Lennox G40UH Series, Installation Instructions Manual

Page 1: ...ments 27 Service 28 Repair Parts List 30 Ignition Control Board Diagnostic Codes 30 Troubleshooting 31 Start Up Performance Check List 34 WARNING Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other ap pliance Installation and service must be performed by a qualified installer service agency or the gas supplier WHAT TO DO IF YOU SMELL GAS Do not t...

Page 2: ...14 q_ i C m Bottom Return Air Opening FRONT VIEW in 14 1 2 17 1 2 21 24 1 2 _OPTIONAL EXTERNAL SIDE RETURN AIR FILTER KIT Either Side 14 3 4 375 406 5 8 16 _1__1 3 4 19 40 1016 3 3 4 95 IP 1 D FLUE OUTLET Top _OPTIONAL EXTERNAL SIDE RETURN AIR FILTER KIT Either Side r 25 635 TOP VIEW TOP VIEW 3 1 4 83 Right I_ 28 1 2 724 _ 8 1 8 206 Left 3 3 L _ 95 _ 91 _ 19 7 16 _ID _ 494 1 4 1 4 108 14 356 Right...

Page 3: ...stion Air Pressure Switch Inducer Limit Shield Primary Limit NOx Insert NO x Units Only Gas Orifices Igniter Bracket Igniter 4_ Secondary Limit Burner Bottom Shield Control Transformer 135 and 155 kBtuh units only Flame rollout switches are located on brackets on the inner sides one J _ on the left and one on the right of the burner box Integrated Ignition Control Board _ Capacitor Door Interlock ...

Page 4: ...nameplate and in the tables in figures 6 and 11 Accessibility and service clearances must take precedence over fire protection clearances NOTE For installation on combustible floors the furnace shall not be installed directly on carpeting tile or other combustible material other than wood flooring For installation in a residential garage the furnace must be installed so that the burner s and the i...

Page 5: ...Dilution and Ventilation Air in a confined space with air from outside The furnace heat exchanger components duct system air filters and evaporator coils must be thoroughly cleaned following final construction clean up All furnace operating conditions including ignition in put rate temperature rise and venting must be verified according to these installation instructions NOTE The Commonwealth of M...

Page 6: ...e components The requirements for providing air for combustion and ven tilation depend largely on whether the furnace is installed in an unconfined or a confined space Unconfined Space An unconfined space is an area such as a basement or large equipment room with a volume greater than 50 cubic feet 1 42 m3 per 1 000 Btu 29 kW per hour of the com bined input rating of all appliances installed in th...

Page 7: ...cts Each opening shall have a minimum free area of 1 square inch 645 mm2 per 4 000 Btu 1 17 kW per hour d total input rating of all equipment in the en closure See figures 3 and 4 When communicating with the outdoors through horizontal ducts each opening shall have a minimum free area of 1 square inch 645 mm 2 per 2 000 Btu 56 kW per total input rating of all equipment in the enclosure See figure ...

Page 8: ...ent connection and installation and service clearances 24 inches 610 mm at unit front The unit must be level NOTE 1 3 hp blower motors are equipped with four flex ible mounting legs and 1 2 hp blower motors are equipped with three flexible legs and one rigid leg The rigid leg is equipped with a shipping bolt and a flat white plastic wash er rather than the rubber mounting grommet used with a flexi...

Page 9: ...sition and filter Transition FIGURE 7 Optional Return Air Base Upflow Applications Only For use with B C and D cabinets only 20 X 25 X 1 508mm X635mm X 25mm Cleanable Filter _ Return Air Plenum J AIR FLOW 14 L 7 1 4 184 17 1 2 446 RAB B 98M60 21 533 RAB C 98M58 24 1 2 622 RAB D 98M59 FRONT VIEW OPTIONAL RAB RETURN AIR BASE 7 8 22 I r 41 102 1 9_ 123 584 fL_ Overall 1 MinimuV_ Maximum 11 279 2 Maxi...

Page 10: ...e of the fur nace base A flat washer may be added between the nut and the bottom of the unit 4 Adjust the outside nut to the appropriate height and tighten the inside nut to secure the arrangement NOTE The unit may be tilted back to front a maximum of 1 This will ensure proper draining of the heat exchanger Leveling Bolt Installation Inches mm 3 8 1o _r Furnace Front _ 3 8 1 3 4 44 1 3 4 44 Leveli...

Page 11: ... are used to sus pend the unit in this way support must be provided for both the ends and the middle of the furnace to prevent sagging The straps must not interfere with the plenum or exhaust piping installation Securing screws should be 1 2 inch from the top edge and 1 1 2 inch from the side edge in all cases Cooling coils and supply and return air plenums must be supported separately NOTE When t...

