Lennox G24-200, Installation Instructions Manual

Page 1: ... Information 35 Other Unit Adjustments and Operation 35 Setting Blower CFM 37 Repair Parts List 39 G24 200 Start up Performance Check List 39 Troubleshooting 40 Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Installation and service must be per formed by a qualified installer ser vice agency or the gas supplier WHAT TO DO IF YOU SM...

Page 2: ...her Side HEAT EXCHANGER BLOWER MOTOR ELECTRICAL INLET Either Side FRONT VIEW SIDE VIEW VENT OUTLETS 52 1 2 1334 BACK VIEW 50 3 8 1280 1 1 16 27 1 1 16 27 2 51 1 25 27 686 1 25 1 25 50 1 2 1283 CONTROL BOX 5 8 16 REAR RETURN AIR OPENING Supply Air Opening SUPPLY AIR OPENING 26 660 50 3 4 1289 1 25 7 8 22 7 8 22 Bottom Return Air Opening Bottom Return Air Opening AIR FLOW 2 1 4 57 ...

Page 3: ...DES 5 127 NOTE Return air filter box may be installed at back or bottom of furnace AIR FLOW AIR FLOW 5 127 32 813 1 25 4 3 4 121 26 1 4 667 1 25 50 1 2 1283 OPENING SAME BOTH SIDES 5 127 1 25 4 3 4 121 26 1 4 667 1 25 1 25 50 1 2 1283 OPENING SAME BOTH SIDES 5 127 NOTE Return air filter box may be installed at back or bottom of furnace TOP VIEW FRONT VIEW 32 813 ...

Page 4: ...AIR BLOWER FLUE BOX IGNITOR SENSOR GAS VALVE two stage BURNER RETENTION BRACKET BURNER MTG BRACKET FLAME ROLLOUT SWITCH IGNITION CONTROL MAKE UP BOX RIGHT SIDE PANEL HEATING COMPARTMENT ACCESS PANEL BLOWER COMPARTMENT AC CESS PANEL CENTER MULLION REAR PANEL TOP REAR PANEL BOTTOM FLEXIBLE CONNECTOR THIS UNIT CONTAINS TWO HEAT SECTIONS EACH HEAT SECTION CONTAINS ONE OF THESE ITEMS CONTROL BOX ...

Page 5: ...ntinued G24 200 BLOWER SECTION WHEEL BLOWER HOUSING CUT OFF PLATE BEARING SHAFT BLOWER PULLEY MOTOR Drive Kit VIBRATION ISOLATOR BASE ASSEMBLY MOTOR BASE ADJUSTMENT ARM MOTOR BASE LOCATING ROD MOTOR PULLEY Drive Kit DRIVE BELT Drive Kit ...

Page 6: ...his furnace Refer to unit nameplate Lennox G24 200 units are CSA international certified to ANSI Z21 47 and CSA 2 3 standard In the USA installation of Lennox gas central furnaces must conform with local building codes In the absence of local codes units must be installed in accordance with the current National Fuel Gas Code ANSI Z223 1 NFPA54 The National Fuel Gas Code is available from American ...

Page 7: ...ce must be adjusted to obtain a tempera ture rise high and low fire within the range s specified on the unit nameplate Failure to do so may cause erratic limit operation Field wiring connection must meet or exceed specifications of type T wire and withstand a maximum temperature rise of 180 F 82 C When the furnace is installed so that supply ducts carry air circulated by the furnace to areas outsi...

Page 8: ...educe exposure to this substance or for further information consult material safety data sheets available from address shown below or contact your supervisor Lennox Industries Inc P O Box 799900 Dallas TX 75379 9900 USA Combustion Dilution Ventilation Air In the past there was no problem in bringing in sufficient outdoor air for combustion Infiltration provided all the air that was needed In today...

Page 9: ... tight construction with weather stripping and caulking around the windows and doors follow the procedures in the air from outside section Confined Space A confined space is an area with a volume less than 50 cu bic feet 1 42 m3 per 1 000 Btu 29 kW per hour of the combined input rating of all appliances installed in that space This definition includes furnace closets or small equipment rooms When ...

Page 10: ... design and free area of protec tive covering is not known for calculating the size opening required it may be assumed that wood louvers will have 20 to 25 percent free area and metal louvers and grilles will have 60 to 75 percent free area Louvers and grilles must be fixed in the open position or interlocked with the equipment so that they are opened automatically during equipment operation EQUIP...

Page 11: ...tom return air furnace filter box must be sealed airtight at the platform to ensure proper and safe operation Select a location that allows for required clearances listed on unit rating plate Also consider gas supply connections electrical supply vent connection installation and service clearances 24 inches 610mm at unit front and filter ac cessibility The furnace must be leveled using shims or le...

