Lennox International Inc. G27M User's Manual
Contents
1. LENNOX PRODUCT LITERATURE 1999 Lennox Industries Inc Dallas Texas 503 589M 7 99 Supersedes 9 98 USERS INFORMATION MANUAL G27M SERIES GAS FURNACE a Z Z EEEN Technical RETAIN THESE INSTRUCTIONS Pee FOR FUTURE REFERENCE Litho USA AWARNING If the information in this manual is not AVA followed exactly a fire or explosion may result causing property damage Chemo personal injury or loss of life Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Installation and service must be per formed by a qualified installer ser vice agency or the gas supplier WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Extinguish any open flames Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Page 1 G27M PARTS IDENTIFICATION BOARD UPFLOW POSITION AWARNING Product contains fiberglass wool Disturbing the insulation in this product during installation maintenance or repair will expose you to fiber glass wool Breathing this may cause lung can cer F2. of this appliance Contact your independent Lennox dealer for an inspection by a qualified service technician Lighting Information and Operation AWARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life BEFORE OPERATING 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 knob Never use tools If the knob will not turn by hand do not try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion Placing Furnace Into Operation G27M furnaces are equipped with an electronic ignition system Do not attempt to manually light burners on these furnaces Each time the thermostat calls for heat the burners will automatically light Gas Valve Operation Figure 2 1 STOP Read the safety information at the beginning of this section 2 Set the thermostat to the lowest setting See figure 1 THERMOSTATS oy 4098 2 2 30 wen CD FIGURE 1 3 Turn off all electrical power to the unit 4 This furnace is equipped with an ignition device which automatically lights the burners Do not try to light the burners by hand 5 Remove the access panel 6 White Rodgers 36E Gas Valve Turn knob
3. on gas valve 180 either way to OFF See figure 1 7 Wait five minutes to clear out any gas If you then smell gas STOP Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you do not smell gas go to next step WHITE RODGERS 36E SERIES GAS VALVE 8 White Rodgers 36E Gas Valve Turn knob on gas valve 180 either way to ON 9 Replace the access panel 10 Turn on all electrical power to to the unit 11 Set the thermostat to desired setting NOTE When unit is initially started steps 1 through 11 may need to be repeated to purge air from gas line 12 If the appliance will not operate follow the instruc tions Turning Off Gas to Unit and call your service technician or gas supplier Turning Off Gas to Unit 1 Set the thermostat to the lowest setting 2 Turn off all electrical power to the unit if service is to be performed 3 Remove the access panel 4 White Rodgers 36E Gas Valve Turn knob on gas valve 180 either way to ON 5 Replace access panel Two Stage Operation The G27M is a two stage gas fired furnace which can be controlled by either a two stage or single stage room thermostat The two stage thermostat monitors the room temperature and sends a signal to the G27M furnace when the temper ature falls below the desired setpoint The furnace is then turned on at low fire first stage
4. If the room temperatures continues to fall the thermostat sends a signal to turn on the unit at high fire second stage Page 4 When a single stage thermostat is being used to control the operation of the G27M furnace the unit can either op erate on high fire second stage at all times or the unit can be made to start on low fire first stage and automatically switch to high fire second stage after a time delay if the demand is not satisfied on low fire first stage NOTE For more details on available options and for unit adjustment contact the Lennox Technical Support De partment G27M series units are equipped with external filters which should be inspected monthly and replaced when necessary to assure proper furnace operation See table 1 for filter sizes Replacement filters used with G27M 60 75 units must have a minimum velocity rat ing of 400 FPM Replacement filters used with G27M 100 120 units require a minimum velocity rating of 625 FPM Figures 3 4 and 5 show possible filter locations TABLE 1 FILTER SIZE MODEL NUMBER UPFLOW DOWNFLOW 1 FILTER 2 FILTERS G27M 45 60 75 16 in X 20 in X 1 in 16 in X 20 in X 1 in G27M 100 120 140 20 in X 20 in X 1 in 16 in X 20 in X 1 in UPFLOW FURNACE BOTTOM RETURN AIR p Y h 4 MUU MUM MUU FIGURE 3 UPFLOW FURNACE SIDE RETURN AIR DOWNFLOW FURNACE FILTERS IN PLENUM RACK MUMMY ps MW WF
5. WU MMU MUU FIGURE 5 Blower Check and clean blower wheel for any debris Blower mo tor is prelubricated for extended bearing life No further lu brication is needed AWARNING Blower door must be securely in place when blower and burners are operating Gas fumes which could contain carbon monoxide can be drawn into living space resulting in personal injury or death Page 5 Burner Flame The G27M burner flame is not adjustable however the flame should be inspected at the beginning of each heat ing season and burners should be cleaned if necessary Burner flame should be blue when burning natural gas BURNER FLAME FLAME APPEARS BLUE IF BURNING NAT GAS HEAT EXCHANGER TUBE FIGURE 6 Venting System Inspection Annually before heating season inspect furnace venting system vent cap heat exchanger and burners for corro sion deterioration or deposits of debris Remove any ob structions Contact your Lennox dealer for a periodic unit inspection by a qualified service technician Flame Rollout Safety Switches Your Lennox furnace is equipped with two flame roll out safety switches which shut off the gas supply to the fur nace in case of heat exchanger blockage If the furnace fails to operate due to the functioning of these safety switches DO NOT attempt to place the furnace into op eration Contact a qualified service technician Service Reminder Call your Lennox service tec
6. bustion gases Flue products must be analyzed and compared to the unit specifications Problems detected during the inspection may make it necessary to temporarily shut down the furnace until the items can be repaired or replaced Pay attention to your furnace Situations can arise be tween annual furnace inspections that may result in un safe operation For instance items innocently stored next to the furnace may obstruct the combustion air supply This could cause incomplete combustion and the produc tion of carbon monoxide gas
