Lennox G24-200 Installation Instructions Manual

Lennox international inc upflow gas furnace installation instructions g24-200

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User's information manual (6 pages)

User's information manual (8 pages)

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Page 1: Table Of Contents
Installation and service must be per- formed by a qualified installer, ser- vice agency or the gas supplier. 08/05 *2P0805* INSTALLATION INSTRUCTIONS G24-200 UPFLOW GAS FURNACE Direct Spark Ignition 503,613M 8/2005 Supersedes 7/2003 Table of Contents G24−200 Unit Dimensions G24−200 Parts Arrangement...
Page 2: G24−200 Unit Dimensions
G24−200 Unit Dimensions − inches (mm) 52-1/2 (1334) VENT 10-1/2 OUTLETS (267) CONTROL 50-3/4 (22) (1289) FRONT VIEW 52-1/2 (1334) 1-1/16 50-3/8 (27) (1280) (25) REAR RETURN AIR OPENING BACK VIEW (432) (16) Either Side 4-1/4 (108) Either Side (1346) PIPING INLET Either Side)
Page 3 (25) (127) 4-3/4 (121) (25) 26-1/4 (667) (25) *OPTIONAL FILTER BOX *NOTE Return air filter box may be installed at back or bottom of furnace. (127) (25) (813) (813) Page 3 FLOW (25) 50-1/2 (1283) OPENING SAME BOTH SIDES BACK VIEW...
Page 4: G24−200 Parts Arrangement
G24−200 Parts Arrangement LIMIT CONTROL* LEFT SIDE PANEL FLUE BOX GASKET* COMBUSTION AIR BLOWER* FLUE BOX* BURNER RETENTION BRACKET* FLAME ROLLOUT SWITCH* BURNER MTG BRACKET* SENSOR* IGNITOR* CENTER MULLION G24−200 HEAT SECTION AND CABINET (THIS UNIT CONTAINS TWO HEAT SECTIONS. EACH HEAT SECTION CONTAINS ONE OF THESE ITEMS.) PRESSURE SWITCH* GAS VALVE*...
Page 5 G24−200 Parts Arrangement Continued G24−200 BLOWER SECTION SHAFT CUT−OFF PLATE BLOWER HOUSING BLOWER PULLEY DRIVE BELT (Drive Kit) MOTOR BEARING (Drive Kit) WHEEL MOTOR PULLEY (Drive Kit) MOTOR BASE ADJUSTMENT ARM BASE ASSEMBLY MOTOR BASE VIBRATION ISOLATOR LOCATING ROD Page 5...
Page 6: G24−200 Gas Furnace
100MBH and each operating in a two- stage (low heat/high heat) mode. The C17−090/120 cooling coil has been designed for use with this furnace and can be connected to either a single condensing unit or to two con- densing units.
Page 7 18 inches (457 mm) above the floor. The furnace must be located or protected to avoid physical dam- age by vehicles. When a furnace is installed in a public garage, hangar, or other building that has a hazardous atmosphere,...
Page 8: General
Lennox G24−200 furnace. The furnace should be placed as close to the center of the air distribution system as possible. The furnace should also be located close to the chimney or vent termination point.
Page 9 When fire- places, exhaust fans, or clothes dryers are used at the same time as the furnace, much more air is required to en- sure proper combustion and to prevent a downdraft. Insuf- ficient air causes incomplete combustion which can result in carbon monoxide.
Page 10 CHIMNEY OR GAS VENT G24−200 FURNACE NOTE−Each opening shall have a free area of at least one square inch (645 mm ) per 1,000 Btu (.29 kW) per hour of the total input rat- ing of all equipment in the enclosure, but not less than 100 square...
Page 11: Setting Equipment
4,000 Btu (1.17 kW) per hour of the total input rating of all other equipment in the enclosure. FIGURE 4 Setting Equipment Do not install the furnace on its front or its back. Do- VENTILATION LOUVERS ing so will adversely affect the operation of the safety (Each end of attic) control devices, which could result in personal inju- ry or death.
