Lennox G40UH


E 2004 Lennox Industries Inc.
Dallas, Texas, USA
504,900M
02/2004
G40UH(X)
SERIES
GAS FURNACE
Litho U.S.A.
WARNING
FIRE OR EXPLOSION HAZARD.
Failure to follow safety warnings exactly could result in serious injury, death,
or property damage.
Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
Installation and service must be
performed by a qualified installer,
service agency or the gas supplier.
02/04
*2P0204*
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.
504,900M
*P504900M*
G40UH(X) Parts Identification
DURALOKTM HEAT
EXCHANGER
ASSEMBLY
TOP CAP
FLUE
COLLAR
COMBUSTION AIR
PROVING
(PRESSURE)
SWITCH
CABINET
COMBUSTION AIR
INDUCER
GAS
VALVE
UPPER ACCESS
PANEL
GAS
MANIFOLD
BURNERS
NAMEPLATE
INTEGRATED
CONTROL BOARD
BLOWER
MOTOR
BLOWER ACCESS
PANEL
CONTROL BOX
FIGURE 1
WARNING
WARNING
Product contains fiberglass wool.
Disturbing the insulation in this product during
installation, maintenance, or repair will expose you
to fiberglass wool. Breathing this may cause lung
cancer. (Fiberglass wool is known to the State of California to cause cancer.)
Fiberglass wool may also cause respiratory, skin,
and eye irritation.
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
NOTE − This manual must be left with the equipment
user.
Page 2
Do not set thermostat below 60°F (16°C) in heating
mode. Setting thermostat below 60°F (16°C) reduces
the number of heating cycles. Damage to the unit
may occur that is not covered by the warranty.
WARNING
If overheating occurs or if gas supply fails to shut off,
shut off the manual gas valve to the appliance before
shutting off electrical supply.
CAUTION
Before attempting to perform any service or maintenance, turn the electrical power to unit OFF at the
disconnect switch.
Your furnace is a gas appliance. It is critical that the gas
WARNING
supplied to the unit be completely burned to avoid the pro-
Do not use this furnace if any part has been under
water. Immediately call a qualified service technician
to inspect the furnace and to replace any part of the
control system and any gas control which has been
under water.
duction of carbon monoxide gas. Complete combustion of
the gas requires, but is not limited to, correct gas pressure
and gas flow rate, adequate combustion, air, and proper
venting.
IMPORTANT
WARNING
Any additions, changes, or conversions required in
order for the appliance to satisfactorily meet the application needs must be made by a Lennox service
technician using factory specified and approved
parts.
Carbon monoxide gas is invisible, odorless and
toxic.
Exposure to carbon monoxide gas can cause personal injury and even death to all occupants, including pets. Any item
that is powered by or gives off heat from a combustion pro-
WARNING
cess (including lawn mowers, automobiles, and fireplaces)
Improper installation, adjustment, alteration, service
or maintenance can cause property damage, personal injury or loss of life. Installation and service must
be performed by a qualified installer, service agency
or the gas supplier.
has the potential to produce carbon monoxide gas. Because
of this, Lennox recommends the use of a carbon monoxide detector in your home, even if you do not own gas
appliances. Reliable detectors are available at reasonable
retail prices. Contact your Lennox dealer for more details
Important Directions
1 − Keep the furnace area clear and free of combustible
material, gasoline, and other flammable vapors and
liquids. If it is installed in an insulated area, the furnace
must be kept free of insulating material. Insulating material may be combustible.
2 − DO NOT obstruct air flow to unit. Unit must receive an
unobstructed flow of combustion and ventilating air.
3 − DO NOT store chlorine or fluorine products near unit
or introduce these products into the combustion air.
These products can cause furnace corrosion.
4 − DO NOT draw return air from a room where this furnace, or any other gas appliance (ie., a water heater), is installed. When return air is drawn from a room,
a negative pressure is created in the room. If a gas appliance is operating in a room with negative pressure,
the flue products can be pulled back down the vent
pipe and into the room. This reverse flow of the flue
gas may result in incomplete combustion and the
formation of carbon monoxide gas. This toxic gas
might then be distributed throughout the house by the
furnace duct system.
