LENNOX Furnace/Heater, Gas Manual L0806908
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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iF GAS KITS AND ACCESSORIES 11-9269 ©1999 Lennox _ndustfiesInc Dallas, Texas INSTALLATION INSTRUCTIONS Litho USA HEAT EXCHANGER 05/99 Supersedes 01/97 TechnICal I Publications FOR HEAT EXCHANGER REPLACEMENT REPLACEMENT KITS KITS TABLE 1 kWARNING HEAT EXCHANGER HEAT EXCHANGERK_ FinalAssemblyNo, 80MGF/G24M Model No. Size Design_ion. 38K92 LB-79824A 2-45A 38K93 LB-79824B 2-45S 38K94 LB-79824C 2-60A 38K95 LB-79824D 2-60S 36K61 LB-79824G 3-60A 36K62 LB-79824H 3-60S "38K96 LB-79824E 2-75A "38K97 LB-79824F 2-75S "36K63 LB-79824J 3-75A "36K64 LB-79824K 3-75S "36K65 LB-79824L 4-75A "36K66 LB-79824M 4-75S Package 1 of 1 contains: 1 - Heat exchanger assembly, including: 1 - flue box assembly 1 - pressure switch 1 - limit control I - Plastic bag 1 - Conversion sticker 2- Wire nuts KIT APPLICATION HEAT EXCHANGERK_ Catalog No. *Note -In 2-75, 3-75, and 4-75 heat exchanger replace- 2 - Wire ties (one of the screw-securing type, one plain) 1 - 4 in flue adapter for the 75 model size only I - Installation instructions ment applications - a - single appliance The entire venting venting applications inches in diameter. If the existing Check all components for shipping damage. If any damage is found, immediately contact the last carrier. b - multiple appliance The vent connector, These kits are for use with the dash 1 and dash 2 versions of the 80MGF and G24M-45/60/75 series gas furnaces. In these units, they replace the existing heat exchanger with the current production heat exchanger, thereby preventing nuisance flashback (burnback) in the burners, as well as sooting of the heat exchanger. Refer to table 1 for heat exchanger kit application. venting system is 3 inches in diameter, it must be converted in diameter. heat exchanger - system must be no less than 4 venting applications to 4 inches - for the furnace undergoing this replacement, must be no less than 4 inches in diameter. If the existing vent connector is 3 inches in diameter, it must be converted to 4 inches in diameter. Failure to adhere to these requirements, Io wflue gases to enterthe injury Page 1 or death. living could al- space, resulting in 1- Beforebeginning theinstallation, verifythatthemodel numbersizedesignation indicated onthereplacement heatexchanger's I.D.Iabelmatches thatofthemodel numbersizedesignation indicated ontheunifsrating plate.Seetable1. 2- Setthethermostat to itslowestsetting. 3- Turn off all electrical power to the furnace. 4- 21 - In 2-75, 3-75, and 4-75 heat exchanger replacement applications a - single appliance venting applications The entire venting system must be no less than 4 inches in diameter. If the existing venting system is 3 inches in diameter, convert it to 4 inches in diameter. b - multiple appliance venting applications The vent connector, for the furnace undergoing this heat exchanger replacement, must be no less than 4 inches in diameter. If the existing vent connector is 3 inches in diameter, convert it to 4 inches in diameter. Turn off the gas at the equipment main manual shut-off valve. 5 - Remove the fumace access panel. Note - Failure to adhere to the requirements, in section a or b above, could allow flue gases to enter the living space, resulting in injury or death. Install the kit-provided 4 in. flue adapter to the outlet of the induced blower. Then connect the flue adapter to the 4 in. vent connector. 6 - Close the fumace gas valve. 7- Disconnect the supply gas line at the furnace gas valve. 8 - Disconnect the wire harness and the ignition lead from the ignition control. 9 - Disconnect the flue adapter with attached vent connector from the induced draft blower. 10 -Remove the heat exchanger assembly, with flue box and burner box assemblies, from the unit. 11 - On the existing heat exchanger, cut the screw-secured wire tie attached to the burner box top. 12 -Cut the induced draft blower leads between the plug and the inducer leaving approximately es (150mm) attached to the plug. 9 inch- 22 - In 2-45, 2-60, and 3-60 heat exchanger replacement applications Reconnect the existing flue adapterwith vent connector to the outlet of the induced blower. 23 - Affix the conversion sticker adjacent to the rating plate. 24 - Reconnect the gas supply line to the gas valve. 25 - Turn on the main manual gas shut-off valve. Carefully check all gas piping connections for leaks. 13 - Labeland then disconnect alIwiring from the burner box to the limit control and pressure switch. 14 - Remove the burner box assembly from the existing heat exchanger and then install it in the replacement heat exchanger. Discard the existing heat exchanger or return it to Lennox for a warranty claim. IMPORTANT 15 -On the replacement heat exchanger, using the screw-securing type of wire tie (kit-provided), in the original wire bundling location, bundle up all of the Ioosewires, including the induced draft blower leads. Do not secure the wire tie to the burner box top at this time. ILCAUTION 16 - Reconnect the limit control wires and the pressure switch wires. 17 - Install the replacement heat exchanger in the cabinet. 18 - Splicethe induced draft blower leads using the kitprovided wire nuts. 19 - Reconnect the wire harness and the ignition lead. 20 -Check the final wire routing, and then fasten the screw-securing type of wire tie to the burner box top, and bundle the remaining wires with the kitprovided wire tie (plain-type). 26 -Start the furnace by following the procedures as indicated in the "Unit Start-Up" section of the installation instructionsprovidedwiththefurnace. 27 - Monitor unit operation, both start-up operation and at least 15 minutes of running operation. Repeat this test two more times. When the test is successful, set the thermostat to its normal heat setting. Page 2
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