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E 2005 Lennox Industries Inc.
Dallas, Texas, USA
HOMEOWNER FOR FUTURE REFERENCE
Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other ap-
pliance.
Installation and service must be
performed by a qualified installer,
service agency or the gas supplier.
05/09
*2P0509*
INSTALLATION
INSTRUCTIONS
G51MP SERIES UNITS
GAS UNITS
505,065M
05/2009
Supersedes 07/2007
Table of Contents
Ignition Control Board Diagnostic Codes
WARNING
FIRE OR EXPLOSION HAZARD.
Failure to follow safety warnings exact-
ly could result in serious injury, death,
or property damage.
WHAT TO DO IF YOU SMELL GAS:
D Do not try to light any appliance.
D Do not touch any electrical switch; do not
use any phone in your building.
D Leave the building immediately.
D Immediately call your gas supplier from a
neighbor's phone. Follow the gas supplier's
instructions.
D If you cannot reach your gas supplier, call
the fire department.
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Table of Contents
Related Manuals for Lennox G51MP SERIES
Summary of Contents for Lennox G51MP SERIES
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Page 1: Table Of Contents
INSTALLATION INSTRUCTIONS E 2005 Lennox Industries Inc. Dallas, Texas, USA G51MP SERIES UNITS GAS UNITS 505,065M 05/2009 Supersedes 07/2007 Litho U.S.A. Table of Contents Unit Dimensions ....... -
Page 2: Unit Dimensions
G51MP Unit Dimensions − inches (mm) *NOTE − 60C and 60D size units installed in upflow applica- tions that require air volumes over 1800 cfm (850 L/s) must have one of the following: 1. Single side return air with transition, to accommodate SUPPLY AIR 20 x 25 x 1 in. -
Page 3: G51Mp Parts Identification
G51MP Parts Arrangement G51MP PARTS IDENTIFICATION TOP CAP DuralokPlus HEAT EXCHANGER ASSEMBLY CABINET BURNER BOX ASSEMBLY GAS VALVE AND MANIFOLD FLUE COLLAR COMBUSTION AIR PRESSURE WARM HEADER PROVE SWITCHES (COLLECTOR) COMBUSTION AIR INDUCER CONDENSER COIL BURNER PRIMARY LIMIT ACCESS PANEL COLD HEADER (COLLECTOR) BLOWER... -
Page 4: Shipping And Packing List
NOTE − G51MP−48C−110 and G51MP−60C−110 units also G51MP Gas Furnace include a 2" diameter PVC street elbow, which is shipped on the blower deck in the heating compartment. The G51MP Category IV gas furnace is shipped ready for G51MP−60D−135 units are shipped with a 3" to 2" PVC re- installation in the upflow, downflow, horizontal left air dis- ducing elbow. -
Page 5: Use Of Furnace As A Construction Heater
Failure to do so may cause erratic limit operation and premature heat Lennox does not recommend the use of G51MP units as a exchanger failure. construction heater during any phase of construction. Very low return air temperatures, harmful vapors and operation This G51MP furnace may be used as a high−static unit... -
Page 6: General
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 Page 6... - Page 7 In the absence of local codes concerning air for combus− construction with weather stripping and caulking around tion and ventilation, use the guidelines and procedures in the windows and doors, follow the procedures in the air this section to install G51MP furnaces to ensure efficient from outside section.
- Page 8 Air from Outside When ducts are used, they shall be of the same cross−sec- tional area as the free area of the openings to which they If air from outside is brought in for combustion and ventila- connect. The minimum dimension of rectangular air ducts tion, the confined space shall be provided with two shall be no less than 3 inches (75 mm).
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Page 9: Installation − Setting Equipment
NOTE − 1/3 hp blower motors are equipped with four flex- Installation − Setting Equipment ible mounting legs, and 1/2 hp blower motors are equipped WARNING with three flexible legs and one rigid leg. The rigid leg is equipped with a shipping bolt and a flat white plastic wash- Do not install the furnace on its front or its back. - Page 10 Return Air −− Upflow Units WARNING Return air can be brought in through the bottom or either side of the furnace installed in an upflow application. If the Blower access panel must be securely in place when furnace is installed on a platform with bottom return, make blower and burners are operating.