WARNING
The blower door must be securely in place when the
blower and burners are operating. Gas fumes, which
could contain carbon monoxide, can be drawn into
the living space resulting in personal injury or death.
Page 3
about this investment in your safety.
Your furnace is designed to meet standards set by national agencies, and to operate safely when properly installed
and maintained. However, the unit’s performance can be
greatly impacted by the individual installation and the operating environment. It is your responsibility to ensure that
this appliance is maintained. Proper maintenance is critical for your safety and the satisfactory operation of the
product. Lennox strongly recommends annual inspection and maintenance of this appliance. Contact
your Lennox dealer for an inspection by a qualified service
technician.
Lighting Information & Operation
WARNING
If you do not follow these instructions exactly, a fire
or explosion may result causing property damage,
personal injury or death.
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 G40UH(X) will be equipped with either a gas control knob or lever. Use only your hand to turn
the gas control knob or push the gas lever. Never use
tools. If the knob or lever will not move by hand, do not try
to repair it. Call a qualified service technician. Force or attempted repair may result in a fire or explosion.
White Rodgers 36E Series Gas Valve
MANIFOLD
PRESSURE
ADJUSTMENT
SCREW
MANIFOLD
PRESSURE
OUTLET
Placing the G40UH(X) furnace into operation:
G40UH(X) units are equipped with an automatic hot surface ignition system. Do not attempt to manually light burners on these furnaces. Each time thermostat calls for heat,
the burners will automatically light. The ignitor does not get
hot when there is no call for heat on units with this ignition
system.
GAS VALVE SHOWN IN OFF POSITION
FIGURE 3
White Rodgers 36F Series Gas Valve
MANIFOLD
PRESSURE
ADJUSTMENT
SCREW
Operating the Gas Valve (Figures 3, 4 and 5)
1 − STOP! Read the safety information at the beginning of
this section.
MANIFOLD
PRESSURE
OUTLET
2 − Set the thermostat to the lowest setting. See figure 2.
3 − Turn off all electrical power to the unit.
THERMOSTATS
GAS VALVE SHOWN IN OFF POSITION
FIGURE 4
Honeywell VR8205 Series Gas Valve
MANIFOLD
PRESSURE
ADJUSTMENT
SCREW
MANIFOLD
PRESSURE
OUTLET
FIGURE 2
ON
4 − This furnace is equipped with an ignition device which
automatically lights the burners. Do not try to light the
burners by hand.
5 − Remove the upper access panel.
6 − White Rodgers 36E/36F Gas Valve − Switch gas
valve lever to OFF.
Honeywell VR8205 Gas Valve − Turn knob on gas
valve clockwise
to OFF. Do not force. See figure
5.
7 − Wait five minutes to clear out any gas. If you then smell
gas, STOP! Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s instructions. If you do not smell gas go to next step.
8 − White Rodgers 36E/36F Gas Valve − Switch gas valve lever to ON. See figure 3 for the White Rodgers 36E
valve and figure 4 for the White Rodgers 36F valve.
Honeywell VR8205 Gas Valve − Turn knob on gas valve
counterclockwise
to ON. Do not force.
Page 4
OFF
GAS VALVE SHOWN IN OFF POSITION
FIGURE 5
9 − Replace the upper access panel.
10 − Turn on all electrical power to to the unit.
11 − Set the thermostat to desired setting.
NOTE − When unit is initially started, steps 1 through 11
may need to be repeated to purge air from gas line.
12− If the appliance will not operate, follow the section
Turning Off Gas to the Unit" and call your service technician or gas supplier.
Turning Off Gas to the Unit
1 − Set the thermostat to the lowest setting.
2 − Turn off all electrical power to the unit if service is to be
performed.
3 − Remove the upper access panel.
4 − White Rodgers 36E/36F Gas Valve − Switch gas
valve lever to OFF.
Honeywell VR8205 Gas Valve − Turn knob on gas
to OFF. Do not force.
valve clockwise
Burner Flame
CAUTION
To ensure proper operation, a qualified technician
should annually check the burner flame.
5 − Replace the upper access panel.
Filters
This unit is not equipped with a filter or rack. A field−provided high−velocity filter is required for the unit to operate
properly.
A filter must be in place whenever the unit is operating.
