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1. WHITE RODG eood FACTORY INSTALLED c PRCA ERE reis Q THERMOSTAT CONNECTIONS TB1 W2 HEAT DEMAND FROM 2ND STAGE T STAT WI HEAT DEMAND FROM IST STAGE T STAT WHITE R CLASS 2 VOLTAGE TO THERMOSTAT G MANUAL FAN FROM T STAT GREEN C THERMOSTAT SIGNAL GROUND CONNECTED TO TRANSFORMER GROUND TR amp CHASIS GROUND GRD YI THERMOSTAT 15 STAGE COOL SIGNAL Y2 THERMOSTAT 2nd STAGE COOL SIGNAL 0 THERMOSTAT SIGNAL TO HEAT PUMP REVERSING VALVE DIP SWITCH ES FUNCTION 1 and 2 Blower Off Delay Heating Mode 3 Second Stage ON Delay Single stage t stat 4 Blower Off Delay Cooling Mode FIGURE 14 Page 12 TABLE 7 TABLE 8 Integrated Control Board 5 Pin Terminal Integrated Control Board Terminals 120VAC Neutral EA Electronic Air Cleaner CIRC Indoor Blower Combustion Air Inducer Neutral 120VAC Line TABLE 9 eme Integrated i Board 12Pin Terminal PARK For Unused Leads Gas Valve 2nd High Fire Second Stage Prove Switch COOL Cooling Speed T Not Used Electronic Air Cleaner 24V Hot Ignitor P HI HEAT High Heat Speed LO HEAT Low Heat Low Cool and Continuous Fan Speed Page 13 TABLE 10 DIAGNOSTIC CODES Diagnostic LEDs are labeled DS1 and DS2 See figure 14 for location of d
2. Page 35 G32 3 UNIT DIAGRAM 120V ACC oR 5102 BLOWER SPEED CHART K43 ECON HIGH HEAT FACTORY CONNECTED SPEED TAPS OTOR IF USED PRESSURE UNIT cooL 1825 1825 SPEEDS SWITCH 6 I 2 MI M2 AVAILABLE SIO 547 03 75 BROWN YELLOW RED 4 an HEAT PRIMARY Q3 4 100 YELLOW RED BROWN 4 PRESSURE ROLLOUT m BLACK SWITCH EM SWITCH 04 5 100 125 YELLOW RED BLUE BROWN 5 HI BLOWER SPEED SELECTION Lo COMBUSTION BLACK BROWN YELLOW RED MOTOR IER BLACK BROWN BLUE YELLOW RED JACKPLUG CHART JACK PLUG CONTROL INTERFACE JACK PLUG TWO SPD CONTROL JACK PLUG BURNER CONTROL JACK PLUG BLOWER DECK JACK PLUG COMB AIR BLOWER ACK PLUG IGNITION 9 55 A92 DOOR INTEGRATED INTERLOCK CONTROL THERMOSTAT HEAT ANTICIPATION SETTING 50 AMP WHITE RODGERS VALVE B WARNING SI TB25 TI ELECTRIC SHOCK HAZARD CAUSE INJURY ROOM THERMOSTAT BLOWER TRANSFORMER OR DEATH UNIT MUST BE GROUNDED IN ACCORDANCE SPEED WITH NATIONAL AND LOCAL CODES CHANGE CB8 NOTE Sap CIRCUIT IF ANY WIRE IN THIS APPLIANCE IS REPLACED IT BREAKER MUST BE REPLACED WITH WIRE OF LIKE SIZE RATING AND INSULATION THICKNESS LINE VOLTAGE FIELD INSTALLED CLASS II
3. BLOWER MULLION INSIDE INSTALLATION Line Voltage Enters Make Up Box Through Side Of Unit and J69 Passes Through Bottom Knockout in Make Up Box BLOWER MULLION FIGURE 2 I UNIT COMPONENTS G32 unit components are shown in figure 1 The gas valve ignition control and burners can be accessed by removing the burner access panel The blower and blower controls can be accessed by removing the blower access door G32 units are designed for bottom and side return air The panels are designed to be knocked out bottom return or cut out side return as required for return air duct connec tion A Make Up Box Figure 3 The line voltage make up box is shown in figure 3 The box may be installed inside or outside the unit and may be installed on the unit left or right side figure 2 MAKE UP BOX POWER ENTRY KNOCKOUT 120V LINE VOLTAGE 3 Y PIGTAIL CONNECTIONS COVER JACK J69 to blower deck Box may be installed inside or outside unit See Figure 2 FIGURE 3 An accessory brown output wire is provided with the make up box The wire provides a 120V connection for optional ac cessories such as electronic air cleaner or humidifier If used the wire is field installed in J69 jack plug by inserting the pin of the brown wire into the open INSTALLING BROWN socket of the jack See figure 4 ACCESSORY WIRE TO J69 120V accessories rated up to 4 amps tot
4. LENNOX vr MIFOFMATION G32 Corp 9729 L12 Service Literature revised 02 2004 G32 SERIES UNITS G32 series units are high efficiency upflow gas furnaces manufactured with DuralokPlus aluminized steel clam shell type heat exchangers G32 units are available in heating capacities of 75 000 to 125 000 Btuh and cooling applications up to 5 tons Refer to Engineering Handbook for proper sizing Units are factory equipped for use with natural gas only LP kits are available All G32 1 through 4 model units feature the Lennox SureLight silicon nitride ignition system G32 5 and later model units feature the SureLight two stage inte grated control board The G32 units meet the California Nitro gen Oxides NO Standards and California Seasonal Effi ciency requirements without modification All units use a two stage gas valve along with a two stage combustion air blow er The gas valve is redundant to assure safety shut off as re quired by A G A or C GA Information contained in this manual is intended for use by qualified service technicians only All specifications are subject to change Procedures outlined in this manual are presented as a recommendation only and do not super sede 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 AWARNING General 22 1 Improper installation
5. Diagnostic lights flash watch guard flame failure NOTE Unit might go into 60 minute Loose sensor wire connection causes Watchguard mode depending on in termittent nature of sensor signal LED 1 Alternating Slow Flash 6 5 1 intermittent loss of flame signal 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 LED 2 Alternating Slow Flash PROBLEM 7 CONTROL SIGNALS LOW FLAME SENSE DURING HEATING MODE Possible Cause Corrective Action Comments 7 0 Unit operates correctly but the diag nostic lights flash low flame sense code LED 1 Slow Flash LED 2 Fast Flash 7 1 1 Sense rod is improperly located on the burner 7 1 2 Sense rod is contaminated ACTION 1 Check the sense rod for proper loca tion on the burner Properly locate the sense rod or replace if rod cannot be located correctly ACTION 1 Check sense rod for contamination or coated surface Clean the sense rod with steel wool or replace sensor DO NOT USE SAND PA PER TO CLEAN ROD SAND PAPER WILL CONTRIBUTE TO THE CONTAMINATION PROBLEM PROBLEM 8 RF STATIC DURING TIME FOR IGNITION Condition 8 0 8 1 1 AM radio interference Ignitor operation ACTION SCO Ene Support Dallas Page 56
6. Gray area indicates 91695 sured on fight s ids 9 bum DO ure The purpose of this chart is to explain unit operation Each unit may vary depending on installation altitude intake exhaust configuration and other factors Y D MANIFOLD PRESSURE positive inches water column N FIGURE 17 Figure 17 show how gas valve output changes as burner box pressure changes Generally a lower burner box pressure produces a leaner gas air mixture and a higher burner box pressure produces a richer mixture A proce dure showing how to check manifold pressure is shown on page 22 14 Differential Pressure Switch S102 all units S128 G32 75 units only Combustion Air Prove Switch All G32 series units are equipped with a differential pressure switch S102 located on the vestibule panel The G32 75 unit only is equipped with a second pressure switch S128 The switches are connected to the combustion air blower hous ing by means of a flexible silicon hose A separate hose con nects the pressure switch to the burner box and the gas valve regulator The silicon hose on 128 will tee into S102 See figure18 The switch monitors air pressure in the com bustion air blower housing and burner box Both switches are a single pole single throw normally open pressure switch electrically connected in series with the igni tion control The purpose of the switch is to prevent burner operation if sufficient combustion
7. 1 1 6 ACTION 1 If all the above items have been Failed control board Checked replace board 1 2 ACTION 1 Manually reset the roll out switch 1 2 1 En pushing the top button ose through nis Only Roll out switch open ACTION 2 Determine the cause of the roll out Diagnostic lights flash the roll out switch activation before leaving furnace code 1 2 2 ACTION 1 Check continuity across roll out I Switch Replace roll out switch if switch is reset Roll out switch failure but does not have continuity LED 1 On Miswiring or improper connections at ACTION 1 Check wiring connections to switch LED 2 Slow Flash roll out switch ACTION 1 Check 9 pin connector for proper 1 2 4 connection to control board Nine pin connector failure ACTION 2 Check continuity of the multi plug pin 1 3 On initial power up the comb air blower does not energize Diagnostic lights flash the reverse ACTION 1 Check the 120V has line and neutral polarity code 1 3 1 correctly input into control i i ACTION 2 Reverse the line and neutral at the 120V main power polarity reversed AA pi YA kaban LED 1 Fast Flash LED 2 Slow Flash 1 4 G32 1 through 3 Units Only 1 4 1 ACTION 1 Check for 120V to combustion air On initial power up the combustion Open combustion air blower motor cir blower If no power check wire and connec air blower does not energize cuit tions Diagnostic lights flash normal power
8. OFF TIME Setting FIGURE 12 7 Two Stage Control A86 TWO STAGE CONTROL BOARD 25M3301 All G32 1 through 4 units are equipped with a two stage control board Two different boards have been used Board 43K9001 and board 25M3301 figure 13 are identical ex cept the 9 pin connector on 43K9001 is replaced by two re lays with quick connect terminals on 25M3301 The two stage board acts as a go between from the indoor thermo stat to the SureLight ignition board The board can be uti lized in three modes with a SINGLE STAGE thermostat a TWO STAGE thermostat or with a second stage high fire delay called W2 TIMED The two stage board is equipped with a jumper see figure 13 which changes operating modes and a jumper which adjusts second stage heat delay during W2 TIMED mode While in the single stage thermostat mode one stage jumper setting the unit will always operate on second Jo k a OPERATION JUMPER 2 e J 0 012 c x 35715 3915 le 01919 omm 2 NIN SH BY JE stage heat The combustion air blower B6 will operate on I ON DELAY high speed and indoor blower B3 will operate on heating I JUMPER speed While in the two stage thermostat mode the unit will op
9. on operation 1 4 2 ACTION 1 If power is present at blower replace LED 1 Slow Flash Failed combustion air blower motor Dower LED 2 Slow Flash Page 51 PROBLEM 1 UNIT FAILS TO OPERATE IN THE COOLING HEATING OR CONTINUOUS FAN MODE ACTION 1 Check that the unit is properly itial th busti 1 5 1 grounded Un initia n e combustion Improper ground to the unit ACTION 2 Install a proper main ground to the air blower remains energized unit Diagnostic lights flash the improper 1 5 2 main ground ACTION 1 Check 6 pin connector for proper 6 Pin connector is improperly at installation Correctly insert connector into con tached to the circuit board trol LED 1 Alternating Fast Flash 1 5 3 ACTION 1 Check that the line voltage is above LED 2 Alternating Fast Flash 75V Determine cause of voltage drop and supply Line voltage is below 75V correct voltage to the control PROBLEM 2 UNIT FAILS TO OPERATE IN THE COOLING OR HEATING MODE BUT COMBUSTION AIR BLOWER OPERATES CONTINUOUS G32 1 through 3 UNITS WITH CONTROL BOARDS DATE CODED AFTER NOV 1 1997 WILL OPERATE IN COOLING WITH COMBUSTION AIR BLOWER CYCL ING 5 SECONDS ON 55 SECONDS OFF BUT NOT IN THE HEATING MODE Possible Cause Corrective Action Comments 2 1 PENES Powerup the ore 2 1 1 ACTION 1 Check for correct wiring and loose all ROWERS Malis energized a connections in the ignitor circuit Check multi Diagnostic lights flash
10. 10 Turn on all electrical power to unit 11 Set thermostat to desired setting 12 If the appliance will not operate follow the instructions To Turn Off Gas To Unit and call your service techni cian or gas supplier Turning Off Gas To Unit 1 Set thermostat to lowest setting Page 26 2 Turn off all electrical power to unit if service is to be per formed 3 Remove access panel 4 White Rodgers 36E gas valve switch lever to OFF Do not force 5 Replace access panel NOTE On initial start ups and when condensate trap is dry unit may turn itself off and on to allow condensate trap to fill This is normal operation C Safety or Emergency Shutdown Turn off unit power 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 covers and vent caps must be in place and secured Refer to Maintenance section of this manual for instruc tions on how to prepare condensate assembly for ex tended period shutdown IV HEATING SYSTEM SERVICE CHECKS A A G A C G A Certification All units are A G A and C G A design certified without modifications Refer to the G32 Operation and Installation Instruction Manual Information B Exhaust CO and CO content Carbon Dioxide is a colorless and odorless gas
11. 92 12057 INTEGRATED CONTROL ou K3 1 2AVAC HLI Wo PS RO 02 0 SEC AN jsp J58 J58 A 58 358A ACB uz ACB ACC P58 P58 LOW HEAT P20 P20N amp 120 5 Pee piss I e J20 CAIN 86 p20 J38 a 1 TWO GAS LIMIT 547 3 STAGE J20Y A86 KI3 SNF CONTROL TWO L 5 A size ROLLOUT STAGE T SWITCH P159 N CONTROL x x PRESSURE yisoXy 7981 ks SWITCH E FLAME SENSOR EE BLOWER PEED CHART R33 IGNITOR GAS VALVE i PROPANE ONLY vale J33 20 STAGE 1436 2 CONTROL 6 gt w Og lt TSGI COMBUSTION AIR HUMIDIFIER BLOWER MOTOR BLACK COOL CONTROL TSG GVI GAS VALVE A92 56 _ IMPORTANT CONTROL 3 Ji56 NEVER CONECT MORE Than LEMAN aries e WIRING DIAGRAM BLOWER MOTOR ONE CONNECTION HEATING UNITS GAS ZA FOR ACCESSORY HOOKUP G3203 75 2 63204 5 5128 USED ON 632Q3 4 100 2 63204 5 832 75 UNIT ONLY N KIO IS USED ONLY SECTION ON W2 TIMED CIRCUIT Sus Form No W DENOTES OPTIONAL COMPONENTS ross Tas Tnavairiae Ine D o
12. DS SLOW FLASH 052 ON GAS VALVE OFF COMB AIR INDUCER OFF AFTER 15 SECOND POST PURGE INDOOR FIRST STAGE LOW FIRE HEAT BLOWER OFF AFTER DELAY PRESSURE SWITCH CLOSED DS1 OFF DS2 FAST FLASH RETURN TO HEAT DEMAND RETURN TO FIRST STAGE HEAT MODE FIRST STAGE CONTINUES UNTIL SECOND RESE TON SEE gt STAGE PRESSURE SWITCH CAN BE PROVEN G320 75 only or HEAT DEMAND IS SATISFIED A FIVE 5 MINUTE WAIT PERIOD IS INITIATED BEFORE RETRY WERE 5 ATTEMPTS MADE FOR Y SECOND STAGE HEAT HEAT DEMAND SATISFIED NO Y DS1 AND DS2 SIMULTANEOUS FAST FLASH SEE BOX C FIRST STAGE HEAT DEMAND SATISFIED V SECOND STAGE HEAT HEAT DEMAND SATISFIED FIRST AND SECOND STAGE HEAT DEMAND SATISFIED DS1 AND DS2 DEMAND SATISFIED SIMULTANEOUSLY DS1 AND DS2 SIMULTANEOUS FAST FLASH DS1 amp 052 SIMULTANEOUS FAST FLASH SIMULTANEOUS FAST FLASH GAS VALVE OFF COMBUSTION AIR GAS VALVE COMBUSTION AIR INDUCER INDUCER OFF AFTER POST PURGE I AND INDOOR BLOWER RETURN TO FIRST PERIOD INDOOR BLOWER OFF AF STAGE OPERATION TER SELECTED DELAY DS1 AND DS2 SIMULTANEOUS FAST FLASH DS1 AND DS2 SIMULTANEOUS FAST FLASH FIRST STAGE HEAT DEMAND SATISFIED DEMAND FOR HEAT SATISFIED GAS VALVE OFF COMBUSTION AIR INDUCER POWER ON STAND BY OFF AFTER 5 SECOND POST PURGE PERIOD DS1 AND DS2 INDOOR BLOWER OFF DELAY INITIATED SIMULTANEOUS SLOW FLASH DS1 amp DS2 SIMULTANEOUS FAST FLASH Page 48 COOLING SEQUENCE OF OPERATION POW
13. Fast flash equals 3 Hz three flashes per second Drop out flame sense current lt 0 21microAmps Page 8 TABLE 3 a Electronic Ignition Figures 11 and 12 On a call for heat the SureLight control monitors the com bustion air blower pressure switch The control will not be gin the heating cycle if the pressure switch is closed by FUNCTION passed Once the pressure switch is determined to be open the combustion air blower is energized When the differential in the pressure switch is great enough the pres Not Used sure switch closes and a 15 second pre purge begins If the pressure switch is not proven within 2 1 2 minutes the control goes into Watchguard Pressure Switch mode for a SureLight BOARD J156 TERMINAL DESIGNATIONS Ignitor Ignitor Neutral Combustion Air Blower Line Voltage 5 minute re set period Not Used After the 15 second pre purge period the SureLight ignitor warms up for 20 seconds after which the gas valve opens Combustion Air Blower Neutral for a 4 second trial for ignition G32 units with board 63K89 24L85 or 56L83 the ignitor stays energized for the first sec TABLE 4 ond of the 4 second trial G32 units with board 97L48 igni SureLight BOARD J58 TERMINAL tor stays energized for the full 4 second trial for ignition If ignition is not proved during the 4 second period the con i trol will try four more times with an inter purge and warm up FUNCTION time between trials of 35 seconds After a total of fi