Page 12: ...oducts must never be allowed to enter the return air system or the living space Use screws and joint tape to seal the return air system to the furnace In platform installations with bottom return air the furnace should be sealed airtight to the return air ple num A door must never be used as a portion of the return air duct system The base must provide a stable support and an airtight seal to the ...

Page 13: ...ly 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 su...

Page 14: ...d belt MEASURE BELT TENSION DEFLECTION 1 64 INCH PER INCH OF SPAN OR 1 5 mm PER 100 mm OF SPAN FORCE FIGURE 8 Venting A vent adapter is factory installed on each of the combus tion air blower outlets Modification of or removal of the adapter s will cause unsafe unit operation and will void CSA unit certification The vent adapter does not re quire insulation The G24 200 units are classified as fan ...

Page 15: ...tor or flue restrictor between the furnace and the chimney If type B1 double wall vent is used inside a chimney no oth er appliance can be vented into the chimney Outer wall of type B1 vent pipe must not be exposed to flue products Insulation for the flexible vent pipe must be an encapsu lated fiberglass sleeve recommended by the flexible vent pipe manufacturer See figure 9 The space between the l...

Page 16: ...e flow area of the vertical vent how ever shall not exceed 7 times the flow area of the listed appliance categorized vent area drafthood out let area or flue collar area unless designed according to approved engineering methods 4 Multiple Appliance Vents The flow area of the largest section of vertical vent or chimney shall not exceed 7 times the smallest listed appliance categorized vent area flu...

Page 17: ...des In absence of local codes refer to NFGC Z223 1 NFPA54 14 No portion of the venting system can extend into or pass through any circulation air duct or plenum 15 Vent connectors serving Category I appliances shall not be connected to any portion of mechanical draft systems operating under positive pressure such as Category III or IV venting systems 16 If vent connectors are combined prior to ent...

Page 18: ... 20 226 22 339 15 5 22 65 30 130 39 219 49 330 10 29 59 40 121 51 206 64 315 15 35 53 48 112 61 195 76 301 0 0 97 0 202 0 349 0 540 2 10 75 14 149 18 250 20 377 20 5 21 71 29 143 38 242 47 367 20 10 28 64 38 133 50 229 62 351 15 34 58 46 124 59 217 73 337 20 48 52 55 116 69 206 84 322 0 0 100 0 213 0 374 0 587 2 9 81 13 166 14 283 18 432 5 21 77 28 160 36 275 45 421 30 10 27 70 37 150 48 262 59 40...

Page 19: ...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 20: ...20 94 303 1 33 89 47 142 64 220 88 298 15 2 35 96 49 153 66 235 91 320 3 36 102 51 163 68 248 93 339 1 33 99 46 157 62 246 86 334 20 2 34 105 48 167 64 259 89 354 3 35 110 50 176 66 271 91 371 1 31 113 45 181 60 288 83 391 30 2 33 118 47 190 62 299 85 408 3 34 123 48 198 64 309 88 423 TABLE 6 CAPACITY OF TYPE B DOUBLE WALL VENTS WITH TYPE B DOUBLE WALL CONNECTORS SERVING TWO OR MORE CATEGORY I APP...

Page 21: ...the system must be corrected as indicated in the general venting requirements section 1 Seal any unused openings in the common venting system 2 Visually inspect the venting system for proper size and horizontal pitch Determine there is no blockage or re striction leakage corrosion or other deficiencies which could cause an unsafe condition 3 To the extent that it is practical close all building do...

Page 22: ...appliance will operate continuously 7 Test for spillage of flue gases at the draft hood relief opening after 5 minutes of main burner operation Use the flame of match or candle or smoke from a ciga rette cigar 8 If improper venting is observed during any of the above tests the venting system must be corrected or sufficient combustion make up air must be provided The venting system should be re siz...

Page 23: ...ntal and below 12 in 305mm minimum above for vent installations in Canada 12 in 305mm minimum for appliances 100 000 Btuh 30 kW 36 in 0 9m minimum for appliances 100 000 Btuh 30 kW F Clearance to mechanical air supply inlet for vent installations in USA 36 in minimum 914mm G Clearance to mechanical air supply inlet for vent installations in Canada 72 in 1829mm minimum H Do not point terminations i...

Page 24: ... for terminations from electric meters gas meters regula tors and relief equipment is 4 ft 1 2m for US installa tions Refer to the current CSA B149 1 for installations in Canada or with authorities having local jurisdiction At vent terminations care must be taken to maintain pro tective coatings over building materials prolonged expo sure to exhaust condensate can destroy protective coatings It is...

