Lennox International Inc. G20 User's Manual
Contents
1. HEM NOX USERS INFORMATION MANUAL 5087544 G20 Supersedes 4 95 SERIES GAS FURNACE Rua Publications Litho U S A WARNING If the information in this manual is not followed exactly a fire or explosion SUR may result causing property damage personal injury or death e Do not try to light any appliance e Extinguish any open flames e Do not touch any electrical switch do not use any phone in your building Installation and service must be per Immediately call your gas supplier from a formed by a qualified installer ser neighbor s phone Follow the gas suppliers instructions MICE AGENCY OT ME QAS SUPPIET e If you cannot reach your gas supplier call the fire department Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Page 1 G20E G20X PARTS IDENTIFICATION REAR BAFFLE HEAT TOP STRIP EXCHANGER BLOCKED VENT SWITCH UPPER ACCESS IGNITION CONTROL GAS MANIFOLD SS ROLL OUT GAS VALVE PILOT ELECTRODE ASSEMBLY REMOVABLE BURNER BURNER BURNERS BOX TOP BOX BLOWER CONTROL BOX BURNER BOX DAMPER ASSEMBLY FIGURE 1 Page 2 A WARNING Product contains fiberglass wool Disturbing the insulation in this product during installation maintenance or repair will expose you to fiberglass wool Breathing this may cause lung cancer Fiberglass wool is known to the State of California to cause can2. Side View FLAME SENSOR ELECTRODE PILOT GAS LINE G20E amp G20X FIGURE 7 2 Burner Flame Start burner and allow to operate for a few minutes to establish normal burning condi tions Check burner flame by observation Flame should be predominantly blue in color strong in ap pearance and should rise directly from the burner ports in the heat exchanger Check to see that flame is burning from all continuous ribbon ports and that flame does not impinge on the sides of the heat ex changer See figure 8 BURNER FLAME NOTE VIEW BURNER FLAME THROUGH OBSERVATION PORT ON BURNER BOX OR DAMPER OPENING Not Shown FIGURE 8 VENTING SYSTEM INSPECTION Annually before heating season inspect furnace venting system draft hood vent cap heat exchanger burners and pilot for corrosion deterioration or deposits of de bris Remove any obstructions Contact your Lennox dealer for a periodic unit inspection by a qualified service technician BLOCKED VENT SHUT OFF SYSTEM Your Lennox furnace is equipped with a blocked vent shut off switch and a flame roll out switch The blocked vent shut off switch shuts offthe gas supply to the furnace in the event of flue or vent blockage The flame roll out switch shuts off the gas supply to the furnace if there is a blockage of the heat exchanger If the furnace fails to op erate due to the functioning of either of these switches DO NOT attempt to place the furnace into o
3. floor because some gas is heavier than air and will settle on the floor Use only your hand to push in or turn the gas control knob or lever Never use tools If the knob or lever will not push in or turn by hand do not try to repair it call a qualified ser vice technician Force or attempted repair may resultina fire or explosion To place G20E or G20X furnace into operation G20E or G20X units are equipped with an intermittent pi lot ignition system Do not attempt to manually light pilots on these furnaces Each time thermostat calls for heat the pilot will automatically light The pilot does not burn when there is no call for heat on units with electronic igni tions Gas Valve Operation Figures 3 and 4 1 STOP Read the safety information at the beginning of this section 2 Set thermostat to lowest setting See figure 2 THERMOSTATS ma 50 60 10 15 2 2s JJ Ir Jb di wr oo FIGURE 2 3 Turn off all electrical power to appliance 4 This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand 5 Remove control access panel Honeywell VR8204 Gas Valve Turn the knob on the gas valve clockwise to OFF See figure 3 Robertshaw 7200 Gas Valve Depress the lever and move to OFF position Do not force See figure 4 o Page 4 7 c 1 10
4. off electric power to furnace 2 Remove blower access panel Wait for blower to stop 3 Remove filter by sliding up and out of filter brackets 4 Wash filter with water and a mild detergent For in creased efficiency filler media should be sprayed with filter Handicoater when dry Filter Handicoater is RP products no 418 and is available as Lennox part no P 8 5069 NOTE If filter media must be replaced order Lennox part no P 9 7831 for 20 x 25 filter P 8 7822 for 16 x 25 filter 97HO601 for 18 x 25 filter 97H0701 for 25 x25 filler and 97H0801 for 24 x 30 filter Reinstall filter Slide filter into top bracket and drop into lower bracket Ci 1 NOTE Do not replace reusable foam filters with throw away filters 6 Replace blower access panel TABLE 1 FILTER SIZE MODEL NO SIDE RETURN BOTTOM RETURN 02 50 03 50 02 75 03 75 16 X 25 X 1 16 X 25 X 1 16 X 25 X 1 18 X 25 X1 Q4 75 Q3 4 100 Q5 6 100 Q3 4 125 Q5 6 125 Blower Check and clean blower wheel for any debris Blower mo tor is prelubricated for extended bearing life No further lu brication is needed Pilot and Burner Flame A CAUTION 20 X 25 X 1 20 X 25 X 1 25 X 25 X 1 24 X 30 X1 Check pilot flame and burner flame periodically to ensure proper operation 1 Pilot Flame Pilot flame must surround the end of flame sensor for proper operation of pilot safety cir cuit See figure 7 Page 5 PILOT FLAME
