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G40UH(X) - HvacPartsShop.com

1. ANSI Z21 20 AUTOMATIC IGNITION SYSTEM 24VAC 60Hz 0 5 A MAX ps2 DATE CODE RIRI 50A65 120 O LENNOX 56L8401 f Y w B l giiel Og 0 24V Not Used N V Primary Limit Ground Gas Valve In 10 Pressure Switch Out Rollout Switch Out 12 Gas Valve Out si FAN OFF TIME ADJUSTMENT 60sec 90sec 120sec 180sec a Electronic Ignition See Figure 7 OFF A g OFF T oF oh T On a call for heat the SureLight control monitors the com ON T T ON g R ON I g a a bustion air inducer prove switch The control will not begin the heating cycle if the prove switch is closed by passed Once the proving switch is determined to be open the com To adjust fan off timing flip dip switch to desired setting FIGURE 6 Page 17 The ignition control is equipped with two LED lights for troubleshooting The diagnostic codes are listed below in table 4 TABLE 4 DIAGNOSTIC CODES Make sure to Identify LED S Correctly Refer to figures 5 and 8 for control board layout DESCRIPTION SIMULTANEOUS SIMULTANEOUS Power on Normal operation SLOW FLASH SLOW FLASH Also signaled during cooling and continuous fan SIMULTANEOUS SIMULTANEOUS 2 dare Normal operation signaled when heating demand initiated at thermostat SLOW FLASH ON Primary or secondary limit switch open Limit must close within 3 minutes or unit goes into 1
2. G40UH X units are equipped with a hot surface igni tion system Do not attempt to light manually Gas Valve Operation Figures 16 15 17 and 18 1 STOP Read the safety information at the beginning of this section 2 Set the thermostat to the lowest setting 3 Turn off all electrical power to the unit 4 This furnace is equipped with an ignition device which automatically lights the burners Do not try to light the burners by hand 5 Remove the upper access panel 6 Honeywell VR8205 Gas Valve with On Off Switch Move gas valve switch to OFF position Do not force See figure 17 Honeywell VR8205 Gas Valve with Control Knob Turn knob on gas valve clockwise 0 OFF Donot force See figure 18 White Rodgers 36E 36F Gas Valve Move gas valve switch to OFF position 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 instruc tions If you do not smell gas go to next step 8 Honeywell VR8205 Gas Valve with On Off Switch Move gas valve switch to ON position Do not force See figure 17 Honeywell VR8205 Gas Valve with Control Knob Turn knob on gas valve counterclockwise 4 to ON Do not force White Rodgers 36E 36F Gas Valve Move gas valve switch to ON position 9 Replace the upper access panel 10 Turn on all electrical power to to the unit 11 Set the thermostat to desired set
3. NO GAS VALVE DE ENERGIZED COMBUSTION AIR INDUCER DE ENERGIZED INDOOR BLOWER ON UNTIL SWITCH CLOSES LED 1 SLOW FLASH LED 2 ON IS LIMIT SWITCH CLOSED HAS PRIMARY SECONDARY LIMIT RESET CLOSED WITHIN 3 MINUTES GAS VALVE POWER OFF COMBUSTION AIR INDUCER POWER ON INDOOR BLOWER ON LED 1 ON LED 2 SLOW FLASH SEQUENCE HOLDS UNTIL ROLLOUT SWITCH IS RESET AND MAIN POWER IS INTERUPTED OR THERMOSTAT IS CYCLED OFF ON FOR 1 TO 20 SEC GAS VALVE DE ENERGIZED COMBUSTION AIR INDUCER ON INDOOR BLOWER OFF WITH DELAY LED 1 OFF LED 2 SLOW FLASH HAS CAB SWITCH CLOSED IN 2 5 MINUTES 5 MINUTE PROVE SWITCH WATCHGUARD MODE Page 33 COOLING SEQUENCE OF OPERATION NORMAL COOLING MODE IGNITION CONTROL MAIN POWER ON CONTROL SELF DIAGNOSTIC CHECK IS CONTROL OPERATING NORMALLY YES IS POLARITY REVERSED NO IS VOLTAGE ABOVE 75 VOLTS YES ROLLOUT SWITCH MONITORED CONTINUOUSLY IS ROLLOUT SWITCH CLOSED YES CHECK FOR MAIN BURNER FLAME SENSE IS MAIN BURNER FLAME OFF YES LED SLOW FLASH RATE REMAINS UNCHANGED THROUGHOUT COOLING CYCLE THERMOSTAT CALLS FOR COOLING COMPRESSOR CONTACTOR AND SYSTEM FAN ENERGIZED WITH 0 SECOND DELAY COOLING SPEED EAC H TERM ENERGIZED THERMOSTAT OPENS COMPRESSOR OFF SYSTEM FAN AND ACC TERM OFF WITH 0 SECOND DELAY ABNORMAL COOLING MODE GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF WITH NORMAL DELAY SIGNAL CIRCUIT
4. 21 Check all piping connections factory and field for gas leaks Use a leak detecting solution or other preferred means Rinse piping after leak test has been com pleted Do not use matches candles flame or other sources of ignition to check for gas leaks 22 If a leak is detected shut gas and electricity off and repair leak 23 Repeat steps 21 and 22 until no leaks are detected 24 Replace front access panel A CAUTION Potential for gas leaks fire or explosion Some soaps used for leak detection are corrosive to certain metals Carefully clean piping thor oughly after leak detection has been completed Can cause damage to piping resulting in gas leaks fire or explosion C Supply Air Blower 1 Check and clean blower wheel 2 Motors used on the Lennox G40UH X series units are permanently lubricated and need no further lu brication D Flue and Chimney Flue must conform to local codes In the absence of local codes flue must meet the National Fuel Gas Code ANSI Z223 1 venting requirements Flue pipe deteriorates from the inside out and must be disconnected in order to check thoroughly Check flue pipe chimney and all con nections for tightness and to make sure there is no block age or leaks E Electrical 1 Check all wiring for loose connections 2 Check for correct voltage 3 Check amp draw on blower motor VII Wiring and Sequence of Operation COMBUSTION AIR INDUCER ON A svi or O
5. ao oa WHITE RODGERS GAS VALVE S18 120V ACC COMBUSTION AIR OR PROVING SWITCH K43 ECON IF USED SIO PRIMARY GAS LIMIT ALTERNATE Ow ON v my HONEYWELL GAS VALVE S47 547 FLAME ROLLOUT RA SWLTCH FLAME_ ROLLOUT SWITCH FLAME J159 SENSOR P159 OO 01010 OO 000 BEF TI TRANSFORMER ss DOOR INTERLOCK LD A Q JI56 A92 32 IGNITION BLOWER ROOM THERMOSTAT lOOHWDOO S21 SECONDARY GAS LIMIT INDOOR BLOWER MOTOR C4 CAPACITOR LINE VOLTAGE FIELO INSTALLED os CLASS II VOLTAGE FIELD WIRING DENOTES OPTIONAL COMPONENTS LENNOX G40UH 24A 045 045X 070 01 02 03 05 06 07 G4QUH 488 0 0 G40UH 36A 070 070X 01 02 03 05 06 07 G40UH 48B 070 03 05 BLOWER SPEED CHART MOTOR Gara SPEED TAPS TOR SECONDARY gt LIMITS USED Na Pank SPFE ka PARK SURTE e 3 N A a dJ 2 o ealn 4 2 Eeom BROWN freLLOw RED J 4 tit RIGHT RIGHT BROWN YELLow 4 RED mer owt ean Tt 488 090 or ac PRH BROWN 4 2 _ Peron fed Ne tow 4 Tata YELLOW 4 J 2 3 RNN pa SS SEINER SPEED SELECTION E one BR ee sneer Paps BLACK BROWN YELLOW R ee a a e E THERMOSTAT HEAT ANTICIPATION SETTINGS 50 AMP WHI TE RODGERS VALVE JACKPLUG CHART J P58 Pl BURNER CO J P135 JACK PLUG SECON J P 156 JACK PI ND NOTE F ANY WIRE IN THIS APPLIANCE IS REPLACED IT ust BE REPLACED WITH WIRE OF LIKE SIZE RATING INSULATION THICK
6. cleanable filter not furnished field provided in place Also see Filter Air Resistance table G40UH 60C 110 1 2 3 with 3 4 hp motor PERFORMANCE Single Side Return Air Air volumes in bold require field fab ricated transition to accommodate 20 x 25 x 1 in 508 x 635 x25 mm cleanable air filter in order to maintain proper air velocity External Static Air Volume Watts at Various Blower Speeds Pressure Medium High Medium Low in w g Pa cfm Lis Watts cfm Lis Watts NOTE All air data is measured external to unit with 1 in 25 mm cleanable filter not furnished field provided in place Also see Filter Air Resistance table Page 8 BLOWER DATA G40UH 60C 110 with 1 hp motor PERFORMANCE Bottom Return Air Side Return Air with Optional RAB Return Air Base Return Air from Both Sides or Return Air from Bottom and One Side External Static Air Volume Watts at Different Blower Speeds Pressure Medium High Medium Low in w g Pa cfm Lis Watts cfm Lis Watts NOTE All air data is measured extemal to unit with 1 in 25 mm cleanable filter not furnished field provided in place Also see Filter Air Resistance table G40UH 60C 110 with 1 hp motor PERFORMANCE Single Side Return Air Air volumes in bold require field fabricated transition to accommodate 20 x 25 x 1 in 508 x 635 x 25 mm cleanable air filter in order to maintain proper air velocity External Static Air Volume Watts at Different Blower Speeds Press
7. mode motor LED 1 Slow Flash F LED 2 Fast Flash Sensor rod is contaminated ACTION 1 Check for 120V at the various calls 7 1 2 for indoor blower by energizing Y G and W z individually on the low voltage terminal strip Note 120V IS not being supplied to the in that when W is energized the blower is delayed door air blower or blower motor fail 45 seconds If there is 120V to each motor tap but ure the blower does not operate replace the motor 7 1 3 ACTION 1 If there is not 120V when Y G or Defective control board W is energized replace the control 7 1 4 ACTION 1 Replace capacitor Defective run capacitor PROBLEM 8 RF STATIC DURING TIME FOR IGNITION 8 0 8 1 2 a ACTION 1 Call Technical Support Dallas AM radio interference Ignitor operation Page 46
8. BOARD FAILURE AT LED INTERRUPT MAIN POWER TO RESET CONTROL SIGNAL POLARITY REVERSED AT LED LED SIGNALS WAITING ON CALL FROM THERMOSTAT CONTROL WILL NOT RESPOND UNTIL VOLTAGE RISES ABOVE 75 VOLTS GAS VALVE OFF COMBUSTION AIR INDUCER ON INDOOR BLOWER ON SIGNAL ROLL OUT SWITCH OPEN AT LED SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF WITH NORMAL DELAY SIGNAL UNWANTED FLAME SENSED AT LED SEQUENCE HOLDS UNTIL FLAME IS NOT SENSED Page 34 CONTINUOUS HEAT SPEED FAN SEQUENCE OF OPERATION LED SLOW FLASH RATE REMAINS UNCHANGED THROUGHOUT SEQUENCE MANUAL FAN SELECTION MADE AT THERMOSTAT CONTROL G ENERGIZES SYSTEM FAN AT HEAT H HEAT SPEED EAC H TERMINAL IS ENERGIZED HUM H TERM ENERGIZES THERMOSTAT CALLS FOR HEAT W WITH COMB AIR BLOWER SYSTEM FAN REMAINS ON HEAT H HEATING SPEED THERMOSTAT OPENS THERMOSTAT CALLS FOR COOLING YES SYSTEM FAN SWITCHED TO COOL H SPEED ate One SAR INDUCE EAC H TERM REMAINS ON THERMOSTAT OPENS SYSTEM FAN REMAINS ON HEAT H HEATING SPEED CONTROL G ENERGIZES SYSTEM FAN AT HEAT H HEAT SPEED EAC H TERM ENERGIZED Page 35 S10 s18 BLOWER SPEED CHART A 20v acc PRIMARY GAS COMBUSTION AIR FACTORY CONNECTED SPEED TAPS WOTOR SEconnany K43 ECON UNIT COOL HEAT PARK Park AVAIL LIMITS USED IF USED ranan F Z4A 045 RED veLLow 3 na 24A 070 ELONI RED am 33 36A 045
9. Blower operation is dependent on thermostat control system 2 Generally blower operation is set at thermostat sub base fan switch With fan switch in ON position blower operates continuously With fan switch in AUTO position blower cycles with demand or runs continuously while heating or cooling circuit cycles 3 Depending on the type of indoor thermostat blower and entire unit will be off when the system switch is in OFF position B Temperature Rise Temperature rise for G40UH X units depends on unit in put blower speed blower horsepower and static pressure as marked on the unit rating plate The blower speed must be set for unit operation within the range of TEMP RISE F listed on the unit rating plate To Measure Temperature Rise 1 Place plenum thermometers in the supply and return air plenums Locate supply air thermometer in the first hori zontal run of the plenum where it will not pick up radiant heat from the heat exchanger 2 Set thermostat to highest setting 3 After plenum thermometers have reached their high est and steadiest readings subtract the two readings The difference should be in the range listed on the unit rating Plate If the temperature is too low decrease blower speed If temperature is too high first check the firing rate Provided the firing rate is acceptable in crease blower speed to reduce temperature To change blower speed taps see the Blower Speed Taps section in this
