Lennox International Inc. G23 User's Manual
Contents
1. GAS VALVE SHOWN IN OFF POSITION FIGURE 3 7 Wait fifteen 15 minutes to clear out any gas If you then smell gas STOP Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you do not smell gas go to next step 8 For Honeywell VR8204 gas valves turn knob on gas valve counterclockwise 4 to ON For White Rodg ers 36E gas valves move switch to ON Do not force 9 Replace upper access panel 10 Turn on all electrical power to unit 11 Set thermostat to desired setting NOTE When unit is first started steps 1 through 11 may need to be repeated to purge air from line 12 If the appliance still will not operate follow the in structions To Turn Off Gas To Unit and call your ser vice technician or gas supplier Turning Off The Gas To The Unit 1 Set thermostat to lowest setting 2 Turn off all electrical power to unit if service is to be performed 3 Remove upper access panel 4 On Honeywell VR8204 gas valves turn knob on gas valve clockwise to OFF For White Rodgers 36E gas valves move switch to OFF Do not force 5 Replace upper access panel A filter must be in place anytime the unit is in operation The filter may be located in the unit optional kit or installed in a return air grille Ask your dealer to show you the filter location The filter should be inspected monthly and cleaned when necessary to as2. LENNQDS W1996 Lennox Industries Inc Dallas Texas 503 517M 9 98 Supersedes 8 96 USERS INFORMATION MANUAL G23 SERIES GAS FURNACE Technical Publications Litho U S A AWARNING If the information in this manual is not followed exactly a fire or explosion may result causing APPROVED 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 CANADIAN GAS ASSOCIATION WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance e Extinguish any open flames e 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 G23 Parts Identification DURALOK HEAT EXCHANGER ASSEMBLY TOP CAP VENT PIPE CONNECTION COMBUSTION AIR PROVING PRESSURE SWITCH COMBUSTION AIR CABINET BLOWER pe IGNITION CONTROL UPPER ACCESS GAS MANIFOLD BLOWER CONTROL BOARD BLOWER BLOWER ACCESS CONTROL BOX MOTOR PANEL FIGURE 1 A WARNING A WARNING Product contains fiberglass wool Do not set thermostat below 60_F
3. 16_C in heating mode Setting thermostat below 60_F 16_C re duces the number of heating cycles Damage to the unit may occur that is not covered by the warranty Disturbing the insulation in this product during installation maintenance or repair will expose you to fiberglass wool dust Breathing this may cause lung cancer Fiberglass wool is known to the State of California to cause cancer Fiberglass wool may also cause respiratory skin and eye irritation 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 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 Page 2 A CAUTION Before attempting to perform any service or mainte nance turn the electrical power to unit OFF at dis connect switch A WARNING Do not use this furnace if any part has been under water Immediately call a qualified service techni cian to inspect the furnace and to replace any part of the control system and any gas control which has been under water 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 specified and
4. and toxic Exposure to this gas can cause personal injury and even death to all occupants including pets Any item that is pow ered by or gives off heat from a combustion process in cluding 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 Reliable detectors are available at reason able retail prices Contact your independent Lennox dealer for more details about this investment 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 responsibility to ensure that this appliance is maintained Proper maintenance is critical for your safety and the satisfactory operation of the product Lennox strongly recommends annual in spection and maintenance of this appliance Contact your independent Lennox dealer for an inspection by a qualified service technician Lighting Information amp Operation A WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life BEFORE LIGHTING smell all around the appliance area for gas Be sure to smell next to the fl
5. age 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 fol lowing items during an annual inspection Power to the unit must be shut off for the service technician s safety Fresh air grilles and louvers on the unit and in the room where the furnace is installed Must be open and 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 dam aged or sagging pipe or disconnected joints Unit appearance Must be inspected for rust dirt signs of water burnt or damaged wires or components Blower access door Must be properly in place and pro vide a seal between the return air and the room where the furnace is installed Return air duct Must be properly attached and provide an air seal to unit Operating performance Unit must be observed during operation to monitor proper performance of the unit and the vent system Combustion gases Flue products must be analyzed and compared to the unit specifications Problems detected during the inspection may make it necessary to temporarily shut down the furnace until the items can be repaired or replaced Pay attention to your furnace Situations can arise be tween annual furnace inspections that may result in un safe operation For instance items innocently stored
6. approved parts Important Directions 1 Keep the furnace area clear and free of combustible material gasoline and other flammable vapors and liquids If installed in an insulated area furnace must be kept free of insulating material Insulating material 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 furnace or any other gas appliance ie a water heater is installed When return air is drawn from a room a negative pressure is created in the room If a gas appliance is operating in a room with negative pressure the flue products can be pulled back down the vent pipe and into the room This reverse flow of the flue gas may result in incomplete combustion and the formation of carbon monoxide gas This toxic gas might then be distributed throughout the house by the furnace duct system Your furnace is a gas appliance It is critical that the gas supplied to the unit be completely burned to avoid the pro duction of carbon monoxide gas Complete combustion of the gas requires but is not limited to correct gas pres sure and gas flow rate adequate combustion air and proper venting A WARNING Carbon monoxide gas is invisible odorless
