Payne PG95XAT42060 User manual

Owner's Manual
NOTE TO INSTALLER:
THIS MANUAL MUST BE LEFT WITH THE
EQUIPMENT USER.
USER: PLEASE READ ALL INSTRUCTIONS
IN THE MANUAL AND RETAIN ALL
MANUALS FOR FUTURE REFERENCE.
FIRE OR EXPLOSION HAZARD
Failure to follow warnings could result in personal injury,
death, or property damage.
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 nearby 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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CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury
and/or death.
Carbon Monoxide is invisible, odorless, and toxic! Install a
carbon monoxide alarm in your home, even if you do not
own a gas appliance. Locate the carbon monoxide alarm in
the living area of your home and away from gas appliances
and doorways to attached garages. Follow the alarm
manufacturer's instruction included with the alarm.
A11300
ELECTRICAL OPERATION HAZARD
Failure to follow this warning could result in personal injury,
death, or property damage.
Do not use this furnace if any part has been under water. A
flood-damaged furnace is extremely dangerous. 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, and electrical
parts that have been wet, or the entire furnace if deemed
necessary.

TABLE OF CONTENTS
WELCOME TO A NEW GENERATION OF COMFORT .... 2
FURNACE COMPONENTS ........................... 3
SAFETY CONSIDERATIONS ......................... 4
BEFORE STARTING YOUR FURNACE ................. 5
STARTING YOUR FURNACE ......................... 5
SHUTTING DOWN YOUR FURNACE .................. 7
PERFORMING ROUTINE MAINTENANCE ............. 8
FILTERING OUT TROUBLE .......................... 9
COMBUSTION AREA AND VENT SYSTEM ............ 9
WINTERIZATION .................................. 13
A CHECK- UP CHECKLIST .......................... 14
BEFORE YOU REQUEST A SERVICE CALL ........... 14
INSTALLATION DATA ............................. 15
WELCOME TO TODAY'S GENERATION
OF COMFORT
Congratulations! In light of rising energy costs, a 90+% AFUE
Condensing Gas Furnace from Payne Heating &Cooling Systems
is 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 two 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.
This furnace is among the safest, most dependable,
energy- efficient furnaces you can buy today. 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 enioyment. 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.
A11300
Always AsR For
Use of theAHRI Certified 'rvMark indicates a
manufacturer's participation in the program. For
verification of certification tbr individual products,
go to www.ahridirectory.org. ISO9001
ELECTRICAL SHOCK, FIRE OR EXPLOSION
HAZARD
Failure to follow safety warnings exactly could result in
dangerous operation, serious iniury, death, or property
damage.
Improper servicing could result in dangerous operation,
serious iniury, death or property damage.
• Before servicing, disconnect all electrical power to
furnace.
• When servicing controls, label all wires prior to discon-
necting. Reconnect wires correctly,
• Verify proper operation after servicing.