14. Thoroughly rinse and drain the heat exchanger Soap solution can be corrosive so take care that entire as sembly is completely rinsed Re install heat exchanger into cabinet making sure that the clamshells of the heat exchanger assembly are resting in the notches of the support located at the rear of the cabinet This can be viewed by removing the indoor blower and examining through the blower opening Re secure the supporting screws along the vestibule sides and bottom to the cabinet Re install cabinet screws on sides and front flange at blower deck Re install the limit switch and pressure switch 75 unit will have a second switch on the vestibule panel Re install 9 pin plug to blower deck and connect it to the 9 pin plug from below the blower deck Re install the combustion air blower Be careful that the plastic orifice on the blower inlet has not fallen out See figure 1 Reconnect the 3 pin plug to the wire har ness Re install the flue transition in the cabinet and re attach the drain tube Route the drain tube below the combustion air blower housing and to the elbow on the cold header collector box trap See figure 18 Re install condensate line with adapter to condensate trap Use fresh Teflon tape to ensure a leak free joint Re connect to condensate line outside of the unit 30 31 32 33 34 35 36 37 38 39 40 41 BARBED PRESSURE SWITCH FITTINGS GATO BURNER BRA FIGURE 43 Re ins
15. 75 volts If voltage lower than 75 volts prior to ignitor warm up control will signal waiting on call from thermostat and will not respond ALTERNATING ALTERNATING SLOW FLASH SLOW FLASH NOTE Slow flash rate equals 1 Hz one flash per second Fast flash rate equals 3 Hz three flashes per second Minimum flame sense current 0 17 0 22 microAmps Page 14 9 Blower Motors and Capacitors All G32 units use direct drive blower motors All motors used are 120V permanent split capacitor motors to ensure maxi mum efficiency See table 11 for ratings TABLE 11 G32 BLOWER RATINGS 120V 1PH G32Q3 5MFD 370V G32Q3 4 1 2 7 5MFD 370V G32Q4 5 3 4 40MFD 370V 10 Combustion Air Blower B6 All G32 units use a two stage combustion air blower to move air through the burners and heat exchanger during heating op eration The blower uses a 120VAC motor The motor oper ates during all heating operation and is controlled by the Sur eLight integrated control A92 and the two stage control board A86 The combustion air blower operates for 15 seconds be fore burner ignition pre purge and for 5 seconds after the gas valve closes post purge The combustion air blower operates on low speed during first stage heat low fire then switches to high speed for second stage heat high fire 11 Primary Limit Control S10 Figure 15 The primary limit S10 on G32 units is located in the middle of the heating vestibule panel When excess
16. ALTERNATING FAST FLASHES PRESSURE SWITCH WATCHGUARD 5 MINUTES COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF LED 1 OFF LED 2 SLOW FLASH WATCHGUARD 60 MINUTE DELAY SIGNAL LIMIT OR IGNITION FAILURE GAS VALVE OFF COMBUSTION AIR AND INDOOR BLOWER OFF LED 1 AND LED 2 ALTERNATING SLOW FLASHES HEATING SEQUENCE CONTINUED NORMAL HEATING MODE PREPURGE 15 SECONDS ABNORMAL HEATING MODE IGNITION SEQUENCE BEGINS Ignition trial counter initiated WATCHGUARD 60 MINUTE DELAY FLAME IGNITOR WARM UP FAILURE GAS VALVE OFF COMBUSTION 20 SECONDS AIR INDUCER OFF INDOOR BLOWER OFF LED 1 amp LED 2 ALTERNATE SLOW FLASH n eus SINGLE STAGE MODE TWO STAGE MODE LI W2 TIMED MODE LI CALL FOR 1st STAGE HEAT L SINGLE STAGE T STAT JL HIGH HEAT ONLY MAIN GAS VALVE OPEN MAIN GAS VALVE OPEN GAS VALVE OPEN CONTROL CHECKS RETRY LOW HEAT ONLY HIGH AND LOW HEAT FOR IGNITION COUNT LOW TEA ONES SEGOND STAGE HAVE FOUR RE TRIES TIME ON BEGINS BEEN COMPLETED 4 SECONDS FLAME RECTIFICATION CURRENT CHECK gt 0 20 microamps FLAME PRESENT GAS VALVE DE ENERGIZED Response time 2 seconds maximum INDOOR BLOWER ON DELAY BEGINS 45 seconds r E WATCHGUARD LIMIT SWITCH GAS SINGLE STAGE MODE VALVE OFF COMBUSTION AIR AND _ L INDOOR BLOWER OFF LED 1 SLOW ON IS 60 MINUTE L 2 INDOOR BLOWER INDOOR BLOWER ON LOW SPEED ON HIGH HEATING SPEED FLAME PRESENT NO Conti
17. INSTRUCTIONS FOR CONTROL BOARD LAYOUT LED 1 LED 2 DESCRIPTION SIMULTANEOUS SIMULTANEOUS Power Normal operation SLOW FLASH SLOW FLASH Also signaled during cooling and continues fan Mak Q FAST SPESE FAST Normal operation signaled when heating demand initiated at thermostat Primary or Secondary limit open Units with board 63K8901 or 24L85 Limit must SLOW FLASH ON close within 5 trials for ignition or board goes into one hour limit Watchguard Units with board 56L83 or 97L48 Limit must close within 3 minutes or board goes into one hour limit Watchguard Pressure switch open or has opened 5 times during a single call for heat OR OFF SLOW FLASH Blocked inlet exhaust vent OR Condensate line blocked OR Pressure switch closed prior to activation of combustion air blower ALTERNATING SLOW ALTERNATING SLOW Watch d b fail to iqnit FLASH FLASH atchguard burners fail to ignite SLOW FLASH Flame sensed without gas valve energized SLOW FLASH Rollout switch open OR 9 pin connector improperly attached ON ON OFF Circuit board failure or control wired incorrectly ON FAST FLASH SLOW FLASH Main power polarity reversed Switch line and neutral SLOW FLASH FAST FLASH Low flame signal Measures below 61 microAmps Replace flame sense rod ALTERNATING FAST ALTERNATING FAST Improper main ground or line voltage below 75 volts OR Broken ignitor OR FLASH FLASH Open ignitor circuit NOTE Slow flash equals 1 Hz one flash per second
18. VOLTAGE FIELD WIRING 1 amp 2 UNPOWERED TERMINALS ALL UNUSED MOTOR LEADS MUST BE PLACED ON EITHER MI OR M2 A NOTE W2 CONNECTION USED FOR TWO STAGE THERMOSTAT ONLY TAPE OFF IF SINGLE STAGE THERMOSTAT IS USED i I Lasi ri l Hi ai Ton AB6 BLOWER MOTOR TWO CARACLTOR dd STAGE SI NM d CONTROL CODE TS61 THERMOSTAT lool A92 LI 4 s51 RY INTEGRATED J69 P69 DOOR INTERLOCK CONTROL 120 vac A92 120 Fi INTEGRATED CONTROL HLI Q 24VAC HLO KI I SEC AN sp 6 58 a QU ACB ACB LOW HEAT PRIMARY GAS LIMIT A86 STAGE ROLLOUT 86 CONTROL LOW HEAT A SWITCH PRESSURE STAGE 7861 SWITCH P159 CONTROL go Ny TSGI vi EE BLOWER PEED CHART lt GAS VALVE GAS VALVE C HI 0 PROPANE ONLY A86 MV No ass PP STAGE CONTROL i HI Og TSGI FLAME SENSOR R33 IGNITOR 1159 AN P159 AN BLACK COOL HU
19. Wiring of pressure switch to furnace 5 Blocked heat exchanger or leak in heat exchanger II PLACEMENT AND INSTALLATION Make sure unit is installed in accordance with installation instructions and applicable codes A PVC Joint Cementing Procedure WARNING DANGER OF EXPLOSION Fumes from PVC glue may ignite during system check Remove spark plug wire from ignition control before 120V power is applied Reconnect wire after two minutes 1 Measure and cut vent pipe to desired length 2 Debur and chamfer end of pipe removing any ridges or rough edges If end is not chamfered edge of pipe may remove cement from fitting socket and result in a leak ing joint Clean and dry surfaces to be joined 4 Test fit joint and mark depth of fitting on outside of pipe 5 Uniformly apply liberal coat of PVC primer for PVC or ABS cleaner for ABS for at least 5 to 15 seconds to in side socket surface of fitting and male end of pipe to depth of fitting socket Remove puddles of primer before applying cement Promptly apply solvent cement to end of pipe and in side socket surface of fitting Cement should be ap plied lightly but uniformly to inside of socket Take care to keep excess cement out of socket Apply second coat to end of pipe NOTE Time is critical at this stage Do not allow primer to dry before applying cement 7 Immediately after applying last coat of cement to pipe and while both inside
20. above sea level G32 75 natural no adjustment G32 100 natural G32 125 natural 3 5 0 88 3 4 0 85 3 3 0 82 3 2 0 80 G32 75 L P no adjustment G32 100 L P 7 5 0 19 7 3 0 185 7 1 0 180 7 0 0 177 632 125 LP 7 5 0 19 7 3 0 185 7 1 0 180 7 0 0 177 INTAKE AND EXHAUST PIPE VENTING TABLE Vent Pipe Minimum Vent Pipe Diameter Required Maximum Equivalent Length 75 000 Btuh 22 0 kW 100 000 Btuh 29 3 kW 125 000 Btuh 36 6 kW Fet Metes im mm i mm 3m m 15 20 N A ME ERE EE f Z a i 10 MINIMUM PIPE LENGTHS FOR FURNACES G32 75 5 feet 1 5 m with two 90 elbows of 2 inch 51 mm diameter pipe 15 equivalent feet 4 6 m total G32 100 5 feet 1 5 m with two 90 elbows of 2 inch 51 mm diameter pipe 15 equivalent feet 4 6 m total G32 125 5 feet 1 5 m with two 90 elbows of 2 inch 51 mm diameter pipe 15 equivalent feet 4 6 m total VENTING NOTES One 90 elbow is equivalent to 5 feet 1 5 m of straight vent pipe Two 45 elbows are equal to one 90 elbow One 45 elbow is equivalent to 2 5 feet 75 m of straight vent pipe One foot 305 mm length of 2 in 51 mm diameter pipe is equivalent to 8 feet 2 4 m of 3 in 76 mm diameter pipe Intake and Exhaust pipes must be the same diameter 2 inch x 3 inch 51 mm x 76 mm adaptor is furnished with 100 and 125 furnaces for exhaust pipe connection Exhaust pip
21. adjustment alteration service Specifications 2 or maintenance can cause property damage person Blower 3 al injury or loss of life Installation and service must be performed by a qualified installer or service High Altitude citer arbe otros ae 4 agency Vent Table 4 I Unit Components 6 WARNING II Placement and Installation 18 A Ill Star Up diis Ada abcde NER 26 Electric shock hazard Can cause injury VI Heating System Service Checks 27 or death Before attempting to perform V Typical Operating Pressures 29 any service or maintenance turn the VI Maint 30 electrical power to unit OFF at discon aintenance nect switch es Unit may have multiple VII Wiring Diagrams and Operating Sequence 34 power supplies VIII Trouble Shooting Guide SureLight Control 51 Teen nical 1998 Lennox Industries Inc Publications Page 1 Litho U S A SPECIFICATIONS Model No x O ModelNo G32Q3 75 G32Q3 4 100 G32Q4 5 100 G32Q4 5 125 Input Btuh kW High finputBuh KW High 75 000 22 0 100 000 29 3 125 000 36 6 Input Btuh kW Low 51 000 15 0 68 000 19 9 85 000 24 9 Output Btuh kW High 68 850 20 2 93 200 27 3 92 400 27 1 116 375 34 1 Output Btuh kW Low 47 275 13 9 63 716 18 7
22. for either right or left side exit of con densate piping Condensate drain line should be routed only within the conditioned space to avoid freezing of con densate and blockage of drain line An electric heat cable should be used where condensate drain is exposed to un conditioned areas The following procedure is for all G32 units 1 Determine which side condensate will exit the unit 2 Connect 1 2 13mm plastic pipe plug provided in the unused end of the condensate trap Install plug so that it is sealed water tight yet able to be removed Do not permanently seal the connection Teflon tape is recommended to seal joint See figure 34 CONDENSATE ASSEMBLY For left or right installation COLD HEADER COMBUSTION AIR BLOWER BRACKET 3 1 NIPPLE ADAPTER CONDENSATE TRAP BOOT OR CAP ADAPTER FIGURE 34 Use the provided adapter 1 2 PVC x 1 2 MPT and the nipple 1 2 PVC to carry drainage outside the cabinet If a field substitute is needed 1 2 CPVC x 1 2 MPT adapter and 1 2 CPVC is acceptable for use Glue nipple to the adapter using the procedures out lined in the Joint Cementing Procedures section The nipple adapter assembly should be connected in a non permanent manner and must be water tight Teflon tape is recommended to seal the joint For Right Hand Side Condensate Exit Install the nipple adapter assembly from the outside of the cabinet and insert the a
23. heat is sensed in the heat exchanger the limit will open If the limit is tripped the furnace control energizes the supply air blower and de energizes the gas valve The limit automati cally resets when unit temperature returns to normal The switch is factory set and cannot be adjusted LIMIT CONTROL S10 FOR G32 SERIES UNITS AND ALTERNATE STYLE Units may be equipped with either style limit INSULATING COVER s z E z z amp 9 a FIGURE 15 Page 15 12 Flame Rollout Switch S47 Flame rollout switch S47 is a SPST N C high temperature limit located on the right side of the burner box assembly see figure 16 S47 is wired to the burner ignition control A92 When S47 senses flame rollout indicating a blockage in the combustion passages the flame rollout switch trips and the ignition control immediately closes the gas valve Switch S47 in all G32 units is factory preset to open at 200 F 12 F 93 C 6 7 C on a temperature rise All flame rollout switches are manually reset FLAME ROLLOUT SWITCH S47 lt FLAME ROLLOUT SWITCH S47 13 Gas Valve The G32 uses a gas valve manufactured by White Rodgers or Honeywell The valve is two stage internally redundant to assure safety shut off If the gas valve must be replaced the same type valve must be used The Honeywell valve can be field converted to LP and is adjustable on both high fire and low fire WhiteRodgers supp
24. is 7 5 in W C and 3 5 in W C for low fire A IMPORTANT For safety connect a shut off valve between 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 Also gas valve regulation varies with burner box pressure figure 17 Manifold Absolute Pressure Measurement and Adjust ment 1 Connect test gauge to outlet tap on gas valve 2 Disconnect pressure sensing hose from gas valve and plug hose Leave hose barb on valve open to at mosphere See figure 39 3 Start unit on high fire and allow 5 minutes for unit to reach steady state 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 MANIFOLD CHECK 632 75 SHOWN HOSE Burner BOX SENSING HOSE GAS VALVE SENSING HOSE GAS VALVE LEFT SIDE OF PRESSURE SWITCH MORE NEGATIVE RIGHT SIDE OF PRESSURE SWITCH LESS NEGATIVE Closer to Zero FIGURE 39 4 While waiting for the unit to stabilize notice the flame Flame should be stable and should not lift from burner Natural gas should burn blue 5 After allowing unit to stabilize for 5 minutes record manifold pressure Manifold pressure should read 3 5 or 0 3 W C for natural gas and 7 5 or 0 3 W C for propane Regu
25. minute reset period the control will begin the ignition sequence again The SureLight control board has an 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 for heat the control will again ramp down until the lowest power is determined and the cycle begins again Page 11 Two Stage Operation Thermostat Selection Jumper The control can be utilized in two modes SINGLE STAGE thermostat or TWO STAGE thermostat The thermostat selection jumper E20 located just below dip switches 1 through 4 figure 14 must be positioned for the particular application The jumper is factory set on TWO for use with a two stage thermostat with two stage heat Re posi tion jumper to SINGLE for use with a single stage thermo stat with two stage heat While in the single stage thermostat mode single jumper setting the burners will always fire on first stage heat The combustion air inducer will operate on low speed and in door blower will operate on low heat speed After a field se lectable 10 or 15 minute delay dip switch 3 the unit will Switch to second stage heat While in the two stage ther mostat mode two jumpe
26. on first stage heat ignitor de energizes 8 After 45 second delay indoor blower B3 is energized on low heat speed The furnace will stay in this mode until first stage de mand is satisfied OR a second stage heat demand is initiated 9 Second stage heat demand initiated A 30 second sec ond stage recognition period begins The combustion air inducer ramps up to high heat speed G23 75 ONLY S102 prove switch closes 11 Gas valve energizes second stage heat 12 B3 indoor blower ramps up to high heat speed 10 Single Stage Thermostat Two Stage Heat Jumper E20 set at SINGLE 1 SureLight control energizes combustion air inducer B6 on low heat speed Combustion air inducer runs until 102 prove switch contacts close switch must close within 2 1 2 minutes or control goes into Watchguard Pressure Switch mode G32 75 ONLY SureLight control energizes combus tion air inducer B6 on low heat speed Combustion air inducer runs until S128 prove switch contacts close switch must close within 2 1 2 minutes or control goes into Watchguard Pressure Switch mode Prove switch 102 may also close A 15 second pre purge follows once 128 closes 2 SureLight control begins 20 second ignitor warm up period 3 Gas valve opens on first stage for a 4 second trial for ignition Ignitor stays energized during the trial or until flame sensed 4 Flame is sensed gas valve remains on first stage heat ignitor de energizes 5 After 45
