LENNOX Furnace/Heater, Gas Manual L0406249

User Manual: LENNOX LENNOX Furnace/Heater, Gas Manual LENNOX Furnace/Heater, Gas Owner's Manual, LENNOX Furnace/Heater, Gas installation guides

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LENNDX

Dallas, Texas, USA

INSTALLATION

INSTRUCTIONS

G26 SERIES UNITS

Technical

GAS UNITS _Publications

504,228M

11/2000 Litho U.S.A.

Supersedes 503,885M

Unit Dimensions ............................... 2

G26 Parts Identification ......................... 3

Requirements .................................. 4

General ....................................... 4

Installation - Setting Equipment .................. 5

Return Air Opening Guidelines ................... 5

Filters & Optional Filter Assembly ................ 6

Duct System ................................... 7

Pipe & Fittings Specifications .................... 7

Vent Piping Guidelines .......................... 8

Joint Cementing Procedure ...................... 8

Venting Practices ............................... 9

Gas Piping ................................... 15

Electrical ..................................... 16

Unit Start-Up ................................. 20

Gas Pressure Adjustment ...................... 21

High Altitude Information ....................... 22

Other Unit Adjustments ........................ 22

Service ...................................... 23

Repair Parts .................................. 26

Troubleshooting ............................... 26

Start-Up & Performance Check List .............. 31

RETAIN THESE INSTRUCTIONS

FOR FUTURE REFERENCE

Do not store or use gasoline or other

flammable vapors and liquids in the vi-

cinity of this or any other appliance.

Installation and service must be per-

formed by a qualified installer, service

agency or the gas supplier.

WHAT TO DO IF YOU SMELL GAS:

• Do not W to light any appliance.

• Extinguish any open flames.

•Do not touch any electrical switch; do not use

any phone in your building.

• Immediately call your gas supplier from a

neighbor's phone. Follow the gas supplier's

instructions.

•If you cannot reach your gas supplier, call the

fire department.

11/00 504,228M

I|UUWIIMLIII Page1 IIIHIIlUlIIIIIgIIHIIIIIlaHII

1 1116

(41)

5/8

116)-I P

35/8 - I,

.L 1 1/16 (92) _ _I-

T (41) l /

_'_ 2_-_ EXHAUST

25 (635) _(51) AIR OUTLET

TOP VIEW

(724)

DRNN

ELECTRICAL

INLET

(Both Sides)

_--23 (584) --_

IcRETURNAIR_

L_ KNOCKOUT

(Either Side)

,1-15/18(,,)I

23 (584)

Return Air

Knockout (Bottom)

SIDE VIEW

21 3/4

(552)

(684)

GAS PIPING

INLET

(Both sides)

4 (102)

L 4(102)

(1168)

EXTERNAL

SIDERE'RJRN

AIR RL'I-r.RKIT

(Bth_S_e)

(opeo._ ,

G H

5/8(

E-I'

qlm A-_---I_

I I

/mmr

AiR FLOW

Return Air

Knockout (Bottom)

FRONT VIEW

Model No, A B C D E F G H

In, mm in. mm In. mm in. mm In. mm In. mm in. mm In. mm

G26Q2-5O

G26Q3-50 16-1/4 413 14-1/8 359 12 305 12 305 2-1/8 54 7-5/8 194 14 356 12-314 324

G26Q3-75

G26Q3/4-100

G26Q4/5-75 21-1/4 540 19-1/8 486 18 457 18 ; 457 1-5/8 41 10-1/8 257 20 508 18-3/4 476

G26Q4/5-100

G26Q3/4-125

G26Q4/5-125 26-114 667 24-1/8 613 18 457 18 457 4-1/8 105 12-5/8 321 20 508 18-3/4 476

Page 2

G26 Pa_ A_ gement ....

n, _,

G26 PARTS IDENTIFICATION

GLASS FIBER GASKET

FRESH AIR

INTAKE FITTING

BURNER BOX _l

ASSEMBLY _."

PATCH

GLASS

BURNER

BOX

COVER GAS VALVE AND

MANIFOLD

BURNER

ACCESS

PANEL

BLOWER

ACCESS

DOOR

PROVE

(PRESSURE)

SWITCH

COMBUSTION AIR

ORIFICE

FLUE COLLAR

WARM

HEADER

(COLLECTOR)

BOX

PATCH PLATE WITH

i BARBED FITTING

AND FLAME

ROLL-OUT SWITCH

DuralokPlus TM

HEAT EXCHANGER

ASSEMBLY ,_

FLUE

TRANSITIO

CABINET

SUPPLY

AIR

BLOWER

PRIMARY LIMIT

(ALTERNATE STYLES)

COIL

TRANSFORMER

CONTROL VOLTAGE

CIRCUIT BREAKER

DOOR INTERLOCK SWITCH

CONTROL BOX COVER

COMBUSTION AIR

INDUCER

COLD HEADER

(COLLECTOR)

BOX

FIGURE 1

Page 3

All G26 units are CSA International certified to ANSI

Z21.47 and CSA 2.3 standards.

In the USA, installation of Lennox gas central fumaces must

conform with local building codes. In the absence of local

codes, units must be installed according to the current Na-

tional Fuel Gas Code (ANSI-Z223.1) in the United States.

The National Fuel Gas Code is available from the following

address:

American National Standards Institute, Inc.

11 West 42nd Street

New York, NY 10036

In Canada, installation must conform with current National

Standard of Canada CAN/CGA-B149.1 "Installation Code

for Natural Gas Burning Appliances and Equipment" and

CAN/CGA-B149.2 "Installation Code for Propane Gas

Burning Appliances and Equipment," local plumbing or

waste water codes and other applicable local codes.

Adequate clearance must be made around the air open-

ings into the vestibule area. Provisions must be made for

proper operation and for combustion air and ventilation air

supply according to the current National Fuel Gas Code or

CAN/CGA-B149 standards.

This fumaca is CSA Intemational certified for installation

clearances to combustible matedal as listed on the unit rating

plate and in table 1.

TABLE 1

Clearances

Service access

To combustible

materials

Location

Front

Condensate side

Top

Exhaust

Side, rear, and front

Flnor

Inches (ram)

24 (610)

3 (76)

(fromsideof unit)

1 (25)

*Appliance shall not be installed directly on carpeting, tile or other combustible mate-

rial other than wood flooring.

NOTE-Service access clearance mum be rnaintalee_

NOTE -For installation on combustible floors, the fumace shall

not be installed directlyon carpeting, bTe,or o_er combustible

material other than wood flooring.

Accessibility and service clearances must take prece-

dence over fire protection clearances.

For installation in a residential garage, the fumace must be

installed so that the bumer(s) and the ignitionsource are lo-

cated no less than 18 inches (457 mm) above the floor. The

furnace must be located or protected to avoid physical dam-

age by vehicles.When a fumace is installedin a publicgarage,

hangar, or other buildingthat has a hazardous atmosphere,

the fumaca must be installed according to recommended

good practice requirements and current Na'donalFuel Gas

Code or CAN/CC_ B149.1 and B149.2 standards.

The fumace must be adjusted to obtain atemperature dse

withinthe range specified on the unit rating plate.

When installed, the furnace must be electrically grounde_:

according to local codes. In addition, in the United States

installation must conform with the current National Electric

Code, ANSI/NFPA No. 70. The National Electric Code

(ANSI/NFPA No. 70) is available from the following ad-

dress:

National Fire Protection Association

1 Battery March Park

Quincy, MA 02269

Wiring to be done in the field, between the furnace and de-

vices not attached to the furnace or between separate de-

vices which are field-installed and located, shall conform

with the temperature limitation for type T wire [63°F (17°C)

rise] when installed in accordance with these instructions.

G26 unit must be installed so that electrical components

are protected from water.

When the furnace is installed so that supplyducts carry air

circulated by the furnace to areas outside of the space con-

taining the furnace, return air shall be handled by a duct(s)

sealed to the fumaca casing and terminating out-side

space containing furnace.

41 WARNING /

NOTE - G26 series units must not be used as aconstruc-

tion heater during any phase of construction. Very low re-

turn air temperatures, harmful vapors and misplacement of

the filters will damage the unit and lower its efficiency.

These inslructJonsare intendedas a general guideand do not_

supersede local codes in any way. Consult authoritieshavir_

judsdic_onbefore installation.

Page 4

Shipping and Packing List

1 - Assembled G26 furnace

1-Bag assembly containing

1 - Electrical make-up box

1 - Wiring harness

1 - Snap bushing

2 - Filter clips

1 - 3 inch x 2 inch vent transitionpiece (-100, -125 units

only)

1 - Adapter

1 - Condensate plug

1 - Nipple

1 - Brown accessory wire

1 - Green ground wire

3 - Wire nuts

2 - Star washers

Shipping Damage

Check equipment for shipping damage. If you find any

damage, immediately contact the last carrier,

WARNING 1

WARNING

Select a location that allows for required clearances

listed on the unit rating plate. Also consider gas supply

connections, electrical supply, vent connection and

installation and service clearances [24 inches (610 mm)

at unit front]. The furnace must be level.

NOTE -1/3 and 1/2 hp blower motors are equipped with ei-

ther four flexible mounting legs or three flexible legs and

one rigid leg. The rigid leg is equipped with a shipping bolt

and a flat white plastic washer (rather than the rubber

mounting grommet used w#h a flexible mounting leg). This

shipping bolt and flat washer must be removed before the

furnace is put into operation. Once the shipping bolt and

washer are removed, the rigidleg will not touch the blower

housing.

CAUTION

Return air can be brought in either side or at the bottom of

the unit. Scribe lines show the outline of each side and the

bottom return air opening.

Bottom Return Air Applications

If cold air return is to terminate through the floor under the

furnace, a direct, airtight and sealed connection must be

made to the bottom of the furnace.

1 - Cut opening infloor or platform. Using knockouts pro-

vided, cut bottom of base panel. See figure 2.

KNOCKOUT PATTERN FOR BOTTOM

RETURN AIR APPLICATION

FIGURE 2

2 - Bend a flange on returnair plenum and lower into floor

or platform opening. See figure 3.

3-Position unit over return air opening. Seal unit air tight

with return air plenum.

Page 5

BOTTOM RETURN AIR APPLICATION

G26 UNIT._I_

I I SUPPLYAIR

kl _-J/LENUM

PROPERLY "iX_

SIZED FLOOR I _

OPENING\ \1

FIGURE 3

NOTE - Be careful not to damage glass fiber insulation.

Check for tight seal.

Side Return Air Applications

For installationswhere the return air is taken from a return

air drop, unit may be installed using either the left or right

side of furnace.

For side return air applications, cut furnace cabinet at the

dimensions given on page 2. Embossed corners are pro-

vided on both cabinet sides for return air opening location.

This unit is not equipped with a filter. Filter racks and re-

usable foam filters are available from Lennox in single

kits (44J20 for 14 x 25 filters; 44J21 for 20 x 25 filters) or

10-pack kits (66K61 for 14 x 25 filters; 66K62 for 20 x 25

filters). A filter must be in place anytime the unit is in op-

eration.