FURNACE COMPONENTS
Furnace shown in upflow position; may be used in downflow or horizontal orientation or applications.
GAS BURNER
HOT SURFACE
IGNITER MANUAL RESET
ROLLOUT SWITCH
FLAME
MANUAL RESET
ROLLOUT SWITCH
GAS VALVE --
OPERATINGINSTRUCTIONS
NOT SHOWN(LOCATED ON
MAIN FURNACE DOOR, SEE
OPERATINGINSTRUCTIONS
INSIDE DOORFIGURE).
ELECTRICAL JUNCTION
BOX (IF REQUIRED,
LOCATION MAY VARY)
BLOWER DOOR
SAFETY SWITCH
FURNACE
CONTROL
BOARD
RATING PLATE NOT SHOWN
(LOCATED ON BLOWER DOOR)
MAIN LIMIT SWITCH
BEHIND GAS VALVE)
INDUCER MOTOR
ASSEMBLY
BLOWERAND
MOTOR
CAPACITOR/
POWER CHOKE
REPRESENTATIVE DRAWING ONLY, SOME MODELS MAY VARY IN APPEARANCE.
Fig. 1 -Furnace Components
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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 flmctions 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 one of two
ways, as a direct- vent (2- pipe- Fig. 2) application or as a
non- direct vent (1- pipe- Fig. 3) application.
•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 two pipes running
from the furnace to the outdoors. In some cases, the inlet air pipe
may be located in an area that has access to outdoor air, such as
an attic. In all cases, the outlet vent pipe must be routed to the
outdoors. (See Fig. 2.) In this application, the vent and
air- intake pipes nmst 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 one
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 ventilation. Do not obstruct the
combustion- air pipe in any way. The vent pipe nmst terminate
outside the structure and must not be obstructed in any way. Do
not block or obstruct air openings or space around furnace.
FIRE OR EXPLOSION HAZARD
Failure to follow warnings could result in personal injury,
death, or property damage.
Keep insulation clear of furnace and maintain clearances
shown on unit clearance label.
Do not keep combustible materials, gasoline, and other
flammable liquids or vapors around your furnace.
\\
Fig. 2 -Exterior Vent Pipes
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Fig. 3 - Interior Combustion -Air Pipe
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FIRE OR EXPLOSION HAZARD
Failure to follow this warning could result in personal iniury,
death, or property damage.
Do not keep combustible materials, gasoline, and other
flammable liquids or vapors around your furnace.
•Keep the area around your furnace clear and free of combustible
materials, gasoline, and other flammable liquids and vapors.
A92182
Fig. 4- NO combustible materials near furnace
• Do not cover the furnace, store trash or debris near it, or in any
way block the flow of fresh air to the unit.
[]NIT OPERATION HAZARD
Failure to follow this caution may result in internfittent unit
operation.
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.
In addition to the safety rules above, make sure that the following
combustion-air requirements are met for non-direct vent
applications:
• Combustion air nmst be clean and uncontanfinated with chlorine
or fuorine. 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 uncontanfinated. If these compounds
are burned in your furnace, the heat exchangers may deteriorate.
• A furnace installed in an attic or other insulated space nmst be
kept free and clear of insulating material. Exanfine 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.
BEFORE STARTING YOUR FURNACE
Exanfine the furnace installation to deternfine that:
1. All flue gas carrying areas external to the furnace (i.e. china-
ney, vent connector) are clear and free of obstructions.
2. The vent connector is in place, slopes upward and is physic-
ally sound without holes or gaps.
3. The return-air duct connection(s) is physically sound, is
sealed to the furnace casing, and ternfinates outside the
space containing the furnace.
4. The physical support of the furnace is sound without sag-
ging 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 (by
comparison with pictorial sketches or drawings of the main
burner flame).
Manifold
Burner Flame
Burner
Al1461
Fig. 5 - Burner Flame Adjustment
STARTING YOUR FURNACE
FIRE AND EXPLOSION HAZARD
Failure to follow this warning could result in personal
iniury, 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 and install
lockout tag.
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 signals
the furnace to start,
Follow these important safeguards:
•Never attempt to manually light the burners with a match
or other source of flame,

Fig.6 - Do Not Light Burner with Match
A92319
• Read and follow the operating instructions on inside of
main furnace door, especially the item that reads as fol-
lows: (See Fig. 31.)
"Wait 5nfinutes to clear out any gas. Then smell for gas,
including near the floor. If you smell gas, STOP! Fol-
low "B" in the safety information on furnace label. If you
don't smell gas, go to the next step."
• If asuspected malfunction occurs with your gas control
system, such as the burners do not light when they
should, refer to the shutdown procedures on inside of
main furnace door, or in the "Shutting Down Your Fur-
nace" section and 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 "Perfornfing Routine Maintenance" section in this
manual. Do not run the furnace without afilter in place.
Then proceed as follows:
STEPS FOR STARTING YOUR FURNACE
1. Set your room thermostat to the lowest temperature setting
and set the "MODE" to "OFF.". See Fig. 7.
Fig. 7 - Lowest Temperature Setting
2. Close the external manual gas valve. See Fig. 8.
A09564
i" I
'--"1
Fig. 8 - Close Valve
3. Turn OFF electrical supply to the furnace. See Fig. 9.
Fig. 9 - Turn Off Electrical Supply
4. Remove the main furnace door. See Fig. 10.
A06188
A92185
Al1302
Fig. 10 - Remove Main Furnace Door (Upflow Configuration)
5. Turn thecontrol switch on thegas control to the OFF position
and wait five nfinutes. See Fig. 10. Then smell for gas, includ-
ing near the floor. If you smell gas, STOP! Follow "B" on fur-
nace label. If you don't smell gas, go to next step.

