Lennox International Inc Furnace G40DFX SERIES User Manual

E 2001 Lennox Industries Inc.  
Dallas, Texas, USA  
504,322M  
4/2001  
G40DF(X)  
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.  
Do not store or use gasoline or other flamĆ  
mable vapors and liquids in the vicinity of  
this or any other appliance.  
D Extinguish any open flames.  
D Do not touch any electrical switch; do not use any  
phone in your building.  
Installation and service must be performed by  
a qualified installer, service agency or the gas  
supplier.  
D Immediately call your gas supplier from a neighbor's  
phone. Follow the gas supplier's instructions.  
D If you cannot reach your gas supplier, call the fire deĆ  
partment.  
04/01  
504,322M  
*2P0401*  
*P504322M*  
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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 pressure  
and gas flow rate, adequate combustion, air, and proper  
venting.  
WARNING  
Do not use this furnace if any part has been under  
water. Immediately call a qualified service technician  
to inspect the furnace and to replace any part of the  
control system and any gas control which has been  
under water.  
IMPORTANT  
WARNING  
Carbon monoxide gas is invisible, odorless and  
toxic.  
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.  
Exposure to carbon monoxide gas can cause personal injuĆ  
ry and even death to all occupants, including pets. Any item  
that is powered by or gives off heat from a combustion proĆ  
cess (including lawn mowers, automobiles, and fireplaces)  
has the potential to produce carbon monoxide gas. Because  
of this, Lennox recommends the use of a carbon monoxĆ  
ide detector in your home, even if you do not own gas  
appliances. When propane is used, Lennox also recomĆ  
mends use of a propane detector. Reliable detectors are  
available at reasonable retail prices. Contact your Lennox  
dealer or propane supplier for more details about this inĆ  
vestment in your safety.  
WARNING  
Improper installation, adjustment, alteration, service  
or maintenance can cause property damage, personĆ  
al injury or loss of life. Installation and service must  
be performed by a qualified installer, service agency  
or the gas supplier.  
Important Directions  
1 - Keep the furnace area clear and free of combustible  
material, gasoline, and other flammable vapors and  
liquids. If it is installed in an insulated area, the furnace  
must be kept free of insulating material. Insulating maĆ  
terial may be combustible.  
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  
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 critiĆ  
cal for your safety and the satisfactory operation of the  
product. Lennox strongly recommends annual inĆ  
spection and maintenance of this appliance. Contact  
your Lennox dealer for an inspection by a qualified service  
technician.  
2 - DO NOT obstruct air flow to unit. Unit must receive an  
unobstructed flow of combustion and ventilating air.  
3 - DO NOT store chlorine or fluorine products near unit  
or introduce these products into the combustion air.  
These products can cause furnace corrosion.  
4 - DO NOT draw return air from a room where this furĆ  
nace, or any other gas appliance (ie., a water heatĆ  
er), is installed. When return air is drawn from a room,  
a negative pressure is created in the room. If a gas apĆ  
pliance 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 distributed throughout the house by the  
furnace duct system.  
Lighting Information & Operation  
WARNING  
If you do not follow these instructions exactly, a fire  
or explosion may result causing property damage,  
personal injury or death.  
WARNING  
The blower door and flue chase must be securely in  
place when the blower and burners are operating.  
Gas fumes, which could contain carbon monoxide,  
can be drawn into the living space resulting in perĆ  
sonal injury or death.  
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.  
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The gas valve on the G40DF(X) will be equipped with eiĆ  
ther a gas control knob or lever. Use only your hand to turn  
the gas control knob or push the gas lever. Never use  
tools. If the knob or lever will not move by hand, do not try  
to repair it. Call a qualified service technician. Force or atĆ  
tempted repair may result in a fire or explosion.  
White Rodgers 36E Series Gas Valve  
Gas  
Valve  
Lever  
Placing the G40DF(X) furnace into operation:  
G40DF(X) units are equipped with a SureLightt ignition  
system. Do not attempt to manually light burners on these  
furnaces. Each time thermostat calls for heat, the burners  
will automatically light. The ignitor does not get hot when  
there is no call for heat on units with the SureLightt ignition  
system.  
GAS VALVE SHOWN IN OFF POSITION  
FIGURE 3  
White Rodgers 36F Series Gas Valve  
Operating the Gas Valve (Figures 3, 4 and 5)  
1 - STOP! Read the safety information at the beginning of  
this section.  
Gas  
Valve  
Lever  
2 - Set the thermostat to the lowest setting. See figure 2.  
3 - Turn off all electrical power to the unit.  
GAS VALVE SHOWN IN OFF POSITION  
THERMOSTATS  
FIGURE 4  
Honeywell VR8205 Series Gas Valve  
Gas  
Valve Knob  
FIGURE 2  
ON  
4 - This furnace is equipped with an ignition device which  
automatically lights the burners. Do not try to light the  
burners by hand.  
OFF  
GAS VALVE SHOWN IN OFF POSITION  
5 - Remove the lower access panel.  
FIGURE 5  
9 - Replace the lower access panel.  
6 - White Rodgers 36E/36F Gas Valve - Switch gas  
valve lever to OFF.  
Honeywell VR8205 Gas Valve - Turn knob on gas  
10 - Turn on all electrical power to to the unit.  
11 - Set the thermostat to desired setting.  
valve clockwise  
5.  
to OFF. Do not force. See figure  
NOTE - When unit is initially started, steps 1 through 11  
may need to be repeated to purge air from gas line.  
