G34E User Manual_Nov 2003
Contents
1. Minimum clearances mm Natural draft Fan assisted Below eaves balconies and other projections Appliances to 50 Mj h input 300 200 Appliances over 50 Mj h input 500 300 300 300 1000 500 75 500 300 Horizontally from an openable window door non mechanical air inlet or any other opening into abuilding with the exception of sub floor ventilation Appliances up to 150 Mj h input 500 300 Appliances over 150 Mj h input up to 200 Mj h input 1500 500 Appliances over 200 Mj h input 1500 1500 All fan assisted flue appliances in the direction of discharge 1500 From a mechanical air inlet including a spa blower 1500 1000 Vertically below an openable window non mechanical air inlet or any other opening into a building with the exception of sub floor ventilation c rioimimijolijoluo Space heaters up to 50 Mj h input 150 150 Other appliances up to 50 Mj h input 500 500 Appliances over 50 Mj h input and up to 150 Mj h input 1000 1000 Appliances over 150Mj h input 1500 1500 Unless appliance is approved for closer installation NOTES 1 All distances are measured to the nearest part of the terminal 2 Prohibited area below electricity meter or fuse box extends to ground level 3 See Clause 5 13 6 6 for restrictions on a flue terminal under a covered area 4 See Appendix J Figures J2 a and J3 a for clearances required from a flue terminal to an LP Gas cylinder A flue terminal is considered2. BE REQUIRED E 24V AS VALVE de LOUT C OY MR H 24V PRESSURE SW I 240V COMBUSTION FAN 240V THREE PIN PLUG TO CONDENSER Figure 6 EGC 3A INTEGRATED CONTROL BOARD HEATING SPEED TAP TERMINAL CONTINUOUS FAN TERMINAL DIAGNOSTIC CODE ERASE JUMPER Remove power to control and short pins for 10 seconds to erase previous code COOLING SPEED TAP TERMINAL RED DIAGNOSTIC BUTTON Depress button and hold for display of last failure code ACCESSORY TERMINALS HEATING ACCESSORY TERMINAL V nonen THERMOSTAT BLOWER TIME NEUTRAL LEDS TERMINAI gt URI ADJUSTMENT JUMPER TERMINALS Page 10 of 26 Figure 7 EGC 3 Ignition Module KEY COMPONENT IGN BOARD 24V TO THERMOSTAT C PRESSURE SWITCH P2 R MAY NOT BE REQUIRED AL AUX LIMIT DPI ROS ROLL OUT SWITCH x P1 PLUG 6 PIN P1 P2 SPADE CONNECTORS GY CMB COMBUSTION BLOWER DP PO w2 2ND STAGE HEAT TERMINAL BI BLOWER INTERLOCK pr CU CONDENSING UNIT lt ELECTRODE TI TRANSFORMER GAS VALVE F LOW VOLAGE FUSE x MANUAL RESET BR dPI RD 3 PIN PLUG gt TO HUM AND CORD CONDENSOR Li 240V GND N 24VAC gt
3. INDOOR BLOWER WITH DELAY OFF REMOVE POWER TO RESET CONTROL DIAG CODE BOTH ON CONTROL SELF CHECK FAILURE OR INCORRECT WIRING GAS VALVE COMB BLOWER AND INDOOR BLOWER WITH DELAY OFF SEQUENCE HOLDS UNTIL ___ ROLL OUT SWITCH IS MANUALLY CLOSED LED FAST FLASH RATE YES COMBUSTION AIR BLOWER ON Y YES PRESSURE SWITCH CLOSED WITHIN 2 5 MIN YES COMB AIR BLOWER PREPURGE 15 seconds COMB AIR BLOWER PRESSURE SWITCH OPEN NO IGNITION TRIAL 7 seconds START IGNITION SPARK OPEN MAIN GAS VALVE HAS FLAME REGISTERED WITHIN 10 SECONDS AFTER IGNITION TRIAL IS FLAME SENSED AFTER 10 SECOND FLAME RECTIFICATION PERIOD INDOOR AIR BLOWER ON 45 SECS AFTER GAS VALVE IS ENERGIZED PRIMARY SECONDARY LIMITS MONITORED IN HEAT CYCLE ARE SWITCHES CLOSED THERMOSTAT OPENS LED SLOW FLASH RATE COMB AIR BLOWER OFF 5 sec delay INDOOR AIR BLOWER OFF After selected 60 90 120 or 180 delay NO DIAG CODE 1 ON 2 FLASHING FLAME ROLL OUT OPEN GAS VALVE COMB BLOWER AND INDOOR BLOWER WITH DELAY OFF SEQUENCE HOLDS UNTIL PRESSURE SWITCH CLOSES OR THERMOSTAT RESETS CONTROL DIAG CODE 1 OFF 2 FLASHING C A B PRESSURE SWITCH OPEN PRESSURE SWITCH WATCHGUARD CONDITION GAS VALVE COMB BLOWER AND INDOOR BLOWER WITH DELAY OFF DIAG CODE 1 OFF 2 FLASHING C A B PRESSURE SWITCH OPEN IS 5 MINUTE RESET PERIOD COMPLETE AS VALVE OFF COMB BLOWER ON INDOOR BLOWER WITH 45 DELAY ON H
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5. Precautions will help to avoid control exposure to electrostatic discharge by putting the furnace the control and the technician at the same electrostatic potential Neutralize electrostatic charge by touching hand and all tools on an unpainted unit surface such as the gas valve or blower deck before performing any service procedure These units operate on 240 volt single phase 50 Hz electrical power Refer to figure 5 for field wiring and figure 7 for schematic wiring diagram and troubleshooting 1 Select circuit protection and wire size according to requirements listed on unit rating plate 2 Snap hole plugs are provided on both sides of cabinet to facilitate wiring 3 Install room thermostat according to instructions provided with thermostat 4 Install a separate disconnect switch protected by either fuse or circuit breaker near the unit so power can be turned off for servicing 5 Before connecting thermostat or power wiring check to make sure wires will be long enough to facilitate servicing at a later date Remove blower access panel and swing panel to check wire length for access Page 9 of 26 10 Complete wiring connections to equipment using wiring diagrams provided with unit and in field wiring diagrams shown in figures 5 Use 18 gauge wire or larger for thermostat connections Electrically ground unit in accordance with local codes Three 240 volt accessory terminals are provided on the contr
6. all flue product carrying areas and materials external to the furnace i e vent terminals etc are clear and free of any obstruction slope upward and have no holes or leaks Check to see that the furnace cabinet is sound and firmly supported without sagging There should be no cracks or gaps between the furnace and the base or floor which would permit entry of unfiltered air It is important that the outside area where the vent terminates is kept clear of any obstructions which might block or impede the venting of the furnace Should venting become blocked at anytime your furnace is equipped with a special safety control to prevent operation of the furnace until the condition has been corrected Contact your dealer if you desire more information about this safety feature Should any unusual conditions be observed during your inspections call an authorized service dealer immediately For proper venting terminations see the Installation Instructions furnished with the furnace Return Air Ascertain that all return air duct connections are tight and sealed to the furnace cabinet and that all return air grilles or registers are located outside the space containing the furnace Cleaning Replacing the Filter It is very important to clean or replace the air filter regularly Dirty filters are the most common cause of inadequate heating or cooling performance and can sharply increase the operational costs of your unit In some
7. cases they can double the cost The air filter should be inspected at least every 6 weeks and cleaned or replaced as required Your furnace may use either a disposable filter or a permanent filter The type of filter may be indicated on a label attached to the filter If a disposable filter is used replace with the same type and size If a permanent filter is used clean filter and place back in furnace To clean a permanent filter shake filter to remove excess dirt and or use a vacuum cleaner Wash filter in soap or detergent water and replace after filter is dry Permanent filters do not need to be oiled after washing Permanent filters may be replaced with disposable filters 20541401 Issue 0230 Refer to Table 1 when selecting the proper size and quantity of disposable filter If your air distribution system has a central return air filtergrille you do not need a filter in your furnace Clean the filter grille the same way permanent filters are cleaned Table 1 EXTERNAL FILTER RACK SIZE SIDE RETURN BOTTOM END RETURN 394 X 635 305 X 635 394 X 635 394 X 635 394 X 635 483 X 635 Note Filters not supplied Safety Interlock Switch The blower compartment door on your furnace is equipped with a safety interlock switch that will automatically shut off your complete system including blower once the door is removed This is for your personal safety Be sure to check your furnace for proper operation once the d
