Lennox International Inc. G24-200 manual

503,613M *P504613M* 08/05 *2P0805* PRODUCT LITERA TURE  2005 Lennox Industries Inc. Dallas, T exas RET AIN THESE INSTRUCTIONS FOR FUTURE REFERENCE INST ALLA TION INSTRUCTIONS G24-200 UPFLOW GAS FURNACE Direct Spark Ignition 503,613M 8/2005 Supersedes 7/2003 T able of Contents G24−200 Unit Dimensions 2 . . . . . . . . . . . . . . . . . . . . . [...]

Page 2 G24−200 Unit Dimensions − inches (mm) 10-1/2 (267) 17 (432) 52-1/2 (1334) 53 (1346) 9 (229) Either Side 29-1/4 (743) 17 (432) 4-1/4 (108) Either Side 5-1/2 (140) VENT OUTLETS GAS PIPING INLET Either Side) HEA T EXCHANGER BLOWER MOT OR ELECTRICAL INLET (Either Side) FRONT VIEW SIDE VIEW VENT OUTLETS 52-1/2 (1334) BACK VIEW 50-3/8 (1280) 1[...]

Page 3 G24−200 Filter Box Dimensions − inches (mm) *OPTIONAL FIL TER BOX BACK VIEW SIDE VIEW 32 (813) 1 (25) 4-3/4 (121) 26-1/4 (667) 1 (25) 1 (25) 50-1/2 (1283) OPENING SAME BOTH SIDES 5 (127) *NOTE  Return air filter box may be installed at back or bottom of furnace. AIR FLOW AIR FLOW 5 (127) 32 (813) 1 (25) 4-3/4 (121) 26-1/4 (667) 1 (25)[...]

Page 4 G24−200 Parts Arrangement G24−200 HEA T SECTION AND CABINET CABINET TOP HEA T EXCHANGER ASSEMBL Y* LIMIT CONTROL* LEFT SIDE P ANEL PRESSURE SWITCH* PRESSURE SWITCH* FLUE BOX GASKET* COMBUSTION AIR BLOWER* FLUE BOX* IGNITOR* SENSOR* GAS V AL VE* (two-stage) BURNER RETENTION BRACKET* BURNER MTG BRACKET* FLAME ROLLOUT SWITCH* IGNITION CONTR[...]

Page 5 G24−200 Parts Arrangement Continued G24−200 BLOWER SECTION WHEEL BLOWER HOUSING CUT−OFF PLA TE BEARING SHAFT BLOWER PULLEY MOTOR (Drive Kit) VIBRA TION ISOLA TOR BASE ASSEMBL Y MOTOR BASE ADJUSTMENT ARM MOTOR BASE LOCA TING ROD MOTOR PULLEY (Drive Kit) DRIVE BEL T (Drive Kit)[...]

Page 6 G24−200 Gas Furnace The G24−200 upflow gas furnace is for use with natural gas only . Each G24−200 requires the installation of a separately or - dered drive kit. The available drive kits are list ed in tables 10 and 15 . Provided in each drive kit is the following: the fur - nace’s blower motor , its 24 volt control transfor mer , a[...]

Page 7 For installation in a residential garage, the furnac e mus t be installed so that the burner(s) and the ignition source are lo - cated no less than 18 inches (457 mm) above the floor . The furnace must be located or pr otected to avoid physical dam- age b y vehicles. W hen a f urnace i s installed in a p ublic garage, hangar , or other build[...]

Page 8 This furnace design has not been CSA international certi- fied for installation in mobile homes, recreational vehicles, or outdoors. W ARNING The blower access panel must be securely in place when the blower and burners are operating. Gas fumes, which could contain carbon monoxide, can be drawn into living space resulting in personal inju- r[...]

