Lennox G23 Series, Installation Instructions Manual

Page 1: ...g 27 Start Up Performance Check List 31 RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE WHAT TO DO IF YOU SMELL GAS 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 ser vice agency or the gas supplier Do not try to light any appliance Do not touch any electrical swi...

Page 2: ...ight Return Air Knockout Bottom Bottom Return Air Knockout 18 7 8 479 23 584 D E Model No A B C D E F G H J G23Q2 X 50 G23Q3 X 50 in 40 16 1 4 14 1 8 12 12 2 1 8 5 14 12 3 4 G23Q3 X 50 G23Q2 3 X 75 mm 1016 413 359 305 305 54 127 356 324 G23Q3 X 100 in 40 21 1 4 19 1 8 14 14 3 5 8 7 1 2 16 14 3 4 G23Q3 X 100 mm 1016 540 486 356 356 92 191 406 375 G23Q4 5 X 75 G23Q3 4 X 100 in 46 21 1 4 19 1 8 18 18...

Page 3: ...L FLAME BAFFLES NOx units only RIGHT MANIFOLD BRACKET ROLL OUT BRACKET MID VEST PANEL PRIMARY LIMIT MANIFOLD END PLUG ROLL OUT SWITCH LEFT MANIFOLD BRACKET COMBUSTION AIR BLOWER PRIMARY LIMIT ALTERNATE STYLE BURNER ASSEMBLY CONTROL BOX SUPPLY AIR OPENING TOP CAP BLOWER ASSEMBLY CAPACITOR AND BRACKET COMBUSTION BLOWER GASKET FLUE BOX GLASS FIBER GASKET COMBUSTION AIR PROVING PRESSURE SWITCH DOOR IN...

Page 4: ... tables and applicable provisions of local building codes For installation in a residential garage the furnace must be installed so that the burner s and the ignition source are located no less than 18 inches 457 mm above the floor The furnace must be located or protected to avoid physical damage by vehicles When a furnace is installed in a public garage hangar or other building that has a hazardo...

Page 5: ...st fans or clothes dryers are used at the same time as the furnace much more air is required to en sure proper combustion and to prevent a downdraft In sufficient air causes incomplete combustion which can re sult in carbon monoxide Combustion Air Requirements WARNING Insufficient combustion air can cause headaches nausea dizziness or asphyxiation It will also cause excess water in the heat exchan...

Page 6: ...r by ducts with the outdoors or spaces crawl or attic that freely communicate with the outdoors or indirectly through vertical ducts Each opening shall have a minimum free area of 1 square inch 645 mm2 per 4 000 Btu 1 17 kW per hour of total input rating of all equipment in the enclosure See figures 3 and 4 When communicating with the outdoors through horizontal ducts each opening shall have a min...

Page 7: ...wer and burners are operating Gas fumes which could contain carbon monoxide can be drawn into living space resulting in personal injury or death WARNING Improper installation of unit can result in personal injury or death Combustion and flue products must never be allowed to enter the return air system or air in the living space Use sheet metal screws and joint tape to seal return air system to fu...

Page 8: ...lter sides Filter clips flex allowing filter to snap into place 4 To remove filter press clip and pull filter up and out Side Return Air Applications An external filter rack ordered separately is available from Lennox FIGURE 8 BOTTOM RETURN FILTER INSTALLATION FURNACE BASE BOTTOM REAR FILTER CLIP RETURN AIR OPENING SIDE FILTER CLIPS 2 FURNACE FRONT FURNACE BACK 1 Align filter rack opening with the...

Page 9: ...nce with all local codes the venting tables provided in this manual and these instructions The G23 X series units are classified as fan assisted Category I type furnaces when vertically vented accord ing to the latest edition of ANSI Z21 47 Central Furnace Standard in the USA The definition of a fan assisted Category I type furnace is an appliance equipped with an integral mechanical means to eith...

Page 10: ...be lined with either type B1 vent or an insu lated single wall flexible vent lining system sized according to the provided venting tables See figures 11 and 12 for common venting A type B1 vent or masonry chimney liner shall terminate above the roof surface with a listed cap or a listed roof as sembly according to the terms of their respective listings and the vent manufacturer s instructions Do n...

Page 11: ...5 elbows equal one 90 elbow beyond two the maximum capacity listed in the venting table should be reduced by 10 percent 0 90 x maximum listed capacity 7 The common venting tables 5 6 7 and 8 were gen erated using a maximum horizontal vent connector length of 1 1 2 feet 46 mm for each inch 25 mm of connector diameter as follows in table 2 TABLE 2 Connector Diameter inches mm Maximum Horizontal Conn...