7. iving space which could cause personal injury or death In Unit Filter with Side Return Air See Figure 5 1 Turn off electric power to furnace 2 Locate the filter door of the filter rack assembly 3 Using the filter door pins pull filter door with filter at tached out of filter rack assembly Remove filter door from filter by pulling up on securing tabs 4 Clean filter with cold water and a mild soap Direct wa ter through filter in the opposite direction of air flow Al low filter to dry then spray with filter handicoater avail able from your Lennox dealer prior to reinstallation 5 Position filter door on end of filter so that the thumb tab side of the filter door is away from the furnace Check for correct air flow position Squeeze thumb tabs to secure filter to door 6 Guide filter and filter door into the filter rack installed on side of furnace Push door into filter rack until secure FILTER DOQR PIN x FILTER FILTER ne FILTER DOQR y LA TAB A L FIGURE 5 Page 5 Seasonal Inspections A qualified service technician should inspect the com plete system each season heating and cooling The fol lowing maintenance procedures should be conducted by a qualified service technician Do not attempt to service the unit in any way Venting System Annually before heating season inspect furnace venting system draft hood vent cap heat exchanger and burners for corro
8. next to the furnace may obstruct the combustion air supply This could cause incomplete combustion and the produc tion of carbon monoxide gas Page 6
9. oor because some gas is heavier than air and will settle on the floor Use only your hand to push in or turn the gas control knob Never use tools If the knob will not push in or turn by hand do not try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion To place G23 furnace into operation G23 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 be automatically lit The ignitor does not get hot when there is no call for heat on units with SureLight ignition system Page 3 Gas Valve Operation Figure 3 1 STOP Read the safety information at the beginning of this section 2 Set thermostat to lowest setting See figure 2 THERMOSTATS HEAT 6 10 15 T E 90 want IL FIGURE 2 3 Turn off all electrical power to appliance 4 This appliance is equipped with an ignition device which automatically lights the burners Do not try to light the burners by hand 5 Remove upper access panel 6 On Honeywell VR8204 gas valves turn knob on gas valve clockwise to OFF For White Rodgers 36E gas valves move switch to OFF Do not force the switch See figure 3 HONEYWELL VR8204 SERIES GAS VALVE WHITE RODGERS 36E GAS VALVE
10. sion deterioration or deposits of debris Remove any obstructions Inspect 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 furnace return air duct connection to ensure duct is sealed to the furnace and terminates outside the space con taining 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 vent ing system Blower Check and clean blower wheel for any debris Blower motor is pre lubricated for extended bearing life No further lubrica tion is needed Burner Flame Burner Flame Start burner and allow to operate for a few minutes to es tablish normal burning conditions Check burner flame by observation Flame should be predominantly blue and strong in appearance A CAUTION To ensure proper operation a qualified technician should periodically check the burner flame Service Reminder Call your Lennox service technician if unit is inoperative Before calling always check the following to be sure ser vice is required 1 Check that electrical disconnect switches are ON 2 Check room
11. sure proper furnace operation Filters used inside the G23 series unit are available from Len nox and must be ordered separately These foam filters may be cleaned for reuse If replacement is necessary order Len nox part no 31J81 for 14 X 25 inch filter for G23Q2 50 Q3 50 and Q2 3 75 units P 8 7822 for 16 X 25 inch filter for G23Q3 100 units and P 8 7831 for 20 X 25 inch filter for G23Q3 4 100 Q3 4 125 Q4 5 75 Q4 5 100 Q5 6 125 and Q5 6 150 units Use the following procedure to clean filter Refer to figure 1 In Unit Filter with Bottom Return Air 1 Turn off electric power to furnace 2 Remove blower access panel 3 Remove filter by pressing side filter clips and pulling filter up and out See figure 4 BOTTOM RETURN FILTER INSTALLATION REAR FILTER CLIP FURNACE FURNACE FRONT FURNACE FIGURE 4 4 Clean filter with cold water and a mild soap Direct water through filter in the opposite direction of air flow Remove all soap residue 5 Allow filter to dry then spray with filter handicoater P 8 5069 available from your Lennox dealer prior to reinstallation Page 4 6 Place filter in bottom of blower compartment beneath rear filter clip Press down on filter sides Filter clips flex allowing filter to snap into place 7 Replace blower access panel A WARNING Blower door must be securely in place when blower and burners are operating Gas fumes which could contain carbon monoxide can be drawn into l
12. thermostat for proper setting 3 Replace any blown fuses or reset circuit breakers 4 Gas valve should be ON 5 Air filter should not be plugged limiting air flow 6 Is gas turned on at meter 7 Is manual main shut off valve open Safety Precautions If you discover any of the following shut down your unit and contact an independent 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 unfamiliar noises If you smell any unusual odors your unit may be oper ating improperly For example units can give off unfa miliar odors if components are required to operate in abnormal conditions Look for visible signs of a malfunctioning unit Exam ples include unusual amounts of condensate on win dows inside your house visibly burnt components or unusual dirt or rust accumulations on the vent pipe or in the unit If you experience headache nausea fatigue or dizzi ness the cause could be exposure to carbon monox ide gas This is often misdiagnosed as the flu because symptoms are similar If you suffer from flu like symp toms that are exaggerated at home but seem to sub side while you are away from the house exposure to carbon monoxide could be the cause Your vigilance may pay off in early detection of a problem before either personal injury or property dam
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