27. produced in small amounts by all furnaces including the G32 during combustion process See table 13 for CO levels when the unit is properly installed and operating normally If unit ap pears to be operating normally at or beyond the upper limit of the CO range the unit should be checked for abnormal ly high CO CO content will be less than 0 04 400 PPM in an air free sample regardless of the firing rate used TABLE 13 G32 MODEL HIGH HEAT NAT LOW HEAT NAT 75 000 7 4 8 8 4 8 6 4 100 000 7 0 9 0 4 6 6 6 125 000 6 9 8 7 5 0 6 5 G32 MODEL HIGH HEAT LP LOW HEAT LP 75 000 7 5 9 2 5 5 6 9 100 000 8 0 9 5 5 2 6 6 125 000 7 9 9 4 5 3 7 0 27 Testing for abnormally high CO2 and CO One method for testing the CO2 CO content is the Bachar ach CO test with the Fyrite CO indicator Other methods of testing CO2 CO are available Closely follow the instruc tions included in the test kit you choose Follow the proce dure below in order to check CO2 CO on the G32 furnace 1 Drill size R or 11 32 in on the exhaust vent just exit ing the cabinet and tap 1 8 27 NPT This hole will be used to draw your CO2 CO sample 2 Install a hose barb connector into test hole 3 Attach one end of Fyrite sampling tube to hose barb 4 Set thermostat to highest setting and allow unit to run 15 minutes 5 When CO CO testing is complete turn off unit re move hose barb from exhaust vent and
28. socket surface and end of pipe are wet with cement forcefully insert end of pipe into Socket until it bottoms out Turn pipe 1 4 turn during as sembly but not after pipe is fully inserted to distribute cement evenly Once joint is made PVC may swell Hold joint together until bonded approximately 20 sec onds NOTE Assembly should be completed within 20 sec onds after last application of cement Hammer blows should not be used when inserting pipe 8 After assembly wipe excess cement from pipe at end of fitting socket A properly made joint will show a bead around its entire perimeter Any gaps may indicate a defective assembly due to insufficient solvent 9 Handle joints carefully and support properly until com pletely set B Venting Considerations The thickness of construction through which vent air intake pipes may be installed is 24 610mm maximum and 3 76mm minimum If a G32 furnace replaces a furnace which was commonly vented with another gas appliance the size of the existing vent pipe for that gas appliance must be checked Without the heat of the original furnace flue products the ex isting vent pipe may be oversized for the single water heater or other appliance The vent should be checked for proper draw with the remaining appliance CAUTION Insufficient combustion air can cause headaches nausea dizziness or asphyxiation Excessive ex posure to contaminated combustion air will result in safety and
29. 2 76 51 OR FOAM 2 x 1 1 2 51 x 38 tally as shown in figure 30 INSULATION REDUCER BUSHING LOCATION FOR OFFSET TERMINATION Front View L 12 EXHAUST VENT OS INTAKE 127 T VENT 3 76 OR 2 51 90 ELBOW 1 2 13 Foam Side View Insulation in Unconditioned Space ZZZZZZZZZZZZZ2 EXHAUST VEN indi INTAKE VENT ME OUTSIDE WALL VENT TERMINATIONS WALL TERMINATION KIT 30G28 WTK Optional Turndowi Not Shown 2 51 90 ELBOW May Be Used on Intake Only FRONT VIEW WALL TERMINATION 22G44 LB 49107CD for 2 51 Venting 44940 LB 65701A for 3 76 Venting FIGURE 27 Inches mm FIGURE 29 Page 22 Front View VENT 1 hy er iej safja Laffer e EXHAUST 5 7 INTAKE VENT E IM box 18 MAX 457 747 EXHAUST VENT Front View 9 kf 229 EXHAUST VENT NOTE Enclosed exhaust pipe is insulated with 1 2 13mm foam insulation If intake and exhaust pipes are reversed slit and remove foam insula tion and reapply to other vent Exhaust vent must be insulated Side View GRADE NNN Side View EXHAUST VENT 4 402 Inches mm INTAKE VENT OPTIONAL VENT TERMINATION FOR MULTIPLE UNIT INSTALLATION WALL TERMINATION KIT WTK FIGURE 30 8 MIN 203 l INTAKE VENT OUTSIDE WALL COVER EXHAUST VENT WITH 4 2 13 FOAM INSULATION VENT TERMINATIONS MODEL WTKX 30G79 EXTENSION RISER F
30. 2 On 6 4 Combustion air blower 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 6 3 1 Unit is firing above 100 of the nameplate input 6 3 2 Gas orifices leak at the manifold con nection 6 3 3 Air leakage at the connections be tween the primary heat exchanger secondary heat exchanger and com bustion air blower 6 3 4 Insufficient flow through the heat ex changer caused by a sooted or re stricted heat exchanger 6 3 5 Burners are not properly located in the burner box 6 4 1 Recirculation of flue gases This con dition causes rough ignitions and op eration Problem is characterized by nuisance flame failures 6 4 2 Improper burner cross overs Page 55 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 gas valve sensing hose to in sure no leaks are present ACTION 4 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 approv
31. 46 HEATING SEQUENCE OF OPERATION THERMOSTAT CALLS FOR HEAT DS1 AND DS2 SIMULTANEOUS FAST FLASH SEE BOX A CONTINUED FLAME SIGNAL ABOVE gt 0 17 microamps LOW FLAME SIGNAL Does not affect control operation YES DS1 SLOW FLASH DS2 FAST FLASH a E TWO STAGE THERMOSTAT MODE E20 SET AT TWO J YES GLE STAGE THERMOSTAT MODE E20 SET SINGLE START SECOND STAGE RECOGNITION ON DELAY 10 OR 15 MINUTES DS1 AND DS2 SIMULTANEOUS FAST FLASH 45 SECOND INDOOR BLOWER ON DELAY BEGINS DS1 AND DS2 SIMULTANEOUS FAST FLASH YES FIRST STAGE LOW FIRE PRIMARY LIMIT AND PRESSURE SWITCH CLOSED ROLLOUT SWITCH CLOSED YES N NO C GAS VALVE OFF COMBUSTION AIR INDUCER OFF FIRST STAGE HEAT DEMAND SATISFIED INDOOR BLOWER ON DS1 SLOW FLASH DS2 ON DS1 AND DS2 SIMULTANEOUS SLOW FLASH GAS VALVE OFF COMBUSTION AIR INDUCER SEE FOLLOWING POST PURGE HAS PRIMARY LIMIT OR ROLLOUT INDOOR BLOWER OFF WITH DELAY Indoor blower on low speed during 3 minule period DS1 AND DS2 SIMULTANEOUS SLOW FLASH SECOND STAGE HEAT DEMAND LIMIT SWITCH WATCHGUARD MODE SECOND STAGE HEAT DEMAND REQUIRED GAS VALVE OFF COMBUSTION AIR INDUCER OFF DS1 AND DS2 SIMULTANEOUS SLOW FLASH INDOOR BLOWER OFF WITH DELAY DS1 AND DS2 ALTERNATING SLOW FLASH IS 60 MINUTE RESET PERIOD COMPLETE SECOND STAGE PRESSURE SWITCH CLOSED ABNORMAL FLASH CODE NOTE IF SECOND STAGE PRESSURE SWITCH GAS VALVE OFF COMBUSTION AIR INDUCER O
32. 5 1685 795 675 1515 715 590 a 4840 870 600 4628 res 60 1478 ess se 1740 820 760 1550 730 ses 1415 670 53 1650 Ter ro uer 6 foss 6 500 1545 730 700 1370 645 530 1260 595 475 520 670 660 4256 890 485 vi7o 850 445 seo 500 620 110 525 445 1025 485 395 560 455 405 1270 1110 1025 825 325 t j 1045 885 420 360 700 330 290 NOTE All air data is measured external to unit with 1 in 25 mm cleanable foam filter not furnished in place Also see Filter Air Resistance table G32Q4 5 100 BLOWER PERFORMANCE External Static Air Volume and Motor Watts at Specific Blower Taps Hoh Medium High Medium Medum ow tow wg Pa m 1 Wate ofm Us watts cm Us Wats em Us Wats cim Us Wats 0 o 1135 1255 2185 1070 1940 915 905 1740 820 765 1570 740 665 410 2 2sso o 1280 2150 1075 1055 1920 905 885 1710 805 755 1525 720 645 20 so 22 1080 1185 2105 995 1025 1875 885 665 1685 795 740 1505 710 640 3 7 2225 1050 1170 2060 970 1005 1845 1655 780 730 700 630 100 2165 1020 1130 2010 950 985 1805 850 835 1620 765 720 1450 685 620 50 425 2105 995 1115 1960 920 960 1755 830 810 158
33. 5 750 700 1415 670 605 60 450 2040 965 1080 1895 895 940 1700 790 4540 725 690 1380 650 595 580 758 1430 675 660 1290 610 580 580 565 NOTE All air data is measured external to unit a in 25 22 cleanable foam filter not furnished in place Also see Filter Air Resistance table G32Q4 5 125 BLOWER PERFORMANCE Air Volume and Motor Watts at Specific Blower Medium High Medium Medumiow low 50 925 056 965 1050 825 800 1620 765 715 1460 690 620 080 965 5 685 70 75 185 200 1815 855 im tenn 740 1450 1315 620 Ec L 1735 820 760 725 1385 655 1245 590 565 NOTE All air data is measured external to unit 2 in 25 TY cleanable foam filter not furnished in place Also see Filter Air Resistance table Page 3 BLOWER DATA FILTER AIR RESISTANCE 1000 470 0 09 20 ET 075 5 TU 027189 2400 1130 0 38 95 2600 1225 0 44 110 HIGH ALTITUDE INFORMATION No gas pressure adjustment is needed when operating from 0 to 4500 ft 0 to 8 m See below for correct manifold pressures for altitudes greater that 4500 ft 1372 m for natural and L P gas Manifold Absolute Pressure outlet in w g kPa Model No 4501 to 5500 ft 5501 to 6500 ft 6501 to 7500 ft Oto 4500 f 0 to 1972 m 1373 to 1676 m 1677 to 1981 m 1982 to 2286 m above sea level above sea level
34. 63 375 18 6 80 070 23 5 1 A F U E 93 0 93 7 93 2 94 2 2 California Seasonal Efficiency 87 3 89 0 87 0 88 9 3JExhaust pipe connection PVC diameter in mm 2 51 3 Intake pipe connection PVC diameter mm 2081 3 76 Condensate drain connection PVC in n 1 2 12 7 Low Fire 30 60 17 33 35 65 19 36 Temperature rise range High Fire 40 70 22 39 50 80 28 44 High static certified by A G A C G A in wg Pa 50 125 Gas Piping Size I P S Natural in m 1 2 12 7 diameter x width 254 x 203 254 x 254 292 x 229 292 x 229 Blower motor output hp W 1 3 249 1 2 373 3 4 560 that can be added kw 3 5 to 10 6 7 0 to 14 1 12 3 to 17 6 3 No amp size of filters in mm 1 14 x 25 x 1 356 x 635 x 25 1 20 x 25 x 1 508 x 635 x 25 Shipping weight Ibs kg 1 package 157 71 186 84 198 90 218 99 Electrical characteristics 120 volts 60 hertz 1 phase all models less than 12 amps OPTIONAL ACCESSORIES Must Be Ordered Extra 33K97 2 inch 51 mm 60L46 3 inch 76 mm Vent Intake Air Roof 2 inch 51 mm 15F75 Termination Kit optional vent size 3 inch 76 mm 44J41 2 inch 51 15F74 ring kit 22G44 close couple 30G28 WTK close couple 4 Vent Intake Air Wall inch 51 mm 30G79 WTKX close couple with extension riser Termination Kit optional vent size 3 inch 76 mm 44J40 close co
35. ACE JACK PLUG MOTOR SPD CHANGE LJ P38 JACK PLUG MOTOR SPD CHANGE bis JACK EL US TWO SPD CONTROL JACK PLUG BURNER CONTROL j P69 JACK PLUG BLOWER DECK A PLUG CO J 551 A92 J P159 DOOR INTEGRATED THERMOSTAT HEAT ANTICIPATION SETTING INTERLOCK CONTROL 50 AMP WHITE RODGERS VALVE WARNING SI TB25 n ELECTRIC SHOCK HAZARD CAN CAUSE INJURY ROOM THERMOSTAT BLOWER TRANSFORMER OR DEATH UNIT MUST BE GROUNDED IN ACCORDANCE O SPEED WITH NATIONAL AND LOCAL CODES O CHANGE NOTE TERMINAL CIRCUIT A IF ANY WIRE IN THIS APPLIANCE IS REPLACED IT BREAKER MUST BE REPLACED WITH WIRE OF LIKE SIZE RATING AND INSULATION THICKNESS LINE VOLTAGE FIELD INSTALLED CLASS II VOLTAGE FIELD WIRING A MI amp M2 ARE UNPOWERED TERMINALS ALL UNUSED MOTOR LEADS MUST BE PLACED ON EITHER MI OR M2 OUTDOOR f Fan nn UNIT eme e pi NOTE W2 CONNECTION USED FOR TWO STAGE THERMOSTAT ONLY TAPE OFF IF SINGLE STAGE A THERMOSTAT IS USED B3 C4 INDOOR 86 CAPACITOR BLOWER MOTOR TWO STAGE a CONTROL SI TSGI ROOM OO 5 2 I t i0 LI I 55 369 P69 DOOR INTERLOCK A92 R INTEGRATED BLACK D CONTROL
36. CTION 1 Check for restricted vent inlet or ex haust Remove all blockage ACTION 2 Check for proper vent sizing See installation instructions ACTION 1 Check that sensor is properly lo cated page 10 and that the sense wire is properly attached 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 0 70 microamps check the sense rod for proper location or contamination ACTION 2 Replace clean or relocate flame sense rod If rod is to be cleaned use steel 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 sense rod PROBLEM 6 BURNERS LIGHT WITH HEATING DEMAND BUT UNIT SHUTS DOWN PREMATURELY CONT Possible Cause Corrective Action Comments Combustion air blower energizes with a heating demand Burners light Roll out switch trips during the heating demand Diagnostic lights flash roll out fail ure G32 1 through 3 Units Only LED 1 On LED 2 Slow Flash G32 5 Units LED 1 Slow Flash LED
37. D COLD HEADER BOX 1 2 MPT PLUG RUBBER BOOT OR CAP SIDE DETAIL OF HEADER BOX CONDENSATION TRAP FLUE DRAIN HOSE Condensate Removal Process 1 Condensate mixed with flue products exits the coil and enters the cold header box Condensate and flue products are separated Flue products are drawn into the combustion air blower while condensate is drained into the header box condensate trap Flue products are expelled into the flue As flue products travel up and out they cool and more condensate is produced Condensate travels down the walls of the flue pipe and into drain hose Water drains down through the flue drain hose and is emptied into the header box con densate trap When the cold header box condensate trap is full water begins draining out the condensate drain pipe An external condensate trap is not required but a vent is required The vent must extend above the height of the condenser coil approx 1 inch above the top of the cold header box 2 HEADER BOX CONDENSATE TRAP OF COLD HEADER CONDENSATE TRAP Y 39 E 1 2 PVC 1 2 MPT TO FEMALE PVC PIPE ADAPTER FRONT DETAIL OF HEADER BOX CONDENSATION TRAP FIGURE 36 Page 25 III 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 nameplat
38. DEMAND SATISFIED SECOND STAGE HEAT DEMAND SATISFIED YES YES INDOOR BLOWER RAMPS DOWN TO FIRST STAGE INDOOR BLOWER RAMPS DOWN TO LOW COOL SPEED HEAT SPEED NOTE Continuous low speed fan and cooling low speed are equal to the low heat fan speed Page 50 VIII Troubleshooting Guide SureLight Control UPON INITIAL POWER UP REMOVE ALL THERMOSTAT DEMANDS TO THE UNIT Unless otherwise noted condition applies to all G32 units PROBLEM 1 UNIT FAILS TO OPERATE IN THE COOLING HEATING OR CONTINUOUS FAN MODE ACTION 1 Check 120V main voltage Both diagnostic lights fail to light up Main voltage 120V not supplied to unit Determine cals of main power faire 1 1 2 n LED 1 Off ACTION 1 Check for correct wiring of 120V to Miswiring of furnace or improper con power make up box and transformer LED 2 Off de prop ACTION 2 Check 24V wiring to control board 1 1 3 ACTION 1 Replace circuit breaker if it is reset AOR a but does not have continuity Circuit breaker tripped or fails to ACTION 2 If circuit breaker still trips check for close short ACTION 1 Check that door switch is activated when door is closed 1 1 4 ACTION 2 Check wire connections to switch re place loose connectors Door interlock switch failure ACTION 3 Check continuity of switch in closed position Replace if malfunctioning 1 1 5 ACTION 1 Check that transformer output is Transformer Failure 24V Replace if malfunctioning
39. ER ON YES IS POLARITY REVERSED SIGNAL POLARITY REVERSED DS1 FAST FLASH DS2 SLOW FLASH SIGNAL IMPROPER LOW VOLTAGE SIGNAL AT DS HOLDS UNTIL VOLTAGE RISES ABOVE 75 VOLTS GROUND AT DS NO SIGNAL HOLDS IS THERE IS VOLTAGE PROPERLY GROUNDED Y THERMOSTAT CALLS FOR FIRST STAGE COOL COMPRESSOR AND CONDENSER FAN ENERGIZED INDOOR BLOWER ENERGIZED ON FIRST STAGE COOL SPEED AFTER 2 SECOND DELAY YES COMPRESSOR AND CONDENSER FAN DE ENERGIZED FIRST STAGE DEMAND FOR COOL SATISFIED NBOOR BLOWER DE ENERGIZED NO THERMOSTAT CALLS FOR SECOND STAGE COOL INDOOR BLOWER RAMPS UP TO SECOND STAGE COOL SPEED SECOND STAGE DEMAND FOR COOL SATISFIED YES UNIT RETURNS TO FIRST STAGE COOL Page 49 CONTINUOUS LOW SPEED FAN SEQUENCE OF OPERATION MANUAL FAN SELECTION MADE AT THERMOSTAT AFTER 2 SECOND DELAY INDOOR BLOWER IS ENERGIZED ON CONTINUOUS FAN SPEED LOW HEAT LOW COOL THERMOSTAT CALLS FOR FIRST STAGE COOL THERMOSTAT CALLS FOR FIRST STAGE HEAT COMPRESSOR IS ENERGIZED AND INDOOR BURNERS IGNITE AND INDOOR BLOWER BLOWER CONTINUES TO OPERATE IN LOW CONTINUES TO OPERATE IN CONTINUOUS COOL SPEED LOW LOW HEAT LOW COOL MODE FIRST STAGE COOL DEMAND SATISFIED FIRST STAGE HEAT DEMAND SATISFIED SECOND STAGE COOL DEMAND THERMOSTAT CALLS FOR SECOND STAGE HEAT YES INDOOR BLOWER RAMPS TO SECOND INDOOR BLOWER SWITCHES TO HIGH HEAT SPEED STAGE COOL SPEED AFTER 30 SECOND RECOGNITION PERIOD YES SECOND STAGE COOL
40. F POLARITY REVERSED LED 1 FAST FLASH LED 2 SLOW FLASH LED 1 AND 2 ALTERNATING FAST FLASH SIGNAL HOLDS UNTIL VOLTAGE RISES ABOVE 75 VOLTS GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF DELAY LED 1 ON LED 2 SLOW FLASH GAS VALVE OFF COMBUSTION AIR INDUCER ON NORMAL OPERATION LED 1 SIMULTANEOUS SLOW FLASH LED 2 SIMULTANEOUS SLOW FLASH THERMOSTAT CALLS FOR HEAT LED 1 FAST FLASH LED 2 FAST FLASH YES PRIMARY LIMIT SWITCH CLOSED Yi PRESSURE SWITCH CONTACTS OPEN HIGH AND LOW HEAT ENERGIZE COMBUSTION AIR BLOWER ENERGIZE HTG ACC TERM IS UNIT PROPERLY GROUNDED Yi IS LINE VOLTAGE ABOVE 75 VOLTS W2 TIMED MODE SINGLE STAGE T STAT L ES YES ES SINGLE STAGE MODE HIGH HEAT ONLY COMBUSTION AIR BLOWER ON LOW SPEED lt 2 5 MINUTES LOW HEAT PRESSURE NO HIGH HEAT PRESSURE NO SWITCH CLOSED SWITCH CLOSED YES YES PREPURGE 15 SECONDS COMBUSTION AIR BLOWER ON HIGH SPEED lt 2 5 MINUTES CONTINUED ON NEXT PAGE Page 38 INDOOR BLOWER ON LED 1 SLOW FLASH LED 2 OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER ON LED 1 SLOW FLASH LED 2 ON GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF DELAY LED 1 OFF LED 2 SLOW FLASH Sequence holds until pressure switch closes or thermostat resets control COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF LED 1 ALTERNATING FAST FLASHES LED 2