Page 12: ... H feet Lateral L feet Appliance Input Rating in Thousands of Btu Per Hour MIN MAX MIN MAX MIN MAX MIN MAX 0 0 78 0 152 0 251 0 375 6 2 13 51 18 97 27 157 32 232 6 4 21 49 30 94 39 153 50 227 6 25 46 36 91 47 149 59 223 0 0 84 0 165 0 276 0 415 8 2 12 57 16 109 25 178 28 263 8 5 23 53 32 103 42 171 53 255 8 28 49 39 98 51 164 64 247 0 0 88 0 175 0 295 0 447 10 2 12 61 17 118 23 194 26 289 10 5 23 ...

Page 13: ... 136 80 225 115 337 15 5 51 63 75 128 102 216 144 326 10 NR NR 95 116 128 201 182 308 15 NR NR NR NR 158 186 220 290 0 35 96 54 200 78 346 114 537 2 37 74 56 148 78 248 113 375 20 5 50 68 73 140 100 239 141 363 20 10 NR NR 93 129 125 223 177 344 15 NR NR NR NR 155 208 216 325 20 NR NR NR NR 186 192 254 306 0 34 99 53 211 76 372 110 584 2 37 80 55 164 76 281 109 429 5 49 74 72 157 98 271 136 417 30...

Page 14: ...TYPE B DOUBLE WALL CONNECTORS SERVING TWO OR MORE CATEGORY I APPLIANCES COMMON VENT CAPACITY Common Vent Diameter D inches Vent Height 4 Inch 5 Inch 6 Inch 7 Inch Height H feet Appliance Input Rating in Thousands of Btu Per Hour H feet FAN FAN FAN NAT FAN FAN FAN NAT FAN FAN FAN NAT FAN FAN FAN NAT 6 92 81 140 116 204 161 309 248 8 101 90 155 129 224 178 339 275 10 110 97 169 141 243 194 367 299 1...

Page 15: ...hroom exhausts so they will operate at maximum speed Do not operate a summer ex haust fan Close fireplace dampers 4 Following the lighting instruction place the appliance being inspected in operation Adjust thermostat so appliance will operate continuously 5 Test for spillage of flue gases at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle ...

Page 16: ...furnished by installer that are external to the unit Union must be of the ground joint type IMPORTANT Compounds used on threaded joints of gas piping must be resistant to the actions of liquified petro leum gases NOTE If an emergency shutoff is required shut off the main manual gas valve and disconnect the main power from the unit Properly label these devices NOTE Install an 1 8 inch NPT plugged t...

Page 17: ...50 55 22 1850 52 38 3 76 2 3 068 77 927 11000 311 48 7700 218 03 6250 176 98 5300 150 07 4750 134 50 4300 121 76 3900 110 43 3700 104 77 3450 97 69 3250 92 03 4 101 6 4 026 102 260 23000 651 27 15800 447 39 12800 362 44 10900 308 64 9700 274 67 8800 249 18 8100 229 36 7500 212 37 7200 203 88 6700 189 72 NOTE Capacity given in cubic feet of gas per hour kilo liters of gas per hour and based on 0 60...

Page 18: ... for the wiring entry hole in the cabinet A snaphole plug is provided to seal the unused wire entry hole 9 Install room thermostat according to instructions pro vided with thermostat See figure 19 for thermostat designations If furnace is being used with heat pump refer to FM21 installation instruction Thermostat FIGURE 19 COMPRESSOR COMMON HS UNIT COMMON HS UNIT COMPRESSOR G23 X Furnace Condensin...

Page 19: ... Blower ACC Accessory Terminal Line Volt TX 120VAC Hot to Transformer HOT 120VAC Hot Input HTG ACCHeat Only Accessory Line Volt NEUTRALS 120VAC Neutrals 24VAC HOT24VAC Hot from Transformer 24VAC RTN24VAC Return from Transformer FLAME SENSE Flame Sense Terminal SURELIGHT INTEGRATED CONTROL BOARD FIGURE 21 TERMINAL DESIGNATIONS Cat No 24L85 2 ...

Page 20: ...Page 20 G23 X SCHEMATIC WIRING DIAGRAM FIGURE 22 ...

Page 21: ...service or mainte nance turn the electrical power to unit OFF at dis connect switch BEFORE LIGHTING 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 The G23 X unit may be equipped with either a gas con trol knob or gas control lever Use only your hand to push the lever or to turn the gas control knob Ne...

Page 22: ...g 2 Turn off all electrical power to unit if service is to be performed 3 Remove upper access panel 4 Honeywell VR8205 Gas Valve Turn knob on gas valve clockwise to OFF Do not force White Rodgers 36E Gas Valve Switch gas valve lever to OFF 5 Replace upper access panel Gas Pressure Adjustment Gas Flow To check for proper gas flow to the combustion chamber determine the Btu kW input from the unit ra...

