Payne OG-PG9M-07 Guide

Condensing
Gas Furnace
NOTE TO INSTALLER:
This manual must be left with the equipment user.
USER’S INFORMATION MANUAL FOR THE OPERATION AND
MAINTENANCE OF YOUR NEW GAS-FIRED FURNACE
USER’S INFORMATION MANUAL
— 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.
• 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
supplier.
WARNING:
CARBON MONOXIDE POISONING HAZARD
Carbon Monoxide is invisible, odorless, and
toxic! Payne Heating & Cooling Systems rec-
ommends a carbon monoxide alarm in your
home, even if you do not own a gas appliance.
Locate the carbon monoxide alarm in the liv-
ing area of your home and away from gas ap-
pliances and doorways to attached garages.
Follow the alarm manufacturer’s instruction
included with the alarm.
!
WARNING:
FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings exactly could
result in serious injury, death, or property damage.
!
Do not use this furnace if any part has been under
water. A flood-damaged furnace is extremely dan-
gerous. Attempts to use the furnace can result in
fire or explosion.A qualified service agency should
be contacted to inspect the furnace and to replace
all gas controls, control system parts, electrical
parts that have been wet or the furnace if deemed
necessary.
USER: Please read all instructions in the manual
and retain all manuals for future reference.

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WELCOMETO A NEW GENERATION OF COMFORT
Congratulations! In light of rising energy costs, the PG9MAB Multipoise, Fixed-Capacity, Direct/Non-DirectVent, Condensing Gas
Furnaces are among the soundest investments today’s homeowner can make.
Your new furnace is truly a triumph of technology in home heating. A revolutionary design employs 2 heat exchangers to “squeeze”
out the maximum amount of heat from the fuel consumed. In fact, your new furnace is so efficient, over 90%* of the heat generated
during combustion is captured and delivered inside your home. That is more than a 30%* increase in heating efficiency over con-
ventional furnaces.
This furnace is among the most energy-efficient furnaces you can buy today. The PG9MAB is also among the safest and most
dependable. We are proud of the technological advances incorporated into the design of this furnace. With only minimal care, your
new furnace will deliver many years of money-saving home comfort and enjoyment. Spend just a few minutes with this manual to
learn the operation of your new furnace and the small amount of maintenance it takes to help keep it operating at peak efficiency
year after year.
* The output capacity and any representations of efficiency for this furnace are based on standard U.S. Department of Energy test procedures.
TABLE OF CONTENTS
WELCOME TO A NEW GENERATION OF COMFORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
FURNACE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
STARTING AND SHUTTING DOWN YOUR FURNACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Steps for Starting Your Furnace. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Shutting DownYour Furnace. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PERFORMING ROUTINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Filtering Out Trouble. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
COMBUSTIONAREA AND VENT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Heading South for the Winter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
A CHECK-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
BEFORE YOU REQUEST A SERVICE CALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
As an ENERGY STAR® Partner,
Payne Heating & Cooling Sys-
tems Company has determined
that this product meets the
ENERGY STAR® guidelines for
energy efficiency.
CERTIFIED
®

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FURNACE COMPONENTS
Burner sight glass for viewing burner flame.
Burner assembly (inside), operates with energy-
saving, inshot burners and hot surface igniter for safe,
dependable heating.
Combustion-air intake connection (right or left side).
Redundant gas valve. Safe and efficient. Features 1 gas
control with 2 internal shutoff valves.
Junction box for 115-v electrical power supply.
Vent outlet, uses PVC pipe to carry flue gas from the fur-
nace’s combustion system (right or left side).
Secondary condensing heat exchanger (inside). Wrings
out more heat through condensation.
Constructed with polypropylene-laminated steel to en-
sure durability.
Pressure switch ensures adequate flow of flue gas
through furnace and out vent system.
Inducer motor. Pulls hot flue gases through the heat ex-
changers, maintaining negative pressure for added safety.
Condensate drain connection, collects moisture
condensed from burned gases for disposal into home
drain system. (location in furnace varies)
Heavy-duty blower, circulates air across the heat
exchangers to transfer heat into the home.
Air filter and retainer. (Location in furnace may vary.)
Rollout switch (manual reset) to prevent
overtemperature.