7. hnician if unit is inoperative Before calling always check the following to be sure ser vice is required 1 Check that electrical disconnect switches are ON 2 Are access panels securely in place 3 Check room thermostat for proper setting 4 Replace any blown fuses or reset circuit breakers 5 Gas valve should be ON 6 Air filter should not be plugged limiting air flow 7 Is gas turned on at meter 8 Is manual main shut off valve open To keep your Lennox gas heating system in peak op erating condition year after year contact your inde pendent Lennox dealer about a planned service pro gram Safety Precautions If you discover any of the following shut down your unit and contact an independent Lennox dealer for an inspection by a qualified technician e If you repeatedly hear any new or unfamiliar sounds while your unit is operating there may be a problem For example poorly performing burners can produce unfamiliar noises If you smell any unusual odors your unit may be oper ating improperly For example units can give off unfa miliar odors if components are required to operate in abnormal conditions Look for visible signs of a malfunctioning unit Exam ples include unusual amounts of condensate on win dows inside your house visibly burnt components or unusual dirt or rust accumulations on the vent pipe or in the unit If you experience headache nausea fatigue or dizzi ness the cause co
8. iberglass wool is known to the State of California to cause cancer Fiberglass wool may also cause respiratory skin and eye irritation To reduce exposure to this substance or for further information consult material safety data sheets available from address shown below or contact your supervisor Lennox Industries Inc P O Box 799900 Dallas TX 75379 9900 AWARNING 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 Page 2 COMBUSTION AIR BLOWER PRESSURE SWITCHES GAS VALVE ROLLOUT SWITCH One on each side BURNERS TWO STAGE CONTROL IGNITION CONTROL BOARD BLOWER o o0 no 0000000 O DOWNFLOW POSITION AWARNING Do not use this furnace if any part has been under water Immediately call a qualified service techni cian to inspect the furnace and to replace any part of the control system and any gas control which has been under water ACAUTION Before attempting to perform any service or mainte nance turn the electrical power to unit OFF at discon nect switch AIMPORTANT Any additions changes or conversions required in order for the appliance to satisfactorily meet the ap plication needs must be made by a Lennox service technician using factory specified and approved parts Impo
9. rtant Directions 1 Keep the furnace area clear and free of combustible material gasoline and other flammable vapors and liq uids If installed in an insulated area furnace must be kept free of insulating material Insulating material may be combustible Inspect furnace venting system to make sure it is in place physically sound and without holes corrosion or blockage Inspect furnace return air duct connection to ensure duct is sealed to the fur nace and terminates outside the space containing the furnace Inspect the physical support of the furnace to guarantee that it is sound without sagging cracks or gaps around base and it maintains seal between base and support 2 DO NOT obstruct air flow to unit Unit must receive an unobstructed flow of combustion and ventilating air 3 DO NOT store chlorine or fluorine products near unit or introduce these products into the combustion air These products can cause furnace corrosion 4 DO NOT draw return air from a room where this furnace or any other gas appliance ie a water heater is installed When return air is drawn from a room a negative pressure is created in the room If a gas appliance is operating in a room with negative pressure the flue products can be pulled back down the vent pipe and into the room This reverse flow of the flue gas may result in incomplete combustion and the formation of carbon monoxide gas This toxic gas might then be distributed throughout
10. the house by the furnace duct system Your furnace is a gas appliance It is critical that the gas supplied to the unit be completely burned to avoid the pro duction of carbon monoxide gas Complete combustion of the gas requires but is not limited to correct gas pres sure and gas flow rate adequate combustion air and proper venting AWARNING Carbon monoxide gas is invisible odorless and toxic Exposure to this gas can cause personal injury and even death to all occupants including pets Any item that is pow ered by or gives off heat from a combustion process in cluding lawn mowers automobiles and fireplaces has the potential to produce carbon monoxide gas Because of this Lennox recommends the use of a carbon monox ide detector in your home even if you do not own gas appliances Reliable detectors are available at reason able retail prices Contact your independent Lennox dealer for more details about this investment in your safety Page 3 Your furnace is designed to meet standards set by nation al agencies and to operate safely when properly installed and maintained However the unit s performance can be greatly impacted by the individual installation and the op erating environment It is your responsibility to ensure that this appliance is maintained Proper maintenance is critical for your safety and the satisfactory operation of the product Lennox strongly recommends annual in spection and maintenance
11. uld be exposure to carbon monox ide gas This is often misdiagnosed as the flu because symptoms are similar If you suffer from flu like symp toms that are exaggerated at home but seem to sub side while you are away from the house exposure to carbon monoxide could be the cause Your vigilance may pay off in early detection of a problem before either personal injury or property damage occurs Do not hesitate to contact a qualified service technician as an investment in your well being Page 6 Planned Service You should expect a service technician to check the fol lowing items during an annual inspection Power to the unit must be shut off for the service technician s safety Fresh air grilles and louvers on the unit and in the room where the furnace is installed Must be open and unob structed to provide combustion air Burners Must be inspected for rust dirt or signs of wa ter Vent pipe Must be inspected for signs of water dam aged or sagging pipe or disconnected joints Unit appearance Must be inspected for rust dirt signs of water burnt or damaged wires or components Fan access door Must be properly in place and provide a seal between the return air and the room where the fur nace is installed Return air duct Must be properly attached and provide an air seal to unit Operating performance Unit must be observed during operation to monitor proper performance of the unit and the vent system Com
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