41. HERMOSTAT CONTROL G ENERGIZES SYSTEM FAN AT ACB LOW SPEED ACC TERM ENERGIZED Page 42 TYPICAL G32 5 6 SCHEMATIC WIRING DIAGRAM ra FACTORY COM SPEED TAPS HI LO si Lo Sr Ear mec ue ksi HIGH HEA HEAT BROWN YELLOW RED YELLOW RED ON ME SHT CK vELLOV RED BLUE 5 VAL HI BLOWER SPEED SELECTION Ht ER EN BLACK BROWN vel YELLOW 4 Ts BLACK BRON BLUE YELLOW f n 5 THERMOSTAT HEAT ANTICIPATION SETTING 1 65 AMPS HONEYWELL VALVE 50 AMPS WHITE RODGERS VALVE ROOM THERMOSTAT VEG ELECTRIC SHOCK HAZARD CAN CAUSE INJURY OR DEATH UNIT MUST BE MEE IN ACCORDANCE WITH NATIONAL AND LOCAL NOTE IF ANE MET Int DOM APPLIANCE IS REPLACED IT MUST BE TH WIRE OF LIKE SIZE RATING AND IN TNSULATION THICKNESS LINE VOLTAGE FIELD INSTALLED CLASS II VOLTAGE FIELD WIRING ZA USE COPPER CONDUCTORS ONLY FIELD SUPPLIED ACC WIRE HOOKUP FOR 100 amp 125 UNITS A ni a ME HEATING UNITS GAS A 2 STAGE AT Ay Y TO Y2 JUMPER FACTORY INSTALLED REMOVE JUMPER Y TO Y2 FOR TWO STAGE COOL THERMOSTAT Ay PARK TERMINAL IS A UNPOWERED TERMINAL ALL UNUSED MOTOR LEADS MUST BE WIRED TO THE PARK TERMINAL New Form Ne 534 270W 2002 Lennox Indwotrioo Ine Lithe U S A Page 43 Sequence of Operation G32 5 6 Sequence depends on type thermostat used Units are applicable for single stage or two stage therm
42. MIDIFIER BLOWER MOTOR LENNOX EATING UNITS GAS INTEGRATED P156 CONTROL z JIS6 A IMPORTANT MOTOR BURNOUT 63203 75 3 63204 5 100 3 23 INDOOR NEVER CONNECT MORE THAN G32Q3 4 100 3 G32Q4 5 125 3 JE ONE MOTOR LEAD TO ANY BLOWER MOTOR ONE CONNECTION SECTION A Supersedes P69 ZA FOR ACCESSORY HOOKUP 3 lt S128_USED ON 533 658W N e 632 75 UNIT ONLY EQUIPMENT N KIO IS USED ONLY NewsFoem Ne GROUND ON W2 TIMED CIRCUIT 533 856W 092001 Lennox Industries Inc Litho U S A DENOTES OPTIONAL COMPONENTS Page 36 Sequence of Operation G32 2 3 Ignitor operation will vary between SureLight boards Boards 24L85 56L83 and 63K89 will energize ignitor for the first second of the 4 second ignition trial Board 97L48 will energize ignitor during the trial until flame is sensed 1 When there is a call for heat W1 of the thermostat en ergizes W of the furnace control with 24VAC 2 SureLight control runs self check for S10 primary limit switch normally closed contacts The control also checks 5128 combustion air prove switch and S102 high fire pressure switch normally open contacts Fol low steps 4 through 8 per respective thermostat Single stage Mode Single stage Thermostat 3 SureLight control energizes combustion air blower B6 on high speed Combustion air blower runs until 5102 high fi
43. N WAS ORIGINALLY FOUND CLOSED INDOOR BLOWER OFF AFTER DELAY ABNORMAL CODE WILL FLASH DS1 OFF DS 2 SLOW FLASH SECOND STAGE PRESSURE SWITCH CLOSED AT BEGINNING OF HEAT DEMAND SECOND STAGE 30 SECOND DELAY ON BEGINS DS1 OFF DS2 SLOW FLASH DS1 AND DS2 SIMULTANEOUS FAST FLASH YES SECOND STAGE COMBUSTION AIR INDUCER SECOND STAGE HEAT DEMAND ON SECOND STAGE GAS VALVE ON HIGH DS1 AND DS2 SIMULTANEOUS SLOW FLASH HEAT INDOOR BLOWER SPEED ON NO DS1 AND DS2 SIMULTANEOUS FAST FLASH RETURNS TO FIRST STAGE HEAT MODE WHICH CONTINUES UNTIL SECOND STAGE PRESSURE SWITCH CAN BE PROVEN or HEAT DEMAND IS SECOND STAGE PRESSURE SWITCH CLOSED SATISFIED FIVE 5 MINUTE WAIT PERIOD IN LESS THAN TEN 10 SECONDS INITIATED BEFORE RETRY WERE 5 ATTEMPTS DS1 AND DS2 SIMULTANEOUS FAST FLASH MADE FOR SECOND STAGE HEAT YES i CONTINUED ON NEXT PAGE NORMAL OPERATION DS1 AND DS2 SIMULTANEOUS SLOW FLASH Page 47 HEATING SEQUENCE OF OPERATION CONTINUED SEE BOXA NORMAL OPERATION DS1 AND DS2 SIMULTANEOUS SLOW FLASH SEE BOX B THERMOSTAT CALLS FOR HEAT DS 1 AND DS 2 SIMULTANEOUS FAST FLASH GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER ON IS PRIMARY LIMIT AND ROLLOUT DS1 SLOW FLASH DS2 ON SWITCH CLOSED HAS PRIMARY LIMIT OR ROLLOUT SWITCH YES CLOSED WITHIN 3 MINUTES 0 LIMIT SWITCH WATCHGUARD MODE GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF WITH DELAY IS 60 MINUTE RESET PERIOD COMPLETE
44. NOT NEEDED DO NOT INSTALL DOOR ACCESSORY WIRE IN J69 INTERLOCK SWITCH N TWO STAGE RELAY CONTROL PIGTAIL TO COMPRESSOR FIELD INSTALLED CLASS II 24V VOLTAGE CONTACTOR FIELD INSTALLED LINE VOLTAGE FIGURE 44 G32 and CONDENSING UNIT THERMOSTAT DESIGNATIONS Refer to specific thermostat and outdoor unit Two Stage SureLight Thermostat Control Board Condensing Unit COOLING HS UNIT COMPRESSOR COMPRESSOR INDOOR BLOWER HEAT G32 TWO STAGE CONTROL BOARD PIGTAIL LEAD ZON 2ND STAGE HEAT 4 N we 7 pasate POWER HS UNIT COMMON COMMON i COMMON Single stage thermostat does not contain W2 terminal and W1 terminal is designated as W FIGURE 45 Page 34 G32 2 UNIT DIAGRAM 120V ACC oR 5102 BLOWER SPEED CHART K43 ECON a HIGH HEAT FACTORY CONNECTED SPEED TAPS OTOR PRESSURE UNIT TB25 1825 SPEEDS IF USED SWITCH cou p 2 MI M2 A AVAILABLE 5128 510 ED 03 75 BROWN YELLOW RED 4 LOW HEAT PRIMARY 0374 100 YELLOW RED BROWN PRESSURE GAS ROLLOUT 04 5 100 125 BLACK YELLOW RED BLUE BROWN LIMIT HI BLOWER SPEED SELECTION Lo B6 T COMBUSTION SPEED BLACK BROWN YELLOW RED AIR BLOWER TAPS BLACK BROWN BLUE YELLOW RED 4 5 JACKPLUG CHART P20 JACK PLUG GAS LJ P33 JACK PLUG CONTROL INTERF
45. OFF COMBUSTION AIR INDUCER OFF CHECK FOR MAIN BURNER FLAME SENSE INDOOR BLOWER OFF WITH NORMAL DELAY IS MAIN BURNER FLAME OFF SIGNAL CIRCUIT BOARD FAILURE AT LED SEQUENCE HOLDS UNTIL FLAME IS NOT SENSED LED SLOW FLASH RATE REMAINS UNCHANGED THROUGHOUT COOLING CYCLE THERMOSTAT CALLS FOR COOLING COMPRESSOR CONTACTOR AND SYSTEM FAN ENERGIZED WITH 0 SECOND DELAY COOLING SPEED ACC TERM ENERGIZED THERMOSTAT OPENS COMPRESSOR OFF SYSTEM FAN AND ACC TERM OFF WITH 0 SECOND DELAY Page 41 CONTINUOUS LOW 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 ACB LOW SPEED ACC TERMINAL IS ENERGIZED HTG ACC TERM ENERGIZES THERMOSTAT CALLS FOR HEAT W M WITH COMB AIR BLOWER BOARD NO 63K8901 SYSTEM FAN DE ENERGIZED SYSTEM FAN ENERGIZES ON ACB HEAT SPEED AFTER NORMAL DELAY THERMOSTAT CALLS FOR COOLING BOARD NO 24L85 56L83 97L48 YES SYSTEM FAN SWITCHES TO ACB HEAT SPEED AFTER NORMAL DELAY fan remains energized SYSTEM FAN SWITCHED TO ACB COOL SPEED ACC TERM REMAINS ON THERMOSTAT OPENS COMBUSTION AIR AND HTG ACC TERMINAL DE ENERGIZE THERMOSTAT OPENS i BOARD 63K89 SYSTEM FAN OFF ACC TERM OFF AFTER OFF DELAY COMPLETED BOARDS 24L85 56L83 AND 97L48 SYSTEM FAN SWITCHES TO LOW SPEED AFTER NORMAL DELAY fan remains energized MANUAL FAN SELECTION MADE AT T
46. ONDS HTG ACC TERM DE ENERGIZED INDOOR BLOWER SELECTED TIME OFF DELAY ABNORMAL HEATING MODE PREPURGE See top of previous page GAS VALVE DE ENERGIZED INDOOR BLOWER DE ENERGIZED COMBUSTION AIR INDUCER ON FOR 2 5 MINUTES PRESSURE SWITCH CLOSED PRESSURE SWITCH WATCHGUARD COMBUSTION AIR INDUCER DE ENERGIZED lt 2 5 MINUTES 5 MINUTE DELAY COMBUSTION AIR INDUCER ON SINGLE STAGE MODE HIGH HEAT ONLY om Pinay eny itcran ov o femme Watchguard low voltage below 75V or ALTERNATING FAST FLASH improper main ground Page 40 COOLING SEQUENCE OF OPERATION NORMAL COOLING MODE ABNORMAL COOLING MODE POWER ON 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 YES INTERRUPT MAIN POWER TO RESET CONTROL TURN INDUCER ON FOR 1 SECOND YES IS POLARITY REVERSED SIGNAL POLARITY REVERSED AT LED SIGNAL IMPROPER GROUND AT LED SIGNAL HOLDS IS THERE IS VOLTAGE LOW VOLTAGE SIGNAL AT LED HOLDS UNTIL UNIT IS UNTIL VOLTAGE RISES ABOVE 75 VOLTS PROPERLY GROUNDED GAS VALVE OFF COMBUSTION AIR INDUCER OFF ROLLOUT SWITCH MONITORED CONTINUOUSLY INDOOR BLOWER OFF WITH NORMAL DELAY IS ROLLOUT SWITCH CLOSED SIGNAL CIRCUIT BOARD FAILURE AT LED SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES YES GAS VALVE
47. OR GRADE CLEARANCE FIGURE 32 Front View INTAKE AIR EXHAUST AIR 12 MIN 305 Above Grade G32 VENTING IN EXISTING CHIMNEY STRAIGHT CUT OR ANGLE CUT IN DIRECTION OF RONF SLOPE EXHAUST VENT 157013 mm WEATHERPROOF INSULATION L6 i IMTAKE VENT F pi SHOULDER OF FITTINGS PROVIDE SUPPORT OF PIRE ON TOP P ATF EXHAUST AIR Ne Side View CX 3e 1 SHEET METAL TOP PLATE DAGA MIN ALTERNATE FOR INTAKE VENT Tom a INTAKE AIR t ABOVE GRADE Z GRADE Y VEN L 4 8 203 Minimum Inches mm lt r 12 305 T TERMINATIONS MODEL WTK WALL TERMINATION KIT 30G28 EXTENDED VENT FOR GRADE CLEARANCE FIGURE 31 Page 23 MIN 127 X04 mms ABOVE ROOF INSULATE 37 8 76mm 203mm EXTERIOR PORTION F CHIMNEY a i NOTE Do not discharge exhaust gases directly into any chimney or vent stack If verti cal discharge through an existing unused chimney or stack is required insert piping inside chimney until the pipe open end is above top of chimney and terminate as illus trated In any exterior portion of chimney the exhaust vent must be insulated An alter nate method is to fill the chimney with vermiculite or equal to take advantage of its acoustic and thermal properties FIGURE 33 Condensate Piping This unit is designed
48. Stage Delay Used with Single Stage Thermostat Only This switch is used to determine the second stage on delay when a single stage thermostat is being used The switch is factory set in the ON position which provides a 10 minute delay before second stage heat is initiated If the switch is toggled to the OFF position it will provide a 15 minute delay before second stage heat is initiated This switch is only activated when the thermo stat selector jumper is positioned for SINGLE stage ther mostat use Switch 4 Cooling Fan off Delay The fan on delay time of 2 seconds is not adjustable Fan off time time that the blower operates after the cool demand has been satisfied can be adjusted by flipping dip switch 4 The unit is shipped with a factory fan off setting of 45 seconds Fan off time will affect comfort and is adjustable to satisfy individual ap plications See table 6 for cool fan off time settings TABLE 6 Cooling Fan Off Delay Delay Seconds Switch 4 Diagnostic LED s DS1 and DS2 Two diagnostic LED S are located on the two stage inte grated control board See figure 14 These light flashes correspond with the codes detailed in table 10 Factory Installed Jumper Y1 to Y2 A factory installed jumper from Y1 to Y2 terminals on the integrated control board terminal strip must be removed for two stage cooling TWO STAGE INTEGRATED CONTROL BOARD e o pel
49. T FLASH DS 2 SIMULTANEOUS FAST FLASH 60 MINUTE LIMIT WATCHGUARD MODE YES GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF WITH DELAY PRIMARYLIMIT DS1 AND DS2 ALTERNATING SLOW FLASH SWITCH CLOSED YES GAS VALVE OFF COMBUSTION AIR INDUCER OFF HAS MANUAL ROLLOUT SWITCH ES BEEN RESET CLOSED WITHIN 3 MINUTES DS1 SLOW FLASH DS2 ON FIRST LOW STAGE PRESSURE SWITCH CONTACTS OPEN GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF CONTROL REMAINS UNTIL SECOND HICH STAGE PRESSURE SWITCH PRESSURE SWITCH IS DETECTED OPEN CONTACTS OPEN G32Q 75 onl DS1 OFF DS2 SLOW FLASH GAS VALVE OFF TWO STAGE OR SINGLE STAGE THERMOSTAT COMBUSTION AIR INDUCER OFF CALL FOR HEAT INDOOR BLOWER OFF CONTROL WILL NOT ATTEMPT SECOND STAGE OPERATION DURING THIS HEAT DEMAND FIRST STAGE OPERATION WILL BE ATTEMPTED COMBUSTION AIR INDUCER ON LOW SPEED DS1 OFF DS2 FAST FLASH DS1 AND DS2 SIMULTANEOUS FAST FLASH CONTINUED ON NEXT PAGE Page 45 HEATING SEQUENCE OF OPERATION CONTINUED FIRST STAGE LOW FIRE PRESSURE SWITCH CLOSED WITHIN 2 5 MINUTES 15 SECOND COMBUSTION AIR INDUCER PRE PURGE INITIATED BY CLOSED FIRST STAGE PRESSURE SWITCH or 15 SECOND INTER PURGE PERIOD DS1 AND DS2 SIMULTANEOUS FAST FLASH IGNITOR WARM UP 20 SECONDS DS1 AND DS2 SIMULTANEOUS FAST FLASH IS VOLTAGE ABOVE 75 VOLTS IS THERE A PROPER GROUND IS IGNITOR INTACT AND CONNECTED AT END OF IGNITOR 20 SECOND
50. WARM UP PERIOD 4 SECOND TRIAL FOR IGNITION GAS VALVE OPENS IGNITOR ENERGIZED DURING 4 SECOND TRIAL UNTIL FLAME SENSED DS1 AND DS2 SIMULTANEOUS FAST FLASH 4 SECOND FLAME STABILIZATION PERIOD DS1 AND DS2 SIMULTANEOUS FAST FLASH FLAME RECTIFICATION CURRENT CHECK CAN FLAME BE PROVEN WITHIN 4 SECONDS AFTER GAS VALVE OPENS gt 0 16 microamps FLAME PRESENT NO CONTINUED ON NEXT PAGE THERMOSTAT CALLS FOR HEAT DS1 AND DS2 SIMULTANEOUS FAST FLASH Refer to box A on previous page GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF UNIT WILL RETRY AFTER 5 MINUTE WAIT PERIOD DS1 OFF DS2 SLOW FLASH COMBUSTION AIR INDUCER OFF IGNITER OFF SIGNAL HOLDS UNTIL VOLTAGE RISES ABOVE 75 VOLTQ DS1 AND DS2 ALTERNATING FAST FLASH COMBUSTION AIR INDUCER OFF IGNITER OFF SIGNAL HOLDS UNTIL UNIT IS PROPERLY GROUNDED DS1 AND DS2 ALTERNATING FAST FLASH COMBUSTION AIR INDUCER OFF IGNITOR OFF SIGNAL HOLDS UNTIL IGNITOR IS REPLACED OR RECONNECTED DS1 AND DS2 ALTERNATING FAST FLASH GAS VALVE OFF COMBUSTION AIR INDUCER ON INDOOR BLOWER OFF DS1 SLOW FLASH DS2 FAST FLASH 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 DS1 AND DS2 ALTERNATING SLOW FLASH IS 60 MINUTE RESET PERIOD COMPLETE HAS CONTROL RESET IGNITION SEQUENCE FOUR 4 TIMES DS1 SLOW FLASH DS2 FAST FLASH Page
51. air is not available On start up the switch senses that the combustion air blow er is operating It closes a circuit to the ignition control when the difference in pressure across the pressure switch in creases above a particular setting See table 12 The pres sure sensed by the switch is relative to the pressure in the burner box In order for the furnace to operate the larger negative must always be on the combustion air blower side of the switch If the flue or air inlet become obstructed during operation the switch senses a loss of pressure differ ential drops below set point and opens the circuit to the ignition control DIFFERENTIAL PRESSURE SWITCH CIRCUITRY G32 75 SHOWN BURNER LOW HEAT DIFFERENTIAL PRESSUR SWITCH TEE HIGH HEAT DIFFERENTIAL PRESSURE SWITCH G32 75 ONLY COMBUSTION AIR BLOWER PRESSURE SWITCH FIGURE 18 The switch is factory set and is not adjustable It is a safety shut down control and MUST not be bypassed Figure 19 shows an example of the pressure differential 20 W C shown required to obtain unit operation If the Switch does not successfully sense the required differen tial the switch cannot close and the furnace cannot oper ate When measuring the pressure differential readings should be taken at the pressure switch TABLE 12 G32 Pre
52. al may be connected to this wire The neutral leg of the accessory is connected to the neutral white wire in the make up box The accessory terminal is energized whenev er the blower is in operation FIGURE 4 B Control Box Components INTERLOCK CIRCUIT BREAKER SURELIGHT CONTROL TWO STAGE CONTROL FIGURE 5 Page 6 Integrated ignition and blower control components A92 unit transformer T1 and 24V circuit breaker CB8 are lo cated in the control box In addition a door interlock switch S51 is located in the control box Jackplugs allow the con trol box to be easily removed for blower service 1 Control Transformer T1 A transformer located in the control box provides power to the low voltage 24volt section of the unit Transformers on all models are rated 40VA with a 120V primary and a 24V secondary 2 Circuit Breaker CB8 A 24V circuit breaker is also located in the control box The switch provides overcurrent protection to the transformer T1 The breaker is rated 3A at 32V If the current exceeds this limit the breaker will trip and all unit operation will shut down The breaker can be manually reset by pressing the button on the face 3 Door Interlock Switch S51 A door interlock switch rated 14A at 125VAC is located on the control box The switch is wired in series with line volt age When the blower door is removed the unit will shut down 4 Flame Sensor A flame sensor is located on
53. al until it is se curely in place 7 Replace harness connector to motor G32 BLOWER REMOVAL To Remove Blower Turn off line voltage power Unplug J69 from P69 located on blower deck Disconnect thermostat wiring connec tions by removing low voltage terminal strip Disconnect J58 P58 located on blower deck Disconnect J43 P43 from blower motor Disconnect any wires which run through the blower deck that are not in a jackplug 6 Loosen screws 2 and remove control box from unit Holes are slotted so screws do not need to be removed Remove screw from lower control board blower Remove screws 2 and remove blower from unit TABLE 15 BLOWER SPEED CHART FACTORY CONNECTED ron UNIT SPEED TAPS MOTOR COOL HEAT CONT AVAILABLE 93 75 12 3 14 14 4 5 Q Q2 4 100 04 5 100 125 5 6 5 R BLOWER SPEED SELECTION SPEED We a2 3 s 4 2 3 5 6 s E Blower Speed Taps Leaded Motors 2 Models Blower speed tap changes are made on the SureLight con trol board See figure 8 Unused taps must be secured on dummy terminals PARK M1 and or PARK M2 on the SureLight board The heating tap is connected to the ACB HEAT terminal and the cooling tap is connected to the COOL terminal The continuous blower tap is con nected to the ACB LOW terminal To change existing heat tap turn off power then switch out speed tap on ACB HEAT with