5. HONEYWELL VR8204 SERIES GAS VALVE GAS VALVE SELECTOR ARM IN OFF POSITION FIGURE 4 Wait five 5b 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 Honeywell VR8204 Gas Valves Turn the knob on the gas valve counterclockwise to ON Robertshaw 7200 Gas Valve Depress the lever and move to ON position Do not force Replace control access panel Turn on all electrical power to unit Set thermostat to desired setting NOTE When unit is initially started steps 1 through 11 may need to be repeated to purge air from pilot line If the furnace still will not operate follow the instruc tions To Turn Off Gas To Unit and call your service technician or gas supplier To Turn Off Gas To Unit 1 5 Set thermostat to lowest setting Turn off all electrical power to unit if service is to be performed Remove control access panel Honeywell VR8204 Gas Valves Turn the knob on the gas valve clockwise to OFF Robertshaw 7200 Gas Valve Depress the lever and move to OFF position Do not force Replace control access panel Filters G20E and G20X series units are equipped with reusable filters which should be inspected monthly and cleaned when necessary to assure proper furnace operation See table 1 for filter sizes Use the following procedure to clean filter 1 Turn
6. cer 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 A WARNING Do not use this furnace if any part has been under water Immediately call a qualified service techni cian to inspect the furnace and to replace any part of the control system and any gas control which has been under water A WARNING If overheating occurs or if gas supply fails to shut off shut off the manual gas valve to the appliance before shutting off electrical supply A IMPORTANT Any additions changes or conversions required in order for the appliance to satisfactory meet the application needs must be made by a Lennox ser vice technician using factory specified and ap proved parts A CAUTION Before attempting to perform any service or main tenance turn the electrical power to unit OFF at disconnect switch IMPORTANT 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 Page 3 holes corrosion or bloc
7. ence headache nausea fatigue or dizzi Page 6 ness the cause could be exposure to carbon monox ide gas This is often misdiagnosed as the flu because symptoms are similar If you suffer from flu like symp toms that are exaggerated at home but seem to sub side while you are away from the house exposure to carbon monoxide could be the cause Your vigilance may pay off early detection of a problem before either personal injury or property damage occurs Do not hesitate to contact a qualified service technician as an investment in your well being PLANNED SERVICE You should expect a service technician to check the 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 unobstructed to provide combustion air Burners Must be inspected for rust dirt or signs of water Vent pipe Must be inspected for signs of water dam aged or sagging pipe or disconnected joints Unit appearance Must be inspected for rust dirt signs of water burnt or damaged wires or components Blower access door Must be properly in place and pro vide a seal between the return air and the room where the furnace is installed Return air duct Must be properly attached and provide an air seal to unit Operating performance Unit must be observed during operation to monitor
8. 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 powered by or gives off heat from a combustion process including lawn mowers automobiles and fire places has the potential to produce carbon monoxide gas Because of this Lennox recommends the use of a carbon monoxide detector in your home even if you do not own gas appliances Reliable detectors are available at reasonable retail prices Contact your independent Lennox dealer for more details about this investment in your safety Your furnace is designed to meet standards set by nation al agencies and to operate safely when properly installed and maintained However the unit s performance can be greatly impacted by the individual installation and the op erating environment It is your responsibility to ensure that this appliance is maintained Proper maintenance is critical for your safety and the satisfactory operation of the product Lennox strongly recommends annual in spection and maintenance of this appliance Contact your independent Lennox dealer for an inspection by a qualified service technician LIGHTING INFORMATION AND OPERATION A WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or death BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the
9. kage 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 the house by the furnace duct system Your furnace is a gas appliance It is critical that the gas supplied to the unit be completely burned to avoid the pro duction of carbon monoxide gas Complete combustion of the gas requires but is not limited to correct gas pres sure and gas flow rate adequate combustion air and proper venting A WARNING Carbon monoxide gas
10. peration Con tact a qualified service person SERVICE REMINDER Call your Lennox service technician if unit is inoperative Before calling always check the following to be sure ser vice is required 1 Check to see that electrical disconnect switches are ON 2 Check room thermostat for proper setting 3 Replace any blown fuses or reset circuit breakers 4 Gas valve should be ON 5 Air filter should not be plugged limiting air flow 6 Is gas turned on at meter 7 ls manual main shut off valve open SAFETY PRECAUTIONS To keep your Lennox gas heating system in peak operat ing condition year after year contact your independent Lennox dealer about a planned service program 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 e If you experi
11. proper performance of the unit and the vent system Combustion gases Flue products must be analyzed and compared to the unit specifications Problems detected during the inspection may make it necessary to temporarily shut down the furnace until the items can be repaired or replaced Pay attention to your furnace Situations can arise be tween annual furnace inspections that may result in un safe operation For instance items innocently stored next to the furnace may obstruct the combustion air supply This could cause incomplete combustion and the produc tion of carbon monoxide gas
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