Table of Contents
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Service Literature
G40DF(X) series units are mid−efficiency gas furnaces
used for downflow applications only, manufactured with
Lennox Duralok Plus heat exchangers formed of alumi-
nized steel. G40DF(X) units are available in heating capac-
ities of 44,000 to 135,000 Btuh and cooling applications up
to 5 tons. Refer to Engineering Handbook for proper sizing.
Units are factory equipped for use with natural gas. Kits are
available for conversion to LPG operation. G40DF(X) model
units are equipped with a hot surface ignition surface. The
G40DF(X) unit meets the California Nitrogen Oxides (NO
Standards and California Seasonal Efficiency requirements.
All units use a redundant gas valve to assure safety shut−off
as required by C.S.A.
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.
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Corp. 0113−L6
Revised 09−2006
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Page 1
IMPORTANT
Improper installation, adjustment, alteration, service
or maintenance can cause property damage, person-
al injury or loss of life. Installation and service must
be performed by a qualified installer, service agency
or the gas supplier.
WARNING
Electric shock hazard. Can cause injury
or death. Before attempting to perform
any service or maintenance, turn the
electrical power to unit OFF at discon-
nect switch(es). Unit may have multiple
power supplies.
WARNING
Sharp edges.
Be careful when servicing unit to avoid sharp edges
which may result in personal injury.
G40DF(X)
© 2001 Lennox Industries Inc.
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Table of Contents
Related Manuals for Lennox G40DF?24A?045
Summary of Contents for Lennox G40DF?24A?045
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Page 1: Table Of Contents
G40DF(X) series units are mid−efficiency gas furnaces used for downflow applications only, manufactured with Lennox Duralok Plus heat exchangers formed of alumi- nized steel. G40DF(X) units are available in heating capac- ities of 44,000 to 135,000 Btuh and cooling applications up to 5 tons. -
Page 2: Specifications
SPECIFICATIONS G40DF G40DF G40DF G40DF G40DF Model No. Heating eat g −24A−045 −36A−045 −36A−070 −36B−090 −48B−070 Performance Low NO Model No. −24A−045X − − − −36A−070X − − − − − − Input − Btuh 44,000 44,000 66,000 88,000 66,000 Output −... -
Page 3: Blower Data
OPTIONAL ACCESSORIES − MUST BE ORDERED EXTRA A" Width Models B" Width Models C" Width Models D" Width Models CABINET ACCESSORIES Down−Flow Additive Base 11M59 11M60 11M61 11M62 CONTROLS Twinning Kit 15L38 15L38 15L38 15L38 Cleanable polyurethane frame type filter. HIGH ALTITUDE High Altitude Pressure LPG/Propane Kit... - Page 4 BLOWER DATA Cont. G40DF−36A−070 PERFORMANCE Air Volume / Watts at Different Blower Speeds External Static External Static Pressure High Medium−High Medium−Low in. w.g. Watts Watts Watts Watts 0.00 1475 1343 1151 0.05 1449 1321 1139 0.10 1423 1298 1127 0.15 1397 1276 1115...
- Page 5 BLOWER DATA Cont. G40DF−36C−110 PERFORMANCE Air Volume / Watts at Different Blower Speeds External Static External Static Pressure High Medium−High Medium−Low in. w.g. Watts Watts Watts Watts 0.00 1660 1425 1205 1015 0.05 1635 1415 1205 1010 0.10 1610 1405 1205 1010 0.15...
- Page 6 BLOWER DATA Cont. 5 ton units with 3/4 hp G40DF−60C−110 PERFORMANCE Air Volume / Watts at Different Blower Speeds External Static Pressure High Medium−High Medium−Low in. w.g. Watts Watts Watts Watts 2450 1155 1170 2355 1110 1005 2145 1015 1845 2430 1150 1165...
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Page 7: High Altitude
BLOWER DATA Cont. 5 ton units with 1 hp G40DF−60C−110 PERFORMANCE Air Volume / Watts at Different Blower Speeds External Static External Static Pressure High Medium−High Medium−Low in. w.g. Watts Watts Watts Watts 2475 1170 1276 2280 1075 1995 1690 2390 1125 1248... -
Page 8: Parts Identification
G40DF(X) PARTS ARRANGEMENT Blower Motor Blower Assembly Internal Flue Pipe Assembly Gasket Capacitor Transformer Flue DoorInterlock Switch Chase Ignition Gasket Limit Sheild with Control −3 Units only Flue Box Gasket Primary Heat Exchanger Limit Flame Rollout Flue Collector Box Switches Flame Sensor Gasket... -
Page 9: I Unit Components
Electrostatic discharge can affect electronic components. Take precautions during furnace installation and service to protect the furnace’s The Lennox SureLight ignition system consists of ignition electronic controls. Precautions will help to control board, ignitor and sensor. The board and ignitor... - Page 10 a−Electronic Ignition (See Figure 8) SURELIGHT INTEGRATED CONTROL BOARD On a call for heat the SureLight control monitors the com- bustion air inducer prove switch. The control will not begin the heating cycle if the prove switch is closed (by−passed). Once the proving switch is determined to be open, the com- bustion air inducer is energized.