Bottom Return Air Applications

1-Remove blower access panel.

2-Install filter clips, provided with unit, by slipping folded

section of clipon edge of bottom opening. See figure 4.

3-Place filter in bottom of blower compartment beneath

rear filterdip. Press down on filter sides. Filterclipsflex

allowing filter to snap into place.

4-To remove filter, press clip and pullfilter up and out.

BOTTOM RETURN FILTER INSTALLATION

SIDE FILTER CLIPS

BACK

FURNACE FURNACE

FRONT BASE BOTTOM

FIGURE 4

Side Retum Air Applications

An external filter rack, ordered separately, is available from

Lennox.

NOTE -The filter door may be shipped in the rack behind

the filter. If necessary, remove the filter, retrieve the door

and continue with the installation of the rack.

1 - Align filter rack opening with the inside edge of the side

return opening. Bottom of rack should be approx-

imately 1 inches (25mm) from the bottom and 3 inch-

es (76mm) from the front of the unit.

2 - Screw filter rack into place with the eight self-drilling,

self-tapping screws provided. See figure 5.

3 - Push filter door pins through the two holes in filter door

from the inside of the u-channel. See figure 6.

4 - Position filter door on end of filter so that the thumb tab

side of the filter door is away from the fumace. Squeeze

thumb tabs to secure filter to door.

SIDE RETURN FILTER INSTALLATION

BLOWER DECK

RETURN 12 In. (305) for

AIR 14 in. (356) Filter

OPENING 18 in. (457) for

20 in, (508) Filter

1-15/16(49)in, _

CABINET BASE BOTTOM "/4

RETURN AIR

PLENUM SIZE

t2-3/4 in. X 23-1/2 in. (324 X 597)

for t4 in. (356) Filter

18-3/4 in. x 23-1/2 in. {476 x 597)

for 20 in. (508) Filter

FIGURE 5

FILTER DOOR ASSEMBLY

FILTERDOOR,

PINS

FILTER DO_

FILTER DOOR

PIN _4,

ILTER

FIGURE 6

5-Guide tilter and filterdoor into the filterrack installed on

side of furnace. Push door into filter rack untilsecure.

6 - To remove filter, pull filter door pins until door is re-.-

leased from filter rack.

Page 6

Useindustry-approvedstandardsto sizeandinstallthe

supplyandreturnairductsystem.Thiswillresultinaquiet

andlow-static system that has uniform air distribution.

Supply Air Plenum

Furnaces installed without a cooling coil require the installa-

tion of a removable access panel in the supply air duct. The

access panel should be large enough to permit inspection (ei-

ther by smoke or reflected light) of the heat exchanger for

leaks after installation. The furnace access panel must al-

ways be in place when the furnace is operating and it must

not allow leaks into the supply air duct system.

Return Air Plenum

See dimension illustration on page 2 for proper return air

duct size.

NOTE -For bottom return air, return air duct should be se-

cured to the unit using rivets or S-locks. For side return air,

secure return air duct to filter rack using screws. When us-

ing screws, take care to avoid interference with the filter

which may cause improper filtration.

The return air must not be drawn from a room where

another gas appliance (ie., a water heater) is installed.

Even though this furnace draws its combustion air from

outside of the structure, other gas appliances that share a

utility room may not, When return air is drawn from a room,

a negative pressure is created in the room. If a gas ap-

pliance is operating in a room with negative pressure, the

flue products can be pulled back down the vent pipe and

into the room. This reverse flow of the flue gas may result in

incomplete combustion and the formation of carbon mon-

oxide gas. This toxic gas might then be distributedthrough

the house by the furnace duct system.

I A CAUTION I

All pipe, fittings, primer and solvent cement must con-

form with American National Standard Institute and the

American Society for Testing and Materials (ANSI/

ASTM) standards. The solvent shall be free flowing and

contain no lumps, undissolved particles or any foreign

matter that adversely affects the joint strength or chemi-

cal resistance of the cement. The cement shall show no

gelation, stratification, or separation that cannot be re-

moved by stirring. Refer to the table 2 below for approved

piping and fitting materials.

TABLE 2

PIPING AND FITTINGS SPECIFICATIONS

PIPE & FITTING MATERIAL

Schedule 40 PVC (Pipe)

Schedule 40 PVC (Cellular Core Pipe)

Schedule 40 PVC (Fittings)

Schedule 40 CPVC (Pipe)

Schedule 40 CPVC (Fittings)

SDR-21 PVC (Pipe) or SDR-26 PVC (Pipe)

SDR-21 CPVC (Pipe) or SDR-26 CPVC (Pipe)

Schedule 40 ABS (Pipe)

Schedule 40 ABS (Fittings)

ABS-DWV (Drain Waste & Vent)

(Pipe & Fittings)

PVC-DWV (Drain Waste & Vent -

Pipe & Fittings)

ASTM

SPECIFICATION

D1785

F891

D2466

F441

F438

D2241

F442

D1527

D2468

D2661

D2665

NOTE -When a W-I'KX termination kit (30G79) is installed

as part of the intake and exhaust piping, add twelve feet to

the equivalent length of the pipe (the two 2inch diameter

90 °elbows and the 27 inch pipe in the kit).

Primers and solvents must meet ASTM specifications.PVC

primer is specified in ASTM F 656. Use PVC solvent cement

as specified in ASTM D 2564 and ABS solvent cement as

specified in ASTM D2235. Low temperature solvent cement

is recommended. Metal or plastic strapping may be used for

vent pipe hangers.

Table 3 lists the available exhaust termination kits. All Len-

nox vent terminations are PVC.

Lennox Pad No.

60G77

33K97

15F75

22G44

15F74

44J41

44J40

30G28

30G79

TABLE 3

TERMINATION KITS

Kit LB# Description-Inches (mm)

2" (50,8) Concentric

LB-49107CE _rmin_tion Kit

LB-87942 2" (50.8) Low Pressure Drop

Con_-_ntricTerm. Kit

2" 50.8) Roof

LB-4gl07CC Tgf nination Kit

LB-49107CD 2" (50.8) Wall

Assembly Termination Kit

LB-49107CB 2" (50.8) Wall Ring Kit

3" 76.2) Roof

LB-65678A Termination K t

LB-65701A 3" (7S.2) Wall

/L_rnhlv Terminatinn Kit

WTK •2" (50.8) Wall

Termination Extended Vent

2" (50.8) Wall

WTKX Termination Extension Riser

When making ABS joints, pieces can be prepared with a

cleaner. When joining ABS to PVC matedals, use PVC sol-

vent cement. Refer to this procedure as specified inASTM

D3138.

Page 7

Pipe used for exhaust and intake lines should be sized ac-

cording to table 4. Note that maximum length of vent pipe is

for one run; either intake or exhaust. Maximum vent length

given is not the total length of intake + exhaust vents.

Each 90 ° elbow is equivalent to 5 feet (1.52m) of vent pipe.

Two 45 ° elbows are equivalent to one 90 ° elbow. One

45°elbow is equal to 2.5 feet (.76m) of vent pipe.

If intake and exhaust piping runs are not equal in length and

number of elbows, the larger diameter pipe must be used

for both runs.

TABLE 4

VENT PIPE SIZING TABLE FOR G26 FURNACES

MINIMUM DIAMETER OF INTAKE/EXHAUST PIPE

Vent Pipe G26-50 G26-75 G26-100 G26-125

Equivalent Length 50,000 75,000 100,000 125,000

Max, Feet (Meters) BTU BTU BTU BTU

15 (4.57m) 1-1/2" 2" 2" 2"

20 (6.10m) 2" 2" 2" 3"

25 (7.62m) 2" 2" 2" 3"

30 (9.14m) 2" 2" 3" 3"

40 (12.19m) 2" 2" 3" 3"

50 (15.24m) 2" 2" 3" 3"

55 (16,76m) 2" 2" 3" 3"

60 (10.29m) 3" 3" 3" 3"

70 (21.34m) 3" 3" 3" 3"

80 (24.38m) 3" 3" 3°3"

90 (27.43m) 3" 3" 3" 3"

100 (30.48m) 3" 3" 3" 3"

110 (33.53m) 3" 3" 3" 3"

120 (36.58m) 3" 3" 3" 3"

130 (39.62m) 3" 3" 3" -

NOTE -M inchpipe forG26-50is 5 feet and2 elbowsof 1.5inch diameter

pipe.

NOTE -M inchpipe forG26-75 is 5 feetand 2 elbowsof 2 inchdiameter

pipe.

NOTE -M inchpipe forG26-100is 5 feetand2 elbows of 2 inchdiameter

pipe.

NOTE -M inchpipe for G26-125 is 5 feetand2 elbowsof 2 inchdiameter

pipe.

NOTE -When a WTtO( termination kit is installed as part of

the intake and exhaust piping, the two 2 inch diameter 90 °

elbows and the 27 inch pipe (in the kit) should be included

in the maximum vent pipe length for each run.

For -50 and -75 kBtuh units, connections are provided for 2

inch diameter venting which should satisfy most venting re-

quirements. No transition pieces are provided or needed

for 2 inch venting.

For -100 and -125 kBtuh units, the intake connection is

sized for 3 inch diameter pipe. The exhaust connection has

a 2 inch nipple. Apipe transition piece is shipped with the

unit to connect to 3 inch pipe. See figure 7 for 2 inch and 3

inch venting applications.

Most venting applications will require 3 inch venting for

proper unit operation. For no reason should the intake

and exhaust pipe be different diameter pipes. Regard-

less of the diameter of pipe used, the standard roof and wall i

terminations described in section Intake and Exhaust Pip-

ing Terminations should be used. Exhaust piping must ter-

minate with 1-1/2 inch pipe for 1-1/2 inch or 2 inch venting

and 2 inch pipe for 3 inch venting.

G26-100 OR -125 WITH 2 IN. VENTING

2 IN. VEN'_,,._P_ ¢,..1 3 IN. X2 IN.

I-1" /REDU'%E'D

I I _PROVIDED

2IN I 3IN'

OUT IN

G26-100 OR -125 WITH 3 IN. VENTING

31N. X21N.

REDUCER _IN. VENT PIPE

2,N IV

PROVIDED _II

NIPPLE 2IN. I 3IN.

OUT IN

FIGURE 7

All cementing of joints should be done according to the

specifications outlined in ASTM D 2855.

1 - Measure and cut vent pipe to desired length.

2 - Debur and chamfer end of pipe, removing any ridges

or rough edges. If end is not chamfered, edge of pipe

may remove cement from fitting socket and result in a

leaking joint.

3 - Clean and dry surfaces to be joined.

4 - Test fitjoint and mark depth of fitting on outside of pipe.

5 - Uniformly apply liberal coat of PVC primer for PVC or

ABS cleaner for ABS to inside socket surface of fitting

and male and of pipe to depth of fittingsocket.