54. and 2 in the Natural Gas and Propane Installation Code in Canada Intake and Exhaust Piping Terminations Intake and exhaust pipes may be routed either horizontally through an outside wall or vertically through the roof In attic or closet installations vertical termination through the roof is preferred Figures 21 through 33 show typical termina tions 1 Use recommended piping materials for both intake and exhaust piping 2 Secure all joints including drain leg gas tight using approved primer and cement 3 Piping diameters should be determined according to length of pipe run See vent pipe specifications on page 6 Locate intake piping upwind prevailing wind from exhaust piping To avoid re circulation of exhaust gas on roof terminations end of exhaust pipe must be higher than intake pipe Exhaust and intake exits must be in same pressure zone Do not exit one through the roof and one on the side Also do not exit the intake on one side and the exhaust on another side of the house or structure 4 Intake and exhaust pipes should be placed as close together as possible at termination end refer to il lustrations Maximum separation is 3 76mm on roof terminations and 6 152mm on side wall ter minations Exhaust piping must terminate straight out or up as shown In rooftop applications a 2 X 1 1 2 reducer for 2 venting 3 x 2 reducer for 3 venting must be used on the exhaust piping after it exit
55. before replacing gas valve ACTION 3 Replace the control board if 24V is not supplied to valve PROBLEM 6 BURNERS LIGHT WITH A HEATING DEMAND BUT UNIT SHUTS DOWN PREMATURELY Possible Cause Corrective Action Comments 6 1 Burners fire with a heating demand Burners light but unit shuts off prior to satisfying T stat demand Diagnostic lights flash the pressure switch code LED 1 Off LED 2 Slow Flash 6 2 Combustion air blower 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 6 1 1 Wrong concentric vent kit used for terminating the unit 6 1 2 Condensate drain line is not draining properly 6 1 3 Low pressure differential at the pres sure switch 6 2 1 Sensor or sense wire is improperly installed 6 2 2 Sensor or sense wire is broken 6 2 3 Sensor or sensor wire is grounded to the unit 6 2 4 Control does not sense flame Page 54 ACTION 1 Check vent termination kit installed 1 1 2 dia concentric vent kit60G77 for 50 and 75 inputs and 2 dia concentric vent kit 33K97 for 100 amp 125 inputs ACTION 1 Check condensate line for proper vent slope and any blockage Condensate should flow freely during operation of furnace Repair or replace any improperly installed con densate lines A
56. cover by loosening bot tom screws 2 and removing cover front screws 5 2 Remove ignitor wire and sensor wire Remove gas valve and manifold assembly 3 Remove burner assembly UNIT VEST PANEL Cleaning the Burner Assembly LI N 1 6 7 e 1 Page 32 NOTE Surgical mask and safety glasses should be worn when cleaning heat exchanger and burners Turn off electrical and gas power supplies to furnace Remove upper and lower furnace access panels Disconnect the gas supply line to gas valve Depend ing on gas plumbing installation the gas manifold may move aside enough that breaking the union may not be necessary Remove five 5 screws from edges of burner box cov er Loosen two 2 screws on bottom of burner box front The cover is key holed at these screw point so screws do not need to be removed Pull off cover and set aside Mark gas valve wires and disconnect them from valve Mark and disconnect sensor wire from the burner box at the SureLight control Disconnect 2 pin plug from the ignitor at the burner box Loosen two 2 screws at the gas manifold support bracket Pull on the left side of the gas manifold and follow with tension to the right side The manifold support bracket will be free of the mounting screws on the vestibule panel Set the gas manifold gas valve assembly aside Take care not to damage foam gaskets on each end of the gas manifold Using a 1 4
57. dapter into the threaded opening in the condensate trap 5 For Left Hand Side Condensate Exit Insert nipple adapter assembly from the left hand side of the cabinet and through the combustion air blower mounting structure into the threaded opening in the condensate trap Connect field supplied plumbing to nipple and route to open drain Plumbing should be vented to a point higher than the condensing coil See figure 35 A CAUTION Do not use copper tubing or existing copper condensate lines for drain line Page 24 CONDENSATE PLUMBING Plumbing must be vented higher than coil FIGURE 35 Connect condensate drain line 1 2 13mm SDR 11 plastic pipe or tubing to condensate connection on drip leg assembly and route to open drain Conden sate line must be sloped downward away from drip leg to drain If drain level is above drip leg condensate pump must be used to condensate line Condensate drain line should be routed within the conditioned space to avoid freezing of condensate and blockage of drain line If this is not possible a heat cable kit may be used on the condensate drip leg and line Heating cable kit is available from Lennox in various lengths 6ft 1 8m kit no 18K48 24ft 7 3m kit no 18K49 and 50ft 15 2m kit no 18K50 G32 CONDENSATE REMOVAL PROCESSYV DETAIL OF FLUE TRAPV COMBUSTION AIR BLOWER DETAIL CONDENSATE FROM COIL COLD HEADER BOX HOSE BARB COIL OPENING BEHIN
58. e If not consult the power company and have voltage condition corrected before starting unit 3 Inspect condition of condensate traps and drain as sembly Disassemble and clean seasonally B Heating Start Up FOR YOUR SAFETY READ BEFORE LIGHTING 4 CAUTION Shock and burn hazard G32 units are equipped with the SureLight ignition system Do not attempt to light manually 4 WARNING Do not use this furnace if any part has been underwater Inspect the furnace and replace any part of the control system and any gas control which has been under water 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 4 CAUTION Before attempting to perform any service or main tenance turn the electrical power to unit OFF at disconnect switch 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 Use only your hand to turn the gas control switch Never use tools If the switch will not turn by hand do not try to re pair it call a qualified service technician Force or at tempted repair may result in a fire or explosion G32 units are equipped with the SureLight ignition system DO NOT attempt to manually light burners on this furnace Each time thermostat calls for heat burners will be automatically lit The ignit
59. e must terminate with 1 1 2 inch 38 mm diameter pipe for furnaces using1 1 2 38 mm or 2 inch 51 mm diameter pipe runs Exhaust pipe must terminate with 2 inch 51 mm diameter pipe for furnaces using 3 inch 76 mm diameter pipe runs Page 4 G32 PARTS ARRANGEMENT GLASS FIBER GASKET FLUE COLLAR FRESH AIR TOP CAP INTAKE FITTING WARM HEADER BURNER BOX p COLLECTOR ASSEMBLY BOX CABINET PATCH PLATE WITH BARBED FITTING AND FLAME ROLL OUT SWITCH DuralokPlus HEAT EXCHANGER _ LOW HEAT DIFFERENTIAL WY PRESSURE FLAME SIGHT SWITCH GLASS HIGH HEAT a Ea BURNER DIFFERENTIAL T BOX PRESSURE TWO STAGE COVER GAS VALVE AND SUPPLY AIR BLOWER PRIMARY LIMIT MES ALTERNATE STYLES ORIFICE CONDENSER COIL CONTROL TRANSFORMER CONTROL VOLTAGE CIRCUIT BREAKER SURELIGHT TWO STAGE INTEGRATED CONTROL BOARD COLD HEADER COLLECTOR BOX DOOR INTERLOCK SWITCH TWO SPEED COMBUSTION AIR INDUCER FIGURE 1 Page 5 MAKE UP BOX INSTALLATION Box may be installed inside or outside cabinet and may be installed on left side or right side of cabinet OUTSIDE INSTALLATION MAKE UP BOX STAR WASHERS MUST BREAK PAINT ON UNIT CABINET FOR PROPER GROUND UNIT CABINET Line Voltage Enters Through Knockout In Make Up Box J69 Passes Through Side Knockout Into Side Of Unit JACK J69 PLUG P69
60. e panel Remove four 4 burner box screws at the vestibule panel and remove burner box and gas valve manifold assembly with bracket Drain condensate trap Disconnect condensate line from the outside of unit Remove condensate line from condensate trap by turning the adapter fitting counter clockwise The fitting has standard right hand threads Page 31 17 18 20 21 22 23 24 25 29 Disconnect the drain hose from the flue transition to the elbow on the cold header collector box trap Disconnect the 3 pin plug from the combustion air blower at the blower deck Remove four 4 screws from combustion air blower and remove flue transition and blower assembly from cabinet Take care not to lose the combustion air orifice Disconnect 9 pin plug from the blower compartment at the blower deck Remove 9 pin plug above the blower deck Remove the limit switch and the pressure switch from the vestibule panel Remove two 2 screws from the front cabinet flange at the blower deck Remove front screws from cabinet at blower deck on left and right sides Cabinet sides must be slightly spread to clear heat exchanger passage Remove screws along vestibule sides and bottom which secure vestibule panel and heat exchanger as sembly to cabinet Remove heat exchanger then re move cold end header box Back wash heat exchanger with soapy water solution or steam If steam is used it must be below 275 F 135 C
61. ed Check gas line pressure with unit firing at maximum rate or high fire Low pressure may result in erratic operation or underfire High pressure can result in permanent damage to gas valve or overfire For G32 units operating pressure at unit gas connection must be between 4 5 W C and 13 0 W C 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 F Check Manifold Pressure Manifold Operating Pressure is the manifold pressure measured during normal operation sensing burner box pressure Manifold Absolute Pressure is the manifold pressure measured when the gas valve regulator is operat ing at factory preset level sensing atmospheric pressure After line pressure has been checked and adjusted check manifold absolute pressure Move pressure gauge to outlet pressure tap located on unit gas valve GV1 Checks of manifold absolute pressure are made as verification of proper regulator adjustment Manifold operating pressure for the G32 can be measured at any time the gas valve is open and is supplying gas to the unit For natural gas units normal manifold operating pres sure for high fire is 3 5 in W C and 1 7 in W C for low fire DO not attempt to adjust WhiteRodgers valve on low fire WhiteRodgers valve is not adjustable on low fire For propane units normal manifold operating pressure for high fire
62. ed meth od for leak detection see unit instructions ACTION 1 Check for air leakage at all joints in the heat exchanger assembly Condition may cause high CO2 with high CO ACTION 2 Seal leakage if possible high tem perature silicon is recommended replace heat exchanger if necessary tag and return heat ex changer to proper Lennox personnel ACTION 1 Check for sooting deposits or other restrictions in the heat exchanger assembly Clean assembly as outlined in instruction manu al ACTION 2 For G32V gas furnaces check for proper combustion and flow CO2 should mea sure between 7 9 and 8 5 for high fire and be tween 5 5 and 6 3 for low fire CO should measure below 04 400PPM in an air free sample of flue gases 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 for proper flow of exhaust gases away from intake vent Remove any ob stacles in front of the intake and exhaust vent which would cause recirculation ACTION 2 Check for correct intake and exhaust vent installation 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 PROBLEM 6 BURNERS LIGHT WITH HEATING DEMAND BUT UNIT SHUTS DOWN PREMATURELY CONT 6 5 Combustion air blower energizes with a heating demand Burners light
63. ee figure 10 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 FAN OFF TIME ADJUSTMENT 60sec 90sec 120sec 180sec 2 1 2 1 2 1 2 1 OFF ay OFF ki ON ON ON ON 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 To adjust fan off timing flip dip switch to desired setting FIGURE 10 Page 9 g gnition Sequence Board 56L83 24L85 63K89 15 34 35 38 Pre Purge Ignitor Warmup Trial for Blower On Ignition Delay GAS VALVE INDOOR BLOWER Blower on time will be 45 seconds after gas valve is energized Blower off time will depend on OFF TIME Setting SureLight Control Ignition Sequence Board 97L48 15 34 38 80 Trial for Blower On Ignition Delay GAS VALVE INDOOR BLOWER Pre Purge Ignitor Warmup Blower on time will be 45 seconds after gas valve is energized Blower off time will depend on
64. er con connections Correct wiring and or replace any loose connections nections at pressure switch ACTION 1 If all the above modes of failure have 4 1 8 been checked the pressure switch may have Pressure switch failure failed Replace pressure switch and determine if unit will operate Page 53 PROBLEM 5 UNIT FAILS TO FIRE IN THE HEATING MODE COMBUSTION AIR BLOWER ENERGIZES IGNITOR IS ENERGIZED CONT Possible Cause Corrective Action Comments 5 1 Unit operates with a cooling and continuous fan demand Combustion air blower energizes with Heating demand Ignitor is energized but unit fails to light LED 1 Alternating Slow Flash LED 2 Alternating Slow Flash 5 1 1 Check that gas is being supplied to the unit 5 1 2 Miswiring of gas valve or loose con nections at multi pin control amp plugs or valve 5 1 3 Malfunctioning gas valve or ignition control 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 check for excessive gas line pressure
65. erate on first stage heat low fire The combustion air blower B6 and indoor blower will operate on low speed O 502 The unit will switch to second stage heat high fire on call from the indoor thermostat W2 While in the W2 TIMED FIGURE 13 mode factory setting 8 minutes the unit will fire on first stage heat low fire with the combustion air blower B6 and indoor blower B3 operating on low speed After a set time delay the unit switches to second stage heat high fire The combustion air blower and indoor blower also Switch to second stage heat mode ON ON Page 10 A WARNING Shock hazard Disconnect power before servicing Integrated Control Board is not field repairable If control is inoperable simply replace entire control Can cause injury or death Unsafe operation will result if repair is attempted 8 Two Stage Integrated Control Board A92 All G32 5 and later units are equipped with the Lennox two stage integrated SureLight control board The system consists of a ignition control board figure 14 with control terminal designations in tables 7 8 and 9 and ignitor fig ure 9 The board and ignitor work in combination to en sure furnace ignition and ignitor durability The board con trols all major furnace operations The board features two LED lights DS1 and DS2 for troubleshooting The board also has two accessory terminals rated at 1 one amp each See table 10 for troublesh
66. form ice in the exhaust termination that prevents the unit from operating properly Longer run times of at least 5 minutes will alleviate most icing problems Also a heating cable may be installed on exhaust piping and termination to prevent freeze ups Heating cable installation kit is avail able from Lennox See Condensate Piping section for part numbers NOTE Care must be taken to avoid re circulation of ex haust back into intake pipe 6 On field supplied terminations for side wall exits ex haust piping should extend a minimum of 12 305mm beyond the outside wall Intake piping should be as short as possible See figure 22 1 2 13 ARMAFLEX INSULATION IN UNCONDITIONED SPACE 12 305 MIN 2 X 1 1 2 51 x 38 PVC REDUCER 1 2 13 ARMAFLEX INSULATION 2 51 PVC COUPLING OUTSIDE 8 203 WALL MINIMUM TOP VIEW WALL RING KIT 15374 LB 49107CB for 2 50 8 Venting FIGURE 22 Inches mm 7 On field supplied terminations a minimum separation distance between the end of the exhaust pipe and the end of the intake pipe is 8 203mm 8 If intake and exhaust piping must be run up a side wall to position above snow accumulation or other obstruc tions piping must be supported every 3 ft 91m as shown in figure 28 Refer to figures 26 and 27 for prop er piping method WTK wall termination kit must be ex tended for use in this application See figure 31 or use kit WTKX shown in figure 32 Whe
67. h 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 In all cases blower and entire unit will be off when the system switch is in OFF position B Temperature Rise Temperature rise for G32 units depends on unit input blow er 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 AIR TEMP RISE F listed on the unit rating plate Page 29 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 manual C External Static Pressure 1 Measure tap locations as shown in figure 40 2 Punch a 1 4 diameter hole 4 MANOMETER in supply upstream of evap o
