Payne PG9YAA036060 User manual

1
PG9YAA
Installation Instructions
95% SINGLE STAGE DIRECT OR
NON---DIRECT VENT GAS FURNACE
UPFLOW / HORIZONTAL
Special Venting Requirements for Installations in Canada
Installation in Canada must conform to the requirements of CSA
B149 code. Vent systems must be composed of pipe, fittings,
cements, and primers listed to ULC S636. The special vent
fittings and accessory concentric vent termination kits and
accessory external drain trap have been certified to ULC S636 for
use with those IPEX PVC vent components which have been
certified to this standard. In Canada, the primer and cement must
be of the same manufacturer as the vent system -- IPEX System
636, PVC/CPVC Primer, Purple Violet for Flue Gas Venting and
IPEX System 636, PVC Cement for Flue Gas Venting, rated
Class IIA, 65 deg C. must be used with this venting system -- do
not mix primers and cements from one manufacturer with a vent
system from a different manufacturer. Follow the manufacturer’s
instructions in the use of primer and cement and never use primer
or cement beyond its expiration date.
The safe operation, as defined by ULC S636, of the vent system
is based on following these installation instructions, the vent
system manufacturer’s installation instructions, and proper use of
primer and cement. All fire stop and roof flashing used with this
system must be UL listed material. Acceptability under Canadian
standard CSA B149 is dependent upon full compliance with all
installation instructions. Under this standard, it is recommended
that the vent system be checked once a year by qualified service
personnel.
The authority having jurisdiction (gas inspection authority,
municipal building department, fire department, etc) should be
consulted before installation to determine the need to obtain a
permit.
Consignes spéciales pour l’installation de ventillation au Canada
L’installation faite au Canada doit se conformer aux exigences du
code CSA B149. Ce systême de ventillation doit se composer de
tuyaux, raccords, ciments et apprêts conformes au ULC S636. La
tuyauterie de ventillation des gaz, ses accessoires, le terminal
concentrique mural ainsi que l’ensemble du drain de condensat
extérieur ont été certifiés ULCS 636 pour l’application des
composantes IPEX PVC qui sont certifiées à ce standard. Au
Canada l’apprêt et le ciment doivent être du même manufacturier
que le systême de ventillation -- IPEX Système 636, Apprêt
PVC/CPVC. Mauve Violette pour conduit en évacuation des gaz
et IPEX Système 636, ciment pour PVC pour conduit en
évacuation des gaz, évalué CLASSEIIA,65deg.C.doitëtre
utilisé avec ce systèeme d’évacuation -- ne pas mélanger l’apprêt
et le ciment d’un manufacturier avec le systême de ventillation
d’un autre manufacturier. Bien suivre les indications du
manufacturier lors de l’utilisation de l’apprêt et du ciment et ne
pas utiliser ceux--ci si la date d’expiration est atteinte.
L’opération sécuritaire, tel que définit par ULC S636, du système
de ventilation est basé sur les instructions d’installation suivantes,
ainsi que l’usage approprié de l’apprêt et ciment. Tout arrët feu et
solin de toit utilisés avec ce système doivent être des matériaux
listés UL. L’acceptation du standard Canadien CSA B419 est
directement relié à l’installation conforme aux instructions ci--
haut mentionnées. Le standard Canadien recommande l’
inspection par un personel qualifié et ce, une fois par année.
Les autoritées ayant juridiction (inspecteurs de gas, inspecteurs
en bâtiments, département des incendies, etc) devraient être
consultées avant l’installation afin de déterminer si un permis est
requis.

2
Required Notice for Massachusetts Installations
IMPORTANT
The Commonwealth of Massachusetts requires compliance with regulation 248 CMR as follows:
5.08: Modifications to NFPA--54, Chapter 10
2) Revise 10.8.3 by adding the following additional requirements:
a. For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used
in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where
the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting,
including but not limited to decks and porches, the following requirements shall be satisfied:
1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented
gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an
alarm and battery back--up is installed on the floor level where the gas equipment is to be installed. In addition, the
installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is
installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled
equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for
the installation of hard wired carbon monoxide detectors
a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard
wired carbon monoxide detector with alarm and battery back--up may be installed on the next adjacent floor level.
b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner
shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty
(30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the
above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.
3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a
minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas
fueled heating appliance or equipment. The sign shall read, in print size no less than one--half (1/2) inch in size, ”GAS
VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.
4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve
the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in
accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4.
5. EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through 4:
(1.) The equipment listed in Chapter 10 entitled ”Equipment Not Required To Be Vented” in the most current edition of
NFPA 54 as adopted by the Board; and
(2.) Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from
the dwelling, building or structure used in whole or in part for residential purposes.
c. MANUFACTURER REQUIREMENTS -- GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the
manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design
or venting system components with the equipment, the instructions provided by the manufacturer for installation
of the equipment and the venting system shall include:
1. Detailed instructions for the installation of the venting system design or the venting system components; and
2. A complete parts list for the venting system design or venting system.
d. MANUFACTURER REQUIREMENTS -- GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When
the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the
parts for venting the flue gases, but identifies “special venting systems”, the following requirements shall be
satisfied by the manufacturer:
1. The referenced “special venting system” instructions shall be included with the appliance or equipment installation
instructions; and
2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall include a
parts list and detailed installation instructions.
e. A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled
equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions
shall remain with the appliance or equipment at the completion of the installation.
PG9YAA

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START--UP CHECK SHEET
For 95% Furnace
(This sheet is optional. Keep this page for future reference.)
Date of Start--Up:
Dealer Name:
Address:
City, State(Province), Zip or Postal Code:
Phone:
Owner Name:
Address:
City, State(Province), Zip or Postal Code:
Model Number:
Serial Number:
Setup Checks
Check the box when task is complete
All Electrical Connections Tight?
Have hoses been relocated for furnace application
(upflow/horizontal)?
Condensate Drain Connected?
Condensate Drain Trapped?
Manual Gas Shut--Off Upstream of
Furnace/Drip--Leg?
Gas Valve turned ON?
Type of Gas: Natural: Propane:
Filter Type and Size:
Calculated Firing Rate:(See Checks and Adjustments
Section).
Heating Check
Measured Line Pressure when Firing Unit:
Measured Manifold Gas Pressure:
Temperature of Supply Air: (°)
Temperature of Return Air: (°)
Temperature Rise (supply--return temperature):(°)
In Rise (see furnace rating plate)? (°)
Static Pressure (Ducts): Supply Air Return
Which blower speed tap is used? (Heating)
Optional Check: CO ? CO2 ?
Cooling Check
Temperature of Supply Air: (°)
Temperature of Return Air: (°)
Temperature Difference: (°)
Static Pressure (Ducts) cooling: Supply Air Return
Blower Speed Tap used for cooling: _______
Dealer Comments:
PG9YAA