Page 9 CAUTION Insufficient combustion air can cause headaches, nausea, dizziness or asphyxiation. It will also cause excess water in the heat exch anger resulting in rust - ing and premat ure heat exchanger failure. Excessive exposure to contaminated combustion air will result in safety and performanc e related problems. A void exposure t o the fo[...]

Page 10 EQUIPMENT IN CONFINED SP ACE ALL AIR FROM INSIDE OPENINGS (T o Adjacent Room) G24−200 FURNACE CHIMNEY OR GAS VENT NOTE−Each opening shall have a free area of at least one square inch (645 mm 2 ) 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 inches (64516 mm 2 [...]

Page 1 1 EQUIPMENT IN CONFINED SP ACE ALL AIR FROM OUTSIDE (All Air Through V entilated Attic) CHIMNEY OR GAS VENT OUTLET AIR VENTILA TION LOUVERS (Each end of attic) INLET AIR (Ends 12 in. above bottom) G24−200 FURNACE NOTE−The inlet and outlet air openings shall each have a free area of at least one square inch (645 mm 2 ) per 4,000 Btu (1.17[...]

Page 12 7 − Install the filters and the filter access door . SIDE VIEW AIR FLOW 2-3/4 (70) 29-1/4 (743) 27-1/4 (692) Furnace Opening 26-1/8 (664) x 50-5/8 (1286) Floor Opening 1 (25) 1 (25) 26-1/4 (667) Filter Box Opening 4-3/4 (121) BOTTOM RETURN AIR FIL TER BOX INST ALLA TION ADHESIVE- BACKED FOAM T APE UNIT FIL TER BOX PLA TFORM RETURN AIR PLE[...]

Page 13 B − Rear Return Air (Refer to figure 6) REAR RETURN AIR FIL TER BOX INST ALLA TION REPOSITION REAR P ANEL WITH FLANGES AS SHOWN. FOUR FIL TERS (Filters may be also installed through top of frame) FIL TER ACCESS P ANEL ADHESIVE-BACKED FOAM T APE (Apply to filter box) (Seal air-tight with adhesive-backed foam tape.) UNIT RETURN AIR FIL TER [...]

Page 14 TYPICAL MOTOR/DRIVE INST ALLA TION MOTOR PULLEY MOTOR MOTOR SECURING HARDW ARE BEL T TENSION ADJUSTING HARDW ARE PULLEY ALIGNMENT BLOWER PULLEY MOTOR PULLEY MOTOR BASE FIGURE 7 B − Blower Belt Adjustment Maximum life and wear can be obtained from belts only if the proper pulley alignment and belt tension are main- tained. T ension new bel[...]

Page 15 V enting Using a Masonry Chimney The following additional requirements apply when a lined masonry chimney is used to vent a G24−200 furnace: Masonry chimneys used to vent Category I central fur- naces must be either tile-lined or lined with a listed metal lining system or dedicated gas vent. Unlined masonry chimneys are prohibited. See fi[...]

Page 16 COMMON VENTING USING TILE−LINED INTERIOR MASONR Y CHIMNEY AND COMBINED VENT CONNECTOR MIN. LENGTH = AS SHORT AS PRACTICAL. FOR MAX. LENGTH SEE NOTE 1 INTERIOR TILE−LINED MASONRY CHIMNEY NOTE − The chimney must be properly sized per provided vent- ing tables and lined with a listed metal lining system. PERMANENTL Y SEALED FIREPLACE OPE[...]

Page 17 10− A vent connector shall be supported without any dips or sags and shall slope a minimum of 1/4inch (6.4 mm) per linear foot (305 mm) of connector , back toward the appliance. See local and national installation codes for support intervals and methods. National installation code i n the U.S.A is current edition of National fuel Gas Code[...]

Page 18 T ABLE 3 CAP ACITY OF TYPE B DOUBLE-W ALL VENTS WITH TYPE B DOUBLE-W ALL CONNECTORS SER VING A SINGLE CA TEGOR Y I APPLIANCE V ent and Connector Diameter − D (inches) Height H Lateral L 3 Inch 4 Inch 5 Inch 6 Inch H ( feet ) L ( feet ) Appliance Input Rating in Thousands of Btu Per Hour (feet) (feet) MIN MAX MIN MAX MIN MAX MIN MAX 0 0 78[...]

