Lennox International Inc Furnace G32 SERIES User Manual

E2001 Lennox Industries Inc.  
Dallas, Texas, USA  
504,390M  
7/2001  
Supersedes 503,743M  
G32  
SERIES  
GAS FURNACE  
Litho U.S.A.  
WARNING  
If the information in this manual is not  
followed exactly, a fire or explosion  
may result causing property damage,  
personal injury or loss of life.  
WHAT TO DO IF YOU SMELL GAS:  
D Do not try to light any appliance.  
D Extinguish any open flames.  
Do not store or use gasoline or other  
flammable vapors and liquids in the  
vicinity of this or any other appliance.  
D Do not touch any electrical switch; do not  
use any phone in your building.  
D Immediately call your gas supplier from a  
neighbor's phone. Follow the gas suppliĆ  
er's instructions.  
Installation and service must be perĆ  
formed by a qualified installer, service  
agency or the gas supplier.  
D If you cannot reach your gas supplier, call  
the fire department.  
07/01  
504,390M  
*2P0701*  
*P504390M*  
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Important Directions  
WARNING  
1 - Keep the furnace area clear and free of combustible  
material, gasoline, and other flammable vapors and  
liquids. If installed in an insulated area, furnace must  
be kept free of insulating material. Insulating material  
may be combustible.  
Product contains fiberglass wool.  
Disturbing the insulation in this product during  
installation, maintenance, or repair will expose you  
to fiberglass wool dust. Breathing this may cause  
lung cancer. (Fiberglass wool is known to the State  
of California to cause cancer.)  
2 - DO NOT obstruct air flow to unit. Unit must receive  
an unobstructed flow of combustion and ventilatĆ  
ing air.  
Fiberglass wool may also cause respiratory, skin,  
and eye irritation.  
3 - DO NOT store chlorine or fluorine products near unit  
or introduce these products into the combustion air.  
These products can cause furnace corrosion.  
To reduce exposure to this substance or for further  
information, consult material safety data sheets  
available from address shown below, or contact  
your supervisor.  
4 - DO NOT draw the return air from a room where  
another gas appliance (ie., a water heater) is  
installed. Even though this furnace draws its comĆ  
bustion air from outside of the structure, other gas  
appliances that share a utility room may not. When  
return air is drawn from a room, a negative pressure  
is created in the room. If a gas appliance is operating  
in a room with negative pressure, the flue products  
can be pulled back 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 distribĆ  
uted through the house by the furnace duct system.  
Lennox Industries Inc.  
P.O. Box 799900  
Dallas, TX 75379-9900  
WARNING  
Do not set thermostat below 60_F (16_C) in heating  
mode. Setting thermostat below 60_F (16_C) reĆ  
duces the number of heating cycles. Damage to the  
unit may occur that is not covered by the warranty.  
WARNING  
Your furnace is a gas appliance. It is critical that the gas  
supplied to the unit be completely burned to avoid the proĆ  
duction of carbon monoxide gas. Complete combustion  
of the gas requires, but is not limited to, correct gas presĆ  
sure and gas flow rate, adequate combustion, air, and  
proper venting.  
If overheating occurs or if gas supply fails to shut  
off, shut off the manual gas valve to the appliance  
before shutting off electrical supply.  
WARNING  
Do not use this furnace if any part has been underĆ  
water. Immediately call a qualified service techniĆ  
cian to inspect the furnace and to replace any part  
of the control system and any gas control which  
has been under water.  
WARNING  
Carbon monoxide gas is invisible, odorless, and  
toxic.  
Exposure to this gas can cause personal injury and even  
death to all occupants, including pets. Any item that is  
powered by or gives off heat from a combustion process  
(including lawn mowers, automobiles, and fireplaces) has  
the potential to produce carbon monoxide gas. Because  
of this, Lennox recommends the use of a carbon monĆ  
oxide detector in your home, even if you do not own  
gas appliances. Reliable detectors are available at reaĆ  
sonable retail prices. Contact your independent Lennox  
dealer for more details about this investment in your safety.  
CAUTION  
Before attempting to perform any service or mainteĆ  
nance, turn the electrical power to unit OFF at disĆ  
connect switch.  
IMPORTANT  
Any additions, changes, or conversions required in  
order for the appliance to satisfactorily meet the apĆ  
plication needs must be made by a Lennox service  
technician using factory specified and approved  
parts.  
Your furnace is designed to meet standards set by nationĆ  
al agencies, and to operate safely when properly installed  
and maintained. However, the unit's performance can be  
Page 3  
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6 - Turn the gas valve knob to OFF. See figure 3.  
greatly impacted by the individual installation and the opĆ  
erating environment. It is your responsibility to ensure  
that this appliance is maintained. Proper maintenance is  
critical for your safety and the satisfactory operation of the  
product. Lennox strongly recommends annual inĆ  
spection and maintenance of this appliance. Contact  
your independent Lennox dealer for an inspection by a  
qualified service technician.  