Page 12: ...down the vent pipe and into the room This reverse flow of the flue gas may result in incomplete combustion and the formation of carbon monoxide gas This toxic gas might then be distributed throughout the house by the furnace duct system In upfiow applications the return air can be brought in through the bottom or either side of the furnace If a furnace with bottom return air is installed on a plat...

Page 13: ...each side of the vent pipe and collar See figure 16 Install the first vent connector elbow at a minimum of six inches 152 mm from the furnace vent outlet Venting Using a Masonry Chimney The following additional requirements apply when a lined masonry chimney is used to vent this furnace Masonry chimneys used to vent Category I central fur naces must be either tile lined or lined with a listed meta...

Page 14: ...ent or chimney suitable for venting G40UH X series units The chimney passageway must be checked periodically to ensure that it is clear and free of obstructions Do not install a manual damper barometric draft regulator or flue restrictor between the furnace and the chimney Never connect a Category I appliance to a chimney that is servicing a solid fuel appliance If a fireplace chimney flue is used...

Page 15: ...ns of single wall connector piping shall be fastened by screws or other approved means 12 When the vent connector used for Category I ap pliances must be located in or pass through a crawl space or other areas which may be cold that portion of the vent connector shall be constructed of listed double wall type B vent material or material having equivalent insulation qualities 13 All venting pipe pa...

Page 16: ... 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 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 59 405 15 33 64 44 141 57...

Page 17: ...7 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 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 NR NR 91 144 122 ...

Page 18: ...3 89 47 142 64 220 15 2 22 53 35 96 49 153 66 235 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 3 22 66 34 123 48 198 64 309 TABLE 6 Common Vent Capacity Type B Double Wall Vents with Type B Double Wall Connectors Serving Two or More Category I Appliances Common Vent...

Page 19: ...d the other appliances which are not operating re main connected to the common venting system If the venting system has been installed improperly you must correct the system as indicated in the general venting re quirements section 1 Seal any unused openings in the common venting sys tem _ Inspect the venting system for proper size and horizontal pitch Determine that there is no blockage restricti...

Page 20: ...onnection to the unit The tap must be accessible for test gauge connection See figure 19 NOTE If emergency shutoff is necessa04 shut off the main manual gas valve and disconnect main power to the fur nace The installer should properly label these devices Nominal Internal Iron Pipe Diameter Size inches inches mm ram 3 8 9 53 1 2 12 7 3 4 19 05 1 25 4 1 1 4 31 75 1 1 2 38 1 2 50 8 2 1 2 63 5 3 76 2 ...

Page 21: ...taller should properly label these devices ACAUTION ELECTROSTATIC DISCHARGE ESD Precautions and Procedures ACAUTION The furnace must be isolated from the gas supply system by closing its individual manual shut off valve during any pressure testing of the gas supply system at pressures less than or equal to 1 2 psig 3 48 kPa 14 inches w c klMPORTANT MANUAL MAIN SHUT OFF VALVE WILLNOTHOLD NORMALTEST...

Page 22: ...properly grounded 7 One line voltage EAC accessory terminal is provided on the furnace control board Any electronic air cleaner rated up to one amp can be connected to this terminal with the neutral leg of the circuit being connected to the any of the NEUTRAL terminals See figure 25 for con trol board configuration This terminal is energized whenever the blower is operating 8 One line voltage HUM ...

Page 23: ...PER CONDUCTORSONLY LINE VOLTAGE FIELD INSTALLED CLASS II VOLTADE FIELD WIRING DENOTES OPTIONAL COMPONENTS WARNING ELECTRIC SHOCK HAZARD CAN CAUSE INJURY OR DEATH UNIT MUST BE GROUNDEDIN ACCORDANCE WITH NATIONAL AND LOCAL CODES S ROOMTHERMOSTAT LI LIL__ SIO 18 PRIMARYGAS COMBIFJTI_ AIR LIMIT PROVINGSWITCH AIR INDUCER kJ TE_ATE _ew Gwi_v Y_HITE ROD_RE HONEY_dELL 6AS VALVE GAS VAt _ _ b s OlqO OOO JF...

Page 24: ...YWELL VALVE 1 50 AMPIWHITE NDDSERS VALVE I JACKPLUS CHART IJ P58 1JACK PLUS BURNER CONTROL J PB A K U _ AAR N R IJ PI56 IJACK PLUG INDUCFR IGNITER IJ PI59 IJACK PLUG IGNITION NOTE F_ IF ANY WIRE IN THIS APPLIANCE IS REPLACED IT P135 MUST BE REPLACED WITH WIRE OF LIKE SIZE J135 RATINS INSULATION THICKNESS AND TERMINATION _ IMPORTANT TO PREVENT MOTOR BURNOUT NEVER CONNECT MORE THAN ONE MOTOR LEAD TO...