4
NOTE: Read the entire instruction manual before starting the
installation.
NOTE: Please retain these instructions with the furnace after
installation for future reference.
ama
CERTIFIED
SAFETY CONSIDERATIONS
FURNACE RELIABILITY HAZARD
Improper installation or misapplication of furnace may
require excessive servicing or cause premature component
failure.
Application of this furnace should be indoors with special
attention given to vent sizing and material combustion air
requirements, gas input rate, air temperature rise, unit
leveling, and unit sizing.
CAUTION
!
FIRE, EXPLOSION, ELECTRICAL SHOCK AND
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal
injury, death, or property damage.
Improper installation, adjustment, alteration, service,
maintenance, or use can cause carbon monoxide poisoning,
explosion, fire, electrical shock, or other conditions which
may cause personal injury or property damage. Consult a
qualified installer, service agency, local gas supplier, or your
distributor or branch for information or assistance. The
qualified installer or agency must use only
factory--authorized and listed kits or accessories when
modifying this product.
!WARNING
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 service personnel. When working
on heating equipment, observe precautions in literature, on tags,
and on labels attached to or shipped with unit and other safety
precautions that may apply.
These instructions cover the minimum requirements and conform
to existing national standards and safety codes. In some instances,
these instructions exceed certain local codes and ordinances,
especially those that may not have kept up with changing
residential construction practices. We require these instructions as
a minimum for a safe installation.
Wear safety glasses and work gloves. Have a fire extinguisher
available during start--up and adjustment procedures and service
calls.
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, 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 a hazard
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.
CUT HAZARD
Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or burrs. Use care
and wear appropriate protective clothing and gloves when
handling parts.
CAUTION
!
TABLE OF CONTENTS
PAGE
IMPORTANT INFORMATION 2.........................
SAFE INSTALLATION REQUIREMENTS 5...............
COMBUSTION & VENTILATION AIR 10.................
CONCENTRIC TERMINATION 30.......................
GAS SUPPLY & PIPING 32.............................
ELECTRICAL WIRING 35..............................
DUCTWORK & FILTER 36.............................
CHECKS & ADJUSTMENTS 38.........................
FURNACE MAINTENANCE 40.........................
SEQUENCE OF OPERATION & DIAGNOSTICS 40.........
PG9YAA

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SAFE INSTALLATION
REQUIREMENTS
FIRE, EXPLOSION, AND ASPHYXIATION HAZARD
Failure to follow this warning could result in personal injury or
death.
Improper adjustment, alteration, service, maintenance or
installation could cause personal injury, death and/or
property damage.
Installation or repairs made by unqualified persons could
result in hazards to you and others. Installation MUST
conform to local codes or, in the absence of local codes,
with codes of all governmental authorities having
jurisdiction.
The information contained in this manual is intended for
use by a qualified service agency that is experienced in
such work, is familiar with all precautions and safety
procedures required in such work, and is equipped with
the proper tools and test instruments.
!WARNING
NOTE: This furnace is design--certified by the CSA
International (formerly AGA and CGA) for installation in the
United States and Canada. Refer to the appropriate codes, along
with this manual, for proper installation.
SUse only the type of gas approved for this furnace (see Rating
Plate on unit). Overfiring will result in failure of heat
exchanger and cause dangerous operation. (Furnaces can be
converted to Propane gas with approved kit.)
SInstall this furnace only in a location and position as specified
in “Installation” of these instructions.
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury or
death.
Do NOT install this furnace in DOWNFLOW applications.
!WARNING
SProvide adequate combustion and ventilation air to the furnace
as specified in “ Combustion and Ventilation Air” of these
instructions.
SCombustion products must be discharged outdoors. Connect
this furnace to an approved vent system only, as specified in
“Vent and Combustion Air Piping” of these instructions.
SNever test for gas leaks with an open flame. Use a
commercially available soap solution made specifically for the
detection of leaks to check all connections, as specified in
“Gas Supply and Piping, Final Check” of these instructions.
SAlways install furnace to operate within the furnace’s intended
temperature--rise range with a duct system which has an
external static pressure within the allowable range, as specified
in “Technical Support Manual” of these instructions. See
furnace rating plate.
SWhen a furnace is installed so that supply ducts carry air
circulated by the furnace to areas outside the space containing
the furnace, the return air shall also be handled by a duct(s)
sealed to the furnace casing and terminating outside the space
containing the furnace.
SA gas--fired furnace for installation in a residential garage must
be installed as specified in “Installation” of these instructions.
SThis furnace is not to be used for temporary heating of
buildings or structures under construction.
SThis furnace is NOT approved for installation in mobile
homes, trailers or recreation vehicles.
SSeal around supply and return air ducts.
SInstall correct filter type and size.
SUnit MUST be installed so electrical components are protected
from direct contact with water.
Safety Rules
Your unit is built to provide many years of safe and dependable
service providing it is properly installed and maintained.
However, abuse and/or improper use can shorten the life of the
unit and create hazards for you, the owner.
The U.S. Consumer Product Safety Commission encourages
installation of carbon monoxide alarms. There can be various
sources of carbon monoxide in a building or dwelling. The
sources could be gas--fired clothes dryers, gas cooking stoves,
water heaters, furnaces, gas--fired fireplaces, wood fireplaces.
Carbon monoxide can cause bodily injury and/or death. Carbon
monoxide or “CO” is a colorless and odorless gas produced when
fuel is not burned completely or when the flame does not receive
sufficient oxygen.
Therefore, to help alert people of potentially dangerous carbon
monoxide levels, you should have a commercially available
carbon monoxide alarm that is listed by a nationally recognized
testing agency in accordance with Underwriters Laboratories Inc.
Standard for Single and Multiple Station Carbon Monoxide
Alarms, ANSI/UL 2034 or the CSA 6.19--01 Residential Carbon
Alarming Devices installed and maintained in the building or
dwelling concurrently with the gas--fired furnace installation (see
Note below). The alarm should be installed as recommended by
the alarm manufacturer’s installation instructions.
There can be numerous sources of fire or smoke in a building or
dwelling. Fire or smoke can cause bodily injury, death, and/or
property damage. Therefore, in order to alert people of potentially
dangerous fire or smoke, you should have fire extinguisher and
smoke alarms listed by Underwriters Laboratories installed and
maintained in the building or dwelling (see Note below).
NOTE: The manufacturer of your furnace does not test any
alarms and makes no representations regarding any brand or type
of alarms.
To ensure safe and efficient operation of your unit, you should do
the following:
1. Thoroughly read this manual and labels on the unit.
This will help you understand how your unit operates and
the hazards involved with gas and electricity.
2. Do not use this unit if any part has been under water.
Immediately call a qualified service technician to inspect
the unit and to replace any part of the control system and
any gas control which has been under water.
3. Never obstruct the vent grilles, or any ducts that
provide air to the unit. Air must be provided for proper
combustion and ventilation of flue gases.
PG9YAA