- Page 11 Setting an Upflow Unit Removing the Bottom Panel When the side return air inlets are used in an upflow ap- plication, it may be necessary to install leveling bolts on the bottom of the furnace. Use field−supplied corrosion−resist- ant 5/16 inch machine bolts (4) and nuts (8). See figure 12. NOTE −...
- Page 12 4 − Adjust the outside nut to the appropriate height and Downflow Application Installation Clearances tighten the inside nut to secure the arrangement. NOTE − The unit may be tilted back−to−front a maximum of 1/2". This will ensure proper draining of the heat exchang- Leveling Bolt Installation Left Side Right Side...
- Page 13 Installation on Combustible Flooring Installation on Cooling Cabinet (Using an Additive Base) 1 − Refer to reverse−flow coil installation instructions for 1 − When unit is installed on a combustible floor, an addi- correctly sized opening in floor and installation of cabi- tive base must be installed between the furnace and net.
- Page 14 Horizontal Applications Suspended Installation of Horizontal Unit NOTE − If unit is suspended, horizontal support kit (Cat No. The G51MP furnace can be installed in horizontal applica- 56J18 ordered separately) or equivalent is recommended tions with either right− or left−hand air discharge. to ensure proper unit support and coil drainage.
- Page 15 Lennox part number 56J18). Position the support Unit Heater Discharge Duct Guidelines frame on top of the blocks and install the unit on the A field−fabricated and installed discharge air duct and grille frame. Leave 5−1/2 inches for service clearance for cabinet is suitable for use with the G51MP heater.
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Page 16: Filters
Filters Pipe & Fittings Specifications This unit is not equipped with a filter or rack. A field−pro- All pipe, fittings, primer and solvent cement must conform vided filter is required for the unit to operate properly. Table with American National Standard Institute and the Ameri- 3 lists recommended filter sizes. - Page 17 Table 5 lists the available exhaust termination kits, as well as vent pipe equivalencies which must be used when siz- ing vent pipe. All Lennox vent terminations are PVC. TABLE 5 OUTDOOR TERMINATION KITS AND CORRESPONDING EQUIVALENCIES...
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Page 18: Vent Piping Guidelines
Direct Vent gas central furnace. ent sizes of vent pipe, a combination vent pipe may be used. Contact Lennox’ Application Department for assis- NOTE − In Non-Direct Vent installations, combustion air is tance in sizing vent pipe in these applications. -
Page 19: Joint Cementing Procedure
IMPORTANT WARNING DANGER OF EXPLOSION! Do not use screens or perforated metal in exhaust terminations. Doing so will cause freeze−ups and Fumes from PVC glue may ignite during system may block the terminations. check. Allow fumes to dissipate for at least 5 minutes before placing unit into operation. - Page 20 Suspend piping using hangers at a minimum of every 5 Exhaust Piping feet (1.52m) for schedule NOTE − A 2" diameter PVC street ell is located on the 40 PVC and every 3 feet blower deck of the 48C−110 and 60C−110 units. In upflow STRAPPING (metal, plastic or downflow applications, the street ell must be glued...
- Page 21 4 − Route piping to outside of structure. Continue with TYPICAL EXHAUST PIPE CONNECTIONS installation following instructions given in piping ter- HORIZONTAL DIRECT OR mination section. NON−DIRECT VENT APPLICATIONS (Horizontal Right−Hand Air Discharge Application Shown) CAUTION *Limit pipe length to 2" −24B−045 2−1/2", in −135 applications.
- Page 22 TYPICAL AIR INTAKE PIPE CONNECTIONS 2−1/2", UPFLOW OR DOWNFLOW DIRECT VENT APPLICATIONS 3" OR (Right−Hand Exit in Upflow Application Shown) 2−1/2", TRANSITION 3" OR TRANSITION *2" −24B−045 PLUG −36B−045 −24B−045 (Must be −24B−045 −36B−070 −36B−045 glued in −36B−045 −36C−090 place) −36B−070 −36B−070 −48C−090...