10. G4QUH 1 through 6 units use a surface type limit factory set to open at 125 F G40UH 7 units and later use an airstream type limit factory set to open at 135 The secondary limit cannot be adjusted TABLE 10 mm o 2 60D 135 ses 2 Page 22 12 Gas Valve Figures 16 15 17 amp 18 The G40UH X uses a gas valve manufactured by Honey well or White Rodgers The valve is internally redundant to assure safety shut off If the gas valve must be replaced the same type valve must be used 24VAC terminals and gas control knob or switch are located on the valve All terminals on the gas valve are connected to wires from the electronic ignition control 24V applied to the ter minals energizes the valve Inlet and outlet pressure taps are located on the valve A regu lator adjustment screw is located on the valve LPG changeover kits are available from Lennox Kits include bumer orifices and a gas valve regulator conversion kit WHITE RODGERS 36F Series Gas Valve MANIFOLD PRESSURE ADJUSTMENT SCREW MANIFOLD PRESSURE x OUTLET GAS VALVE SHOWN IN OFF POSITION FIGURE 15 WHITE RODGERS 36E SERIES GAS VALVE MANIFOLD PRESSURE ADJUSTMENT SCREW MANIFOLD PRESSURE OUTLET HONEYWELL VR8205 SERIES GAS VALVE MANIFOLD MANIFOLD PRESSURE PRESSURE ADJUSTMENT OUTLET SCREW GAS VALVE SHOWN IN OFF POSITION FIGURE 17 Page 23 HONEYWELL VR8205 SERIES GAS VALVE
11. Watts at Various Blower Speeds Pressure Medium High Medium Low in w g cfm Watts cfm Watts NOTE All air data is measured extemal to unit with 1 in cleanable filter not furnished field provided in place Also see Filter Air Resistance table G40UH 36A 070 PERFORMANCE External Static Air Volume Watts at Various Blower Speeds Pressure Medium High Medium Low in w g Pa Lis Watts Lis Watts 0 60 150 1150 545 560 1015 480 430 810 380 355 655 310 290 0 70 175 1060 500 535 940 445 405 730 345 330 585 275 270 0 80 200 955 450 515 800 375 370 655 310 305 480 225 260 0 90 225 785 370 475 605 285 325 585 275 270 410 195 255 NOTE All air data is measured extemal to unit with 1 in 25 mm cleanable filter not furnished field provided in place Also see Filter Air Resistance table External Static Air Volume Watts at Various Blower Speeds Pressure Medium High Medium Low in w g Pa cfm Lis Watts Lis Watts 0 15 37 1450 685 675 1235 585 555 1035 490 440 885 420 355 0 20 50 1435 675 660 1225 580 545 1030 485 435 880 415 350 0 25 62 1420 670 645 1215 575 530 1025 485 425 875 415 345 0 30 75 1400 660 630 1200 565 520 1020 480 415 870 410 340 0 40 100 1345 635 595 1170 550 495 1000 470 400 855 405 330 0 50 125 1300 615 575 1135 535 475 965 455 380 830 390 300 0 60 150 1235 585 545 1080 510 445 930 440 360 780 370 290 0 70 175 1165 550 510 1020 480 415 870 410 340 740 350 280 0 80 200 1080 510 480 940 445 385 800 380 315 670 3
12. YES SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES GAS VALVE OFF COMBUSTION AIR INDUCER ON BURNER OFF INDOOR BLOWER ON HEATING SPEED CONTINUOUS FLAME CHECK LED 1 SLOW FLASH LED 2 OFF ves NORMAL OPERATION LED 1 SLOW FLASH LED 2 SLOW FLASH THERMOSTAT CALLS FOR HEAT LED 1 FAST FLASH LED 2 FAST FLASH COMBUSTION AIR INDUCER OFF INDOOR BLOWER ON YES LED 1 SLOW FLASH RATE PRIMARY AND SECONDARY LIMIT SWITCH LED 2 ON CLOSED GAS VALVE OFF COMBUSTION AIR INDUCER OFF IS COMBUSTION AIR INDOOR BLOWER OFF WITH DELAY PROVE SWITCH OPEN LED 1 OFF LED 2 SLOW FLASH YES Sequence holds until pressure switch IS COMBUSTION AIR INDUCER closes or thermostat resets control ENERGIZED YES PROVE SWITCH IS IN WATCHGUARD MODE HAS COMBUSTION AIR PROVE SWITCH NO GAS VALVE OFF COMBUSTION AIR INDUCER OFF CLOSED IN 2 5 MINUTES INDOOR BLOWER OFF WITH DELAY YES i LED 1 OFF LED 2 SLOW FLASH IS 5 MINUTE RESET PERIOD COMPLETE CONTINUED NEXT PAGE Page 32 HEATING SEQUENCE CONTINUED NORMAL HEATING MODE sar eee alia SECOND COMBUSTION AIR INDUCER PREPURGE sar eee alia BY CLOSED PROVE SWITCH YES A IGNITOR WARM UP 20SECONDS WARM e 20 SECONDS 4 seon am FOR IGNITION GAS VALVE OPENS CONTROL 56L84 IGNITOR ENERGIZED FOR 1 SECOND AFTER VALVE OPENS CONTROL 10M93 IGNITOR ENERGIZED DURING 4 SECOND TRIAL NO FLAME SENSED DURING THIS PERIOD YES FLA
13. are complete place brush end of cable snake into the bottom openings of each of the heat exchanger sections Clean the bottom opening as described in step 7 10 Remove cable from heat exchanger Use a vacuum to remove debris knocked loose during cleaning from each heat exchanger section Attach the exhaust end positive pressure of the vacuum to the top of the heat exchanger sections Any loose debris will be forced to the bottom of the heat exchanger section Vacuum debris from bottom openings 11 12 Replace collector box and combustion air inducer prove switch combination Check gaskets for damage Dam aged seals must be replaced to avoid heat exchanger leaks Replace all screws to the collector box and com bustion air inducer Leaving off screws may cause leaks 13 Clean burner by running a vacuum with a soft brush at tachment over face of burners Visually inspect inside of burners and crossovers for any blockage caused by for eign matter Remove any blockage 14 For NOX units replace inserts in each heat exchanger section DO NOT BEND 15 Replace burner manifold assembly onto vestibule panel 16 Reconnect wires to pressure switch roll out switch gas valve and combustion air inducer Refer to unit wiring diagram 17 Reconnect vent pipe to combustion blower outlet 18 Reconnect gas supply piping Page 29 19 Turn on power and gas supply to unit 20 Set thermostat and check for proper operation
14. is made from a non porous high strength proprietary ce ramic material that provides long life and trouble free maintenance The ignition control continuously monitors O line voltage and maintains the ignitor power at a consis FIGURE 8 tent level to provide proper lighting and maximum ignitor life TABLE 5 TABLE 7 4 Pin Terminal Designation FUNCTION Combustion Air Inducer Line TERMINAL DESIGNATIONS 120 Volt Hot Cool Speed Combustion Air Inducer Neutral Ignitor Neutral TABLE 6 High Limit Input Heat Speed e eombusion Park Park Electronic Air Cleaner Transformer Line Humidifier 120 Volt Neutral CIRC Blower XMFR Transformer Gas Valve Common HUM Humidifier Prove Switch In UNE T Gas Valve Out Flame FS Flame Signal Page 19 Electronic Ignition See Figure 7 On a call for heat the ignition board monitors the combus tion air inducer prove switch The control board will not be gin the heating cycle if the prove switch is closed by passed Once the prove switch is determined to be open the combustion air inducer is energized When the differen tial in the prove switch is great enough the prove switch closes and a 15 second pre purge begins If the prove switch is not proven within 2 1 2 minutes the control board goes into Watchguard Pressure S
15. manual C External Static Pressure 1 Tap locations shown in figure 22 2 Punch a 1 4 diameter hole STATIC PRESSURE TEST in supply and return air ple nums Insert manometer hose flush with inside edge of hole or insulation Seal around the hose with perma gum Connect the zero end of the manometer to the dis FIGURE 22 charge supply side of the system On ducted sys tems connect the other end of manometer to the return duct as above For systems with non ducted returns leave the other end of the manometer open to the at mosphere 3 With only the blower motor running and the evaporator coil dry observe the manometer reading Adjust blow er motor speed to deliver the air desired according to the job requirements 4 External static pressure drop must not be more than 0 5 W C 5 Seal around the hole when the check is complete D Blower Speed Taps Blower speed tap changes are made on the ignition control board See figures 5 and 8 On G40DF 1 through 8 units the heating tap is connected to the HEAT H terminal and the cooling tap is connected to the COOL H terminal On G40UHF 8 and later units the heating tap is connected to the HEAT terminal and the cooling tap is connected to t he COOL terminal On all units the continuous blower tap is the same as the heating tap and unused taps must be se cured on two dummy terminals labeled PARK To change out existing speed tap turn off po
16. operate PROBLEM 4 UNIT FAILS TO FIRE IN THE HEATING MODE COMBUSTION AIR BLOWER ENERGIZES IGNITOR IS ENERGIZED Possible Cause Corrective Action Comments 4 1 Unit operates with a cooling and continuous fan demand Combustion air inducer energizes with Heating demand Ignitor is energized but unit fails to light LED 1 Alternating Slow Flash LED 2 Alternating Slow Flash 4 1 1 Check that gas is being supplied to the unit 4 1 2 Miswiring of gas valve or loose con nections at multi pin control amp plugs or valve 4 1 3 Defective gas valve or ignition con trol ACTION 1 Check line pressure at the gas valve Pressure should not exceed 13 WC for both nat ural and propane Line pressure should read a minimum 4 5 WC for natural and 8 0 WC for pro pane ACTION 1 Check for correct wiring and loose connections Correct wiring and or replace any loose connections ACTION 1 Check that 24V is supplied to the gas valve approximately 35 seconds after heat de mand is initiated ACTION 2 Replace the valve if 24V is supplied but valve does not open ACTION 3 Replace the control board if 24V is not supplied to valve PROBLEM 5 BURNERS LIGHT WITH A HEATING DEMAND BUT UNIT SHUTS DOWN PREMATURELY Possible Cause Corrective Action Comments 5 1 Burners fire with a heating demand Burners light but unit shuts off prior to satisfying T stat demand Diagnostic lights flash the pres
17. still blows check for short ACTION 1 Check that door switch is activated when door is closed 1 1 4 ACTION 2 Check wire connections to switch re F place loose connectors Door interlock switch failure ACTION 3 Check continuity of switch in closed position Replace if defective 1 1 5 ACTION 1 Check that transformer output is Transformer Failure 24V Replace if defective 1 1 6 ACTION 1 If all the above items have been Failed control board checked replace board 1 2 1 2 1 ACTION 1 Manually reset the roll out switch a by pushing the top button Roll out switch open ACTION 2 Determine the cause of the roll out i switch activation before leaving furnace Diagnostic lights flash the roll out code 1 2 2 ACTION 1 Check continuity across roll out switch Replace roll out switch if switch is reset Roll out switch failure but does not have continuity LED 1 On LED 2 Slow Flash Miswiring or improper connections at ACTION 1 Check wiring connections to switch roll out switch ACTION 1 Check pin connector for proper 1 2 4 connection to control board 24 volt pin connector failure ACTION 2 Check continuity of the multi plug pin 1 3 On initial power up the comb air in dies does not enelgize ACTION 1 Check the 120V has li d neutral s x ec as line and neutra Diagnostic lights flash the reverse 1 3 1 correctly input into control polarity code ACTION 2 Reverse th
18. to incorrect routing of the prove switch lines 3 1 2 Prove switch does not close due to obstructions in the pressure lines 3 1 3 3 1 4 3 1 5 Prove switch does not close due to a low differential pressure across the prove switch 3 1 6 Wrong prove switch installed in the unit or prove switch is out of calibra tion 3 1 7 Miswiring of furnace or improper con nections at prove switch 3 1 8 Prove switch failure Page 43 ACTION 1 Check that the prove switch lines are correctly routed Correctly route prove switch lines ACTION 1 Remove any obstructions from the the pressure lines and or taps ACTION 1 Check prove switch lines for leaks Replace any broken lines ACTION 1 Check prove switch lines for conden sate Remove condensate from lines ACTION 1 Check the differential pressure across the prove switch This pressure should exceed the set point listed on the switch ACTION 2 Check for restricted inlet vent Re move all blockage ACTION 3 Check for proper vent sizing and run length See installation instructions ACTION 1 Check that the proper prove switch is installed in the unit Replace prove switch if necessary ACTION 1 Check for correct wiring and loose connections Correct wiring and or replace any loose connections ACTION 1 If all the above modes of failure have been checked the prove switch may have failed Replace prove switch and determine if unit will
