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Service Literature

G24M series units are mid-efficiency gas furnaces manufac-
tured with tubular steel heat exchangers formed of alumi-
nized steel. G24M units are available in heating capacities of
45,000 to 140,000 Btuh and cooling applications up to 5
tons. Refer to Engineering Handbook for proper sizing.
Units are factory equipped for use with natural gas. A kit is
available for conversion to LPG operation. Early model G24M
units use electronic (direct spark) ignition. Late model G24M
model units feature the Lennox SureLightT silicon-nitride
ignition system. The G24MX unit meets the California Nitro-
gen Oxides (NO
) Standards and California Seasonal Effi-
x
ciency requirements. All units use a redundant gas valve to
assure safety shut-off as required by A.G.A. or C.G.A.
Units may be installed in upflow, downflow or horizontal posi-
tion. The heat exchanger is designed for upright or horizon-
tal use only. When the unit is installed in the downflow posi-
tion, the heat exchanger is field removed and reinstalled so it
is upright when the cabinet is inverted. No field conversion is
required when the unit is installed in the horizontal position.
The heat exchanger, burners and manifold assembly can
easily be removed for inspection and service by simply dis-
connecting gas, unplugging wiring harness and spark wires
and removing four screws holding the heat exchanger in
place. Then the heat exchanger slides out of the cabinet.
Model No.
Input Btuh (kW)
Output Btuh (kW)
lA.F.U.E.
California Seasonal Efficiency
Flue size connection diameter — in. (mm) round
Temperature Rise range — _F (_C)
High static certified by A.G.A./C.G.A. — in wg. (Pa)
Gas Piping Size I.P.S. Natural or LPG/propane
Blower wheel nominal
Blower wheel nominal
diameter x width
Blower motor output — hp (W)
Nominal cooling
Nominal cooling
that can be added
Shipping weight — lbs. (kg) 1 package
Electrical characteristics
LPG/propane kit
Twinning Kit
Up-Flow/Horizontal Filter and Filter Rack Kits
}No. & size of filters - in. (mm)
Catalog No.
¡Down-flow
¡Down-flow
No. & Size of Filters — in. (mm)
Filter Kit
Down-flow Combustible Floor Base
Sidewall Power Venting Kit
Hanging Bracket Kit
lAnnual Fuel Utilization Efficiency based on U.S. DOE test procedures and according to FTC labeling regulations. Isolated combustion system rating for non-weatherized
furnaces.
}Polyurethane frame type filter is furnished with kit.
¡Filters are not furnished with kit and must be ordered extra.
Corp. 9723-L12
Revised 07-2001
G24M SERIES UNITS
G24M2(X)-45
45,000 (13.2)
36,900 (10.8)
80.1%
75.4%
30 - 60 (17 - 33)
in.
mm
229 x 178
1/4 (187)
Tons
1, 1-1/2 or 2
kW
3.5, 5.3 or 7.0
130 (59)
b Optional Accessories (Must Be Ordered Extra) b
All specifications in this manual are subject to change. Pro-
cedures outlined in this manual are presented as a recom-
mendation only and do not supersede 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 and do not constitute
code.
G24M2-60
G24M3(X)-60
60,000 (17.6)
49,200 (14.4)
80.5%
80.5%
76.4%
75.9%
3 (76)
.50 (125)
1/2 (13)
9 x 7
10 x 7
254 x 178
1/3 (224)
2, 2-1/2 or 3
7.0, 8.8 or 10.6
120 volts — 60 hertz — 1 phase (less than 12 amps) All models
LB-69845L (38K84)
96J69 — 5 lbs. (2 kg)
Single (32J02) Ten Pack (66K64)
(1) 16 x 20 x 1 (406 x 508 x 25)
LB-69843A (32J01) — 3 lbs. (1 kg)
(2) 16 x 20 x 1 (406 x 508 x 25)
LB-79239A (67J91) — 10 lbs. (4 kg)
79J15 — 25 lbs. (11 kg)
LB-69957 (46J66) — 15 lbs. (8 kg)
Page 1
G24M
G24M2-75
G24M3(X)-75
75,000 (22.0)
61,700 (18.1)
80.1%
76.8%
4 (102)
45 - 75 (25 - 42)
9 x 7
229 x 178
254 x 178
1/4 (187)
1, 1-1/2 or 2
2, 2-1/2 or 3
3.5, 5.3 or7.0
7.0, 8.8 or 10.6
135 (61)
ã 1998 Lennox Industries Inc.
Litho U.S.A.
80.0%
76.8%
10 x 7
1/3 (224)

