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Lennox G21V Series Installation Instructions Manual
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Lennox G21V Series Installation Instructions Manual

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352'8&7 /,7(5$785(
¤
 /HQQR[ ,QGXVWULHV ,QF
'DOODV 7H[DV
5(7$,1 7+(6( ,16758&7,216
)25 )8785( 5()(5(1&(
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, service
agency or the gas supplier.
£
If the information in this manual is not
followed exactly, a fire or explosion
may result causing property damage,
personal injury or loss of life.
,167$//$7,21
,16758&7,216
G21V SERIES UNITS
GAS UNITS
503,226M
7/97
Supersedes 7/96
7$%/( 2) &217(176
UNIT DIMENSIONS
PARTS ARRANGEMENT
G21V TYPICAL INSTALLATION
REQUIREMENTS
GENERAL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION--Setting and Leveling Equipment
RETURN AIR OPENING GUIDELINES
FILTER ASSEMBLY AND FILTERS
DUCT SYSTEM
EXHAUST, INTAKE & CONDENSATE PIPING
GAS PIPING
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT START--UP
GAS PRESSURE ADJUSTMENT
HIGH ALTITUDE INFORMATION
OTHER UNIT ADJUSTMENTS
ELECTRONIC IGNITION
VSP2--1 BLOWER CONTROL BOARD
BLOWER SPEED AND ADJUSTMENT
VSP2--1 OPERATION
SERVICE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPAIR PARTS LIST
START--UP AND PERFORMANCE CHECK LIST
G21V TROUBLESHOOTING
WARNING
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.
3DJH 
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Summary of Contents for Lennox G21V Series

  • Page 1 ,167$//$7,21 £ ,16758&7,216 352'8&7 /,7(5$785( ¤  /HQQR[ ,QGXVWULHV ,QF G21V SERIES UNITS 'DOODV 7H[DV GAS UNITS 503,226M 7/97 Supersedes 7/96 Litho U.S.A. 7$%/( 2) &217(176 UNIT DIMENSIONS ....... .
  • Page 2 *9 81,7 ',0(16,216,1&+(6 00       6833/< & &20%867,21 23(1,1* ,17$.(   /HIW 5LJKW   *$6 3,3,1* ,1/(76 ERWK VLGHV (/(&75,&$/ ,1/(76 ERWK VLGHV  $,5 )/2: (;+$867 $,5 287/(76 ERWK VLGHV   5(7851 $,5 (LWKHU VLGH RU ERWWRP ...
  • Page 3 *9 3$576 $55$1*(0(17 +($7 (;&+$1*(5 $66(0%/< ',))(5(17,$/ 35(6685( 9(67,%8/( 3$1(/ 6:,7&+ /,0,7 $1' 02'8/$7,21 25,),&( &21752/ (;3$16,21 7$1. *$6 9$/9( 39& $,5 ,17$.( 6(1625 ),77,1* 35,0$5< ,*1,7,21 &21752/ 63$5. 3/8* $,5 ,17$.( &+$0%(5 )/$33(5 9$/9( 385*( %/2:(5 &21752/ '225 ,17(5/2&. 6:,7&+ &29(5 %/2:(5...
  • Page 4 *9 7<3,&$/ ,167$//$7,21 INTAKE PIPE 2” FLEXIBLE BOOT IN DUCT OR PLENUM (SUPPLY AIR) (51mm) PVC FLEXIBLE ISOLATION HANGER SUPPLY AIR RETURN MUFFLER** FLEXIBLE BOOT IN EXHAUST PIPE DUCT OR PLENUM 2”(51mm) PVC (RETURN AIR) SUPPLY AIR PLENUM MANUAL 1.5 TO 3 LB. (24 TO 48 kg) DENSITY, MAIN SHUT OFF MATTE FACE, 1”...
  • Page 5 C.G.A (Canadian Gas Association) certified. in the heating element. With a parallel flow arrange- Installation of Lennox gas central furnaces must con- ment, damper (or other means to control flow of air) form with local building codes or, in the absence of local...
  • Page 6 Heating cable kit is available sulation. Insulation should not overlap mounting from Lennox in various lengths; 6 ft. (1.8m) - - kit no. pads. Trim away any excess insulation from strips. 18K48; 24 ft. (7.3m) - - kit no. 18K49; and 50 ft. (15.2m) - - kit no.
  • Page 7 Two mufflers (one each in the exhaust and intake piping) are required and furnished for use with the G21- -80/100 G21V series unit is equipped with a reusable foam filter. units. See table 2 for optional usage of mufflers with G21 Filter must be in place any time unit is in operation.
