not use this furnace if any
parthasbeenunderwater.Immediately
call a qualified service technician to in-
spect the furnace and to replace any
part of the control system and any gas
control which has been under water.
NOTE: The qualified installer or
agency must use only factory-autho-
rized replacement parts, kits, and
accessories when modifying or repair-
ing this product.
This furnace contains safety devices
whichmust be manuallyreset. If thefur-
nace is left unattended for an extended
period of time, have it checked periodi-
cally for proper operation. This precau-
tion will prevent problems associated
withnoheat,suchasfrozenwaterpipes,
etc. See “BeforeYou Request a Service
Call” section in this manual.
SAFETY
CONSIDERATIONS
Installing and servicing heating equip-
ment can be hazardous due to gas and
electrical components. Only trained
and qualified personnel should install,
repair, or service heating equipment.
Untrainedpersonnelcan perform basic
maintenance functions such as clean-
ing and 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 fur-
nace and other safety precautions that
may apply.
Recognize safety information: This is
the safety-alert symbol . When you
see this symbol on the furnace and in
instructions or manuals, be alert to the
potential for personal injury.
Understand the signal words—DAN-
GER, WARNING, and CAUTION.
These words are used with the safety-
alert symbol. DANGER identifies the
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most serious hazards which will result
in severe personal injury or death.
WARNING signifies hazards which
could resultinpersonalinjuryordeath.
CAUTION is used to identify unsafe
practice, which
would result in minor
personalinjuryorproductandproperty
damage.
STARTING YOUR
FURNACE
Instead of a continuously burning pilot
flame, your furnace uses an automatic
hot surface ignition system to light the
burners each time the thermostat calls
for heat.
Follow these important safe-
guards:
• Never attempt to manually light the
burnerswith a match or other source of
flame.
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• Read and follow the operating in-
structions on the furnace, 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.
• If a suspected malfunction occurs
with your gas control system, such as
the burners not lighting when they
should, refer to the shutdown proce-
dures on the furnace or in the next sec-
tion to turn off your system, then call
your dealer as soon as possible.
• 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.) Then proceed as
follows:
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STEPS FOR STARTING
YOUR FURNACE
1. Set your room thermostat to the
lowest temperature setting.
(See Fig. 7.)
2. Close the external manual gas
valve. (See Fig. 8.)
3. Turn OFF the electrical supply
to your furnace.
(See Fig. 9.)
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4. Remove the furnace access
door(s).
a. Downflow/Horizontal—remove
blower door after removing 2
screws, then remove the control
door. (See Fig. 10.)
b. Upflow—remove control door.
(See Fig. 11.)
5. The gas valve will have EITHER a
control knob or control switch to
turn off and on. Turn the control
knob or switch on the gas valve to
the OFF position and wait 5 min-
utes. (See Fig. 12 or 13.)
6. After waiting 5 minutes, turn the
control knob or switch on the gas
valve to the ON position. (See Fig.
14 or 15.)
7. Replace the access door(s). See
Fig. 16 for upflow and Fig. 17 for
downflow. Replace control door
first on downflow furnaces. Then
replaceblowerdoor(secure with 2
screws).
8. Turn ON the electrical supply to
the furnace. (See Fig. 18.)
9. Open the external manual gas
valve. (See Fig. 19.)
10. Set the room thermostat to a tem-
perature slightly above the room
temperature. This will automati-
cally signal the furnace to start.
The inducer motor will start, and
the hot surface ignitor will ener-
gize. When hot, the ignitor will
have an orange glow.
WARNING
Should overheating occur, or
the gas valve fail to shut off the
gas supply, turn off the manual
gas valve (See Fig. 8) to the fur-
nace BEFORE turning off the
electrical supply. A failure to
follow this warning could re-
sult in a fire or explosion, and
personal injury or death.
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11. After 15 to 70 sec, the gas valve
permits gas to flow to the main
burners where it is ignited. Hot
flamesbegintowarmthe furnace’s
heat exchanger.After a time delay
of approximately 45 sec, the fur-
nace blower is switched on.
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NOTE: If the main burners fail to ig-
nite, 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.
12. Set your thermostat to the temper-
ature that satisfies your comfort
requirements. SUGGESTION:
Setting the thermostat back a few
degrees—and compensating for
the difference with warmer cloth-
ing—can make a big difference in
your fuel consumption on
extremely cold days. The few
degrees at the top of your thermo-
stat “comfort level” are the most
costly degrees to obtain.
When the room temperature drops be-
low the temperature selected on the
thermostat, the furnace will be auto-
maticallyswitchedon.Whentheroom
temperature reaches the degree se-
lected on the thermostat, the furnace
will be automatically switched off.
Some thermostats have a “fan” mode
with2selections:AUTOorON.When
set on AUTO, the furnace blower cy-
cles on and off, controlled by the ther-
mostat. In the ON position, the
furnace blower runs continuously ex-
cept for a 45-sec delay at the “call for
heat.”Thiskeepsthetemperaturelevel
inyour homemoreevenlybalanced.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 proce-
dures must be followed:
1. Set your room thermostat to the
lowest temperature setting. (See
Fig. 20.)