6 - Promptly apply solvent cement to end of pipe and in-

side socket surface of fitting. Cement should be ap-

plied lightly but uniformly to inside of socket. Take care

to keep excess cement out of socket. Apply second

coat to end of pipe.

Page 8

NOTE - -iTmeis cdtical at this stage. Do not allow pnm-

er to dry before applying cement.

7- Immediately after applying last coat ofcement to pipe,

and while both inside socket surface and end of pipe

are wet with cement, forcefully insert end of pipe into

socket until it bottoms out. Tum pipe 1/4 turn dudng as-

sembly (but not after pipe is fully inserted) to distribute

cement evenly.

NOTE-Assembly should be completed within 20 sec-

onds after last application of cement. Hammer blows

should not be used when inserting pipe.

8 - After assembly, wipe excess cement from pipe at end

of fitting socket. A properly made joint will show a

bead around its entire perimeter. Any gaps may indi-

cate a defective assembly due to insufficient solvent.

9 - Handle joints carefully until completely set.

The thickness of construction through which vent/air intake

pipes may be installed is a minimum of 3 inches (610 mm),

and a maximum of 24 inches (610mm). If a G26 furnace re-

places a fumace which was commonly vented with another

gas appliance, the size of the existing vent pipe for that gas

appliance must be checked. Without the heat of the odginal

furnace flue products, the existing vent pipe is probably

oversized for the single water heater or other appliance.

The vent should be checked for proper draw with the re-

maining appliance.

1 - Cement intake piping in slip connector located at top

of unit.

2 - Route piping to outside of structure. Continue with

installation following instructions given in exhaust and

intake piping termination section.

Exhaust Piping

1 - Cement exhaust piping into flue collar socket located

on the left side of the top cap.

2 - All horizontal runs of exhaust pipe must slope back to-

ward unit. A minimum of a 1/4 inch (6mm) drop for each

12 inches (305mm) of horizontal run is mandatory for

drainage. Horizontal runs of exhaust piping must be

supported every 5 feet (1.52m) using hangers.

NOTE -Exhaust piping should be checked carefully to

make sure there are no sags or low spots.

NOTE -Exhaust piping must be insulated with 1/2 inch

(13mm) Armaflex or equivalent when run through un-

heated space. Do not leave any area of exhaust pipe

open to outside air; exterior exhaust must be insulated

with 1/2 inch (13mm) Armaflex or equivalent.

A WARNING

Intake Piping

CAUTION

Removal of Unit from Common Venting System

In the event that an existing furnace is removed from a

venting system commonly run with separate gas ap-

pliances, the ventingsystem is likelyto be too large to prop-

edy vent the remaining attached appliances. The following

test should be conducted while all appliances (both in op-

eration and those not in operation) are connected to the

common venting system. If the venting system has been

installed improperly, corrections must be made as outlined

in the previous section.

1-Seal any unused openingsin the common ventingsys-

tem.

2 - Visually inspect the venting system from proper size

and horizontal pitch and determine there is no block-

age or restdction, leakage, corrosion and other deft-

ciencies which could cause an unsafe condition.

Page 9

3- Close all building doors and windows and all doors be-

tween the space in which the appliances remaining

connected to the common venting system are located

and other spaces of the building.Turn on clothes dry-

ers and any appliances notconnected to the common

venting system. Turn on any exhaust fans, such as

range hoods and bathroom exhausts, so they will op-

erate at maximum speed. Do not operate a summer

exhaust fan. Close fireplace dampers.

4 - Follow the lightinginstruction.Place the appliance be-

ing inspected in operation. Adjust thermostat so ap-

pliance will operate continuously.

5 - Test for spillage at the draft hood relief opening after 5

minutes of main burner operation. Use the flame of a

match or candle, or smoke fl'om a cigarette, or a cigar.

6- After you have determined that each appliance re-

maining connected to the common venting system

properly vents when tested as outlined above, return

doom, windows, exhaust fans, fireplace dampers and

any other gas-burning appliance to their previous con-

dition of use.

7- If improper venting is observed during any of the

above tests, the common venting system must be cor-

rected. The common venting system should be re-

sized to approach the minimum size as determined by

using the appropriate tables in appendix G in the cur-

rent standards of the National Fuel Gas Code ANSI

Z223-1 in the U.S.A., and the appropdate Category 1

Natural Gas and Propane appliances venting sizing

tables in the current standards of the CAN/

CGA-B149.1 and .2 in the Natural Gas and Propane

Installation Code in Canada.

Intake and Exhaust Piping Terminations

Intake and exhaust pipes may be routed either horizontally

through an outside wall or vertically through the roof. In at-

tic or closet installations, vertical termination through the

roof is preferred. Figures 8 through 20 show typical ter-

minations.

1-Use recommended piping materials for both intake

and exhaust piping.

2 - Secure all joints, including drain leg, gas tight using

approved cement.

3-Piping diameters should be determined according to

length of pipe run. See table 4. Locate intake piping

upwind (prevailingwind) from exhaust piping. To avoid

re-circulation of exhaust gas on roof terminations, end

of exhaust pipe must be higher than intake pipe.

Exhaust and intake exits must be in same pressure

zone. Do not exit one through the roof and one on the

side. Also, do not exit the intake on one side and the

exhaust on another side of the house or structure.

Intake and exhaust pipes should be placed as close

together as possible at termination end (refer to il-

lustrations). Maximum separation is 3 inches (76mm) ,-

on roof terminations and 6 inches (152mm) on side

wall terminations.

Exhaust piping must terminate straight out or up as

shown. In rooftop applications, a 2 inch X 1-1/2 inch re-

ducer for 2 inch venting, 3 inch x 2 inch reducer for 3

inch venting must be used on the exhaust piping at the

point where it exits the structure to improve the velocity

of exhaust away from the intake piping.

On roof terminations, the intake piping should termi-

nate straight down using two 90° elbows (See figure 8).

A IMPORTANT

NOTE -If winter design temperature is below 32°F (O°C),

exhaust piping must be insulated with 1/2 inch (13mm),

Armaflex or equivalent when run through unheated

apace. Do not leave any surface area of exhaust pipe

open to out-side air; exterior exhaust pipe must be insu-

lated with I/2 inch (13mm) Armaflex or equivalent. In ex-

treme cold climate areas, 3/4 inch (19mm) Armaflex or

equivalent is recommended. Insulation on outside runs oi

exhaust pipe must be painted or wrapped to protect in-

sulation from deterioration.

Inches(mm) 3(76 MAX.__ 3 x 2 (76 x 51) OR

_2 x 1-1/2 (51 x38)

/PVC REDUCER

8 (203I MIN 1/2 (13) FOAM

INSULATION IN

UNCONDITIONED

12 (305) ABOVE SPACE

AVE"*OESNOW

ACCUMULATION

3 (76) OR UNCONDITIONED

2 (51) PVC ATTIC SPACE

PROVIDE SUPPORT

FOR INTAKE AND

EXHAUST LINES

ROOF TERMINATION KIT

(15F75) LB-49107CC for 2 (51) Venting

(44J41) LB-65678A for 3 (76) Venting

FIGURE 8

NOTE -Dudng extremely cold temperatures, belov_

approximately 20°F (6.67°C), units with long runs of venl

pipe through unconditioned space, even when insulated,

may form ice in the exhaust termination that prevents the

Page 10

unit from operating properly. Longer run times of at least 5

minutes will alleviate most icing problems. Also, a heating

cable may be installed on exhaust piping and termination to

prevent freeze-ups. Heating cable installation kit is avail-

able from Lennox. See Condensate Piping section for part

numbers.

NOTE -Care must be taken to avoid recirculation of ex-

haust back into intake pipe.

6 - On field supplied terminations for side wall exits, ex-

haust piping should extend a maximum of 12 inches

(3O5mm) beyond the outside wall. Intake piping

should be as short as possible. See figure 9.

1/2 (13) ARMAFLEX

INSULATION IN

UNCONDITIONED SPACE

12 (305) MIN.

2 X 1-1/2

(51x 38)

1-1/2 30 _VC

2(011 _ 0(J02)

1/2 (13) ARMAFLEX I

INSULATION MAXIMUM

Z2 21_ PVC

COUPLING

OUTSlOEJ

WALL MINIMUM [

Inches (ram) TOP VIEW

WALL RING KiT

(15J74) LB-49107CB for 2 (50.8) Venting

FIGURE 9

7 - On field supplied terminations, a minimum separation

distance between the end of the exhaust pipe and the

end of the intake pipe is 8 inches (203mm).

8- If intake and exhaust piping must be run up a side wall

to position above snow accumulation or other ob-

structions. Piping must be supported every 3 feet

(.91m) as shown in figure 15. Refer to figures 13 and

14 for proper piping method. WTK wall termination kit

must be extended for use in this application. See fig-

ure 18 or use kit WTKX shown in figure 19. When ex-

haust and intake piping must be run up an outside

wall, the exhaust piping is reduced to 1-1/2 inches

(38ram) after the final elbow. The intake piping may

be equipped with a 90° elbow turndown. Using turn-

down will add 5 feet (1.5m) to the equivalent length of

the pipe.

112 (12.7) FOAM INSULATION

IN UNCONDITIONED SPACE Inches(mm)

Optional Turndown

Shown

(Intake Only)

TOP VIEW

WALL TERMINATION

(22G44) LB49107CD for 2 (50.8) Venting

(44J40) LB-65701A for 3 (76.2) Venting

FIGURE 10

EXHAUST

TERMINATION _ _ 12 (305) ABOVE

AVERAGE SNOW

ACCUMULATION

_INTAKE

TERMINATION

F.XHAUST INTAKE

CONCENTRIC ROOFTOP TERMINATION

(60G77) LB49107CE for G26-50 & -75 Units Only

(33K07) LB-87942 for G26-t00 & -125 Units Only

FIGURE 11

EXHAUST

Inches (mm)

EXHAUST

INATION

TERMINATION I

12(305)Mln,

CONCENTRIC WALL TERMINATION

(60G77) LB-49107CE for G26-50 & -75 Units Only

(33K97) LB-87942 for G26-100 & -t25 Units Only

FIGURE 12

Page 11

Inches(ram)

UNCONDITIONED

SPACE

12 (305) MIN. for 2 (51)

20 (508) MAX. for 3 (75)I

OUTSIDE WALL

PROVIDE SUPPORT 12 A

FOR INTAKE AND

EXHAUST LINES EVERY BOVE

36 (914) AVERAGE SNOW

ACCUMULATION

1/2 (13) FOAM

INSULATION IN --

UNCONDITIONED 1/2 (13) FOAM

SPACE INSULATION

SIDE VIEW

WALL RING TERMINATION

(15F74)LB-49107CBfor2 in.(51)Venting

"This reducer is not necessary for G26-50 units using 1-1/2 In. venting,

See venting table 4 for maximum venting lengths with this arrangement.

FIGURE 13

g-Position terminationends so they are flee from any ob-

structions and above the level of snow accumulation

(where applicable). Termination ends must be a mini-

mum of 12 inches (305mm) above grade level. Do not

point into window wells, stairwells, alcoves, courtyard

areas or other recessed areas. Do notpositiontermina-

tion ends directlybelow roofeaves or above a walkway.

