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E 2000 Lennox Industries Inc.
Dallas, Texas, USA
INSTALLATION
INSTRUCTIONS
G26 SERIES UNITS
GAS UNITS
504,228M
11/2000
Supersedes 503,885M
Litho U.S.A.
Table of Contents
Unit Dimensions
Requirements
General
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G26 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation - Setting Equipment
Return Air Opening Guidelines
Filters & Optional Filter Assembly
. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
Duct System
Pipe & Fittings Specifications
. . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vent Piping Guidelines
. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . .
Joint Cementing Procedure
Venting Practices
Gas Piping
Electrical
Unit Start-Up
. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas Pressure Adjustment
High Altitude Information
Other Unit Adjustments
Service
. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Parts
. . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start-Up & Performance Check List . . . . . . . . . . . . . .
6
7
5
5
4
4
2
3
8
9
7
8
15
16
23
26
26
31
20
21
22
22
RETAIN THESE INSTRUCTIONS
FOR FUTURE REFERENCE
WARNING
If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or death.
Do not store or use gasoline or other flammable vapors and liquids in the viĆ cinity of this or any other appliance.
Installation and service must be performed by a qualified installer, service agency or the gas supplier.
WHAT TO DO IF YOU SMELL GAS:
D Do not try to light any appliance.
D Extinguish any open flames.
D Do not touch any electrical switch; do not use any phone in your building.
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.
11/00
*2P1100* Page 1
504,228M
*P504228M*
G26 Unit Dimensions - inches (mm)
1 1/16
(41)
5/8
(16)
1 1/16
(41)
3 5/8
(92)
18 7/8
(479)
B
SUPPLY
AIR
OPENING
23 3/4 (603)
25 (635)
TOP VIEW
28 1/2
(724)
F
2
(51)
COMBUSTION
AIR INTAKE
2 1/2 (64)
EXHAUST
AIR OUTLET
21 3/4
(552)
4 1/2
(114)
23
(584) CONDENSATE
DRAIN
(Both Sides)
ELECTRICAL
INLETS
(Both Sides)
C
23 (584)
RETURN AIR
KNOCKOUT
(Either Side)
1Ć15/16 (49)
23 (584)
Return Air
Knockout (Bottom)
SIDE VIEW
GAS PIPING
INLET
(Both Sides)
4 (102)
4 (102)
46
(1168)
EXTERNAL
SIDE RETURN
AIR FILTER KIT
(Either Side)
(Optional)
G H
A
AIR FLOW
5/8 (16)
E D
Return Air
Knockout (Bottom)
FRONT VIEW
G26Q2-50
G26Q3Ć50
G26Q3Ć75
G26Q3/4Ć100
G26Q4/5-75
G26Q4/5Ć100
G26Q3/4-125
G26Q4/5Ć125 in.
A mm in.
B C D E mm in.
mm in.
mm in.
mm in.
F mm
16Ć1/4 413 14Ć1/8 359 12 305 12 305 2Ć1/8 54 7Ć5/8 194 in.
G mm
14 in.
H mm
356 12Ć3/4 324
21Ć1/4 540 19Ć1/8 486 18 457 18 457 1Ć5/8 41 10Ć1/8 257 20 508 18Ć3/4 476
26Ć1/4 667 24Ć1/8 613 18 457 18 457 4Ć1/8 105 12Ć5/8 321 20 508 18Ć3/4 476
Page 2
G26 Parts Arrangement
GLASS FIBER GASKET
FRESH AIR
INTAKE FITTING
BURNER BOX
ASSEMBLY
PATCH
PLATE
G26 PARTS IDENTIFICATION
FLUE COLLAR
WARM
HEADER
(COLLECTOR)
BOX
PATCH PLATE WITH
BARBED FITTING
AND FLAME
ROLL-OUT SWITCH
DuralokPlus TM
HEAT EXCHANGER
ASSEMBLY
TOP CAP
FLUE
TRANSITION
CABINET
FLAME SIGHT
GLASS
BURNER
BOX
COVER GAS VALVE AND
MANIFOLD
COMBUSTION AIR
PROVE
(PRESSURE)
SWITCH
SUPPLY
AIR
BLOWER
BURNER
ACCESS
PANEL
BLOWER
ACCESS
DOOR
COMBUSTION AIR
INDUCER
COMBUSTION AIR
ORIFICE
COLD HEADER
(COLLECTOR)
BOX
FIGURE 1
Page 3
PRIMARY LIMIT
(ALTERNATE STYLES)
CONDENSER COIL
CONTROL TRANSFORMER
CONTROL VOLTAGE
CIRCUIT BREAKER
DOOR INTERLOCK SWITCH
CONTROL BOX COVER
Requirements
All G26 units are CSA International certified to ANSI
Z21.47 and CSA 2.3 standards.