HONEYWELL VR8205 Series Gas Valve  
high fire adjusting screw  
(under cap)  
manifold  
pressure  
tap  
low fire  
adjusting screw  
(under cap)  
Lighting and Operating Information  
inlet pressure tap  
Gas Valve Shown In OFF Position  
Figure 3  
WARNING  
7 - Wait five (5) minutes to clear out any gas. 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 next step.  
If you do not follow these instructions exactly, a fire  
or explosion may result causing property damage,  
personal injury or loss of life.  
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.  
8 - Turn the gas valve knob to ON. Do not force the knob.  
9 - Replace the unit access panel.  
10 - Turn on all electrical power to the unit.  
11 - Set thermostat to desired setting.  
The unit is equipped with a gas control knob. Use only  
your hand to move the gas control knob. Never use tools.  
If the knob will not move by hand, do not try to repair it. Call  
a qualified service technician. Force or attempted repair  
may result in a fire or explosion.  
NOTE - When the unit is first started, steps 1 through  
11 may need to be repeated to purge air from pilot  
line.  
12 - If the appliance still will not operate, follow the inĆ  
structions Turning Off Gas to the Unit" and call your  
service technician or gas supplier.  
Turning Off Gas to the Unit  
To place G32 furnace into operation:  
G32 units are equipped with a SureLightt ignition sysĆ  
tem. Do not attempt to manually light these furnaces.  
Each time thermostat calls for heat, the burners will be auĆ  
tomatically lit by the ignitor. The ignitor does not get hot  
when there is no call for heat.  
1 - Set thermostat to lowest setting.  
2 - Turn off all the electrical power to unit if service is to  
be performed.  
3 - Remove the upper access panel.  
4 - Turn the gas valve knob to OFF. Do not force the  
knob.  
Operating the Gas Valve (Figure 3)  
1 - STOP! Read the safety information at the beginning  
5 - Replace the upper access panel.  
of this section.  
2 - Set thermostat to lowest setting. See figure 2.  
Filters  
A filter must be in place any time the unit is operating.  
Ask your dealer to show you where the filter is located.  
The filter should be inspected monthly and cleaned  
when necessary to assure proper furnace operation.  
THERMOSTATS  
Foam filters may be cleaned for reuse. If replacement is  
necessary, order Lennox part no. 31J81 for 14 X 25 inch  
filter used in G32-75 units or P-8-7831 for 20 X 25 inch  
filter used in G32-100 and -125 units. Use the following  
procedure to clean filter.  
Figure 2  
Bottom Return Air Filter Installation (Figure 4)  
1 - Turn off electric power to furnace.  
2 - Remove blower access panel.  
3 - Turn OFF all electrical power to appliance.  
4 - This appliance is equipped with an ignition device  
which automatically lights the burners. Do not try to  
light the burners by hand.  
3 - Remove filter by pressing side filter clips and pulling  
filter up and out. See figure 4.  
5 - Remove upper access panel.  
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BOTTOM RETURN FILTER INSTALLATION  
REAR FILTER CLIP  
REMOVING / REPLACING FILTER DOOR  
FURNACE  
BACK  
FILTER DOOR  
PIN  
TAB  
SIDE FILTER CLIPS (2)  
RETURN AIR OPENING  
FILTER  
FILTER DOOR  
FURNACE  
FURNACE  
FRONT  
BASE BOTTOM  
Figure 4  
FILTER DOOR  
PIN  
4 - Clean filter with cold water and a mild soap. Direct  
water through filter in the opposite direction of air  
flow. Remove all soap residue.  
TAB  
Figure 5  
5 - Allow filter to dry then spray with filter handicoater  
prior to reinstallation. Filter handicoater is available  
from your Lennox dealer as P-8-5069.  
Seasonal Inspections  
A qualified service technician should inspect the comĆ  
plete system each season (heating and cooling). The folĆ  
lowing maintenance procedures should be conducted by  
a qualified service technician. Do not attempt to service  
the unit in any way.  
6 - Place filter in bottom of blower compartment beneath  
rear filter clip. Press down on filter sides. Filter clips  
flex, allowing filter to snap into place.  
7 - Replace blower access panel.  
During a seasonal check the service technician will inĆ  
spect the indoor blower, the burner flame and the venting  
system.  
WARNING  
Blower door must be securely in place when blower  
and burners are operating. Gas fumes, which could  
contain carbon monoxide, can be drawn into living  
space resulting in personal injury or death.  
Venting System  
Annually (before heating season) inspect furnace ventĆ  
ing system, heat exchanger and burners for corrosion,  
deterioration, or deposits of debris. Remove any obĆ  
structions.  
Side Return Air Filter Installation (Figure 5)  
Inspect furnace venting system to make sure it is in place,  
physically sound, and without holes, corrosion, or blockĆ  
age. Vent connector must be in correct position, sloped  
upward and be physically sound without holes or excesĆ  
sive corrosion.  