68. has been obtained Take care to replace pressure tap plug I Flame Signal A microamp DC meter is needed to check the flame signal on the SureLight control Use a flame signal transducer part number 78H5401 available from Lennox to measure the flame signal if meter used will not read microamp signal Flame microamp signal is an electrical current which passes from the ignition control through the sensor elec trode during unit operation Current passes from the sen sor through the flame to ground to complete a safety circuit To Measure Flame Signal 1 Setthe volt meter to the DC voltage scale Insert trans ducer into the VDC and common inputs Observe cor rect polarities Failure to do so results in negative values Turn off supply voltage to control Disconnect flame sensor lead from terminal of ignition control Connect lead of transducer to ignition control sen sor connection Connect lead of the transducer to sensor wire Turn supply voltage on and close thermostat contacts to cycle system When unit lights read voltage on meter display Re member 1 DC volt 1 DC microamp N oun WN 1 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 Blower operation is dependent on thermostat control system 2 Generally blower operation is set at thermostat sub base fan switch Wit
69. iagnostic LEDs DS2 DESCRIPTION SIMULTANEOUS SIMULTANEOUS Power on Normal operation SLOW FLASH SLOW FLASH Also signaled during cooling and continuous fan SIMULTANEOUS SIMULTANEOUS Normal operation signaled when heating demand initiated at thermostat FAST FLASH FAST FLASH ON SLOW FLASH Primary limit or rollout switch open Limits must close within 3 minutes or unit goes in to 1 hour Watchguard Low fire pressure switch open G32Q 75 only OFF SLOW FLASH OR Blocked inlet exhaust vent OR Low pressure switch closed prior to activation of combustion air inducer High fire pressure switch open FAST FLASH OR Blocked inlet exhaust vent OR High pressure switch closed prior to activation of combustion air inducer Watchguard burners failed to ignite OR limit open more than 3 minutes OR lost flame sense 5 times in one heating cycle OR pressure switch opened 5 times in one heating cycle SLOW FLASH Flame sensed without gas valve energized ON ON ON Circuit board failure or control wired incorrectly Check 24 and 115 volts to board OFF FAST FLASH SLOW FLASH Main power polarity reversed Switch line and neutral SLOW FLASH FAST FLASH Low flame signal Measures below 23 microAmps Replace flame sense rod The following conditions are sensed during the ignitor warm up period only 1 Improper main ground ALTERNATING ALTERNATING 2 Broken ignitor OR Open ignitor circuit FAST FLASH FAST FLASH 3 Line voltage below
70. ification The SureLight ignitor is made of durable sili con nitride Ignitor longevity is also enhanced by voltage ramping by the control board The board finds the lowest ignitor temperature which will successfully light the burn er thus increasing the life of the ignitor SURELIGHT CONTROL BOARD TABLE 1 SURELIGHT CONTROL TERMINAL DESIGNATIONS elsk 135 VAC RETO ACB COOL Blower Cooling Speed Line Volt ME LON TX POTS ACC M DUK ACB HEAT Blower Heating Speed Line Volt 1 1 111 111 Alternate Blower Speeds Dead NEUTRALS ACB LOW Continuous Low Speed Blower n 9 ACC Accessory Terminal Line Volt 10006 TX 120VAC Hot to Transformer HOT 120VAC Hot Input TOMTA SYSTEM e HTG ACC Heat Only Accessory Line Volt mmm NEUTRALS 120VAC Neutrals 24VAC HOT 24VAC Hot from Transformer 24VAC RTN 24VAC Return from Transformer P FLAME SENSE Flame Sense Terminal HEAT OFF DELAY J58 51 1 51 1 TIME YO WE 000 AA SURELIGHT IGNITOR MEASUREMENT IS TO I D OF RETENTION RING 50A62 120 CAT NO 63K8901 FIGURE 8 FIGURE 9 TABLE 2 DIAGNOSTIC CODES MAKE SURE TO ID LED S CORRECTLY REFER TO INSTALLATION
71. ion is required D Electrical 1 Check all wiring for loose connections 2 Check circuit breaker located in unit control box 3 Check for correct voltage at unit unit operating 4 Check amp draw on blower motor Motor Nameplate Actual E Intake and Exhaust Lines Check intake and exhaust lines and all connections for tightness and make sure there is no blockage Also check condensate line for free flow during operation F Insulation Outdoor piping insulation should be inspected yearly for deteri oration If necessary replace with same materials G Winterizing and Condensate Trap Care 1 Turn off power to unit 2 Have a shallow pan ready to empty condensate water Avoid spilling water into the control box 3 Remove clamp from flue assembly and remove boot or cap Empty water from cap Visually inspect bottom of flue assembly Replace boot and clamp 4 Remove boot from condensate trap and empty water Inspect trap then replace boot VII WIRING DIAGRAMS amp SEQUENCE OF OPERATION TYPICAL G32 FIELD WIRING DIAGRAM FLAME FURNACE MAY BE CONTROLLED BY EITHER ROLLOUT LIMIT IGNITION A SINGLE OR TWO STAGE THERMOSTAT SWITCH CONTROL TWO STAGE THERMOSTAT SHOWN LOW HEAT HIGH HEAT PRESSURE PRESSURE SWITCH SWITCH 75 ONLY GAS COMBUSTION VALVE AIR BLOWER 43 71VLSNI AG GIHSINYNA LINDUID YO LOANNOOSIG qasna THERMOSTAT TRANSFORMER TO ACCESSORY IF USED ELECTRONIC AIR CLEANER IF
72. ized specifically to the unit Refer to Lennox Repair Parts Listing for correct sizing information A flame retention ring in the end of each burner maintains correct flame length and shape and keeps the flame from lifting off the burner head In addition the burner entrance to each clamshell is fitted with a corbel cup orifice used to direct the flow of combustion prod ucts TYPICAL BURNER ASSEMBLY 4 DANGER Shock hazard Disconnect power before servicing Control is not field repairable If control is inoperable simply re place entire control 6 SureLight Ignition System A92 All G32 1 through 4 units are equipped with the Lennox SureLight ignition system The system consists of ignition control board figure 8 with control terminal designations in table 1 and ignitor figures 6 and 9 The board and igni tor work in combination to ensure furnace ignition and ig nitor durability The SureLight integrated board controls all major furnace operations The board also features two LED lights for troubleshooting and two accessory termi nals rated at 4 four amps See table 2 for troubleshooting diagnostic codes NOTE Do not remove blower access panel to read Sur elight LED lights A sight glass is provided on the access panel for viewing Tables 3 and 4 show jack plug terminal designations Units equipped with the SureLight board can be used with either electronic or electro mechanical thermostats without mod
73. lator cap must be installed when reading pressures NOTE Shut unit off and remove manometer as soon as an accurate reading has been obtained Take care to re place pressure tap plug NOTE During this test procedure the unit will be overfiring e Operate unit only long enough to obtain accurate read ing to prevent overheating heat exchanger e Attempts to clock gas valve during this procedure will be inaccurate Measure gas flow rate only during nor mal unit operation 6 When test is complete remove obstruction from hose and return hose to gas valve barb G Proper Gas Flow Approximate 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 14 below Adjust manifold pressure on gas valve to match time needed NOTE To obtain accurate reading shutoff all other gas appliances connected to meter TABLE 14 GAS METER CLOCKING CHART Seconds for One Revolution ied EMI MERC wass 1 cu ft 2 cu ft Dial DIAL 240 o 780 72 144 Natural 1000 btu cu ft LP 2500 btu cu ft Page 28 H High Altitude Derate See specifications section in this manual for manifold pres sure settings for installations at altitudes from 0 to 7500ft 0 to 2286m A IMPORTANT For safety shut unit off and remove manometer as soon as an accurate reading
74. lies two separate valves for natural and LP and is adjustable on high fire ONLY 24VAC terminals and gas control knob are located on top of the valve Terminals on the gas valve are connected to wires from the SureLight integrated control and the two stage con trol 24V applied to the terminals energizes the valve Inlet and outlet pressure taps are located on the valve A regu lator adjustment screw is located on the side of the valve Re fer to figure 37 in section III START UP for location of valve features 100 Sealed Combustion The burner box is completely sealed and operates under a negative pressure A pressure hose is connected from the burner box to the gas valve regulator and differential pres sure switch The gas valve senses the pressure in the burn er box and changes gas valve output based on changes in burner box pressure The intent is to compensate for differ ent vent configurations which can greatly affect the rate of the unit NORMAL OPERATION Natural Gas Units e e OPERATION AT THIS EXTREME MAY INDICATE A BLOCKED OUTLET OR OTHER PROBLEM e T e w e e o N N 2 n 2 2 gt o lt N Si OPERATION AT THIS EXTREME MAY INDICATE A BLOCKED INLET OR OTHER PROBLEM 0 2 0 4 0 6 0 8 BURNER BOX PRESSURE Negative inches water gauge
75. n exhaust and in take piping must be run up an outside wall the exhaust piping is reduced to 1 1 2 38mm after the final el bow The intake piping may be equipped with a 90 el bow turndown Using turndown will add 5ft 1 5m to the equivalent length of the pipe Page 20 1 2 12 7 FOAM INSULATION IN UNCONDITIONED SPACE Inches mm MMM MMM MA OUTSIDE WALL INTAKE TERMINATION 12 305 Min above grade Optional Turndown Shown TOP VIEW Intake Only WALL TERMINATION 22644 LB 49107CD for 2 50 8 Venting mm E CONCENTRIC WALL TERMINATION 44J40 LB 65701A for 3 76 2 Venting 60677 LB 49107CE for G32 75 Units Only FIGURE 23 33K97 LB 87942 for G32 100 amp 125 Units Only FIGURE 25 INTAKE EXHAUST TERMINATION EXHAUST Inches 12 305 MIN for 2 51 Inches mm 0 508 MAX for 3 76 UNCONDITIONED SPACE EXHAUST 12 305 ABOVE AVERAGE SNOW ACCUMULATION OUTSIDE WALL gt PROVIDE SUPPORT FOR INTAKE AND EXHAUST LINES EVERY 12 305 ABOVE 36 914 AVERAGE SNOW ACCUMULATION INTAKE TERMINATION N N NSSSSSSSSI 1 2 13 FOAM _ INSULATION IN a UNCONDITIONED 1 2 13 FOAM SPACE INSULATION Inches mm SIDE VIEW WALL RING TERMINATION EXHAUST INTAKE 15F74 LB 49107CB for 2 51 Venting CONCENTRIC ROOFTOP TERMINATION 60G77 LB 49107CE for G32 75 Units Only FIGURE 26 33K97 LB 87942 for G32 100 amp 125 Units Only FIGURE 24 9 Position
76. n which the ap pliances remaining connected to the common venting system are located and other spaces of the building Turn on clothes dryers and any appliances not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers 4 Follow the lighting instruction Place the appliance be ing inspected in operation Adjust thermostat so ap pliance will operate continuously 1 Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use a draft gauge or the flame of match or candle or smoke from a cigarette cigar 6 After it has been determined that each appliance re maining connected to the common venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous con dition of use 7 If improper venting is observed during any of the above tests the common venting system must be cor rected The common venting system should be re sized to approach the minimum size as determined by using the appropriate tables in appendix G in the cur rent standards of the National Fuel Gas Code ANSI Z223 1 in the U S A and the appropriate Category 1 Natural Gas and Propane appliances venting sizing tables in the current standards of the CAN CGA B149 1
77. nd or replace any Combustion air blower will not start nections to combustion air blower connections with a Heating demand Diagnostic lights flash the pressure switch failure code 3 2 2 ACTION 1 Check that the pressure switch is open without the combustion air blower operat LED 1 Off Pressure switch stuck closed ing Replace if malfunctioning LED 2 Slow Flash Page 52 PROBLEM 3 UNIT FAILS TO FIRE IN THE HEATING MODE COMBUSTION AIR BLOWER DOES NOT ENERGIZE CONT Possible Cause Corrective Action Comments 3 3 Unit operates with a cooling and con 3 3 1 tinuous fan demand Combustion air blower will not start with a Heating demand Diagnostic lights flash the pressure switch failure code 2 5 minutes after heating demand ACTION 1 Check for correct wiring and loose Miswiring of furnace or improper con connections Correct wiring and or replace any A loose connections nections to combustion air blower 3 3 2 ACTION 1 If there is 120V to combustion air blower and it does not operate replace combus LED 1 Off Combustion air blower failure tion air blower LED 2 Slow Flash PROBLEM 4 UNIT FAILS TO FIRE IN THE HEATING MODE COMBUSTION AIR BLOWER ENERGIZES IGNITOR IS NOT ENERGIZED 4 1 4 1 1 Unit t ith li d P itch d t cl d ACTION 1 Check that the pressure switch tub Unit operates with a Cooling an ressure switc oes not close aue ing is correctly routed Correctly route p
78. nuous flame check LOW FLAME SIGNAL LED 1 SLOW FLASH FLAME SIGNAL LED 2 FAST FLASH gt 0 60 microamps GAS VALVE DE ENERGIZED COMBUSTION AIR INDUCER DE ENERGIZED INDOOR BLOWER ON LED 1 SLOW FLASH LED 2 ON HAS LIMIT CLOSED NO PRESSURE SWITCH CLOSED HAS PRIMARY SECONDARY LIMIT RESET CONTINUED ON NEXT PAGE See table 2 DIAGNOSTIC CODES for limit reset operation YES GAS VALVE DE ENERGIZED COMBUSTION AIR INDUCER DE ENERGIZED CONTINUED ON NEXT PAGE INDOOR BLOWER OFF DELAY Selected time LED 1 ON LED 2 SLOW FLASH Page 39 HEATING SEQUENCE CONTINUED NORMAL HEATING MODE PRESSURE SWITCH CLOSED W2 TIMED MODE SINGLE STAGE T STAT E r TWO STAGE MODE L CALL FOR tst STAGE HEAT L CALL FOR 2nd STAGE HEAT HIGH HEAT FROM THERMOSTAT 2nd STAGE ON DELAY ON CONTROL BOARD COMPLETE 8 12 OR 15 MIN INDOOR BLOWER ON HIGH HEATING SPEED COMBUSTION AIR INDUCER ON HIGH SPEED HIGH HEAT PRESSURE SWITCH CLOSED YES HIGH HEAT GAS VALVE OPEN 8 SEC DELAY NO 71 L TWO STAGE MODE W2 TIMED MODE L CALL FOR 1st STAGE HEAT SINGLE STAGE T STAT i QNS cnp a CONTROL CHECKS FLAME PRESENCE CLOSED PRIMARY LIMIT CLOSED PRESSURE SWITCHES CONTINUOUSLY CLOSED ROLLOUT SWITCH during heating cycle SEE PREVIOUS SEQUENCES FOR FAILURE MODES DEMAND FOR HEAT SATISFIED THERMOSTAT OPENS GAS VALVE DE ENERGIZED COMBUSTION AIR INDUCER POST PURGE 5 SEC
79. nut driver remove the burner mounting screws from underneath the burners While supporting ignitor and sensor lines at the grom met grasp burners and simultaneously pull burners and grommet out of the burner box Remove ignitor and sensor assemblies from burners using a 1 4 nut driver to remove two screws from each bracket 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 Re install ignitor and sensor bracket assemblies on burners NOTE Ignitor must be installed on the opposite side of the burner from the metal button protrusions Screws which attached the ignitor bracket must be installed from the same side as the ignitor and through the brack et to engage in the smaller holes located in the burner The correct burner orientation is with metal button pro trusions always pointing up 15 Replace burner ignitor assembly back into burner box so that grommet groove fits back into sheet metal notch and makes a good seal The burners sit on top of the burner box flanges Make certain that the screws from underneath the box pass through the larger holes in the flange and engage in the smaller holes in the burner Re install the two screws 16 Re install the gas manifold gas valve assembly by first inserting the right hand side of the gas manifold into the burner box Swing lef
80. o operate Lack of differential usually indicates problems in the intake or exhaust piping but may indicate problems in the heat ex changer condenser coil header boxes combustion blower or other components Generally if both readings are closer to zero figure 19 the unit may have a restricted flue outlet or oth er problem If both readings are farther from zero figure 19 the unit may have a restricted flue inlet or other problem Measuring pressure differential The differential pressure is the difference in pressure mea sured on either side of the pressure switch 1 Remove thermostat demand and allow to cycle off 2 Disconnect hose from left side of pressure switch and install Tee as shown in figure 20 Page 17 TEE AND 1 4 i d RUBBER HOSE FIELD PROVIDED USED FOR MEASURING PRESSURE A ACROSS BURNER BOX AND COM BUSTION AIR BLOWER TO PRESSURE SENSING HOSE TO PRESSURE SWITCH TO DRAFT GAUGE FIGURE 20 Install draft gauge to open end of Tee Operate unit and observe draft gauge reading Read ings will change as heat exchanger warms a Take one reading immediately after startup b Take a second reading after unit has reached steady state approximately 5 minutes Remove thermostat demand and allow to cycle off Remove draft gauge and Tee Reinstall combustion air sensing hose to left side of pressure switch Disconnect hose from right side of pressure switch and install Tee as shown in figure 20 Ins