In the USA, installation of Lennox gas central furnaces must conform with local building codes. In the absence of local codes, units must be installed according to the current NaĆ tional Fuel Gas Code (ANSI-Z223.1) in the United States.
The National Fuel Gas Code is available from the following address:
American National Standards Institute, Inc.
11 West 42nd Street
New York, NY 10036
In Canada, installation must conform with current National
Standard of Canada CAN/CGA-B149.1 Installation Code for Natural Gas Burning Appliances and Equipment" and
CAN/CGA-B149.2 Installation Code for Propane Gas
Burning Appliances and Equipment," local plumbing or waste water codes and other applicable local codes.
Adequate clearance must be made around the air openĆ ings into the vestibule area. Provisions must be made for proper operation and for combustion air and ventilation air supply according to the current National Fuel Gas Code or
CAN/CGA-B149 standards.
This furnace is CSA International certified for installation clearances to combustible material as listed on the unit rating plate and in table 1.
TABLE 1
Clearances Location Inches (mm)
Service access
Front
Condensate side
24 (610)
3 (76)
(from side of unit) materials
Top
Exhaust
Side, rear, and front
1 (25)
0
0
Floor 0*
*Appliance shall not be installed directly on carpeting, tile or other combustible mateĆ rial other than wood flooring.
NOTE-Service access clearance must be maintained.
NOTE - For installation on combustible floors, the furnace shall not be installed directly on carpeting, tile, or other combustible material other than wood flooring.
Accessibility and service clearances must take preceĆ dence over fire protection clearances.
For installation in a residential garage, the furnace must be installed so that the burner(s) and the ignition source are loĆ cated no less than 18 inches (457 mm) above the floor. The furnace must be located or protected to avoid physical damage by vehicles. When a furnace is installed in a public garage, hangar, or other building that has a hazardous atmosphere, the furnace must be installed according to recommended good practice requirements and current National Fuel Gas
Code or CAN/CGA B149.1 and B149.2 standards.
The furnace must be adjusted to obtain a temperature rise within the range specified on the unit rating plate.
When installed, the furnace must be electrically grounded according to local codes. In addition, in the United States, installation must conform with the current National Electric
Code, ANSI/NFPA No. 70. The National Electric Code
(ANSI/NFPA No. 70) is available from the following address:
National Fire Protection Association
1 Battery March Park
Quincy, MA 02269
Wiring to be done in the field, between the furnace and deĆ vices not attached to the furnace or between separate deĆ vices which are field-installed and located, shall conform with the temperature limitation for type T wire [63°F (17°C) rise] when installed in accordance with these instructions.
G26 unit must be installed so that electrical components are protected from water.
When the furnace is installed so that supply ducts carry air circulated by the furnace to areas outside of the space conĆ taining the furnace, return air shall be handled by a duct(s) sealed to the furnace casing and terminating out-side space containing furnace.
WARNING
Product contains fiberglass wool.
Disturbing the insulation in this product during installation, maintenance, or repair will expose you to fiberglass wool dust. 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 - G26 series units must not be used as a construcĆ tion heater during any phase of construction. Very low return air temperatures, harmful vapors and misplacement of the filters will damage the unit and lower its efficiency.
General
These instructions are intended as a general guide and do not supersede local codes in any way. Consult authorities having jurisdiction before installation.
Page 4
Shipping and Packing List
1 - Assembled G26 furnace
1 - Bag assembly containing
1 - Electrical make-up box
1 - Wiring harness
1 - Snap bushing
2 - Filter clips
1 - 3 inch x 2 inch vent transition piece (-100, -125 units only)
1 - Adapter
1 - Condensate plug
1 - Nipple
1 - Brown accessory wire
1 - Green ground wire
3 - Wire nuts
2 - Star washers
Shipping Damage
Check equipment for shipping damage. If you find any damage, immediately contact the last carrier.
WARNING
Improper installation, adjustment, alteration, service or maintenance can cause property damage, personĆ al injury or loss of life. Installation and service must be performed by a qualified installer, service agency or the gas supplier.
CAUTION
As with any mechanical equipment, personal injury can result from contact with sharp sheet metal edges. Be careful when you handle this equipment.
Installation - Setting Equipment
Select a location that allows for required clearances listed on the unit rating plate. Also consider gas supply connections, electrical supply, vent connection and installation and service clearances [24 inches (610 mm) at unit front]. The furnace must be level.
NOTE - 1/3 and 1/2 hp blower motors are equipped with eiĆ ther four flexible mounting legs or three flexible legs and one rigid leg. The rigid leg is equipped with a shipping bolt and a flat white plastic washer (rather than the rubber mounting grommet used with a flexible mounting leg). This shipping bolt and flat washer must be removed before the furnace is put into operation. Once the shipping bolt and washer are removed, the rigid leg will not touch the blower housing.