Page 12 In platform installations with bottom return air, the furnace should be sealed airtight to the return air ple- num. A door must never be used as a portion of the return air duct system. The base must provide a stable support and an airtight seal to the furnace.
Page 13: Duct System
3 − Apply adhesive-backed foam tape to the filter box (side facing furnace) all around the opening. Refer to figure 6. 4 − Position the filter box over the furnace return air open- ing. The top of the filter box should be in the up" posi- tion and the filter box and the furnace edges flush at the sides and bottom.
Page 14: Venting
ANSI Z21.47 Gas-fired Central Furnace Standard in the USA and the current standard CSA 2.3 Gas-fired Cen- tral Furnace in Canada. The definition of a fan assisted fur- nace is an appliance equipped with an integral mechanical means to either draw or force products of combustion through the combustion chamber and/or heat exchanger.
Page 15 Do not install a manual damper, barometric draft regula- tor, or flue restrictor between the furnace and the chimney. If type B1 double-wall vent is used inside a chimney, no oth- er appliance can be vented into the chimney. Outer wall of type B1 vent pipe must not be exposed to flue products.
Page 16 COMMON VENTING USING TILE−LINED INTERIOR MASONRY CHIMNEY AND COMBINED VENT CONNECTOR NOTE 1 − Refer to provided venting tables for installations in the USA and the vent- ing tables in current CSA−B149.1 for installations in Canada. VENT CONNECTOR SEE NOTE 2 Note 2 −...
Page 17 Code (ANSI−Z223.1/NFPA54). National installation codes in Canada are current editions of CSA−B149 codes. 11− Vent connectors shall be firmly attached to furnace flue collars by sheet metal screws or other approved means, except vent connectors of listed Type B vent material which shall be assembled according to the manufacturer’s instructions.
Page 18 CAPACITY OF TYPE B DOUBLE-WALL VENTS WITH TYPE B DOUBLE-WALL CONNECTORS Height Lateral 3 Inch (feet) (feet) (feet) (feet) NOTE − Single appliance venting configurations with zero lateral lengths are assumed to have no elbows in the vent system. For all other vent configurations, the vent system is assumed to have two 90_ elbows.
Page 19 CAPACITY OF TYPE B DOUBLE-WALL VENTS WITH SINGLE-WALL METAL CONNECTORS Height Lateral 3 Inch (feet) (feet) (feet) (feet) NOTE − Single appliance venting configurations with zero lateral lengths are assumed to have no elbows in the vent system. For all other vent configurations, the vent system is assumed to have two 90_ elbows.
Page 20 CAPACITY OF TYPE B DOUBLE-WALL VENTS WITH TYPE B DOUBLE-WALL CONNECTORS SERVING TWO OR MORE CATEGORY I APPLIANCES Vent Vent Connector Connector 4 Inch Height Height Rise Rise (feet) (feet) (feet) (feet) CAPACITY OF TYPE B DOUBLE-WALL VENTS WITH TYPE B DOUBLE-WALL CONNECTORS SERVING TWO OR MORE CATEGORY I APPLIANCES Vent Vent...
Page 21 FAN + NAT Removal of the Furnace from Common Vent In the event that an existing furnace is removed from a venting system commonly run with separate gas ap- pliances, the venting system is likely to be too large to prop- erly vent the remaining attached appliances.
Page 22 After the furnace has been started, the following test should be conducted to ensure proper venting and suffi- cient combustion air has been provided to the furnace, as well as to other gas-fired appliances which are separately vented. The test should be conducted while all appliances (both in operation and those not in operation) are con- nected to the venting system being tested.
Page 23 A − Clearance above grade − 12 in. (305mm) minimum. B − Clearance to window or door − for vent installations in USA − 48 in. (1219mm) minimum horizontal and below, 12 in. (305mm) minimum above. for vent installations in Canada − 12 in. (305mm) minimum for appliances 100,000 Btuh (30 kW);...