81. of exhaust pipe open to outside air exterior exhaust must be insulated with 1 2 13mm Armaflex or equivalent CAUTION Do not discharge exhaust into an existing stack or stack that also serves another gas appliance If vertical discharge through an existing unused stack is required insert PVC pipe inside the stack until the end is beyond the top or outlet end of the metal stack A CAUTION The exhaust vent pipe operates under positive pressure and must be completely sealed to pre vent leakage of combustion products into the liv ing space Removal of Unit from Common Venting System In the event that an existing furnace is removed from a venting system commonly run with separate gas ap pliances the venting system may be too large to properly vent the remaining attached appliances The following test should be conducted while all appliances both in operation and those not in operation are connected to the common venting system If the venting system has been installed improperly corrections must be made as outlined in the previous section 1 Seal any unused openings in the common venting sys tem Page 19 2 Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition 3 Insofar as is practical close all building doors and win dows and all doors between the space i
82. ooting diagnostic codes Electronic Ignition At the beginning of each heat cycle SureLight control mon itors the first stage and second stage combustion air induc er prove switch The control will not begin the heating cycle if the first stage prove switch is closed by passed Like wise the control will not begin the second stage heating cycle if the second stage prove switch is closed and will al low first stage heat only However if the second stage prove switch closes during the first stage pre purge the control will still respond to second stage heat Once the first stage prove switch is determined to be open the combustion air inducer is energized on low first stage heat speed When the differential in the prove switch is great enough the prove switch closes and a 15 second pre purge begins If the switch is not proven within 2 1 2 minutes the control goes into Watchguard Pressure Switch mode for a 5 min ute re set period After the 15 second pre purge period the SureLight ignitor warms up for 20 seconds after which the gas valve opens for a 4 second trial for ignition The ignitor energizes during the trial until flame is sensed If ignition is not proved during the 4 second period the control will try four more times with an inter purge and warm up time between trials of 35 sec onds After a total of five trials for ignition including the ini tial trial the control goes into Watchguard Flame Failure mode After a 60
83. or does not get hot when there is no call for heat on units with SureLight ignition system How To Operate Gas Valve Figure 37 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 1 STOP Read the safety information at the beginning of this section 2 Set thermostat to lowest setting Turn off all electrical power to furnace 4 This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand 5 Remove unit access panel 6 White Rodgers 36E Gas Valve switch lever to OFF Do not force See figure 37 Wait five 5 minutes to clear out any gas If you then smell gas STOP Immediately call your gas supplier from a neighbors phone Follow the gas suppliers instruc tions If you do not smell gas go to next step WHITE RODGERS 36E SERIES GAS VALVE SM C PRESSURE ADJUSTMENT HI N ON SIDE o under cap T F ON MANIFOLD PRESSURE UTLET ON a HONEYWELL VR8205 SERIES Gas Valve HIGH HEAT MANIFOLD MANIFOLD Ej PRESSURE PRESSURE k LET under cap MANIFOLD PRESSURE ADJUSTMENT under cap BOTH VALVES SHOWN IN OFF POSITION FIGURE 37 8 White Rodgers 36E Gas Valve switch lever to ON Do not force 9 Replace access panel
84. ostats Both type thermostats are described below Thermo stat jumper E20 dictates which mode unit will operate in See flow chart for more sequence detail SureLight Control Self Check When there is a call for heat the SureLight integrated con trol runs a self check The control checks for S10 primary limit S21 secondary limit s and S47 rollout switch nor mally closed contacts The control also checks for S102 high heat and 128 low heat prove switch G32 75 only normally open contacts Once self check is complete and all safety switches are operational heat call can continue Two Stage Thermostat Two Stage Heat Jumper E20 set at TWO 4 SureLight control energizes combustion air inducer B6 on low heat speed Combustion air inducer runs until 102 prove switch contacts close switch must close within 2 1 2 minutes or control goes into Watchguard Pressure Switch mode G32 75 ONLY SureLight control energizes combus tion air inducer B6 on low heat speed Combustion air inducer runs until 128 prove switch contacts close switch must close within 2 1 2 minutes or control goes into Watchguard Pressure Switch mode Prove switch 102 may also close A 15 second pre purge follows once 128 closes 5 SureLight control begins 20 second ignitor warm up period 6 Gas valve opens on first stage for a 4 second trial for ignition Ignitor stays energized during the trial or until flame sensed 7 Flame is sensed gas valve remains
85. pens on high fire second stage Two stage Mode Two stage Thermostat SureLight control energizes combustion air blower B6 on low speed Combustion air blower runs until com bustion air blower switch 5102 closes or S128 on G3275 units Switch will close within 2 1 2 minutes or control goes into Watchguard Pressure Switch mode A 15 second pre purge follows once S102 closes SureLight control energizes ignitor A 20 second warm up period begins Gas valve is energized on first stage only 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 indoor blower B3 is energized on low speed Call for second stage heat comes from indoor thermo stat W2 G32 2 amp 3 HEATING SEQUENCE OF OPERATION NORMAL HEATING MODE ABNORMAL HEATING MODE GAS VALVE OFF COMBUSTION AIR INDUCER ON POWER ON INDOOR BLOWER ON LED 1 AND 2 CONTROL SELF CHECK OKAY ALTERNATING FAST FLASH CHECK FOR BROKEN IGNITOR OR OPEN IGNITOR CIRCUIT GAS VALVE OFF COMBUSTION AIR INDUCER OFF COMBUSTION AIR BLOWER ON FOR 1 SECOND POLARITY OKAY YES LED 1 AND 2 ALTERNATING FAST FLASH SIGNAL HOLDS UNTIL UNIT IS PROPERLY GROUND ROLLOUT SWITCH CLOSED YES BURNER OFF CONTINUOUS FLAME CHECK YES S NO IS THERE A YES IS VOLTAGE PROPER GROUND ABOVE 75 VOLTS YE INDOOR BLOWER DELAY OFF LED 1 ON LED 2 ON RESET CONTROL BY TURNING MAIN POWER OF
86. performance related problems Avoid exposure to the following substances in the combustion air supply Permanent wave solutions Chlorinated waxes and cleaners Chlorine base swimming pool chemicals Water softening chemicals De icing salts or chemicals Carbon tetrachloride Halogen type refrigerants Cleaning solvents such as perchloroethylene Printing inks paint removers varnishes etc Hydrochloric acid Cements and glues Antistatic fabric softeners for clothes dryers and Masonry acid washing materials Page 18 Intake Piping 1 Cement intake piping in slip connector located at top of unit 2 Route piping to outside of structure Continue with installation following instructions given in exhaust and intake piping termination section Exhaust Piping 1 Cement exhaust piping into flue collar socket located on the left side of the top cap N All horizontal runs of exhaust pipe must slope back to ward unit A minimum of 1 4 6mm drop for each 12 305mm of horizontal run is mandatory for drainage Horizontal runs of exhaust piping must be supported ev ery 5 ft 1 52m using hangers for schedule 40 pipe All other pipe must be supported every 3 ft 91m NOTE Exhaust piping should be checked carefully to make sure there are no sags or low spots NOTE Exhaust piping must be insulated with 1 13mm Armaflex or equivalent when run through un heated space Do not leave any area
87. r setting the burners will fire on first stage heat The combustion air inducer will operate on low speed and indoor blower will operate on low heat speed The unit will switch to second stage heat on call from the indoor thermostat If there is a simultaneous call for W1 and W2 first and second stage heat the unit will fire on first stage heat and will switch to second stage heat after 30 seconds of operation See Sequence of Operation flow charts in the back of this manual for more detail Dip Switch Settings Dip Switches 1 and 2 Heating Fan off Delay The fan on time of 45 seconds is not adjustable Fan off time time that the blower operates after the heat demand has been satis fied can be adjusted by flipping the dip switches 1 and 2 located on the SureLight integrated control The unit is shipped with a factory fan off setting of 90 seconds Fan off time will affect comfort and is adjustable to satisfy individual applications For customized comfort monitor the supply air temperature once the heat demand is satisfied Note the supply air temperature at the instant the blower is de ener gized Adjust the fan off delay to achieve a supply air tem perature between 90 110 at the instant the blower is de energized Longer delay times allow for lower air tempera ture shorter delay times allow for higher air temperature See table 5 for dip switch settings TABLE 5 Heating Fan Off Delay Em Cu Switch 3 Second
88. rator 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 discharge supply side of the system On ducted systems connect the other end of manometer to the return duct as above For systems with non ducted returns leave the other end of the ma nometer open to the atmosphere 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 Pressure drop must not exceed 0 5 W C G32 UNIT FIGURE 40 5 Seal around the hole when the check is complete D Blower Speed Taps Leadless Motors 1 Models Blower speed tap selection is accomplished by changing the taps at the blower motor harness connector Disconnect har ness connector from motor to expose speed selectors Blow er speed selections are listed in table 15 To Change Blower Speed 1 Turn off electric power to furnace 2 Remove blower access door 3 Disconnect blower motor harness from motor 4 Pull harness connector and wires through blower ac cess panel opening 5 Select desired speeds for heating and cooling Red heating Black cooling White common 6 Depress harness connector tab to release wire termi nal Select connector location for new speed refer to unit wiring diagram Insert wire termin
89. re pressure switch closes switch will close with in 2 1 2 minutes or control goes into Watchguard Pressure Switch mode A 15 second pre purge fol lows after S102 closes 4 SureLight control energizes ignitor A 20 second warm up period begins 5 Gas valve is energized on first stage heat low Gas valve opens for a 4 second trial for ignition 6 Flame is sensed After 8 seconds from when gas valve opens valve energizes on second stage high heat 7 After 45 second delay indoor blower is energized on heating speed Page 37 Two stage Mode Single stage Thermostat SureLight control energizes combustion air blower B6 on low speed Combustion air blower runs until com bustion air blower switch S102 or 5128 onG32 75 units closes switch will close within 2 1 2 minutes or control goes into Watchguard Pressure Switch mode A 15 second pre purge follows once 5102 closes SureLight control energizes ignitor A 20 second warm up period begins Gas valve is energized on first stage Gas valve opens for a 4 second trial for ignition Signal is sent from con trol module to two stage control board to begin W2 second stage ON delay Flame is sensed gas valve remains open for the heat call After 45 second delay indoor blower B3 is energized on low speed Second stage time on delay complete 8 12 or 15 minutes Combustion air blower B6 switches to high speed indoor blower B3 switches to heating speed and gas valve o
90. ressure continuous fan demand to incorrect routing of the pressure switch tubing Combustion air blower energizes switch tubing with a heating demand 412 Diagnostic lights flash the pressure ACTION 1 Remove any obstructions from the switch failure code 2 5 minutes after Pressure switch does not close due pressure tubing and or taps heating demand to obstructions in the pressure tubing 4 1 3 ACTION 1 Check pressure switch tubing for LED 1 Off Pressure switch tubing damaged leaks Replace any broken tubing LED 2 Slow Flash 4 1 4 ACTION 1 Check pressure switch tubing for condensate Remove condensate from tubing Condensate in pressure switch tub Check that the condensate tubing is located cor ing rectly ACTION 1 Check the differential pressure across the pressure switch This pressure 4 1 5 should exceed the set point listed on the Pressure switch does not close due switch to a low differential pressure across ACTION 2 Check for restricted inlet and ex the pressure switch haust vent Remove all blockage ACTION 3 Check for proper vent sizing and run length See installation instructions 4 1 6 ACTION 1 Check that the proper pressure Wrong pressure switch installed in the switch is installed in the unit Replace pressure unit or pressure switch is out of cal switch if necessary ibration 4 1 7 ACTION 1 Check for correct wiring and loose Miswiring of furnace or improp
91. s the structure to im prove the velocity of exhaust away from the intake pip ing On roof terminations the intake piping should termi nate straight down using two 90 elbows See figure 21 3 76 MAX 3x2 76 x 51 OR a 2 x 1 1 2 51 x 38 PVC REDUCER Inches mm 8 ie 1 2 13 FOAM INSULATION IN z id UNCONDITIONED 12 305 ABOVE AVERAGE SNOW ACCUMULATION 3 76 OR 74 2 51 PVC PROVIDE SUPPORT FOR INTAKE AND EXHAUST LINES UNCONDITIONED ATTIC SPACE ROOF TERMINATION KIT 15F75 LB 49107CC for 2 51 Venting 44J41 LB 65678A for 3 76 Venting FIGURE 21 A IMPORTANT Do not use screens or perforated metal in intake and exhaust terminations Doing so will cause freeze ups and may block the terminations NOTE If winter design temperature is below 32 F 0 C ex haust piping must be insulated with 1 2 13mm Armaflex or equivalent when run through unheated space Do not leave any surface area of exhaust pipe open to outside air exterior exhaust pipe must be insulated with 1 2 13mm Armaflex or equivalent In extreme cold climate areas 3 4 19mm Arma flex or equivalent is recommended Insulation on outside runs of exhaust pipe must be painted or wrapped to protect insula tion from deterioration NOTE During extremely cold temperatures below approximately 20 F 6 67 C units with long runs of vent pipe through unconditioned space even when insulated may
92. second delay indoor blower B3 is energized on low heat speed 6 10 minute factory set or 15 minute field set second stage heat delay period begins 7 The combustion air inducer ramps up to high heat speed G32 75 ONLY S102 prove switch closes 8 Gas valve energizes second stage heat 9 B3 indoor blower ramps up to high heat speed Page 44 G32 5 amp 6 HEATING SEQUENCE OF OPERATION NORMAL AND ABNORMAL HEATING MODE GAS VALVE OFF COMBUSTION AIR INDUCER POWER ON OFF INDOOR BLOWER OFF CHECK FOR BROKEN IGNITOR OR OPEN IGNITER CIRCUIT CONTROL SELF CHECK OKAY DS1 AND DS2 ALTERNATING FAST FLASH GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF RESET CONTROL BY TURNING MAIN POWER OFF DS1 ON DS2 ON POLARITY REVERSED POLARITY OKAY DS1 FAST FLASH YES DS2 SLOW FLASH IS THERE A SIGNAL HOLDS UNTIL UNIT IS PROPERLY GROUNDED PROPER GROUND DS1 AND DS2 ALTERNATING FAST FLASH IS VOLTAGE SIGNAL HOLDS UNTIL VOLTAGE RISES ABOVE 75 VOLTS ABOVE 75 VOLTS DS1 AND DS2 ALTERNATING FAST FLASH YES BURNER OFF GAS VALVE OFF COMBUSTION AIR INDUCER ON CONTINUOUS FLAME CHECK INDOOR BLOWER ON HEATING SPEED DS1 SLOW FLASH DS2 OFF YES A NORMAL OPERATION DS 1 SIMULTANEOUS SLOW FLASH DS 2 SIMULTANEOUS SLOW FLASH COMBUSTION AIR INDUCER OFF INDOOR BLOWER ON HAS PRIMARY LIMIT RESET WITHIN 3 MINUTES B DS1 SLOW FLASH DS2 ON THERMOSTAT CALLS FOR HEAT DS 1 SIMULTANEOUS FAS
