Lennox G23(X), Unit Information

Page 1: ...cal or state codes In the absence of lo cal or state codes the guidelines and procedures outlined in this manual except where noted are recommended only SPECIFICATIONS Model No G23Q2 X 50 G23Q3 X 50 G23Q2 3 X 75 G23Q4 5 X 75 G23Q3 X 100 Input Btuh kW 50 000 14 7 75 000 22 0 100 000 29 3 Output Btuh kW 40 000 11 7 61 000 17 8 80 000 23 4 lA F U E 80 7 80 8 80 4 80 1 California Seasonal Efficiency 7...

Page 2: ... External Static Pressure High Medium Low in w g Pa cfm L s Watts cfm L s Watts cfm L s Watts 0 0 1225 580 530 950 450 375 785 370 295 10 25 1215 575 520 945 445 375 770 365 290 20 50 1190 560 505 925 435 360 745 350 280 30 75 1150 545 485 895 420 350 720 340 275 40 100 1090 515 460 865 410 335 690 325 265 50 125 1030 485 440 820 385 320 645 305 250 60 150 960 455 415 760 360 300 595 280 235 70 17...

Page 3: ... 20 50 2290 1080 1325 2055 970 1155 1800 850 985 1560 735 830 1325 625 705 30 75 2235 1055 1310 2010 950 1135 1780 840 970 1530 720 820 1310 620 700 40 100 2175 1025 1275 1970 930 1115 1735 820 945 1500 710 910 1290 610 690 50 125 2110 995 1250 1910 900 1085 1700 800 930 1480 700 800 1265 610 685 60 150 2030 960 1215 1855 875 1060 1650 780 910 1450 685 790 1250 590 675 70 175 1955 925 1185 1765 83...

Page 4: ...95 635 30 75 2315 1090 1235 2090 985 1050 1880 885 895 1645 775 745 1440 680 630 40 100 2255 1065 1210 2045 965 1040 1840 870 890 1610 760 735 1420 670 625 50 125 2195 1035 1185 1995 940 1010 1815 855 880 1575 745 725 1390 655 615 60 150 2135 1010 1155 1950 920 1000 1770 835 870 1530 720 715 1350 635 600 70 175 2075 980 1145 1890 890 985 1710 805 850 1490 705 700 1295 610 595 80 200 1985 935 1105 ...

Page 5: ... External Static Air Volume and Motor Watts at Specific Blower Taps External Static Pressure High Medium High Medium Medium Low Low in w g Pa cfm L s Watts cfm L s Watts cfm L s Watts cfm L s Watts cfm L s Watts 0 0 2565 1210 1430 2300 1085 1160 2055 970 970 1840 870 825 1620 765 680 10 25 2560 1210 1420 2265 1070 1155 2020 955 960 1810 855 825 1590 750 680 20 50 2555 1205 1410 2225 1050 1140 1980...

Page 6: ...en Pack 66K61 1 14 x 25 x 1 356 x 635 x 25 Single 44J21 Ten Pack 66K62 1 20 x 25 x 1 508 x 635 x 25 Single 44J22 Ten Pack 66K63 1 16 x 25 x 1 406 x 635 x 25 Horizontal Power Venter Kit 79J15 all models Twinning Kits Non continuous low speed 64H88 all models Twinning Kits Continuous low speed 35J93 all models Continuous Low Speed Blower Switch 44J06 all models Not used with Twinning Kits HIGH ALTIT...

Page 7: ... COMPARTMENT FIGURE 2 G23 X GENERAL PARTS ORIENTATION COMBUSTION AIR BLOWER COMBUSTION AIR BLOWER PROVE PRESSURE SWITCH GAS VALVE PRIMARY LIMIT MANIFOLD BURNERS SUPPLY AIR BLOWER BLOWER CAPACITOR CONTROL BOX BLOWER COMPARTMENT HEATING COMPARTMENT FLUE TRANSITION BLOWER DOOR INTERLOCK SWITCH IGNITION CONTROL 1 through 4 models only SUPPLY AIR DUCT FLANGE ROLLOUT SWITCH CIRCUIT BREAKER ...