6
Frozen Water Pipe Hazard
WATER DAMAGE TO PROPERTY HAZARD
Failure to follow this caution may result in property damage.
Do not leave your home unattended for long periods during
freezing weather without turning off water supply and
draining water pipes or otherwise protecting against the risk
of frozen pipes and resultant damage.
CAUTION
!
Your furnace is designed solely to provide a safe and comfortable
living environment. The furnace is NOT designed to ensure that
water pipes will not freeze. It is equipped with several safety
devices that are designed to turn the furnace off and prevent it
from restarting in the event of various potentially unsafe
conditions.
If your furnace remains off for an extended time, the pipes in
your home could freeze and burst, resulting in water damage.
If the structure will be unattended during cold weather you should
take these precautions.
1. Turn off the water supply to the structure and drain the wa-
ter lines if possible and add an antifreeze for potable water
to drain traps and toilet tanks. Open faucets in appropriate
areas.
-- o r --
2. Have someone check the structure frequently during cold
weather to make sure it is warm enough to prevent pipes
from freezing. Instruct them on a service agency to call to
provide service, if required.
-- o r --
3. Install a reliable remote sensing device that will notify
somebody of freezing conditions within the home.
Winter Shutdown
If you go away during the winter months and do not leave the
heat on in your home, the plastic transition box and the
condensate trap on the furnace must be protected from freeze
damage. (See Fig. 10 through Fig. 17)
1. Disconnect the 5/8″OD rubber hose from the vent drain
fitting that is located downstream of the combustion
blower. Insert a funnel into the hose and pour four(4)
ounces of sanitary type (RV) antifreeze into the condensate
trap. Reconnect the 5/8″OD rubber hose to the stub on the
vent drain fitting. Secure with the hose clamp.
2. Disconnect the 3/4″OD rubber hose from the condensate
trap. Insert a funnel into the hose and and pour four(4)
ounces of sanitary type (RV) antifreeze into the plastic
Transition box. Squeeze the hose together near the end and
quickly reconnect the 3/4″OD rubber hose to the stub on
the condensate trap. Secure with the hose clamp.
When you return home, your furnace will be ready to start, as it is
not necessary to drain the antifreeze from the furnace.
Installation
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury or
death.
This furnace can NOT be common vented or connected
to any type B, BW or L vent or vent connector, nor to
any portion of a factory--built or masonry chimney. If
this furnace is replacing a previously common-vented
furnace, it may be necessary to resize the existing vent
and chimney to prevent oversizing problems for the
other
remaining appliance(s). See Venting and Combustion Air
Check in Gas Vent Installation section.This furnace
MUST be vented to the outside.
!WARNING
Location and Clearances
1. Refer to Fig. 1 for typical installation and basic connecting
parts required. Refer to Fig. 4 for typical horizontal direct
vent installation and basic connecting parts required. Sup-
ply and return air plenums and duct are also required.
2. If furnace is a replacement, it is usually best to install the
furnace where the old one was. Choose the location or
evaluate the existing location based upon the minimum
clearance and furnace dimensions (Fig. 2).
Vent Pipes MUST be
supported Horizontally
and Vertically
*8″Min.
20′Max.
in same atmospheric
zone
*8″Min.
20′Max.
in same
atmospheric
zone
Coupling on ends of
exhaust pipe. Total
pipe & coupling out-
side structure = 8″
Aluminum or non- rusting shield recommended. (See
Vent Termination Shielding for dimensions).
* Increase minimum from 8″to 18″for cold climates (sustained temperatures 0 °F
and below for 24 or more consecutive hours).
DISCHARGE AIR
Inlet Pipe (not
used on Single
Pipe model)
A07700
Fig. 1 -- Typical Upflow Installation
PG9YAA

7
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury or
death.
Do NOT operate furnace in a corrosive atmosphere containing
chlorine, fluorine or any other damaging chemicals, which
could shorten furnace life.
Refer to Combustion & Ventilation Air section, Contaminated
Combustion Air for combustion air evaluation and remedy.
!WARNING
FROZEN AND BURST PIPE HAZARD
Failure to follow this caution may result in property damage.
Special precautions MUST be made is installing furnace in
an area which may drop below freezing. This can cause
improper operation or damage to equipment. If furnace
environment has the potential of freezing, the drain trap and
drain line must be protected. The use of electric heat tape or
RV antifreeze is recommended for these installations. (See
“Condensate Trap Freeze Protection Section”)
CAUTION
!
Do NOT operate furnace in a corrosive atmosphere
containing chlorine, fluorine or any other damaging
chemicals. Refer to Combustion & Ventilation Air section,
Contaminated Combustion Air.
Installation Requirements
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury or
death.
Do NOT install this furnace in DOWNFLOW applications.
!WARNING
1. Install furnace level.
2. This furnace is NOT to be used for temporary heat of
buildings or structures under construction.
3. Install the vent pipes as short as practical. (See Gas Vent
Installation section).
4. Do NOT install furnace directly on carpeting, tile or other
combustible material other than wood flooring.
5. Maintain clearance for fire safety and servicing. A front
clearance of 24″(609.6 mm) required and 30″(762.0
mm)recommended for access to the burner, controls and
filter. See clearance requirements in Fig. 2.
6. Use a raised base if the floor is damp or wet at times.
7. Residential garage installations require:
SBurners and ignition sources installed at least 18″above the
floor.
SFurnace must be located or physically protected from possible
damage by a vehicle.
8. If the furnace is to be suspended from the floor joists in a
basement or a crawl space or the rafters in an attic, it is
necessary to use steel pipe straps or an angle iron frame to
attach the furnace. These straps should be attached to the
furnace with sheet metal screws and to the rafters or joists
with bolts. The preferred method is to use an angle iron
frame bolted to the rafters or joists.
9. Local codes may require a drain pan under the entire fur-
nace and condensate trap when the furnace is installed in
attic application.
This furnace may be used for construction heat provided that all
the following conditions are met:
SThe furnace is permanently installed with all electrical wiring,
piping, venting and ducting installed according to these
installation instructions. A return air duct is provided, sealed
to the furnace casing, and terminated outside the space
containing the furnace. This prevents a negative pressure
condition as created by the circulating air blower, causing a
flame rollout and/or drawing combustion products into the
structure.
SThe furnace is controlled by a thermostat. It may not be “hot
wired” to provide heat continuously to the structure without
thermostatic control.
SClean outside air is provided for combustion. This is to
minimize the corrosive effects of adhesives, sealers and other
construction materials. It also prevents the entrainment of
drywall dust into combustion air, which can cause fouling and
plugging of furnace components.
SThe temperature of the return air to the furnace is maintained
between 55°F(13°C) and 80°F(27°C) , with no evening
setback or shutdown. The use of the furnace while the
structure is under construction is deemed to be intermittent
operation per our installation instructions.
SThe air temperature rise is within the rated rise range on the
furnace rating plate, and the firing rate has been set to the
rating plate value.
SThe filters used to clean the circulating air during the
construction process must be either changed or thoroughly
cleaned prior to occupancy.
SThe furnace, ductwork and filters are cleaned as necessary to
remove drywall dust and construction debris from all HVAC
system components after construction is completed.
SAfter construction is complete, verify furnace operating
conditions including ignition, input rate, temperature rise and
venting according to these instructions.
Knockouts
CUT HAZARD
Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or burrs. Use care
and wear appropriate clothing, safety glasses and gloves
when handling parts and servicing furnaces.
CAUTION
!
Use a hammer and screwdriver to strike a sharp blow (See Fig. 3)
directly to the knockout tie points or use a hammer in the upper
left corner of the desired knockout. Remove any burrs and sharp
edges.
PG9YAA

8
PG9YAA036060
21
5/8
13/8
811/16
TOP
F
G
E
H
AIR INTAKE
VENT
ELECTRICAL
1
1/4
TRAP (KO) (COUNTERFLOW)
LEFT SIDE
GAS
VENT
413/16
1
1/16
AIR INTAKE (KO)
(ALTERNATE)
TRAP (KO)
UPFLOW/HORIZONTAL
THERMOSTAT
111/16
175/16
241/16
283/4
297/8
3111/16
1311/16
1913/16
21/4
131/4
17/8
215/8
24
47/8
7
FRONT
A
B
DBOTTOM
37/8
231/8
23/8
AIR INTAKE (KO)
(ALTERNATE)
RIGHT SIDE
TRAP (COUNTERFLOW)
ELECTRICAL (KO)
VENT (KO)
TRAP (KO)
UPFLOW/HORIZONTAL
THERMOSTAT
11/4
27/8
281/2
181/23/4
TYP.
45/16
11/16
GAS
413/16
111/16
175/16
111/16
273/16
297/8
215/8
3311/16
17/8
913/16
13/16
47/8
2
1/4
24
40
191/4
7
ALL DIMENSIONS IN INCHES
1IN=25.4MM
Drawing is representative,
but some models may vary
NOTE: Evaporator “A” coil drain pan dimensions
may vary from furnace duct opening size. Always
consult evaporator specifications for duct size
requirements.
Furnace is designed for bottom return or side
return.
Return air through back of furnace is NOT allowed.
C
(KO)
KO = Knockout
(KO)
Specifications are subject to change without notice
MINIMUM CLEARANCES TO
COMBUSTIBLE MATERIALS FOR ALL UNITS
REAR 0
FRONT (combustion air openings in
furnace and in structure)
3″
Required For Service *24″
ALL SIDES Of SUPPLY PLENUM 1″
SIDES 0
VENT 0
TOP OF FURNACE 1″
*30″clearance recommended for furnace removal.
Horizontal position: Line contact is permissible only between
lines formed by intersections of top and two sides of furnace
jacket, and building joists, studs or framing.
Unit
Ca pacity
Cabinet Bottom Top
ABC DEFGH
191/8175/821/8143/443/841/221/291/2
223/4211/4115/16 183/443/841/225/8113/8
223/4211/4115/16 183/443/841/225/8113/8
PG9YAA048080
241/223 7/16 23 43/841/221/4121/4
PG9YAA036080
PG9YAA060100
A07701
Fig. 2 -- Dimensions and Clearances
PG9YAA