Page 24 Center. No other Field brand venting kits or any other manufacturer’s venting kits are acceptable. Horizontal venting of this furnace without the use of the above stated kits is prohibited. NOTE − Each heat section of the G24−200 unit re- quires its own sidewall venting kit.
Page 25: Gas Piping
FIELD PROVIDED AND INSTALLED 2 − When connecting the gas supply, factors such as length of run, number of fittings and furnace rating must be considered to avoid excessive pressure drop. Table 9 lists recommended pipe sizes for typical ap- plications.
Page 26 (362.44) (308.64) (274.67) The furnace must be isolated from the gas supply system by closing its individual manual shut-off valve during any pressure testing of the gas supply system at pressures equal to or less than 1/2 psig (3.48 kPa).
Page 27: Electrical
3ph, 60hz *Note − This transformer has a nominal 230 volt output rating and a 460 volt input rating; however, when wired to the furnace as shown in figure 15, a 115 volt input will produce a 230 volt output.
Page 28 G24−200 FIELD WIRING DIAGRAM (120V SINGLE PH 60HZ) PRIMARY COMBUSTION LIMIT AIR BLOWER VALVE (Alternate make-up DOOR box right side) INTERLOCK MAKE-UP BOX T3 TRANSFORMER See Note 3 TERMINAL STRIP TB34 See Note 1 RELAY K109 YELLOW YELLOW RELAY BLUE K105 BLUE RELAY...
Page 29 24v: blue − yellow 208v: red − black 240v: orange − black Three phase shown. This lead not used in single phase applications G24-200 FIELD WIRING DIAGRAM P UNITS − 208/230V 1PH 60 HZ Y UNITS − 208/230V 3PH 60HZ PRIMARY COMBUSTION PRESSURE...
Page 30 COMBUSTION PRIMARY AIR BLOWER LIMIT VALVE (Alternate make-up DOOR box right side) INTERLOCK MAKE-UP BOX T3 TRANSFORMER 460v: white − red 230v: white − black TERMINAL STRIP TB34 SEE NOTE 1 RELAY GROUND K109 YELLOW YELLOW RELAY BLUE K105 BLUE RELAY K3 CONTACTOR T1 TRANSFORMER...
Page 31 SCHEMATIC WIRING DIAGRAM FOR G24−200 UNITS (120V SINGLE PHASE 60HZ ) FIGURE 18 Page 31...
Page 32 WIRING SCHEMATIC DIAGRAM FOR G24−200 P UNITS − 208/230V 1PH 60 HZ Y UNITS − 208/230V 3PH 60HZ G UNITS − 460V 3PH 60HZ J UNITS − 575V 3PH 60HZ FIGURE 19 Page 32...
Page 33: Unit Start−Up
Unit Start−Up FOR YOUR SAFETY READ BEFORE LIGHTING WARNING Do not use this furnace if any part has been under water. A flood−damaged furnace is extremely dan- gerous. Attempts to use the furnace can result in fire or explosion. A qualified service agency...
Page 34: Heating Sequence Of Operation
12 −If the furnace does not light the first time (the gas line may not be fully purged), it will attempt up to two more ignitions before locking out. 13 −If lockout occurs, repeat steps 1 through 10. 14 −If the appliance will not operate, follow the instructions Turning Off Gas To Unit"...
Page 35: Gas Pressure Adjustment
K25 control board and are non-ad- MANIFOLD PRESSURE justable. The board is located in the control box. in. w.c. (kPa) If abnormal furnace operation causes either high limit (S10 3.5 (0.87) or S99) to open, the relays K20, K123 and K36 maintain 3.5 (0.87) blower operation until the limit(s) is reset.
Page 36 −Lennox part number P−8−6256) in parallel with K13 relay coil. Electrical 1 − Check all wiring for loose connections. 2 − Check for the correct voltage at the furnace (furnace operating). 3 − Check amp-draw on blower motor. Motor service factor amps...