Primary serpentine heat exchanger (inside),
stretches fuel dollars with the S-shaped heat-flow
design. Solid construction of corrosion-resistant
aluminized steel means reliability.
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MODEL PG9MAB FURNACE
(SHOWN IN UPFLOW POSITION) 1
3-amp fuse provides electrical and component
protection.
Status code light emitting diode (LED) on furnace control
board. Status code light is for diagnosing furnace opera-
tion and service requirements.
Furnace control board.
Blower access panel safety interlock switch.
Transformer (24v) behind furnace control board provides
low-voltage power to furnace control board and
thermostat.
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SAFETY CONSIDERATIONS
Installing and servicing of 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 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 furnace
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 DANGER, WARNING, CAUTION, and NOTE. DANGER, WARNING, and CAUTION 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
may result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in
enhanced installation, reliability, or operation.
To minimize the possibility of serious personal injury, fire, damage to your furnace, or improper operation,
carefully follow these
safety rules
which apply to both direct-vent and non-direct vent applications:
Your new gas furnace may have been installed in 1 of 2 ways, as a direct-vent (2-pipe) application or as a non-direct vent (1-pipe)
application.
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In a direct-vent (2-pipe) application, your furnace uses air from outside the home for combustion and vents flue gas to the outdoors.
This type of application will have 2 pipes running from the furnace to the outdoors. (See Fig. 2.) In this application, the vent and air-
intake pipes must terminate outside the structure and must not be obstructed in any way. Do not block or obstruct air openings on
furnace or spaces around furnace.
In a non-direct vent (1-pipe) application, your furnace uses air from adjacent to the furnace for combustion and vents flue gas to the
outdoors. This type of application will have only 1 pipe running from the furnace to the outdoors. (See Fig. 3.) The other pipe will
terminate in the same space as the furnace and is the source of combustion air for your furnace. Therefore, the furnace must not be
enclosed in an airtight room or be sealed behind solid doors. It must have adequate airflow for efficient combustion and safe venti-
lation. Do not obstruct the combustion-air pipe in any way. The vent pipe must terminate outside the structure and must not be
obstructed in any way. Do not block or obstruct air openings or space around furnace.
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• Keep the area around your furnace clear and free of combustible materials, gasoline, 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.
In addition to the safety rules above, make sure that the following combustion-air requirements are met for non-direct vent applica-
tions:
• Combustion air must be clean and uncontaminated with chlorine or fluorine. These compounds are present in many products
around the home, such as: water softener salts, laundry bleaches, detergents, adhesives, paints, varnishes, 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 uncontaminated. If these compounds are burned in your furnace, the heat exchangers may deteriorate.
• A furnace installed in an attic or other insulated space must be kept free and clear of insulating material. Examine the furnace area
when the furnace is installed or when insulation is added. Some insulation materials may be combustible.
• Should the gas supply fail to shut off or if overheating occurs, shut off the gas valve to the furnace before shutting off electrical
supply.
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
.
WARNING:
FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in fire, personal injury/death or property damage.
Do not keep combustible materials, gasoline, and other flammable liquids or vapors around your furnace.
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.
Examine the furnace installation monthly 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.
3. The return-air duct connection(s) is physically sound, is sealed to the furnace casing, and terminates outside the space
containing the furnace.
4. The physical support of the furnace is sound without sagging cracks, gaps, etc. around the base.
5. There are no obvious signs of deterioration of the furnace.
6. The burner flames are in good adjustment. (See Fig. 5.)
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STARTING AND SHUTTING DOWNYOUR FURNACE
Instead of a continuously burning pilot flame which wastes valuable energy, your furnace uses an automatic, hot surface ignition
system to light the burners each time the thermostat starts your furnace.
Follow these important safeguards:
6
• Never attempt to light the burners manually 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 furnace 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 procedures on the inside of main furnace door, or in the “Shutting DownYour Furnace” section, and call your dealer as
soon as possible.
WARNING:
FIRE AND UNIT OPERATION HAZARD
Failure to follow this warning could result in fire, personal injury/death or property damage.
For proper and safe operation the furnace needs air for combustion and ventilation. Do not block or obstruct
the openings on the furnace, air openings to the area in which the furnace is installed, and the space around
the furnace.