Page 25: ...waiters or elevator shafts 4 The piping should be sloped 1 4 inch 6 4 mm 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 A drip leg should be installed in ver tical pipe runs to the unit 5 In some localities codes may require installation of a manual main shut off valve...

Page 26: ... 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 m3 of gas per hour and based on 0 60 specific gravity gas Leak Check After gas piping is completed carefully check all piping connections factory and...

Page 27: ...figure 15 16 or 17 and make the wiring connections between the transformers and the furnace 6 Select a field wiring diagram according to the power supply voltage and phase being used see figure 15 16 or 17 and make wiring connections between the blower motor and the furnace The connecting wires are provided in the drive kit 7 An accessory relay K109 is provided with the G24 200 furnace Any accesso...

Page 28: ...box right side See Note 1 NOTES 1 Relay K109 can be used for an accessory rated at the same voltage as power supply REMOVE FACTORY INSTALLED JUMPER IN TWO STAGE MODE WHITE BLUE 2 Field installed and supplied resistor R3 is required in two stage applications when using electro mechanical thermo stat Use a 150 ohm 10 watt resistor Lennox part number P 8 6256 R3 See Note 2 COMBUSTION AIR BLOWER COMBU...

Page 29: ...side Alternate make up box right side SEE NOTE 1 NOTES 1 Relay K109 can be used for an accessory rated at the same voltage as power sup ply REMOVE JUMPER IN TWO STAGE MODE L3 L2 L2 RED Y UNITS 208 230V 3PH 60HZ G24 200 FIELD WIRING DIAGRAM 2 Field installed and supplied re sistor R3 is required in two stage applications when using electro mechanical thermostat Use a 150 ohm 10 watt resistor Lennox...

Page 30: ...IP MAKE UP BOX MAKE UP BOX L1 L2 PLUG BLOWER DECK BLUE YELLOW BLACK RED RED BLUE RED RED Alternate make up box left side Alternate make up box right side SEE NOTE 1 NOTES 1 Relay K109 can be used for an accessory rated at the same voltage as power supply REMOVE JUMPER IN TWO STAGE MODE BLACK BLACK BLUE RED RED L1 L2 L3 G UNITS 460V 3PH 60HZ J UNITS 575V 3PH 60HZ L3 2 Field installed and supplied r...

Page 31: ...Page 31 SCHEMATIC WIRING DIAGRAM FOR G24 200 UNITS 120V SINGLE PHASE 60HZ FIGURE 18 ...

Page 32: ...Page 32 WIRING SCHEMATIC DIAGRAM FOR G24 200 P UNITS 208 230V 1PH 60 HZ G UNITS 460V 3PH 60HZ Y UNITS 208 230V 3PH 60HZ J UNITS 575V 3PH 60HZ FIGURE 19 ...

Page 33: ... hand do not try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion Placing Furnace Into Operation G24 200 units are equipped with two direct spark ignition systems one for each heat section Do not attempt to manually light burners on these furnaces Each time ther mostat calls for heat the burners will automatically light WARNING Danger of ...

Page 34: ...cts open and both gas valves GV1 and GV3 close on second stage after 3 seconds and then close on first stage 7 For troubleshooting purposes an ignition attempt after lockout may be re established manually Move thermo stat from Heat to OFF then back to Heat The heat ing sequence then restarts at step 1 B Applications with Two Stage Thermostat 1 When the thermostat calls for heat the K13 relay con t...

Page 35: ...ertification for installation at altitudes over 4500 feet 1372m above sea level is the jurisdiction of the local authorities High Altitude Information In Canada certification for installation at altitudes over 4500 feet 1372m above sea level is the jurisdiction of the local authorities See table 12 for the correct high heat manifold pressures to be maintained for natural gas Check the gas line pre...

Page 36: ...d flue will open pressure switches and cause unit to shut down Check flue and outlet for blockages 4 Reset manual flame rollout switches on burner box covers Burner Flame Adjustment The G24 200 burner flame is not adjustable however the flame should be inspected at the beginning of each heating season If necessary clean the burners Burner flame should be blue when burning natural gas See figure 21...

Page 37: ... 0 45 0 34 720 0 55 0 41 755 0 65 0 48 825 0 75 0 56 875 0 85 0 63 920 0 95 0 71 965 1 05 0 78 2600 1225 545 0 35 0 26 610 0 40 0 30 670 0 50 0 37 725 0 60 0 45 780 0 70 0 52 830 0 80 0 60 875 0 90 0 67 920 1 00 0 75 965 1 10 0 82 2800 1320 560 0 40 0 30 620 0 45 0 34 680 0 55 0 41 735 1 05 0 48 785 0 75 0 56 835 0 85 0 63 880 0 95 0 71 925 1 05 0 78 965 1 15 0 86 3000 1415 570 0 45 0 34 630 0 55 ...