2. Close the external manual gas
valve. (See Fig. 8 on page 4.)
3. Turn OFF the electrical supply to
your furnace. (See Fig. 21.)
4. Removethecontrolaccessdooron
your furnace. (See Fig. 10 or 11.)
On upflow furnaces, removing the
blower access door is not required.
5. Turn the control knob or switch on
the gas valve to the OFF position.
(See Fig. 22 or 23.)
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6. Replace the control access door.
(See Fig. 16 or 17.)
7. If the furnace is being shut down
because of a malfunction, call
your dealer as soon as possible.
PERFORMING
ROUTINE
MAINTENANCE
With the proper maintenance and care,
yourfurnacewilloperateeconomically
and dependably. Basic maintenance,
which can easily be accomplished by
following the directions, is found on
this and the following pages. However,
before beginning maintenance, follow
these safety precautions:
FILTERING OUT
TROUBLE
Adirtyfilterwillcauseexcessivestress
on the furnace blower motor and can
cause it to overheat and automatically
shutdown.The furnace filter should be
checkedevery3or4weeksandcleaned
if necessary.
If your furnace filter needs replacing,
be sure to use the same size and type of
filter that was originally supplied. Use
the Furnace Filter Table and compare
your furnace size with the proper filter
size.
The air filter for upflow furnaces is
normally located in the blower com-
partment. Filters for the downflow fur-
naces are normally located in the
return-air plenum above the blower. If
thefiltershavebeeninstalledinanother
location, contact your dealer for in-
structions. To inspect, clean, and/or re-
place the air filter(s), follow these
steps:
•
UPFLOW FURNACES ONLY:
1. Turn OFF the electrical supply to
the furnace. (See Fig. 21.)
2. Removecontrolandbloweraccess
doors.
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3. Push filter retainer toward the
bracket opening to release the fil-
ter. (See Fig. 24.)
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4. Gently remove the filter and care-
fullyturnthedirtysideup(ifdirty)
to avoid “spilling” dirt from the fil-
ter. (See Fig. 25.)
5. Inspect the filter. If torn, replace
the filter.
6 Wash the filter (if dirty) in a 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
the filter in the opposite direction
of airflow. Allow filter to dry.
7. Reinstall the clean filter.
8. Put filter retainer back in the
bracket opening and lock it in
place.
9. Replace the blower and control
access doors and turn ON electri-
cal power to your furnace. (See
Fig. 16, 17, and 26.)
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WARNING
Turn off electrical power sup-
ply to your furnace before re-
moving the access doors to
service or perform mainte-
nance. A failure to follow this
warning could result in per-
sonal injury or death.
CAUTION
Although special care has
been taken to minimize sharp
edges, be extremely careful
when handling parts or reach-
ing into the furnace.
CAUTION
Never operate your furnace
without a filter in place. Doing
so may damage the furnace
blower motor. An accumula-
tion of dust and lint on internal
parts of your furnace can
cause a loss of efficiency.
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NOTE: For upflow models only—if
side return ducts are used, 2 filters may
be required in some models. The pro-
cedure listed above may be used to re-
move side filters.
27 28
• DOWNFLOW/HORIZONTAL
FURNACES ONLY:
Two filters are located in the return-air
plenum above the blower (above line-
of-sight) resting in the V-shaped chan-
nel on top of the furnace. (See Fig. 27.)
1. Turn OFF electrical supply to the
furnace. (See Fig. 21.)
2. Remove blower access door after
removing 2 screws.
3. Remove the left-side filter by tip-
ping the filter toward the center—
raise it from theV-shaped channel
in which it rests. (See Fig. 27
and 28.)
4. Lower filter down along side of
the blower and remove from the
furnace.
5. To remove the second filter, lift
from V-shaped channel and
remove the same way as left side
filter.
6. Inspect the filters. If torn, replace
the filter.
7. Wash the filters (if dirty) in a 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
the filter in the opposite direction
of airflow. Allow filter to dry.
8. Reinstall clean filters.
9. Replace blower door (secure with
2 screws) and turn ON electrical
power to your furnace.
UPFLOW FURNACE FILTER
TABLE
FURNACE
CASING
WIDTH
FILTER SIZE FILTER
TYPESide Return Bottom Return
14-3/16 (1)16x25x1* (1)14x25x1*Cleanable
17-1/2 (1)16x25x1* (1)16x25x1*Cleanable
21 (1)16x25x1*(1)20x25x1* Cleanable
24-1/2 (2)16x25x1* (1)24x29x1*Cleanable
DOWNFLOW/HORIZONTAL
FURNACE FILTER TABLE
* Factory-provided with the furnace. Fil-
ters may be field modified by cutting to
size. Alternate sizes and additional fil-
ters may be ordered from your dealer.
COMBUSTION AREA
AND VENT SYSTEM
Inspect the combustion 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. If your fur-
nacemakesa loudnoise whenthe main
burners are ignited, shut down the fur-
nace—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 the electrical supply to
the furnace and remove the access
doors. (See Fig. 9 and 10, or 11.)