Since the G26 is acertified direct vent, Category IV gas

furnace, the location of the termination is limited by lo-

cal building codes. In the absence of local codes, refer

to the current National Fuel Gas Code ANSI Z223-1 in

U.S.A., and current standards CAN/CGA-B149.1/.2 of

the Natural Gas and Propane Installation Instructions in

Canada for details. The termination should be at least

12 inches (305mm) from any opening through which

flue products could enter the building.

When horizontally vented, minimum clearance for ter-

mination from electric meters, gas meters, regulators

and relief equipment is 4 feet (1.2m) for US installa-

tions. Refer to the current CAN/CGA-B149.1 and .2 for

installations in Canada or with authoritieshaving local

jurisdiction.

At vent termination, care must be taken to maintain

protective coatings over building materials (pro-

longed exposure to exhaust condensate can destroy

protective coatings). It is recommended that the ex-

haust outlet not be located within 6 feet (1.8m) of a

condensing unit because the condensate can dam-

age the painted coating.

A IMPORTANT

Inches(mm) 1/2 (13)

FOAM

iNSULATION

3(75)OR

2 (51) 90 °ELBOW

3x2(76x51) OR

2x 1-1/2(51 x 38)

REDUCER BUSHING LOCATION

FOR OFFSET TERMINATION

3(75)OR

(NOt Shown) _t _, 2 (51) 90 °ELBOW

May Be Used on

Intake Only Inches (mm)

FRONT VIEW

WALL TERMINATION

(22G44) LD-49107CD for 2(51) Venting

(44,140) LB-65701A for 3(76) Venting

FIGURE 14

METAL OR PLASTIC

STRAPPING _,_

OR LARGE WIRE TIES

FIGURE 15

10 - Suspend pipingusing hangers at a minimum of every-

5 feet (1.52m) for schedule 40 PVC and every 3 feet

(.91m) for ABS-DWV, PVC-DWV, SPR-21 PVC, and

SDR-26 PVC piping. A suitable hanger can be fabri-

cated by using metal or plastic strapping or a large

wire tie.

11 - In areas where piping penetrates joists or interior

walls, hole must be large enough to allow clearance on

all sides of pipe through center of hole using a hanger.

12 - Isolate pipingat the pointwhere it exits the outsidewall

or roof.

Page 12

13 -When furnace is installed in a residence where unit is

shut down for an extended peded of time, such as a

vacation home, make provisions for draining conden-

sate collection trap and lines.

14 - Based on the recommendation of the manufacturer, a

multiple furnace installation may use a group of up to

four termination kits WTK assembled together horizon-

tally, as shown in figure 17.

Front View Iq_ 1_5,-_/ EXHAUSTVENT

VENT

1/2 (13) Foam f

Inches (mini E

VENTTERMINATIONS

WALLTERMINATIONKIT(30G28) WTK

Side View

EXHAUST VEN_

INTAKE VENT

OUTSIDE WALL

FIGURE 16

Front View EXHAUST

p--- I

EXHAUST VENT

Side View ':" :/"

Inches (ram) _NTAKE

_ VENT

OPTIONAL VENT TERMINATION FOR

MULTIPLE UNIT INSTALLATION

WALL TERMINATION KITWTK

FIGURE 17

Front View

INTAKE

AIR

(127) _

(3os) COVEREXHAUST

VENT WITH

112 (13)

FOAM

INSULATION

EXHAUST

AIR

12 MIN

(305)

AbOveGrade

INTAKE

AIR

/ / Side View

/ /

/ / ----_n II

//// U_im_ Inches (ram)

/ / 12 305

/ / Mnmum

ABOV_GRADE

/ / GRADE

_JIIIIIIIIIIIIIII

VENT TERMINATIONS

MOOEL WTK WALL TERMINATION KIT (30G28)

EXTENDED VENT FOR GRADE CLEARANCE

Front View

FIGURE 18

I'- -'I

0,,_ _. EXHAUSTvENT

NOTE-Enclosed exhaust pipe

is insulated with 1/2 in, (13ram)

INTAKE foam Insulatfon. ff intake and

VENT exhaustpipe8arerev,,._,s_

and remove foam insulation

and reapply to other vent. Ex-

haust vent must be insulated.

12 _ GRADE

...l_'::_J_.._.. ,,,

Side View 4

STVENT

°°

VENT TERMINATIONS

MODEL w'rKx (30G79)

EXTENSION RISER FOR GRADE CLEARANCE

FIGURE 19

Page 13

G26 VENTING IN EXISTING CHIMNEY

c_x1_ n_r

or vent stack. If verti-

cal discharge through an existing unused chimney or stack is required, insertpiping

inside chimney un_lthe pipeopen end is above top of chimney and terminate as illuS-

trated. In any exteriorper6on of chimney, Itm exhaust vent mustbe insulated. An aHer-

hate method is to fill the chimney w_h ¥emliculita or equal to take advantage of its

acoustic and thermal properties.

FIGURE 20

Condensate Piping

This unit is designed for either dght- or left-side exit of con-

densate piping. Condensate drain line should be routed

only within the conditioned space to avoid freezing of con-

densate and blockage of drain line, An electric heat cable

should be used where condition is exposed to uncondi-

tioned areas.

A CAUTION

1 - Determine which side condensate will exit the unit.

2 - Connect a 1/2 inch (13mm) plastic pipe plug (provided)

inthe unused end ofthe condensate trap, Installplug so

that it is sealed water tight yet able to be removed. Do

not permanently seal the connection. Teflontape is rec-

ommended to seal joint. See figure 21.

CONDENSATE ASSEMBLY

(Forleftor rlghtInstallation)

COMBUSTION AIR

INDUCER BRACKET

COLD HEADER

BOX

NIPPLE

ADAPTER

NIPPLE

ADAPTER

CONDENSATE TRAP

PLUG BOOT OR CAP

FIGURE 21

3- Use the provided adapter (1/2 inch PVC x 1/2 inch

MPT) and the nipple (1/2 inch PVC) to carry drainage

outside the cabinet. If a field substitute is needed, 1/2

inch CPVC x 1/2 inch MPT adapter and 1/2 inch CPVC

is acceptable for use.

4 - Glue nipple to the adapter using the procedures out-

lined in the "Joint Cementing Procedures" section.

The nipple/adapter assembly should be connected in

a non-permanent manner and must be water tight.

Teflon tape is recommended to seal the joint.

For Right-Hand Side Condensate Exit:

Install the nipple/adapter assembly from the outside

of the cabinet and insert the adapter into the threaded

opening in the condensate trap.

For Left-Hand Side Condensate Exit:

Insert nipple/adapter assembly from the left hand

side of the cabinet and through the combustion air

inducer mounting structure into the threaded open-

ing in the condensate trap.

5-Connect field supplied plumbingto nipple and route to

open drain. Plumbing shouldbe vented to a pointhigher

than the condensing coil. See figure 22.

CONDENSATE PLUMBING

(Plumbing must be vented higher than coil.)

FIGURE 22

Connect condensate drain line (1/2 inch [13mm] SDR

11 plastic pipe or tubing) to condensate connection on

drip leg assembly and route to open drain. Conden-

sate line must be sloped downward away from drip leg

to drain. If drain level is above drip leg, condensate

pump must be used to condensate line. Condensate

drain line should be routed within the conditioned

space to avoid freezing of condensate and blodkage of

drain line. If this is not possible, a heat cable kit may be

Page 14

used on the condensate drip leg and line. Heating

cable kit is available from Lennox in various lengths;

6feet (1.8m) - kit no. 18K48; 24 feet (7.3m) - kit no.

18K49; and 50 feet (15.2m) - kit no. 18K50.

..... I

1 - Gas piping may be routed into the unit through either

the left- or right-hand side. Supply piping enters into

the gas valve from the bottom of the valve as shown in

figure 23.

LEFT SIDE PIPING

MANUAL

MAIN SHUT-

OFF

VALVE

1/8 IN. NPT

PLUGGED

TAP _I_, _

GAS VALVE

_ .... _ RIGHT SIDE PIPING

___ _=_L_ (STANDARD)

_' _=" 1/8 IN. NPT

/BPLUGGED

//TAP

GAS VALVE

FIGURE 23

2- When connecting the gas supply, factors such as

length of run, number of fittings and furnace rating

must be considered to avoid excessive pressure drop

Table 5 lists recommended pipe sizes for typical ap-

plications.

NOTE- Use two wrenches when connecting gas pip-

ing to avoid transferring torque to the manifold.

3 - The gas piping must not run in or through air ducts,

clothes chutes, gas vents or chimneys, dumb waiters

or elevator shafts. Center gas line through pipinghole.

Gas line should not touch side of unit.

When left-hand gas plumbing is required, gas line

should be installedin the lower half of knockoutso that

piping will clear combustion air inducer.See figure 23.

The pipingshould be sloped 1/4 inch (6.4 ram) per 15

feet (4.57 m) upward toward the meter from the fur-

nace. The piping must be supported at proper inter-

vals [every 8 to 10 feet (2.44 to 3.01 m)] using suitable

hangers or straps. Adrip leg should be installed inver-

tical pipe runs to the unit.

In some localities, codes may require installation of a

manual main shut-offvalve and union(furnished by in-

staller) external to the unit. Union must be of the

ground joint type.

AIMPORTANT

HO"A' ES'P"E"O"EII

118IN.13.2mmlN.P.T.1_. II ISOLATE

FIGURE 24

NO TE -Install a 1/8 inch NPT plugged tap in the field pip-

ing upstream of the gas supply connection to the unit.

The tap must be accessible for test gauge connection.

See figure 24.

Leak Check

After gas piping has been completed, carefully check all

piping connections (factory and field) for gas leaks. Use a

leak detecting solution or other preferred means.