CAUTION
G26 unit should not be installed in areas normally subject to freezing temperatures.
Page 5
Return Air Opening Guidelines
WARNING
Blower door must be securely in place when blower and burners are operating. Gas fumes, which could contain carbon monoxide, can be drawn into living space resulting in personal injury or death.
WARNING
Improper installation of unit can result in personal inĆ jury or death. Combustion and flue products must never be allowed to enter the return air system or air in the living space. Use sheet metal screws and joint tape to seal return air system to furnace.
In platform installations with furnace return, the furĆ nace should be sealed airtight to the return air pleĆ 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. AlĆ low absolutely no sagging, cracks, gaps, etc.
For no reason should return and supply air duct sysĆ tems ever be connected to or from other heat-ing deĆ vices such as a fireplace or stove, etc. Fire, exploĆ sion, carbon monoxide poisoning, personal injury and/or property damage could result.
Return air can be brought in either side or at the bottom of the unit. Scribe lines show the outline of each side and the bottom return air opening.
Bottom Return Air Applications
If cold air return is to terminate through the floor under the furnace, a direct, airtight and sealed connection must be made to the bottom of the furnace.
1 - Cut opening in floor or platform. Using knockouts proĆ vided, cut bottom of base panel. See figure 2.
KNOCKOUT PATTERN FOR BOTTOM
RETURN AIR APPLICATION
FIGURE 2
2 - Bend a flange on return air plenum and lower into floor or platform opening. See figure 3.
3 - Position unit over return air opening. Seal unit air tight with return air plenum.
BOTTOM RETURN AIR APPLICATION
G26 UNIT
PROPERLY
SIZED FLOOR
OPENING
SUPPLY AIR
PLENUM
FIGURE 3
NOTE - Be careful not to damage glass fiber insulation.
Check for tight seal.
Side Return Air Applications
For installations where the return air is taken from a return air drop, unit may be installed using either the left or right side of furnace.
For side return air applications, cut furnace cabinet at the dimensions given on page 2. Embossed corners are proĆ vided on both cabinet sides for return air opening location.
Filters & Optional Filter Assembly
This unit is not equipped with a filter. Filter racks and reusable foam filters are available from Lennox in single kits (44J20 for 14 x 25 filters; 44J21 for 20 x 25 filters) or
10-pack kits (66K61 for 14 x 25 filters; 66K62 for 20 x 25 filters). A filter must be in place anytime the unit is in opĆ eration.
Bottom Return Air Applications
1 - Remove blower access panel.
2 - Install filter clips, provided with unit, by slipping folded section of clip on edge of bottom opening. See figure 4.
3 - Place filter in bottom of blower compartment beneath rear filter clip. Press down on filter sides. Filter clips flex allowing filter to snap into place.
4 - To remove filter, press clip and pull filter up and out.
BOTTOM RETURN FILTER INSTALLATION
REAR FILTER CLIP
FURNACE
BACK
SIDE FILTER CLIPS (2)
RETURN AIR OPENING
FURNACE
FRONT
FIGURE 4
FURNACE
BASE BOTTOM
Side Return Air Applications
An external filter rack, ordered separately, is available from
Lennox.
NOTE - The filter door may be shipped in the rack behind the filter. If necessary, remove the filter, retrieve the door and continue with the installation of the rack.
1 - Align filter rack opening with the inside edge of the side return opening. Bottom of rack should be approxiĆ mately 1 inches (25mm) from the bottom and 3 inch-es
(76mm) from the front of the unit.
2 - Screw filter rack into place with the eight self-drilling, self-tapping screws provided. See figure 5.
3 - Push filter door pins through the two holes in filter door from the inside of the u-channel. See figure 6.
4 - Position filter door on end of filter so that the thumb tab side of the filter door is away from the furnace. Squeeze thumb tabs to secure filter to door.
SIDE RETURN FILTER INSTALLATION
BLOWER DECK
RETURN
AIR
OPENING
12 in. (305) for
14 in. (356) Filter
18 in. (457) for
20 in. (508) Filter
RETURN AIR
PLENUM SIZE
12-3/4 in. X 23-1/2 in. (324 X 597) for 14 in. (356) Filter
18-3/4 in. x 23-1/2 in. (476 x 597) for 20 in. (508) Filter
1-15/16 in.
(49)
CABINET BASE BOTTOM
FIGURE 5
15/16 in.
(24)
FILTER DOOR ASSEMBLY
FILTER DOOR
PINS
TAB
FILTER DOOR
FILTER
FILTER DOOR
PIN
TAB
FIGURE 6
5 - Guide filter and filter door into the filter rack installed on side of furnace. Push door into filter rack until secure.
6 - To remove filter, pull filter door pins until door is released from filter rack.
Page 6
Duct System
Use industry-approved standards to size and install the supply and return air duct system. This will result in a quiet and low-static system that has uniform air distribution.