19. 0 1895 895 1106 1840 870 806 1710 805 683 1500 705 571 90 225 1855 875 1064 1740 820 776 1620 765 655 1430 675 551 NOTE All air data is measured external to unit with 1 in 25 mm cleanable filter not furnished field provided in place Also see Filter Air Resistance table G40UH 60D 155 with 1 hp motor PERFORMANCE Single Side Return Air Air volumes in bold require field fabricated transition to accommodate 20 x 25 x 1 in 508 x 635 x 25 mm cleanable air filter in order to maintain proper air velocity External Static Air Volume Watts at Different Blower Speeds Pressure Medium High Medium Low Low in w g Pa cfm L s Watts cfm L s Watts cfm L s Watts 1620 765 675 1610 760 667 1605 755 658 1600 755 647 1595 750 628 1575 745 618 1540 725 601 1465 690 568 1415 665 548 1345 635 527 NOTE All air data is measured external to unit with 1 in 25 mm cleanable filter not furnished field provided in place Also see Filter Air Resistance table Page 12 FILTER AIR RESITANCE HIGH ALTITUDE All 1 to 14 models Pressure regulator adjustment may be required depending on altitude See below for proper pressure regulator setting iManifold Pressure OuuaHl In wig kPa ALTITUDE ft m 1000 470 0 09 20 FUEL 0 4500 4501 5500 5501 6500 6501 7500 1200 565 0 12 30 0 1372 1373 1676 1677 1981 1982 2286 1400 660 0 15 35 35 Natural Gas 3 5 87 3 3 82 3 2 80 3 1 77 1600 7
20. 15 260 0 90 225 985 465 445 840 395 355 710 335 290 600 285 245 NOTE All air data is measured extemal to unit with 1 in 25 mm cleanable filter not furnished field provided in place Also see Filter Air Resistance table Page 5 BLOWER DATA G40UH 36C 110 PERFORMANCE External Static Air Volume Watts at Various Blower Speeds Pressure Medium High Medium Low cfm cfm 0 30 75 1440 680 645 1260 595 495 1050 495 405 880 415 330 0 40 100 1385 655 615 1230 580 485 1030 485 390 865 410 320 0 50 125 1320 625 590 1190 560 460 995 470 375 835 395 300 0 60 150 1260 595 570 1135 535 430 960 455 355 815 385 295 0 70 175 1190 560 545 1075 505 410 915 430 345 775 365 285 0 80 200 1090 515 515 970 460 385 860 405 325 760 360 280 0 90 225 975 460 485 880 415 360 790 375 305 705 335 275 NOTE All air data is measured external to unit with 1 in 25 mm cleanable filter not furnished field provided in place Also see Filter Air Resistance table G40UH 48B 070 PERFORMANCE External Static Air Volume Watts at Different Blower Speeds Pressure Medium High Medium Low in w g Pa cfm L s Watts cfm L s Watts 00 0 1810 855 764 1535 725 634 10 25 1790 845 714 1520 715 600 20 50 1760 830 675 1515 715 566 NOTES All air data is measured extemal to unit with 1 in 25 mm cleanable filter not furnished field provided in place Also see Filter Air Resistance table Air volume based on bottom air return air Actual air vol
21. 55 0 19 45 1800 850 0 23 55 10 0 2 49 2000 945 0 27 65 A 65 All 15 and later models Pressure regulator adjustment is 2200 1040 0 33 80 not rquired See below for proper pressure regulator setting 2400 1130 0 38 95 2600 1225 0 44 110 Manifold Pressure Outlet in w g kPa ALTITUDE ft m FUEL 0 10 000 0 3048 Natural Gas 3 5 87 LPG Propane 10 0 2 49 HIGH ALTITUDE 1 High Altitude High Altitude Prove LPG Propane Kit Orifice Kit Switch Kit G40UH 1 Natural Gas Only to 14 4501 7500 ft 7501 10 000 ft 0 7500 ft 7501 10 000 ft 1373 2236m 2287 3048m 0 2286m 2286 3048m 045 47M82 56L32 56L32 45L60 47M81 070 090 47M82 49L90 15M22 45L60 47M81 110 47M82 49L90 15M22 45L60 47M81 135 47M82 49L90 15M22 45L60 47M81 155 47M82 49L90 15M22 45L60 47M81 1 High Altitude High Altitude Pressure LPG Propane Kit and later y 4501 7500 ft 7501 10 000 ft 0 7500 ft 7501 10 000 ft 1373 2286m 2287 3048m 0 2286m 2286 3048m all models 59M17 NO CHANGE 56L32 25W20 25W21 1 Required for proper operation at altitudes from 7501 to 10 000 ft Page 13 G40UH X PARTS ARRANGEMENT Air Deflector G40UH 48C 135 G40UH 36C 110 G40UH 60D 155 amp G40UH 60C 110 1 2 3 Units Only Gasket Pressure Port Location For 1 to 14 Units Combustion Air Orifice lt Combustion Air Prove Switch Port Combustion Air Inducer Flame Sensor N L
22. 92 immediately closes the gas valve to prevent burner operation Horizontal Applications The G40UH X furnace can be installed in horizontal ap plications The combustion air inducer may be rotated clockwise or counterclockwise by 90 to allow for vertical vent discharge in a horizontal application Remove the four mounting screws rotate the assembly assembly consists of orifice plate proving switch gasket and combustion air inducer then reinstall the mounting screws See figure 12 Use the provided wire tie to bundle the pressure switch wires with the inducer motor power leads Route the wires away from moving parts and the heat of the inducer motor to prevent damage to the wires Use sheet metal shears to remove the cut out from the side of the cabinet See figure 13 Use the two provided sheet metal screws to install the cut out on the top cap to cover the original flue outlet open ing Page 21 G40UH 15 and later assembly shown Combustion Air Inducer Upflow Position MOUNTING SCREWS Remove Flue Transition Moyning mA PNS Power Leads FIGURE 12 Optional Flue Outlet Horizontal Installation Top View of Furnace Supply Air Opening Flue Outlet Hole Reattach Cutout Here Optional Flue Outlet FIGURE 13 TABLE 8 ee 1 875 5 1 48C 60C 110 6 and later 48C 60C 110 1 2 3 units 48C 60C 110 4 5 units 2 156 4 5 units 135 1 2 3 4 5 un
23. A92 energizes indoor blower B3 When heat demand is satisfied W1 of the indoor thermostat de energizes W of the ignition control which de energizes the gas valve Combustion air inducer B6 continues a 5 second post purge period and indoor blower B3 completes a selected OFF time delay Page 36 G40UH with Ignition Control 78M47 amp 100973 01 LED 1 AN1 LED 2 AN2 HEATING SEQUENCE OF OPERATION NORMAL HEATING MODE ABNORMAL HEATING MODE GAS VALVE OFF COMBUSTION AIR INDUCER OFF POWER ON INDOOR BLOWER DELAY OFF CONTROL SELF CHECK OKAY LED 1 ON LED 2 ON RESET CONTROL BY TURNING MAIN POWER OFF POLARITY REVERSED IS POLARITY CORRECT LED 1 FAST FLASH LED 2 SLOW FLASH IMPROPER GROUND IS THERE A PROPER GROUND LED 1 ALTERNATING FAST FLASH LED 2 ALTERNATING FAST FLASH LED SIGNALS LOW VOLTAGE CONTROL WILL IS VOLTAGE NOT RESPOND UNTIL VOLTAGE RISES ABOVE ABOVE 90 VOLTS 90 VOLTS GAS VALVE OFF COMBUSTION AIR INDUCER ON INDOOR BLOWER ON ROLLOUT SWITCH CLOSED LED 1 ON LED 2 SLOW FLASH SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES AND POWER IS RESET OR T STAT IS INTERRUPTED FOR MINIMUM OF 1 SECOND GAS VALVE OFF COMBUSTION AIR INDUCER ON BURNER OFF INDOOR BLOWER ON HEATING SPEED CONTINUOUS FLAME CHECK LED 1 SLOW FLASH LED 2 OFF NORMAL OPERATION LED 1 SLOW FLASH LED 2 SLOW FLASH COMBUSTION AIR INDUCER OFF INDOOR BLOWER ON LED 1 SLOW FLASH RATE LE
24. D 2 ON THERMOSTAT CALLS FOR HEAT LED 1 FAST FLASH LED 2 FAST FLASH YES PRIMARY AND SECONDARY LIMIT SWITCH CLOSED GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF WITH DELAY IS COMBUSTION AIR LED 1 OFF PRESSURE SWITCH OPEN LED 2 SLOW FLASH YES Sequence holds until pressure switch opens or thermostat resets control IS COMBUSTION AIR INDUCER ENERGIZED YES PRESSURE SWITCH IS IN WATCHGUARD MODE HAS COMBUSTION AIR PRESSURE NO_ GAS VALVE OFF COMBUSTION AIR INDUCER OFF SWITCH CLOSED IN 2 5 MINUTES INDOOR BLOWER OFF WITH DELAY YES LED 1 OFF LED 2 SLOW FLASH IS 5 MINUTE RESET PERIOD COMPLETE CONTINUED NEXT PAGE Page 37 HEATING SEQUENCE CONTINUED NORMAL HEATING MODE 15 SECOND COMBUSTION AIR INDUCER PREPURGE INITIATED BY CLOSED PRESSURE SWITCH LEDS SIGNAL YES t ALTERNATING IGNITOR WARM UP 20 SECONDS IS VOLTAGE ABOVE 90 VOLTS FAST FLASH UNTIL VOLTAGE IS ABOVE YES j 95 VOLTS THEN RESTARTS HEATING 4 SECOND TRIAL FOR IGNITION SEQUENCE GAS VALVE OPENS IGNITOR ENERGIZED FOR UP TO 3 SECONDS ABNORMAL HEATING MODE GAS VALVE OFF COMBUSTION AIR INDUCER ON INDOOR BLOWER OFF HAS CONTROL FAILED TO SENSE FLAME FOR FLAME STABILIZATION PERIOD FIVE CONSECUTIVE TRIES DURING A SINGLE HEAT DEMAND 4 SECONDS FLAME RECTIFICATION CURRENT WATCHGUARD MODE GAS VALVE OFF CHECK CAN FLAME BE PROVEN WITHIN COMBUSTION AIR INDUCER OFF 4 SECONDS AFTER GAS VALVE
25. Ignitor on control 57L84 will energize for the first second ONLY of the 4 second ignition trial ignitor on control 78M47 amp 100973 01 will energize the first three seconds ONLY of the 4 second ignition trial FIGURE 7 Page 18 4 Integrated Ignition Control A92 78M47 amp 100973 01 A WARNING INTEGRATED IGNITION CONTROL OOOO O KOS gt AN NA NEUTRALS N Shock hazard Disconnect power before servicing Control is not field repairable If control is inoperable sim ply replace entire control Can cause injury or death Unsafe operation will result if repair is attempted LAL X X The hot surface ignition control system consisting of an in tegrated control board figure 8 with control terminal des ignations in table 7 sensor figure 10 and ignitor figure 11 The ignition control board and ignitor work in com bination to ensure furnace ignition and ignitor durability The ignition control controls all major furnace operations The ignition control also features two LED lights AN1 red and AN2 green for troubleshooting and two accessory terminals rated at 1 one amp The ignition control also features a 3 amp fuse for overcurrent protection Tables 5 O and 6 show jack plug terminal designations See table 4 for AN1 AN2 f Be in eA a0 RED GREEN troubleshooting diagnostic codes The mini nitride ignitor
26. ME STABILIZATION PERIOD 4 SECONDS FLAME RECTIFICATION CURRENT CHECK CAN FLAME BE PROVEN WITHIN 4 SECONDS AFTER GAS VALVE OPENS gt 0 15 microamps YES FLAME PRESENT FLAME SIGNAL 0 18 OR GREATER MICROAMPS __ q YES INDOOR BLOWER ON DELAY BEGINS 45 seconds PRIMARY AND SECONDARY LIMIT SWITCHES CLOSED ROLLOUT SWITCH CLOSED COMBUSTION AIR PROVE SWITCH CLOSED THERMOSTAT DEMAND SATISFIED YES LED 1 amp 2 SIMULTANEOUS SLOW FLASHES COMB AIR INDUCER CONTINUES 5 SECOND POST PURGE AFTER T STAT DEMAND IS SATISFIED INDOOR AIR BLOWER COMPLETES SELECTED OFF DELAY BEFORE SHUTTING OFF ABNORMAL HEATING MODE CO C_______C_C_C_ oo IS VOLTAGE ABOVE 75 VOLTS VOLTAGE ABOVE 75 VOLTS ma IS THERE s OR GROUND LEDS SIGNAL ALTERNATING FAST FLASH IS IGNITOR INTACT AND CONNECTED gt GAS VALVE OFF COMBUSTION AIR INDUCER ON INDOOR BLOWER OFF HAS CONTROL FAILED TO SENSE FLAME FOR FIVE CONSECUTIVE TRIES DURING A SINGLE HEAT DEMAND WATCHGUARD MODE GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF WITH DELAY LEDs SIGNAL WATCHGUARD FAILURE CODE IS 60 MINUTE RESET PERIOD COMPLETE YES SEQUENCE FOUR TIMES LIMIT SWITCH WATCHGUARD MODE GAS VALVE OFF COMB AIR INDUCER OFF INDOOR BLOWER OFF WITH DELAY LED 1 SLOW FLASH LED 2 ON IS 60 MINUTE RESET PERIOD COMPLETE LOW FLAME SIGNAL Does not affect operation of control LED 1 SLOW FLASH LED 2 FAST FLASH
27. NESS AND TERMINATION IMPORTANT TO PREVENT MOTOR BURNOUT NEVER CONNECT MORE THAN ONE MOTOR LEAD TO ANY ONE CONNECTION AX PARK TERMINALS ARE UNPOWERED TERMINALS ALL UNUSED MOTOR LEADS MUST BE WIRED TO A PARK TERMINAL AA FOR CORRECT NUMBER OF SECONDARY LIMITS USED SEE SECONDARY LIMIT SECTION OF BLOWER SPEED CHART G40UH 36B 090 AND G40UH 48C 135 ONLY D0 NOT USE RED LOW SPEED MOTOR LEA p FOR HEATING LEAVE ON P A FIELD SUPPLIED ACC WIRE SI ROOM THERMOSTAT A USE COPPER CONDUCTORS ONLY J135 1 s21 HEATING UNITS GAS 02 03 05 06 07 3 04 05 06 07 02 03 04 05 06 07 G40UH G40UH 36B 090 at 02 03 05 06 07 G40UH 36C 110 01 02 03 05 06 07 WARNING ELECTRIC SHOCK HAZARD CAN CAUSE INJURY OR_ DEATH MUST BE GROUNDED IN ACCORDANCE WITH NATIONAL AND LOCAL CODES 2005 Lennox Industries Inc When there is a call for heat W1 of the thermostat en ergizes W of the furnace control with 24VAC 10 primary limit switch S47 rollout switch and 21 secondary limit are closed Call for heat can continue SureLight control A92 energizes combustion air in ducer B6 Combustion air inducer runs until S18 com bustion air prove switch closes switch must close within 2 1 2 minutes or control goes into 5 minute Watchguard Pressure Switch delay Once S18 closes a 15 second pre purge follows SureLight control A92 energizes ignitor A 20 sec ond warm up period begins jupersedes 534 500W