ACAUTION

Page 15

Nominal

Iron Pipe Size

-Inches(mm)

1/4

(6.35)

3/8

(9.53)

1/2

(12.7)

3/4

(19.05)

(25.4)

1-1/4

(31.75)

1-1/2

(36.1)

(50.8)

2-1/2

(63.5)

(76.2)

(101.6)

TABLE 5

GAS PIPE CAPACITY -FT31HR (kL/HR)

Internal Length of Pipe-Feet(m)

Diameter 10 20 30 40 50 60 70

-Inches(mm) (3,048) (6.096) (9.144) (12.192) (15.240) (18.288) (21.336)

364

(9.246)

.493

(12.522)

,622

(17.799)

824

(20.930)

1.049

(26.645)

1.380

(35.052)

1.610

(40.894)

2.967

(52.802)

2.469

(67.713)

3.068

(77.927)

4.026

(102.260)

(1J3)

(2.69)

175

(4,96)

360

(10,19)

68O

(19.25)

1490

(39.64)

2106

(89.46)

3950

(111.85)

6300

(178.39)

11000

(311.48)

23000

(651.27)

29 24 20 18 16 15

(.82) (.68) (.57) (.51) (,45) (.42)

65 52 45 40 36 33

(1.84) (1.47) (1.27) (1.13) (1.02) (.73)

120 97 82 73 66 61

(3.40) (2.75) (2,32) (2.07) (1.87) (1.73)

250 200 170 151 138 125

(7.08) (5.66) (4.61) (4.28) (3.91) (3.54)

465 375 326 285 260 240

(13.17) (10.62) (9.06) (8.07) (7.36) (6.80)

950 770 660 580 530 490

(25.90) (21.60) (16,69) (16.42) (15.01) (13,67)

460 1180 990 900 810 750

(41.34) (33.41) (26.03) (25.46) (22,94) (21.24)

2750 2200 1900 1680 1520 1400

(77.87) (62.30) (53.80) (47.57) (43.04) (39.64)

4350 3520 3000 2650 2400 2250

(123.17) (99.67) (84.95) (75.04) (67.96) (63.71)

7700 6250 5300 4750 4300 3900

(218.03) (176.98) (150.07) (134.50) (121.76) (110.43)

15800 12800 10900 9700 8800 8100

(44739) (362.44) (308.64) (274.67) (249,18) (229.36)

NOTE-Capacity given in cubic feet of gas per hour (kilo liters of gas per hour) and based on 0.60 specific gravity gas.

80 90 100

(24.384) (27.432) (30,480)

14 13 12

(.40) (.37) (34)

31 29 27

(.88) (.82) (.76)

57 53 50

(1.61) (1.50) (1.42)

118 110 103

(3.34) (3.11) (2.92)

220 205 195

(6.23) (5.80) (5.52)

460 430 400

(13.03) (12.18} (11.33)

690 650 620

(19.54) (16.41) (17.56)

1300 1220 1150

(36.81) (34.55) (32,56)

2050 1950 1850

(58.05) (58.22) (52.38)

3700 3450 3250

(104,77) (97.69) (92.03)

7560 7200 6700

(212.37) (203.88) (189.72)

The furnace must be isolated from the gas supply system

by closing its individual manual shut-off valve during any

pressure testing of the gas supply system at pressures less

than or equal to 1/2 psig (3.48 kPa, 14 inches w.c.).

tion purposes. Refer to figure 29 for control box arrange-

ment, figure 30 for adetail of the Surelight TM integrated

control, figure 31 for schematic wiring diagram and trou-

bleshooting, and figure 32 for point to point field wiring. :

ELECTROSTATIC DISCHARGE (ESD)

Precautions and Procedures

ACAUTION 1

Afield make-up box is provided for line voltage wiring. Line

voltage wiring to unit is done through the J69 jack from the

field make-up box to plug P69 from the control box. See fig-

ures 25 and 26 for make-up box installation.

Figure 28 shows thermostat designations for identifica-

1 - Install field make-up box on either side, inside or out of

the cabinet. Knockouts are provided in box and cabi-

net to run wiring. See figures 25 and 26.

Page 16

INTERIORMAKE-UPBOXINSTALLATION

BUSHING P69 from

Control Box

FIGURE 25

EXTERIOR MAKE-UP BOX INSTALLATION

MAKE-UP

BOX BUSHING

J69

(Shown wlth

accessory

wire connected)

P69 from

Control Box

FIGURE 26

2- Remove cap from knockout in blower deck on the

same side as the installed make-up box.

AIMPORTANT

3 - Electrically ground unit in accordance with local codes

or, inthe absence of local codes, inaccordance withthe

current National Electdc Code (ANSI/NFPA No. 70)

and inCanada withthe currentCanadian Electdc Code

part 1 (CSA standard C22.1). The ground wire is pro-

vided in the field make-up box.

To ensure proper grounding of the furnace, two star

washers are included in the electrical make-up box

bag assembly. Place the star washer on securing

screw before installing the make-up box. Make sure

10-

the star washer breaks the paint on the cabinet so

that the washer is touching metal. Unit is not prop-

erly grounded if paint has not been removed by star

washer.

An optional 120 volt accessory wire is provided with

G26 units. Install brown accessory wire into J69 jack

plug by inserting the pin of the brown wire into the open

socket of the jack. See fig- INSTALLINGBROWN

ure 27. Any accessory rated ACCESSORYWIRETOJ69

up to 4 amps can be con-

nected to this wire. Connect BROWN

the neutral leg of the acces-

sory to the neutral white wire NEUTRAL

in the make-up box. The ac-

cessory terminal is ener-

gized whenever the blower

is in operation.

Insert the three-pin (P69)

plug from the control box FIGURE 27

into the knockout provided in the blower deck.

Connect jack (J69) from make-up box to jack plug in

blower deck.

Select wire size accordingto the blower motoramps.

Snaphole bushing is providedfor the widng entry hole

in the cabinet. Asnaphole plug is provided to seal the

unused wire entry hole.

Install room thermostat according to instructionspro-

vided with thermostat. See figure 28 for thermostat des-

ignations. Iffurnace is being used withheat pump refer

to FM21 installation instruction.

Install a separate fused disconnect switch near the

unit so power can be turned off for servicing.

G26 and CONDENSING UNIT

THERMOSTAT DESIGNATIONS

(Refer to specific thermostat and outdoor unit.)

Thermostat G26 Condensing Unit

Furnace

_ _ HS UNIT

® coMP.Esso.

® ,NDOO,.LOWE,®1

owE, ®j .SUNiT

COMMON @COMMON /_COMMON

FIGURE 28

11 - Complete widng connecfions to equipment using wiring

diagrams provided_unitand infigures31 and 32. Use

18-gauge wire or largerfor thermostat connections.

Page 17

IndoorBlowerSpeeds(Referto Figure31)

1-When the thermostat is set to "FAN ON", the indoor

blower will run continuously on low speed when there

is no cooting or heating demand.

2-When there is a cooling demand, the indoor blowerwill

run on the cooling speed.

3-When there is a heating demand, the indoor blower

will run on the heating speed.

G26CONTROLBOX

TRANSFORMER

CIRCUIT

• BREAKER

DOOR _

INTERLOCK SURELIGH DETACHABLE

SWITCH CONTROL TERMINAL STRIP

FIGURE 29

SURELIGHT INTEGRATED CONTROL BOARD

P_ PAF_ ACB

I_ MI LOW

IIH 111t

I6_ITION SYST(_

ANSI _ZI _Z0 ATG_IATIC

Z4VAC 60Hz 0_5 AMAX_ ÷

ACC 12OVAC HTG 12o VAC RETtJ_

-- NEUTRALS --

TX.o,,co÷ Ilnll

mMEUTRALS m

C>j2 _ ÷

FLAME

HEATOFFBELAY SENSE j

S!-I SI-2 TIME

0_F OFF 60 9EC

OFF ON 90 5EC

(_N OFF +20 SIEC

D-

r-- 1

I I I

I i I

__ --_ L

F -- 1

___ ®®

Y G W R C

Y G W RC

ACS COOL

ACS HEAT

PARK

ACB LOW

ACC

HOT

HTG ACC

NEUTRALS

24VAC HOT

24VAC RTN

FLAME SENSE

TERMINAL DESIGNATIONS

Blower - Cooling Speed (Line Volt)

Slower - Heating Speed (Line Volt)

Alternate Blower Speeds (Dead)

Continuous Low Speed Blower

Accessory Terminal (Line Volt)

120VAC Hot to Transformer

120VAC Hot Input

Heat Only Accessory (Line Volt)

120VAC Neutrals

24VAC Hot fTomTransformer

24VAC Return fTom Transformer

Flame Sense Terminal

FIGURE 30

Page 18

TYPICAL G26 WIRING DIAGRAM

I20v ACC

K43 EC_I

(IF US_}

LI m

ROOMTHERf_TAT

SiS 510

_UB_STION AIR PRIMARY 6AS $47

LIMIT FL_ME R_J=0UT

SVITGH

CIOR__USTU_ON

MOTOR

JI56_ CIRCUIT

(J2) BI_J_I_

_TAT HEAT

.'_HTICIPAT I_4_l_TTIN65

BLOtER _PEEO CHART

IFACTOAy CONNECTED5PE]EDTAPS

_.-50 I..... I....

.... YELLOW

El B{.ACE .... Ig_qO_q

.... I'_I.LOI

_]_-IO0, I_1 IYI[U.IN I InA_lnl IBI_IE

HI • BLOCRRSPEE_ _TI_, LO

IELAf_X YI_J_q R_)

I_LACE BROTH PaIF YELLO_ R£D

lAdlING-

_LEC_IIC _ HAZARDCAN _U_ INJURy

0t fl_IIt,UN T _8_ _ IN A_clO_E

FIGURE 31

Page19

TYPICAL G26 FIELD WIRING DIAGRAM

I I , i

,II'

i I

TO COMPRESSOR

CONTACTOR

FLAME @

ROLLOUT LIMIT

SWITCH

COMBUSTION

AIR PROVE FIELD

SWITCH MAKE-UP

BOX

v%,%

TRANSFORMER

7CONTROL

ooddl .ox

ILIGAON L DOOR

INTERLOCK

SWITCH

FOR YOUR SAFETY READ BEFORE LIGHTING

AWARNING

_L1 GND

==odi

°°l

--Z

znl

00(3

RI ACK

WHITE

BROWN

TO ACCESSORY IF USED.

(ELECTRONIC AIR CLEANER)

IF NOT NEEDED, DO NOT INSTALL

ACCESSORY WIRE IN J69.

-- -- -- FIELD INSTALLED CLASS II 24V VOLTAGE

-- FIELD iNSTALLED UNE VOLTAGE

FIGURE 32

Gas valve may be equipped with either agas control knob

or lever. Use only your hand to push in or turn the gas con-

trol knob or move the gas control lever. Never use tools. If

the knob will not push in or turn or if lever will not move by

hand, do not try to repair it, call a qualified service techni-

cian. Force or attempted repair may result in a fire or explo-

sion.

G26 units are equipped with a SureLighU" ignition sys-

tem. Do not attempt to manually light burners on this fur-

nace. Each time the thermostat cells for heat, the burners

will automatically light. The ignitor does not get hot when

there is no cell for heat on units with SureLight TM ignition

system.

Gas Valve Operation (Figure 33)

AWARNING

ACAUTION

BEFORE OPERATING smell all around the appliance area

for gas. Be sure to smell next to the floor because some gas

is heavier than air and will settle on the floor.

1- STOP! Read the safety informationat the beginningof

this section.

2 - Set thermostat to lowest setting.

3 - Turn off all electrical power to furnace.

4- This furnace is equipped with an ignition device

which automatically lights the burner. Do not try to

light the burners by hand.

5-Remove the unit access panel.

Page 20

HONEYWELLVR8205SERIESGASVALVE

GAS VALVE SHOWN IN OFF POSITION

WHITE RODGERS

36E GAS VALVE

GAS VALVE _

SHOWN

iN OFF

POSITION

FIGURE 33

6 - Whffe Rodgers 36E Gas Valve -Switch gas valve le-

verto OFF. See figure 33.

