Lennox International Inc Furnace G20 User Manual

PRODUCT LITERATURE  
1992 Lennox Industries Inc.  
Dallas, Texas  
502,754M  
9/98  
Supersedes 4/95  
*ꢀꢁ  
6(5,(6  
*$6 )851$&(  
Litho U.S.A.  
:$51,1*  
If the information in this manual is not  
followed exactly, a fire or explosion  
may result causing property damage,  
personal injury, or death.  
- Do not try to light any appliance.  
- Extinguish any open flames.  
- Do not touch any electrical switch; do not  
use any phone in your building.  
- Immediately call your gas supplier from a  
neighbor’s phone. Follow the gas supplier’s  
instructions.  
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.  
- If you cannot reach your gas supplier, call  
the fire department.  
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holes, corrosion, or blockage. Inspect furnace return  
air duct connection to ensure duct is sealed to the fur-  
nace and terminates outside the space containing the  
furnace. 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.  
WARNING  
Product contains fiberglass wool.  
Disturbing the insulation in this product during  
installation, maintenance, or repair will expose you  
to fiberglass wool. 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 ventilating 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 return air from a room where this  
furnace, or any other gas appliance (ie., a water  
heater), is installed. 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 distributed throughout the house  
by the furnace duct system.  
Lennox Industries Inc.  
P.O. Box 799900  
Dallas, TX 75379-9900  
WARNING  
Do not use this furnace if any part has been under  
water. Immediately call a qualified service techni-  
cian to inspect the furnace and to replace any part  
of the control system and any gas control which  
has been under water.  
Your furnace is a gas appliance. It is critical that the gas  
supplied to the unit be completely burned to avoid the pro-  
duction of carbon monoxide gas. Complete combustion  
of the gas requires, but is not limited to, correct gas pres-  
sure and gas flow rate, adequate combustion, air, and  
proper venting.  
WARNING  
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  
Carbon monoxide gas is invisible, odorless, and  
toxic.  
IMPORTANT  
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 fire-  
places) has the potential to produce carbon monoxide  
gas. Because of this, Lennox recommends the use  
of a carbon monoxide detector in your home, even  
if you do not own gas appliances. Reliable detectors  
are available at reasonable retail prices. Contact your  
independent Lennox dealer for more details about this  
investment in your safety.  
Any additions, changes, or conversions required  
in order for the appliance to satisfactory meet the  
application needs must be made by a Lennox ser-  
vice technician using factory specified and ap-  
proved parts.  
CAUTION  
Before attempting to perform any service or main-  
tenance, turn the electrical power to unit OFF at  
disconnect switch.  
Your furnace is designed to meet standards set by nation-  
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 op-  
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  
IMPORTANT DIRECTIONS  
1- Keep the furnace area clear and free of combustible  
material, gasoline, and other flammable vapors and liq-  
uids. If installed in an insulated area, furnace must be  
kept free of insulating material. Insulating material may  
be combustible. Inspect furnace venting system to  
make sure it is in place, physically sound, and without  
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product. Lennox strongly recommends annual in-  
spection and maintenance of this appliance. Contact  
your independent Lennox dealer for an inspection by a  
qualified service technician.  
LIGHTING INFORMATION AND OPERATION  
ON  
OFF  
WARNING  
GAS VALVE SHOWN IN OFF POSITION  
If you do not follow these instructions exactly, afire  
or explosion may result causing property damage,  
personal injury or death.  
FIGURE 3  
BEFORE OPERATING 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.  
GAS VALVE  
SELECTOR  
ARM  
IN OFF  
POSITION  
Use only your hand to push in or turn the gas control knob  
or lever. Never use tools. If the knob or lever will not push  
in or turn by hand, do not try to repair it, call a qualified ser-  
vice technician. Force or attempted repair may result in a  
fire or explosion.  
To place G20E or G20X furnace into operation:  
G20E or G20X units are equipped with an intermittent pi-  
lot ignition system. Do not attempt to manually light pilots  
on these furnaces. Each time thermostat calls for heat,  
the pilot will automatically light. The pilot does not burn  
when there is no call for heat on units with electronic igni-  
tions.  
