LENNOX Furnace/Heater, Gas Manual L0806918
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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ZENNDX GAS KITS & ACCESSORIES 2003 Lennox Industries Inc. Dalias, Texas, USA 504,659M 6/2003 INSTALLATION INSTRUCTIONS ALL G40UH, G41UF, G50UH & G50UHi I HIGH ALTITUDE KIT FOR HIGH ALTITUDE KIT (47M82) USED WITH UNITS & G51MP-135 UNITS FUELED BY NATURAL GAS WARNING ,CAUTION 1 - Set the thermostat to the lowest setting. Shut off the gas supply to the furnace, then disconnect the electrical power. 2 - Remove the heating compartment access panel and burner box cover, if necessary. Turn the automatic gas valve knob, or switch the gas valve lever, to the OFF position. See figures 3, 4,5 and 6. Package 1 of I contains the following: 7 - Main burner orifices (0.081) 1 - Gas converter sticker 3 - Disconnect the gas supply from the gas valve. Mark the wires for identification and disconnect the wiring at the gas valve. 1 - Nameplate conversion sticker High altitude kit (47M82) is used to convert all G40UH, G41UF, G50UH and G50UHi units and G51MP-135 units which are fueled by natural gas for operation at altitudes from 7501 to 10,000 ft. (2287 to 3048 m).Units installed in these high altitude applications also require installation of a replacement pressure switch, which is ordered separately. Refer to table 1 for pressure switch requirements. 4 - Remove the four manifold securing screws. Remove the manifold/gas valve assembly. Replace the main burner orifices with the provided orifices (.081). See figure 1. 5 - Re-install the manifold/valve assembly. Reconnect wiring to the gas valve. MANIFOLD/GAS VALVE ASSEMBLY REMOVAL (G41UF Unit Shown) TABLE 1 Pressure Switch Requirements Altitude Model Number 750140,000 ft. (2287 - 3048 m) G40UH/G50UH(i)=045 G40UH/G50UH(i)=070 BURNERS ORIFICES Pressure Switch 56L32 G40UH/G50UH(i)-090 G40UH/G50UH(i)=110 G40UH/G50UH(i)q 35 G40UH/G50UH(i)q 55 15M22 MANIFOLD / GAS VALVE ASSEMBLY G41UF=045 G41UF=070 G41UF=090 G41UF-110 46M94 G41UF-135 46M95 G51MP=135 56M06 NOTE - Pressure switch is factory set. No adjustment FIGURE 1 necessary. 06/03 Page IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII 504,659M 1 IIIIIIIIIIIIIIIIIIIIIIIIII 6 - All units installed at altitudes above 7,500 ft. (2286m) require a replacement pressure switch assembly. See table 1 for the proper switch assembly. Refer to figure 2 for pressure switch location. Pressure Switch Replacement GASKET G40UH and GSOUH(i) Units a - Remove the tubing from the barbed fitting on the pressure switch(es) COLLECTOR BOX b - Remove screw(s) which secure pressure switch assembly(ies). Install replacement pressure switch(es) using existing screw(s). TUBING GASKET_ COMBUSTION AIR ORIFICE c- PRESSURE SWITCH Securely attach flexible tubing to fitting on replacement pressure switch assembly(ies). See figure 2. AWARNING COMBUSTION AIR INDUCER 7 - Reconnect the gas supply to the manifold and turn on gas supply to unit. G41UF Units A IM PORTANT PRESSURE SWITCH CAUTION COLLECTOR BOX TUBING COMBUSTION AIRINDUCER G51MP-135 8 - Replace burner box cover, if necessary. COLLECTOR BOX PRESSURE SWITCH \ / / / TUBING AIR INDUCER 10-Affix nameplate nameplate, conversion sticker next to unit 11 - Complete the information required on the converter sticker: date, name, and address. Affix sticker to the exterior of the unit in a visible area. / COMBUSTION 9 - Restore the electical power to the unit, 12 - Follow the steps given in the start-up and adjustment section. _ PRESSURE SWITCH TUBING 13 - Energize the thermostat several times to ensure the ignition control is operating and that the SureLight ® ignitor glows. FIGURE 2 14 - Replace the heating compartment access panel. Page 2 White Rodgers 36E Series Gas Valve BEFORELIGHTING- Smellall around the appliance MANIFOLD PRESSURE ADJUSTMENT SCREW area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. Use only your hand to turn the gas control knob or the control lever. Never use tools. If the knob or lever will not turn by hand, do not try to repair it. Call a qualified