- Page 23 TYPICAL AIR INTAKE PIPE CONNECTIONS DOWNFLOW NON−DIRECT VENT APPLICATIONS (Right−Hand Exit in Downflow Applications Shown) 2" SWEEP INTAKE DEBRIS SCREEN (Provided) 6 in. Max. PLUG PLUG (Must be glued in (Must be place) glued in place) 2" 18 in. 2" SWEEP ELL INTAKE DEBRIS SCREEN (Provided)
- Page 24 National Fuel prevent freeze−ups. Heating cable installation kit is avail- Gas Code ANSI Z223−1/NFPA 54 in U.S.A., and current able from Lennox. See Condensate Piping section for part CSA−B149 Natural Gas and Propane Installation Codes in numbers.
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Page 25: Vent Termination Clearances
‡ Permitted only if veranda, porch, deck or balcony is fully open on a minimum of two sides beneath the floor. Lennox recommends avoiding this location if possible. FIGURE 29 Page 25... - Page 26 ‡ Permitted only if veranda, porch, deck or balcony is fully open on a minimum of two sides beneath the floor. Lennox recommends avoiding this location if possible. FIGURE 30 Page 26...
- Page 27 Details of Intake and Exhaust Piping Terminations for 1/2 (13) ARMAFLEX Direct Vent Installations (Figure 30) 12 (305) MAX. INSULATION IN UNCONDITIONED SPACE NOTE − In Direct Vent installations, combustion air is taken 1/2" (13) from outdoors and flue gases are discharged to outdoors. ARMAFLEX Intake and exhaust pipes may be routed either horizontally INSULATION...
- Page 28 EXHAUST VENT EXHAUST 12" (305) ABOVE TERMINATION AVERAGE SNOW ACCUMULATION Front View INTAKE Inches (mm) VENT INTAKE TERMINATION 1/2" (13) Foam Insulation Top View in Unconditioned Space FIELD− FIELD−PROVIDED PROVIDED EXHAUST VENT REDUCER MAY BE REQUIRED REDUCER MAY TO ADAPT LARGER VENT BE REQUIRED PIPE SIZE TO TERMINATION TO ADAPT...
- Page 29 12" (305) MAX. for 2" (51) 20" (508) MAX. for 3" (76) Inches (mm) COVER EXHAUST 12" (305) VENT WITH 1/2" (13) EXHAUST FOAM INSULATION 8" (203) INTAKE INTAKE Minimum 12" MIN. EXHAUST (305) Above Grade or average snow 5" 12"...
- Page 30 3 − If exhaust piping must be run up a side wall to position Condensate Piping above snow accumulation or other obstructions, pip- This unit is designed for either right- or left-side exit of con- ing must be supported every 3 feet (.9m) as shown in densate piping in either upflow or downflow applications;...
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Page 31: Gas Piping
Heating cable kit is available from Lennox in various figure 48 or 48. lengths; 6 ft. (1.8m) − kit no. 26K68; 24 ft. (7.3m) − kit no. - Page 32 3 − Gas piping must not run in or through air ducts, clothes Leak Check chutes, chimneys or gas vents, dumb waiters or eleva- After gas piping is completed, carefully check all piping tor shafts. Center gas line through piping hole. Gas connections (factory−...
- Page 33 Horizontal Applications Possible Gas Piping Configurations MANUAL MAIN SHUT−OFF Horizontal Application VALVE Left−Side Air Discharge MANUAL MAIN SHUT−OFF VALVE GROUND JOINT UNION GROUND JOINT DRIP LEG UNION DRIP LEG MANUAL MAIN SHUT−OFF Horizontal Application VALVE Right−Side Air Discharge (With 1/8 in. NPT Plugged Tap Shown) GROUND...