1 - Turn off electric power to furnace.  
2 - Locate the filter door of the filter rack assembly.  
3 - Using the filter door pins, pull filter door, with filter atĆ  
tached, out of filter rack assembly. Remove filter door  
from filter by pulling up on securing tabs.  
Inspect furnace return air duct connection to ensure duct  
is sealed to the furnace and terminates outside the space  
containing the furnace.  
4 - Clean filter with cold water and a mild soap. Direct  
water through filter in the opposite direction of air  
flow. Allow filter to dry, then spray with filter handiĆ  
coater prior to reinstallation. Filter handicoater is  
available from your Lennox dealer as P-8-5069.  
Inspect the physical support of the furnace to guarantee  
that it is sound without sagging, cracks or gaps around  
base and it maintains seal between base and support.  
5 - Position filter door on end of filter so that the thumb  
tab side of the filter door is away from the furnace.  
Check for correct air flow position. Squeeze thumb  
tabs to secure filter to door.  
Inspect and clean the condensate traps and drain.  
Blower  
6 - Guide filter and filter door into the filter rack  
installed on side of furnace. Push door into filter  
rack until secure.  
Check and clean blower wheel for any debris. Blower moĆ  
tor is preĆlubricated for extended bearing life. No further  
lubrication is needed.  
Page 5  
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Burner Flame  
D If you experience headache, nausea, fatigue, or dizziĆ  
ness, the cause could be exposure to carbon monoxĆ  
ide gas. This is often misdiagnosed as the flu because  
symptoms are similar. If you suffer from flu-like sympĆ  
toms that are exaggerated at home, but seem to subĆ  
side while you are away from the house, exposure to  
carbon monoxide could be the cause.  
Burner Flame - Start burner and allow to operate for a few  
minutes to establish normal burning conditions. Check  
burner flame by observation. Flame should be predomiĆ  
nantly blue in color and strong in appearance.  
CAUTION  
Periodically look through the flame sight glass to  
check the burner flame.  
Your vigilance may pay off in early detection of a problem  
before either personal injury or property damage occurs.  
Do not hesitate to contact a qualified service technician as  
an investment in your well being.  
Contact your Lennox dealer for a periodic unit inspection  
by a qualified service technician.  
Planned Service  
Service Reminder  
Call your Lennox service technician if unit is inoperative.  
Before calling, always check the following to be sure serĆ  
vice is required.  
You should expect a service technician to check the folĆ  
lowing items during an annual inspection. Power to the  
unit must be shut off for the service technician's safety.  
Burners- Must be inspected for rust, dirt, or signs of waĆ  
ter.  
1 - Check that electrical disconnect switches are ON.  
2 - Check room thermostat for proper setting.  
3 - Replace any blown fuses or reset circuit breakers. InĆ  
vestigate reason for blown fuses or tripped breakers.  
Vent pipe - Must be inspected for dirt, damaged or sagĆ  
ging unsupported pipe, or disconnected joints.  
Unit appearance - Must be inspected for rust, dirt, signs  
of water, and burnt or damaged wires components.  
Blower access door - Must be properly in place and proĆ  
vide a seal between the return air and the room where the  
furnace is installed.  
4 - Make sure gas valve is in ON position.  
5 - Air filter should not be plugged limiting air flow.  
6 - Is gas turned on at meter?  
7 - Is manual main shutĆoff valve open?  
Safety Precautions  
Return air duct - Must be properly attached and provide  
an airtight seal to unit.  
If you discover any of the following, shut down your  
unit, and contact an independent Lennox dealer for  
an inspection by a qualified technician.  
Operating performance - Unit must be observed during  
operation to monitor proper performance of the unit and  
the vent system.  
D If you repeatedly hear any new or unfamiliar sounds  
while your unit is operating, there may be a problem.  
For example, poorly performing burners can produce  
unfamiliar noises.  
Combustion gases - Flue products must be analyzed  
and compared to the unit specifications.  
Problems detected during the inspection may make it  
necessary to temporarily shut down the furnace until the  
items can be repaired or replaced.  
D If you smell any unusual odors, your unit may be operĆ  
ating improperly. For example, units can give off unfaĆ  
miliar odors if components are required to operate in  
abnormal conditions.  
Pay attention to your furnace. Situations can arise beĆ  
tween annual furnace inspections that may result in unĆ  
safe operation. For instance, items innocently stored next  
to the air inlet may obstruct the combustion air supply.  
This could cause incomplete combustion and the producĆ  
tion of carbon monoxide gas.  
D Look for visible signs of a malfunctioning unit. ExamĆ  
ples include unusual amounts of condensate on winĆ  
dows inside your house, visibly burnt components, or  
unusual accumulation of rust in the unit.  
Page 6  
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