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.  
8- Honeywell VR8204 Gas Valves - Turn the knob on  
Gas Valve Operation (Figures 3 and 4)  
the gas valve counterclockwise  
to ON.  
1- STOP! Read the safety information at the beginning  
of this section.  
Robertshaw 7200 Gas Valve - Depress the lever and  
move to ON position. Do not force.  
2- Set thermostat to lowest setting. See figure 2.  
9- Replace control access panel.  
10- Turn on all electrical power to unit.  
11- Set thermostat to desired setting.  
THERMOSTATS  
NOTE-When unit is initially started, steps 1 through 11  
may need to be repeated to purge air from pilot line.  
12- If the furnace still will not operate, follow the instruc-  
tions “To Turn Off Gas To Unit” and call your service  
technician or gas supplier.  
FIGURE 2  
To Turn Off Gas To Unit  
1- Set thermostat to lowest setting.  
3- Turn off all electrical power to appliance.  
2- Turn off all electrical power to unit if service is to be  
performed.  
4- This appliance is equipped with an ignition device  
which automatically lights the pilot. Do not try to light  
the pilot by hand.  
3- Remove control access panel.  
5- Remove control access panel.  
4- Honeywell VR8204 Gas Valves - Turn the knob on the  
6- Honeywell VR8204 Gas Valve - Turn the knob on the  
gas valve clockwise  
to OFF.  
gas valve clockwise  
to OFF. See figure 3.  
Robertshaw 7200 Gas Valve - Depress the lever and  
move to OFF position. Do not force.  
Robertshaw 7200 Gas Valve - Depress the lever and  
move to OFF position. Do not force. See figure 4.  
5- Replace control access panel.  
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Filters  
PILOT FLAME  
(Side View)  
G20E and G20X series units are equipped with reusable  
filters which should be inspected monthly and cleaned  
when necessary to assure proper furnace operation. See  
table 1 for filter sizes. Use the following procedure to  
clean filter.  
FLAME SENSOR  
BURNER  
1- Turn off electric power to furnace.  
ELECTRODE  
(G20E & G20X)  
PILOT GAS  
LINE  
2- Remove blower access panel. Wait for blower to stop.  
3- Remove filter by sliding up and out of filter brackets.  
FIGURE 7  
4- Wash filter with water and a mild detergent. For in-  
creased efficiency, filter media should be sprayed  
with filter Handicoater when dry. Filter Handicoater is  
RP products no. 418 and is available as Lennox part  
no. P-8-5069.  
2- Burner Flame -- Start burner and allow to operate for  
a few minutes to establish normal burning condi-  
tions. Check burner flame by observation. Flame  
should be predominantly blue in color, strong in ap-  
pearance and should rise directly from the burner  
ports in the heat exchanger. Check to see that flame  
is burning from all continuous ribbon ports and that  
flame does not impinge on the sides of the heat ex-  
changer. See figure 8.  
NOTE-If filter media must be replaced, order Lennox  
part no. P-9-7831 for 20” x 25 ” filter, P-8-7822 for 16”  
x 25” filter, 97H0601 for 18” x 25” filter, 97H0701 for  
25” x25” filter, and 97H0801 for 24” x 30” filter.  
5- Reinstall filter. Slide filter into top bracket and drop  
into lower bracket.  
BURNER FLAME  
NOTE-Do not replace reusable foam filters with  
throw-away filters.  
6- Replace blower access panel.  
NOTE-VIEW BURNER FLAME  
THROUGH OBSERVATION PORT ON  
BURNER BOX OR DAMPER OPENING  
(Not Shown)  
Q2-50, Q3-50, Q2-75,  
16 X 25 X 1  
16 X 25 X 1  
16 X 25 X 1  
18 X 25 X 1  
Q3-75,  
Q4-75, Q3/4-100  
FIGURE 8  
Q5/6-100, Q3/4-125,  
Q5/6-125  
20 X 25 X 1  
20 X 25 X 1  
VENTING SYSTEM INSPECTION  
Annually (before heating season) inspect furnace venting  
system, draft hood, vent cap, heat exchanger, burners  
and pilot for corrosion, deterioration, or deposits of de-  
bris. Remove any obstructions.  