28. New Form No 534 542W Litho U S A 5 Gas valve opens for a 4 second trial for ignition 6 Flame is sensed gas valve remains open for the heat call 7 After 45 second delay SureLight control A92 ener gizes indoor blower B3 8 When heat demand is satisfied W1 of the indoor ther mostat de energizes W of the SureLight control which de energizes the gas valve Combustion air inducer B6 continues a 5 second post purge period and in door blower B3 completes a selected OFF time delay Page 30 G40UH with Ignition Control 10M93 or 56L84 HEATING SEQUENCE OF OPERATION NORMAL HEATING MODE ABNORMAL HEATING MODE GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER DELAY OFF LED 1 ON LED 2 ON RESET CONTROL BY TURNING MAIN POWER OFF POLARITY REVERSED IS POLARITY CORRECT LED 1 FAST FLASH LED 2 SLOW FLASH IMPROPER GROUND IS THERE A PROPER GROUND e LED 1 ALTERNATING FAST FLASH YES LED 2 ALTERNATING FAST FLASH LED SIGNALS LOW VOLTAGE CONTROL WILL IS VOLTAGE NOT RESPOND UNTIL VOLTAGE RISES ABOVE ABOVE 75 VOLTS 75 VOLTS YES NO GAS VALVE OFF COMBUSTION AIR INDUCER ON INDOOR BLOWER ON ROLLOUT SWITCH CLOSED LED 1 ON LED 2 SLOW FLASH SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES YES AND POWER IS RESET OR T STAT IS INTERRUPTED FOR MINIMUM OF 1 SECOND GAS VALVE OFF COMBUSTION AIR INDUCER ON BURNER OFF INDOOR BLOWER ON HEATING SPEED CONTINUOUS FLAME CHECK LED 1 SLO
29. ONTROL J156 J2 TERMINAL DESIGNATIONS FUNCTION Combustion Air Inducer Line Combustion Air Inducer Neutral Ignitor Neutral Ignitor Line Page 16 bustion air inducer is energized When the differential in the SURELIGHT INTEGRATED CONTROL BOARD prove switch is great enough the prove switch closes and a COOLS CARRS 1 PARK EINES 15 second pre purge begins If the prove switch is not ae Ho ae He C O proven within 2 1 2 minutes the control goes into Watch WARNING LINE N guard Pressure Switch mode for a 5 minute re set period AREA HUM N After the 15 second pre purge period the SureLight ignitor p EAC N warms up for 20 seconds during which the gas valve opens XFMR N at 19 seconds for a 4 second trial for ignition Units with control 56L84 the ignitor stays energized for the first sec ond of the 4 second trial Units with control 10M93 ignitor stays energized the full 4 second trial If ignition is not proved during the 4 second period the control 56L84 or 10M93 will try four more times with an inter purge and warm up time between trials of 35 seconds After a total of five trials for ignition including the initial trial the control goes into Watchguard Flame Failure mode After a 60 min ute reset period the control will begin the ignition sequence again The SureLight control board has a
30. OPENS INDOOR BLOWER OFF WITH DELAY gt 0 5 microamps LEDs SIGNAL WATCHGUARD FAILURE CODE IS 60 MINUTE RESET PERIOD COMPLETE YES T YES 2 HAS CONTROL RESET IGNITION YES FLAMEFBESEND SEQUENCE FOUR TIMES NO al YES NO LOW FLAME SIGNAL LIMIT SWITCH WATCHGUARD Does not affect operation of control MODE GAS VALVE COMB AIR FLAME SIGNAL 1 5 MICROAMPS OR GREATER _ e LED 1 SLOW FLASH INDUCER AND INDOOR BLOW YES LED 2 FAST FLASH ER OFF LEDs SIGNAL LIMIT SWITCH OPEN UNTIL MAIN INDOOR BLOWER ON POWER IS AFTER 4S SECOND DELAY GAS VALVE DE ENERGIZED INTERRUPTED OR YES COMBUSTION AIR INDUCER DE ENERGIZED T STAT IS CYCLED INDOOR BLOWER ON UNTIL SWITCH CLOSES OFF ON FOR 1 PRIMARY AND SECONDARY LIMIT LED 1 SLOW FLASH LED 2 ON SEC MINIMUM SWITCHES CLOSED IS LIMIT SWITCH CLOSED 60 MINUTE WATCH GUARD PERIOD STARTS AT TIME HAS PRIMARY SECONDARY LIMIT CLOSES IS 60 MIN PERIOD LIMIT RESET TIME Apes EXCEEDED 3 MINUTES GAS VALVE POWER OFF COMBUSTION AIR INDUCER POWER ON ROLLOUT SWITCH CLOSED INDOOR BLOWER ON LED 1 ON LED 2 SLOW FLASH SEQUENCE HOLDS UNTIL ROLLOUT SWITCH IS RESET AND MAIN POWER IS INTERRUPTED OR COMBUSTION AIR PRESSURE THERMOSTAT IS CYCLED OFF ON FOR 1 SEC MINIMUM SWITCH CLOSED YES GAS VALVE DE ENERGIZED COMBUSTION AIR INDUCER ON THERMOSTAT DEMAND SATISFIED INDOOR BLOWER OFF WITH DELAY YES LED 1 OFF LED 2 SLOW FLASH HAS CAB SWITCH CLOSED IN 2 5 MIN
31. OSTAT OPENS COMPRESSOR OFF SYSTEM FAN AND EAC TERM OFF WITH 0 SECOND DELAY UNITS WITH BOARD 100973 01 FAN OFF AFTER 45 SECOND DELAY Page 39 CONTINUOUS HEAT SPEED FAN SEQUENCE OF OPERATION LED SLOW FLASH RATE REMAINS UNCHANGED THROUGHOUT SEQUENCE MANUAL FAN SELECTION MADE AT THERMOSTAT CONTROL G ENERGIZES SYSTEM FAN AT HEAT SPEED EAC TERMINAL IS ENERGIZED HUM TERM ENERGIZES THERMOSTAT CALLS FOR HEAT W WITH COMB AIR INDUCER YES THERMOSTAT CALLS FOR COOLING SYSTEM FAN REMAINS ON YES HEATING SPEED SYSTEM FAN SWITCHED TO COOL SPEED i THERMOSTAT OPENS EAC TERM REMAINS ON THERMOSTAT OPENS HUM TERM DE ENERGIZES WITH COMB AIR INDUCER MANUAL FAN SELECTION MADE AT THERMOSTAT CONTROL G ENERGIZES SYSTEM FAN AT HEAT SYSTEM FAN REMAINS ON SPEED EAC TERM ENERGIZED HEATING SPEED Page 40 TROUBLE SHOOTING GUIDE UPON INITIAL POWER UP REMOVE ALL THERMOSTAT DEMANDS TO THE UNIT PROBLEM 1 UNIT FAILS TO OPERATE IN THE COOLING HEATING OR CONTINUOUS FAN MODE A ER 3 y ACTION 1 Check 120V main voltage Both diagnostic lights fail to light up Main voltage 120V not supplied to unit Determine cause of main power failure LED 1 Off 1 1 2 ACTION 1 Check for correct wiring of 120V to 3 Miswiring of furnace or improper power make up box and transformer LED 2 Off ee prop ACTION 2 Check 24V wiring to control board 1 1 3 ACTION 1 Replace fuse Blown fuse ACTION 2 If fuse
32. PEED MOTOR LEAD FOR HEATING LEAVE ON PARK eee LINE VOLTAGE FIELD INSTALLED TIELE SUECUTED ACG MIRE CLASS II VOLTAGE FIELD WIRING USE COPPER CONDUCTORS ONLY DENOTES OPTIONAL COMPONENTS EQUIPMENT GROUND slo EE BLOWER PIs PEED CHART A 13 PI hn JI35 cr 120V NEUTRAL RK HEATING UNITS GAS G40UH 24A 045 045X 070 G40UH 48B 090 090X G40UH 36A 045 070 070X G40UH 48C 110 G40UH 48B 070 G40UH 60C 110 110X G40UH 36B 090 G40UH 48C 135 G40UH 36C 110 G40UH 600 135 155 Supersedes WARNING ELECTRIC SHOCK HAZARD CAN CAUSE INJURY 535 36W OR_DEATH UNIT MUST BE GROUNDED IN ACCORDANCE f WITH NATIONAL AND LOCAL CODES New Form No 535 321W 2006 Lennox Industries Ine Litho U S A When there is a call for heat W1 of the thermostat energizes W of the furnace control with 24VAC S10 primary limit switch S47 rollout switch and S21 secondary limit are closed Call for heat can continue Ignition control A92 energizes combustion air inducer B6 Combustion air inducer runs until S18 combustion air prove switch closes switch must close within 2 1 2 minutes or control goes into 5 minute Watchguard Pressure Switch delay Once S18 closes a 15 second pre purge follows Ignition control A92 energizes ignitor A 20 second warm up period begins Gas valve opens for a 4 second trial for ignition Flame is sensed gas valve remains open for the heat call After 45 second delay ignition control
33. Teenie Publications LENNOX J Service Literature G40UH X series units are mid efficiency gas furnaces used for upflow or horizontal applications only manufac tured with Lennox Duralok Plus heat exchangers formed of aluminized steel G4OUH X units are available in heating capacities of 44 000 to 154 000 Btuh and cooling applica tions up to 5 tons Refer to Engineering Handbook for prop er sizing Units are factory equipped for use with natural gas Kits are available for conversion to LPG operation G4OUH X model units are equipped with a hot surface ignition system The G40UH X unit meets the California Nitrogen Oxides NO Standards and California Seasonal Efficiency requirements All units use a redundant gas valve to assure safety shut off as required by C S A All specifications in this manual are subject to change Pro cedures outlined in this manual are presented as a recom mendation only and do not supersede or replace local or state codes In the absence of local or state codes the guidelines and procedures outlined in this manual except where noted are recommended only and do not constitute code TABLE OF CONTENTS Specifications 022000 eee eee Page 2 Blower Data 002000 cece eeeee Page 4 High Altitude 02 002 2c eae Page 13 Parts Identification Page 14 Unit Components Page 16 IInstallatiOhy Scene gear dee t
34. UTES LED 1 amp 2 SIMULTANEOUS SLOW FLASHES COMB AIR INDUCER CONTINUES 5 SECOND 5 MINUTE PRESSURE SWITCH POST PURGE AFTER T STAT DEMAND IS SATISFIED WATCHGUARD MODE INDOOR AIR BLOWER COMPLETES SELECTED OFF DELAY BEFORE SHUTTING OFF Page 38 COOLING SEQUENCE OF OPERATION NORMAL COOLING MODE IGNITION CONTROL MAIN POWER ON GAS VALVE OFF COMBUSTION AIR INDUCER OFF CONTROL SELF DIAGNOSTIC CHECK INDOOR BLOWER OFF WITH NORMAL DELAY IS CONTROL OPERATING NORMALLY SIGNAL CIRCUIT BOARD FAILURE AT LED INTERRUPT MAIN POWER TO RESET CONTROL ABNORMAL COOLING MODE SIGNAL IMPROPER GROUND AT LED IS THERE A PROPER GROUND e CONTROL WILL CONTINUE TO CALL FOR COOLING IN THIS CONDITION SIGNAL POLARITY REVERSED AT LED CONTROL IS POLARITY CORRECT WILL CONTINUE TO CALL FOR COOLING IN THIS CONDITION IS VOLTAGE LED SIGNALS LOW VOLTAGE CONTROL WILL ABOVE 90 VOLTS CONTINUE TO CALL FOR COOLING IN THIS CONDITION GAS VALVE OFF COMBUSTION AIR INDUCER ON INDOOR BLOWER ON ROLLOUT SWITCH MONITORED CONTINUOUSLY SIGNAL ROLL OUT SWITCH OPEN AT LED IS ROLLOUT SWITCH CLOSED SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES AND MAIN POWER IS INTERRUPTED OR THERMOSTAT IS CYCLED OFF ON FOR 1 SEC MINIMUM LED SLOW FLASH RATE REMAINS UNCHANGED THROUGHOUT COOLING CYCLE THERMOSTAT CALLS FOR COOLING COMPRESSOR CONTACTOR AND SYSTEM FAN ENERGIZED WITH 2 SECOND DELAY COOLING SPEED EAC TERM ENERGIZED THERM
35. W FLASH LED 2 OFF NORMAL OPERATION LED 1 SLOW FLASH LED 2 SLOW FLASH THERMOSTAT CALLS FOR HEAT S te A EA OFF LED 1 FAST FLASH LED 1 SLOW FLASH RATE LED 2 FAST FLASH LED 2 ON YES PRIMARY AND SECONDARY LIMIT SWITCH CLOSED GAS VALVE CFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF WITH DELAY IS COMBUSTION AIR LED 1 OFF PRESSURE SWITCH OPEN LED 2 SLOW FLASH YES Sequence holds until pressure switch opens or thermostat resets control IS COMBUSTION AIR INDUCER ENERGIZED YES PRESSURE SWITCH IS IN WATCHGUARD MODE HAS COMBUSTION AIR PRESSURE NO GAS VALVE OFF COMBUSTION AIR INDUCER OFF SWITCH CLOSED IN 2 5 MINUTES INDOOR BLOWER OFF WITH DELAY YES LED 1 OFF LED 2 SLOW FLASH IS 5 MINUTE RESET PERIOD COMPLETE CONTINUED NEXT PAGE Page 31 HEATING SEQUENCE OF OPERATION NORMAL HEATING MODE ABNORMAL HEATING MODE POWERON GAS VALVE OFF COMBUSTION AIR INDUCER OFF POWER ON INDOOR BLOWER DELAY OFF LED 1 ON CONTROL SELF CHECK OKAY NO LED 2 ON YES RESET CONTROL BY TURNING MAIN POWER OFF YES IS POLARITY REVERSED POLARITY REVERSED LED 1 FAST FLASH LED 2 SLOW FLASH NO LED SIGNALS WAITING ON CALL FROM IS VOLTAGE THERMOSTAT CONTROL WILL NOT RESPOND ABOVE 75 VOLTS UNTIL VOLTAGE RISES ABOVE 75 VOLTS YES ne GAS VALVE OFF COMBUSTION AIR INDUCER ON INDOOR BLOWER ON p gt ROLLOUT SWITCH CLOSED LED 1 ON LED 2 SLOW FLASH
36. With On Off Switch MANIFOLD PRESSURE ADJUSTMENT SCREW under cap MANIFOLD PRESSURE OUTLET GAS VALVE ON OFF SWITCH SHOWN IN ON POSITION FIGURE 18 13 Combustion Air Inducer Proving Switch S18 G40UH X series units are equipped with a combustion air proving switch located on the combustion air inducer orifice bracket The switch is connected to the combustion air in ducer housing by means of a flexible silicone hose It moni tors negative air pressure in the combustion air inducer housing The switch is a single pole single throw proving switch elec trically connected to the furnace control The purpose of the switch is to prevent burner operation if the combustion air in ducer is not operating or if the flue becomes obstructed On start up the switch senses that the combustion air in ducer is operating It closes a circuit to the furnace control when pressure inside the combustion air inducer de creases to a certain set point Set points vary depending on unit size See table 11 The pressure sensed by the switch is negative relative to atmospheric pressure If the flue be comes obstructed during operation the switch senses a loss of negative pressure pressure becomes more equal with atmospheric pressure and opens the circuit to the fur nace control and gas valve A bleed port on the switch al lows relatively dry air in the vestibule to purge switch tub ing to prevent condensate build up The switch is factory se