service technician. Force or attempted repair may result in a fire or explosion. OUTLET PRESSURE TAP INLET PRESSURE TAP GAS VALVE SHOWN IN OFF POSITION FIGURE 4 A - Placing the Unit into Operation White Rodgers 36F Series Gas Valve A IMPORTANT MANIFOLD PRESSURE ADJUSTMENT SCREW G40UH, G41UF, G50UH(i) and G51MP series units are equipped with a Surelight ® ignition system. The Surelight ¢ ignition system automatically lights the burners each time the thermostat calls for heat. OUTLET PRESSURE TAP INLET PRESSURE TAP GAS VALVE SHOWN IN OFF POSITION FIGURE 1 - STOP] Read the safety information at the beginning of this section. 5 White Rodgers 36G Series Gas Valve OUTLET 2 - Set the thermostat to its lowest setting. 3 - Turn offall electrical power to the furnace. 4 - Do not try to light the burners by hand. 5 - Remove the unit access panel. 6 - Turn the knob on the gas valve clockwise _' (or POST move the lever) to the OFF position. Do not force. See figures 3, 4, 5 and 6. 7 - Wait five (5) minutes for any gas to clear out. If you then smell gas, STOP? Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions. If you do not smell gas, go to the next step. GAS VALVESHOWNIN OFFPOSITION FIGURE 6 9 - Replace the unit access panel. 10 - Turn on all electrical power to the unit, 11 - Set the thermostat to desired setting. 12-If Honeywell VR8205 Series Gas Valve the furnace will not operate, see the section "Turning Off Gas to the Unit" and call your service technician or gas supplier. 8 - Turn the knob on the gas valve counterclockwise (or move the lever) to the ON position. MANIFOLD PRESSURE ADJUSTMENT SCREW P22#&E B - Turning Off Gas To the Unit 1 - Set the thermostat to its lowest setting. 2 - Turn off all the electrical power to the unit. REGULATOR ADJUSTMENT 3 - Remove the heat section access panel. 4- Turn the knob on the gas valve clockwise11_' (or move the lever) to the OFF position. Do not force. PRESSURE INLET T_ C - Verifying the Gas Line Pressure GAS VALVE SHOWN IN OFF POSITION FIGURE 3 Check the gas line pressure while the unit is operating. Maintain a minimum of 4.5" w.c. (1.12 kPa) and a maximum of 10.5" w.c. (2.61 kPa). See figures 3.4, 5 and 6 for the location of the inlet pressure tap on the gas valve. Page 3 D - Measuring & Adjusting the Manifold Pressure E - Verifying 1 - Connect a manometer to outlet tap on gas valve, 2 - Start unit and allow 5 minutes for the unit to stabilize. 3 - Check the burner flame, The flame should be stable and should not lift from the burners. The flame should be blue and should burn continuously from all burners. 4- After allowing the unit to stabilize for 5 minutes, check the manifold pressure. Manifold pressure for natural gas-fired units installed at altitudes of 7501 10000 ft. above sea level is 3.5" w.c. (0.87kPa). See figures 3, 4, 5 and 6 for the location of the pressure adjustment screws. ,IMPORTANT the Gas Rate The gas input must not exceed the amount shown on the unit's rating plate. In cases where gas is not metered, the service technician who is performing the conversion will need to install a temporary meter to perform this procedure. Check the input by the following method: Contact the utility company for the heating value of the gas. Shut offall other appliances during the input check. Locate the meter just upstream in regulated pressure [4.5" w.c. to 10.5" w.c. (1.12kPa to 2.61 kPa)]. To check the Btu input rate, time the dial hand on the gas meter for at least one revolution, using the one cubic foot dial. To assure accurate measurements, use temperature and pressure correction factors for the meter. To determine the number of seconds required for the flow of one cubic foot of gas, use the following formula: (BTU Content) Heating Value Of Gas X 3600 Furnace Btuh Input Example: 1000 BTU gas Furnace input 100,000 BTUH Seconds for one cubic foot = NOTE - Turn off the unit and remove the manometer as soon as you have obtained an accurate reading. Replace the pressure tap plug. Page 4 1000 X 3600 100,000 = 36 seconds
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