Page 19 T ABLE 4 CAP ACITY OF TYPE B DOUBLE-W ALL VENTS WITH SINGLE-W ALL MET AL CONNECTORS SER VING A SINGLE CA TEGOR Y I APPLIANCE V ent and Connector Diameter − D (inches) Height H Lateral L 3 Inch 4 Inch 5 Inch 6 Inch H ( feet ) L ( feet ) Appliance Input Rating in Thousands of Btu Per Hour (feet) (feet) MIN MAX MIN MAX MIN MAX MIN MAX 0 38 7[...]

Page 20 T ABLE 5 CAP ACITY OF TYPE B DOUBLE-W ALL VENTS WITH TYPE B DOUBLE-W ALL CONNECTORS SER VING TWO OR MORE CA TEGOR Y I APPLIANCES VENT CONNECTOR CAP ACITY V ent Connector V ent and Connector Diameter − D (inches) V ent Hei g ht C onnector Rise 4 Inch 5 Inch 6 Inch 7 Inch Height H (feet) Rise R (feet) Appliance Input Rating in Thousands of [...]

Page 21 T ABLE 7 CAP ACITY OF TYPE B DOUBLE-W ALL VENT WITH SINGLE-W ALL MET AL CONNECTORS SER VING TWO OR MORE CA TEGOR Y I APPLIANCES − VENT CONNECTOR CAP ACITY V ent Connector V ent and Connector Diameter − D (inches) V ent Hei g ht C onnector Rise 4 Inch 5 Inch 6 Inch 7 Inch Height H (feet) Rise R (feet) Appliance Input Rating in Thousands [...]

Page 22 T esting for Proper V enting and Sufficient Combustion Air (Non−Direct V ent Applications Only) W ARNING CARBON MONOXIDE POISONING HAZARD! Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monox- ide poisoning or death. The following steps shall[...]

Page 23 FIGURE 1 1 VENT TERMINA TION CLEARANCES FOR INST ALLA TIONS IN THE USA AND CANADA* 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 v ent installations i n Canada − 12 in. (305mm) [...]

Page 24 Horizontal V enting This furnace design is certified by CSA international for horizontal venting through an outside wall, only with the use of two Field Controls Company Model SWG-4L side- wall venting kits, available from any Lennox Dealer Service Center . No other Field brand venting kits or any other manufacturer’s venting kits are acc[...]

Page 25 Gas Piping NOTE − The flexible connector supplied with the unit must not be modified and must be installed between the two combination gas controls. 1 − Piping can be installed to enter either side of cabinet. Refer to figure 13 . Left-Side Installation − Install flexible connector (supplied with unit) between gas valves and connect s[...]

Page 26 T ABLE 9 GAS PIPE CAP ACITY − FT 3 /HR (KL/HR) Nominal Internal Length of Pipe - Feet (m) Nominal Iron Pipe Size Inches(mm) Internal Diameter Inches(mm) 10 (3.048) 20 (6.096) 30 (9.144) 40 (12.192) 50 (15.240) 60 (18.288) 70 (21.336) 80 (24.384) 90 (27.432) 100 (30.480) 1/4 (6.35) .364 (9.246) 43 (1.13) 29 (.82) 24 (.68) 20 (.57) 18 (.51)[...]

Page 27 Electrical CAUTION Electrostatic discharge can affect electronic com- ponents. T ake precautions du ring furnace installa - tion and service to protect the furnace’s electronic controls. Precautions will help to avoid control ex- posure t o electrostatic d ischarge by putting the fur- nace, the control and the technician at the same elect[...]