Page 25: ...this section 2 Set the thermostat to the lowest setting 3 Turn off all electrical power to the unit 4 This furnace is equipped with an ignition device which automatically lights the burners Do not try to light the burners by hand 5 Remove the upper access panel 6 Honeywell VR8205 Gas Valve with QN QFF Switch Move gas valve switch to OFF See figure 27 Honeywell VR8205 Gas Valve with Control Knob Tu...

Page 26: ...zes 4 After a 20 second igniter warm up period the gas valve solenoid opens 5 Gas is ignited flame sensor proves the flame and the combustion process continues 6 If flame is not detected after first ignition trial the igni tion control will repeat steps 3 and 4 four more times before locking out the gas valve WATCHGUARD flame failure mode The ignition control will then auto matically repeat steps ...

Page 27: ...t to the combustion air inducer This switch checks for proper combustion air inducer operation before allow ing ignition trial The switch is factory set and requires no adjustment Temperature Rise Place the unit into operation with a heating demand After supply and return air temperatures have stabilized check the temperature rise If necessary adjust the blower speed to maintain the temperature ri...

Page 28: ... of each heating season a qualified techni cian should check the system as follows Blower Check the blower wheel for debris and clean if necessary The blower motors are prelubricated for extended bearing life No further lubrication is needed WARNING Filters All G40UH X filters are installed external to the unit Fil ters should be inspected monthly Clean or replace the fil ters when necessary to en...

Page 29: ...heat exchanger Use a vacuum cleaner to remove debris knocked loose during clean ing from each heat exchanger section 12 Attach the exhaust end positive pressure d the vacu um cleaner to the top d the heat exchanger section Any loose debris will be forced to the bottom of the heat exchanger section Vacuum debris from bottom open ings 13 Replace collector box and combustion air inducer Check gaskets...

Page 30: ...IMULTANEOUS Normal operation signaled when heating demand initiated at thermostat FAST FLASH FAST FLASH SLOW FLASH ON Primary or secondary limit switch open Limit must close within 3 minutes or unit goes into 1 hour Watchguard Pressure prove switch open OFF SLOW FLASH OR Blocked inlet exhaust vent OR Pressure switch closed prior to activation of combustion air inducer ALTERNATING ALTERNATING Watch...

Page 31: ... FAST FLASH LED 2 SLOW FLASH IMPROPER GROUND LED 1 ALTERNATING FAST FLASH LED 2 ALTERNATING FAST FLASH LEDs SIGNAL FAST ALTERNATING FLASH CONTROL WILL NOT RESPOND TO A CALL FOR HEATING UNTIL VOLTAGE RISES ABOVE 95 VOLTS GAS VALVE OFF COMBUSTION AIR INDUCER ON INDOOR BLOWER ON LED 1 ON LED 2 SLOW FLASH SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES AND POWER IS RESET OR T STAT IS INTERRUPTED FOR MINIMU...

Page 32: ...EAT DEMAND F VE CONSECUT VE TR ES DUR NG A S NGLE _t ES I__ WATCHGUARD MODE GAS VALVE OFF I_ COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF WITH DELAY LEDs SIGNAL WATCHGUARD FAILURE CODE IS 60 MINUTE RESET PERIOD COMPLETE _t HAS CONTROL RESET IGNITION pI NO SEQUENCE FOUR TIMES YES I LOW FLAME SIGNAL LIMIT SWITCH WATCHGUARD Does not affect operation of control MODE GAS VALVE COMB AIR LED 1 SLOW FLASH...

Page 33: ...T LED CONTROL I WILL CONTINUE TO CALL FOR COOLING IN THIS CONDITION NO 1 LED SIGNALS LOW VOLTAGE CONTROL WILL CONTINUE TO CALL FOR COOLING IN THIS CONDITION YES I GAS VALVE OFF COMBUSTION AIR INDUCER ON T NO LI INDOOR BLOWER ON ROLLOUT SWITCH MONITORED CONTINUOUSLY _ SIGNAL ROLL OUT SWITCH OPEN AT LED IS ROLLOUT SWITCH CLOSED I_1 SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES J AND MAIN POWER IS INTER...

Page 34: ...CER SYSTEM FAN REMAINS ON HEATING SPEED THERMOSTAT OPENS HUM TERM DE ENERGIZES WITH COMB AIR INDUCER SYSTEM FAN REMAINS ON HEATING SPEED 1 Job Name Job No Job Location City Installer City Unit Model No Technician Serial No Electrical Connections Tight Blower Motor Amps Fuel Type Natural Gas Furnace Btu Input Regulator Pressure __ w c Nat Flue Connections Tight Combustion Gas Tested CO2 Fan Control...