Honeywell VR8205 Gas Valve - Turn knob on gas

valve clockwise_lt' to OFF. Do not force. See figure

33.

7 - Wait five minutes to clear out any gas. If you then smell

gas, STOP! Immediately call your gas supplier from a

neighbor's phone. Follow the gas supplier's instruc-

tions. If you do not smell gas go to next step.

8 - White Rodgers 36E Gas Valve - Switch gas valve lever

to ON.

Honeywell VR8205 Gas Valve -Tum knob on gas valve

counterctockwi_ to ON. Do not force.

9 - Replace unit access panel.

10- Turn on all electrical power to unit.

11- Set thermostat to desired setting.

NOTE -When unit is initiallystarted, _eps 1 through 11

may need to be repeated to purge air from line.

NOTE- On initial start-up and when condensate trap is

dry, unit may turn itseff off and on to allow condensate

trap to fill. This is normal operation.

12- If the furnace wii/not operate, follow the instructions

=ToTurn Off Gas To Unit" and call your service techni-

cian or gas supplier.

To Turn Off Gas To Unit

1 - Set thermostat to lowest setting.

2-Turn offall electricalpower to unit if service is to be per-

formed.

3 - Remove heat section access panel.

4 - On Honeywell VR8205 gas valves, turn knob on gas

valve clockwise4_ to OFF. For White Rodgers 36E

gas valves, move switch to OFF Do not force.

5 - Replace the unit access panel.

JGas Pressure Adjustment I

Gas Line Pressure

Check gas fine pressure with unit firing at maximum rate. A

minimum of 4.5 inches w.c. (1.12kPa) for natural gas or 8.5

inches w.c. (2.11kPa) for LP/propane gas should be main-

tained.

Gas Manifold Pressure

After line pressure has been checked and adjusted, check

regulator pressure. See table 6 for correct manifold pres-

sures for LP/propane and natural gas at altitudes in a range

of 0 to 7500 feet (0 to 2248m).

TABLE 6

Unit (Fuel) Manifold Pressure (outlet)

from 0 to 7500 ft. (0 to 2248nl) above sea level

Natural 3.5" w.c. (.87 kPa)

L.P.IPropane 7.5" w.c. (1.86 kPa)

&WARNING

GAS VALVE

CONTROL KNOB

OUTLET

PRESSURE

TAP c

FIGURE 34

HONEYWELL GAS VALVE

WIRING

TERMINALS

INLET

PRESSURE

TAP

_BARBED

FITnNG FOR

PRESSURE

SWITCH

HOSE

PRESSURE

REGULATOR

(UNDER CAP SCREW)

Page 21

WHITE RODGERS 36E GAS VALVE

REGULATOR ADJUSTMENT SCREW LOCATION

_'_ REGULATOR

COVER SCREW

ADJUSTING

SCREW

FIGURE 35

Manifold Pressure Measurement & Adjustment

NOTE -Pressure test adaptor kit (10L34) is available from

Lennox to facilitate manifold pressure measurement.

1 - Connect test gauge to outlet tap on gas valve.

2 - Disconnect pressure sensing hose from gas valve and

plug hose by covering opening with tape or equivalent.

Leave barbed fitting on valve open to atmosphere.

See figure 36.

DIFFERENTIAL PRESSURE SWITCH CIRCUITRY

BURNER

BOX

BARB

PRESSURE

BOX

COMBUSTION SENSING

AIR PRESSURE _HOSE

SENSING HOSE

GAS

VALVE

SENSING

HOSE

GAS

VALVE

AIRINDUCER •PRESSURE

SWITCH

SENSING

HOSE

LEFT SIDE OF PRESSURE SWITCH = MORE NEGATIVE

RIGHT SIDE OF PRESSURE SWITCH = LESS NEGATIVE (Closer to Zero)

FIGURE 36

3 - Start unit and allow 5 minutes for unit to reach steady

state.

4-Examine the burner flame. The flame should be stable

and should not liftfrom the burner. Natural gas should

bum blue. L.P./propane gas should bum mostly blue

with some orange streaks.

5 - After allowing unit to stabilize for 5 minutes, record

manifold pressure and compare to values given in

table 6.

NOTE -Shut unit off and remove manometer as soon as an

accurate reading has been obtained. Take care to replace

pressure tap plug.

NOTE -During this test procedure, the unit unit will be over-

firing:

•Operate unit only long enough to obtain accurate reading to

prevent oveilleaUng heat exchanger.

• Attempts to clock gas valve during this procedure will be

inaccurate. Measure gas flow rate only during nor-mal

unit operation.

6 - When test is complete remove obstruction from hose

and return hose to gas valve barbed fitting.

Gas Flow

To checkfor propergas flow tothe combustionchamber, de-

termine the Btu (kW) inputfrom the unit rating plate. Divide

this inputratingby the Btu(kW) per cubic foot (cubic meter)

of available gas. The result is the required number of cubic

feet (cubic meter) per hour. Determine the flow of gas

through the gas meter for two minutes and multiplyby 30 to

get the houdyflow of gas.

Unit does notneed gas pressure adjustmentwhen operating

from 0 to 7500 feet (0 to 2248m). See table 6 for correctman-

ifoldpressuresfor LP/propane and natural gases.

Natural to LP/Propane Changeover

A natural gas to LP/propane gas changeover kit is required

to convert unit. Refer to installation instructions supplied

with kit for conversion procedure.

Heat Anticipation Settings

Thermostat anticipator setting (if adjustable) should be set

accordingto amps listed on wiring diagram on unit.

Flame Rollout Switch

Factory set: No adjustment necessary.

Limit Control

Factory set: No adjustment necessary.

Pressure Switch

Factory set: No adjustment is necessary.

Fan Control

The fan-on delay of 45 seconds is not adjustable. The fan-

off delay (time that the blower operates after the heating

demand has been satisfied) can be adjusted by moving the

jumper on the SureLight TM integrated control. The unit is

shipped with a factoryfan-off delay of 90 seconds. The fan-

off delay will affect comfort and is adjustable to satisfy indi-

vidual applications. See figure 37.

FAN-OFF TIME ADJUSTMENT

60sec, 90sec. 120sec. 180sec.

To adjust fan-off timing, flip dip switch to desired setting.

FIGURE 37

Page 22

TemperatureRise

Check temperature rise and, if necessary, adjust blower

speed to maintain temperature risewithin range shown on

unit rating plate.

Electrical

1 - Check all wiring for loose connections.

2 - Check circuit breaker located on unit control box.

3 - Check for correct voltage at the furnace (furnace oper-

ating).

4 - Check amp-draw on blower motor.

Motor Nameplate Actual

NOTE -Do not secure electrical conduit directly to ducting

or structure.

Blower Speeds

Refer to blower speed selection chart on unit wiring dia-

gram.

NOTE -CFM readings are taken external to unit with a dry

evaporator coil, filter installed and without any other acces-

sories.

Electronic Ignition

The SureLight" integrated control has an added internal

watchguard feature. The feature serves as an automatic

reset device for ignition controls locked out because the

burner has failed to light. This type of nuisance lockout is

usually attributedto low gas line pressure. After one hourof

continuous thermostat demand for heat, the watchguard

will break and remake thermostat demand to the furnace

and automatically reset the control to relight the furnace.

Burner Flame

Burner Flame - Start burner and allow to operate for afew

minutes to establish normal burning conditions. Check

burner flame by observation. Flame should be predomi-

nantly blue and strong in appearance.

Check burner flame periodically to ensure proper operation.

&WARNING

&CAUTION

Annual Service

At the beginning of each heating season, system should be

checked as follows by a qualified service technician:

Electrical

1 - Check all wiring for loose connections.

2-Check circuit breaker located on unit control box.

3 - Check for correct voltage at unit (unit operating).

4 - Check amp-draw on blower motor.

Motor Nameplate Actual

5 - Check to see that heat (if applicable) is operating.

Blower

C'heck the blower wheels for debris and clean if necessary.

The blower motors are prelubricated for ex-tended bearing

life. No further lubrication is needed.

Filters

1 - Filters must be cleaned or replaced when dirty to as-

sure proper furnace operation.

2 - Reusable foam filters used with G26 can be washed

with water and mild detergent. When dry, they should

be sprayed with filter handicoater prior to reinstalla-

tion. Filter handicoater is RP Products coating no. 418

and is available as Lennox part no. P-8-5069.

3 - If replacement is necessary, order Lennox part no.

31J81 for 14 inch x 25 inch (356 x 635mm) filter for

G26-50 and -75 units and P-8-7831 for 20 inch x 25

inch (508 x 635mm) filter for G26Q415-75, G26-100

and -125 units.

Intake and Exhaust Lines

Check intake and exhaust lines and all connections for

tightness and make sure there is no blockage. Also check

condensate line for free flow during operation.

Insulation

Outdoor piping insulation should be inspected yearly for

deterioration. If necessary, replace with same materials.

Winterizing and Condensate Trap Care

1 - Turn off power to unit.

2 - Have a shallow pan ready to empty condensate water.

Avoid spilling water into the control box.

3 - Remove clamp from flue assembly and remove boot

or cap. Empty water from cap. Visually inspect bottom

of flue assembly. Replace boot and clamp.

4 - Remove boot from condensate trap and empty water.

Inspect trap then replace boot.

Cleaning DuralokPlus TM Heat Exchanger

If it is necessary to clean the heat exchanger, follow the pro-

cedure below and refer to figure 1 when disassembling the

unit. Use papers or protective covering in front of furnace

while removing heat exchanger assembly.

1 - Turn off electrical and gas power supplies to furnace.

2 - Remove upper and lower furnace access panels.

3- Remove four screws around air intake fittingand lift in-

take pipe up and away.

4 - Loosen hose clamp securing top of flue transition to

bottom of flue collar. Remove screw securing flue col-

lar to top cap and lift exhaust pipe and flue collar up

and away.

5 - If electrical field make-up box is located inside the unit,

it must be removed.

6 - Remove gas supply line connected to gas valve.

Page 23

7-Mark all gas valve wires and disconnect them from

valve. Mark and remove wires from flame roll-out

switch.

8 - Remove top cap of unit.

9- Remove sensor wire from SureLight" control. Dis-

connect 2-pin plug from the ignitor.

10- Mark and disconnect pressure switch tubing from both

sides of the pressure switch.

11 - Loosen two screws holding gas manifold support at

vestibule panel.

12 - Remove four burner box screws at the vestibule panel

and remove burner box and gas valve/manifold as-

sembly with bracket.

13- Drain condensate trap. Disconnect condensate line

from the outside of unit. Remove condensate line from

condensate trap by turning the adapter fitting counter-

clockwise. The fitting has standard right-hand

threads.

14 - Disconnect the drain hose from the flue transition to

the elbow on the cold header (collector) box trap.