8. local telephone directory under the Heating Equipment or Air Conditioning Contractors amp Systems headings for dealer listing or see the first page of the installation instruction section of this manual for the name and address to contact Have available the Model No and Serial No located on the unit rating label located on the furnace to insure correct replacement part WARNING Improper installation adjustment alteration service or maintenance can cause personal injury or property damage Consult a qualified installer service agency or your local gas supplier for information or assistance 20541401 Issue 0230 Page 6 of 6 G34E G34EV EXTERNAL ee SERIES GAS FURNACES RNATIONAL PROV INSTALLATION AND SERVICING INSTRUCTIONS TABLE OF CONTENTS cia Leila E INN Lei 1 Electrical illa Biala lla Lal 8 Furnace SpecificatiONS i 2 Wining Diagrams isminin adas peene 10 Installation Equipment aaa 3 Start Uber 11 D ct System meone aed pado ae 4 Unit Adjustments reete tentent 13 Installing Optional Cooling Coil 4 Service Procedures spisanie T au Enean e u hai 8 14 Ventingi amp Fl elrig uu uu root aaa naha sta 5 Pants LISTINGS assioni ii 16 Setting up Procedures 8 cott ei 6 Coil Fitting Instructions hed nasties ee ebore tera
9. passages and flue box for corrosion If necessary clean as outlined below 1 Turn off the electrical power and gas supply to the furnace 2 Disconnect the wiring to the combustion air fan 3 Remove the screws securing the flue box to the furnace Clean the flue box with a wire brush brass bristle brush recommended 4 Disconnect the gas supply piping and the igniter and sensor wires Remove the burner assembly from the furnace 5 Reinstall the flue box using a new gasket 6 Reconnect the combustion air fan wiring 7 Reinstall the burner box igniter and sensor wires and the gas supply piping 8 Carefully check all piping connections factory and field for gas leaks Use a leak detecting solution or other preferred means AIMPORTANT Some soaps used for leak detection are corrosive to certain metals Carefully rinse piping thoroughly after leak test has been completed Do not use matches candles flame or other sources of ignition to check for gas leaks 9 Restore electrical power and gas supply Follow lighting instructions on front of unit Check burner flame and adjust if necessary Page 16 of 26 REPAIR PARTS LIST The following repair parts are available through independent Lennox dealers When ordering parts include the complete furnace model number listed on the unit rating plate Example G24E3 75 CABINET PARTS ELECTRICAL PARTS BLOWER PARTS Front louver door Transformer Blower wheel Bl
10. set 4 lf the furnace still does not start call your service technician AWARNING Should the gas supply fail to shut off or if overheating occurs shut off the gas valve to the furnace before shutting off the electrical supply Page 3 of 6 Maintenance Of Your Furnace AWARNING Always shut off all power to the unit before following attempting any of the maintenance procedures Failure to do so may result in personal injury There are routine maintenance steps you should take to keep your furnace operating efficiently This maintenance will assure longer life lower operating costs and fewer service calls In addition to the maintenance procedures listed in this manual there are also other service and maintenance procedures that require the skills of a service person who has specialized tools and training See Servicing the Furnace section of the Installation and Servicing part of this booklet Personal injury can result if you are not qualified to do this work Please call your dealer when service is needed Cleaning The cabinet of the furnace can be cleaned with soap and water Grease spots can be removed with a household cleaning agent The cabinet can be kept attractive by polishing with automotive wax at least twice a year Installations Around Insulation Insulating materials may be combustible Therefore a furnace installed in an attic or other insulated space must be kept free and clear of in
11. the furnace can result in fire or explosion A qualified service agency should be contacted to inspect the furnace and to replace all gas controls control system parts electrical parts that have been wet or the furnace if deemed necessary WARNING The furnace area must be kept clear and free of combustible materials gasoline and other flammable vapors and liquids Failure to do so could cause actions that may result in property damage personal injury or loss of life Operating Your Furnace Lighting Instructions 1 STOP Read the previous safety information 2 Set the thermostat to the lowest setting 3 Turn off all electric power to the furnace 4 Remove the burner compartment access panel 5 This appliance is equipped with an automatic ignition device Do not try to light the burners by hand 6 Move the gas control switch to OFF see Figure 1 Figure 1 Gas Control Diagram PRESSURE REGULATOR ADJUSTMENT UNDER CAP SCREW INLET PRESSURE TEST SPIGOT WIRING TERMINALS 2 GAS CONTROL KNOB F0000319 7 Wait 5 minutes to clear out any gas Then smell for gas including at the bottom of the unit near the ground If you smell gas stop and follow the directions in What to do if you smell gas on page 1 If you don t smell gas continue to next step 8 Move the gas control switch to ON 9 Replace the burner compartment access panel 10 Turn on all electric power to
12. the shipping bolt and washer are removed the rigid leg will not touch the fan housing Select a unit location that will allow for required clearances per local AG 601 codes and in figure 1 Also consider gas supply connections electrical supply vent termination and installation and service clearances 600mm front Accessibility and service clearances must not take precedence over fire protection clearances The Lennox G34E EV furnace should be set on a field provided platform to keep the unit base out of water The unit is equipped with base rails which lift the bottom of the unit off of the platform Unit must be leveled using shims or leveling bolts Knockouts are provided in unit base to install field provided leveling bolts Page 5 of 26 DUCT SYSTEM The unit is provided with knockouts for either right or left side connection of the supply and return air plenums Refer to the dimensioned drawing on page 2 to locate and size the plenum entry into the side of the building Cover plates are provided to seal the unused knockouts and these become convenient access ports for regular service and maintenance Size and install supply and return air duct system using industry approved standards that result in a quiet and low static system with uniform air distribution The furnace access panel must always be in place when the unit is in operation and it must not allow leaks into the duct system Construct a protective covering m