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Summary of Contents for Lennox G24M SERIES

  • Page 1: Service Literature

    Service Literature Revised 07-2001 G24M SERIES UNITS G24M series units are mid-efficiency gas furnaces manufac- All specifications in this manual are subject to change. Pro- cedures outlined in this manual are presented as a recom- tured with tubular steel heat exchangers formed of alumi- mendation only and do not supersede or replace local or nized steel.
  • Page 2: Specifications

    SPECIFICATIONS Model No. G24M4(X)-75 G24M3/4(X)-100 G24M4/5(X)-100 Input Btuh (kW) 75,000 (22.0) 100,000 (29.3) Output Btuh (kW) 61,700 (18.1) 82,000 (24.0) A.F.U.E. 80.0% 80.1% 80.0% California Seasonal Efficiency 76.3% 76.5% 77.0% Flue size connection diameter — in. (mm) round 4 (102) Temperature rise range —...
  • Page 3: Blower Data

    SPECIFICATIONS Model No. G24M4/5-140 G24M3/4-120 G24M4/5(X)-120 Input Btuh (kW) 140,000 (41.0) 120,000 (35.2) Output Btuh (kW) 114,800 (33.6) 98,400 (28.8) A.F.U.E. 80.0% 80.0% 80.1% California Seasonal Efficiency Not Available Not Available 75.5% Flue size connection diameter — in. (mm) round 4 (102) 5 (127) Temperature rise range —...
  • Page 4 BLOWER DATA G24M3-60 AND G24M3-75 BLOWER PERFORMANCE Air Volume at Various Blower Speeds External Static External Static Pressure High Medium-High Medium-Low in. w.g. 1425 1240 1000 1415 1230 1400 1220 1385 1200 1370 1180 1350 1160 1330 1140 1280 1095 1210 1040 1135...
  • Page 5 BLOWER DATA G24M4/5-100, G24M4/5-120 AND G24M4/5-140 BLOWER PERFORMANCE Air Volume at Various Blower Speeds External Static External Static Pressure High Medium-High Medium Medium-Low in. w.g. 2450 1155 2160 1020 1970 1700 1500 2440 1150 2155 1015 1965 1695 1500 2430 1145 2150 1015...
  • Page 6: Parts Identification

    VENT ADAPTER G24M CABINET TOP PARTS IDENTIFICATION HEAT EXCHANGER ASSEMBLY FLUE BOX COMBUSTION AIR BLOWER PRESSURE SWITCH G24M CABINET PRIMARY LIMIT FRONT LOUVERED LOW PRESSURE SWITCH PANEL (Propane Only) TURBULATOR BURNER ASSEMBLY TRANSFORMER SECONDARY LIMITS CABINET BOTTOM BLOWER ASSEMBLY CONTROL BOARD DOOR INTERLOCK SWITCH FIGURE 1...
  • Page 7 G24M BURNER ASSEMBLY (shown in upflow position with SureLight ignition system) SURELIGHT ROLLOUT IGNITOR SWITCHES BURNER BOX VEST PANEL UPPER BURNER MOUNTING RAIL LOWER BURNER MOUNTING RAIL FLAME BURNER SENSOR HEAT EXCHANGER PRIMARY LIMIT Back ORIFICE Left GAS VALVE Right Front BURNER BOX MANIFOLD...
  • Page 8 a-flame sensor Page 8...
  • Page 9: Diagnostic Codes