93. ssure Pressure Switch Setting model ELM in W C btuh a E 05 100 000 btuh S102 25 05 125 000 btuh 102 20 05 Page 16 CHART REPESENTS NORMAL OPERATING CHARACTERISTICS OF THE PRESSURE SWITCH ONLY AND SHOULD NOT BE USED FOR TROUBLSHOOTING 1 2 2 2 S d 40 DIFFERENTIAL SWITCH CLOSED ag a L O w i 0 8 ES S 2 lt m 0 6 So DIFFERENTIAL SWITCH OPEN oc Furnace will not operate lt 0 4 2 a 8 0 2 0 0 0 2 0 4 0 6 0 8 1 0 1 2 BURNER BOX STATIC PRESSURE FIGURE 19 Temporarily jumpering the pressure switch when trouble shooting will determine if the pressure switch and furnace are operating properly However this may not indicate if the sealed combustion system is operating properly If the unit cannot attain the required inches differential see table 12 the unit will not operate Be sure to remove jumper when finished See Warning this page A WARNING Safety Hazard Turn off gas supply before jump ering switch or testing switch differential If switch is operating properly and sealed com bustion system is operating improperly a po tentially lethal situation will be created when switch is bypassed DO NOT ALLOW UNIT TO OPERATE WITH SAFETY SYSTEMS BYPASSED Checks of pressure differential can be made as an aid in trou bleshooting It is important to remember that the switch must see the required differential in order for the furnace t
94. t be taken to maintain FIGURE 28 protective coatings over building materials prolonged 10 Suspend piping using hangers at a minimum of every exposure to exhaust condensate can destroy protec 5 feet 1 52m for schedule 40 PVC and every 3 feet 91m for ABS DWV PVC DWV SPR 21 PVC and SDR 26 PVC piping A suitable hanger can be fabri cated by using metal or plastic strapping or a large wire tie tive coatings It is recommended that the exhaust out let not be located within 6 feet 1 8m of a condensing unit because the condensate can damage the painted coating 11 In areas where piping penetrates joists or interior walls hole must be large enough to allow clearance on all sides of pipe through center of hole using a hanger A IM PORTANT 12 Isolate piping at the point where it exits the outside wall Combustion air intake inlet and exhaust outlet or roof should not be located within 6 ft 1 8m of dryer 13 When furnace is installed in a residence where unit is vent or combustion air inlet or outlet of another ap pliance Piping should not exit less than 3 ft 91m from opening into another building shut down for an extended period of time such as a vacation home make provisions for draining conden sate collection trap and lines 14 Based on the recommendation of the manufacturer a multiple furnace installation may use a group of up to four termination kits WTK assembled together horizon Inches mm 112 13 3x
95. t is necessary order Lennox part no 31J81 for 14 x 25 856 x 635mm filter for G32Q3 75 units and P 8 7831 for 20 x 25 508 x 635mm filter for G32 100 and 125 units B Cleaning Heat Exchanger and Burners NOTE Surgical mask and safety glasses should be worn when cleaning heat exchanger and burners If cleaning the heat exchanger becomes necessary follow the below procedures and refer to figure 1 when disassem bling unit Use papers or protective covering in front of fur nace while removing heat exchanger assembly 1 2 3 4 c 1 6 T 8 9 10 11 13 Turn off electrical and gas power supplies to furnace Remove upper and lower furnace access panels Remove four 4 screws around air intake fitting and lift intake pipe up and away Loosen hose clamp securing top of flue transition to bottom of flue collar Remove screw securing flue col lar to top cap and lift exhaust pipe and flue collar up and away If electrical field make up box is located inside the unit it must be removed Remove gas supply line connected to gas valve Mark all gas valve wires and disconnect them from valve Mark and remove wires from flame roll out switch Remove top cap of unit Remove sensor wire from SureLight control Discon nect 2 pin plug from the ignitor Mark and disconnect pressure switch tubing from both sides of the pressure switch Loosen two 2 screws holding gas manifold support at vestibul
96. t side of manifold into box while en gaging support bracket to vestibule panel screws Check that foam gaskets are providing a seal around each end of the gas manifold All gas orifices should be engaged If at this point the burners were mounted in the wrong holes this needs to be corrected The saddle brackets on the gas manifold should be flush with the front surfaces on the burner box sides 17 Inspect the dual layered metal pieces at the front lip of the cover These pieces must sandwich around the metal Re install burner box cover 18 Re install the screws to secure the burner box cover Make sure screws are tight to ensure a leak tight burn er box Tighten the two screws underneath the box Again inspect the grommet to ensure a tight seal 19 Tighten the two screws holding the manifold bracket to the vestibule panel Re install the electrical connections to the gas valve Brown wire to H1 yellow wire to C2 and orange wire to M 20 Page 33 21 Re install the sensor wire to the spade connector on the SureLight control Re install the 2 pin ignitor plug at the burner box 22 Reconnect gas line to gas valve 23 Replace lower access panel 24 Following lighting instructions and gas line connection test procedures from installation manual 25 Replace upper access panel C Supply Air Blower 1 Check and clean blower housing and blower wheel 2 Motors are prelubricated for extended life no further lubricat
97. tall draft gauge to open end of Tee Operate unit and observe draft gauge reading Read ings will change as heat exchanger warms a Take one reading immediately after startup b Take a second reading after unit has reached steady state approximately 5 minutes Both readings should fall above the line shown in figure 19 Compare readings to figure 19 Be sure to compare only like readings compare startup reading to startup reading then compare steady state reading to steady state reading Subtract the absolute steady state readings from one another This will be the pressure differential In order for the furnace to operate the larger negative must always be on the combustion 3 4 5 6 N 8 9 air blower side of the switch Example one side of the pressure switch reads 60 and the other side of the pressure switch reads 10 Pressure differential is 60 10 50 The pressure differential should be greater than the settings in table 12 11 When test is complete remove thermostat demand and allow unit to cycle off 12 Remove draft gauge and Tee Reinstall pressure switch sensing hose to left side of pressure switch If pressure switch does not close at start up or differential is less than set point the following should be checked 1 Restriction in exhaust and or intake vent 2 Pressure switch lines are routed correctly and for dam age 3 Condensate in pressure switch lines 4
98. tall the burner box Tighten the screws holding the support bracket It is important that the glass fiber gasket not be damaged so it will provide a continuous seal between the burner box and the vestibule panel Reconnect pressure switch tubing by connecting the tubing from the burner box to the barb on the bottom and the tubing from the combustion air blower to the barb on the top See figure 18 Note G32 75 units will have two pressure switches Reconnect the sensor and ignitor wires Re install top cap to unit Re install electrical connections to gas valve Brown wire to H1 yellow wire to C2 and orange wire to M Re connect wires to flame roll out switch NOTE Unit is polarity sensitive 120V supply wiring must be installed correctly Reconnect main gas line to gas valve Re install field make up box if removed Re install exhaust pipe flue collar and secure flue col lar to the unit top cap using existing screw Insert the bottom of the flue collar into the top of the flue transi tion and tighten hose clamp Re install intake pipe fitting to burner box with screws Replace both upper and lower access panels Refer to instruction on verifying gas and electrical con nections when re establishing supply Following lighting instructions from installation manu al light and run unit for 5 minutes to ensure heat ex changer is clean dry and operating safely MOUNTING PATCH PLATE CKET Simplified Burner Removal 1 Remove
99. tap connected to PARK M1 or PARK M2 See table 16 for blower motor tap colors for each speed TABLE 16 BLOWER SPEED CHART FACTORY CONNECTED SPEED TAPS MOTOR coo 1825 1825 lu uz REEDS 2 AVAILABLE YELLOW RED 4 0374 100 BROWN 4 YELLOW RED Q4 5 100 125 SLACK YELLOW RED BLUE BROWN 5 HI BLOWER SPEED SELECTION L ET F J SPEED BLACK BROWN w RED TAPS BLACK BROWN BLUE YELLOW RED 5 VI MAINTENANCE 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 Retainers for factory supplied return air filter are shown in figure 42 BOTTOM RETURN FILTER REAR FILTER CLIP FURNACE SIDE FILTER CLIPS 2 WS OPENING ps Pd FURNACE FURNACE BASE BOTTOM Page 30 A Filters At the beginning of each heating season the system should be checked as follows Filters should be inspected monthly and must be cleaned or replaced when dirty to ensure proper fur nace operation Reusable foam filters used with the G32 can be washed with water and mild detergent When dry they should be sprayed with filter handicoater prior to rein stallation Filter handicoater is RP Products coating no 418 and is available as Lennox part no P 8 5069 If replacemen
100. termination ends so they are free from any ob structions and above the level of snow accumulation where applicable Termination ends must be a mini mum of 12 305mm above grade level Do not point into window wells stairwells alcoves courtyard areas or other recessed areas Do not position termination ends closer than 12 below roof eaves or above a walk way Since the G32 is a certified direct vent Category A IM PO RTANT IV gas furnace the location of the termination is limited by building codes In the absence of local codes refer For Canadian Installations Only to the current National Fuel Gas Code ANSI Z223 1 in In accordance to CAN CGA B149 1 and 2 the U S A and current standards CAN CGA B149 1 2 of minimum allowed distance between the combus the Natural Gas and Propane Installation Instructions in tion air intake inlet and the exhaust outlet of other Canada for details The termination should be at least appliances shall not be less than 12 305mm 12 805mm from any opening through which flue products could enter the building Page 21 When horizontally vented minimum clearance for ter MA e METAL OR PLASTIC mination from electric meters gas meters regulators STRAPPING and relief equipment is 4 ft 1 2m for US installations OR LARGE WIRE TIES Refer to the current CAN CGA B149 1 and 2 for installations in Canada or with authorities having local jurisdiction At vent termination care mus
101. the improper Open ignitor circuit plug connections for correct installation main ground G32 1 to 3 Units with control boards date coded after Nov 1 1997 combustion air blower will cycle 5 seconds on 55 seconds off 2 1 2 ACTION 1 Unplug ignitor and read resistance d ux across ignitor If resistance does not read be Broken or failed ignitor tween 10 9 and 19 7 ohms replace the ignitor LED 1 Alternating Fast Flash LED 2 Alternating Fast Flash PROBLEM 3 UNIT FAILS TO FIRE IN THE HEATING MODE COMBUSTION AIR BLOWER DOES NOT ENERGIZE Possible Cause Corrective Action Comments ACTION 1 Check continuity across switch es Unit operates with a uem or contin 3 1 1 Switches reset automatically upon cool down uous fan demand Rollout switch must be reset manually Combustion air blower will not start Primary or secondary if equipped or ACTION 2 Check for restrictions on blower inlet a air including filter and outlet air Determine with a Heating demand rollout limit switch open cause for limit activation before placing unit back Diagnostic lights flash the limit failure in operation mode 3 12 ACTION 1 Check for correct wiring and loose iswiri i connections Correct wiring and or replace any LED 2 On i 3 2 Unit operates with a cooling and con 3 2 1 ACTION 1 Check for correct wiring and loose tinuous fan demand Miswiring of furnace or improper con Connections Correct wiring a
102. the left side of the burner sup port See figure 6 The sensor is mounted on a bracket in the burner support and the tip protrudes into the flame en velope of the left most burner The sensor is fastened to burner supports and can be removed for service without re moving any part of the burners During operation flame is sensed by current passed through the flame and sensing electrode The SureLight control allows the gas valve to re main open as long as flame signal is sensed x SENSOR y cl 3 8 FIGURE 6 NOTE The G32 furnace contains electronic compo nents that are polarity sensitive Make sure that the fur nace is wired correctly and is properly grounded Page 7 5 Burners All units use inshot burners see figure 7 Burners are factory set and do not require adjustment A sight glass is furnished in the burner box assembly for flame viewing Always operate the unit with the burner box cover in place Burn ers can be removed as an assembly for service Burner main tenance and service is detailed in the MAINTENANCE sec tion of this manual Each burner uses an orifice which is pre cisely matched to the burner input see nameplate for orifice size The orifice is threaded into the burner manifold The burner is supported by the orifice and will easily slide off for service Each orifice and burner are s
103. uple 81J20 WTK close couple Condensate Drain Heat Cable 26K68 6 ft 1 8 m 26K69 24 ft 7 3 m 26K70 50 ft 15 2 m Heat Cable Tape 39G04 1 2 in 38 mm fiberglass or 39G03 2 in 25 mm aluminum foil 1 roll L P KIt 34L29 1 2 units 11M55 3 units 1 Annual Fuel Utilization Efficiency based on U S DOE test procedures and FTC labeling regulations Isolated combustion system rating for non weatherized furnaces 2 Meets California Nitrogen Oxides NO Standard and California Seasonal Effieciency requirements 3 Polyurethane frame type filter 4 Determine from venting tables proper intake and exhaust pipe size and termination kit required NOTE 2 inch x 3 inch 51 mm x 76 mm adaptor is furnished with 100 and 125 furnaces for exhaust pipe connection Concentric Vent Intake Air Roof Termination Kit optional 60G77 1 1 2 inch 38 mm 33K97 2 inch 51 mm Page 2 BLOWER WATTS DATA G32Q3 75 BLOWER PERFORMANCE 1060 0 630 595 605 550 560 54 540 965 375 345 870 NOTE All air data is external to unit with 1 in 25 cleanable foam filter not furnished in place Also see SET Air Resistance table G32Q3 4 100 BLOWER PERFORMANCE External Static Air Volume and Motor Watts at Specific Blower Taps Pressure LOHN enor p el c 1525 910 84
104. use a1 8 plastic plug to close off port C Gas Piping Gas supply piping should not allow more than 0 5 W C drop in pressure between gas meter and unit Supply gas pipe must not be smaller than unit gas connection D Testing Gas Piping 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 38 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 TYPICAL FURNACE MANUAL MAIN SHUT OFF VALVE WILL NOT HOLD NORMAL TEST PRESSURE ISOLATE GAS VALVE GAS VALVE WILL NOT HOLD TEST PRESSURE IN EXCESS OF 0 5 PSIG 14 W C FIGURE 38 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 When checking piping connections for gas leaks use pre ferred means Kitchen detergents can cause harmful corro sion on various metals used in gas piping Use of a specialty Gas Leak Detector is strongly recommended It is available through Lennox under part number 31B2001 Do not use matches candles flame or any other source of ignition to check for gas leaks E Testing Gas Supply Pressure When testing supply gas pressure connect test gauge to inlet pressure tap field provid
105. ve 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 Roll Out Switch Out The SureLight control board has an added feature that pro longs the life of the ignitor After a successful ignition the SureLight control utilizes less power to energize the ignitor Pressure Switch In 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 Not Used amount of power is used for 255 cycles On the 256th call for heat the control will again ramp down until the lowest power is determined and the cycle begins again Primary Limit In Gas Valve Common Gas Valve 24V Pressure Switch and Primary Limit Out Roll Out Switch In KI e LED m mE 0 mw p o ecce NE E ee Ke mo Ooo Ground b Fan Time Control The fan on time of 45 seconds is not adjustable Fan off ELECTROSTATIC DISCHARGE ESD time time that the blower operates after the heat demand Precautions and Procedures has been satisfied can be adjusted by flipping the dip switches located on the SureLight integrated control The A CAUTION unit is shipped with a factory fan off setting of 90 seconds Fan off time will affect comfort and is adjustable to satisfy individual applications S

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