13. tightness and to make sure there is no blockage D BURNERS Burners and burner flame should be inspected at the beginning of each heating season Clean burners if necessary as indicated below 1 Turn off electrical and gas supply to unit 2 Disconnect gas supply piping and remove gas manifold 3 Disconnect igniter and flame sensor leads 4 Remove burner tray and burners 5 Clean the inside of each burner with a bottle brush as shown figure 12 Cleaning Burners BOTTLE BRUSH Figure 14 6 Replace burners and burner tray making sure burners are properly seated in slots on tray and orifice in manifold 7 Check electrode gap using appropriately sized twist drills or feeler gauges Gap should be between 0 110 and 0 140 inches 2 79 to 3 56mm 8 Reinstall burner box and gas supply piping Reconnect igniter and flame sensor leads 9 Carefully check all piping connections factory and field for gas leaks Use a leak detecting solution or other preferred means A IMPORTANT Some soaps used for leak detection are corrosive to certain metals Carefully rinse piping thoroughly after leak test has been completed Do not use matches candles flame or other sources of ignition to check for gas leaks 10 Restore electrical power and gas supply Follow lighting instructions on front of unit Check burner flame and adjust if necessary HEAT EXCHANGER Periodically inspect heat exchanger
14. to be a source of ignition 5 For appliances not addressed above approval shall be obtained from the Authority Page 6 of 26 GENERAL G34E amp EV SERIES THERMOSTAT INSTALLATION Install a room thermostat according to the instructions furnished with it Select a location on an inside wall and not subject to drafts direct sunshine or other heat sources The initial heat anticipator setting should be equal to the total current draw of the control circuit Low voltage thermostat connections are to be made as indicated on the furnace 2 STAGE wiring diagram FURNACE CHECK OUT Before leaving the installer should make the following checks to ensure that the controls are functioning properly CHECKING AND ADJUSTING GAS INPUT The minimum permissible gas supply pressure for the purpose of input adjustment is 5 in W C 1 25 kPa for natural gas 11 in W C 2 74 kPa for propane gas GAS PRESSURE REGULATOR Gas input must never exceed the value shown on the furnace rating plate The furnace is equipped for rated input at manifold pressures of 1 2 in W C 0 30 kPa 1st stage and 3 5 0 87 kPa 2nd stage for natural gas 3 6 in W C 0 90 kPa 1st stage and 10 0 in W C 2 49 kPa 2nd stage for propane gas The manifold pressure can be measured by connecting a water manometer or gauge to the pressure tap in the downstream side of the gas valve Only small variations in gas input may be made by adjus
15. 0 jar f e IND 1109 S0Y qm m 1a HOUINS 38 51380 d wa DIO 1 ONE Page 23 of 26 UT IGNITION TROUBLE SHOOTING WITH LED INDICATOR ASSISTANCE LED Flash Code Indicates Check Repair S OFF Control not powered or gas valve control failure 1 Line voltage input power at L1 and L2 connectors on IFC Board 2 Low voltage 24Vac power at 24VAC and COM on IFC board 3 Fuse open on IFC board 4 System wiring harness in good condition and securely connected at both ends 6 Control not functioning replace Heartbeat Normal Operation Standby Fast Call for heat Heartbeat 2 Flashes Ignition re try or recycle error 1 Gas supply off or supply pressure too low to operate appliance 2 Damaged or broken spark element 3 Appliance power supply not properly earth grounded 4 Flame sense rod contaminated grounded to appliance chassis or in incorrect location 5 Spark element or flame sense wiring not properly connected 6 Gas valve stuck replace 7 Move gas control switch to ON 3 Flashes Pressure switch closed when should be 1 Pressure switch stuck closed open system waits until pressure switch 2 Pressure switch miswired jumpered or tubing open opens then proceeds with ignition 3 Pressure switch captured or out of calibration sequence Pressure switch or aux limit replace was still open 60 seconds after the inducer 4 Inducer and inducer wiring not c
16. AS CONTROL FAILED FLAME SENSE 5 TIMES CONSECUTIVELY DURING ONE HEAT DEMAND IF YES SYSTEM GOES INTO A HARD LOCKOUT REMOVE POWER TO RESET CONTROL DIAG CODE 1 ALT FLASHING 2 ALT FLASHING IF NO GO TO COMB AIR BLOWER ON GAS VALVE OFF COMB BLOWER OFF INDOOR BLOWER ON UNTIL LIMIT CLOSES DIAG CODE 1 FLASHING 2 ON LIMIT OPEN IS LIMIT NOW CLOSED HAS PRIMARY LIMIT OPENED 5 TIMES DURING ONE UNSATISFIED HEAT DEMAND IF YES SYSTEM GOES INTO 60 MIN WATCHGUARD DIAG CODE 1 FLASHING 2 ON IF NO GO TO COMB AIR BLOWER ON GAS VALVE COMB BLOWER AND INDOOR BLOWER WITH DELAY OFF DIAG CODE 1 OFF 2 FLASHING NO C A B PRESSURE SWITCH OPEN HASC A B RESSURE SWITCH CLOSED IN 2 5 MINUTES Page 20 of 26 COOLING SEQUENCE OF OPERATION NORMAL COOLING MODE ABNORMAL COOLING MODE GAS VALVE OFF COMBUSTION AIR BLOWER OFF IGNITION CONTROL MAIN POWERON INDOOR BLOWER OFF WITH NORMAL DELAY SIGNAL CIRCUIT BOARD FAILURE AT LED O INTERRUPT MAIN POWER TO RESET CONTROL CONTROL SELF DIAGNOSTIC CHECK IS CONTROL OPERATING NORMALLY YES GAS VALVE OFF COMBUSTION AIR BLOWER OFF ROLLOUT SWITCH MONITORE D CONTINUOUSLY INDOOR BLOWER OFF WITH NORMAL DELAY IS ROLLOUT SWITCH CLOSED ii SIGNAL CIRCUIT BOARD FAILURE AT LED vm SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES ER GAS VALVE OFF COMBUSTION AIR BLOWER OFF 1S MAIN BURNER FLAME OFF INDOOR BLOWER OFF WITH NORMAL DELAY SIGNAL CIRCUIT BOARD FAILUR
17. CT CONNECTIONS AND ACCESS HATCHES ARE INTERCHANGEABLE FROM SIDE TO SIDE Page 3 of 26 FURNACE BLOWER SPECIFICATIONS AND AIR FLOW DATA BLOWER SYSTEM BLOWER EXTERNAL STATIC IN W C pa SPEED 0 6 150 0 7 175 0 8 200 0 9 225 1 0 250 G34E EVQ3 50 LOW 270 241 214 185 157 254 X 152 WHEEL MED 418 386 353 318 1 3HP MOTOR HIGH 416 G34E EVQ3 80 254 X 152 WHEEL 1 3HP MOTOR G34E EVQ4 80 305 X 228 WHEEL 1HP MOTOR G34E EVQ4 110 305 X 228 WHEEL 1HP MOTOR G34E EVQ5 110 305 X 305 WHEEL 1HP MOTOR G34E EVQ5 130 305 X 305 WHEEL 1HP MOTOR NOTES 1 Air flow values in L s 2 Data taken without filters in place or A C evaporator in place WARNING When operating the furnace in the heating mode the static pressure and the temperature rise supply air temperature minus return air temperature must be within those limits specified on the rating label Failure to follow this warning could lead to severe furnace damage A WARNING Turn OFF all gas and electrical power to furnace before performing any maintenance or service on unit Unless specific test requires gas and electrical supplies Failure to take this precaution may result in personal injury due to electrical shock or uncontrolled gas leakage Page 4 of 26 SHIPPING AND PACKING LIST Package 1 of 1 contains 1 Assembled unit 1 Flue adapter cowl field
18. E AT LED SEQUENCE HOLDS UNTIL FLAME IS NOT SENSED LED SLOW FLASH RATE REMAINS UNCHANGED THROUGHOUT COOLING CYCLE THERMOSTAT CALLS FOR COOLING COMPRESSOR CONTACTOR AND SYSTEM FAN ENERGIZED WITH 0 SECOND DELAY ACB COOL SPEED IS ENERGIZED ACC TERM ENERGIZED THERMOSTAT OPENS Y COMPRESSOR OFF SYSTEM FAN AND ACC TERM OFF WITH 0 SECOND DELAY CONTINUOUS LOW SPEED FAN SEQUENCE OF OPERATION LED Slow flash rate REMAINS UNCHANGED THROUGHOUT SEQUENCE CONTINUOUS FAN SELECTION MADE AT THERMOSTAT CONTROL ENERGIZES SYSTEM FAN AT CONTINUOUS SPEED ACC TERMINAL ENERGIZED 1 THERMOSTAT CALLS FOR HEAT NO YES SYSTEM FAN SWITCHES TO HEATING SPEED AFTER THERMOSTAT Gon FORCOONING SELECTED DELAY ACC TERM REMAINS ENERGIZED l ves NO SYSTEM FAN SWITCHED TO COOLING SPEED ACC TERMINAL REMAINS ENERGIZED THERMOSTAT SYSTEM FAN SWITCHED OFF AFTER THERMOSTAT OPENS DELAY ACC TERMINAL DE ENERGIZED SYSTEM FAN SWITCHES TO CONTINUOUS SPEED AND ENERGIZES ACC TERMINAL BOTH REMAIN ON UNTIL CONTINUOUS FAN IS SWITCHED OFF AT THERMOSTAT Page 21 of 26 EGC 3A INTEGRATED CONTROL BOARD RED DIAGNOSTIC BUTTON Depress button and hold for DIAGNOSTICS LEDS display of last failure code Beee ERASE JUMPER Remove power to control and short pins for 10 seconds to erase previo
19. ER hi INDOOR BLOWER MOTOR Page 11 of 26 Figure 9 U T Ignition Module IGN BOARD 24V TO THERMOSTAT C MAY NOT BE REQUIRED 24 VAC P2 R F dPI P2 G 2 240V 5E x PAY Ti c U 24V DPI P2 CX BK WH L SPARK C 700994 2R05665 lt ELECTRODE GAS VALVE 2 STAGE FLAME SENSOR A DO e 3 PIN PLUG DO a gt P TO AND CORD L1 240V N 701081 E CMB C BLWR HUM ACC ACC COOL LO HEAT QD W2 RELAY 2 5 NDUCER BLUE E ON FE OO INDOOR RN gt BLOWER CO Nc MOTOR GEN WH BK UNIT START UP FOR YOUR SAFETY READ BEFORE LIGHTING A CAUTION WARNING Before attempting to perform any service or Do not use this furnace if any part has been underwater Immediately call a qualified service technician to mSpect the turnace and to BEFORE LIGHTING smell all around the appliance area any part o