    SURELIGHT CONTROL BOARD TABLE 1 LATE MODEL G24M UNITS SURELIGHT CONTROL TERMINAL DESIGNATIONS ACB COOL Blower - Cooling Speed (Line Volt) ACB HEAT Blower - Heating Speed (Line Volt) PARK Alternate Blower Speeds (Dead) ACB LOW Continuous Low Speed Blower Accessory Terminal (Line Volt) 120VAC Hot to Transformer 120VAC Hot Input...
  • Page 10 TABLE 3 not proven within 2-1/2 minutes, the control goes into Watchguard-Pressure Switch mode for a 5-minute re-set SureLight BOARD J156 (J2) TERMINAL DESIGNATIONS period. NOTE - The G24M furnace contains electronic com- PIN # FUNCTION ponents that are polarity sensitive. Make sure that the Ignitor furnace is wired correctly and is properly grounded.
  • Page 11 4-- Ram Control (A3) Ignition Control Early Model G24M Units The ignition control is a direct spark ignition control module integral to the furnace control. See figure 9. The furnace control combines burner ignition func- When there is a call for heat, the control delays ignition tions with blower control functions.
  • Page 12 EARLY MODEL G24M FURNACE CONTROL (A3) SPARK OUTPUT 24VAC VOLT TERMINAL CONNECTIONS LINE VOLTAGE TERMINAL CONNECTIONS PLUG P20 See Table 6 for Terminal Functions FAN-OFF TIMING SWITCHES THERMOSTAT CONNECTIONS DIAGNOSTIC FIGURE 9 TABLE 5 When flame is sensed, the indoor blower starts after a .Krnace Control A3 Limit Response During Operation 45 second delay.
  • Page 13 TABLE 7 position. Figure 10 shows the various fan “off” timings Furnace Control A3 Diagnostic LED and how switches should be positioned. Unit is shipped LED State Meaning Remedy with a factory fan “off” setting of 180 seconds. Fan “off” time will affect comfort and efficiency and is adjustable Steady On Control Failure...
  • Page 14 N.C. SPST manual-reset limit connected in series SECONDARY LIMIT CONTROL (S21) with the ignition control A3. When S47 senses rollout, FOR G24M SERIES UNITS the ignition control immediately stops ignition and closes the gas valve. If unit is running and flame roll-...
  • Page 15 Refer to figure 17 or 18 for location of valve features. FIGURE 17 An LPG changeover kit is available from Lennox. The kit includes burner orifices and a regulator conversion kit. WHITE RODGERS...
  • Page 16 III--START-UP The switch is a single-pole single-throw pressure switch electrically connected to the furnace control. A--Preliminary and Seasonal Checks The purpose of the switch is to prevent burner opera- 1 - - Inspect electrical wiring, both field and factory tion if the combustion air blower is not operating. installed for loose connections.
  • Page 17 Gas Leak Detector is strongly recommended. It 2 - - While waiting for the unit to stabilize, notice the available through Lennox under part number flame. Flame should be stable and should not lift 31B2001. See Corp. 8411- -L10, for further details.
  • Page 18 NOTE- To obtain accurate reading, shut off all other gas appliances connected to meter. NOTE- To obtain accurate reading, shut off all other gas appliances connected to meter. NOTE-In Canada, certification for installation at alti tudes over 4500 ft. (1372m) above sea level is the juris diction of the local authorities.
  • Page 19 ° NOTE- The following is a generalized procedure and does not apply to all thermostat controls. Page 19...
  • Page 20 NOTE-Use papers or protective covering in front of fur nace while cleaning furnace. Page 20...
  • Page 21 1 - - Check and clean blower wheel. 7 - - Replace burners and burner tray, making sure 2 - - Motors used on the Lennox G24M series units burners are properly seated in slots on tray and ori- are permanently lubricated and need no further fice in manifold.
  • Page 22: Troubleshooting