Page 38: ...e Cooling Tons Drive Kit Model No Voltage Phase Motor Output hp kW Minimum Circuit Motor Pulley in Groove Blower Pulley in Groove RPM Range Belt Shipping Weight Tons kW Model No Phase min max Circuit Ampacity in Groove in Groove Range Belt Weight lbs kg DKG24 200 1 115v 1ph 25 42 19 7 5 10 DKG24 200 2 230v 1ph 14 42 19 7 5 or 10 26 4 or 35 2 DKG24S 200 3 208 230v 3ph 1 5 1 1 1 7 1 3 9 7 8 x 4 3 4 ...

Page 39: ... 2 Wheel pulley Roll out switch 2 Combustion air blower 2 Belt Primary limit 2 Flexible gas connector Bearing 2 Pressure switch 2 Vibration isolators 4 Blower timing control board Locating rods 2 Accessory relay Blower operation relays Contactor Combustion air blower operation relays G24 200 Start up and Performance Check List Job Name Job Number Date Job Location City State Province Installer Cit...

Page 40: ...9 ROLLOUT SWITCH IS THE B6 B15 COMBUSTION AIR BLOWER ON CHECK K13 1 CONTACT OPERATION AND WIRING TO B6 B15 COMBUSTION AIR BLOWER NO YES IS THE S18 S45 COMBUSTION AIR BLOWER PROVING SWITCH CLOSED CHECK SENSING TUBE FOR BLOCKAGE AND S18 S45 SWITCH FOR PROPER OPERATION NO NO GV1 GV3 GAS VALVE CLOSED SPARK OFF INCREMENT TRAIL REGISTER DURING RETRY PERIOD LED FLASHES 5 SEC ON AND 2 5 SEC OFF ARE THE TH...

Page 41: ...OMBUSTION AIR BLOWER OFF B3 SYSTEM BLOWERS OFF AFTER 150 SEC DELAY NO YES NO POWER FROM W2 ENERGIZES K19 RELAY SECOND STAGE OF GV1 GV3 GAS VALVE ENERGIZED HIGH HEAT AFTER APPROXIMATELY 3 SEC IS W2 DEMAND SATISFIED YES CLOSE SECOND STAGE OF GV1 GV3 GAS VALVE AFTER APPROXIMATELY 3 SEC AND THEN RETURN TO LOW HEAT OPERATION LED CODES 1 ON NORMAL OPERATION WITH THERMOSTAT CALLING FOR HEAT 2 0 5 SEC ON ...

Page 42: ...BEFORE RESETTING THE MANUALLY RESET S47 S69 ROLLOUT SWITCH IS THE B6 B15 COMBUSTION AIR BLOWER ON CHECK K13 1 CONTACT OPERATION AND WIRING TO B6 B15 COMBUSTION AIR BLOWER NO YES IS THE S18 S45 COMBUSTION AIR BLOWER PROVING SWITCH CLOSED CHECK SENSING TUBE FOR BLOCKAGE AND S18 S45 SWITCH FOR PROPER OPERATION NO NO GV1 GV3 GAS VALVE CLOSED SPARK OFF INCREMENT TRAIL REGISTER DURING RETRY PERIOD LED F...

Page 43: ...IS W1 DEMAND OF THERMOSTAT SATISFIED A3 A12 LED OFF YES B6 B15 COMBUSTION AIR BLOWER OFF B3 SYSTEM BLOWERS OFF AFTER 150 SEC DELAY NO YES NOTE IF ECONOMIZER INSTALLED ECONOMIZER OPERATES WHEN BLOWER POWERED LED CODES 1 ON NORMAL OPERATION WITH THERMOSTAT CALLING FOR HEAT 2 0 5 SEC ON AND 2 5 SECS OFF IN IGNITION RETRY PERIOD 3 OFF NO POWER OR DETECTED FAULT SECOND STAGE OF GV1 GV3 GAS VALVE CLOSES...

Page 44: ...T CONTACTOR OPENS YES IS Y1 DEMAND SATISFIED FIRST STAGE COOLING UNIT CONTACTOR OPENS AND B3 SYSTEM BLOWERS OFF FOR TWO CONDENSING UNITS FOR A SINGLE CONDENSING UNIT THERMOSTAT CALLS FOR COOLING Y1 POWERED COOLING CONTACTOR OF CONDENSING UNIT CLOSES AND SYSTEM BLOWERS START YES IS Y1 DEMAND SATISFIED COOLING UNIT CONTACTOR OPENS AND B3 SYSTEM BLOWERS OFF MANUAL FAN OPERATION THE BLOWERS RUN CONTIN...