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Lennox International Inc. G50UH-60D-155 manual

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Table of contents for the manual

  • Page 1

    ,1_ 2006 Lennox industries Inc. Dallas, Texas, USA INSTALLATION INSTRUCTIONS G50UH(X) Series GAS FURNACE 505,254M _ Technical 8/2006 .L_ ._L Publications Supersedes 504,957M Lithe U.S.A. RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE Unit Dimensions ................................ 2 G50UH(X) Parts Arrangement .................... 3 G50UH(X) Gas Fu[...]

  • Page 2

    1 NOTE - 60C and 60D size units 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 20 x 25 x 1 in. (508 x 635 x 25 mm) air filter. Required to maintain proper air velocity across the filter. 2. Single side return air with optional RAB Return Air Base 3. Bottom r[...]

  • Page 3

    Gasket Flue Box Gasket Heat Exchanger Flue Collector Box Air Deflector G50UH-48C-135, G50UH-60C-110 & G50UH-60D-155 Units Only Flue Transition % Flame Sensor _ Flame Rollout Switches* Flame Rollout Bracket Gas Valve Gas Orifices Ignitor Bracket Ig'_itor Combustion Air Orifice Combustion Air Pressure Switch Air Inducer Limit Shield Primary [...]

  • Page 4

    The G50UH(X) gas furnace is shipped ready for installa- tion in theupfiow or horizontal position (left or right). The furnace is shipped with the bottom panel in place. The bot- tom panel must beremoved if the unit is to be installed in a horizontal application. The panel may also be removed in upfiow applications. Package 1 of 1 contains 1 - Assem[...]

  • Page 5

    When installed, this furnace must be electrically grounded according to local codes. Inaddition, in the United States, installation must conform with the current National Elec- tricCode, ANSI/NFPA No. 70. The National Electric Code (ANSI/NFPA No. 70) is available fromthe following ad- dress: National Fire Protection Association 1 Battery March Park[...]

  • Page 6

    Inthe past, there was noproblem inbringing insufficient out- door air for combustion. Infiltration provided all theair that was needed. Intoday's homes, tight construction practices make it necessary to bring in airfrom outside forcombus- tion. Take into account that exhaust fans, appliance vents, chimneys, and fireplaces force additional air [...]

  • Page 7

    CHIMNEY VENT EQUIPMENT IN CONFINED SPACE ALL AIR FROM INSIDE WiTER / HEATER FURNACE 1_ OPENINGS (To Adjacent Room) I I I I 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 mm2). F[...]

  • Page 8

    CHIMNEY OR GAS VENT_ EQUIPMENT IN CONFINED SPACE ALL AIR FROM OUTSIDE (All Air Through Ventilated Attic) VENTILATION LOUVERS (Each end of attic) FURNACE INLET AIR (Ends 12 in. above bottom) HEATER NO TE- 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 kW) per hour of the total[...]

  • Page 9

    Return Air -- Upflow Applications Return air can be brought in through the bottom or either side of the furnace installed in an upflow application. If the furnace is installed on a platform with bottom return, make an airtight seal between the bottom of the furnace and the platform to ensure that the furnace operates properly and safely. The furnac[...]

  • Page 10

    Removing the Bottom Panel Remove the two screws that secure the bottom cap to the furnace. Pivot the bottom cap down to release the bottom panel. Once the bottom panel has been removed, reinstall the bottom cap, See figure 9. Removing the Bottom Panel Screw / Bottom Cap Bottom FIGURE 9 Leveling an Upflow Unit When the side return air inlets are us[...]

  • Page 11

    This furnace may be installed in either anatticora crawl- space. Either suspend the furnace from roof rafters or floor joists, as shown infigure 12, or install the furnace on a platform, as shown in figure 13. The unitmust be sup- ported at both ends andbeneath the blower deck to pre- vent sagging. Typical Horizontal Application Unit Suspended in A[...]

  • Page 12

    This unit is not equipped with a filter or rack. A field-pro- vided high-velocity filter is required for the unit to operate properly. Table 1 lists recommended filter sizes. A filter must be in place anytime the unit is operating. Furnace Cabinet Size 14-1/2" 17-112" 21" 24-1/2" TABLE 1 Filter Size Side Return 16X25X 1 (1) 16X2[...]

  • Page 13

    Use sheet metal shears to remove the cut out from the side of the cabinet. Use the two provided sheet metal screws to install the cutout on the top cap to cover the original flue outlet opening. See figure 15. The G50UH(X) series units are classified as fan-assisted Category I furnaces when vertically vented according to the latest edition of Natio[...]

  • Page 14

    Common Venting Using Tile-Lined Interior Masonry Chimne MINIMUM LENGTH = AS SHORT AS PRACTICAL. FOR MAXIMUM LENGTH SEE NOTE TO LEFT NOTE- Refer to provided venting tables for installations in the USA and the venting tables in current CSA B149 for installations in Canada. _ OTHER APPLIANCE m FU J _Row ' and Combined Vent Connector J INTERIOR TI[...]