Page 23: ...tch is factory set No adjustment is nec essary See High Altitude Section for pressure switch changout for certain applications Limit Control The Limit Control is factory set No adjustment necessary Fan Control The fan on delay of 45 seconds is not adjustable Fan off delay time that the blower operates after the heat de mand has been satisfied can be adjusted by moving the dip switch S1 on the Sure...

Page 24: ...3 4 100 Q3 4 125 Q4 5 75 Q4 5 100 Q5 6 125 and Q5 6 150 units Flue and Chimney Check flue pipe chimney and all connections for tight ness and to make sure there is no blockage Electrical Check 1 Check all wiring for loose connections 2 Check for correct voltage at unit unit operating 3 Check amp draw on blower motor Motor Nameplate__________Actual__________ Cleaning DuralokTM Heat Exchanger and Bu...

Page 25: ...and combustion air blower Check gaskets for damage Damaged seals must be replaced to avoid heat exchanger leaks Replace all screws to the collector box and combustion air blower Leaving off screws may cause leaks 15 Replace upper vestibule panel top cap pressure switch and ignition control 16 Clean burner by running a vacuum with a soft brush attachment over face of burners Visually inspect in sid...

Page 26: ...Cap Control Panel Parts Transformer SureLight ignition board Circuit breaker Door interlock switch Blower Parts Blower wheel Motor Motor mounting frame Motor capacitor Blower housing cut off plate Heating Parts Flame Sensor Heat exchanger assembly Gas manifold Combustion air blower Gas valve Main burner cluster Ignition control Main burner orifices Pressure switch Ignitor Primary limit control Fla...

Page 27: ... HEATING SPEED LED 1 SLOW FLASH LED 2 OFF GAS VALVE OFF COMBUSTION AIR BLOWER OFF INDOOR BLOWER OFF WITH DELAY LED 1 OFF LED 2 SLOW FLASH Sequence holds until pressure switch closes or thermostat resets control NO NO YES NO IS THERE PROPER GROUND IS VOLTAGE ABOVE 75 VOLTS LOW VOLTAGE SIGNAL AT LED HOLDS UNTIL VOLTAGE RISES ABOVE 75 VOLTS NO YES NO SIGNAL IMPROPER GROUND AT LED SIGNAL HOLDS UNTIL U...

Page 28: ...ION GAS VALVE OPENS IGNITOR ENERGIZED FOR 1 SECOND AFTER VALVE OPENS NO FLAME SENSED DURING THIS PERIOD YES FLAME STABILIZATION PERIOD GAS VALVE OFF COMBUSTION AIR BLOWER ON INDOOR BLOWER OFF HAS CONTROL FAILED TO SENSE FLAME FOR FIVE CONSECUTIVE TRIES DURING A SINGLE HEAT DEMAND NO WATCHGUARD MODE GAS VALVE OFF COMBUSTION AIR BLOWER OFF INDOOR BLOWER OFF WITH DELAY LEDs SIGNAL WATCHGUARD FAILURE ...

Page 29: ...UNCHANGED THROUGHOUT COOLING CYCLE THERMOSTAT CALLS FOR COOLING COMPRESSOR CONTACTOR AND SYSTEM FAN ENERGIZED WITH 0 SECOND DELAY ACB HEAT SPEED TERMINAL IS ENERGIZED ACC TERMINAL IS ENERGIZED COMPRESSOR OFF THERMOSTAT OPENS SYSTEM FAN AND ACC TERM OFF WITH 0 SECOND DELAY NO YES NO GAS VALVE OFF COMBUSTION AIR BLOWER OFF INDOOR BLOWER OFF WITH NORMAL DELAY SIGNAL CIRCUIT BOARD FAILURE AT LED SEQUE...

Page 30: ...THERMOSTAT OPENS SYSTEM FAN SWITCHED TO COOLING SPEED ACC TERM REMAINS ON THERMOSTAT OPENS SYSTEM FAN OFF ACC TERM OFF AFTER OFF DELAY COMPLETED MANUAL FAN SELECTION MADE AT THERMOSTAT CONTROL G ENERGIZES SYSTEM FAN AT LOW SPEED ACC TERM ENERGIZED NO YES YES NO HTG ACC TERM ENERGIZES WITH COMB AIR BLOWER BOARD NO 63K8901 SYSTEM FAN DE ENERGIZED SYSTEM FAN ENERGIZES ON ACB HEAT SPEED AFTER NORMAL I...

Page 31: ... City Serial No Date State Technician Flue Connections Tight Heating Section Thermostat Calibrated Heat Anticipator Properly Set Level Fuel Type Natural Gas Blower Motor Amps Blower Motor H P Blower Motor Lubrication O K Gas Piping Connections Tight Leak Tested Proper Draft Vent Clear State Temperature Rise Fan Control Off Setting Fan Control Setting 45 Seconds Fixed On Regulator Pressure w c Nat ...