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A07702
Fig. 3 -- Hammer and Screwdriver used for Knockout
NOTE: If a knockout does not come out after two sharp blows,
pull and snip as needed to remove the knockout.
Installation Positions
This furnace can be installed in an upflow or horizontal (either
left or right) airflow position. DO NOT install this furnace in the
downflow position or on its back. For the upflow position, the
return air ductwork can be attached to either the left or right side
panel and/or the bottom. For horizontal positions, the return air
ductwork must be attached to the bottom:
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury or
death.
Do NOT install this furnace in DOWNFLOW applications.
!WARNING
Furnace Installation Considerations
The installation of the furnace for a given application will dictate
the position of the furnace, the airflow, ductwork connections,
vent and combustion air piping. Consideration must be given to
the following:
Condensate Trap and Drain Lines
The supplied condensate trap must be attached to the furnace side
panel on either the left or right side. For horizontal installations,
the drain trap is vertically attached to the side panel below the
furnace. A minimum clearance of 6″below the furnace is
required for the condensate trap. Downward slope of the
condensate drain line from the condensate trap to the drain
location must be provided. Adequate freeze protection of the
drain trap and the drain line must be provided. See “Condensate
Drain Trap” section for further details.
Leveling
Proper leveling of the furnace must be provided to insure proper
drainage of the condensate from the furnace. The furnace must be
level to within 1/4″(6.35 mm) from front to back and from side to
side for upflow installations or top to bottom for horizontal
installations.
Vent and Combustion Air Connections
For venting information literature, contact www.cac--bdp.com
with the complete model and serial number of the furnace.
NOTE: Furnaces installed in Canada must use vent systems that
are certified to the standard for Type BH Gas Venting Systems,
ULC--S636. ULC--S636 certified plastic vent system material or
the components of ULC--S636 certified vent systems must not be
interchanged with other vent systems or unlisted pipe/fittings.
Vent components supplied with the furnace and components in
factory authorized vent kits may be used with ULC--S636
certified vent systems.
The ULC--S636 certified plastic components, and specified
primers and glues of the certified system must be from a single
system manufacturer and not intermixed with other system
manufacturer’s vent system parts.
The first 3 ft. (900 mm) of the venting system must be readily
accessible for inspection.
In some provinces the combustion air system may also be
required to be ULC--S636 certified.
The vent and combustion air pipes attach to the furnace through
the top panel or to the alternate locations on the furnace side
panels.
Note: Repositioning of the combustion blower is required for the
vent pipe connection to the furnace through the “right side”
panel. See “Vent and Combustion Air Piping” section for further
details.
Horizontal Furnace Installation
Inlet Pipe (not used on Single Pipe model)
Vent
Pipe
Condensate
Trap
NOTE: 6
″
bottom clearance required for condensate trap.
A07703
Fig. 4 -- Typical Horizontal Installation
This furnace can be installed horizontally in an attic, basement,
crawl space, alcove, or suspended from a ceiling in a basement or
utility room. See Fig. 4.Donotinstall furnace on its back or in
the reverse airflow positions as safety control operation will be
adversely affected.
If the furnace is to be installed in a crawl space, consult local
codes. A suitable concrete pad or blocks are recommended for
crawl space installation on the ground.
NOTE: 6″bottom clearance required for condensate trap.
Twenty four (24) inches between the front of the furnace and
adjacent construction or other appliances MUST be maintained
for service clearance.
Keep all insulating materials clear from louvered door. Insulating
materials may be combustible.
The horizontal furnaces may be installed directly on combustible
wood flooring or supports as long as all required furnace
clearances are met. See Fig. 4.
PG9YAA

10
Minimum One Inlet and One Outlet Air Supply is Required
MaybeinanyCombinationShown
Inlet Air Opening Must be Within12″of floor
Outlet Air Opening Must be Within12″of ceiling
(1) 1 Square Inch per 4000 BTUH
(2) 1 Square Inch per 2000 BTUH
This installation NOT approved in Canada
Gas Vent
Gable Vent
Ventilated Attic
Top Above Insulation
Alternate Inlet Air (1)
Ventilated Crawl Space
Outlet Air (1) Soffit Vent
Outlet
Air (1)
Inlet
Air (1)
Outlet
Air (2)
Inlet
Air (2)
Gas Vent
Inlet
Air (2)
Soffit Vent
Gas Vent
Gable Vent
Ventilated Attic
Top Above Insulation
Inlet
Air (1)
OutletAir (1)
alternate Inlet Air (1)
A07704
Fig. 5 -- Outside Air
(This is ONLY a guide. Subject to codes of country having jurisdiction).
This furnace MUST NOT be installed directly on carpeting or
tile or other combustible material other than wood flooring or
supports.
For horizontal installation over a finished living space. A field
fabricated auxiliary drain pan with drain pipe is required to
prevent damage by overflow due to blocked condensate drain.
COMBUSTION & VENTILATION AIR
For Single Pipe Installation
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury or
death.
Use methods described here to provide combustion and
ventilation air.
!WARNING
Furnaces require ventilation openings to provide sufficient air for
proper combustion and ventilation of flue gases. All duct or
openings for supplying combustion and ventilation air must
comply with the gas codes, or in the absence of local codes, the
applicable national codes.
Combustion and ventilation air must be supplied in accordance
with one of the following:
NOTE: The Combustion & Ventilation Air Section in this
document, uses tables and information from the ANSI
Z223.1/NFPA 54. For use in Canada, use CSA B149.1 for this
information.
1. Section 9.3, Air for Combustion and Ventilation, of the
National Fuel Gas Code, (NFGC), ANSI
Z223.1--2006/NFPA 54--2006 in the U.S.,
2. Sections 8.2, 8.3, 8.5, 8.6, 8.7, and 8.8 of National Stand-
ard of Canada, Natural Gas and Propane Installation Code
(NSCNGPIC), CSA B149.1--05 in Canada,
3. Applicable provisions of the local building code.
This furnace can NOT be common vented or connected to any
type B, BW or L vent or vent connector, nor to any portion of a
factory--built or masonry chimney. Multistory venting is NOT
permitted. If this furnace is replacing a previously
common-vented furnace, it may be necessary to resize the
existing vent and chimney to prevent oversizing problems for the
other remaining appliance(s). See “Venting and Combustion Air
Check” in this section.This furnace MUST be vented to the
outside.
When the installation is complete, check that all appliances have
adequate combustion air and are venting properly. See Venting
And Combustion Air Check in “Gas Vent Installation” Section in
this manual.
Outdoor Combustion Air Method
A space having less than 50 cubic feet per 1,000 BTUH input
rating for all gas appliances installed in the space requires
outdoor air for combustion and ventilation.
Air Openings and Connecting Ducts
1. Total input rating for all gas appliances in the space
MUST be considered when determining free area of open-
ings.
2. Connect ducts or openings directly to the outdoors.
3. When screens are used to cover openings, the openings
MUST be no smaller than 1/4″(6.35 mm) mesh.
4. The minimum dimension of air ducts MUST NOT be less
than 3″.
5. When sizing a grille, louver, or screen use the free area of
opening. If free area is NOT stamped or marked on grill or
louver, assume a 20% free area for wood and 60% for met-
al. Screens shall have a mesh size not smaller than 1/4″
(6.35 mm) .
Confined Space Installation
NOTE: A confined space is defined as an area with less than 50
cubic feet per 1,000 BTUH input rating for all gas appliances
installed in the area.
Requirements
1. Provide the space with sufficient air for proper combustion
and ventilation of flue gases using horizontal or vertical
ducts or openings.
PG9YAA