20. FLAME SENSOR E CMB ACB ACB ACB BLWR HUM ACC ACC COOL LO HEAT E LED FAULT CODES es BLOWER STEADY OFF NO POWER HEARTBEAT NORMAL OPERATION FAST HEARTBEAT CALL FOR HEAT 2 FLASHES GAS VALVE LOCKOUT 3 FLASHES PRESSURE SWITCH CLOSED OR OPEN 4 FLASHES HIGH LIMIT OPEN 5 FLASHES FLAME SENSE WITH GAS VALVE OFF BK BLACK GR GREEN VI VIOLET BL BLUE OR ORANGE WH WHITE BR BROWN RD RED YL YELLOW Figure 8 U T Ignition Module IGN BOARD 24V TO THERMOSTAT C PIE NOT BE REQUIRED gt P1 DPI Pe 240V P2CYX 24V DP BK WH LE dei 700994 2R05665 lt ELECTRODE GAS VALVE x 2 STAGE FLAME SENSOR SO bn 3 PIN PLUG DO gt a HUM AND CORD L1 240V ga GND N 24VAC gt 701081 E CMB UN C BLWR HUM ACC ACC COOL USED HEAT Ge 1 2 W2 RELAY 6 m NDUCER BLOW
21. MOSTAT HEAT ANTICIPATION Set thermostat heat anticipation to 0 50 amps White Rodgers gas valves 0 70 amps Honeywell gas valves ELECTRICAL 1 Check all wiring for loose connections 2 Check for correct voltage at unit unit operating 3 Check amp draw on blower motor Motor Nameplate Actual BLOWER SPEEDS Note CFM Ls readings are taken external to unit with a dry evaporator coil and without accessories 1 Turn off electrical power to furnace 2 Disconnect existing speed tap at control board speed terminal NOTE TERMINATION OF ANY UNUSED MOTOR LEADS MUST BE INSULATED 3 Refer to blower speed selection chart on unit wiring diagram for desired heating or cooling speed 4 Connect selected speed tap at control board speed terminal 5 Turn on electrical power to furnace Page 14 of 26 UNIT ADJUSTMENTS CONT FLUE 1 Check flue termination and all connections for tightness and to make sure there is no blockage 2 Check unit for proper draft 3 Is pressure switch closed Obstructed flue will cause unit to shut off at pressure switch Check flue and outlet for blockages 4 Reset manual flame rollout switches on burner box cover BURNER FLAME ADJUSTMENT The G34E EV burner flame is not adjustable however the flame should be inspected at the beginning of each heating season and burners should be cleaned if necessary Burner flame should be blue when burning natural gas blue yellow whe
22. NSION VALVE 2 COVER PLATE BULB FIX AFTER WELDING 2 viva col A LIQUID LINE A Z SUGTION LINE OVERFLOW IRAIN Val v VA n FURNATE CORNER POST OR Back PLATE 42 APPLICABLE 4 i Z G34 SHOWN WITH TOP AND END PENOVED Ces 51 65 COIL 2 RUN 3 4 POLY DRAIN TO SAFE LOCATION IF UNIT IS FITTED INTERNALLY INSTALL A SAFETY TRAY UNDER THE WHOLE FURNACE AND DRAIN SEPARATELY TO SAFE LOCATION LIQUID LINE SUCTION y y caver POTE Vu ey UEPLIEE vera con x lt eic EXPANSION VALVE k 54 BULE FIX AFTER WELDING VY OA 7 4 Li 0 0 DVERFLOW 4 DRAIN 5 x lt ie FURNACE CORNE PLATE AD APPLICABLE 9 4 0 G34 SHOWN WITH TOP AND END REMOVED C23 41 AND SMALLER COILS Page 19 of 26 TROUBLESHOOTING HEATING SEQUENCE OF OPERATION NORMAL HEATING MODE CONTROL MAIN POWER ON FLAME OFF CONTROL SELF CHECK OKAY Y YES ROLL OUT SWITCH CLOSED a Y YES LED SLOW FLASH RATE THERMOSTAT CALLS FOR HEAT ABNORMAL HEATING MODE GAS VALVE OFF COMB BLOWER ON INDOOR BLOWER ON HEAT SPEED SEQUENCE HOLDS UNTIL NO FLAME SENSED OR MAIN POWER IS INTERRUPTED AND RESET DIAG CODE 1 FLASHING 2 OFF FLAME SENSED WITHOUT VALVE ENERGIZED GAS VALVE COMB BLOWER AND
23. USER S MANUAL GAS FURNACES 50 Hz A G34E G34EV G34E G34EV A EEE lt EXTERNAL SERIES GAS FURNACE NOVEMBER 2003 RNATIONAL PRO USER S INFORMATION MANUAL INSTALLER AFFIX THIS INSTRUCTION PACKET ADJACENT TO THE FURNACE HOMEOWNER RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE LENNOX HEATING amp AIR CONDITIONING DIVISION OF HEATCRAFT AUSTRALIA PTY LTD Note Due to an ongoing commitment to quality and design improvements specifications ratings and dimensions are subject to change without notice and without liability Heatcraft Australia Pty Ltd 2003 Owner Record Furnace Model Serial Installation Date INSTALLED BY Dealer Address Telephone Contact Person Other Equipment Installed Equipment Type Model Equipment Type Model Equipment Type Model Licence Installation Date Serial Installation Date Serial Installation Date Serial USER S INFORMATION MANUAL Gas Fired Furnace READ ALL INSTRUCTIONS IN THIS MANUAL AND RETAIN THIS AND ALL ADDITIONAL INSTRUCTIONS FOR FUTURE REFERENCE Congratulations you have one of the most modern gas furnaces made Your unit has been carefully selected to keep you warm and comfortable during the winter months It will deliver superb performance with only minimal help from you To keep your operating costs low and to eliminate u
24. ade of suitable materials to shield the plenum connections from rain Rain shield should be attached to the side of the unit cabinet above the plenum connections and span the distance to the building wall above the plenum entry into the structure Rain shield connections must be caulked so that they are weather tight INSTALLING OPTIONAL COOLING COIL If optional cooling coil is to be used install coil according to the steps indicated below 1 Remove G34E EV unit rear panel side panel on G34E EV130 NOTE Installation of larger evaporator coils may require removal of unit top panel as well 2 Place cooling coil on unit coil deck in cooling compartment 3 Using template provided with the coil cut holes for refrigeration and drain piping Align coil with piping holes in panel Seal holes around piping 4 Reinstall G34E EV panel 5 Make refrigerant piping connections to condensing unit per local codes and sound plumbing practices VENTING The G34E unit is shipped standard for top flue discharge A flue adapter is supplied with the furnace It must be installed on the outside of the furnace Figure 1 FLUE TERMINATION CLEARANCES A E k ta 9 d Hl C m T 2 b h g t N furnace T Flue terminal M Gas meter Shading Indicates prohibited Mechanical air inlet P Electricity meter or fuse box areas for flue termination
25. al performance from your gas furnace Combustion Air WARNING Adequate combustion and ventilation air must reach your gas furnace to provide for proper and safe operation Do not block or obstruct air openings on the furnace air openings communicating with the area in which the furnace is instaled and the spacing around the furnace Any obstruction of this airflow can cause an unsafe condition which may result in death or permanent injury Furnaces located in a closet alcove or utility room must have provision for adequate air supply by means of upper and lower grilles in the door or by the introduction of outside air or both AGA codes must be adhered to Flueing and Furnace Support Flueing of this furnace must comply with our published instructions Be sure the installer has followed these requirements If not you should request the installer to comply as soon as possible For your safety please note the following 1 Non condensing furnaces may be common vented with another appliance in certain circumstances Refer to the installation instructions Refer to the installation instructions and AGA 601 code for proper installation guidelines Page 4 of 6 The vent from your furnace may rise vertically and terminate above the roof When horizontal flueing a non condensing furnace an approved flue cowl must be used Refer to the installation instructions for further information on horizontal flueing Make sure