Page 8: ...NEL FLAME BAFFLES NOx UNITS ONLY RIGHT MANIFOLD BRACKET ROLLOUT BRACKET MID VEST PANEL PRIMARY LIMIT PRIMARY LIMIT ALTERNATE STYLE MANIFOLD END PLUG ROLLOUT SWITCH LEFT MANIFOLD BRACKET COMBUSTION AIR BLOWER TOP CAP GLASS FIBER GASKET COMBUSTION BLOWER GLASS FIBER GASKET FIGURE 4 CONTROL BOX 1 through 4 G23X models BCC CONTROL TRANSFORMER DOOR INTERLOCK SWITCH LOW VOLTAGE STRIP CIRCUIT BREAKER FIG...

Page 9: ...r vice 1 Control Transformer T1 A transformer located in the control box provides power to the low voltage 24volt section of the unit Transformers on all models are rated 40VA with a 120V primary and a 24V secondary 2 Circuit Breaker CB8 A 24V circuit breaker is also located in the control box The switch provides overcurrent protection to the transformer T1 The breaker is rated 3A at 32V If the cu...

Page 10: ...not present the blower stops immediate ly FIGURE 9 FAN OFF TIME ADJUSTMENT To adjust fan off timing Remove jumper from BCC and select one of the other pin combinations to achieve the desired time TIMING JUMPER TIMING PINS seconds Leave jumper off for 330 second fan off timing SHOCK HAZARD MAKE SURE TO DISCONNECT POWER BEFORE CHANGING FAN OFF TIMING CAUTION Electrostatic discharge can affect electr...

Page 11: ...ermittent pilot ignition control manufactured by Johnson Controls The igni tion control is located on a bracket on the upper vest panel Unit Operation When there is a call for heat the control is prevented from beginning an ignition sequence until the pressure switch proves combustion air blower operation When the pressure switch closes the control generates a spark and opens the pilot valve to ig...

Page 12: ... If pilot flame is not sensed before the end of the 85 second trial for ignition the control enters the 100 shutoff mode The spark circuit and pilot valve de energize and the igni tion control automatically begins the 60 minute retry delay period During the 60 minute delay the diagnostic LED continually flashes on for one second and off for five se conds After the delay period another trial for ig...

Page 13: ...ses rollout the ignition control immediately stops ignition and closes the gas valve If unit is running and flame rollout is detected the gas valve will close and ignition control will be disabled Rollout can be caused by a reverse draft blocked flue or lack of com bustion air The switch is factory set and cannot be ad justed The switch may have different setpoints for each unit model number Howev...

Page 14: ... is allowed to open Typically a 2 to 4 second delay occurs between the pilot ignition and the main valve opening Figure 16 shows the gap between tip of the electrodes and the burner surface It is important that the gap be main tained for consistent ignition of pilot flame A flame retention ring in the end of each burner is used to maintain correct flame length and shape and to keep the flame from ...

Page 15: ...ght board can be used with either electron ic or electro mechanical thermostats without modifica tion The SureLight ignitor is made of durable silicon ni tride Ignitor longevity is also enhanced by voltage ramp ing by the control board The board finds the lowest igni tor temperature which will successfully light the burner thus increasing the life of the ignitor ODPH 6HQVRU A flame sensor is locat...

Page 16: ...r 24L85 Limit must close within 5 trials for ignition or board goes into one hour limit Watchguard Units with board 56L83 or 97L48 Limit must close within 3 minutes or board goes into one hour limit Watchguard OFF SLOW FLASH 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...

Page 17: ...up for 20 seconds after which the gas valve opens for a 4 second trial for ignition G23X units equipped with board 24L85 56L83 or 63K89 the ignitor stays energized for the first second of the 4 second trial Units equipped with board 97L48 ignitor stays energized during the trial until flame is sensed If ignition is not proved during the 4 second period the control will try four more times with an ...

Page 18: ... switch is a single pole single throw pressure switch electrically connected in series with the ignition control The purpose of the switch is to prevent burner operation if the combustion air blower is not operating On start up the switch senses that the combustion air blow er is operating It closes a circuit to the ignition control when pressure inside the combustion air blower increases above th...

Page 19: ...ms Avoid exposure to the following substances in the combustion air supply Permanent wave solutions Chlorinated waxes and cleaners Chlorine base swimming pool chemicals Water softening chemicals De icing salts or chemicals Carbon tetrachloride Halogen type refrigerants Cleaning solvents such as perchloroethylene Printing inks paint removers varnishes etc Hydrochloric acid Cements and glues Antista...

Page 20: ...ATER OPENINGS To Adjacent Room G23 X FURNACE Air from Outside If air from outside is brought in for combustion and ventila tion the confined space shall be provided with two perma nent openings One opening shall be within 12 inches of the top of the enclosure and one within 12 inches of the bottom These openings must communicate directly or by ducts with the outdoors or spaces crawl or attic that ...