15 - Disconnect the 2-pin plug from the combustion air in-

ducer at the blower deck. Remove four screws from

combustion air inducer and remove flue transition and

inducer assembly from cabinet. Take care not to lose

the combustion air orifice.

16 - Disconnect 9-pin plug from the blower compartment at

the blower deck.

17 - Remove 9-pin plug above the blower deck.

18 - Remove the limit switch and the pressure switch from

the vestibule panel.

19 - Remove two screws from the front cabinet flange at

the blower deck. Remove front screws from cabinet at

blower deck on left and dght sides. Cabinet sides must

be slightly spread to clear heat exchanger passage.

20- Remove screws along vestibule sides and bottom

which secure vestibule panel and heat exchanger as-

sembly to cabinet. Remove heat exchanger.

21- Back wash heat exchanger with soapy water solution

or steam. If steam is used it must be below 275°F

(135°C).

22 - Thoroughly rinse and drain the heat exchanger. Soap

solution can be corrosive so take care that entire as-

sembly is completely rinsed.

23 - Re-install heat exchanger into cabinet making sure

that the clamshells of the heat exchanger assembly

are resting inthe notches of the support located at the

rear of the cabinet. This can be viewed by removing

the indoor blower and examining through the blower

opening.

24 - Re-secure the supporting screws along the vestibule

sides and bottom to the cabinet.

25 -Re-install cabinet screws on sides and front flange at

blower deck.

26 - Re-install the limit switch and pressure switch on the

vestibule panel.

27 - Re-install 9-pin plug to blower deck and connect it to

the 9-pin plug from below the blower deck.

28 - Re-install the combustion air inducer. Check the plas-

tic orifice in the inducer inlet to make sure it has not

fallen out. See figure 1. Reconnect the 2-pin plug to

the wire harness. Re-install the flue transition in the

cabinet and re-attach the drain tube. Route the drain

tube below the combustion air inducer housing and to

the elbow on the cold header (collector) box trap. See

figure 36.

29 - Re-install condensate line with adapter to condensate

trap. Use fresh Teflon tape to ensure a leak-free joint.

Re-connect to condensate line outside of the unit.

30 - Re-install the burner box. Tighten the screws holding

the support bracket. It is important that the glass fiber

gasket not be damaged so it will provide a continuous

seal between the burner box and the vestibule panel

31 - With the pressure switch mechanism oriented on the

right, reconnect pressure switch tubing by connecting

the tubing from the burner box to the barbed fitting on

the bottom. Connect the tubing from the combustion

air inducer to the barbed fitting on the top. See figure

36.

32 - Reconnect the sensor and ignitorwires.

33 -Re-install top cap to unit.

34 - Re-instaU electrical connections to gas valve. Orange

wire to M1 and yellow wire to C2. Reconnect wires to

flame roll-out switch.

NOTE -Unit is polarity-sensitive. 120V supply wiring

must be installed correctly.

35 - Reconnect main gas line to gas valve.

36 - Re-install field make-up box if removed.

37 - Re-install exhaust pipe/flue collar and secure flue col-

lar to the unit top cap using existing screw. Insert the

bottom of the flue collar into the top of the flue transi-

tion and tighten hose clamp.

38 - Re-install intake pipe fitting to burner box with screws.

39 - Replace both upper and lower access panels.

40 - Refer to instruction on verifying gas and electrical con-

nections when re-establishing supply.

41 - Following lighting instructions from installation manu-

al, light and run unit for 5 minutes to ensure heat ex-

changer is clean, dry and operating safely.

Cleaning the Burner Assembly

1-Turn off electrical and gas power supplies to fumaca.

Remove upper and lower furnace access panels.

2-Disconnect the gas supply line to gas valve. Depend-

ing on gas plumbing installation,the gas manifold may

move aside enough that breaking the union may not

be necessary.

3 - Remove five screws from edges of burner box cover.

G26-50 units have only four screws.

4 - Loosen two screws on bottom of burner box front. The

cover is key holed at these screw point so screws do

not need to be removed. Pull off cover and set aside.

6 - Mark all gas valve wires and disconnect them from

valve.

7 - Mark and disconnect sensor wires from the burner box

at the ignition control. Disconnect 2-pin plug from the

ignitor at the burner box,

Page 24

8-Loosen two screws at the gas manifold support brack-

et.

9 - Pull on the left side of the gas manifold and follow with

tension to the right side. The manifold support bracket

will be free of the mounting screws on the vestibule

panel. Set the gas manifold/gas valve assembly aside.

Take care not to damage foam gaskets on each end of

the gas manifold.

10 -Using a 1/4 inch nut driver, remove the burner mount-

ing screws from underneath the burners.

11 - While supporting ignitor and sensor lines at the grom-

met, grasp burners and simultaneously pull burners

and grommet out of the burner box.

12 - Remove ignitor and sensor bracket assemblies from

burners using a 1/4 inch nut driver to remove two

screws from each bracket.

13 - Clean burner by running a vacuum with a soft brush at-

tachment over face of burners. Visually inspect inside of

burners and crossovers for any blockage caused by for-

eign matter. Remove any blockage.

14 - Re-install ignitor and sensor bracket assemblies on

burners.

NO TE -Ignitor must be installed on the opposite side of

the burner from the metal button protrusions. Screws

which attached the ignitor bracket must be installed

from the same side as the ignitor and through the brack-

et to engage in the smaller holes located in the burner.

The correct burner orientation is with metal button pro-

trusions always pointing up.

15 - Replace burner ignitor assembly back into burner box

so that grommet groove fits back into sheet metal

notch and makes a good seal. The bumers sit on top of

the burner box flanges. Make certain that the screws

from the underneath the box pass through the larger

holes in the flange and engage in the smaller holes in

the burner. Re-install the two screws.

16 - Re-install the gas manifold/gas valve assembly by first

inserting the right hand side of the gas manifold into

the burner box. Swing left side of manifold into box

while engaging support bracket to vestibule panel

screws. Check that foam gaskets are providing a seal

around each end of the gas manifold. All gas orifices

should be engaged. If at this point the burners were

mounted in the wrong holes, this needs to be cor-

rected. The saddle brackets on the gas manifold

should be flush with the front surfaces on the burner

box sides.

17 - Inspect the dual layered metal pieces at the front lip of

the cover. These pieces must sandwich around the

metal. Re-install burner box cover.

18 - Re-install the screws to secure the burner box cover.

Make sure screws are tight to ensure a leak tight bum-

er box. Tighten the two screws underneath the box.

Again, inspect the grommet to ensure a tight seal.

19 - Tighten the two screws holding the manifold bracket to

the vestibule panel.

20 - Re-install the electrical connections to the gas valve.

Orange wire to M1 and yellow wire to C2.

21 - Re-install the 2-pin ignitor plug at the burner box. Re-

install sensor line to ignition control spade connector.

22 - Reconnect gas line to gas valve.

23 - Replace lower access panel.

24 - Following lighting instructions and gas line connection

test procedures from installation manual.

25 - Replace upper access panel.

Page 25

The following repair parts are available through Lennox dealers.

number listed on the unit rating plate. Example: G26Q3-75.

CABINET PARTS

Cabinet cap

Blower panel

Upper access panel

CONTROL PANEL PARTS

Surelight" integrated control

Transformer

Circuit breaker

Door interlock switch

BLOWER PARTS

Blower wheel

Motor

Motor mounting frame

Motor capacitor

Blower housing cut-off plate

Blower housing

When ordering parts, include the complete fumace model

HEATING PARTS

Heat exchanger/coil assembly

Gas manifold

Main burner orifices

Main burners

Gas valve

Ignitor

Primary limit control

Flame rollout switch

Filter and filter rack assembly

Flue transition

Pressure switch

Flame sensor

Sight glass and grommet

Rubber boot trap

Foam manifold gaskets

Combustion air inducer

Condensate pipe plug and adapter

Cold end header (collector) box

DIAGNOSTIC CODES

LED #1

SIMULTANEOUS

SLOW FLASH

SIMULTANEOUS

FAST FLASH

SLOW FLASH

OFF

ALTERNATING

SLOW FLASH

OFF

FAST FLASH

SLOW FLASH

ALTERNATING

FAST FLASH

LED #2

SIMULTANEOUS

SLOW FLASH

SIMULTANEOUS

FAST FLASH

SLOW FLASH

ALTERNATING

SLOW FLASH

OFF

SLOW FLASH

OFF

SLOW FLASH

FAST FLASH

ALTERNATING

FASTFLASH

DESCRIPTION

Power on - Normal operation.

Alan _inn_l_d dHrinn t_nnlinn _nd r_nfin=JnH_ fan

Normal operation - signaled when heating demand initiated at

thermostat

Primary or secondary limit switch open.

Pressure switch open or has opened 5 times during a single call for heat;

OR: Blocked inlet/exhaust vent; OR: Condensate line blocked;

OR: Pressure switch closed prior to activation of combustion air inducer.

Watchguard -burners failed to ignite.

Flame sensed without _las valve energized.

Rollout switch open. OR: 9-pin connector improperly attached.

Circuit board failure or control wired incorrectly.

Main power polarity reversed. Switch line and neutral.

Low flame signal. Measures below .7 microAmps. Replace flame sense rod.

Improper main ground or line voltage below 75 volts;

OR: Broken ieniter: OR: Oeen ieniter circuit.

NOTE -Slow flash equals 1Hz :one flash per second). Fast flash equals 3 Hz (three flashes per second).

Minimum flame sense current =O.15 mieroAmps.

Page 26

SURELIGHTCONTROL

HEATINGSEQUENCEOFOPEPu_,TION

NORMALHEATINGMODE

I POWERONI !

ICONTROL SELF-CHECK OKAY? NI-NI-NI-NI-NI-NI-NoO

ICOMBUSTION AIR INDUCER ON FOR 1 SECOND. I

ABNORMAL HEATING MODE

GAS VALVE OFE COMBUSTION AIR INDUCER ON.

INDOOR BLOWER ON.

LED #1 ALTERNATING FAST FLASH

LED#2 ALTERNATING FAST FLASH

CHECK FOR BROKEN IGNITOR OR

OPEN IGNITOR CIRCUIT

L GAS VALVE OFE COMBUSTION AIR INDUCER OFF.

[

TURN INDUCER ON FOR, SECOND. _ -_1 INDOOR B_EODWERDELAY OFF.

I ,sPOLAR,TYREVERSED? / LEDON

- , I.o I [ (RESET CONTROL BY TURNING MAIN POWER OFF.)

LED#1 AND LED#2 /

ALTERNATINGFASTI _ / _ POLARITYREVERSED

FLASH. SIGNAL NO / LED #1 - FAST FLASH

HOLDSUNTILUNITISI_ ISTHERE IYES.J ISVOLTAGEI N° I LED#2- SLOWFLASH

PROPERLY GROUND.I _ PROPER GROUND? ABOVE 75 VOLTS? I_------"l I

gYES III I LED#1 AND LED#2 ALTERNATING FAST

•NO I_ FLASH. SIGNAL HOLDS UNTIL VOLTAGE

---_1 ROLLOUTSWITCHCLOSED? _ _ RISESAEOVE75VOLTS. I

wsI II

II_ GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

I_ _1 INDOOR BLOWER OFF WITH DELAY.