11
2. Fig. 5 illustrates how to provide combustion and ventila-
tion air when two permanent openings, one inlet and one
outlet, are used.
f. One opening MUST commence within 12″of the floor
and the second opening MUST commence within 12″
of the ceiling.
g. Size openings and ducts per Tab le 1 .
h. Horizontal duct openings require 1 square inch of free
area per 2,000 BTUH (1,100 mm2/kW) of combined
input for all gas appliances in the space (see Table 1).
i. Vertical duct openings or openings directly communic-
ating with the outdoors require 1 square inch of free
area per 4,000 BTUH (550 mm2/kW) for combined
input of all gas appliances in the space (see Table 1).
3. When one permanent outdoor opening is used, the opening
requires:
a. 1 sq. in of free area per 3,000 BTUH (700 mm2/kW)
for combined input of all gas appliances in the space
(see Table 1) and
b. not less than the sum of the areas of all vent connect-
ors in the space.
The opening shall commence within 12″of the top of the
enclosure. Appliances shall have clearances of at least 1″from
the sides and back and 6″from the front. The opening shall
directly communicate with the outdoors or shall communicate
through a vertical or horizontal duct to the outdoors or spaces
(crawl or attic) that freely communicate with the outdoors.
4. Combination of Indoor and Outdoor Air shall have:
a. Indoor openings that comply with the Indoor Com-
bustion Air Method below and
b. Outdoor openings located as required in the Outdoor
Combustion Air Method above and
c. Outdoor openings sized as follows.
(3.) Calculate the Ratio of all Indoor Space volume
divided by required volume for Indoor Combus-
tion Air Method.
(4.) Outdoor opening size reduction Factor is 1minus
the Ratio in 1) above.
(5.) Minimum size of Outdoor openings shall be the
size required in Outdoor Combustion Air Meth-
od above multiplied by reduction Factor.
BTUH
Input
Rating
Minimum Free Area Required for Each Opening or Duct to Outdoors
Two Horizontal Ducts
(sq. in./2,000 BTUH)
Single Opening
(sq. in./3,000 BTUH)
Two Vertical Ducts or Openings
(sq. in./4,000 BTUH)
Round Duct
(sq. in. /4,000 BTUH)
60,000 30 sq. in. 20 sq. in. 15 sq. in. 5″
80,000 40 sq. in. 26.7 sq. in. 20.0 sq. in. 5″
100,000 50 sq. in. 33.3 sq. in. 25 sq. in. 6″
EXAMPLE: Determining Free Area
Furnace
100,000
Furnace
100,000
+
+
Water Heater
30,000
Water Heater
30,000
=
=
Total Input
(130,000 ÷4,000)
Total Input
(130,000 ÷2,000)
= 32.5 Sq. In. Vertical
= 65 Sq. In. Horizontal
Table 1 – Free Area
Indoor Combustion Air (Unconfined Space)
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury or
death.
Most homes will require additional air from outdoors for
combustion and ventilation. A space with at least 50 cubic
feet per 1,000 Btuh Input rating or homes with tight
construction may need outdoor air, supplied through ducts, to
supplement air infiltration for proper combustion and
ventilation of flue gasses.
!WARNING
Standard and Known- Air- Infiltration Rate Methods
©NFPA&AGA
Indoor air is permitted for combustion and ventilation, if the
Standard or Known--Air--Infiltration Rate Method is used.
The Standard Method may be used, if the space has no less
volume than 50 cubic feet per 1,000 BTUH input rating for all
gas appliances installed in the space. The standard method
permits indoor air to be used for combustion and ventilation air.
The Known Air Infiltration Rate Method shall be used if the
infiltration rate is known to be less than 0.40 air changes per hour
(ACH) and equal to or greater than 0.10 ACH. Infiltration rates
greater than 0.60 ACH shall not be used. The minimum required
volume of the space varies with the number of ACH and shall be
determined per Table 2 or Equations 1 and 2. Determine the
minimum required volume for each appliance in the space, and
add the volumes together to get the total minimum required
volume for the space.
CARBON MONOXIDE POISONING HAZARD
Failure to supply additional air by means of ventilation grilles
or ducts could result in personal injury or death.
An unconfined space or homes with tight construction may not
have adequate air infiltration for proper combustion and
ventilation of flue gasses. Most homes will require additional
air.
!WARNING
PG9YAA