Page 21: ...nual and these instructions The G23 X series units have been classified as fan as sisted Category I type furnaces when vertically vented in accordance with the latest edition of ANSI Z21 47 Central Furnace Standard The definition of a fan assisted Catego ry I type furnace is an appliance equipped with an integral mechanical means to either draw or force products of com bustion through the combusti...

Page 22: ...APPLIANCE VENTING OF A FAN ASSISTED FURNACE INTO A TILE LINED MASONRY CHIMNEY INTERIOR OR OUTSIDE WALL IS PROHIBITED THE CHIMNEY MUST FIRST BE LINED WITH EITHER TYPE B VENT OR AN INSULATED SINGLE WALL FLEXIBLE VENT LINING SYSTEM SIZED IN ACCORDANCE WITH THE PROVIDED VENTING TABLES See figures 29 and 30 for common venting A Type B vent or masonry chimney liner shall terminate above the roof surface...

Page 23: ...nt 0 90 x maximum listed capacity 7 The common venting tables 11 12 13 and 14 were generated using a maximum horizontal vent connec tor length of 1 1 2 feet 18 inches for each inch of connector diameter as follows CONNECTOR DIAMETER INCHES MAXIMUM HORIZONTAL CONNECTOR LENGTH FEET 3 4 1 2 4 6 5 7 1 2 6 9 7 10 1 2 8 If the common vertical vent is offset the maximum common vent capacity listed in the...

Page 24: ... 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 57 32 113 41 187 52 280 10 30 51 41 104 54 176 67 267 0 0 94 0 191 0 327 0 502 2 11 69 15 136 20 226 22 339 15 5 22 65 30 130 39 219 49 330 5 10 29 59 40 121 51 206 64 315...

Page 25: ... 225 115 337 15 5 51 63 75 128 102 216 144 326 5 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 10 N...

Page 26: ...69 220 1 21 50 33 89 47 142 64 220 15 2 22 53 35 96 49 153 66 235 5 3 24 55 36 102 51 163 68 248 1 21 54 33 99 46 157 62 246 20 2 22 57 34 105 48 167 64 259 3 23 60 35 110 50 176 66 271 1 20 62 31 113 45 181 60 288 30 2 21 64 33 118 47 190 62 299 30 3 22 66 34 123 48 198 64 309 TABLE 12 CAPACITY OF TYPE B DOUBLE WALL VENTS WITH TYPE B DOUBLE WALL CONNECTORS SERVING TWO OR MORE CATEGORY I APPLIANCE...

Page 27: ...nremain connected to the common venting system If the venting system has been installed improperly the system must be corrected as outlined in the previous section 1 Seal any unused openings in the common venting system 2 Visually inspect the venting system for proper size and horizontal pitch and determine there is no block age or restriction leakage corrosion and other defi ciencies which could ...

Page 28: ...anually WARNING Shock and burn hazard G23 X 5 and 6 model units are equipped with the SureLight ignition system Do not attempt to light manually WARNING Do not use this furnace if any part has been under water Inspect the furnace and replace any part of the control system and any gas control which has been under water CAUTION Before attempting to perform any service or main tenance turn the electr...

Page 29: ...switch to OFF Do not force 5 Replace upper access panel C Safety or Emergency Shutdown Turn off unit power Close manual and main gas valves D Extended Period Shutdown Turn off thermostat or set to UNOCCUPIED mode Close all gas valves both internal and external to unit to guaran tee no gas leak into combustion chamber Turn off power to unit All access panels covers and vent caps must be in place an...

Page 30: ...Pressure outlet in W C TABLE 15 GAS VALVE REGULATION 3 5 0 3 Natural L P 10 0 0 5 Unit Fuel The gas valve is factory set and should not require ad justment See table 15 Manifold Adjustment Procedure 1 Connect a test gauge to outlet pressure tap on gas valve Start unit and allow 5 minutes for unit to reach steady state 2 While waiting for the unit to stabilize notice the flame Flame should be stabl...

Page 31: ...s per hour and based on 0 60 specific gravity gas F Proper Gas Flow Approximate Furnace should operate at least 5 minutes before check ing gas flow Determine time in seconds for two revolu tions of gas through the meter Two revolutions assures a more accurate time Divide by two and compare to time in table 17 below Adjust manifold pressure on gas valve to match time needed NOTE To obtain accurate ...