37. YELLOW BROWN 4 ALTERNATE 070 aen verro on a 368 090 BROWN YELLOW RED 4 I RIGHT Owv BROWN REO YELLOW 4 T 1 RIGHT ev Ov ON 070 RED YELLOW BROWN 4 oF 488 0901 acy meL o Ren teron a tae 110 BROWN T RED fYELLOW 4 _t RIGHT _ 48c 135 BROWN RED YELLOW WHITE RODGERS HONEYWELL YELLOW Cred Penn 4 trf RIGHT OWN 4 2 J GAS VALVE GAS VALVE RED _ YELLOW BROWN YELLOW RED LBROWN E S O 3 BLOWER SPEED SELECTION __ Back __ _YELLOw ___ _ReD _3_ _ BROWN YELLOW 4 S47 FEAE Roce our IGNITERIB33 THERMOSTAT HEAT ANTICIPATION SETTINGS FLAME J159 FLAME ROLLOUT 65 AMP HONEYWELL VALVE SENSOR P159 FA SWITCH 50 AMP WHITE RODGERS VALVE JACKPLUG CHART TI J P58__ JACK PLUG BURNER CONTROL TRANSFORMER J P84 JACK PLUG COMB AIR INDUCER J P135 JACK 7PLUG SECONDARY LIMIT J P156 JACK PLUG INDUCER IGNITER J P159 TJACK PLUG IGNITION NOTE 12 HERI YIEE SDE ARUN gH I CPOO THERWOSTAT IGNITION RATING INSULATION THICKNESS AND TERMINATION IMPORTANT TO PREVENT MOTOR BURNOUT NEVER CONNECT MORE THAN ONE MOTOR LEAD TO ANY ONE CONNECTION S2 PARK TERMINALS ARE UNPOWERED TERMINALS ALL SECONDARY UNUSED MOTOR LEADS MUST BE WIRED TO A wise GAS LIMIT PARK TERMINAL 5i FOR CORRECT NUMBER OF SECONDARY ROOM THERMOSTAT BLOWER Horor C4 LIMITS USED SEE SECONDARY LIMIT lod SECTION OF BLOWER SPEED CHART uae G40UH 36B 090 AND G4QUH 48C 135 ONLY DO NOT USE RED LOW S
38. ata lbs 1 package Electrical characteristics G40UH 48B 070 G40UH 48B 090 48B 090X 88 000 G40UH 36B 090 72 100 80 0 50 40 70 Gas Model No 1 G40UH G40UH G40UH G40UH G40UH G40UH Heating i 36C 110 48C 110 60C 110 48C 135 60D 135 60D 155 Performance Low NO Model No 60C 110X Input Btuh 110 000 110 000 110 000 132 000 132 000 154 000 Output Btuh 90 200 88 500 89 400 106 900 106 900 124 700 2 AFUE 80 0 80 0 80 0 80 0 80 0 80 0 High static CSA in w g 50 50 50 50 50 50 Temperature rise range F 50 80 40 70 30 60 50 80 45 75 50 80 Connections Flue in round 4 4 4 34 34 34 Gas pipe size IPS in 1 2 1 2 1 2 1 2 1 2 1 2 Indoor Wheel nom dia x width in 10x 8 10 x 10 11 1 2 x 10 10x 10 11 1 2 x 10 11 1 2 x 10 Blower Motor output hp 1 3 1 2 1 1 2 1 1 Tons of add on cooling 2 3 3 4 4 5 2 5 4 4 5 4 5 Shipping Data Ibs 1 package 166 169 175 178 195 204 Electrical characteristics NOTE Filters and provisions for mounting are not furnished and must be field provided 1 Canada Only 120 volts 60 hertz 1 phase less than 12 amps 2 Annual Fuel Utilization Efficiency based on DOE test procedures and according to FTC labeling regulations Isolated combustion system rating for non weatherized furnaces 3 Flue connection on the unit is 4 in diameter Most applications will require 5 in venting and field supplied 4 x 5 in adapt
39. aterial Ignitor longevity is enhanced by controlling the voltage to the ignitor The check ignitor measure its resistance A value of 50 to 450 ohms indicates a good ignitor NOTE The G40UH X furnace contains electronic components that are polarity sensitive Make sure that the furnace is wired correctly and is properly grounded FIGURE 10 Page 20 Ignitor Location IGNITOR TYPE Silicon nitride MEASUREMENT IS TO I D OF RETENTION RING BRACKET BURNERS FRONT VIEW FIGURE 11 7 Combustion Air Inducer B6 All G40UH X units use a combustion air inducer to move air through the burners and heat exchanger during heating operation The blower uses a 120VAC motor The motor operates during all heating operation and is controlled by furnace control A92 The inducer also operates for 15 sec onds before burner ignition pre purge and for 5 seconds after the gas valve closes post purge A proving switch connected to the combustion air inducer ori fice plate is used to prove inducer operation The combustion air inducer orifice will be different for each model See table 8 for orifice sizes The switch monitors air pressure in the induc er housing During normal operation the pressure in the housing is negative If pressure becomes less negative sig nifying an obstruction the proving switch opens When the proving switch opens the furnace control A
40. between gas meter and unit Supply gas pipe must not be smaller than unit gas connection Page 24 Compounds used on gas piping threaded joints should be resistant to action of liquefied petroleum gases C Testing Gas Piping ACAUTION If a flexible gas connector is required or allowed by the authority that has jurisdiction black iron pipe shall be installed at the gas valve and extend outside the furnace cabinet A IMPORTANT In case emergency shutdown is required turn off the main shut off valve and disconnect the main power to unit These controls should be properly labeled by the installer A WARNING Do not exceed 600 in lbs 50 ft lbs torque when attaching the gas piping to the gas valve When pressure testing gas lines the gas valve must be dis connected and isolated Gas valves can be damaged if subjected to more than 0 5psig 14 W C See figure 19 If the pressure is equal to or less than 0 5psig 14 W C use the manual shut off valve before pressure testing to isolate furnace from gas supply GAS PIPING TEST PROCEDURE MANUAL MAIN SHUT OFF VALVE WILL NOT HOLD TEST PRESSURE IN EXCESS OF 0 5 PSIG 14 W C oT l o GAS VALVE FIELD PROVIDED LINE PRESSURE TAP FIGURE 19 When checking piping connections for gas leaks use pre ferred means Kitchen detergents can cause harmful corro sion on various metals used in ga
41. ces and inspect Remove any burrs that are present or replace ori fice ACTION 1 Inspect vent pipe installation and for any restriction Remove restriction ACTION 2 Check prove switch reliability ACTION 1 Check that the sensor is properly lo cated ACTION 2 Check that the sense wire is properly attached to both the sensor and the control Pay extra attention to the pin connectors ACTION 1 Check for proper ground and repair as necessary PROBLEM 6 CONTROL SIGNALS LOW FLAME SENSE DURING HEATING MODE 6 0 6 1 1 ACTION 1 Check the sensor rod for proper loca Unit operates correctly but the diag Sensor rod is improperly located on_ tion on the burner Properly locate the sensor rod nostic lights flash low flame sense the burner or replace if rod cannot be located correctly code ACTION 1 Check sensor rod for contamination or coated surface Clean the sensor rod with steel 6 1 2 wool or replace sensor DO NOT USE SAND PA PER TO CLEAN ROD SAND PAPER WILL CONTRIBUTE TO THE CONTAMINATION PROBLEM PROBLEM 7 INDOOR BLOWER FAILS TO OPERATE IN COOLING HEATING OR CONTINUOUS FAN MODE Possible Cause Corrective Action Comments 7 0 7 1 1 F DA ooien i ACTION 1 Correct wiring and or replace any Indoor blower fails to operate in Miswiring of furnace or improper con loose connections Check for correct wiring and continuous fan cooling or heating nections at control or indoor blower loose connections
42. dels FILTER KITS 1 Air Filter Horizontal Catalog No 87L95 87L96 87L97 87L98 and Rack Kit end Size of filter 14x25x1 18x25x1 20x25x1 25x25 x 1 In Side Return Single 44 522 44 522 44322 44522 Ten Pack 66K63 66K63 66K63 66K63 Size of filter in 16 x 25x 1 16 x 25x 1 16 x 25x 1 16 x 25x 1 EZ Filter Catalog No Ship Wt Ibs 73P55 7 73P56 7 73P57 8 73P58 10 Base oe Size of field provided filter in 14x 25x 1 16x 25x 1 20 x 25x 1 24x 24x11 CABINET ACCESSORIES Horizontal Support Frame Kit Horizontal 56J18 56J18 56J18 56J18 Only Return Air Base Up Flow Only fee 98M60 98M58 98M59 CONTROLS Twinning Kit 15L38 15L38 15L38 15L38 VENTING Vent Adaptor 6 in connection size up flow applications only LPG Propane Kits See Page 13 1 Cleanable polyurethane frame type filter Page 3 BLOWER DATA External Static Air Volume Watts at Various Blower Speeds Pressure in w g Pa NOTE All air data is measured external to unit with 1 in 25 mm cleanable filter not furnished field provided in place Also see Filter Air Resistance table G40UH 24A 070 PERFORMANCE External Static Air Volume Watts at Various Blower Speeds Pressure Medium NOTE All air data is measured external to unit with 1 in 25 mm cleanable filter not furnished field provided in place Also see Filter Air Resistance table Page 4 BLOWER DATA G40UH 36A 045 PERFORMANCE External Static Air Volume
43. e line and neutral at the 120V main power polarity reversed 120V field connection LED 1 Fast Flash LED 2 Slow Flash 1 4 On initial power up the combustion 1 4 1 ACTION 1 Check for 120V to combustion air air inducer does not energize Open combustion air inducer motor inducer If no power check wire and connec Andap tions Diagnostic lights flash normal power circuit me on operation 1 4 2 ACTION 1 If power is present at blower replace LED 1 Slow Flash Failed combustion air inducer motor ower LED 2 Slow Flash Page 41 PROBLEM 1 UNIT FAILS TO OPERATE IN THE COOLING HEATING OR CONTINUOUS FAN MODE Diagnostic ikea flash the improper main ground LED 1 Alternating Fast Flash LED 2 Alternating Fast Flash 1 5 1 Improper ground to the unit 1 5 2 120 volt Pin connector is improperly attached to the circuit board 1 5 3 Line voltage is below 75V 1 through 8 units Line voltage is below 90V 9 and later units 1 5 4 Open ignitor circuit 1 through 8 units 1 5 5 Broken or failed ignitor 1 through 8 units ACTION 1 Check that the unit is properly ground ACTION 2 Install a proper main ground to the unit ACTION 1 Check 4 pin connector for proper installation Correctly insert connector into con trol ACTION 1 Check that the line voltage is above 75V Determine cause of voltage drop and supply correct voltage to the control ACTION 1 Check for c
44. ees eee Page 24 MSat UD Ais cate Kyat nian area Gee d Page 24 IV Heating System Service Checks Page 24 V Typical Operating Characteristics Page 28 VI Maintenance 2 05 Page 28 VII Wiring and Sequence of Operation Page 30 VIII SureLight Troubleshooting Guide Page 41 Page 1 UNIT INFORMATION G40UH X Corp 0006 L3 Revised 09 2006 A IMPORTANT Improper installation adjustment alteration service or maintenance can cause property damage person al injury or loss of life Installation and service must be performed by a qualified installer service agency or the gas supplier AWARNING Electric shock hazard Can cause injury or death Before attempting to perform any service or maintenance turn the electrical power to unit OFF at discon nect switch es Unit may have multiple power supplies A WARNING Sharp edges Be careful when servicing unit to avoid sharp edges which may result in personal injury 2000 Lennox Industries Inc SPECIFICATIONS Model No G40UH G40UH 1 G40UH G40UH 24A 045 36A 045 24A 070 36A 070 Low NO Model No 24A 045X 36A 070X Gas Input Btuh Heating Performance Output Btuh 2 AFUE High static CSA in w g Temperature rise range F Connections Flue in round Gas pipe size IPS in Indoor Wheel nom dia x width in Blower Motor output hp Tons of add on cooling Shipping D
45. et and compare to table 14 The maximum carbon monoxide reading should not exceed 100ppm NOTE To obtain accurate reading shut off all other gas appliances connected to meter A IMPORTANT For safety shut unit off and remove manometer as soon as an accurate reading has been obtained Take care to replace pressure tap plug TABLE 13 GAS METER CLOCKING CHART Seconds for One Revolution LP Dial _ DIAL DIAL 70 272 204 e j e e CA LP 2500 btu cu ft 10 110 135 155 A a a a 3 gt D O Natural 1000 btu cu ft TABLE 14 6400H Unit Oz Range Nat CO2 Range tP 36A 070 X 7 80 8 80 48B 070 7 80 8 80 36B 090 48B 090 X 36C 110 7 50 8 50 48C 110 8 50 9 50 60C 110 X 7 50 8 50 7 20 8 20 7 70 8 70 7 20 8 20 7 70 8 70 Page 26 G Flame Signal A microamp DC meter is needed to check the flame signal on the ignition control Flame microamp signal is an electrical current which passes from the furnace control through the sensor during unit opera tion Current passes from the sensor through the flame to ground to complete a safety circuit To Measure Flame Signal Ignition Control A transducer Part 78H5401 available from Lennox Repair Parts is g required to measure flame R signal if meter used will not X ES read a low micro amp sig Ne nal See figure 20 The transducer converts mi FIGURE 20 croamps to volts on a 1 1 conversion See tab