Page 37: Setting Blower Cfm
(0.93) (1.01) NOTE − All air data is measured external to furnace using rear return air opening without air filters in place. Bold text indicates 2 H.P. (1.5 kW) drive kits. 2 − The table yields a value for design BHP and RPM.
Page 38 Model C17−090/120 Coil in. w.g. 2400 1135 0.14 2600 1225 0.16 2800 1320 0.19 3000 1415 0.22 3200 1510 0.24 3400 1605 0.27 3600 1700 0.30 3800 1795 0.33 4000 1890 0.36 4200 1980 0.38 4400 2075 0.42 4600 2170 0.45 4800 2265...
Page 39: Retain These Instructions Repair Parts List
Electrical Connections Tight? Blower Motor Amps Blower Motor Lubrication OK? Gas Piping Connections Tight & Leaks Tested? Fuel Type: Natural Gas? Furnace Btu (kw) Input Regulator Pressure w.c./Pa −− Nat. Connections Tight? Temperature Rise Calibrated? Heat Anticipator Properly Set? Example: G24−200. Refer to page 4 and 5 for parts identifi-...
Page 40: Troubleshooting
Troubleshooting HEATING SEQUENCE OF OPERATION WITH TWO-STAGE THERMOSTAT NOTE − THIS FURNACE FUNCTIONS WITH TWO INDEDPENDENTLY CONTROLLED HEAT SECTIONS. THE GRAY BOXES INDICATE COMPONENTS WHICH EFFECT BOTH HEAT SECTIONS SIMULTANEOUSLY. NORMAL HEATING MODE POWER ON THERMOSTAT CALLS FOR HEAT (W1 ENERGIZED) K13 RELAY ENERIZED.
Page 41 HEATING SEQUENCE OF OPERATION WITH TWO-STAGE THERMOSTAT CONTINUED NORMAL HEATING MODE IS THE S10 (S99) HIGH LIMIT CLOSED? HAS ROOM AIR TEMPERATURE CONTINUED TO DROP BELOW THE THERMOSTAT"S W2 SET POINT? POWER FROM W2 ENERGIZES K19 RELAY SECOND-STAGE OF GV1 (GV3) GAS VALVE ENERGIZED (HIGH HEAT) AFTER APPROXIMATELY 3 SEC.
Page 42 HEATING SEQUENCE OF OPERATION WITH SINGLE-STAGE THERMOSTAT NOTE − THIS FURNACE FUNCTIONS WITH TWO INDEPENDENTLY CONTROLLED HEAT SECTIONS. THE GRAY BOXES INDICATE COMPONENTS WHICH EFFECT BOTH HEAT SECTIONS SIMULTANEOUSLY. NORMAL HEATING MODE POWER ON THERMOSTAT CALLS FOR HEAT (W1 ENERGIZED) K13 AND K19 RELAY ENERIZED.
Page 43 HEATING SEQUENCE OF OPERATION WITH SINGLE-STAGE THERMOSTAT CONTINUED NORMAL HEATING MODE IS THE S10 (S99) HIGH LIMIT CLOSED? IS W1 DEMAND OF THERMOSTAT SATISFIED? A3 (A12) LED OFF SECOND-STAGE OF GV1 (GV3) GAS VALVE CLOSES AFTER APRROXIMATELY 3 SEC. AND THEN FIRST-STAGE CLOSES.
Page 44 COOLING SEQUENCE OF OPERATION FOR TWO CONDENSING UNITS FOR A SINGLE CONDENSING UNIT THERMOSTAT CALLS FOR COOLING THERMOSTAT CALLS FOR COOLING (Y1 POWERED) (Y1 POWERED) COOLING CONTACTOR OF FIRST-STAGE COOLING CONTACTOR OF CONDENSING UNIT CONDENSING UNIT CLOSES AND SYSTEM CLOSES AND SYSTEM BLOWERS START. BLOWERS START.

Lennox G24-200 Installation Instructions Manual

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