  • Page 8 PVC pipe used for exhaust and intake lines should be 6- - Promptly apply solvent cement to end of pipe and sized per table 4. Note that maximum length of vent inside socket surface of fitting. Cement should be pipe is for one run; either intake or exhaust. Maximum applied lightly but uniformly to inside of socket.
  • Page 9 Heating cable kit is avail- (Must be left open.) (Factory Installed) able from Lennox in various lengths; 6ft. (1.8m) - - CONDENSATE CONNECTION kit no. 18K48; 24ft. (7.3m) - - kit no. 18K49; and 50ft.
  • Page 10 5- - Route piping to outside of structure. Continue system. Turn on any exhaust fans, such as range with installation following instructions given in ex- hoods and bathroom exhausts, so they will oper- haust and intake piping termination section. ate at maximum speed. Do not operate a summer exhaust fan.
  • Page 11 -ups. Heating cable installation kit is 1- -1/2” (51mm x 38mm) reducer must be used on available from Lennox. See Exhaust and Condensate the exhaust piping at the point where it exits the Piping section for part numbers.
  • Page 12 1/2 (12.7) FOAM INSULATION IN UNCONDITIONED SPACE Inches(mm) OUTSIDE WALL Optional Turndown Shown (Intake Only) TOP VIEW WALL TERMINATION (22G44) LB- -49107CD for 2 (50.8) Venting (44J40) LB- -65701A for 3 (76.2) Venting ),*85(  IMPORTANT Combustion intake inlet exhaust outlet EXHAUST 12 (305) ABOVE...
  • Page 13 )URQW 9LHZ EXHAUST (;+$867 9(17  TERMINATION EXHAUST  ,17$.( 9(17 6LGH 9LHZ INTAKE   )RDP TERMINATION ,QVXODWLRQ LQ 8QFRQGLWLRQHG 6SDFH 12 (305mm) Min. INTAKE above grade. (;+$867 9(17 ,QFKHV PP CONCENTRIC WALL TERMINATION (60G77) LB- -49107CE for 2 (50.8) Venting Only FIGURE 11 ,17$.( 9(17 12 (305) MIN.
  • Page 14 COVER EXHAUST Front View (228.6) (305) VENT WITH Front View 1/2 (13) EXHAUST FOAM VENT INSULATION INTAKE NOTE- -Enclosed exhaust pipe is insulated with 1/2” (13mm) EXHAUST INTAKE foam insulation. If intake and exhaust pipes are reversed, slit VENT and remove foam insulation 12 MIN.
  • Page 15 *$6 3,3,1* 2- - The use of one of the following gas connectors is recommended: A- -Gas Supply $16 = $SSOLDQFH &RQQHFWRUV RI &RUUXJDWHG The unit is shipped standard for right- -side installation 0HWDO 7XELQJ DQG )LWWLQJV of gas piping. A piping hole is also fabricated in the left $16= $VVHPEOHG )OH[LEOH $SSOLDQFH &RQ side for an alternate piping arrangement.
  • Page 16 (/(&75,&$/ LEFT SIDE PIPING MANUAL MAIN SHUT- -OFF VALVE 1- - Select fuse and wire size according to blower mo- GAS VALVE tor amps. For V5 units, the minimum circuit am- GROUND JOINT UNION pacity is 17.4 amps and maximum fuse or circuit breaker size is 25 amps.
  • Page 17 “W2” This terminal is used for two- -stage heating. CAUTION Two- -stage heating is not available when using the non- -modulating NM terminal. Do not connect the heat demand wire to both the G21V TERMINAL STRIP W1 and the NM terminals. Damage to the unit will occur.
  • Page 18 81,7 67$5783 ROBERTSHAW 7200 GAS VALVE FOR YOUR SAFETY READ BEFORE LIGHTING GAS VALVE SELECTOR ARM IN OFF WARNING POSITION 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.
  • Page 19 VSP2- -1 energizes the blower on NOTE - - G21V series units are NOT shipped with the heating speed. The limit automatically resets when the...
