Lennox International Inc. G40DF(X) SERIES User's Manual
Contents
1. and burners are operating Gas fumes which could contain carbon monoxide can be drawn into the living space resulting in per sonal injury or death Page 3 Your furnace is a gas appliance It is critical that the gas supplied to the unit be completely burned to avoid the pro duction of carbon monoxide gas Complete combustion of the gas requires but is not limited to correct gas pressure and gas flow rate adequate combustion air and proper venting A WARNING Carbon monoxide gas is invisible odorless and toxic Exposure to carbon monoxide gas can cause personal inju ry and even death to all occupants including pets Any item that is powered by or gives off heat from a combustion pro cess including lawn mowers automobiles and fireplaces has the potential to produce carbon monoxide gas Because of this Lennox recommends the use of a carbon monox ide detector in your home even if you do not own gas appliances When propane is used Lennox also recom mends use of a propane detector Reliable detectors are available at reasonable retail prices Contact your Lennox dealer or propane supplier for more details about this in vestment in your safety Your furnace is designed to meet standards set by nation al agencies and to operate safely when properly installed and maintained However the unit s performance can be greatly impacted by the individual installation and the op erating environment It is your respon2. to the lowest setting See figure 2 3 Turn off all electrical power to the unit THERMOSTATS HEAT 10 16 4 A p Wnt Co FIGURE 2 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 lower access panel 6 White Rodgers 36E 36F Gas Valve Switch gas valve lever to OFF Honeywell VR8205 Gas Valve Turn knob on gas valve clockwise to OFF Do not force See figure 5 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 White Rodgers 36E 36F Gas Valve Switch gas valve le ver to ON See figure 3 for the White Rodgers 36E valve and figure 4 for the White Rodgers 36F valve Honeywell VR8205 Gas Valve Turn knob on gas valve counterclockwise 4 to ON Do not force Page 4 White Rodgers 36E Series Gas Valve go GAS VALVE SHOWN IN OFF POSITION FIGURE 3 White Rodgers 36F Series Gas Valve fe pa Gas Valve Lever GAS VALVE SHOWN IN OFF POSITION FIGURE 4 Honeywell VR8205 Series Gas Valve GAS VALVE SHOWN IN OFF POSITION FIGURE 5 9 Repla
3. LENNOX 2001 Lennox Industries Inc Dallas Texas USA 504 322M 4 2001 USER S INFORMATION MANUAL G40DF X SERIES GAS FURNACE Technical Publications Litho U S A A WARNING If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life Do not store or use gasoline or other flam mable vapors and liquids in the vicinity of this or any other appliance Installation and service must be performed by a qualified installer service agency or the gas supplier 04 01 IANA WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Extinguish any open flames Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire de partment 504 322M UNA N G40DF X Parts Identification CABINET CONTROL BOX DURALOK HEAT EXCHANGER ASSEMBLY COMBUSTION AIR INDUCER FLUE COLLAR TOP CAP FLUE CHASE BLOWER ACCESS PANEL E SURELIGHT A CONTROL BOARD COMBUSTION AIR PROVING PRESSURE SWITCH GAS VALVE GAS MANIFOLD LOWER ACCESS PANEL FIGURE 1 AWARNING Product contains fiberglass wool Disturbing the insulation in this product during installation maintenance or repair will expose
4. ce the lower access panel 10 Turn on all electrical power to to the unit 11 Set the thermostat to desired setting NOTE When unit is initially started steps 1 through 11 may need to be repeated to purge air from gas line 12 If the appliance will not operate follow the section Turning Off Gas to the Unit and call your service tech nician or gas supplier Turning Off Gas to the 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 lower access panel 4 White Rodgers 36E 36F Gas Valve Switch gas valve lever to OFF Honeywell VR8205 Gas Valve Turn knob on gas valve clockwise amp to OFF Do not force 5 Replace the lower access panel This unit is not equipped with a filter or rack A field pro vided high velocity filter is required for the unit to operate properly A filter must be in place whenever the unit is operating Seasonal Inspections A qualified service technician should inspect the complete system each season heating and cooling The following maintenance procedures should only be conducted by a qualified service technician Do not attempt to service the unit in any way Venting System A WARNING Asphyxiation Hazard The exhaust vent for this furnace must be securely connected to the furnace flue collar at all times For your safety and to fulfill the terms of the limited warranty a q
5. e unit specifications Problems detected during the inspection may make it nec essary to temporarily shut down the furnace until the items can be repaired or replaced Pay attention to your furnace Situations can arise be tween annual furnace inspections that may result in unsafe operation For instance items innocently stored next to the furnace may obstruct the combustion air supply This could cause incomplete combustion and the production of car bon monoxide gas
6. fied and approved parts A WARNING 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 Important Directions 1 Keep the furnace area clear and free of combustible material gasoline and other flammable vapors and liquids If it is installed in an insulated area the furnace must be kept free of insulating material Insulating ma terial may be combustible 2 DO NOT obstruct air flow to unit Unit must receive an unobstructed flow of combustion and ventilating air 3 DO NOT store chlorine or fluorine products near unit or introduce these products into the combustion air These products can cause furnace corrosion 4 DO NOT draw return air from a room where this fur nace or any other gas appliance ie a water heat er is installed When return air is drawn from a room a negative pressure is created in the room If a gas ap pliance is operating in a room with negative pressure the flue products can be pulled back down the vent pipe and into the room This reverse flow of the flue gas may result in incomplete combustion and the formation of carbon monoxide gas This toxic gas might then be distributed throughout the house by the furnace duct system A WARNING The blower door and flue chase must be securely in place when the blower