26. f the control system and any gas for gas Be sure to smell next to the floor because some control which has been under water gas is heavier than air and will settle on the floor maintenance turn the electrical power to unit OFF at disconnect switch Use only your hand to turn the gas control knob Never use tools If the knob will not turn by hand A WARNING do not try to repair it call a qualified service technician If overheating occurs or if gas supply fails to Force or attempted repair may result in a fire or shut off shut off the manual gas valve to the explosion appliance before shutting off electrical supply Page 12 of 26 UNIT START UP CONT PLACING UNIT INTO OPERATION G34E EV units are equipped with a direct spark ignition system Do not attempt to manually light burners on these furnaces Each time thermostat calls for heat the burners will automatically light AWARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life GAS VALVE OPERATION Figures 8 and 9 WHITE RODGERS 36E SERIES GAS VALVE N MANIFOLD PRESSURE ADJUSTMENT SCREW MANIFOLD PRESSURE OUTLET 74 GAS VALVE SHOWN IN OFF POSITION Figure 10 HONEYWELL VR8205 SERIES GAS VALVE MANIFOLD PRESSURE ADJUSTMENT MANIFOLD SCREW PRESSURE OV OUTLET GAS VALVE SHOWN IN OFF POSITION Figure 11 1 STOP Read the safety informati
27. installed 2 Starting collars The following additional items may be ordered separately if required 1 Cooling coil 1 Thermostat 1 LP Changeover kit Check unit for shipping damage Receiving party should contact last carrier immediately if any shipping damage is found GENERAL These instructions are intended as a general guide and do not supersede local codes in any way Consult AGA AG 601 INSTALLATION CODE or authorities having jurisdiction before installation The G34E EV furnace is approved for installation outside the building only with clearances as listed in figure 1 Installation of Lennox outdoor central furnaces must be in accordance with these instructions local gas fitting regulations municipal building codes electrical wiring regulations and the current edition of the Australian Gas Installation Code AG 601 The following general recommendations should be considered when installing the Lennox G34E EV furnace LOCATION PLACEMENT The Lennox G34E EV can be installed in either right or left hand mode NOTE On some models 1 3 and 1 2 hp blower motors are equipped with either four flexible mounting legs or three flexible legs and one rigid leg The rigid leg is equipped with a shipping bolt and a flat white plastic washer rather than the rubber mounting grommet used with a flexible mounting leg This shipping bolt and flat washer must be removed before the furnace is put into operation Once
28. ion This requirement is negated if the gas valve in the unit is fitted with an integral pressure tapping point NOTE If emergency shutoff is required shut off main manual gas valve and disconnect main power to unit These devices should be properly labelled by the installer LEAK CHECK After gas piping has been completed carefully check all piping connections factory and field for gas leaks Use a leak detecting solution or other preferred means A CAUTION Some soaps used for leak detection are corrosive to certain metals Carefully rinse piping thoroughly after leak test has been completed Do not use matches candles flame or other sources of ignition to check for gas leaks 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 equal to or less than 1 2 psig 3 48 kPa AIMPORTANT When testing pressure of gas lines gas valve must be disconnected and isolated See figure 4 Gas valves can be damaged if subjected to more than 1 2 psig 3 48 kPa MANUAL MAIN SHUT OFF VALVE WILL NOT HOLD NORMAL TEST PRESSURE FURNACE Figure 4 Page 8 of 26 ELECTRICAL ELECTROSTATIC DISCHARGE ESD Precautions and Procedures A CAUTION Electrostatic discharge can affect electronic components Take precautions during furnace installation and service to protect the furnace s electronic controls
29. knob on White Rodgers gas valve 180 either way to OFF turn knob on Honeywell valve clockwise to OFF Do not force 5 Replace the access panel HEATING SEQUENCE OF OPERATION 1 When thermostat calls for heat combustion air blower starts after a 5 second delay 2 Combustion air pressure switch proves blower operation and then allows power to ignition control Switch is factory set and requires no adjustment 3 After 15 second prepurge spark igniter energizes and gas valve solenoid valves open 4 Spark ignites gas ignition sensor proves the flame and combustion process continues 5 If flame is not detected after first ignition trial ignition control will repeat steps 3 and 4 four more times before locking out To re establish ignition UNIT ADJUSTMENTS PRIMARY LIMIT The primary limit is located on the heating compartment vestibule panel This limit is factory set and does not require field adjustment FLAME ROLLOUT SWITCHES TWO These manually reset switches are located just above the burner box If tripped a check for adequate combustion air should be made before resetting COMBUSTION AIR PRESSURE SWITCH The combustion air pressure switch is located on the heating compartment vestibule panel This switch checks for proper combustion air blower operation before allowing ignition trial The switch is factory set and requires no field adjustment FAN TIMER CONTROL The fan control is part of the co
30. n burning propane gas BURNER FLAME FLAME APPEARS BLUE IF BURNING NAT GAS BLUE YELLOW FOR PROPANE Figure 13 FAILURE TO OPERATE If unit fails to operate check the following 1 Is thermostat calling for heat 2 ls main disconnecting switch closed 3 Is there a blown fuse or tripped circuit breaker 4 15 filter dirty or plugged Dirty or plugged filters will cause unit to go off on limit control 5 Is gas turned on at meter 6 Is manual main shut off valve open 7 ls internal manual shut off valve open 8 Is unit ignition system in lock out If unit locks out again call serviceman to inspect unit for blockages SERVICE AWARNING Disconnect power before servicing unit At the beginning of each heating season the system should be checked as follows A ELECTRICAL 1 Check all wiring for loose connections 2 Check for correct voltage at unit unit operating 3 Check amp draw on blower motor Motor Nameplate Actual Page 15 of 26 B BLOWERS Check and clean blower wheels for any debris Blower motors are prelubricated for extended bearing life No further lubrication is needed WARNING The blower access panel must be securely in place when the blower and burners are operating Gas fumes which could contain carbon monoxide can be drawn into living space resulting in personal injury or death SERVICE CONT C FLUE TERMINATION Check flue termination for
31. nly with type of gas approved for this furnace Refer to the furnace rating plate Install this furnace only in a location and position as specified in The Location Placement Section on page 4 of these instructions Never test for gas leaks with an open flame Use a commercially available soap solution made specifically for the detection of leaks to check all connections as specified in the Gas Piping section on page 7 of these instructions Always install furnace to operate within the furnace s intended temperature rise range with a duct system which has an external static pressure within the allowable range as specified in Furnace Specifications on page 3 of these instructions See furnace rating plate The furnace is not to be used for temporary heating of buildings or structures under construction Page 2 of 26 G34E EV FURNACE SPECIFICATIONS DIMENSIONS mm MODEL G34E EVQ3 80 G34E EVQ4 80 G34E EVQ4 110 G34E EVQ5 110 G34E EVQ5 130 OPTIONAL DUCT FLASHING KIT FITS EITHER SIDE FLUE TERMINAL PART 700960 REFRIGERATION ACCESS PLATE 050 080 110 130 amp CONDENSATE DRAIN CONNECTIONS 150 BACK VIEW 050 080 90 110 130 130 FLUE TERMINAL 050 080 35 L10 130 45 FLUE TERMINAL REGISTRATION ACCESS PLATE L10 L30 amp CONDENSATE DRAIN CONNECTIONS DUCT CONNECTIONS GAS ELECTRICAL CONNECTION INLETS 3 4 FRONT VIEW 16 NOTE DU