Seasonal Inspections
A qualified service technician should inspect the complete
system each season (heating and cooling). The following
maintenance procedures should only be conducted by a
qualified service technician. Do not attempt to service
the unit in any way.
Venting System
WARNING
Service Reminder
Call your Lennox service technician if the unit will not operate. Before calling, always check the following to be sure
service is required:
1 − Check that electrical disconnect switches are ON.
2 − Check room thermostat for proper setting.
3 − Replace any blown fuses or reset circuit breakers.
4 − Gas valve should be ON.
5 − Air filter should not be plugged, which will limit air flow.
6 − Is gas turned on at meter?
7 − Is manual main shut−off valve open?
Record the model and serial number of the furnace. These
numbers are on the unit nameplate, which is located below
the burners.
Asphyxiation Hazard
Serial Number
The exhaust vent for this furnace must be securely
connected to the furnace flue collar at all times.
Model Number __________________
For your safety and to fulfill the terms of the limited
warranty, a qualified service technician must annually inspect this furnace and its vent system.
Annually (before heating season) inspect furnace venting
system, vent cap, heat exchanger, and burners for corrosion, deterioration, or deposits of debris. Remove any obstructions.
__________________
Safety Precautions
If you discover any of the following, shut down your
unit, and contact a Lennox dealer for an inspection by
a qualified technician.
D
If you repeatedly hear any new or unfamiliar sounds
while your unit is operating, there may be a problem. For
example, poorly performing burners can produce unfamiliar noises.
D
If you smell any unusual odors, your unit may be operating improperly. For example, units can give off unfamiliar odors if components are required to operate in abnormal conditions.
D
Look for visible signs of a malfunctioning unit. Examples
include unusual amounts of condensate on windows inside your house, visibly burnt components or unusual
dirt or rust accumulations on the vent pipe or in the unit.
D
During a seasonal check the service technician will inspect
the indoor blower and the burner flames along with the
venting system.
If you experience headache, nausea, fatigue, or dizziness, the cause could be exposure to carbon monoxide
gas. This is often misdiagnosed as the flu because
symptoms are similar. If you suffer from flu−like symptoms that are exaggerated at home, but seem to subside while you are away from the house, exposure to
carbon monoxide could be the cause.
Blower
Check blower wheel for any debris and clean, if necessary.
Blower motor is pre−lubricated for extended bearing life. No
further lubrication is needed.
Your vigilance may pay off in early detection of a problem
before either personal injury or property damage occurs.
Do not hesitate to contact a qualified service technician as
an investment in your well being.
Inspect the furnace venting system to make sure it is in
place, physically sound, and without holes, corrosion, or
blockage. Vent connector must be in correct position,
sloped upward and be physically sound without holes or
excessive corrosion.
Inspect the furnace return air duct connection to ensure
duct is sealed to the furnace and terminates outside the
space containing the furnace.
Inspect the physical support of the furnace to guarantee
that it is sound without sagging, cracks or gaps around
base and it maintains seal between base and support.
Page 5
Planned Service
You should expect a service technician to check the following items during an annual inspection. Power to the unit
must be shut off for the service technician’s safety.
Fresh air grilles and louvers (on the unit and in the room
where the furnace is installed) − Must be open and unobstructed to provide combustion air.
Burners − Must be inspected for rust, dirt, or signs of water.
Vent pipe − Must be inspected for signs of water, damaged
or sagging pipe, or disconnected joints.
Unit appearance − Must be inspected for rust, dirt, signs
of water, burnt or damaged wires, or components.
Blower access door − Must be properly in place and provide a seal between the return air and the room where the
furnace is installed.
Page 6
Return air duct − Must be properly attached and provide
an air seal to the unit.
Operating performance − Unit must be observed during
operation to monitor proper performance of the unit and the
vent system.
Combustion gases − Flue products must be analyzed and
compared to the unit specifications.
Problems detected during the inspection may make it necessary to temporarily shut down the furnace until the items
can be repaired or replaced.
Pay attention to your furnace. Situations can arise between annual furnace inspections that may result in unsafe
operation. For instance, items innocently stored next to the
furnace may obstruct the combustion air supply. This could
cause incomplete combustion and the production of carbon monoxide gas.