  • Page 20 VSP2--1 VARIABLE SPEED CONTROL BOARD SELECTIONS HIGH SPEED 13 PIN PLUG SELECTOR PINS (BOARD TO MOTOR) HIGH ADJUST HEAT (COOLING ONLY) TEST HEATING SPEED SELECTOR PINS NORM LOW SPEED HTG. OPERATIONAL SELECTOR PINS HEAT HI/LOW BLOWER SELECTOR PINS (COOLING AND HEATING) (Affects both heating and ON/OFF cooling modes)
  • Page 21 TABLE 7 G21V3- -60/80 BLOWER MOTOR PERFORMANCE For Static Pressure 0.0” to 0.8” w.g.(0 Through 200 Pa) BDC2 Jumper Speed Positions “ADJUST” “LOW” Speed (Cool Or Continuous Fan) “HIGH” Speed (Cool) “HEAT” Speed Jumper Jumper Setting Setting 540 255 700 330 830 390 1000 470 1150 545 1260 595 1400 660 1410 665 1150 545 1250 590 1350 635 1420 670 NORM 490 230 630 295 740 350 880 415 1040 490 1140 540 1240 585 1265 595 1030 485 1140 540 1220 575 1300 615 —...
  • Page 22 VSM CHECK- -OUT The LOW jumper is used to determine CFM during low A kit is available from the Lennox parts center to use in speed cooling. These jumper selections are activated testing the variable speed motor. The kit 70J11 includes Follow a test plug harness to facilitate vsm check- -out.
  • Page 23 information has been repeated from the previous sec- 963 23(5$7,21 tion to provide an example. Refer to each diagnostic Table 9 outlines the operation of the variable speed LED or jumper settings section for more information. motor in relation to specific modes of operation. Some TABLE 9 VSP2- -1 OPERATION HEATING MODE...
  • Page 24 14- - Break union in gas line just below gas decoupler. nox part no. P- -8- -5069. Remove gas valve / gas decoupler / piping assem- 3- - If replacement is necessary, order Lennox part bly. number P- -8- -7822 for 16” X 25” (406 X 635) filter 15- - Remove remaining gas piping from fitting at vesti- for V3- -60 and V3- -80 units;...
  • Page 25 5(3$,5 3$576 /,67 The following repair parts are available through independent Lennox dealers. When ordering parts, in- clude the complete furnace model number listed on the unit rating plate. Example: G21V3- -60- -1. CABINET PARTS...
  • Page 26 67$5783 $1' 3(5)250$1&( &+(&. /,67 Job Name Job No. Date Job Location City State Installer City State Technician Unit Model No. Serial No. HEATING SECTION Electrical Connections Tight? Blower Motor H.P. Supply Voltage Gas Piping Connections Blower Motor Amps Tight & Leak--Tested? Blower Motor Lubrication O.K.? Fuel Type: Natural Gas? LP/Propane Gas?
  • Page 27 G21 TROUBLESHOOTING FLOW CHART (continued from flow chart on previous page) NOTE—Numbered steps refer to illustrations on next to last page. UNIT WILL NOT RUN ELECTRICAL IS THERMOSTAT PROPERLY SET? CHECKS SYSTEM MAY BE LOCKED OUT. TURN THERMOSTAT HEATING DEMAND SET FOR HEAT DEMAND OFF AND ON AGAIN.
  • Page 28 G21 TROUBLESHOOTING FLOW CHART (continued from flow chart on previous pages) NOTE—Numbered steps refer to illustrations on next to last page. CONTINUED FORM CHECKS CHECK FOR LEAKS IN UNIT MANIFOLD PIPING. UNIT WILL NOT RUN FLOW CHART ON PREVIOUS PAGE IS GAS SUPPLY NATURAL OR L.P.? LEAKS NO LEAKS...
  • Page 29 G21V TROUBLESHOOTING FLOW CHART — UNIT WILL NOT RUN CHECK VOLTAGE AT TERMINAL AND CHECKING VOLTAGE AT PRIMARY CONTROL CHECKING THERMOSTAT DEMAND 24VAC? PRIMARY CONTROL LOW VOLTAGE TERMINAL STRIP WITH 3 AMP FUSE WIRING HARNESS PLUG (JP1) LOCATED ON CONTROL BOX 24VAC 24VAC POWER?
  • Page 30 G21V VSM BLOWER AND VSP2--1 BLOWER CONTROL BOARD TROUBLESHOOTING FLOW CHART DOES UNIT OPERATE? CHECK: 1--UNIT POWER IS 24VAC ACROSS R 2--INTERLOCK SWITCH AND C? 3--TRANSFORMER COOLING MODE 4--LIMIT SWITCH PLACE JUMPER ACROSS R AND G. IS BLOWER ON LOW SPEED AND IS “ON/ CHECK UNIT WIRING OFF”...

This manual is also suitable for:

G21v3-60G21v3-80G21v5-80G21v5-100