Supply Air Plenum
Furnaces installed without a cooling coil require the installaĆ tion of a removable access panel in the supply air duct. The access panel should be large enough to permit inspection (eiĆ ther by smoke or reflected light) of the heat exchanger for leaks after installation. The furnace access panel must always be in place when the furnace is operating and it must not allow leaks into the supply air duct system.
Return Air Plenum
See dimension illustration on page 2 for proper return air duct size.
NOTE - For bottom return air, return air duct should be seĆ cured to the unit using rivets or SĆlocks. For side return air, secure return air duct to filter rack using screws. When usĆ ing screws, take care to avoid interference with the filter which may cause improper filtration.
The return air must not be drawn from a room where another gas appliance (ie., a water heater) is installed.
Even though this furnace draws its combustion air from outside of the structure, other gas appliances that share a utility room may not. When return air is drawn from a room, a negative pressure is created in the room. If a gas apĆ pliance 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 monĆ oxide gas. This toxic gas might then be distributed through the house by the furnace duct system.
Pipe & Fittings Specifications
CAUTION
Solvent cements for plastic pipe are flammable liqĆ uids and should be kept away from all sources of ignition. Do not use excessive amounts of solvent cement when making joints. Good ventilation should be maintained to reduce fire hazard and to minimize breathing of solvent vapors. Avoid contact of ceĆ ment with skin and eyes.
All pipe, fittings, primer and solvent cement must conĆ form with American National Standard Institute and the
American Society for Testing and Materials (ANSI/
ASTM) standards. The solvent shall be free flowing and contain no lumps, undissolved particles or any foreign matter that adversely affects the joint strength or chemiĆ cal resistance of the cement. The cement shall show no gelation, stratification, or separation that cannot be reĆ moved by stirring. Refer to the table 2 below for approved piping and fitting materials.
TABLE 2
PIPING AND FITTINGS SPECIFICATIONS
PIPE & FITTING MATERIAL
ASTM
SPECIFICATION
Schedule 40 PVC (Pipe)
Schedule 40 PVC (Cellular Core Pipe)
Schedule 40 PVC (Fittings)
Schedule 40 CPVC (Pipe)
Schedule 40 CPVC (Fittings)
SDR-21 PVC (Pipe) or SDR-26 PVC (Pipe)
SDR-21 CPVC (Pipe) or SDR-26 CPVC (Pipe)
Schedule 40 ABS (Pipe)
Schedule 40 ABS (Fittings)
ABS-DWV (Drain Waste & Vent)
(Pipe & Fittings)
PVC-DWV (Drain Waste & Vent -
Pipe & Fittings)
D1785
F891
D2466
F441
F438
D2241
F442
D1527
D2468
D2661
D2665
NOTE - When a WTKX termination kit (30G79) is installed as part of the intake and exhaust piping, add twelve feet to the equivalent length of the pipe (the two 2 inch diameter
90° elbows and the 27 inch pipe in the kit).
Primers and solvents must meet ASTM specifications. PVC primer is specified in ASTM F 656. Use PVC solvent cement as specified in ASTM D 2564 and ABS solvent cement as specified in ASTM D 2235. Low temperature solvent cement is recommended. Metal or plastic strapping may be used for vent pipe hangers.
Table 3 lists the available exhaust termination kits. All LenĆ nox vent terminations are PVC.
Lennox Part No.
60G77
33K97
15F75
22G44
15F74
44J41
44J40
30G28
30G79
TABLE 3
TERMINATION KITS
Kit LB#
LB-49107CE
LB-87942
LB-49107CC
LB-49107CD
Description-Inches (mm)
2" (50.8) Concentric
Termination Kit
2" (50.8) Low Pressure Drop
Concentric Term. Kit
2" (50.8) Roof
Termination Kit
2" (50.8) Wall
Assembly Termination Kit
LB-49107CB
LB-65678A
LB-65701A
WTK
WTKX
2" (50.8) Wall Ring Kit
3" (76.2) Roof
Termination Kit
3" (76.2) Wall
Assembly Termination Kit
2" (50.8) Wall
Termination Extended Vent
2" (50.8) Wall
Termination Extension Riser
When making ABS joints, pieces can be prepared with a cleaner. When joining ABS to PVC materials, use PVC solĆ vent cement. Refer to this procedure as specified in ASTM
D3138.
Page 7
Vent Piping Guidelines
Pipe used for exhaust and intake lines should be sized acĆ cording to table 4. Note that maximum length of vent pipe is for one run; either intake or exhaust. Maximum vent length given is not the total length of intake + exhaust vents.
Each 90° elbow is equivalent to 5 feet (1.52m) of vent pipe.
Two 45° elbows are equivalent to one 90° elbow. One
45°elbow is equal to 2.5 feet (.76m) of vent pipe.