BURNER OFF? L- I LED #1 - ON. LED #2 - SLOW FLASH.

(CONTINUOUS FLAME CHECK) I_L ROLLOUT SWITCH CLOSES

YES _

LED #1 -- SLOW FLASH GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

LED #2 -- SLOW FLASH INDOOR BLOWER ON HEATING SPEED.

LED #1 - SLOW FLASH

LED #2 - OFF

ITHERMOSTAT CALLS FOR HEAT:

LED #1 - FAST FLASH

LED #2 -FAST FLASH I

GAS VALVE OFF./

YES _,: COMBUSTION AIR INDUCER OFF. I

I IS COMBUSTION AIR ,NO _INDOOR BLOWER OFF WITH DELAY.

IPRESSURE SWITCH OPEN? I" LED #1 OFF I

/LED #2 SLOW FLASH

YES (Sequence holds until pressure switch

I IS COMBUSTION AIR INDUCER ENERGIZED? I closes or thermostat resets control.)

I(HTG ACC TERMINAL IS ENERGIZED WITH C.A.B.) Iq

YEsYEST_ _ PRESSURE SWITCH IS IN WATCHGUARD MODE.

I HAS COMBUSTION AIR PRESSURE GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

SWITCH CLOSED IN 2.5 MINUTES? INDOOR BLOWER OFF WITH DELAY.

/ LED #1 - OFF. LED #2 - SLOW FLASH.

IS 5-MINUTE RESET PERIOD COMPLETE?

5-SECOND COMBUSTION AIR INDUCER PREPURGE I

INITIATED BY CLOSED PRESSURE swITCH. I

YES _

CONTINUED NEXT PAGE

Page 27

[Troub!eshoot!ng

NORMAL HEATING MODE

15-SECOND COMBUSTION AIR INDUCER PREPURGE il

[NT ATED BY CLOSED PRESSURE SW TCH. j

ABNORMAL HEATING MODE

YES JN'_O IS VOLTAGE ABOVE 75 VOLTS?

YES -1 NO _I

_t_ IS THERE A PROPER GROUND? I--_1

YEs Nol

IS IGNITOR INTACT AND CONNECTED?_I

IGNITOR WARM-UP -- 20 SECONDS.

yes

4-SECOND TRIAL FOR IGNITION.

GAS VALVE OPENS. IGNITOR IS ENERGIZED

YES _

FLAME STABILIZATION PERIOD.

4SECONDS J[

FLAME RECTIFICATION CURRENT

CHECK, CAN FLAME BE PROVEN WITHIN

4SECONDS AFTER GAS VALVE OPENS?

( > 0.15 mJcroamps)

YES _

FLAME PRESENT?

YES l

FLAME SIGNAL ABOVE 0.7 MICROAMPS?

YES _

INDOOR BLOWER ON DELAY BEGINS

(45 seconds, )

YES _

PRIMARY AND SECONDARY LIMIT

SWITCHES CLOSED?

YES

LEDS SIGNAL

ALTERNATING

FAST FLASH

/ GAS VALVE OFF. COMBUSTION AIR INDUCER ON. I

NDOOR BLOWER OFF I

I I N°I HAS CONTROL FAILED TO SENSE FLAME FOR INO

I I FIVE CONSECUTIVE TRIES DURING A SINGLE I

I I HEAT DEMAND? I

]1 ' t YEs

_1 IIGNITION WATCHGUARD MODE, GAS VALVE OFF. I" --

I I COMBUSTION AIR INDUCER OFF. |

IIINDOOR BLOWER OFF WITH DELAY 14-----i

LED 1ALT. SLOW FLASH LED 2ALT SLOW FLASH II

IIS 60-MINUTE RESET PERIOD COMPLETE? I I

YES

]___ HAS CONTROL RESET IGNITION _-_-_JNO

II SEQUENCE FOUR TIMES? I"

(Does nLoOta%FctLAoMEraS_oGNoAfLcont rol)

LED #1 - SLOW FLASH

I LED #2 - FAST FLASH

GAS VALVE DE-ENERGIZED.

COMBUSTION AIR INDUCER

DE-ENERGIZED. INDOOR BLOWER

ON UNTIL SWITCH CLOSES,LED #1

-SLOW FLASH. LED #2 - ON.

IS LIMIT SWITCH CLOSED?

YES f

lHAS PRIMARY/SECONDARY LIMIT

RESET (CLOSED) WITHIN 3

MINUTES?

YES l"

LIMIT SWITCH WATCH-

GUARD MODE. GAS

VALVE OFF. COMB. AIR

INDUCER OFF. INDOOR

BLOWER OFF WITH

DELAY. LED#I-SLOW

FLASH LED#2 - ON. IS

60MINUTE RESET

PERIOD COMPLETE?

YES

ROLLOUT SWITCH CLOSED?

YES

ICOMBUSTION AIR PRESSURE<- SWITCH CLOSED?

YES _1

[THERMOSTAT DEMAND SATISFIED.

YES

[LED #1 &#2 SIMULTANEOUS SLOW FLASHES.

YES

COMB. AIR INDUCER CONTINUES 5-SECOND I

POST PURGE AFTER TSTAT DEMAND tS SATISFIED. I

INDOOR AIR BLOWER COMPLETES SELECTED OFF

DELAY BEFORE SHUTTING OFF.

E_ GAS VALVE POWER OFF.

COMBUSTION AIR INDUCER POWER OFF.

INDOOR BLOWER OFF WITH DELAY

LED #1 - ON. LED #2 - SLOW FLASH.

SEQUENCE HOLDS UNTIL ROLLOUT SWITCH IS RESET

YES

GAS VALVE DE-ENERGIZED.

YES

I COMBUSTION AIR INDUCER ON.

1INDOOR BLOWER OFF WITH DELAY

LED #1 - OFF. LED #2 - SLOW FLASH,

1HAS CAB SWITCH CLOSED IN 2.5 MINUTES?

INo

5-MINUTE PRESSURE SWITCH

WATCHGUARD MODE. 1

IlL:

Page 28

SURELIGHTCONTROL

COOLINGSEQUENCEOFOPERATION

NORMALCOOLINGMODE ABNORMALCOOLINGMODE

[

I POWER ON I

IGNITION CONTROL MAIN POWER ON. I

CONTROL SELF DIAGNOSTIC CHECK.

IS CONTROL OPERATING NORMALLY?

YES JI

TURN INDUCER ON FOR 1SECOND. I

YES r

IS POLARITY REVERSED? L-_=-z--_l

LED#1 AND LED#2 1NO J,

ALTERNATING FAST I NO ,IS THERE•' '

FLASH, SIGNAL _IYE&I IS VOLTAGE

HOLDS UNTIL UNIT IS _ PROPER GROUND? I_"WlABOVE 75 VOLTS?

PROPERLY GROUND. J

GAS VALVE OFF. COMBUSTION AIR INDUCER OFE

INDOOR BLOWER OFF WITH NORMAL DELAY.

SIGNAL CIRCUIT BOARD FAILURE AT LED.

INTERRUPT MAIN POWER TO RESET CONTROL•

LED#1 FAST FLASH LED#2 SLOW FLASH ]

NILED#1 AND LED#2 ALTERNATING FAST

I_O-_ FLASH. SIGNAL HOLDS UNTIL VOLTAGE

I<_1 RISES ABOVE 75 VOLTS•

ROLLOUT SWITCH MONITORED CONTINUOUSLY.

IS ROLLOUT SWITCH CLOSED?

YES_

CHECK FOR MAIN BURNER FLAME SENSE.

IS MAIN BURNER FLAME OFF?

LED: SLOW FLASH RATE REMAINS UNCHANGED

THROUGHOUT COOLING CYCLE.

THERMOSTAT CALLS FOR COOLING,

€

COMPRESSOR CONTACTOR AND SYSTEM FAN

ENERGIZED WiTH 0-SECOND DELAY, ACB

COOL SPEED TERMINAL IS ENERGIZED. ACC,

TERMINAL IS ENERGfZED.

€

THERMOSTAT OPENS•

COMPRESSOR OFE

€

SYSTEM FAN AND ACC. TERM. OFF

WITH 0_ECOND DELAY,

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF WITH NORMAL DELAY.

SIGNAL CIRCUIT BOARD FAILURE AT LED,

SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES

GAS VALVE OFF. COMBUSTION AIR INDUCER OFE

INDOOR BLOWER OFF WITH NORMAL DELAY.

SIGNAL CIRCUIT BOARD FAILURE AT LED.

SEQUENCE HOLDS UNTIL FLAME IS NOT SENSED.

Page 29

SURELIGHTCONTROL

CONTINUOUSFANSEQUENCEOFOPERATION

LED: SLOW FLASH RATE REMAINS I

UNCHANGED THROUGHOUT SEQUENCE. I

MANUAL FAN SELECTION MADE AT THERMOSTAT.

CONTROL (G) ENERGIZES INDOOR BLOWER AT

ACB LOW SPEED. ACC. TERM. IS ENERGIZED.

THERMOSTAT CALLS FOR HEAT (W}. ]_1_

ITHERMOSTAT CALLS FOR COOLING.

_YES

IINDOOR BLOWER SWITCHES TO ACS COOL SPEED. I

I THERMOSTAT OPENS.

YES

INDOOR BLOWER SWITCHES TO ACB HEAT

SPEED AFTER NORMAL DELAY.

HTG ACC. TERM. ENERGIZES I

WITH COMB. AIR INDUCER. I

THERMOSTAT OPENS. COMBUSTION AIR INDUCER

AND HTG ACC. TERMINAL ARE DE-ENERGIZED.

INDOOR BLOWER SWITCHES TO ACB LOW

SPEED. ACC. TERM. REMAINS ENERGIZED.

INDOOR BLOWER SELECTED TIME OFF DELAY BEGINS.

AFTER DELAY ACB HEAT SPEED DE-ENERGIZED.

(blower remains energized during continuous fan mode).

Page 30

JobName

Job Location

Installer

Unit Model No.

Serial No.

START-UP AND PERFORMANCE CHECK LIST

Job No.

City

Technician

HEATING SECTION

Electrical Connections Tight? 17

Supply Voltage

Blower Motor Amps

Fuel Type: Natural Gas? [] LP/Propane Gas? []

Furnace Btu Input

Line Pressure

Regulator Pressure: __ w.c. -- Nat.; __

Flue Connections Tight? []

Fan Control Setting (45 Seconds Fixed On)

Fan Control Off Setting

Filter Clean & Secure? [_1

Date

State

Heat Anticipator Properly Set? []

Blower Motor H.P.

Gas Piping Connections

Tight & Leak-Tested? [--7

w.c. -- LP/Propane

Temperature Rise

Vent Clear?

THERMOSTAT

Level? []

Page 31

LENNOX Furnace/Heater, Gas Manual L0406249

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