  • Page 15

    5 - The entire length of single wall metal vent connector shall be readily accessible for inspection, cleaning, and replacement. 6 - Single appliance venting configurations with zero lat- eral lengths (tables 3 and4) areassumed to have no elbows in the vent system. For allother vent configura- tions, the vent system is assumed to have two 90 ° el-[...]

  • Page 16

    TABLE 3 Capacity of Type B Double-Wall Vents with Type B Double-Wall Connectors Serving a Single Category I Appliance Vent and Connector Diameter - D (inches) Height Lateral 3 Inch 4 Inch 5 Inch 6 Inch H L (feet) (feet) Appliance Input Rating in Thousands of Btu Per Hour MIN MAX MIN MAX MIN MAX MIN MAX 0 0 78 0 152 0 251 0 375 2 13 51 18 97 27 157 [...]

  • Page 17

    TABLE 4 Capacity of Type B Double-Wall Vents with Single-Wall Metal Connectors Serving a Single Category I Appliance Vent and Connector Diameter - D (inches) Height Lateral 3 Inch 4 Inch 5 Inch 6 Inch H L (feet) (feet) Appliance Input Rating in Thousands of Btu Per Hour MIN MAX MIN MAX MIN MAX MIN MAX 0 38 77 59 151 85 249 126 373 2 39 51 60 96 85 [...]

  • Page 18

    TABLE 5 Vent Connector Capacity Type B Double-Wall Vents with Type B Double-Wall Connectors Serving Two or More Category I Appliances Vent and Connector Diameter - D (inches) Vent Connector Height Rise 3 Inch 4 Inch 5 Inch 6 Inch H R Appliance Input Rating in Thousands of Btu Per Hour (feet) (feet) MIN MAX MIN MAX MIN MAX MIN MAX 1 22 37 35 66 46 1[...]

  • Page 19

    TABLE 7 Vent Connector Capacity Type B Double-Wall Vents with Single-Wall Metal Connectors Serving Two or More Category I Appliances Vent and Connector Diameter - D (inches) Vent Connector Height Rise 3 Inch 4 Inch 5 Inch 6 Inch H R Appliance Input Rating in Thousands of Btu Per Hour (feet) (feet) MIN MAX MIN MAX MIN MAX MIN MAX I NR NR NR NR NR NR[...]

  • Page 20

    Resize the common venting system to the minimum vent pipe size determined by using the appropriate tables in appendix G. (These are in the current stan- dards of the National Fuel Gas Code ANSI Z223.1 in the USA, and the appropriate Category 1 Natural Gas and Propane appliances venting sizing tables in the current standards of the CSA B149 Natural [...]

  • Page 21

    MANUAL MAIN SHUT-OFF VALVE (With 1/8 in. NPT Plugged Tap Shown) GROUND JOINT UNION Left Side Piping (Standard) AUTOMATIC GAS VALVE (with manual shut-off valve / AUTOMATIC MANUAL GAS VALVE (with manual VALVE shut-off valve) (With 1/8 in. NPT Shown) JOINT UNION DRIP LEG DRIP LEG FIELD PROVIDED AND INSTALLED FIGURE 19 Leak Check After gas piping is co[...]

  • Page 22

    INTERIOR MAKE-UP BOX INSTALLATION MAKE-UP Left side / BOX _ ° FIGURE 22 Refer to figure 24 for field wiring and figure 26 for schematic wiring diagram and troubleshooting. 1 - Select circuit protection and wire size according to the unit nameplate. The power supply wiring must meet Class I restrictions, 2 - Holes are on both sides of the furnace c[...]

  • Page 23

    TYPICAL G50UH(X) FIELD WIRING DIAGRAM WARNING- ELECTRIC SHOCK HAZARD,CAN CAUSE INJURY OR DEATH.UNIT MUST BE GROUNDED IN ACCORDANCE WITH NATIONAL AND LOCAL CODES, IF ANY WIRE IN THIS APPLIANCE IS REPLACED, IT MUST BE REPLACED WITH WIRE OF LIKE SIZE, RATING,INSULATION THICKNESS AND TERMINATION. _ IMPORTANT- TO PREVENT MOTOR BURNOUT,NEVER CONNECT MORE[...]

  • Page 24

    G5OUH(X) Schematic Wiring Diagram 120V ADO /_ SIS BLOWER SPEED CHART L_ OR SlO COMBUSTION AIR FACTORY CONNECTED SPEED TAPS MOTOR SECONDARY PROVING SWITCH SREE_ K43 ECON PRIMARY GAS UNIT COOL HEAT FAN PARK PARK AVAIL, L_DTS (IF USED) LIMIT COMBUSTION AIR _ 24A-045 fELLOW RED ........ 3 N/A INDUCER MOTOR 2¢A-070 fELLOW RED 3 2 "-L£P./ 36A-070 [...]