If intake and exhaust piping runs are not equal in length and number of elbows, the larger diameter pipe must be used for both runs.
TABLE 4
VENT PIPE SIZING TABLE FOR G26 FURNACES
MINIMUM DIAMETER OF INTAKE/EXHAUST PIPE
Vent Pipe
Equivalent Length
Max. Feet (Meters)
G26-50
50,000
BTU
G26-75
75,000
BTU
G26-100
100,000
BTU
G26-125
125,000
BTU
15 (4.57m)
20 (6.10m)
25 (7.62m)
30 (9.14m)
40 (12.19m)
50 (15.24m)
55 (16.76m)
60 (18.29m)
70 (21.34m)
80 (24.38m)
90 (27.43m)
100 (30.48m)
110 (33.53m)
120 (36.58m)
130 (39.62m)
3"
3"
3"
3"
3"
3"
2"
2"
2"
3"
3"
3"
3"
3"
3"
2"
2"
2"
2"
3"
3"
2"
2"
2"
3"
3"
3"
3"
3"
3"
1-1/2"
2"
2"
2"
2"
2"
2"
3"
3"
3"
3"
3"
3"
3"
3"
3"
3"
3"
3"
3"
3"
2"
3"
3"
3"
3"
3"
3"
3"
--
NOTE - M inch pipe for G26-50 is 5 feet and 2 elbows of 1.5 inch diameter pipe.
NOTE - M inch pipe for G26-75 is 5 feet and 2 elbows of 2 inch diameter pipe.
NOTE - M inch pipe for G26-100 is 5 feet and 2 elbows of 2 inch diameter pipe.
NOTE - M inch pipe for G26-125 is 5 feet and 2 elbows of 2 inch diameter pipe.
NOTE - When a WTKX termination kit is installed as part of the intake and exhaust piping, the two 2 inch diameter 90° elbows and the 27 inch pipe (in the kit) should be included in the maximum vent pipe length for each run.
For -50 and -75 kBtuh units, connections are provided for 2 inch diameter venting which should satisfy most venting reĆ quirements. No transition pieces are provided or needed for 2 inch venting.
For -100 and -125 kBtuh units, the intake connection is sized for 3 inch diameter pipe. The exhaust connection has a 2 inch nipple. A pipe transition piece is shipped with the unit to connect to 3 inch pipe. See figure 7 for 2 inch and 3 inch venting applications.
Most venting applications will require 3 inch venting for proper unit operation. For no reason should the intake and exhaust pipe be different diameter pipes. RegardĆ less of the diameter of pipe used, the standard roof and wall terminations described in section Intake and Exhaust PipĆ ing Terminations should be used. Exhaust piping must terĆ minate with 1-1/2 inch pipe for 1-1/2 inch or 2 inch venting and 2 inch pipe for 3 inch venting.
G26-100 OR -125 WITH 2 IN. VENTING
2 IN. VENT PIPE
3 IN. X 2 IN.
REDUCER
3 IN. FIELD
PROVIDED
NIPPLE
2 IN
OUT
3 IN.
IN
G26-100 OR -125 WITH 3 IN. VENTING
3 IN. X 2 IN.
REDUCER
2 IN. FIELD
PROVIDED
NIPPLE
3 IN. VENT PIPE
2 IN.
OUT
3 IN.
IN
FIGURE 7
Joint Cementing Procedure
All cementing of joints should be done according to the specifications outlined in ASTM D 2855.
WARNING
DANGER OF EXPLOSION! Fumes from pvc glue may ignite during system check. Remove spark plug wire from ignition control before 115v power is applied.
Reconnect wire after two minutes.
1 - Measure and cut vent pipe to desired length.
2 - Debur and chamfer end of pipe, removing any ridges or rough edges. If end is not chamfered, edge of pipe may remove cement from fitting socket and result in a leaking joint.
3 - Clean and dry surfaces to be joined.
4 - Test fit joint and mark depth of fitting on outside of pipe.
5 - Uniformly apply liberal coat of PVC primer for PVC or
ABS cleaner for ABS to inside socket surface of fitting and male end of pipe to depth of fitting socket.
6 - Promptly apply solvent cement to end of pipe and inside socket surface of fitting. Cement should be applied lightly but uniformly to inside of socket. Take care to keep excess cement out of socket. Apply second coat to end of pipe.
Page 8
NOTE - Time is critical at this stage. Do not allow primĆ er to dry before applying cement.
7 - Immediately after applying last coat of cement to pipe, and while both inside socket surface and end of pipe are wet with cement, forcefully insert end of pipe into socket until it bottoms out. Turn pipe 1/4 turn during asĆ sembly (but not after pipe is fully inserted) to distribute cement evenly.
NOTE-Assembly should be completed within 20 secĆ onds after last application of cement. Hammer blows should not be used when inserting pipe.