32. nnecessary service calls we have provided a few guidelines These guidelines will help you understand how your gas furnace operates and how to maintain it so you can get years of safe and dependable service AWARNING FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury death or property damage Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance What to do if you smell gas Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Leave the building immediately Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier TABLE OF CONTENTS SAFETY OPERATING YOUR FURNACE Lighting Instructions Temperature Control Fan Operation MAINTENANCE OF YOUR FURNACE Periodic Inspections Cleaning Replacing the Filter Parts Replacement Guide 20541401 Issue 0230 Page 1 of 6 For your safety Read before operating Here are a few Do s and Don ts Do become familiar with the instructions Do check to see that your home has adequate insulation weatherstripping caulking and storm windows Elimination of infiltration of outside air and drafts can save u
33. ntrol board located on the heating compartment vestibule panel The preset fan on delay time of 45 seconds is not adjustable The fan off delay time is factory adjusted at 120 seconds and can be adjusted by moving the jumper on the integrated control board See figure 10 for settings EGC board only FAN OFF TIME To adjust fan off Remove timing jumper and select one of the other pin combinations to achieve desired time TIMING PINS seconds Figure 12 Note EGC Ignition Board Only GAS FLOW To check for proper gas flow to combustion chamber determine Btu input from appliance rating plate Divide this input rating by the Btu per cubic foot of available gas Result is the required number of cubic ft per hour Determine the flow of gas through gas meter for two minutes and multiply by 30 to get the hourly flow of gas GAS PRESSURE 1 Check gas line pressure with unit firing at maximum rate A minimum of 1 13 kPa for natural gas or 2 75 kPa for LP propane gas should be maintained 2 After line pressure has been checked and adjusted check regulator pressure Refer to the unit rating plate for manifold pressure settings See figures 8 and 9 for manifold pressure adjustment screw location A natural gas to LP propane gas changeover kit is required to convert unit TEMPERATURE RISE Check temperature rise and if necessary adjust blower speed to maintain temperature rise within range shown on unit rating plate THER
34. ntroom or other internal location This kit must be installed to prevent overheating of components due to high ambient environments T 2 Remove furnace access door Remove 2 rainshields from back of door Attach appropriate new wiring diagram and lighting instructions Remove 2 rainshields from side of furnace as shown below Remove existing weatherproof lid and discard Replace lid with New vented lid supplied Be sure to peel off plastic coating if present Replace modified door If cooling coil is fitted a safety drain is recommended under the entire unit drained to a safe location especially in ceiling applications This optional part must be ordered separately RAIN SHIELDS FROM FURNACE SIDES NEW LID Page 18 of 26 COIL FITTING INSTRUCTIONS CUTOUTS ESTABLISH CENTRES AND FIT INSULATION SQUARE ER PIPE oh I _ f USING 37mmd 7 16 HOLE HILE WELDING T USING COVER PLATE FROM COIL GUT 4 HOLES 5 ai PROTECT PAINTWDRK AS A TEMPLATE o BEES LINE UP INDICATED SCRE INSERT COIL THROUGH HOLES AND FIT CAUTION HOLES AND SCRIBE uis COVER PLATE SEALING AROUND PIPES FIT VALVE THERMAL BULB AFTER Se ELDIMG CLAMP AND IMSULATE FIT PIPE INSULATION AND GLUE TO CASING SEAL WATERTIGHT WITH SILICONE AS NECESSARY EXPA
35. ol board Two are energized with the indoor blower and one is energized with the combustion air blower Any accessory rated up to one amp can be connected to the accessory terminals with the neutral leg of the circuit connected to the 240 volt neutral wires This unit is equipped with an integrated control board that controls blower operation fan off timings EGC Board Only and ignition The board includes a terminal strip for thermostat connections and two diagnostic LEDs See figure 6 for control board configuration Diagnostic codes are given in a chart at the back of this manual The red diagnostic button can be used to view the last failure code EGC Ignition Board Only Refer to blower speed chart on wiring diagrams for factory set cooling heating and continuous fan speeds Systems using a cooling thermostat sub base may operate the blower continuously factory set at low speed through the thermostat FAN ON switch Systems which do not include a cooling sub base require a toggle switch which must be wired between terminals R and G on the thermostat connection terminal strip The blower motor will operate at the designated speed during cooling or heating demand however when demand is satisfied blower speed will revert to selected continuous speed Figure 5 TYPICAL G34 ELD WIRING DIAGRAM 4 CONTROL BOARD B TRANSFORMER C BOOR INTERLOCK 24V THERMOSTAT 240V CONNECTOR C MAY NOT
36. on at the beginning of this section 2 Set the thermostat to 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 access panel Page 13 of 26 6 White Rodgers 36E Gas Valve Turn knob on gas valve 180 either way to OFF See figure 8 Honeywell VR8205 Gas Valve Turn knob on gas valve clockwise 49 amp to OFF Do not force See figure 9 7 Wait five 5 minutes to clear out any gas If you then smell gas STOP Immediately call your gas supplier from a neighbour s phone Follow the gas supplier s instructions If you do not smell gas go to next step 8 White Rodgers 36E Gas Valve Turn knob on gas valve 180 either way to ON Honeywell VR8205 Gas Valve Turn knob on gas valve counterclockwise 4 to ON Do not force 9 Replace the access panel 10 Turn on all electrical power to unit 11 Set the thermostat to desired setting NOTE When unit is initially started steps 1 through 11 may need to be repeated to purge air from gas line 12 If the appliance will not operate follow the instructions Turning Off Gas To Unit and call your service technician or gas supplier TURNING OFF GAS TO UNIT 1 Setthe thermostat to the lowest setting 2 Turn off all electrical power to the unit if service is to be performed 3 Remove the access panel 4 Turn
37. onnected was energized System is in 5 minute delay 5 Low line voltage power supply mode with inducer on After 5 minute 6 Obstructions or restrictions in appliance air intake or delay new ignition sequence is initiated exhaust flue system that prevent proper combustion air flow 7 Circulating air blower not operating 8 Open auxiliary temperature limit 4 Flashes Limit or flame rollout switch open 1 Open high temperatures limit Combustion air blower is energized The 2 Open manual reset flame rollout switch in the limit heat speed circulating air fan will be circuit energized System waits for limit string to 3 Limit and rollout switch circuit wiring in good condition close then initiates a new ignition sequence and securely connected System will remain waiting until flame rollout 4 Circulating air fan wiring and operation manual reset is activated Dirty air filters Blower speed too low Registers closed 5 Flashes Flame signal sensed out of proper sequence Flame at main burner with flame signal still present Combustion Flame sense ground to chassis blower energized The heat speed circulation air fan will be energized after the selected heat fan on delay System waits for flame signal to disappear then goes to Soft Lockout Control board fault hard lockout 1 System wiring harness in good condition and securely connected at both ends 2 All components functioning properly i e inducer bl