12
Other Than Fan- Assisted Total
(1,000 Btuh)
Fan- assisted Total (1,000’s Btuh)
ACH 30 40 50 50 75 100 125
0.60 1,050 1,400 1,750 1,250 1,875 2,500 3,125
0.50 1,260 1,680 2,100 1,500 2,250 3,000 3,750
0.40 1,575 2,100 2,625 1,875 2,813 3,750 4,688
0.30 2,100 2,800 3,500 2,500 3,750 5,000 6,250
0.20 3,150 4,200 5,250 3,750 5,625 7,500 9,375
0.10 6,300 8,400 10,500 7,500 11,250 15,000 18,750
0.00 NP NP NP NP NP NP NP
Table 2 – Minimum Space Volume for 100% Combustion and Ventilation Air from Indoors (ft3)
NP = Not Permitted
NO TAG Minimum Space Volumes were determined by using
the following equations from the National Fuel Gas Code ANSI
Z223.1/NFPA 54--2006, 9.3.2.2:
1. For appliances other than fan--assisted appliances (such
as a draft hood--equipped water heater), calculate using the
following equation:
1000 Btu / hr
21 ft
3
(I
other
)
Required Volume other ²
ACH
2. For fan--assisted appliances (such as this furnace), calcu-
late using the following equation:
1000 Btu / hr
15 ft3
(
Ifan
)
Required Volume fan ²
ACH
where:
Iother = all appliances other than fan--assisted input in Btu
per hour
Ifan =fan--assisted appliance input in Btu per hour
ACH = air change per hour (percent of volume of space
exchanged per hour, expressed as a decimal)
3. For purposes of this calculation, an infiltration rate greater
than 0.60 ACH shall not be used in the equations above.
The following requirements apply to the Standard Method and to
the Known Air Infiltration Rate Method.
SAdjoining rooms can be considered part of a space, if there are
no closeable doors between rooms.
SCombining spaces on the same story. Each opening shall have
a minimum free area of at least 1 in.2/1,000 BTUH (2,200
mm2/kW) of the total input rating of all appliances in the space
but not less than 100 in.2(0.06 m2). One opening shall
commence within 12 in. (304.8 mm) of the top, and one
opening shall commence within 12 in. (304.8 mm) of the
bottom, of the enclosure. The minimum dimension of air
openings shall not be less than 3 in. (76.2 mm).
SCombining spaces in different stories. The volumes of spaces
on different stories shall be considered as communicating
spaces where such spaces are connected by one or more
openings in doors or floors having a total minimum free area of
2in.
2/1,000 BTUH (4,400 mm2/kW) of total input rating of all
appliances.
SAn attic or crawl space may be considered a space that freely
communicates with the outdoors provided there are adequate
ventilation openings directly to outdoors. Openings MUST
remain open and NOT have any means of being closed off.
Ventilation openings to outdoors MUST be at least 1 square
inch of free area per 4,000 BTUH (550 mm2/kW) of total input
rating for all gas appliances in the space.
SIn spaces that use the Indoor Combustion Air Method,
infiltration should be adequate to provide air for combustion,
ventilation and dilution of flue gases. However, in buildings
with unusually tight construction, additional air MUST be
provided using the methods described in section titled Outdoor
Combustion Air Method:
SUnusually tight construction is defined as Construction with:
1. Walls and ceilings exposed to the outdoors have a continu-
ous, sealed vapor barrier. Openings are gasketed or sealed
and
2. Doors and openable windows are weather stripped and
3. Other openings are caulked or sealed. These include joints
around window and door frames, between sole plates and
floors, between wall--ceiling joints, between wall panels, at
penetrations for plumbing, electrical and gas lines, etc.
Ventilation Air
Some provincial codes and local municipalities require
ventilation or make--up air be brought into the conditioned space
as replacement air. Whichever method is used, the mixed return
air temperature across the heat exchanger MUST not fall below
60°so that flue gases will not condense excessively in the heat
exchanger. Excessive condensation will shorten the life of the
heat exchanger and possibly void your warranty.
Venting and Combustion Air Check
NOTE: If this installation replaces an existing furnace from a
commonly vented system, the original venting system may no
longer be sized to properly vent the attached appliances. An
improperly sized venting system may cause the formation of
condensate in the vent and the leakage or spillage of vent gases.
To make sure there is adequate combustion air for all appliances,
MAKE THE FOLLOWING CHECK.
Typical Gas
Water Heater
Draft Hood
Vent Pipe
Match
A07688
Fig. 6 -- Vent Check
PG9YAA

13
The following information is supplied to allow the installer to
make adjustments to the setup of existing appliances, IF
REQUIRED, based on good trade practices, local codes, and
good judgement of the installer. Manufacturer does NOT take
responsibility for modifications made to existing equipment.
CARBON MONOXIDE POISONING HAZARD
Failure to follow the steps outlined below for each
appliance connected to the venting system being placed
into operation, could result in carbon monoxide
poisoning or death:
The following steps shall be followed for each appliance
connected to the venting system being placed into
operation, while all other appliances connected to the
venting system are not in operation:
1. Seal any unused openings in the venting system.
2. Inspect the venting system for proper size and
horizontal pitch, as required in the National Fuel Gas
Code, ANSI Z223.1/NFPA 54 or CSA B149.1, Natural
Gas and Propane Installation Code and these
instructions. Determine that there is no blockage or
restriction, leakage, corrosion and other deficiencies
which could cause an unsafe condition.
3. As far as practical, close all building doors and
windows and all doors between the space in which the
appliance(s) connected to the venting system are
located and other spaces of the building.
4. Close fireplace dampers.
5. Turn on clothes dryers and any appliance not
connected to the venting system. Turn on any exhaust
fans, such as range hoods and bathroom exhausts, so
they are operating at maximum speed. Do not operate
a summer exhaust fan.
6. Follow the lighting instructions. Place the appliance
being inspected into operation. Adjust the thermostat
so appliance is operating continuously.
7. Test for spillage from draft hood equipped appliances
at the draft hood relief opening after 5 minutes of
main burner operation. Use the flame of a match or
candle. (Fig. 6)
8. If improper venting is observed, during any of the
above tests, the venting system must be corrected in
accordance with the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 and/or CSA B149.1, Natural Gas and
Propane Installation Code.
9. After it has been determined that each appliance
connected to the venting system properly vents when
tested as outlined above, return doors, windows,
exhaust fans, fireplace dampers and any other
gas--fired burning appliance to their previous
conditions of use.
!WARNING
For Two Pipe Installation (Direct Vent)
This furnace can NOT be common vented or connected to any
type B, BW or L vent or vent connector, nor to any portion of a
factory--built or masonry chimney. If this furnace is replacing a
previously common-vented furnace, it may be necessary to resize
the existing vent and chimney to prevent oversizing problems for
the other remaining appliance(s). See “Venting and Combustion
Air Check” in this section.This furnace MUST be vented to the
outside.
VENT AND COMBUSTION AIR PIPING
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury or
death.
Use methods described here to provide combustion and
ventilation air.
!WARNING
Dual Certified (PG9YAA Models)
This furnace is certified as a category IV appliance. This furnace
can be installed as a direct vent furnace using outside air for
combustion or the furnace can use air from inside the structure
for combustion. The INLET air pipe is optional. If combustion
air comes from inside the structure, adequate make up air MUST
be provided to compensate for oxygen burned. See Confined
Space Installation in the Combustion and Ventilation Air
chapter. If combustion air is drawn from outside the structure, it
MUST be taken from the same atmospheric pressure zone as the
vent pipe.
Contaminated Combustion Air
Installations in certain areas or types of structures will increase
the exposure to chemicals or halogens that may harm the furnace.
The following areas or types of structures may contain or have
exposure to the substances listed below. The installation must be
evaluated carefully as it may be necessary to provide outside air
for combustion.
SCommercial buildings.
SBuildings with indoor pools.
SFurnaces installed in laundry rooms.
SFurnaces installed in hobby or craft rooms.
SFurnaces installed near chemical storage areas.
SPermanent wave solutions for hair.
SChlorinated waxes and cleaners.
SChlorine based swimming pool chemicals.
SWater softening chemicals.
SDe--icing salts or chemicals.
SCarbon tetrachloride.
SHalogen type refrigerants.
SCleaning solvents (such as perchloroethylene).
SPrinting inks, paint removers, varnishes, etc.
SHydrochloric acid.
SSulfuric Acid.
SSolvent cements and glues.
SAntistatic fabric softeners for clothes dryers.
SMasonry acid washing materials.
Vent and Combustion Air Piping Guidelines
This furnace is approved for venting with Schedule 40 PVC,
CPVC, ABS fittings, and Cellular Core and SDR--26 PVC pipe.
PG9YAA