8 - After assembly, wipe excess cement from pipe at end of fitting socket. A properly made joint will show a bead around its entire perimeter. Any gaps may indiĆ cate a defective assembly due to insufficient solvent.
9 - Handle joints carefully until completely set.
Venting Practices
The thickness of construction through which vent/air intake pipes may be installed is a minimum of 3 inches (610 mm), and a maximum of 24 inches (610mm). If a G26 furnace replaces a furnace which was commonly vented with another gas appliance, the size of the existing vent pipe for that gas appliance must be checked. Without the heat of the original furnace flue products, the existing vent pipe is probably oversized for the single water heater or other appliance.
The vent should be checked for proper draw with the reĆ maining appliance.
WARNING
Insufficient combustion air can cause headaches, nausea, dizziness or asphyxiation. It will also cause excess water in the heat exchanger resulting in rustĆ ing and premature heat exchanger failure. Excessive exposure to contaminated combustion air will result in safety and performance related problems. Avoid exposure to the following substances in the comĆ bustion air supply:
Permanent wave solutions
Chlorinated waxes and cleaners
Chlorine base swimming pool chemicals
Water softening chemicals
De-icing salts or chemicals
Carbon tetrachloride
Halogen type refrigerants
Cleaning solvents (such as perchloroethylene)
Printing inks, paint removers, varnishes, etc.
Hydrochloric acid
Cements and glues
Antistatic fabric softeners for clothes dryers
Masonry acid washing materials
Intake Piping
1 - Cement intake piping in slip connector located at top of unit.
2 - Route piping to outside of structure. Continue with installation following instructions given in exhaust and intake piping termination section.
Exhaust Piping
1 - Cement exhaust piping into flue collar socket located on the left side of the top cap.
2 - All horizontal runs of exhaust pipe must slope back toward unit. A minimum of a 1/4 inch (6mm) drop for each
12 inches (305mm) of horizontal run is mandatory for drainage. Horizontal runs of exhaust piping must be supported every 5 feet (1.52m) using hangers.
NOTE - Exhaust piping should be checked carefully to make sure there are no sags or low spots.
NOTE - Exhaust piping must be insulated with 1/2 inch
(13mm) Armaflex or equivalent when run through unĆ heated space. Do not leave any area of exhaust pipe open to outside air; exterior exhaust must be insulated with 1/2 inch (13mm) Armaflex or equivalent.
CAUTION
Do not discharge exhaust into an existing stack or stack that also serves another gas appliance. If vertiĆ cal discharge through an existing unused stack is reĆ quired, insert PVC pipe inside the stack until the end is even with the top or outlet end of the metal stack.
CAUTION
The exhaust vent pipe operates under positive presĆ sure and must be completely sealed to prevent leakĆ age of combustion products into the living space.
Removal of Unit from Common Venting System
In the event that an existing furnace is removed from a venting system commonly run with separate gas apĆ pliances, the venting system is likely to be too large to propĆ erly vent the remaining attached appliances. The following test should be conducted while all appliances (both in opĆ eration and those not in operation) are connected to the common venting system. If the venting system has been installed improperly, corrections must be made as outlined in the previous section.
1 - Seal any unused openings in the common venting sysĆ tem.
2 - Visually inspect the venting system from proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion and other defiĆ ciencies which could cause an unsafe condition.
Page 9
3 - Close all building doors and windows and all doors beĆ tween the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryĆ ers and any appliances not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will opĆ erate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.
4 - Follow the lighting instruction. Place the appliance beĆ ing inspected in operation. Adjust thermostat so apĆ pliance will operate continuously.
5 - Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, or a cigar.
6 - After you have determined that each appliance reĆ maining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-burning appliance to their previous conĆ dition of use.
7 - If improper venting is observed during any of the above tests, the common venting system must be corĆ rected. The common venting system should be resized to approach the minimum size as determined by using the appropriate tables in appendix G in the current standards of the National Fuel Gas Code ANSI
Z223-1 in the U.S.A., and the appropriate Category 1
Natural Gas and Propane appliances venting sizing tables in the current standards of the CAN/
CGA-B149.1 and .2 in the Natural Gas and Propane
Installation Code in Canada.
Intake and Exhaust Piping Terminations
Intake and exhaust pipes may be routed either horizontally through an outside wall or vertically through the roof. In attic or closet installations, vertical termination through the roof is preferred. Figures 8 through 20 show typical terĆ minations.
1 - Use recommended piping materials for both intake and exhaust piping.
2 - Secure all joints, including drain leg, gas tight using approved cement.
3 - Piping diameters should be determined according to length of pipe run. See table 4. Locate intake piping upwind (prevailing wind) from exhaust piping. To avoid re-circulation of exhaust gas on roof terminations, end of exhaust pipe must be higher than intake pipe.