- Page 11 Can cause injury or death. Unsafe operation will result if repair is attempted. 4. SureLight Ignition Control (A92) Figure 5 Control 69M08 The Lennox SureLight ignition system consists of ignition 3 AMP, 32 VAC FUSE control board, ignitor and sensor. The board and ignitor work in combination to ensure furnace ignition and ignitor durability.
- Page 12 c−Electronic Ignition (See Figure 8) TABLE 7 On a call for heat the SureLight control monitors the com- S1 DIP SWITCH SETTINGS bustion air inducer prove switch. The control will not begin Heat Off Delay the heating cycle if the prove switch is closed (by−passed). Switch 1 Switch 2 Seconds...
- Page 13 TABLE 10 INTEGRATED CONTROL BOARD TERMINAL DESIGNATIONS 120 Volt Hot COOL Cool Speed HEAT Heat Speed PARK Park PARK Park Electrconic Air Cleaner XFMR Transformer LINE Line Humidifier 120 Volt Neutral CIRC Blower XMFR Transformer Humidifier LINE Line Flame FS Flame Signal Electronic Ignition (See Figure 8) On a call for heat the ignition board monitors the combus-...
- Page 14 between 90° − 110° at the instant the blower is de−ener- FAN-OFF TIME ADJUSTMENT gized. (Longer delay times allow for lower air temperature, shorter delay times allow for higher air temperature). See figure 7. Board 100973−0 only has a 45 second fan off delay after cooling demand is satisfied.
- Page 15 6.Flame Sensor (Figure 9) Ignitor Location A flame sensor is located on the left side of the burner sup- IGNITOR TYPE A" B" port. See parts arrangement figure1. The sensor is Silicon nitride .625 .406 mounted on the flame rollout plate and the tip protrudes .685 .306 Mini Nitride...
- Page 16 LPG changeover kits are available from Lennox. Kits include G40DF UNITS burner orifices and a gas valve regulator conversion kit. WITH SHIELD WHITE RODGERS 36E SERIES GAS VALVE MANIFOLD PRESSURE ADJUSTMENT SCREW G40DF−1, −2 UNITS MANIFOLD WITHOUT SHIELD PRESSURE OUTLET...
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Page 17: Combustion Air Inducer
13.Combustion Air Inducer (B6) 14.Combustion Air Inducer Proving Switch (S18) All G40DF(X) units use a combustion air inducer to move G40DF(X) series units are equipped with a combustion air air through the burners and heat exchanger during heating proving switch located on the combustion air inducer orifice operation. -
Page 18: Installation
II−PLACEMENT AND INSTALLATION 3 − Remove access panel. 4 − Switch lever on White Rodgers gas valve to OFF; turn Make sure unit is installed in accordance with installation knob on Honeywell valve clockwise to OFF. Do not instructions and applicable codes. force. - Page 19 Use of a specialty Gas Leak Detector is strongly recommended. It is available F− Proper Gas Flow (Approximate) through Lennox under part number 31B2001. See Corp. Furnace should operate at least 5 minutes before check- 8411−L10, for further details.
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Page 20: Typical Operating Characteristics
(−) TO transducer (Part FLAME TRANSDUCER SENSOR #78H5401 available from (PART #78H5401) Lennox Repair Parts) is required to measure flame FIGURE 20 signal if meter used will not read a low micro amp sig- nal. See figure 19. The WARNING... -
Page 21: Maintenance
B−Temperature Rise VI−MAINTENANCE Temperature rise for G40DF(X) units depends on unit in- At the beginning of each heating season, the system put, blower speed, blower horsepower and static pressure should be checked as follows: as marked on the unit rating plate. The blower speed must A−Filters be set for unit operation within the range of TEMP. - Page 22 1 − Check and clean blower wheel. 11− Attach the exhaust end (positive pressure) of the 2 − Motors used on the Lennox G40DF(X) series units vacuum to the top of the heat exchanger sections. are permanently lubricated and need no further lu- Any loose debris will be forced to the bottom of the brication.