Page 32: ...rates continuously With fan switch in AUTO posi tion blower cycles with demand or runs continuously while heating or cooling circuit cycles 3 In all cases blower and entire unit will be off when the system switch is in OFF position B Temperature Rise Temperature rise for G23 X units depends on unit input blower speed blower horsepower and static pressure as marked on the unit rating plate The blow...

Page 33: ...ing White common See table 20 6 Depress harness connector tab to release wire termi nal Select connector location for new speed refer to unit wiring diagram Insert wire terminal until it is se curely in place See figure 39 7 Replace harness connector to motor TABLE 20 FIGURE 39 DEPRESS TAB TO RELEASE WIRE TERMINAL SELECT CON NECTOR LOCATION FOR NEW SPEED REFER TO UNIT WIRING DIAGRAM INSERT WIRE UN...

Page 34: ...und the brush so that the brush is se cured and will not come off during cleaning Attach the oth er end of the cable to the reversible drill to complete the tool for cleaning the heat exchanger See figure 3 for parts arrangement when disassembling furnace 1 Turn off both electrical and gas power supplies to fur nace 2 Remove flue pipe and top cap from unit Mark and dis connect wiring from pressure...

Page 35: ...spect inside of burners and crossovers for any blockage caused by for eign matter Remove any blockage 17 For NOX units replace flame baffles in each heat ex changer section DO NOT BEND baffles Baffles should sit on the bottom of each heat exchanger sec tion 18 Replace burner manifold assembly onto lower vesti bule panel 19 Reconnect wires to ignition control 1 through 4 mod el units pressure switc...

Page 36: ... BLOWER COMBUSTION AIR PROVE SWITCH FIELD MAKE UP BOX 1 7 TO ACCESSORY IF USED ELECTRONIC AIR CLEANER IF NOT NEEDED DO NOT INSTALL ACCESSORY WIRE IN J69 5 685 7 21752 THERMOSTAT TO COMPRESSOR CONTACTOR 5 7KHUPRVWDW 2035 6625 20021 G23 X Furnace Condensing Unit G23 X and CONDENSING UNIT THERMOSTAT DESIGNATIONS Refer to specific thermostat and outdoor unit COMMON POWER HEAT INDOOR BLOWER COOLING R W...

Page 37: ...energizes the combus tion air blower B6 When the combustion air blower nears full speed combustion air prove switch S18 closes 5 When S18 closes assuming the flame rollout switch S47 primary limit S10 and secondary limits S21 are closed the ignition control opens the pilot valve and begins spark 6 When flame is sensed spark stops and main valve opens to light main burners 7 After 45 seconds blower...

Page 38: ...O IS 120VAC ACROSS N1 CAB CHECK COMBUSTION AIR BLOWER YES YES ARE BURNERS LIT NO CHECK 1 COMBUSTION AIR BLOWER 2 IGNITION CONTROL 3 GAS VALVE 4 IGNITOR 5 LIMIT SWITCHES 6 PROVE SWITCH YES IS BLOWER RUNNING ON LOW SPEED 45 SEC AFTER FURNACE LIGHTS NO IS 120VAC ACROSS N1 H YES IS 24VAC ACROSS T V REPLACE BCC NO NO CHECK WIRING YES IS 120VAC ACROSS N1 ACC YES REMOVE R W JUMPER AFTER THE SELECTED TIME...

Page 39: ... 1 and ground Replace Control Is inlet gas pressure per manufacturer s specifications Correct gas pressure WARNING Explosion Hazard Do not use match to test for gas pressure Is gas at pilot burner Make sure pilot line is not kinked or obstructed Check for clean orifice If OK replace pilot valve Is spark gap 0 1 inch and located in pilot stream Correct or replace pilot burner Shield from drafts Che...

Page 40: ...t Determine the Cause 1 Flameout cycling 2 Internal malfunction 3 Flame present when it should not be Did pilot remain lit from previous cycle Replace gas valve Turn OFF supply voltage Is high voltage cable securely connected to spark transformer Connect securely then turn ON supply voltage Is high voltage cable brittle burnt or cracked Replace cable Is spark electrode ceramic cracked Replace pilo...

Page 41: ...pped around any pipe or accessories Is main valve wiring securely connected to terminals 4 and ground Connect securely Replace sensor Is sensor ceramic cracked Correct Correct Is sensor cable grounded out Is sensor or sensor connector shorted to a metal surface Does sensor cable lack continuity or good insulation Replace cable Disconnect main valve lead from terminal 3 and sensor cable from termin...