Exhaust and intake exits must be in same pressure zone. Do not exit one through the roof and one on the side. Also, do not exit the intake on one side and the exhaust on another side of the house or structure.
Page 10
4 - Intake and exhaust pipes should be placed as close together as possible at termination end (refer to ilĆ lustrations). Maximum separation is 3 inches (76mm) on roof terminations and 6 inches (152mm) on side wall terminations.
5 - Exhaust piping must terminate straight out or up as shown. In rooftop applications, a 2 inch X 1-1/2 inch reĆ ducer for 2 inch venting, 3 inch x 2 inch reducer for 3 inch venting must be used on the exhaust piping at the point where it exits the structure to improve the velocity of exhaust away from the intake piping.
On roof terminations, the intake piping should termiĆ nate straight down using two 90° elbows (See figure 8).
IMPORTANT
Do not use screens or perforated metal in intake and exhaust terminations. Doing so will cause freezeups and may block the terminations.
NOTE - If winter design temperature is below 32°F (0°C), exhaust piping must be insulated with 1/2 inch (13mm),
Armaflex or equivalent when run through unheated space. Do not leave any surface area of exhaust pipe open to out-side air; exterior exhaust pipe must be insuĆ lated with 1/2 inch (13mm) Armaflex or equivalent. In exĆ treme cold climate areas, 3/4 inch (19mm) Armaflex or equivalent is recommended. Insulation on outside runs of exhaust pipe must be painted or wrapped to protect inĆ sulation from deterioration.
Inches(mm)
3(76) MAX.
3 x 2 (76 x 51) OR
2 x 1-1/2 (51 x 38)
PVC REDUCER
8 (203) MIN
12 (305) ABOVE
AVERAGE SNOW
ACCUMULATION
3 (76) OR
2 (51) PVC
PROVIDE SUPPORT
FOR INTAKE AND
EXHAUST LINES
1/2 (13) FOAM
INSULATION IN
UNCONDITIONED
SPACE
UNCONDITIONED
ATTIC SPACE
ROOF TERMINATION KIT
(15F75) LB-49107CC for 2 (51) Venting
(44J41) LB-65678A for 3 (76) Venting
FIGURE 8
NOTE - During extremely cold temperatures, below approximately 20°F (6.67°C), units with long runs of vent pipe through unconditioned space, even when insulated, may form ice in the exhaust termination that prevents the
unit from operating properly. Longer run times of at least 5 minutes will alleviate most icing problems. Also, a heating cable may be installed on exhaust piping and termination to prevent freeze-ups. Heating cable installation kit is available from Lennox. See Condensate Piping section for part numbers.
NOTE - Care must be taken to avoid recirculation of exĆ haust back into intake pipe.
6 - On field supplied terminations for side wall exits, exĆ haust piping should extend a maximum of 12 inches
(305mm) beyond the outside wall. Intake piping should be as short as possible. See figure 9.
1/2 (13) ARMAFLEX
INSULATION IN
UNCONDITIONED SPACE
2 (51) PVC
1/2 (13) ARMAFLEX
INSULATION
12 (305) MIN.
2 X 1-1/2
(51 x 38)
PVC REDUCER
1-1/2 (38) PVC
6 (152)
MAXIMUM
2 (51) PVC
COUPLING
OUTSIDE
WALL
8 (203)
MINIMUM
Inches (mm) TOP VIEW
WALL RING KIT
(15J74) LB-49107CB for 2 (50.8) Venting
FIGURE 9
7 - On field supplied terminations, a minimum separation distance between the end of the exhaust pipe and the end of the intake pipe is 8 inches (203mm).
8 - If intake and exhaust piping must be run up a side wall to position above snow accumulation or other obĆ structions. Piping must be supported every 3 feet
(.91m) as shown in figure 15. Refer to figures 13 and
14 for proper piping method. WTK wall termination kit must be extended for use in this application. See figĆ ure 18 or use kit WTKX shown in figure 19. When exĆ haust and intake piping must be run up an outside wall, the exhaust piping is reduced to 1-1/2 inches
(38mm) after the final elbow. The intake piping may be equipped with a 90° elbow turndown. Using turnĆ down will add 5 feet (1.5m) to the equivalent length of the pipe.
1/2 (12.7) FOAM INSULATION
IN UNCONDITIONED SPACE
OUTSIDE WALL
Optional Turndown
Shown
(Intake Only)
TOP VIEW
WALL TERMINATION
(22G44) LB-49107CD for 2 (50.8) Venting
(44J40) LB-65701A for 3 (76.2) Venting
FIGURE 10
EXHAUST
TERMINATION
12 (305) ABOVE
AVERAGE SNOW
ACCUMULATION
INTAKE
TERMINATION
Inches(mm)
Inches (mm)
EXHAUST INTAKE
CONCENTRIC ROOFTOP TERMINATION
(60G77) LB-49107CE for G26-50 & -75 Units Only
(33K97) LB-87942 for G26-100 & -125 Units Only
FIGURE 11
EXHAUST
INTAKE
INTAKE
TERMINATION
12 (305) Min.
above grade.