14
Applicable ASTM Standards for Vent Materials
Materi-
als
Sch. 40
Pipe
SDR
Pipe
Cell
Core
Pipe
Fittings Primer Solvent
Cement
ABS D1527 __ F628
D2468
&
D2661
-- -- D2235
PVC D1785 D2241 F891
D2466
&
D2665
F656 D2564
CPVC F441 F442 -- -- F438 -- -- F493
ABS
to
PVC
-- -- -- -- -- -- -- -- -- -- D3138
NOTE:
1. In Canada, all pipe, fittings & cements must conform to
applicable CSA standards or to local codes having juris-
diction.
2. Only use solvent cements that are marked for use with the
specific venting material.
3. ABS to PVC transition joints REQUIRE a special solvent
cement that meets the requirements of ASTM D3138.
4. Refer to ASTM D2855 for general procedure to use for
cementing plastic pipe and fittings.
NOTE: In order to create a seal that allows future removal of
pipe, RTV sealant MUST be used on the inlet pipe where it
joins to the furnace.
NOTE: All vent piping MUST be installed in compliance with
local codes or ordinances, these instructions, good trade practices,
and codes of country having jurisdiction.
1. Determine the best routing and termination for the vent
pipe and air inlet pipe by referring to all of the instructions
and guidelines in this Section.
2. Determine the size required for the vent pipe and air inlet
pipe.
3. Loosely assemble all venting parts without adhesive (pipe
joint cement) for correct fit before final assembly.
4. Furnace shall be installed so as to prevent the accumula-
tion of condensate.
5. Use of vertical piping is preferred because there will be
some moisture in the flue gases that may condense as it
leaves the vent pipe (See Instructions For Horizontal
Ve n t s ).
6. The vertical vent pipe MUST be supported so that no
weight is allowed to rest on the combustion blower.
7. Exhaust vent piping or air inlet piping diameter MUST
NOT be reduced.
8. All exhaust vent piping from the furnace to termination
MUST slope upwards. A minimum of 1/4″(6.35 mm) per
foot of run is required to properly return condensate to the
furnace drain system.
9. Use DWV type long radius elbows whenever possible, as
they provide for the minimum slope on horizontal runs and
they provide less resistance in the vent system. If DWV
elbows cannot be used, use two, 45°elbows when pos-
sible. On horizontal runs the elbows can be slightly mis-
aligned to provide the correct slope.
10. All horizontal pipe runs MUST be supported at least every
five feet with galvanized strap or other rust resistant ma-
terial. NO sags or dips are permitted.
11. All vertical pipe runs MUST be supported every six feet
where accessible.
12. The minimum pipe run length is 2′(.6 M).
13. The piping can be run in the same chase or adjacent to
supply or vent pipe for water supply or waste plumbing. It
can also be run in the same chase with a vent from another
90+ furnace.
NOTE:InNO case can the piping be run in a chase where
temperatures can exceed 140°F(60°C). or where radiated heat
from adjacent surfaces would exceed 140°F(60°C).
14. The vent outlet MUST be installed to terminate in the
same atmospheric pressure zone as the combustion air in-
let.
15. The vent system can be installed in an existing unused
chimney provided that:
SBoth the exhaust vent and air intake run the length of the
chimney.
SNo other gas fired appliance or fireplace (solid fuel) is vented
into the chimney.
SThe top of the chimney MUST be sealed flush or crowned up
to seal against rain or melting snow so ONLY the piping
protrudes.
SThe termination clearances showninFig.7and8 are
maintained.
16. Furnace applications with vertical vents requiring vent dia-
meter increaser fittings must have increaser fittings in-
stalled in vertical portion of the vent. Condensate will be
trapped in the vent if the vent diameter is increased prior
to having an elbow turned upward. This could cause nuis-
ance tripping of the pressure switch.
Combustion Air and Vent Piping Insulation
Guidelines
NOTE: Use closed cell, neoprene insulation or equivalent. If
Fiberglass or equivalent insulation is used it must have a vapor
barrier. Use R values of 7 up to 10′,(2.1 --3.0M) R--11if
exposure exceeds 10′. If Fiberglass insulation is used, exterior to
the structure, the pipe MUST be boxed in and sealed against
moisture.
1. When the vent or combustion air pipe height above the
roof exceeds 30″(762.0 mm), or if an exterior vertical riser
is used on a horizontal vent to get above snow levels, the
exterior portion MUST be insulated.
2. When combustion air inlet piping is installed above a sus-
pended ceiling, the pipe MUST be insulated with moisture
resistant insulation such as Armaflex or other equivalent
type of insulation.
3. Insulate combustion air inlet piping when run in warm, hu-
mid spaces.
Sizing Combustion Air and Vent Pipe
Consult Tab le 3 to select the proper diameter exhaust and
combustion air piping. Exhaust and combustion air piping is sized
for each furnace BTUH size based on total lineal vent length (on
inlet or outlet side), and number of 90°elbows required. Two 45°
elbows can be substituted for one 90°elbow. The elbow or
elbows used for vent termination outside the structure ARE
counted, including elbows needed to bring termination above
expected snow levels. The elbow inside the furnace on the
PG9YAA IS NOT included in the count.
PG9YAA

15
PIPE DIAMETER TABLE
PG9YAA MODEL
60,000 BTUH Furnaces
40′& (5) 90°elbows with 2″PVC pipe or
70′& (5) 90°elbows with 3″PVC pipe
80,000 BTUH Furnace
40′& (5) 90°elbows with 2″PVC pipe or
40′& (5) 90°elbows with 3″PVC pipe
100,000 BTUH Furnace
30′& (4) 90°elbows with 2″PVC pipe or
40′& (5) 90°elbows with 3″PVC pipe
Elbows are DWV Long Radius Type for 2″and 3″vents.
If more than five elbows are required, reduce the length of both the
inlet and exhaust pipes 5′for each additional elbow used. If less than
five elbows are required, the length can be INCREASED by 5′for each
additional elbow NOT used.
Table 3 – Pipe Diameter Table
NOTE: It is allowable to use larger diameter pipe and fitting
than shown in the tables but not smaller diameters than shown.
For “Concentric Termination Kit” Venting see Table 4 in
this manual.
Vent Termination Clearances
CARBON MONOXIDE POISONING HAZARD
Failure to follow this warning could result in personal injury or
death.
Inlet and outlet pipes may NOT be vented directly above each
other.
!WARNING
1. Determine termination locations based on clearances spe-
cified in following steps and as shown in Fig. 7, Fig. 8,
Fig. 19 through Fig. 27.
For “Concentric Termination Kit” clearances, see Fig. 28
through Fig. 33 in this manual.
2. For Single Pipe Installation refer to Fig. 8 for vent termin-
ation clearances.
3. For Direct Vent Installation refer to Fig. 7 for vent termin-
ation clearances.
PG9YAA

16
12 inches (30 cm) for applieances >10,000 Btuh(3 kW)
and < 100,000 Btuh(30kW), 36 inches (91cm) for
appliances > 100,000 Btuh(30kW)
A06675
Fig. 7 -- Direct Vent Termination Clearance
PG9YAA