Page 42: ... 1 2 minutes or control goes into 5 minute Watchguard Pressure Switch delay Once S18 closes a 15 sec ond pre purge follows 4 Surelight control energizes ignitor A 20 second warm up period begins 5 Gas valve opens for a 4 second trial for ignition 6 Flame is sensed gas valve remains open for the heat call 7 After 45 second delay Surelight control energizes in door blower B3 8 When heat demand is sa...

Page 43: ...NG 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 UNIT IS...

Page 44: ...1 IGNITOR ENERGIZED FOR 1 SECOND AFTER VALVE OPENS BOARD 97L48 IGNITOR ENERGIZES THROUGH OUT 4 SECOND TRIAL 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 FAIL...

Page 45: ...ANGED 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 SEQUENCE ...

Page 46: ...AY THERMOSTAT OPENS COMBUSTION AIR AND HTG ACC TERMINAL DE ENERGIZE SYSTEM FAN SWITCHED TO ACB COOL SPEED ACC TERM REMAINS ON THERMOSTAT OPENS BOARD 63K89 SYSTEM FAN OFF ACC TERM OFF AFTER OFF DELAY COMPLETED MANUAL FAN SELECTION MADE AT THERMOSTAT CONTROL G ENERGIZES SYSTEM FAN AT ACB LOW SPEED ACC TERM ENERGIZED NO YES YES NO HTG ACC TERM ENERGIZES WITH COMB AIR BLOWER BOARD NO 24L85 56L83 97L48...

Page 47: ...tch open ACTION 1 Manually reset the roll out switch by pushing the top button ACTION 2 Determine the cause of the roll out switch activation before leaving furnace code LED 1 O 1 2 2 Roll out switch failure ACTION 1 Check continuity across roll out switch Replace roll out switch if switch is reset but does not have continuity LED 1 On LED 2 Slow Flash 1 2 3 Mi i i i ti ACTION 1 Check wiring conne...

Page 48: ... 1 1997 combus tion air blower will cycle 5 seconds on 55 seconds off LED 1 Alternating Fast Flash LED 2 Alternating Fast Flash 2 1 2 Broken or failed ignitor ACTION 1 Unplug ignitor and read resis tance across ignitor If resistance does not read between 10 9 and 19 7 ohms replace the ignitor PROBLEM 3 UNIT FAILS TO FIRE IN THE HEATING MODE COMBUSTION AIR BLOWER DOES NOT ENERGIZE Condition Possibl...

Page 49: ...ch failure code 2 5 min utes after heating demand 4 1 2 Pressure switch does not close due to obstructions in the pressure lines ACTION 1 Remove any obstructions from the the pressure lines and or taps LED 1 Off LED 2 Slow Flash 4 1 3 Pressure switch lines damaged ACTION 1 Check pressure switch lines for leaks Replace any broken lines LED 2 Slow Flash 4 1 4 Condensate in pressure switch line ACTIO...

Page 50: ...and Diagnostic lights flash the pres sure switch code 6 1 2 Condensate drain line is not drain ing properly ACTION 1 Checkcondensatelineforproper vent slope and any blockage Condensate should flow freely during operation of fur nace Repair or replace any improperly installed condensate lines LED 1 Off LED 2 Slow Flash 6 1 3 Low pressure differential at the pressure switch ACTION 1 Check for restri...

Page 51: ...age if possible replace heat exchanger if necessary tag and return heatexchangertoproperLennoxpersonnel 6 3 4 Insufficient flow through the heat exchanger caused by a sooted or restricted heat exchanger ACTION1 Checkforsootingdepositsoroth er restrictions in the heat exchanger assem bly Cleanassemblyasoutlinedininstruction manual ACTION 2 Check for proper combustion CO2 should measure 6 5 8 5 CO s...

Page 52: ...N 1 Check sense rod for contamina tion or coated surface Clean the sense rod with steel wool or replace sensor DO NOT USE SAND PAPER TO CLEAN ROD SAND PAPER WILL CONTRIBUTE TO THE CON TAMINATION PROBLEM PROBLEM 8 INDOOR BLOWER FAILS TO OPERATE IN COOLING HEATING OR CONTINUOUS FAN MODE Condition Possible Cause Corrective Action Comments 8 0 Indoor blower fails to operate in continuous fan cooling o...