7 - Wait five 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 instrucĆ  
tions. If you do not smell gas go to next step.  
12- If the appliance will not operate, follow the section  
Turning Off Gas to the Unit" and call your service techĆ  
nician or gas supplier.  
Turning Off Gas to the Unit  
8 - White Rodgers 36E/36F Gas Valve - Switch gas valve leĆ  
ver to ON. See figure 3 for the White Rodgers 36E  
valve and figure 4 for the White Rodgers 36F valve.  
1 - Set the thermostat to the lowest setting.  
2 - Turn off all electrical power to the unit if service is to be  
performed.  
Honeywell VR8205 Gas Valve - Turn knob on gas valve  
counterclockwise  
to ON. Do not force.  
3 - Remove the lower access panel.  
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4 - White Rodgers 36E/36F Gas Valve - Switch gas  
valve lever to OFF.  
Honeywell VR8205 Gas Valve - Turn knob on gas  
Burner Flame  
CAUTION  
To ensure proper operation, a qualified technician  
should annually check the burner flame.  
valve clockwise  
to OFF. Do not force.  
5 - Replace the lower access panel.  
Filters  
Service Reminder  
This unit is not equipped with a filter or rack. A field-proĆ  
vided high-velocity filter is required for the unit to operate  
properly.  
Call your Lennox service technician if the unit will not operĆ  
ate. Before calling, always check the following to be sure  
service is required:  
A filter must be in place whenever the unit is operating.  
1 - Check that electrical disconnect switches are ON.  
2 - Check room thermostat for proper setting.  
3 - Replace any blown fuses or reset circuit breakers.  
4 - Gas valve should be ON.  
Seasonal Inspections  
A qualified service technician should inspect the complete  
system each season (heating and cooling). The following  
maintenance procedures should only be conducted by a  
qualified service technician. Do not attempt to service  
the unit in any way.  
5 - Air filter should not be plugged, which will limit air flow.  
6 - Is gas turned on at meter?  
7 - Is manual main shut-off valve open?  
Record the model and serial number of the furnace. These  
numbers are on the unit nameplate, which is located below  
the burners.  
Venting System  
WARNING  
Asphyxiation Hazard  
Serial Number __________________  
Model Number __________________  
The exhaust vent for this furnace must be securely  
connected to the furnace flue collar at all times.  
Safety Precautions  
For your safety and to fulfill the terms of the limited  
warranty, a qualified service technician must annualĆ  
ly inspect this furnace and its vent system.  
If you discover any of the following, shut down your  
unit, and contact a Lennox dealer for an inspection by  
a qualified technician.  
Annually (before heating season) inspect furnace venting  
system, vent cap, heat exchanger, and burners for corroĆ  
sion, deterioration, or deposits of debris. Remove any obĆ  
structions.  
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 unfaĆ  
miliar noises.  
Inspect the furnace venting system to make sure it is in  
place, physically sound, and without holes, corrosion, or  
blockage. Vent connector must be in correct position,  
sloped upward and be physically sound without holes or  
excessive corrosion.  
D If you smell any unusual odors, your unit may be operatĆ  
ing improperly. For example, units can give off unfamilĆ  
iar odors if components are required to operate in abĆ  
normal conditions.  
D Look for visible signs of a malfunctioning unit. Examples  
include unusual amounts of condensate on windows inĆ  
side your house, visibly burnt components or unusual  
dirt or rust accumulations on the vent pipe or in the unit.  
Inspect the furnace return air duct connection to ensure  
duct is sealed to the furnace and terminates outside the  
space containing the furnace.  
D If you experience headache, nausea, fatigue, or dizziĆ  
ness, the cause could be exposure to carbon monoxide  
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.  
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.  
During a seasonal check the service technician will inspect  
the indoor blower and the burner flames along with the  
venting system.  
Blower  
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.  
Check blower wheel for any debris and clean, if necessary.  
Blower motor is pre-lubricated for extended bearing life. No  
further lubrication is needed.  
Page 5  
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Return air duct - Must be properly attached and provide  
Planned Service  
an air seal to the unit.  
You should expect a service technician to check the followĆ  
ing items during an annual inspection. Power to the unit  
must be shut off for the service technician's safety.  
Operating performance - Unit must be observed during  
operation to monitor proper performance of the unit and the  
vent system.  
Fresh air grilles and louvers (on the unit and in the room  
where the furnace is installed) - Must be open and unobĆ  
structed to provide combustion air.  
Combustion gases - Flue products must be analyzed and  
compared to the unit specifications.  
Burners - Must be inspected for rust, dirt, or signs of water.  
Problems detected during the inspection may make it necĆ  
essary to temporarily shut down the furnace until the items  
can be repaired or replaced.  
Vent pipe - Must be inspected for signs of water, damaged  
or sagging pipe, or disconnected joints.  
Unit appearance - Must be inspected for rust, dirt, signs  
of water, burnt or damaged wires, or components.  
Pay attention to your furnace. Situations can arise beĆ  
tween annual furnace inspections that may result in unsafe  
operation. For instance, items innocently stored next to the  
furnace may obstruct the combustion air supply. This could  
cause incomplete combustion and the production of carĆ  
bon monoxide gas.  
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.  
Flue chase - Must be properly installed and sealed beĆ  
tween the top cap and blower deck during unit operation.  
Page 6  
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