    VII--WIRING, OPERATION SEQUENCE &TROUBLESHOOTING A--Field Wiring, Thermostat Connections 7<3,&$/ *0 ),(/' :,5,1* ',$*5$0 ),(/' ,167$//(' &/$66 ,, 9 ),(/' ,167$//(' /,1( 92/7$*( &20%867,21 $,5 %/2:(5 35(6685( 6:,7&+ 35,0$5< /,0,7 7+(50267$7 9$/9( : 5 < )/$0( 52//287 6:,7&+(6 75$16)250(5 6(&21'$5< /,0,76 %/$&.
  • Page 23 B--Early Model G24M Series With Ram Ignition Control 1 - - When disconnect is closed, 120V is routed through limits (S21) are closed, the furnace control begins a 45 second time-delay (pre-purge). door interlock switch (S51) to feed the line voltage...
  • Page 24 C--Ram Ignition Control Troubleshooting Guide RAM CONTROL HEATING TROUBLE SHOOTING SEQUENCE NORMAL HEATING MODE ABNORMAL HEATING MODE LED: SLOW FLASH RATE THERMOSTAT CALLS FOR HEAT LED: FAST FLASH RATE LOCKOUT: MAIN VALVE OFF COMB. AIR AND SYSTEM FANS ON RESET THERMOSTAT FLAME OFF? LED: 5 flash if flame sensed with valve off LED: Steady on if control board failure...
  • Page 25 RAM CONTROL COOLING TROUBLE SHOOTING SEQUENCE LED: Slow flash rate. REMAINS UNCHANGED THROUGHOUT COOLING CYCLE. THERMOSTAT CALLS FOR COOLING. COMPRESSOR CONTACTOR AND SYSTEM FAN ENERGIZED AT COOLING SPEED AFTER 1 SECOND DELAY. ACC TERMINAL ENERGIZED. THERMOSTAT OPENS. COMPRESSOR OFF. SYSTEM FAN AND ACC TERMINAL OFF AFTER COMPLETING SELECTED DELAY INTERVAL (At dip switches).
  • Page 26 D-Late Model G24M Series With SureLight Ignition Control TYPICAL G24M DIAGRAM (-11 MODEL SHOWN) 1 - When there is a call for heat, W1 of the thermostat ener- 5 - Gas valve opens for a 4-second trial for ignition. Ignitor gizes W of the furnace control with 24VAC.
  • Page 27 SURELIGHT CONTROL HEATING SEQUENCE OF OPERATION NORMAL HEATING MODE ABNORMAL HEATING MODE POWER ON GAS VALVE OFF. COMBUSTION AIR BLOWER ON. INDOOR BLOWER ON. LED #1 ALTERNATING FAST FLASH CONTROL SELF--CHECK OKAY? LED#2 ALTERNATING FAST FLASH CHECK FOR BROKEN IGNITOR OR OPEN IGNITOR CIRCUIT COMBUSTION AIR BLOWER ON FOR 1 SECOND.
  • Page 28 NORMAL HEATING MODE ABNORMAL HEATING MODE 15-SECOND COMBUSTION AIR INDUCER PREPURGE INITIATED BY CLOSED PRESSURE SWITCH. IS VOLTAGE ABOVE 75 VOLTS? LEDS SIGNAL IGNITOR WARM-UP -- 20 SECONDS. ALTERNATING IS THERE A PROPER GROUND? FAST FLASH IS IGNITOR INTACT AND CONNECTED? 4-SECOND TRIAL FOR IGNITION.
  • Page 29 SURELIGHT CONTROL COOLING SEQUENCE NORMAL COOLING MODE ABNORMAL COOLING MODE POWER ON IGNITION CONTROL MAIN POWER ON. GAS VALVE OFF. COMBUSTION AIR BLOWER OFF. INDOOR BLOWER OFF WITH NORMAL DELAY. CONTROL SELF DIAGNOSTIC CHECK. SIGNAL CIRCUIT BOARD FAILURE AT LED. IS CONTROL OPERATING NORMALLY? INTERRUPT MAIN POWER TO RESET CONTROL.
  • Page 30 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). WITH COMB.
  • Page 31 E--SureLight Ignition Control Troubleshooting Guide UPON INITIAL POWER UP , REMOVE ALL THERMOSTAT DEMANDS TO THE UNIT PROBLEM: 1 UNIT FAILS TO OPERATE IN THE COOLING, HEATING, OR CONTINUOUS FAN MODE Condition Possible Cause Corrective Action / Comments 1.1.1 ACTION 1 - - Check 120V main voltage. Both diagnostic lights fail to light Main voltage 120V not supplied to Determine cause of main power failure.
  • Page 32 PROBLEM 1: UNIT FAILS TO OPERATE IN THE COOLING, HEATING, OR CONTINUOUS FAN MODE Condition Possible Cause Corrective Action / Comments ACTION 1 - - Check that the unit is properly 1.5.1 ground. On initial power--up the combus- Improper ground to the unit. ACTION 2 - - Install a proper main ground to tion air blower remains energized.
  • Page 33 PROBLEM 3: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR BLOWER DOES NOT ENERGIZE (CONT.). Condition Possible Cause Corrective Action/Comments -- Unit operates with a cooling and 3.3.1 continuous fan demand. Miswiring of furnace or improper ACTION 1 - - Check for correct wiring and Combustion air blower will not loose connections.
  • Page 34: Pressure Switch

    PROBLEM 5: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR BLOWER ENERGIZES, IGNITOR IS ENERGIZED. (CONT.) Condition Possible Cause Corrective Action/Comments ACTION 1 - - Check line pressure at the gas 5.1.1 valve. Pressure should not exceed 13” WC for -- Unit operates with a cooling and Check that gas is being supplied to both natural and propane.
  • Page 35 PROBLEM 6: BURNERS LIGHT WITH HEATING DEMAND BUT UNIT SHUTS DOWN PREMATURELY (CONT.) Condition Possible Cause Corrective Action/Comments Check that the manifold pressure ACTION 1 - - matches value listed on nameplate. See installation instructions for proper proce- -- Combustion air blower ener- dure.
  • Page 36 PROBLEM 6: BURNERS LIGHT WITH HEATING DEMAND BUT UNIT SHUTS DOWN PREMATURELY (CONT.) -- Combustion air blower ener- gizes with a heating demand. -- Burners light. -- Diagnostic lights flash watch Check that the sensor is properly guard flame failure. 6.5.1 ACTION 1 - - located.

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