46. hour Watchguard Prove switch open OFF SLOW FLASH OR Blocked inlet exhaust vent OR Prove switch closed prior to activation of combustion air inducer ALTERNATING ALTERNATING N SLOW FLASH Flame sensed without gas valve energized SLOW FLASH Rollout switch open OR 24V pin connector improperly attached ON ON ON OFF Circuit board failure or control wired incorrectly OFF ON FAST FLASH SLOW FLASH Main power polarity reversed Switch line and neutral SLOW FLASH FAST FLASH Low flame signal See Table 15 for flame sense The following conditions are sensed Improper main ground Control 10M93 57L84 during ignitor warm up period ONLY improper main ground continuously Control 78M47 amp 100973 01 OR Broken ignitor Control 10M93 57L84 OR Open ignitor circuit Control 78M47 amp 100973 01 OR Line voltage below 75V Control 10M93 57L84 90V Control 78M47 amp 100973 01 NOTE Slow flash rate equals 1 Hz one flash per second Fast flash rate equals 3 Hz three flashes per second ALTERNATING ALTERNATING FAST FLASH FAST FLASH IGNITION CONTROL 10M93 amp 56L84 amp 78M47 amp 100973 01 15 34 38 80 A ON Pre Purge Ignitor Warm up Trial f r Blower On Ignition Delay LLLLLLLL INDOOR BLOWER GAS VALVE Blower on time will be 45 seconds after gas valve is energized Blower off time will depend on OFF TIME Setting
47. imit Shield Flame Rollout Switches i Secondary Limit as required Capacitor Blower Assembly 135 and 155 kBtuh units only Flame rollout switches are located on brackets on the inner sides one on the left and one on the right of the burner box Doorlnterlock Switch SureLight Control FIGURE 1 Page 14 G40UH X PARTS IDENTIFICATION HORIZONTAL POSITION BLOWER ASSEMBLY SECONDARY LIMIT BLOWER ACCESS PANEL HEAT EXCHANGER ASSEMBLY PROVE _ SWITCH Ht _ _ CONTROL ae gt BOARD BURNER COMBUSTION AIR _ BURNER ASSEMBLY INDUCER ACCESS PANEL PRIMARY LIMIT GAS VALVE Air Deflector G40UH 48C 135 G40UH 36C 110 G40UH 60D 155 amp a G40UH 60C 110 1 2 3 Units Only FLUE COLLECTOR BOX HEAT EXCHANGER COMBUSTION AIR INDUCER PROVE SWITCH L_A aoa i PRIMARY LIMIT SHIELD NO Insert ee a gt NO Units Only PEG HOTT X Z ial 435 and 155 kBtuh units only PRIMARY LIMIT SS Flame rollout switches are located S on brackets on the inner sides one MANIFOLD BURNER of on the left and one on the right of ASSEMBLY the burner box FIGURE 3 Page 15 I UNIT COMPONENTS G40UH X unit components are shown in figures 1 2 3 and 4 The gas valve combustion air inducer and burners can be accessed by removing the burner access panel Electrical components are in the control box figure 4 found in the bl
48. its 2 156 135 6 and later units 2 375 8 Flame Rollout Switches S47 Flame rollout switch is a high temperature limit located on top of the burner box 135 and 155 Btuh units rollout switches are located on inner sides of burner box See heating components figure 3 Each furnace is equipped with two identical switches One switch is located over the leftmost burner and the other switch is located over the rightmost burner The limit is a N C SPST manual reset limit connected in series with the ignition control A92 When S47 senses rollout the ignition control immediately stops ignition and closes the gas valve If unit is running and flame rollout is detected the gas valve will close and igni tion control will be disabled Rollout can be caused by a blocked heat exchanger flue or lack of combustion air The switch is factory set and cannot be adjusted See table 9 The switch can be manually reset To manually reset a tripped switch push the reset button located on the control TABLE 9 BTUH INPUT Rollout Switch Setpoint 045 110 135 SUPPLY AIR BLOWER AND SECONDARY LIMIT S 250 F Right Side Set gt SECONDARY LIMIT S MOTOR BLOWER CAPACITOR ASSEMBLY To Remove Blower From Unit Disconnect Power Remove Control Box Remove Bolts and Unplug Motor Wires From Control Board Then Slide Out Front of Unit FIGURE 14 9 Blower Motors and Capacitors All G40UH X units use direct drive blower motors A
49. l wool or replace sensor DO NOT CLEAN ROD WITH SAND PAPER SAND PAPER WILL CONTRIBUTE TO THE CONTAMINATION PROBLEM NOTE Do not attempt to bend sensor rod ACTION 3 Check that there is proper ground to burner box Repair as necessary PROBLEM 5 BURNERS LIGHT WITH HEATING DEMAND BUT UNIT SHUTS DOWN PREMATURELY CONT Possible Cause Corrective Action Comments Combustion air inducer energizes with a heating demand Burners light Roll out switch trips during the heating demand Diagnostic lights flash roll out fail ure LED 1 On LED 2 Slow Flash 5 4 Combustion air inducer energizes with a heating demand Burners light roughly and the unit fails to stay lit Diagnostic lights flash watchguard flame failure LED 1 Alternating Slow Flash LED 2 Alternating Slow Flash 5 5 Combustion air inducer energizes with a heating demand Burners light Diagnostic lights flash watch guard flame failure NOTE Unit might go into 60 minute Watchguard mode depending on in termittent nature of sensor signal LED 1 Alternating Slow Flash LED 2 Alternating Slow Flash 5 3 1 Unit is firing above 100 of the nameplate input 5 3 2 Gas orifices leak at the manifold con nection 5 3 3 Insufficient flow through the heat ex changer caused by a sooted or re stricted heat exchanger 5 3 4 Burners are not properly located in the burner box 5 4 1 Poor Venting 5 4 2 Impro
50. le15 for flame signal A digital readout meter must be used The transduc er plugs into most meters See figure 21 for proper use of transducer 1 Set the volt meter to the DC voltage scale Insert transducer into the VDC and common inputs Ob serve correct polarities Failure to do so results in negative values 2 Turn off supply voltage to control 3 Disconnect ignition control flame sensor wire from the flame sensor 4 Connect lead of the transducer to flame sensor 5 Connect lead of transducer to the ignition control sen sor wire 6 Turn supply voltage on and close thermostat contacts to cycle system 7 When main burners are in operation for two minutes take reading Remember 1 DC volt 1 DC microamp TABLE 15 Flame Signal in Microamps Drop Out 56L84 TOMSA gt 0 18 0 16 0 17 lt 0 15 78M47 moo Gi gt 15 05 14 lt 04 NOTE MUST USE DIGITAL METER TRANSDUCER PART 78H5401 SET DIAL TO MEASURE VDC RED COLLAR INDICATES POSITIVE LEAD TO IGNITION CONTROL SENSOR WIRE FIGURE 21 Page 27 A WARNING Fire and explosion hazard These instructions MUST be followed exactly Can cause a fire or explosion resulting in property damage personal injury or loss of life V TYPICAL OPERATING CHARACTERISTICS A Blower Operation and Adjustment NOTE The following is a generalized procedure and does not apply to all thermostat controls 1
51. ll mo tors are 120V permanent split capacitor motors to ensure maximum efficiency Ratings for capacitors will be on motor nameplate NOTE The shaft on 1 HP motors have 2 flat sides and are matched with blower wheels with 2 set screws 10 Primary Limit Control S10 The primary limit S10 on G4QUH X units is located in the heating vestibule panel When excess heat is sensed in the heat exchanger the limit will open If the limit is open the fur nace control energizes the supply air blower and closes the gas valve The limit automatically resets when unit tempera ture returns to normal The switch must reset within three min utes or SureLight board will go into Watch guard for one hour The switch is factory set and cannot be adjusted The switch may have a different setpoint for each unit model number If limit switch must be replaced refer to Lennox Repair Parts handbook 11 Secondary Limit Controls S21 The secondary limit S21 on G4QUH X 24A 045 will not have a secondary limit units is located in the blower compart ment in the back side of the blower housing See figure 14 Table 10 and the blower speed chart on the wiring diagram show secondary limit quantities per unit When excess heat is sensed in the blower compartment the limit will open If the limit is open the furnace control energizes the supply air blow er and closes the gas valve The limit automatically resets when unit temperature returns to normal
52. m Low in w g Pa cfm Lis Watts Lis Watts NOTE All air data is measured extemal to unit with 1 in 25 mm cleanable filter not furnished field provided in place Also see Filter Air Resistance table Page 11 BLOWER DATA G40UH 60D 155 1 2 3 with 3 4 hp motor PERFORMANCE Single Side Return Air Air volumes in bold require field fab ricated transition to accommodate 20 x 25 x 1 in 508 x 635 x25 mm cleanable air filter in order to maintain proper air velocity External Static Air Volume Watts at Various Blower Speeds Pressure Medium High Medium Low in w g Pa cfm Lis Watts cfm Lis Watts NOTE All air data is measured external to unit with 1 in 25 mm cleanable filter not furnished field provided in place Also see Filter Air Resistance table G40UH 60D 155 with 1 hp motor PERFORMANCE Bottom Return Air Side Return Air with Optional RAB Return Air Base Return Air from Both Sides or Return Air from Bottom and One Side External Static Air Volume Watts at Different Blower Speeds Pressure High Medium High Medium Low Low in w g Pa cfm Lis Watts cfm Lis Watts cfm L s Watts cfm L s Watts 1700 800 706 1690 795 696 1640 775 662 1635 770 649 40 100 2345 1105 1246 2150 1015 922 1925 910 778 1630 770 633 50 125 2255 1065 1217 2095 990 897 1890 890 752 1615 760 618 60 150 2170 1025 1182 2010 950 863 1840 870 733 1590 750 605 70 175 2090 985 1139 1925 910 833 1785 840 708 1550 730 588 80 20
53. mbustion air inducer G40UH X BURNER amp HEAT HEAT EXCHANGER eae BURNER BOX ASSEMBLY FIGURE 23 3 Remove four screws securing the combustion air induc er Carefully remove the combustion air inducer and prove switch together as a unit to avoid damaging blow er gasket If gasket is damaged it must be replaced to prevent leakage 4 Remove collector box located behind combustion air inducer Care must be taken to avoid damaging the col lector box gasket If the gasket is damaged it must be replaced to prevent leakage 5 Mark then disconnect wires from gas valve and rollout switch 6 Disconnect gas supply piping Remove six screws se curing the burner manifold assembly to the lower vesti bule panel and remove the assembly from the unit NO units only remove screws holding NO inserts Carefully remove inserts from each heat exchanger clam See figure 24 NOX UNITS ONLY 806 NOx INSERTS Es ae 006 P 7 7 7 FIGURE 24 Page 28 N 1 Insert brush end of cable snake into top of one of the heat exchanger openings DO NOT FORCE CABLE INTO HEAT EXCHANGER Once the cable has been inserted operate drill on slow speed Move the cable in and out of the heat exchanger section three or four times or until sufficient cleaning is accomplished Re verse drill and slowly work cable out of opening 8 Repeat procedure for each heat exchanger section 9 When the top heat exchanger sections