38. oor or panel has been replaced If the system does not operate once the panel has been replaced try removing and replacing it once again If the furnace still does not operate call your dealer for service Rollout Switch This unit is equipped with a manual reset high temperature sensor or rollout switch In the unlikely event of a sustained main burner flame rollout the rollout switch will shut off the flow of gas by closing the main gas valve The switch is located inside the gas burner area Flame rollout can be caused by blockage of the power vent system a blocked heat exchanger or improper gas pressure or adjustment If this event occurs the unit will not operate properly The gas supply to the unit should be shut off and no attempt should be made to place it in operation The system should be inspected by a qualified service technician Lubrication Lubrication of the bearings in the circulating air blower motor and the combustion blower motor is not recommended Burner Flame While the furnace is in operation observe the mainburner flames Compare these observations to Figure 3 to determine if proper flame adjustment is present If your observations indicate improper flame adjustment call your authorized service dealer for service Page 5 of 6 HEAT EXCHANGER IH T GAS BURNER MANIFOLD FLAME F0000258 Blue Only Figure 3 Do not attempt to adjust flame Your service representati
39. ower ignitor 3 Replace IFC control board Soft Lockout more than 1 second or removing the thermostat call for The control shall not initiate a call for heat or call for heat for more than 1 and less than 20 seconds continuous fan while in lockout A call for cooling Hard Lockout operates as normal The control will still respond to an open limit and desired flame Lockout shall automatically reset after 1 hour Lockout may be manually reset by removing power from the control for If the control detects a fault on the control board the status LED will be energized steady and the control will lockout as long as the fault remains A hard lockout will automatically reset if the hardware fault clears Page 24 of 26 NOTES Page 25 of 26 NOTES Page 26 of 26
40. ower access panel Control board Direct Spark Motor Cabinet rear panel Ignition Cabinet top Door interlock switch Blower housing cut off plate Gas valve FLUE PARTS Motor capacitor Flame sensor Flue box Cabinet bottom Ignition cable Combustion air blower HEATING PARTS Direct spark omer Flue adapter rectangular to round Heat exchanger Flame rollout switch two Flue mounting plate Main burners bu batles Flue connector Main burner orifices Primary limit control Gasket Gas manifold Burner box assembly Pressure switch Wire harness plug cap EXTERNAL CABINET PARTS COIL DECK FLUE BAFFLES 75 only HEAT EXCHANGER ASSEMBLY Ss AS XX gt x gt NR AY AY YY gt lt iX SES SE x S amp S CSS 3 BURNER ASSEMBLY CONTROL BOARD BLOWER ASSEMBLY 9 H 3 TRANSFORMER BLOWER ACCESS DOOR INTERLOCK SWITC PANEL Page 17 of 26 IN ROOF VENTILATION KIT INSTALLATION PROCEDURE G34E EV 080 110 130 KIT MODEL 701115 701116 KIT CONTENTS New lid Old Model 80100350 80110350 New lid New Model 80100353 801103SN New wiring diagram G34E 532889W 532889W G34EV AUS71A AUS71A G34 532909W 532909W New lighting instructions G34 42J88 42J88 G34 58K8001 58K8001 Modification Sticker 701121 701121 OPTIONAL PART Drain tray 701118 701119 APPLICATION This kit is for applications where a G34E G34EV External weatherproof furnace is to be installed internally in a roofspace pla
41. p to 40 of your fuel bill Do consider adding a humidifier to your heating system Higher indoor humidity slows evaporation of perspiration making the home seem warmer Don t waste fuel by setting your thermostat too high Energy conservation experts recommend a daytime thermostat setting of 20 C with a lower setting at night Do lower the thermostat setting a few degrees if you expect to be away for more than a day Your normal temperature setting can then be restored more economically Don t turn off the furnace when you expect to be away for more than a day Instead lower the thermostat setting a few degrees You can then restore normal comfort level quickly and save fuel too Don t block registers with furniture Don t put a lamp TV or radio too near your thermostat This will cause it to give a false reading WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life These furnaces are equipped with an ignition device which automatically lights the burners Do not try to light the burners by hand If the switch will not move by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion Do not use this furnace if any part has been under water 20541401 Issue 0230 A flood damaged furnace is extremely dangerous Attempts to use
42. ssary adjust blower speed to maintain temperature rise within the range shown on the unit rating plate GAS PIPING GAS SUPPLY This unit is to be installed by a licensed gas plumber fully in accordance with AG601 installation regulations 1 This unit is shipped standard for centre installation of gas piping Piping can be converted for right side connection Simply connect gas supply to piping assembly 2 When connecting gas supply factors such as length of run number of fittings and furnace rating must be considered to avoid excessive pressure drop Unit connection at gas manifold is 1 2 in 12mm Size piping according to gas regulations 3 Gas piping must not run in or through air ducts clothes chutes chimneys or gas vents dumb waiters or elevator shafts 4 Piping should be sloped 6mm per 380mm upward toward the meter from the furnace The piping must be supported at proper intervals 2M using suitable hangers or straps 5 In some localities codes may require installation of a manual main shut off valve and union furnished by installer external to the unit Union must be of the ground joint type A IMPORTANT Compounds used on threaded joints of gas piping must be resistant to the actions of liquified petroleum gases NOTE Installer must provide a 1 8 in 3 mm N PT plugged tap in the field piping upstream of the gas supply connection to the unit Tap must be accessible for test gauge connect
43. sulating materials Make sure to examine the furnace area when the furnace is installed or additional insulation has been added Periodic Inspections Your gas furnace is designed to give many years of efficient satisfactory service However the varied air pollutants commonly found in most areas can affect longevity and safety Chemicals contained in everyday household items such as laundry detergents cleaning sprays hair sprays deodorizers and other products which produce airborne residuals may have an adverse affect upon the metals used to construct your appliance It is important that you conduct periodic physical inspections of your appliance paying special attention to the gas burner and the flue outlet from the furnace These components are located at the front of the unit A flashlight will be useful for these inspections Make one inspection prior to the beginning of the heating season and another during the middle 20541401 Issue 0230 Should you observe unusual amounts of any of the following conditions it is important that you call your authorized dealer at once to obtain a qualified service inspection Rust flakes or other deposits Coatings Corrosion Even if no unusual rust or other conditions are observed it is recommended that the furnace be inspected and serviced at least once per year by a qualified service technician Regular inspection and planned maintenance will assure many years of economic