TWO4TAGE GAS CONTROL
GAS CONTROL SWITCH
SHOWN IN "OFF" POSITION
Fig. 11 - Control Switch to OFF
Al1320
6. After waiting five minutes, turn control switch on the gas con-
trol to the ON position. Turn the control switch to ON. See
Fig. 12.
TWO-STAGE GAS CONTROL
GAS CONTROL SWITCH --
SHOWN IN "ON" POSITION
Fig. 12 - Control Switch to ON
7. Replace main furnace door. See Fig. 13.
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@
A11301
Fig. 13 - Furnace Door Replaced (Upflow Configuration)
8. Turn ON the electrical supply to the furnace and wait one
minute. See Fig. 14.
Fig. 14 - Turn on Electrical Supply
A92359
9. Open the external manual gas valve, See Fig. 15.
i t
Fig. 15 - Open Valve
A06189
10. Set the room thermostat "MODE" to "HEAT" and adjust the
setpoint to a temperature slightly above the room temperature.
This will automatically signal the furnace to start.
11. When the furnace receives the start signal, the combustion air
draft inducer is started. When the pressure switch senses that
there is sufficient combustion air, the hot surface igniter is en-
ergized.
After the hot surface igniter is heated for about 20 seconds, the
gas valve permits gas to flow to the main burners. After igni-
tion and a time delay of up to 60 seconds, the furnace blower
will start. Variable- capacity furnaces start at low speed until
the control makes the necessary adjustments to operate the
blower at either the low- or high- heat speed.
NOTE: If the main burners fail to ignite after four attempts, the
furnace control system will lock out. If lockout occurs, 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 thermo-
stat back a few degrees--and compensating for the differ-
ence with warmer clothing--can make a big difference in
your fuel consumption on extremely cold days. The few de-
grees 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 automatically switched off.
Continuous Fan Operation -Some thermostats have a "FAN"
switch with two selections: AUTO and ON. When the thermostat is
set on AUTO, the furnace blower cycles on and off, controlled by
the thermostat. In ON position, the furnace blower runs
continuously. Continuous fan keeps the temperature level in your
home more evenly balanced. It also continuously filters the indoor
air.
On all but the base series furnace, the blower speed can be
increased or decreased if desired due to change of seasons, large

gatherings in your home, etc. Simply change your FAN from ON
to OFF for 1 to 3 seconds (or AUTO depending on your
thermostat), and then return to ON. The blower will switch to the
next higher speed. There are at least three speeds to choose from.
If the blower is running on its highest speed, a request to change
will direct the blower to return to its lowest speed.
SHUTTING DOWN YOUR FURNACE
Should you need to shut down your furnace for service or
maintenance, you will need to turn the furnace off. The following
procedures must be followed:
1. Set your room thermostat to the lowest temperature setting
and set the "MODE" to "OFF." See Fig. 16.
Fig. 16 - Lowest Temperature Setting
2. Close the external manual gas valve. See Fig. 17.
¢,
,===t I
1
Fig. 17 - Close the External Manual Valve
3. Turn off electrical supply to the furnace. See Fig. 18.
A09564
A06188
TWO4TAGE GAS CONTROL
GAS CONTROL SWITCH
SHOWNIN"OFF"POSITION
Fig. 19 -Control Switch to OFF
Al1320
4. Remove main furnace door. See Fig. 10.
5. Turn control switch on the gas control to "OFF" position.
See Fig. 19.
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.
UNIT AND PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in unit component or
property damage.
Furnace is not to be installed, operated, and then turned off
and left turned off in an unoccupied structure during winter.
See "Winterization" procedures in this manual.
PERFORMING ROUTINE MAINTENANCE
NOTE: The qualified installer or agency must use only
factory-authorized replacement parts, kits, and accessories when
modifying this product.
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 nmst 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.
With proper maintenance and care, your furnace will operate
econonfically and dependably. Instructions for basic maintenance
are found on this and the following pages. However, before
beginning maintenance, follow these safety precautions:
Fig. 18 - Turn Off Electrical Supply
A92185
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
iniury or death.
Turn off electrical power supply to your furnace and
install lockout tag before removing the access doors to
service or perform maintenance.