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CHECK AIR FILTER: Before attempting to start your furnace, be sure the furnace air filter is clean and in place. See “Performing
Routine Maintenance” section in this manual. Then proceed as follows:
STEPS FOR STARTINGYOUR 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 electrical supply to the furnace. (See Fig. 9.)
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4. Remove the main furnace door. (See Fig. 10.)
5. Gas valve will have a control switch to turn ON or OFF. Turn control switch on the gas control to the OFF position and wait 5
minutes. (See Fig. 11.) Then smell for gas, including near the floor. If you smell gas,
STOP! Follow operating instructions on
main furnace door.
10 11
6. After waiting 5 minutes, turn control switch on the gas control to the ON position. (See Fig. 12.)
7. Replace main furnace door. (See Fig. 13.)
12 13
8. Turn ON electrical supply to the furnace and wait 1 minute. (See Fig. 14.)
WARNING:
FIRE HAZARD
Failure to follow this warning could result in a fire or explosion, and personal injury/death or property damage.
Should the gas supply fail to shut off or if overheating occurs, turn off the manual gas valve to the furnace
BEFORE turning off the electrical supply. (See Fig. 8.)
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9. Open external manual gas valve. (See Fig. 15.)
10. Set the room thermostat to a temperature slightly above room temperature. (See Fig. 16.) This will automatically signal the
furnace to start.
14 15 16
11. When the furnace receives the start signal, the hot surface igniter at the main burners is automatically heated for 15 to 20 sec. When
the microprocessor control verifies that there is sufficient heat to ignite, the gas valve permits gas to flow to the main burners. After
ignition and a time delay of approximately 60 sec, the furnace blower starts.
NOTE: If the burners fail to ignite after 4 attempts, the furnace control system will lock out. If lockout occurs, the main burners fail
to light, or blower does not come on, shut down the furnace and call your dealer for service.
12. 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 consumption. The few degrees at the top of your thermostat “comfort level” are the most
costly degrees to obtain.
When room temperature drops below the temperature selected on the thermostat, the furnace will be switched on automatically.
When room temperature reaches the temperature selected on the thermostat, the furnace will be switched off automatically.
Some thermostats have a FAN mode with 2 selections, AUTO and ON. When thermostat is set to AUTO, the furnace blower
cycles on and off. In ON mode, the furnace blower runs continuously. Continuous fan keeps the temperature level in your
home more evenly balanced. It also permits the indoor air to be continuously filtered.
SHUTTING DOWNYOUR FURNACE
Should you need to shut down your furnace for service or maintenance, you will need to turn the furnace off.
17 18 19
The following procedures must be followed:
1. Set your room thermostat to the lowest temperature setting. (See Fig. 17.)
2. Close the external manual gas valve. (See Fig. 18.)
3. Turn off electrical supply to the furnace. (See Fig. 19.)
4.
Remove main furnace door. (See Fig. 10.)
5. Turn control switch on the gas control to OFF position. (See Fig. 20.)
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6. Replace main furnace door. (See Fig. 13.)
7. If the furnace is being shut down because of a malfunction, call your dealer as soon as possible.
PERFORMING ROUTINE MAINTENANCE
NOTE: The qualified installer or agency must use only factory-authorized replacement parts, kits, and accessories when modifying
or repairing this product.
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 and replacing air filters.
All other operations must be performed by trained and qualified service agency personnel. Observe safety precautions in this manual,
on tags, and on labels attached to the furnace, and other safety precautions that may apply.
With proper maintenance and care, your furnace will operate economically and dependably. Instructions for basic maintenance are
found on this and the following pages. However, before beginning maintenance, follow these safety precautions:
FILTERING OUT TROUBLE
A dirty air filter will cause a loss of airflow in your duct system. When excessive loss of airflow occurs, the furnace may cycle on its
safety controls. If this condition is left unattended, the furnace will eventually lock out. It is recommended that the furnace filter be
checked every 3 or 4 weeks and cleaned 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 once a year.
The air filter is normally located in the blower compartment. (See Fig. 1.) If the air filter has been installed in another location, contact
your dealer for instructions. To inspect, clean, and/or replace the air filter(s), follow these steps:
1. Turn off electrical supply to the furnace. (See Fig. 21.)
2. Remove main furnace door. (See Fig. 22.)
3. Remove blower access panel. (See Fig. 23.)
NOTE: It will be necessary to remove 2 screws.