2. Carefully inspect the gas burner
(see Fig. 29) for dirt, rust, or scale.
Then inspect the relief box, flue
connection area, and the vent pipe
for rust.
29
NOTE: If dirt, rust, soot, or scale accu-
mulations are found, call your servic-
ing dealer. DO NOT OPERATE THE
FURNACE.
3. Inspect the vent pipe for a sag,
holes, or a disconnection. A hori-
zontal vent pipe must slope
upward.If rustyjointsorseams, or
signs of water leakages are found
call your dealer for service.
4. Replace the access doors and
restore electrical power to the fur-
nace. Be sure bottom door flange
is inside of the furnace casing.
(See Fig. 16, 17, and 26.)
5. Start the furnace and observe its
operation. If possible, watch the
burner flames.Are they burning
bright blue? If not (or if you sus-
pect some other malfunction), call
your servicing dealer.
BEFOREYOUREQUEST
A “SERVICE CALL”
BEFOREYOU CALL FOR
SERVICE, CHECK FOR
SEVERAL EASILY SOLVED
PROBLEMS:
• Check for sufficient airflow. Check
the air filter for dirt. Check for blocked
return-air or supply-air grilles. Be sure
they are open and unobstructed. If this
is not the cause, call your servicing
dealer.
If your furnace is not 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 board.)
Has a circuit breaker tripped?
• Is the manual shutoff 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 right angles (closed)?
NOTE: Before proceeding with the
next checks, turn OFF the electrical
power supply to the furnace. Remove
the access doors.
• Is the control knob or switch on the
gas valve turned to the ON position? If
this or the preceding check shows an
interruption in the gas supply, make
FURNACE
CASINGWIDTH
FILTER SIZE FILTERTYPE
14-3/16 (2)16x20x1* Cleanable
17-1/2 (2)16x20x1* Cleanable
21 (2)16x20x1* Cleanable
24-1/2 (2)16x20x1* Cleanable
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 FUR-
NACE. Call your dealer for ser-
vice. A failure to follow this
warning could result in per-
sonal injury or death.
!

Cancels OM04-18 OM04-25
© 1996 BDP Co.Indpls., IN 46206 Printed in U.S.A.
8
Catalog No. PA-3348-011 1-96

sure the gas has not been shut off for
safety reasons. If nothing else seems to
bewrong,follow the startup procedures
found on pages 4 and 5 of this booklet.
•If forsomereasontheventis blocked,
the draft safeguard switch will shut off
the furnace. Reset the switch by push-
ing the button located on top of the
switch (see page 3 for switch location).
If the switch trips a second time, turn
off the furnace and call for service.
•
DOWNFLOW/HORIZONTAL
ONLY
—Check the manual-reset
auxiliary limit switch (when used)
located on the blower housing. If the
blowermotorfails,thisswitchwillshut
off the furnace. Reset it by pushing the
button on the switch. If it trips again,
turn off the furnace and call for service.
• Check the manual-reset limit
switch(es) located near the burners. If
the furnace has experienced a high-
temperature condition, due to inade-
quate combustion air, these switches
will shut off the furnace. Reset the
switch(es) by pushing the button on the
switch.Ifthe switchtripsa second time,
turn off the furnace and call for service.
• If your furnace still fails to operate,
call your servicing dealer for trouble-
shooting and repairs. Tell your dealer
the model and serial numbers for your
furnace. (You should have them re-
corded 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 main-
tenance you might be willing to do,
your furnace should be inspected regu-
larly by a properly trained service tech-
nician. An annual inspection (or
biennial inspection, at least) should in-
clude the following:
1. Inspection of all flue product pas-
sages—includingtheburners,heat
exchanger, relief box, and vent
pipe.
2. Inspection of all combustion
and ventilation air passages and
openings.
3. Close check of all gas pipes lead-
ing to (and inside of) your furnace.
4. Inspection, cleaning, and lubrica-
tion (when required) of the blower
motor and wheel.
NOTE: Refer to the unit Service Pro-
cedures for blower motor oiling infor-
mation. When required, the motor
must be oiled by a qualified service
technician.
5. Routine inspection and cleaning/
replacement of the air filter.
6. Inspection of all supply- and
return-air ducts for obstructions,
air leaks, and insulation. Any
problems found should be
resolved at this time.
7. Inspection of furnace installation
for proper support and any obvi-
ous deterioration of the furnace.
The support must be sound and
without sags, gaps, cracks, etc.,
around the furnace base so as to
provide an air seal between the
support and furnace.
8. A check for loose connections
attaching individual components.
Inspection of all electrical wiring
and their connections.
9. Operational check of the furnace
itself to determine working condi-
tion. Repair or adjustment should
be made at this time.
Ask your servicing dealer for
further details about an economical
service contract that covers seasonal
inspections.
INSTALLATION DATA
Date Installed
Dealer Name
Address
City
State Zip
Telephone
FURNACE
Product No.
Model No.
Serial No.
SPLIT-SYSTEM
OUTDOOR UNIT:
Product No.
Model No.
Serial No.
INDOOR COIL:
Product No.
Model No.
Serial No.