  • Page 25

    FOR YOUR SAFETY READ BEFORE LIGHTING AWARNING AWARNING ACAUTION BEFORE LIGHTING smell all around the appliance area for gas, Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. The gas valve on the G50UH(X) unit may be equipped with either a gas control knob or gas control lever. Use only your hand [...]

  • Page 26

    8 - Honeywell VR8205 Gas Valve with ON/OFF Switch - Move gas valve switch to ON. See figure 27. Honeywell VR8205 Gas Valve with Control Knob - Turn knob on gas valve counterclockwise _ to ON, Do not force. See figure 28, White Rodgers 36G Gas Valve - Move gas valve switch to ON, See figure 29, 9 - Replace the upper access panel, 10- Turn on all ele[...]

  • Page 27

    ral gas atall altitudes is 3.5" w.c. Manifold pressure for all units fueled by L.R/propane gas at all altitudes is 10.0" w,c. See figures 27, 28and 29 forthe location of the manifold pressure adjustment screws, NOTE - In Canada, certification for installations at eleva- tions over 4500 feet (1372 m) is the jurisdiction of local au- thorit[...]

  • Page 28

    Flue And Chimney 1 - Check flue pipe, chimney and all connections fortight- ness and to make sure thereisno blockage, 2 - Check unit for proper draft, 3 - Is pressure switch closed? Obstructed flue will cause unit toshut off at pressure switch, Check flue and outlet for blockages. 4- Reset manual flame rollout switches on burner box cover. Failure [...]

  • Page 29

    4 - Remove the collector boxlocated behind the combus- tion air inducer. Be careful with the collector boxgas- ket. If the gasket is damaged, it must be replaced to prevent leakage, 5 - Label the wires from gas valve androllout switches, then disconnect them. 6 - Disconnect gas supply piping. Remove four screws se- curing the burner manifold assemb[...]

  • Page 30

    The following repair parts are available through Lennox dealers. When ordering parts, include the complete furnace model number listed on theCSA International nameplate -- Example: G50UH(X)-24A-045-8, Cabinet Parts Upper access panel Blower panel Top cap Control Panel Parts Transformer SureLight ®ignition board Door interlock switch Circuit breake[...]

  • Page 31

    SURELIGHT ® CONTROL HEATING SEQUENCE OF OPERATION NORMAL HEATING MODE ABNORMAL HEATING MODE I POWER ON ] I GAS VALVE OFF. COMBUSTION AIR INDUCER ON. _' I INDOOR BLOWER ON. CONTROL SELF-CHECK OKAY'_ I,_ _ LED #1 ALTERNATING FAST FLASH I " ; NO | LED#2 ALTERNATING FAST FLASH I | CHECK FOR BROKEN IGNITOR OR -I GAS VALVE OFF. COMBUSTION[...]

  • Page 32

    NORMAL HEATING MODE 15-SECOND COMBUSTION AIR INDUCER PREPURGE 9 N T ATED BY CLOSED PRESSURE SW TCH. YES _ I IGNITOR WARM-UP -- 20 SECONDS. YES I 4-SECOND TRIAL FOR IGNITION. GAS VALVE OPENS, IGNITOR ENERGIZED FOR UP TO 4 SECONDS, YES I FLAME STABILIZATION PERIOD. 4 SECONDS FLAME RECTIFICATION CURRENT CHECK. CAN FLAME BE PROVEN WITHIN 4 SECONDS AFTE[...]

  • Page 33

    SURELIGHT®CONTROL COOLING SEQUENCE OF OPERATION NORMALCOOLING MODE ABNORMALCOOLING MODE I POWER ON l I IGNITION CONTROL MA, N POWER ON I I CO.T O S O,A .OS ,OO. OK IS CONTROL OPERATING NORMALLY? GAS VALVE OFF, COMBUSTION AIR INDUCER OFR INDOOR BLOWER OFF WITH NORMAL DELAY. SIGNAL CIRCUIT BOARD FAILURE AT LED. INTERRUPT MAIN POWER TO RESET CONTROL,[...]

  • Page 34

    I SURELIGHT ® CONTROL CONTINUOUS FAN SEQUENCE OF OPERATION I ! LED: SLOW FLASH RATE REMAINS I I UNCHANGED THROUGHOUT SEQUENCE. MANUAL FAN SELECTION MADE AT THERMOSTAT. CONTROL (G) ENERGIZES INDOOR BLOWER AT FAN SPEED. EAC TERM. IS ENERGIZED. / THERMOSTAT CALLS FOR HEAT (W). I--l't / NO THERMOSTAT CALLS FOR COOLING. _YES INDOOR BLOWER SWITCHES[...]

  • Page 35

    Job Name Job Location Job No. City Date State Installer Unit Model No. Serial No. Heating Section Electrical Connections Tight? Supply Voltage Blower Motor Amps [] Fuel Type: Natural Gas? Furnace BtuInput City Technician State [] [] Blower Motor H.P. Gas Piping Connections Tight & Leak-Tested? LP/Propane Gas? [] D Line Pressure Regulator Pressu[...]