Page 28 1 1 2 2 G24−200 FIELD WIRING DIAGRAM (120V SINGLE PH 60HZ) PRIMARY LIMIT PRESSURE SWITCH G Y1 IGNITION CONTROL BOARD L1 N FUSED OR CIRCUIT BREAKER DISCONNECT (Furnished by installer) THERMOST A T C GND GAS VA LV E W1 DOOR INTERLOCK PRIMARY LIMIT PRESSURE SWITCH DOOR INTERLOCK GAS VA LV E FLAME ROLLOUT SWITCH K3 CONT ACTOR T3 TRANSFORMER S[...]

Page 29 1 1 2 2 P UNITS − 208/230V 1PH 60 HZ PRIMARY LIMIT PRESSURE SWITCH G Y1 L1 FUSED OR CIRCUIT BREAKER DISCONNECT (Furnished by installer) THERMOST A T C GND GAS VA LV E FLAME ROLLOUT SWITCH W1 DOOR INTERLOCK PRIMARY LIMIT PRESSURE SWITCH DOOR INTERLOCK GAS VA LV E FLAME ROLLOUT SWITCH K3 CONT ACTOR T1 TRANSFORMER 24v: blue − yellow 208v: [...]

Page 30 1 1 2 2 G24−200 FIELD WIRING DIAGRAM PRIMARY LIMIT PRESSURE SWITCH G Y1 L1 FUSED OR CIRCUIT BREAKER DISCONNECT (Furnished by installer) THERMOST A T C GND GAS VA LV E W1 DOOR INTERLOCK PRIMARY LIMIT PRESSURE SWITCH DOOR INTERLOCK GAS VA LV E FLAME ROLLOUT SWITCH K3 CONT ACTOR T3 TRANSFORMER 460v: white − red 230v: white − black T1 TRA[...]

Page 31 SCHEMA TIC WIRING DIAGRAM FOR G24−200 UNITS (120V SINGLE PHASE 60HZ ) FIGURE 18[...]

Page 32 WIRING SCHEMA TIC DIAGRAM FOR G24−200 P UNITS − 208/230V 1PH 60 HZ G UNITS − 460V 3PH 60HZ Y UNITS − 208/230V 3PH 60HZ J UNITS − 575V 3PH 60HZ FIGURE 19[...]

Page 33 Unit Start−Up FOR YOUR SAFETY READ BEFORE LIGHTING W ARNING Do not use this furnace if any part has been under water . A flood−damaged fu rnace is extremely dan- gerous. Attempts to use the furnace can result in fire or explosion. A qualified service agency should be contacted to in spect the furnace and to replace a ll g as c ontrols, [...]

Page 34 12 − If the furnace does not light the f irst time ( the gas line may n ot b e f ully purged), i t w ill a ttempt u p 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 Of f Gas T o Unit" and call your service tech[...]

Page 35 Gas Pressure Adjustment Gas Flow (Approximate) 1− Operate unit at least 15 minutes before checking gas flow . Determine the time in seconds for two revolu- tions of gas through the meter . (T wo revolutions as- sures a more accurate time.) A portable LP gas meter (17Y44) is available for LP applications. 2− Divide th e number of seconds[...]

Page 36 T emperature Rise Check the temperature rise and, if necessary , adjust the blower speed to maintain the temperature rise within the range shown on the unit rating plate. Electro-mechanical Thermostat Heat Anticipation In single-stage heat applications, set the heat anticipation to 0.2 amps. In two-stage heat applications, set the heat anti[...]

Page 37 Setting blower CFM Note − T urn electrical power of f w hen adjusting mo- tor pulley. B lower RPM adjust ment is accomplis hed by changing the motor pulley opening. Loosen Allen screw and turn pulley clockwis e to i ncreas e RPM or turn coun- terclock wise to decrease. Re-tighten Allen screw . (See B lo we r mo t o r/ d ri ve i n st a l l[...]