Blower  
Check and clean blower wheel for any debris. Blower mo-  
tor is prelubricated for extended bearing life. No further lu-  
brication is needed.  
Contact your Lennox dealer for a periodic unit inspection  
by a qualified service technician.  
Pilot and Burner Flame  
CAUTION  
BLOCKED VENT SHUT-OFF SYSTEM  
Check pilot flame and burner flame periodically to  
ensure proper operation.  
Your Lennox furnace is equipped with a blocked vent  
shut-off switch and a flame roll-out switch. The blocked  
vent shut-off switch shuts off the gas supply to the furnace  
in the event of flue or vent blockage. The flame roll-out  
switch shuts off the gas supply to the furnace if there is a  
1- Pilot Flame -- Pilot flame must surround the end of  
flame sensor for proper operation of pilot safety cir-  
cuit. See figure 7.  
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blockage of the heat exchanger. If the furnace fails to op-  
erate due to the functioning of either of these switches,  
DO NOT attempt to place the furnace into operation. Con-  
tact a qualified service person.  
ness, the cause could be exposure to carbon monox-  
ide gas. This is often misdiagnosed as the flu because  
symptoms are similar. If you suffer from flu-like symp-  
toms that are exaggerated at home, but seem to sub-  
side while you are away from the house, exposure to  
carbon monoxide could be the cause.  
SERVICE REMINDER  
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.  
Call your Lennox service technician if unit is inoperative.  
Before calling, always check the following to be sure ser-  
vice is required.  
1- Check to see that electrical disconnect switches are  
ON.  
You should expect a service technician to check the fol-  
lowing items during an annual inspection. Power to the  
unit must be shut off for the service technician’s safety.  
Fresh air grilles and louvers (on the unit and in the  
room where the furnace is installed) - Must be open and  
unobstructed to provide combustion air.  
2- Check room thermostat for proper setting.  
3- Replace any blown fuses or reset circuit breakers.  
4- Gas valve should be ON.  
5- Air filter should not be plugged limiting air flow.  
6- Is gas turned on at meter?  
Burners- Must be inspected for rust, dirt, or signs of water.  
Vent pipe - Must be inspected for signs of water, dam-  
aged or sagging pipe, or disconnected joints.  
Unit appearance - Must be inspected for rust, dirt, signs  
of water, burnt or damaged wires, or components.  
Blower access door - Must be properly in place and pro-  
vide a seal between the return air and the room where the  
furnace is installed.  
7- Is manual main shut-off valve open?  
To keep your Lennox gas heating system in peak operat-  
ing condition year after year, contact your independent  
Lennox dealer about a planned service program.  
If you discover any of the following, shut down your  
unit, and contact an independent Lennox dealer for  
an inspection by a qualified technician.  
Return air duct - Must be properly attached and provide  
an air seal to unit.  
Operating performance - Unit must be observed during  
operation to monitor proper performance of the unit and  
the vent system.  
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.  
If you smell any unusual odors, your unit may be oper-  
ating improperly. For example, units can give off unfa-  
miliar odors if components are required to operate in  
abnormal conditions.  
Problems detected during the inspection may make it  
necessary to temporarily shut down the furnace until the  
items can be repaired or replaced.  
Pay attention to your furnace. Situations can arise be-  
tween annual furnace inspections that may result in un-  
safe operation. For instance, items innocently stored next  
to the furnace may obstruct the combustion air supply.  
This could cause incomplete combustion and the produc-  
tion of carbon monoxide gas.  
Look for visible signs of a malfunctioning unit. Exam-  
ples include unusual amounts of condensate on win-  
dows inside your house, visibly burnt components or  
unusual dirt or rust accumulations on the vent pipe or  
in the unit.  
If you experience headache, nausea, fatigue, or dizzi-  
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