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Page 23: Wiring And Sequence Of Operation
VII− Wiring and Sequence of Operation 1 − When there is a call for heat, W1 of the thermostat energizes 5 − Gas valve opens for a 4−second trial for ignition. W of the furnace control with 24VAC. 6 − Flame is sensed, gas valve remains open for the heat call. -
Page 24: Heating Sequence Of Operation
SuRELight Control 56L84, 10M93, 32M88, 69M08 LED#1 = DS1 LED#2 = DS2 HEATING SEQUENCE OF OPERATION ABNORMAL HEATING MODE NORMAL HEATING MODE GAS VALVE OFF. COMBUSTION AIR INDUCER OFF. POWER ON INDOOR BLOWER DELAY OFF. LED #1 ON LED #2 ON CONTROL SELF−CHECK OKAY? (RESET CONTROL BY TURNING MAIN POWER OFF.) IS POLARITY REVERSED? - Page 25 HEATING SEQUENCE CONTINUED NORMAL HEATING MODE ABNORMAL HEATING MODE 15-SECOND COMBUSTION AIR INDUCER PREPURGE INITIATED BY CLOSED PROVE SWITCH. IS VOLTAGE ABOVE 75 VOLTS? LEDS SIGNAL IGNITOR WARM-UP −− 20 SECONDS. ALTERNATING IS THERE A PROPER GROUND? FAST FLASH 4-SECOND TRIAL FOR IGNITION. GAS VALVE OPENS. IS IGNITOR INTACT AND CONNECTED? CONTROL 56L84: IGNITOR ENERGIZED FOR 1 SECOND AFTER VALVE OPENS.
- Page 26 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 LED. IS CONTROL OPERATING NORMALLY? INTERRUPT MAIN POWER TO RESET CONTROL.
- Page 27 SURELIGHT CONTROL CONTINUOUS HEAT SPEED FAN SEQUENCE OF OPERATION LED: SLOW FLASH RATE REMAINS UNCHANGED THROUGHOUT SEQUENCE. MANUAL FAN SELECTION MADE AT THERMOSTAT. CONTROL (G) ENERGIZES HEAT SPEED AND EAC ACCESSORY TERMINAL. HUM TERMINAL ENERGIZES WITH COMB. AIR INDUCER. THERMOSTAT CALLS FOR HEAT (W). SYSTEM FAN REMAINS ON HEATING SPEED WITHOUT INTERUPTION THERMOSTAT OPENS.
- Page 28 1 − When there is a call for heat, W1 of the thermostat energizes 5 − Gas valve opens for a 4−second trial for ignition. W of the furnace control with 24VAC. 6 − Flame is sensed, gas valve remains open for the heat call. 2 −...
- Page 29 SuerLight Control 78M47 & 100973−01 LED#1 = AN1 LED#2 = AN2 HEATING SEQUENCE OF OPERATION ABNORMAL HEATING MODE NORMAL HEATING MODE POWER ON GAS VALVE OFF. COMBUSTION AIR INDUCER OFF. INDOOR BLOWER DELAY OFF. CONTROL SELF−CHECK OKAY? LED #1 ON LED #2 ON (RESET CONTROL BY TURNING MAIN POWER OFF.) POLARITY REVERSED.
- Page 30 HEATING SEQUENCE CONTINUED NORMAL HEATING MODE ABNORMAL HEATING MODE 15-SECOND COMBUSTION AIR INDUCER PREPURGE INITIATED BY CLOSED PRESSURE SWITCH. LEDS SIGNAL ALTERNATING FAST FLASH UNTIL IS VOLTAGE ABOVE 90 VOLTS? IGNITOR WARM-UP −− 20 SECONDS. VOLTAGE IS ABOVE 95 VOLTS, THEN RESTARTS HEATING 4-SECOND TRIAL FOR IGNITION.
- Page 31 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 LED. IS CONTROL OPERATING NORMALLY? INTERRUPT MAIN POWER TO RESET CONTROL.
- Page 32 CONTINUOUS HEAT 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 HEAT SPEED. EAC TERMINAL IS ENERGIZED. HUM TERM. ENERGIZES THERMOSTAT CALLS FOR HEAT (W). WITH COMB.
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Page 33: Surelight Troubleshooting Guide
TROUBLE SHOOTING 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. −... - Page 34 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. − Diagnostic lights flash the improper ACTION 2 − Install a proper main ground to the Improper ground to the unit.
- Page 35 PROBLEM 2: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR INDUCER DOES NOT ENERGIZE (CONT.). Condition Possible Cause Corrective Action/Comments 2.3.1 − Unit operates with a cooling and con- ACTION 1 − Check for correct wiring and loose tinuous fan demand.
- Page 36 PROBLEM 4: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR BLOWER ENERGIZES, IGNITOR IS ENERGIZED. Condition Possible Cause Corrective Action/Comments ACTION 1 − Check line pressure at the gas valve. 4.1.1 Pressure should not exceed 13" WC for both nat- −...
- Page 37 PROBLEM 5: BURNERS LIGHT WITH HEATING DEMAND BUT UNIT SHUTS DOWN PREMATURELY (CONT.) Condition Possible Cause Corrective Action/Comments ACTION 1 − Check that the manifold pressure matches value listed on nameplate. See installa- − Combustion air inducer energizes 5.3.1 tion instructions for proper procedure. with a heating demand.
- Page 38 PROBLEM 6: CONTROL SIGNALS LOW FLAME SENSE DURING HEATING MODE Condition Possible Cause Corrective Action/Comments 6.1.1 ACTION 1 − Check the sensor rod for proper loca- − Unit operates correctly but the diag- tion on the burner. Properly locate the sensor rod Sensor rod is improperly located on or replace if rod cannot be located correctly.