54. n added feature that pro longs the life of the ignitor After a successful ignition the SureLight control utilizes less power to energize the ignitor on successive calls for heat The control continues to ramp down the voltage to the ignitor until it finds the lowest amount of power that will provide a successful ignition This amount of power is used for 255 cycles On the 256th call FIGURE 5 for heat the control will again ramp down until the lowest TABLE 3 power is determined and the cycle begins again SUERLIGHT CONTROL J58 J1 TERMINAL b Fan Time Control DESIGNATIONS The fan on time of 45 seconds is not adjustable Fan off FUNCTION time time that the blower operates after the heat demand Secondary Limit has been satisfied can be adjusted by flipping the dip Not Used switches located on the SureLight integrated control The unit is shipped with a factory fan off setting of 90 seconds For customized comfort monitor the supply air tempera ture once the heat demand is satisfied Note the supply air Rollout Switch In temperature at the instant the blower is de energized Ad 4 just the fan off delay to achieve a supply air temperature between 90 110 at the instant the blower is de ener gized Longer delay times allow for lower air temperature shorter delay times allow for higher air temperature See figure 6 CIR N LENNOX FLAME SENSE O O O
55. n will result if repair is attempted 3 SureLight Integrated Ignition Control A92 10M93 amp 56L84 The Lennox SureLight ignition system consists of ignition control figure 5 with control terminal designations in table 1 sensor figure 10 and ignitor figure 11 The ignition control and ignitor work in combination to ensure furnace ignition and ignitor durability The ignition control controls all major furnace operations The ignition control also fea tures two LED lights for troubleshooting and two accesso ry terminals rated at 1 one amp Tables 2 and 3 show jack plug terminal designations See table 4 for troubleshooting diagnostic codes Units equipped with the SureLight sys tem can be used with either electronic or electro mechani cal thermostats without modification The SureLight igni tor is made of durable silicon nitride Ignitor longevity is also enhanced by voltage ramping by the ignition control The ignition control finds the lowest ignitor temperature which will successfully light the burner thus increasing the life of the ignitor TABLE 1 SURELIGHT CONTROL TERMINAL DESIGNATIONS COOL Blower Cooling Speed 120V HEAT Blower Heating Speed 120V PARK Unused Blower Lead not energized FAN ee R Cm Continuous Low Blower Speed Accessory Terminal 120V Transformer 120V Input 120V Heat Only Accessory 120V 120V Neutral Flamer Sensor 5 Terminals TABLE 2 SURELIGHT C
56. or See Venting Tables in the Installation Instructions for detailed information Page 2 SPECIFICATIONS Model No G40UH 60C 110 G40UH 60D 135 G40UH 60D 155 1 2 3 units 1 2 3 units 1 2 3 units hee Input Btuh kW 110 000 32 2 132 000 38 7 154 000 45 1 eatin Performance Output Btuh kW 90 200 26 4 106 900 31 3 124 700 36 5 XAFUE 80 0 80 0 80 0 California Seasonal Efficiency 75 7 75 0 75 6 High static AGA CGA in w g Pa 50 124 50 124 50 124 Flue connection in mm round 4 102 4 4 102 4 4 102 Gas pipe size IPS in mm 1 2 12 7 1 2 12 7 1 2 12 7 Temperature rise range F C 35 65 19 36 45 75 25 42 50 80 28 44 coor Wheel nominal diameter x width in mm 11 1 2 x 10 292 x 254 11 1 2 x 10 292 x 254 11 1 2 x 10 292 x 254 ower Motor output hp W 3 4 560 3 4 560 3 4 560 Tons kW of add on cooling 5 17 6 5 17 6 5 17 6 Shipping weight 1 package 172 Ibs 78 kg 192 Ibs 87 kg 201 Ibs 91 kg Matching Coils C33 36C 2F Up flow cased C33 48C 2F C33 60D 2F C33 62D 2F C33 50 60C 2F CH33 36C 2F Horizontal CH33 48C 2F CH33 60D 2F CH33 62D 2F CH33 50 60C 2F Electrical characteristics 120 volts 60 hertz 1 phase less than 12 amps OPTIONAL ACCESSORIES MUST BE ORDERED EXTRA A Width Models B Width Models C Width Models D Width Mo
57. orrect wiring and loose connections in the ignitor circuit Check multi plug connections for correct installation ACTION 1 Unplug ignitor and read resistance across ignitor If resistance does not read be tween 10 9 and 19 7 ohms replace the ignitor PROBLEM 2 UNIT FAILS TO FIRE IN THE HEATING MODE COMBUSTION AIR BLOWER DOES NOT ENERGIZE Possible Cause Corrective Action Comments 2 1 Unit operates with a cooling or contin uous fan demand Combustion air inducer will not start with a Heating demand Diagnostic lights flash the limit failure mode LED 1 Slow Flash LED 2 On 2 2 Unit operates with a cooling and con tinuous fan demand Combustion air inducer will not start with a Heating demand Diagnostic lights flash the pressure switch failure code LED 1 Off LED 2 Slow Flash 2 1 1 Primary or secondary if equipped limit open 2 1 2 Miswiring of furnace or improper con nections at limit switch es 2 2 1 Miswiring of furnace or improper con nections to combustion air inducer 2 2 2 Prove switch stuck closed Page 42 ACTION 1 Check continuity across switch es Switches reset automatically upon cool down ACTION 2 Check for restrictions on blower inlet air including filter and outlet air Determine cause for limit activation before placing unit back in operation ACTION 1 Check for correct wiring and loose connections Correct wiring and or replace any loo
58. ower section G40UH X units are factory equipped with a bottom retum air panel in place The panel is designed to be field removed as required for bottom air return Markings are provided for side return air and may be cut out in the field 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 Precautions will help to avoid control exposure to electrostatic dis charge by putting the furnace the control and the technician at the same electrostatic poten tial Neutralize electrostatic charge by touching hand and all tools on an unpainted unit surface such as the gas valve or blower deck before per forming any service procedure 1 Control Transformer T1 A transformer located in the control box provides power to the low voltage section of the unit Transformers on all models are rated 40VA with a 120V primary and a 24V sec ondary 2 Door Interlock Switch S51 A door interlock switch rated 14A at 125VAC is wired in se ries with line voltage When the blower door is removed the unit will shut down CONTROL BOX G40UH X FIGURE 4 A WARNING Shock hazard Disconnect power before servicing Control is not field repairable If control is inoperable sim ply replace entire control Can cause injury or death Unsafe operatio
59. per burner cross overs 5 4 3 Burrs in gas orifices 5 4 4 Prove Switch opens 5 times during a single demand 5 5 1 Loose sensor wire connection causes intermittent loss of flame signal 5 5 2 Poor ground to burner box Page 45 ACTION 1 Check that the manifold pressure matches value listed on nameplate See installa tion instructions for proper procedure ACTION 2 Verify that the installed orifice size match the size listed on the nameplate or installa tion instructions ACTION 3 Check the input rate to verify rate matches value listed on nameplate ACTION 1 Tighten orifice until leak is sealed NOTE Be careful not to strip orifice threads ACTION 2 Check for gas leakage at the threaded orifice connection Use approved meth od for leak detection see unit instructions ACTION 1 Check for sooting deposits or other restrictions in the heat exchanger assembly Clean assembly as outlined in instruction manu al ACTION 2 Check for proper combustion ACTION 1 Check that the burners are firing into the center of the heat exchanger openings Cor rect the location of the burners if necessary ACTION 1 Check vent pipe and remove any ob structions ACTION 2 Check for correct exhaust vent installation See instructions ACTION 1 Remove burner and inspect the cross overs for burrs or any restriction or if crossover is warped Remove restriction or re place burners ACTION 1 Remove gas orifi
60. r higher air temperature See figure 9 Board 100973 01 only has a 45 second fan off delay after cooling demand has been met This delay is factory set and not adjustable FAN OFF TIME ADJUSTMENT HEAT OFF JUMPER POSITION DELAY OFF OFF 180 PINT PIN PIN2 PIN3 90 PIN3 PINA 120 PIN4 PINS 80 To adjust fan off timing reposition jumper across pins to achieve desired setting FIGURE 9 5 Flame Sensor Figure 10 A flame sensor is located on the left side of the burner sup port See figure 10 The sensor is mounted on the flame rol lout plate and the tip protrudes into the flame envelope of the left most burner The sensor can be removed for ser vice without removing any part of the burners During op eration flame is sensed by current passed through the flame and sensing electrode The ignition control allows the gas valve to remain open as long as flame signal is sensed 6 Ignitor Figure 11 The SureLight ignitor used on G40UH units is made of du rable silicon nitride The board finds the lowest ignitor tem perature which will successfully light the burner thus in creasing the life of the ignitor Due to this feature of the board voltage cannot be measured The check ignitor measure its resistance A value of 10 9 to 19 7 ohms indi cates a good ignitor The mini nitride ignitor used on G40UH units equipped with control 78M47 or 100973 01 is made from a propri etary ceramic m
61. s piping Use of a specialty Gas Leak Detector is strongly recommended It is available through Lennox under part number 31B2001 See Corp 8411 L10 for further details Do not use matches candles flame or any other source of ignition to check for gas leaks Page 25 D Testing Gas Supply Pressure When testing supply gas pressure connect test gauge to inlet pressure tap field provided See figure 19 Check gas line pressure with unit firing at maximum rate Low pres sure may result in erratic operation or underfire High pres sure can result in permanent damage to gas valve or over fire See table 12 for operating pressure at unit gas connec tion line On multiple unit installations each unit should be checked separately with and without units operating Supply pres sure must fall within range listed in previous paragraph E Check Manifold Pressure After line pressure has been checked and adjusted check manifold pressure Move pressure gauge to outlet pres sure tap located on unit gas valve GV1 Checks of man ifold pressure are made as verification of proper regulator ad justment Manifold pressure for the G40UH X can be mea sured at any time the gas valve is open and is supplying gas to the unit See table 12 for normal operating manifold pres sure TABLE 12 Manifold Pressure WC 10 0 All G40UH Units Line Pressure WC A IMPORTANT For safety connect a shut off valve bet
62. se connections ACTION 1 Check for correct wiring and loose connections Correct wiring and or replace any loose connections ACTION 1 Check that the prove switch is open without the combustion air inducer operating Re place if defective PROBLEM 2 UNIT FAILS TO FIRE IN THE HEATING MODE COMBUSTION AIR INDUCER DOES NOT ENERGIZE CONT Possible Cause Corrective Action Comments 2 3 Unit operates with a cooling and con tinuous fan demand Combustion air inducer will not start with a Heating demand Diagnostic lights flash the pressure switch failure code 2 5 minutes after heating demand LED 1 Off LED 2 Slow Flash 2 3 1 Miswiring of furnace or improper con nections to combustion air inducer 2 3 2 Combustion air inducer failure ACTION 1 Check for correct wiring and loose connections Correct wiring and or replace any loose connections ACTION 1 If there is 120V to combustion air in ducer and it does not operate replace combus tion air inducer PROBLEM 3 UNIT FAILS TO FIRE IN THE HEATING MODE COMBUSTION AIR BLOWER ENERGIZES IGNITOR IS NOT ENERGIZED Possible Cause Corrective Action Comments 3 1 Unit operates with a cooling and continuous fan demand Combustion air inducer energizes with a heating demand Diagnostic lights flash the pressure switch failure code 2 5 minutes after heating demand LED 1 Off LED 2 Slow Flash 3 1 1 Prove switch does not close due