44. tere nate 18 GaS PIPINO aerei 7 Trouble Shooting 19 RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE lt the information in this manual is not followed exactly a fire or explosion may result causing property damage n personal injury or loss of life Do not store or use petrol or other flammable vapors and liquids in the vicinity of this or any other appliance Installation and service must be performed by a qualified installer service agency or the gas supplier to AGA 601 installation codes Installation by an unqualified person may lead to equipment damage and or a hazardous condition which may cause bodily injury and harm and as such at the sole discretion of the manufacturer the entire warranty may be voided and be of no further force and effect DANGER Eleciric Shock Hazard Turn Off All Power Before Servicing WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Extinguish any open flame Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbour s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Page 1 of 26 SAFETY The following is a list of safety precautions and their locations in this manual These safety rules and precautions must be followed when installing this furnace 1 2 Use o
45. the furnace Page 2 of 6 11 Set the thermostat to the desired setting 12 1 the furnace will not operate follow the instructions in To Turn Off Gas to Furnace and call your service technician or gas supplier To Turn Off Gas to Furnace 1 Set the thermostat to the lowest setting 2 Turn off all electric power to the furnace if service is to be performed 3 Remove the burner compartment access panel 4 Move the gas control switch to OFF see Figure 1 Do not force 5 Replace the burner compartment access panel Temperature Control There are many types and styles of thermostats Yours may look different from the one pictured in Figure 2 depending on the type of thermostat and whether cooling was installed with the system However almost all thermostats perform the same basic functions described in the following section Thermostat Selector Switch Fan Switch Cooling if applicable amp p Heating Room or Temperature Temperature Setting Figure 2 Thermostat Operation There are two 2 switches located on the thermostat see Figure 2 One switch controls the heating and cooling if applicable functions The other switch is for FAN operation either continuous or automatic On the thermostat is the temperature range for the heating temperature and the cooling temperature desired To put the system into operation push the switch to either HEAT or COOL position After yo
46. ting the regulator In no case should the final manifold pressure vary more than 0 3 in W C 0 07 kPa from the above specified pressures Page 7 of 26 2 STAGE SET UP Turn the gas valve ON To adjust the regulator turn the adjusting screw on the regulator clockwise to increase pressure and input Counter clockwise to decrease pressure and input There are separate adjusting screws for 1st stage marked LO on top of solenoid coil and 2nd stage marked HI on outlet end of valve NOTE The pressure regulator adjustment is sensitive one turn of the adjusting screw will result in a relatively large change in manifold pressure If adjustments are being made for propane gas follow this procedure 1 Adjust high fire setting by turning hex adjustment screw full clockwise 2 Set low fire setting by turning the low fire adjustment screw clockwise located on top of 2nd stage coil to desired rate 3 Set high fire setting by turning the high fire adjustment screw counter clockwise to 10 0 in W C 2 49 kPa manifold pressure Important Make sure the final high and low fire manifold pressures are within the allowable ranges specified above for the gas being used Check the furnace rate by observing the gas meter when available making sure all other gas appliances are turned off The test hand on the meter should be timed for at least one revolution TEMPERATURE RISE Check the temperature rise and if nece
47. u have chosen the type of operation you desire move the thermostat dial or lever to select the temperature you would like the system to maintain 20541401 Issue 0230 Fan Operation You may wish to increase your comfort by setting your system for continuous air circulation of the indoor air The fan switch on the thermostat permits you to do this With the switch in the ON position the fan will operate continuously AUTO position gives fan operation only when the unit is in either heating or cooling What to do if your unit is not heating properly If your furnace is operating but fails to provide complete comfort check the following before calling for service 1 Be sure the thermostat setting is correct 2 Check to see if the filter is clean 3 Check with the contractor for return air grille locations 4 Be sure air can circulate freely throughout your home Do not block supply registers or return air grilles with furniture or rugs And if you also have cooling 5 Keep surface of the outdoor coil free from dirt lint paper or leaves 6 Check and clean indoor coil if necessary This check should be made at the start of each cooling season by your service technician What to do if your unit fails to operate 1 Be sure the main switch that supplies power to the furnace is in the ON position 2 Replace any burned out fuses or reset circuit breakers 3 Be sure the thermostat is properly
48. us code oo an 20 20 DSI BOARD MODE DIAGNOSTIC PATTERNS INDICATION REMEDY Together None Slow flashing LED signifies Normal Operation normal operation Fast flashing LED Flashing indicates a heating demand Together Flashing This LED pattern indicates that either the pri Limit Switch Open mary or secondary limit switch has opened Both switches are auto reset On Off This LED pattern indicates that the pressure Pressure switch opened during operation due to Switch Open reduced flow of combustion products or a Flashing blocked condensate drain Flashing Alternately Failed laniti The system is in Hard Lockout mode ailed Ignition Remove power to reset control Flashing Alternately Flashing This LED pattern indicates that a flame was sensed without power to the gas valve Off This LED pattern indicates that the flame roll out On switch has opened Check continuity of switch Flame Roll Out and for blockage in heat exchanger Manually Flashing reset switch Continuously on Control Board Remove power to reset control Failure Run cycle Check control wiring and replace the control board if necessary Continuously on Page 22 of 26 UT IGNITION BOARD WIRING DIAGRAM CSEQD00 TOALNOI eUNNSX av NAWAOASNVaL AOLINIL XSVds zi
49. ve will perform this adjustment correctly Warranty Procedure When warranty parts are required 1 Be prepared to furnish the following information a Purchaser s name b Complete model number serial number and date of installation c An accurate description of the problem or defective parts 2 Contact your dealer or distributor Keep this User s Information Manual including Warranty and proof of purchase for your records Your warranty is determined from your date of installation If proof of your date of installation is not supplied the warranty will be based on the manufacture date code Failure to follow the correct warranty procedure could result in disallowance of warranty claim PARTS REPLACEMENT INFORMATION GUIDE CASING GROUP GAS CONTROL Top Panel Manifold Bottom Panel Burner Cabinet Wrapper Partition Orifice Front Door Gas Control Blower Door Sensor Ignitor ELECTRICAL GROUP Control Box Limit Switch Fan Timer Control Board Rollout Switch Transformer Shield Top amp Bottom HEAT EXCHANGER Primary Heat Exchanger Flue Box Inducer Burner Opening Panel Burner Inlet Plate Flue Opening Pane GROUP BLOWER GROUP Blower Assembly Blower Housing Blower Motor Blower Wheel Capacitor Blower Cutoff Blower Support GROUP INDUCER GROUP Pressure Switch Blower amp Motor Inducer Adapter Plate TO OBTAIN INFORMATION ON PARTS Consult your installing dealer or classified section of your
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