17
Fig. 8 -- Other than Direct Vent Termination Clearance
PG9YAA

18
Condensate Drain Trap
This furnace removes both sensible and latent heat from the
products of combustion. Removal of the latent heat results in
condensation of the water vapor. The condensate is removed from
the furnace through the drains in the plastic transition and the
vent fitting. The drains connect to the externally mounted
condensate drain trap on the left or right side of the furnace.
The startup of a new furnace will involve a cycle or two of the
furnace to properly prime the condensate trap with water. Until
the trap is fully primed, some condensate will be pulled into the
combustion blower. The furnace may cycle on the pressure switch
connected to the plastic transition box due to condensate buildup.
After the trap is primed, the condensate will start draining from
the furnace. The combustion blower will clear out any remaining
condensate in the blower housing through the vent fitting
downstream of the blower. Note that the condensate trap can also
be primed by pouring water into the 1/2″drain hose. Remove
the1/2″ID drain hose from either the gutter or the white PVC tee
trap. Using a funnel pour eight (8) ounces of water into 1/2″ID
drain hose. Water will flow through the drain hose and into the
condensate drain trap. This will prime both the vent and the
transition sides of the trap. Reconnect the 1/2″ID drain hose to
the original component, either the gutter or the PVC tee trap.
The condensate drain trap supplied with the furnace MUST be
used. The drain connection on the condensate drain trap is sized
for 3/4″PVC or CPVC pipe, however alternate 1/2″CPVC
(nominal 5/8″O.D.) or vinyl tubing with a minimum inner
diameter (I.D.) of 5/8″may also be used, as allowed by local
codes. Alternate drain pipes and hoses may be used as allowed by
local codes.
The drain line must maintain a 1/4″(6.4 mm) per foot downward
slope toward the drain. 1/4″(6.4 mm) per foot is recommended.
Installation of an overflow line is recommended when the 1/4″
(6.4 mm) per foot slope to the condensate drain cannot be
maintained. A drain tube clip is included in the furnace to prevent
kinking/buckling of the drain tube. The clip should remain in the
furnace (between the door switch plate and the blower shelf, Fig.
9) during operation. See Fig. 17 for proper routing and
installation of the overflow.
DO NOT trap the drain line in any other location than at the
condensate drain trap supplied with the furnace.
FROZEN AND BURST WATER PIPE HAZARD
Failure to follow this caution may result in property damage.
If a condensate pump is installed, a plugged condensate drain
or a failed pump may cause the furnace to shut down. Do
not leave the home unattended during freezing weather
without turning off water supply and draining water pipes or
otherwise protecting against the risk of frozen pipes.
CAUTION
!
If possible, DO NOT route the drain line where it may freeze.
The drain line must terminate at an inside drain to prevent
freezing of the condensate and possible property damage.
1. A condensate sump pump MUST be used if required by
local codes, or if no indoor floor drain is available. The
condensate pump must be approved for use with acidic
condensate.
2. A plugged condensate drain line or a failed condensate
pump will allow condensate to spill. If the furnace is in-
stalled where a condensate spill could cause damage, it is
recommended that an auxiliary safety switch be installed
to prevent operation of the equipment in the event of pump
failure or plugged drain line. If used, an auxiliary safety
switch should be installed in the R circuit (low voltage)
ONLY.
3. If the auxiliary switch in the condensate pump is used, the
furnace may shut down due to a blocked condensate line
or failed pump. To prevent frozen water pipes see the
“Frozen Water Pipe Hazard” Installation Section of this
manual.
Drain Tube
Clip
Door
Switch
Blower
Shelf
Representative drawing only, some models may vary in appearance.
A07705
Fig. 9 -- Drain Tube Clip Location
Condensate Drain Trap Freeze Protection
Special precautions MUST be made if installing furnace in an
area which may drop below freezing. This can cause improper
operation or damage to the equipment. If the the furnace
environment has the potential of freezing, the drain trap and drain
line must be protected. Use 3 to 6 watt per foot at 115 volt, 40°F
(4.4°C) self--regulating shielded and waterproof heat tape. Wrap
the drain trap and drain line with the heat tape and secure with the
ties. Follow the heat tape manufacturer’s recommendations.
PG9YAA

19
INLET
EXHAUST
IN
ON
OFF
V
E
NT
AIR FLOW
Street Elbow
1
/
2
″
CPVC
(Loose parts bag)
Casing Grommet
Black Rubber
5
/
8
″
ID
(Loose parts bag)
Drain Tee
Drain Connector Black PVC
3
/
4
″
PVC X
1
/
2
″
CPVC
(Loose parts bag)
Drain Line Vent Tee
3
/
4
″
PVC or
1
/
2
″
CPVC (Field supplied)
Drain Tube
Black Rubber
1
/
2
″
ID & Clamps
Drain Tube
Corrugated
5
/
8
″
ID
& Clamps
Relief Tube
Black Rubber
3
/
16
″
ID
Coupling & Clamps
(Optional)
2 5 -- 2 4 -- 8 0
Single Pressure
Switch
Dual Pressure Switch Detail
Drain Tube Black Rubber
5
/
8
″
ID & Clamps,
Cut length to fit (Loose parts bag)
On Some Models
ONLY
Plastic Caps (2)
Yellow or black
Vent Drain
&Clamps
Representative drawing only, some models may vary in appearance.
A07706
Fig. 10 -- Upflow Installations Top Vent
Upflow Installations Top Vent (See Fig.
10)
SRemove knockout from the side of the furnace casing where
drain tube will exit.
SInstall casing grommet (black rubber 5/8″ID grommet -- in
loose parts bag)
SInstall the 1/2″CPVC street elbow on discharge of trap
SInstall the black PVC tube connector (3/4″PVC x 1/2″CPVC
from loose parts bag) as shown in the illustration above.
SCut the black drain tube (5/8″ID -- in loose parts bag) to length
to fit between trap and tube connector through grommet.
SClamp both ends of the drain tube using clamps provided.
SGlue the CPVC street elbow to the trap using appropriate
cleaner and solvent cement.
SThe field supplied 3/4″PVC or 1/2″CPVC drain line vent tee
must vent outside the furnace cabinet (see exploded view
above).
NOTE: It is recommended that all PVC piping and fitting
connections be fit up and inspected before final cementing. Trap
must be primed before operation. Verify all condensate drain
connections are securely clamped. A coupling and clamps (in
loose part bag) may be installed as shown for future servicing of
the vent system.
NOTE:“PVC” is used as a generic term. Pipe and fitting
materials used must be acceptable to the local code officials
having jurisdiction.
PG9YAA

20
INLET
EXHAUST
IN
ON
OFF
V
ENT
Casing Grommet
Black Rubber
5
/
8
″
ID
(Loose parts bag)
Drain Connector Black PVC
3
/
4
″
PVC X
1
/
2
″
CPVC
(Loose parts bag)
Drain Line Vent Tee
3
/
4
″
PVC or
1
/
2
″
CPVC (Field supplied)
Drain Tube
Black Rubber
1
/
2
″
ID & Clamps
3
/
16
″
ID Rubber Tube
Coupling & Clamps
(Optional)
25--24--81
Single Pressure
Switch
Dual Pressure Switch Detail
Tee Trap White PVC
(loose parts bag)
2
″
PVC Coupling
On Some Models
ONLY
Plastic Cap
Yellow or black
Vent Drain
&Clamps
Rotate downward
5
°
to 10
°
NOTE: Built--in channel will
be angled 5°to 10°also.
SIDE VIEW
Either: The PVC
Drain Tee or a field
supplied 2
″
PVC Tee
AIR FLOW AIR FLOW
Drain Tube
Corrugated
5
/
8
″
ID & Clamps
Representative drawing only, some models may vary in appearance.
A07707
Fig. 11 -- Upflow Installations Vent through Left Side
Upflow Installations Vent through Left
Side (See Fig. 11)
SRemove drain tee from inducer discharge and remove black
drain tube (1/2″ID) from bottom of drain tee.
SInstall Vent Pipe grommet in side of casing.
SCut an appropriate length of 2″PVC pipe long enough to exit
the cabinet and connect the vent drain to either:
— A standard field supplied 2″PVC tee, or
—A2″PVC coupling fastened onto the drain tee.
SInstall tee trap into bottom of tee.
SRemove knockout from the side of the furnace casing where
drain tube will exit.
SInstall the 1/2″CPVC street elbow on discharge of trap
SInstall the black PVC drain connector (3/4″PVC x 1/2″CPVC
from loose parts bag) as shown in the illustration above.
SCut the black drain tube (5/8″ID -- in loose parts bag) to length
to fit between trap and tube connector through grommet.
SClamp both ends of the drain tube using clamps provided.
SGlue the CPVC street elbow to the trap using appropriate
cleaner and solvent cement.
SConnect the tee trap and the main drain line exiting the casing
as shown in Fig. 17.
NOTE: It is recommended that all PVC piping and fitting
connections be fit up and inspected before final cementing. Both
the internal trap and the external tee trap must be primed
before operation. Verify all condensate drain connections are
securely clamped. A coupling and clamps (in loose part bag) may
be installed as shown for future servicing of the vent system.
PG9YAA