63. sure switch code LED 1 Off LED 2 Slow Flash 5 2 Combustion air inducer energizes with a heating demand Burners light but fail to stay lit After 5 tries the control diagnostics flash the watchguard burners failed to ignite code LED 1 Alternating Slow Flash LED 2 Alternating Slow Flash 5 1 1 Low pressure differential at the prove switch 5 2 1 Sensor or sensor wire is improperly installed 5 2 2 Sensor or sensor wire is broken 5 2 3 Sensor or sensor wire is grounded to the unit 5 2 4 Control does not sense flame Page 44 ACTION 1 Check for restricted exhaust vent Remove all blockage ACTION 2 Check for proper vent sizing See installation instructions ACTION 1 Check that sensor is properly lo cated and that the sense wire is properly at tached to both the sensor and the control ACTION 1 Check for a broken sensor ACTION 2 Test continuity across the sense wire If wire or sensor are damaged replace the component ACTION 1 Check for resistance between the sensor rod and the unit ground ACTION 2 Check for resistance between the sensor wire and the unit ground ACTION 3 Correct any shorts found in circuit ACTION 1 Check the microamp signal from the burner flame If the microamp signal is be low normal microamps check the sensor rod for proper location or contamination ACTION 2 Replace clean or relocate flame sensor rod If rod is to be cleaned use stee
64. t and is not field adjustable It is a safety shut down control in the furnace and must not be by passed for any reason If switch is closed or by passed the control will not initiate ignition at start up TABLE 11 PROVE SWITCH SET POINTS 1 to 14 0 4500ft 4501 7500 7501 10 000 Units 0 1372m 1373m 7500m 2287 3048m 0 47 3 3 116Pa 0 36 89Pa 0 36 89Pa 0 47 R A 116Pa 0 36 89Pa 0 36 89Pa 0 51 0 47 116Pa 0 43 106Pa 126Pa 0 58 14Pa 0 47 116Pa 0 43 106Pa 0 51 F z 126Pa 0 47 116Pa 0 43 106Pa 155 gat 0 47 116 0 43 106P 126Pa 47 116a 43 106Pa All 15 and S later models 0 40 99pa no change 0 36 89Pa NOTE 1 to 14 units require a high altitude prove switch kit if installed above 4500 ft 1370 m NOTE 15 and later units require a high altitude prove switch kit if installed above 7500 ft 2286 m ll PLACEMENT AND INSTALLATION Make sure unit is installed in accordance with installation instructions and applicable codes lll START UP A Preliminary and Seasonal Checks 1 Inspect electrical wiring both field and factory installed for loose connections Tighten as required 2 Check voltage at disconnect switch Voltage must be within range listed on the nameplate If not consult the power company and have voltage condition corrected before starting unit B Heating Start Up A WARNING Shock and burn hazard
65. th Sides or Return Air from Bottom and One Side External Static Air Volume Watts at Different Blower Speeds Pressure Medium High Medium Low in w g Pa cfm Lis Watts cfm Lis Watts 2715 1280 1407 2640 1245 1403 2540 1200 1355 60 150 2205 1040 1210 2020 955 876 1815 855 731 1595 750 611 10 175 2080 980 1161 1935 915 839 1760 830 707 1545 730 588 80 200 2010 950 1122 1855 875 810 1690 795 679 1495 705 568 90 225 1880 885 1071 1755 830 781 1585 745 646 1430 675 545 NOTE All air data is measured extemal to unit with 1 in 25 mm cleanable filter not furnished field provided in place Also see Filter Air Resistance table G40UH 60D 135 with 1 hp motor PERFORMANCE Single Side Return Air Air volumes in bold require field fabricated transition to accommodate 20 x 25 x 1 in 508 x 635 x 25 mm cleanable air filter in order to maintain proper air velocity External Static Air Volume Watts at Different Blower Speeds Pressure Medium High Medium Low in w g Pa cfm Lis Watts cfm Lis Watts NOTE All air data is measured extemal to unit with 1 in 25 mm cleanable filter not furnished field provided in place Also see Filter Air Resistance table G40UH 60D 155 1 2 3 with 3 4 hp motor PERFORMANCE Bottom Return Air Side Return Air with Optional RAB Re turn Air Base Return Air from Both Sides or Return Air from Bottom and One Side External Static Air Volume Watts at Various Blower Speeds Pressure Medium High Mediu
66. ting 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 techni cian or gas supplier Turning Off Gas to Unit 1 Set the thermostat to the lowest setting 2 Turn off all electrical power to the unit if service is to be performed 3 Remove the upper access panel 4 Honeywell VR8205 Gas Valve with On Off Switch Move gas valve switch to OFF position Do not force See figure 17 Honeywell VR8205 Gas Valve with Control Knob Turn knob on gas valve clockwise to OFF Do not force See figure 18 White Rodgers 36E 36F Gas Valve Switch gas valve lever to OFF 5 Replace the upper access panel C Safety or Emergency Shutdown Disconnect main power to unit Close manual and main gas valves D Extended Period Shutdown Turn off thermostat or set to UNOCCUPIED mode Close all gas valves both internal and external to unit to guaran tee no gas leak into combustion chamber Turn off power to unit All access panels and covers must be in place and se cured IV HEATING SYSTEM SERVICE CHECKS A C S A Certification All units are C S A formally A G A and C G A combined design certified without modifications Refer to the G40UH X Installation Instruction B Gas Piping Gas supply piping should not allow more than 0 5 W C drop in pressure
67. ume may vary on side return air applications G40UH 48B 090 PERFORMANCE External Static Air Volume Watts at Various Blower Speeds Pressure Medium High Medium Low in w g Pa cfm Lis Watts cfm Lis Watts NOTE All air data is measured external to unit with 1 in 25 mm cleanable filter not furnished field provided in place Also see Filter Air Resistance table Page 6 BLOWER DATA G40UH 48C 110 PERFORMANCE External Static Air Volume Watts at Various Blower Speeds Pressure Medium High Medium Low in w g Pa Lis Watts Lis Watts NOTE All air data is measured extemal to unit with 1 in 25 mm cleanable filter not furnished field provided in place Also see Filter Air Resistance table G40UH 48C 135 PERFORMANCE External Static Air Volume Watts at Various Blower Speeds Pressure Medium High Medium Low in w g Pa Lis Watts cfm Lis Watts NOTE All air data is measured extemal to unit with 1 in 25 mm cleanable filter not furnished field provided in place Also see Filter Air Resistance table Page 7 BLOWER DATA G40UH 60C 110 1 2 3 with 3 4 hp motor PERFORMANCE Bottom Return Air Side Return Air with Optional RAB Return Air Base Return Air from Both Sides or Return Air from Bottom and One Side External Static Air Volume Watts at Various Blower Speeds Pressure Medium High Medium Low in w g Pa cfm Lis Watts cfm Lis Watts NOTE All air data is measured external to unit with 1 in 25 mm
68. ure Medium High Medium Low in w g Pa cfm Lis Watts cfm Lis Watts NOTE All air data is measured extemal to unit with 1 in 25 mm cleanable filter not furnished field provided in place Also see Filter Air Resistance table Page 9 BLOWER DATA G40UH 60D 135 1 2 3 with 3 4 hp motor PERFORMANCE Bottom Return Air Side Return Air with Optional RAB Re turn Air Base Return Air from Both Sides or Return Air from Bottom and One Side External Static Air Volume Watts at Various Blower Speeds Pressure Medium High Medium Low in w g Pa cfm Lis Watts cfm Lis Watts NOTE All air data is measured external to unit with 1 in 25 mm cleanable filter not furnished field provided in place Also see Filter Air Resistance table G40UH 60D 135 1 2 3 with 3 4 hp motor PERFORMANCE Single Side Return Air Air volumes in bold require field fab ricated transition to accommodate 20 x 25 x 1 in 508 x 635 x25 mm cleanable air filter in order to maintain proper air velocity External Static Air Volume Watts at Various Blower Speeds Pressure Medium High Medium Low in w g Pa cfm Lis Watts cfm Lis Watts NOTE All air data is measured external to unit with 1 in 25 mm cleanable filter not furnished field provided in place Also see Filter Air Resistance table Page 10 BLOWER DATA G40UH 60D 135 with 1 hp motor PERFORMANCE Bottom Return Air Side Return Air with Optional RAB Return Air Base Return Air from Bo
69. ween the manometer and the gas tap to permit shut off of gas pressure to the manometer The gas valve is factory set and should not require adjust ment All gas valves are factory regulated See specifica tions section of this manual for High Altitude manifold pres sure settings Manifold Adjustment Procedure 1 Connect a test gauge to outlet pressure tap on gas valve See figures 16 15 and 17 Start unit and allow 5 minutes for unit to reach steady state 2 While waiting for the unit to stabilize notice the flame Natural gas should burn blue L P gas should burn mostly blue with some orange streaks After allowing unit to stabilize for 5 minutes record manifold pressure oO 1 NOTE Shut unit off and remove manometer as soon as an accurate reading has been obtained Take care to re place pressure tap plug F Proper Gas Flow Approximate amp Combustion Furnace should operate at least 5 minutes before check ing gas flow Determine time in seconds for two revolu tions of gas through the meter Two revolutions assures a more accurate time Divide by two and compare to time in table 13 below Adjust manifold pressure on gas valve to match time needed Manifold pressure should not exceed values listed in table 12 If manifold pressure matches table 12 and rate is incorrect check gas orifices for proper size and restriction After furnace has operated for 15 min utes take a combustion sample beyond the flue outl
70. wer and switch out speed tap with tap connected to PARK See blower speed tap table on unit diagram for motor tap colors for each speed VI MAINTENANCE At the beginning of each heating season the system should be checked as follows A Filters All G40UH X filters are installed external to the unit Filters should be inspected monthly Clean or replace the filters when necessary to ensure that the furnace operates prop erly Replacement filters must be rated for high velocity air flow B Heat Exchanger and Burners Cleaning the Heat Exchanger and Burners NOTE Use papers or protective covering in front of fur nace while cleaning furnace Cleaning the heat exchanger requires a steel spring snake a reversible drill and a vacuum cleaner The steel spring snake may be constructed by purchasing a 4 ft long by 1 4 diameter steel wire cable and a 1 4 diameter wire brush These items are available at a hardware store In sert wire end of brush into the open end of the spring cable Crimp the cable around the brush so that the brush is se cured and will not come off during cleaning Attach the oth er end of the cable to the reversible drill to complete the tool for cleaning the heat exchanger See figure 1 for parts ar rangement when disassembling furnace 1 Turn off both electrical and gas power supplies to fur nace 2 Remove flue pipe and top cap from unit Mark and dis connect wiring from prove switch and co
71. witch mode for a 5 min ute re set period After the 15 second pre purge period the ignitor warms up for 20 seconds during which the gas valve opens at 19 sec onds for a 4 second trial for ignition The ignitor remains energized for the first 3 seconds during the 4 second trial If ignition is not proved during the 4 second period the con trol will try four more times with an inter purge and warm up time between trials of 35 seconds After a total of five trials for ignition including the initial trial the control goes into Watchguard Flame Failure mode After a 60 minute reset period the control will begin the ignition sequence again The control board has an added feature of ignitor power regulation to maintain consistent lighting and longer ignitor life under all line voltage conditions Fan Time Control The fan on time of 45 seconds is not adjustable Fan off time time that the blower operates after the heat demand has been satisfied can be adjusted by moving the jumper to a different setting The unit is shipped with a factory fan off setting of 90 seconds For customized comfort monitor the supply air temperature once the heat demand is satis fied Note the supply air temperature at the instant the blower is de energized Adjust the fan off delay to achieve a supply air temperature between 90 110 at the instant the blower is de ener gized Longer delay times allow for lower air temperature shorter delay times allow fo

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