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Page 34: Electrical
The unit is equipped with a field make−up box. The make− Electrical up box may be moved to the right side of the furnace to fa- ELECTROSTATIC DISCHARGE (ESD) cilitate installation. If the make−up box is moved to the right Precautions and Procedures side, the excess wire must be pulled into the blower compartment. - Page 35 mon leg of the circuit being connected to the C" ter- G51MP and CONDENSING UNIT minal of the thermostat terminal block, which is lo- THERMOSTAT DESIGNATIONS (Refer to specific thermostat and outdoor unit.) cated on the control board. Install the room thermostat according to the instruc- Thermostat G51MP Condensing...
- Page 36 ® SURELIGHT INTEGRATED CONTROL BOARD TERMINAL DESIGNATIONS COOL Blower − Cooling Speed (120VAC) HEAT Blower − Heating Speed (120VAC) PARK Unused Blower (Not energized) Continuous Low Blower Speed Accessory Terminal (120VAC) XFMR Transformer (120VAC) LINE Input (120VAC) Heat Only Accessory (120VAC) 5 Terminals 120 Volt Neutral Flame Sensor...
- Page 37 TYPICAL G51MP WIRING DIAGRAM FIGURE 54 Page 37...
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Page 38: Unit Start−Up
BEFORE LIGHTING the unit, smell all around the fur- Unit Start−Up nace area for gas. Be sure to smell next to the floor be- FOR YOUR SAFETY READ BEFORE OPERATING cause some gas is heavier than air and will settle on the floor. -
Page 39: Gas Pressure Adjustment
4 − White Rodgers 36G Gas Valve − Move gas valve White Rodgers 36G Series Gas Valve switch to OFF. OUTLET Honeywell VR8205 Gas Valve − Move gas valve PRESSURE switch to OFF. POST 5 − Replace the upper access panel. Heating Sequence Of Operation When thermostat calls for heat, combustion air inducer MANIFOLD... - Page 40 Manifold Pressure Measurement To correctly measure manifold pressure, the differential pressure between the positive gas manifold and the nega- tive burner box must be considered. Use pressure test adapter kit (available as Lennox part 10L34) to assist in measurement. Page 40...
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Page 41: High Altitude Information
TABLE 11 High Altitude Information Manifold Pressure (Outlet) inches w.c. NOTE − In Canada, certification for installations at eleva- Altitude (feet) Model tions over 4500 feet (1372 m) is the jurisdiction of local au- Fuel Input 0− 4501− 5501− 6501− 7501−... - Page 42 Testing for Proper Venting and Sufficient Combustion Air for Non−Direct Vent Applications horizontal pitch. Determine there is no blockage or re- WARNING striction, leakage, corrosion, or other deficiencies which could cause an unsafe condition. CARBON MONOXIDE POISONING HAZARD! 3 − To the extent that it is practical, close all building doors Failure to follow the steps outlined below for each and windows and all doors between the space in which appliance connected to the venting system being...
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Page 43: Other Unit Adjustments
Electrical Other Unit Adjustments 1 − Check all wiring for loose connections. 2 − Check for the correct voltage at the furnace (furnace Primary and Secondary Limits operating). 3 − Check amp-draw on the blower motor. The primary limit is located on the heating compartment Motor Nameplate__________Actual__________ vestibule panel. -
Page 44: Blower Motor Performance
Blower Motor Performance G51MP−24B−045 PERFORMANCE (Less Filter) G51MP−36B−045 PERFORMANCE (Less Filter) Air Volume / Watts at Different Blower Speeds Air Volume / Watts at Different Blower Speeds External External Medium− Medium− Medium− Medium− Static Static High High Pressure High Pressure High in. - Page 45 G51MP−60C−090 PERFORMANCE (Less Filter) Air Volume / Watts at Different Blower Speeds Bottom Return Air, Side Return Air with Optional RAB Single Side Return Air − Air volumes in bold require field External Return Air Base, Return Air from Both Sides or Return fabricated transition to accommodate 20 x 25 x 1 in.