CAUTION:
UNIT AND PROPERTY DAMAGE
Failure to follow this caution may result in damage to the furnace and other property damage.
Furnace is not to be installed, operated, and then turned off and left turned off in an unoccupied structure dur-
ing winter. (See “Heading South for the Winter?” procedures in maintenance section on page 11).
WARNING:
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury/death.
Turn off electrical power supply to your furnace before removing the main furnace door to service or perform
maintenance.
CAUTION:
CUT HAZARD
Failure to follow this caution may result in minor personal injury.
Although special care has been taken to minimize sharp edges, be extremely careful when handling parts or
reaching into the furnace.
CAUTION:
UNIT PERFORMANCE HAZARD
Failure to follow this caution may result in product damage.
Never operate your furnace without a filter in place. Doing so may damage the furnace blower motor. An accu-
mulation of dust and lint on internal parts of your furnace can cause a loss of efficiency.
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21 22 23
4. Remove air filter from furnace.
• AIR FILTER(S) LOCATED IN END OF FURNACE:
a. Slide air filter retainer sideways until it is free of latch. (See Fig. 24.)
b. Slide air filter out of furnace. (See Fig. 25.)
24 25
• AIR FILTER LOCATED IN SIDE OF FURNACE:
a. Remove air filter retainer from latch. (See Fig. 26.)
b. Gently remove air filter and carefully turn the dirty side up (if dirty) to avoid spilling dirt from the filter. (See Fig. 27.)
26 27
5. Inspect the filter. If torn, replace it.
NOTE: If washable filter that was shipped with the furnace has been replaced with an electronic air cleaner (EAC), refer to the EAC
Owner’s Manual for maintenance information.
6. If washable filter, wash 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 filter in the opposite direction of airflow. Allow filter to dry.
7. Reinstall clean air filter.
8. Reinstall filter retainer.
9. Replace blower access panel and main furnace door with two screws. (See Fig. 28 and 29.) Turn on electrical supply to the
furnace. (See Fig. 30.)

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28 29 30
If your furnace air filter needs to be replaced, be sure to use a factory authorized filter of the same size that was originally supplied.
Use the furnace air filter table and compare your furnace size with the proper filter size.
FURNACE AIR FILTER TABLE
* Furnace with a side return-air inlet may have a different filter size. Measure the filter to obtain the correct size.
COMBUSTION AREA AND VENT SYSTEM
Visually inspect the combustion area and vent system before each heating season. Make sure that all PVC pipes leading into the
combustion area and vent are free from any cracks and sags.
Check the combustion-air intake adjacent to the furnace or outside your home for blockage. Also check the vent pipe on the outside
of your home for blockage.
When dirt, soot, scale, or rust is allowed to build up, your furnace can suffer a loss of efficiency and perform improperly. Accumu-
lations on the main burners can result in firing out of normal sequence. This delayed ignition creates an alarmingly loud sound.
To inspect the combustion area and vent system, you will need a flashlight. Refer to Fig. 1, and proceed as follows:
1. Turn off gas and electrical supplies to the furnace and remove the main furnace door. (See Fig. 8 and 9.)
2. Remove burner enclosure front. (See Fig. 31 or 32.)
Inspect the gas burners, igniter area, and remainder of furnace for dirt, soot, rust, or scale.
FURNACE CASING WIDTH (IN.) FILTER SIZE* (IN.) FILTER TYPE
17-1/2 (1) 16 x 25 x 1 Cleanable
21 (1) 20 x 25 x 1 Cleanable
24-1/2 (1) 24 x 25 x 1 Cleanable
WARNING:
PERSONAL INJURY HAZARD
Failure to follow this warning could result in personal injury.
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.
WARNING:
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury or death.
If holes are found in the pipes or if any portion has become disconnected, toxic fumes can escape into your home.
DO NOT OPERATE YOUR FURNACE. Call your dealer for service.
CAUTION:
UNIT OPERATION HAZARD
Failure to follow this caution may result in minor property damage.
If your furnace makes an especially loud noise when the main burners light, shut down your furnace and call
your dealer.
WARNING:
Failure to follow this warning could result in personal injury or death.
If dirt, rust, soot, or scale accumulations are found, call your dealer. Do not operate your furnace.
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