CUTHAZARD
Failureto follow this caution may result in personal injury.
Although special care has been taken to minimize sharp
edges, be extremely careful when handling parts or reaching
into the furnace. Wear safety glasses, gloves, and
appropriate protective clothing.
FILTERING OUT TROUBLE
NOTE: The manufacturer has specified filters which will enable
your furnace to provide lasting comfort and efficiency throughout
its life. Contact your dealer to help you choose filters for your
furnace that both collect dirt before it enters your furnace, as well
as provide a low resistance to circulating air. Avoid filters that
report high cleaning efficiencies, but do not allow air to pass easily
through them.
UNIT PERFORMANCE HAZARD
Failure to follow this caution may result in unit component
damage,
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,
b. Slide air filter out of furnace. Keep dirty side up (if
dirty) to avoid spilling dirt. See Fig. 23 and 24.
3. Inspect the filter. If torn replace it.
NOTE: If a washable filter was suppliedwith the furnace and has
been replaced by:
• Disposable media filter- - Do not clean. If dirty, replace
only with media filter having the same part number and
size. Install with airflow direction arrow pointing to-
wards blower.
• Electronic Air Cleaner (EAC), refer to the EAC Owner's
Manual for maintenance information.
4. 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 fil-
ter to dry.
5. Reinstall clean air filter.
6. Turn on electrical supply to the furnace.
If your furnace air filter needs to be replaced, be sure to use a
factory-authorized filter of the same size that was originally
specified. Use the filter tables and compare your furnace size with
the proper filter size.
PERSONAL INJURY HAZARD
Failure to follow this caution may result in personal iniury.
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.
Fig. 20 -Turn Off Electrical Supply
A92185
A dirty filter will cause excessive stress on the furnace, heat
exchanger, and blower motor, and can cause it to overheat and
automatically shut down. The furnace filter should be checked
every four weeks and be 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 once 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 an external filter
cabinet attached to the side or bottom of the furnace casing. 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. 20.
2. Remove air filter from the filter cabinet.
a. Remove filter cabinet door. (See Fig. 21 and 22.)
NOTE: It maybe necessary to remove one thumbscrew.
A00225
Fig. 21 - Removal of Filter Cabinet Door from Side Blower
Cabinet

A00226
Fig. 22 -Removal of Filter Cabinet Door from Bottom
Blower Cabinet
A00228
Fig. 24 -Removal of Filter from Bottom Blower Cabinet
A00227
Fig. 23 -Removal of Filter from Side Blower Cabinet
A00229
Fig. 25 -Replacement of Filter Cabinet Door to Side Blower
Cabinet
Fig. 26 -Replacement of Filter Cabinet Door to Bottom Blower Cabinet
A00230
Table I -Air Filter Located in Filter Cabinet
FILTER OABINET HEIGHT -IN (MM) FILTER SiZE - IN (MM) FILTER TYPE
(1) 16 x 25 x 6/4"
(406 x 635 x 19) or Washablet
16 (406) (1) 16x25x4- 5/16
(406 x 665 x 11 O)
(1) 20 x 25 x 6/4"
(508 x 635 x 19) or Washablet
20 (508) (1) 20 x 25 x 4- 5/16
(508 x 635 x 110)
(1) 24 x 25 x 3/4"or
(610 x 635 x 19) or Washablet
24 (610) (1) 24 x 25 x 4- 5/16
(610 x 635 x 110)
Filters with a side return- air may have a different filter size. Measure the filter to obtain the correct size.
Recommended to maintain air filter face velocity. See Product Data for part number.
10