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Page 46: Service
Winterizing and Condensate Trap Care Service 1 − Turn off power to the unit. 2 − Have a shallow pan ready to empty condensate water. WARNING 3 − Remove the drain plug from the condensate trap and empty water. Inspect the trap then reinstall the drain ELECTRICAL SHOCK, FIRE, plug. - Page 47 17 − Remove the primary limit from the vestibule panel. 37 − Reconnect sensor wire and reconnect 2−pin plug from ignitor. 18 − Remove two screws from the front cabinet flange at the blower deck. Spread cabinet sides slightly to allow 38 −...
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Page 48: Planned Service
Repair Parts List The following repair parts are available through Lennox dealers. When ordering parts, include the complete furnace model number listed on the CSA nameplate −− Example: G51MP−24B−045−1. All service must be performed by a licensed pro- fessional installer (or equivalent), service agency, or gas supplier. -
Page 49: This Manual Must Be Left With The Troubleshooting
® SureLight Troubleshooting: Heating Sequence of Operation SURELIGHT CONTROL HEATING SEQUENCE OF OPERATION NORMAL HEATING MODE ABNORMAL HEATING MODE POWER ON GAS VALVE OFF. COMBUSTION AIR INDUCER ON. INDOOR BLOWER ON. DS1 ALTERNATING FAST FLASH CONTROL SELF−CHECK OKAY? DS2 ALTERNATING FAST FLASH CHECK FOR BROKEN IGNITOR OR OPEN IGNITOR CIRCUIT GAS VALVE OFF. - Page 50 ® SureLight Troubleshooting: Heating Sequence of Operation (Continued) NORMAL HEATING MODE ABNORMAL HEATING MODE 15-SECOND COMBUSTION AIR INDUCER PREPURGE INITIATED BY CLOSED PRESSURE SWITCH. IS VOLTAGE ABOVE 75 VOLTS? DS1 & DS2 SIGNAL IGNITOR WARM-UP −− 20 SECONDS. IS THERE A PROPER GROUND? ALTERNATING FAST FLASH.
- Page 51 ® SureLight Troubleshooting: Cooling Sequence of Operation SURELIGHT CONTROL COOLING SEQUENCE OF OPERATION NORMAL COOLING MODE ABNORMAL COOLING MODE POWER ON. IGNITION CONTROL MAIN POWER ON. GAS VALVE OFF. COMBUSTION AIR INDUCER OFF. INDOOR BLOWER OFF WITH NORMAL DELAY. CONTROL SELF DIAGNOSTIC CHECK. SIGNAL CIRCUIT BOARD FAILURE AT DS1 &...
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Page 52: Ignition Control Board Diagnostic Codes
® SureLight Troubleshooting: Continuous Fan Sequence of Operation SURELIGHT CONTROL CONTINUOUS FAN SEQUENCE OF OPERATION DS1 & DS2: SLOW FLASH RATE REMAINS UNCHANGED THROUGHOUT SEQUENCE. MANUAL FAN SELECTION MADE AT THERMOSTAT. CONTROL (G) ENERGIZES INDOOR BLOWER AT FAN SPEED. EAC TERM. IS ENERGIZED. HUM (120 VAC &... -
Page 53: Vent Pipe Sizing Worksheet
Vent Pipe Sizing Worksheet Step 1 Proposed vent pipe size : ______ Equivalent Feet Step 2 Termination kit catalog number : _____________ Vent pipe equivalency value from table 5 : ______ Step 3 Total number of 90° elbows required (indoors and outdoors) ______ X 5 = ______ equivalent feet of pipe Step 4 Total number of 45°... - Page 54 Requirements for Commonwealth of Massachusetts Modifications to NFPA−54, Chapter 10 4 − INSPECTION. The state or local gas inspector of the side wall, horizontally vented, gas−fueled equipment Revise NFPA−54 section 10.8.3 to add the following re- shall not approve the installation unless, upon inspec- quirements: tion, the inspector observes carbon monoxide detec- For all side wall, horizontally vented, gas−fueled equipment...