Page 38 T ABLE 14 ACCESSOR Y AIR RESIST ANCE Model C17−090/120 Coil Pleated Filter − 1 in. (25 mm) *Disposa ble Filter − 1 i n . ( 2 5 m m) EMD17M−95 EMD17M−135 cfm L/s in. w .g. Pa in. w.g. Pa in. w.g. Pa in. w.g. Pa in. w.g. Pa 2400 1 135 0.14 35 0.17 42 0.05 12 .04 10 −−−− −−−− 2600 1225 0.16 40 0.18 45 0.06 15 .05 12 ?[...]

Page 39 Repair Parts List The following repair p arts are available through independent Lennox dealers. W hen ordering parts, include the complete f ur - nace m odel n umber listed o n the C SA i nternational. r ating p lat e  E x ample: G24−200. R efer to p age 4 and 5 f or parts identifi- cation. Cabinet Parts Electrical Part s Heating Parts[...]

Page 40 T roubleshooting HEA TING SEQUENCE OF OPERA TION WITH TWO-ST AGE THERMOST A T NORMAL HEA TING MODE ABNORMAL HEA TING MODE YES YES POWER ON IS THE S47 (S69) ROLLOUT SWITCH CLOSED? B6 (B15) COMBUSTION AIR BLOWER PREPURGE FOR 30 SECS. DETERMINE WHY AUTOMA TIC-RESET S10 (S99) HIGH LIMIT OPEN. YES NO NO 8 SEC TRIAL FOR IGNITION − ST ART IGNITI[...]

Page 41 HEA TING SEQUENCE OF OPERA TION WITH TWO-ST AGE THERMOST A T CONTINUED NORMAL HEA TING MODE ABNORMAL HEA TING MODE YES HAS ROOM AIR TEMPERA TURE CONTINUED TO DROP BELOW THE THERMOST A T"S W2 SET POINT? DETERMINE WHY AUTOMA TIC-RESET S10 (S99) HIGH LIMIT OPEN. K20, (K123), K36 RELA YS MAINT AIN BLOWER OPERA TION. IS THE S10 (S99) HIGH L[...]

Page 42 HEA TING SEQUENCE OF OPERA TION WITH SINGLE-ST AGE THERMOST A T NORMAL HEA TING MODE ABNORMAL HEA TING MODE YES YES POWER ON IS THE S47 (S69) ROLLOUT SWITCH CLOSED? B6 (B15) COMBUSTION AIR BLOWER PREPURGE FOR 30 SECS. DETERMINE WHY AUTOMA TIC-RESET S10 (S99) HIGH LIMIT OPEN. YES NO NO 8 SEC TRIAL FOR IGNITION − ST ART IGNITION TRAIL, GV1 [...]

Page 43 HEA TING SEQUENCE OF OPERA TION WITH SINGLE-ST AGE THERMOST A T CONTINUED NORMAL HEA TING MODE ABNORMAL HEA TING MODE DETERMINE WHY AUTOMA TIC-RESET S10 (S99) HIGH LIMIT OPEN. K20, (K123), K36 RELA YS MAINT AIN BLOWER OPERA TION. IS THE S10 (S99) HIGH LIMIT CLOSED? IS W1 DEMAND OF THERMOST A T SA TISFIED? A3 (A12) LED OFF YES B6 (B15) COMBU[...]

Page 44 THERMOST A T CALLS FOR COOLING (Y1 POWERED) COOLING CONT ACTOR OF FIRST-ST AGE CONDENSING UNIT CLOSES AND SYSTEM BLOWERS ST ART . YES HAS ROOM AIR TEMPERA TURE CONTINUED T O RISE ABOVE THE THERMOST A T"S Y2 SET POINT? COOLING CONT ACTOR OF SECOND-ST AGE CONDENSING UNIT CLOSES. IS Y2 DEMAND SA TISFIED? YES SECOND-ST AGE COOLING UNIT CON[...]