7. itches are ON 2 Check room thermostat for proper setting 3 Replace any blown fuses or reset circuit breakers 4 Gas valve should be ON 5 Air filter should not be plugged which will limit air flow 6 Is gas turned on at meter 7 Is manual main shut off valve open Record the model and serial number of the furnace These numbers are on the unit nameplate which is located below the burners Serial Number Model Number Safety Precautions If you discover any of the following shut down your unit and contact a Lennox dealer for an inspection by a qualified technician e If you repeatedly hear any new or unfamiliar sounds while your unit is operating there may be a problem For example poorly performing burners can produce unfa miliar noises If you smell any unusual odors your unit may be operat ing improperly For example units can give off unfamil iar odors if components are required to operate in ab normal conditions Look for visible signs of a malfunctioning unit Examples include unusual amounts of condensate on windows in side your house visibly burnt components or unusual dirt or rust accumulations on the vent pipe or in the unit If you experience headache nausea fatigue or dizzi ness the cause could be exposure to carbon monoxide gas This is often misdiagnosed as the flu because symptoms are similar If you suffer from flu like symp toms that are exaggerated at home but seem to s
8. sibility to ensure that this appliance is maintained Proper maintenance is criti cal for your safety and the satisfactory operation of the product Lennox strongly recommends annual in spection and maintenance of this appliance Contact your Lennox dealer for an inspection by a qualified service technician AWARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or death BEFORE LIGHTING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor The gas valve on the G40DF X will be equipped with ei ther a gas control knob or lever Use only your hand to turn the gas control knob or push the gas lever Never use tools If the knob or lever will not move by hand do not try to repair it Call a qualified service technician Force or at tempted repair may result in a fire or explosion Placing the G40DF X furnace into operation G40DF X units are equipped with a SureLight ignition system Do not attempt to manually light burners on these furnaces Each time thermostat calls for heat the burners will automatically light The ignitor does not get hot when there is no call for heat on units with the SureLight ignition system Operating the Gas Valve Figures 3 4 and 5 1 STOP Read the safety information at the beginning of this section 2 Set the thermostat
9. ualified service technician must annual ly inspect this furnace and its vent system Annually before heating season inspect furnace venting system vent cap heat exchanger and burners for corro sion deterioration or deposits of debris Remove any ob structions Inspect the furnace venting system to make sure it is in place physically sound and without holes corrosion or blockage Vent connector must be in correct position sloped upward and be physically sound without holes or excessive corrosion Inspect the furnace return air duct connection to ensure duct is sealed to the furnace and terminates outside the space containing the furnace Inspect the physical support of the furnace to guarantee that it is sound without sagging cracks or gaps around base and it maintains seal between base and support During a seasonal check the service technician will inspect the indoor blower and the burner flames along with the venting system Blower Check blower wheel for any debris and clean if necessary Blower motor is pre lubricated for extended bearing life No further lubrication is needed Page 5 Burner Flame A CAUTION To ensure proper operation a qualified technician should annually check the burner flame Service Reminder Call your Lennox service technician if the unit will not oper ate Before calling always check the following to be sure service is required 1 Check that electrical disconnect sw
10. ub side while you are away from the house exposure to carbon monoxide could be the cause Your vigilance may pay off in early detection of a problem before either personal injury or property damage occurs Do not hesitate to contact a qualified service technician as an investment in your well being Planned Service You should expect a service technician to check the follow ing items during an annual inspection Power to the unit must be shut off for the service technician s safety Fresh air grilles and louvers on the unit and in the room where the furnace is installed Must be open and unob structed to provide combustion air Burners Must be inspected for rust dirt or signs of water Vent pipe Must be inspected for signs of water damaged or sagging pipe or disconnected joints Unit appearance Must be inspected for rust dirt signs of water burnt or damaged wires or components Blower access door Must be properly in place and pro vide a seal between the return air and the room where the furnace is installed Flue chase Must be properly installed and sealed be tween the top cap and blower deck during unit operation Page 6 Return air duct Must be properly attached and provide an air seal to the unit Operating performance Unit must be observed during operation to monitor proper performance of the unit and the vent system Combustion gases Flue products must be analyzed and compared to th
11. you to fiberglass wool Breathing this may cause lung cancer Fiberglass wool is known to the State of Cal ifornia to cause cancer Fiberglass wool may also cause respiratory skin and eye irritation To reduce exposure to this substance or for further information consult material safety data sheets available from address shown below or contact your supervisor Lennox Industries Inc P O Box 799900 Dallas TX 75379 9900 NOTE This manual must be left with the equipment user Page 2 A WARNING Do not set thermostat below 60 F 16 C in heating mode Setting thermostat below 60 F 16 C reduces the number of heating cycles Damage to the unit may occur that is not covered by the warranty A WARNING If overheating occurs or if gas supply fails to shut off shut off the manual gas valve to the appliance before shutting off electrical supply A CAUTION Before attempting to perform any service or mainte nance turn the electrical power to unit OFF at the disconnect switch A WARNING Do not use this furnace if any part has been under water Immediately call a qualified service technician to inspect the furnace and to replace any part of the control system and any gas control which has been under water A IMPORTANT Any additions changes or conversions required in order for the appliance to satisfactorily meet the ap plication needs must be made by a Lennox service technician using factory speci
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