Inches (mm)
CONCENTRIC WALL TERMINATION
(60G77) LB-49107CE for G26-50 & -75 Units Only
(33K97) LB-87942 for G26-100 & -125 Units Only
FIGURE 12
EXHAUST
TERMINATION
Page 11
Inches(mm)
UNCONDITIONED
SPACE
OUTSIDE WALL
PROVIDE SUPPORT
FOR INTAKE AND
EXHAUST LINES EVERY
36 (914)
12 (305) MIN. for 2 (51)
20 (508) MAX. for 3 (76)
8 (203)
MIN.
12 (305) ABOVE
AVERAGE SNOW
ACCUMULATION
1/2 (13) FOAM
INSULATION IN
UNCONDITIONED
SPACE
SIDE VIEW
WALL RING TERMINATION
1/2 (13) FOAM
INSULATION
(15F74) LB-49107CB for 2 in. (51) Venting
*This reducer is not necessary for G26-50 units using 1-1/2 in. venting.
See venting table 4 for maximum venting lengths with this arrangement.
FIGURE 13
IMPORTANT
Combustion air intake inlet and exhaust outlet should not be located within 6 feet (1.8m) of dryer vent or comĆ bustion air inlet or outlet of another appliance. Piping should not exit less than 3 feet (.91m) from opening into another building.
IMPORTANT
For Canadian Installations Only:
In accordance to CAN/CGA-B149.1 and .2, the miniĆ mum allowed distance between the combustion air intake inlet and the exhaust outlet of other apĆ pliances shall not be less than 12 inches (305mm).
Inches(mm)
1/2 (13)
FOAM
INSULATION
3 (76) OR
2 (51) 90° ELBOW
3 x 2 (76 x 51) OR
2 x 1-1/2 (51 x 38)
REDUCER BUSHING LOCATION
FOR OFFSET TERMINATION
9 - Position termination ends so they are free from any obĆ structions and above the level of snow accumulation
(where applicable). Termination ends must be a minimum of 12 inches (305mm) above grade level. Do not point into window wells, stairwells, alcoves, courtyard areas or other recessed areas. Do not position terminaĆ tion ends directly below roof eaves or above a walkway.
Since the G26 is a certified direct vent, Category IV gas furnace, the location of the termination is limited by loĆ cal building codes. In the absence of local codes, refer to the current National Fuel Gas Code ANSI Z223-1 in
U.S.A., and current standards CAN/CGA-B149.1 /.2 of the Natural Gas and Propane Installation Instructions in
Canada for details. The termination should be at least
12 inches (305mm) from any opening through which flue products could enter the building.
When horizontally vented, minimum clearance for terĆ mination from electric meters, gas meters, regulators and relief equipment is 4 feet (1.2m) for US installaĆ tions. Refer to the current CAN/CGA-B149.1 and .2 for installations in Canada or with authorities having local jurisdiction.
At vent termination, care must be taken to maintain protective coatings over building materials (proĆ longed exposure to exhaust condensate can destroy protective coatings). It is recommended that the exĆ haust outlet not be located within 6 feet (1.8m) of a condensing unit because the condensate can damĆ age the painted coating.
Optional Turndown
(Not Shown)
May Be Used on
Intake Only
3 (76) OR
2 (51) 90° ELBOW
FRONT VIEW
WALL TERMINATION
Inches (mm)
(22G44) LB-49107CD for 2(51) Venting
(44J40) LB-65701A for 3(76) Venting
METAL OR PLASTIC
STRAPPING
OR LARGE WIRE TIES
FIGURE 14
FIGURE 15
10 - Suspend piping using hangers at a minimum of every
5 feet (1.52m) for schedule 40 PVC and every 3 feet
(.91m) for ABS-DWV, PVC-DWV, SPR-21 PVC, and
SDR-26 PVC piping. A suitable hanger can be fabriĆ cated by using metal or plastic strapping or a large wire tie.
11 - In areas where piping penetrates joists or interior walls, hole must be large enough to allow clearance on all sides of pipe through center of hole using a hanger.
12 - Isolate piping at the point where it exits the outside wall or roof.
Page 12
13 - When furnace is installed in a residence where unit is shut down for an extended period of time, such as a vacation home, make provisions for draining condenĆ sate collection trap and lines.
14 - Based on the recommendation of the manufacturer, a multiple furnace installation may use a group of up to four termination kits WTK assembled together horizontally, as shown in figure 17.
Front View 12
(305)
COVER EXHAUST
VENT WITH
1/2 (13)
FOAM
INSULATION
INTAKE
AIR
5
(127)
EXHAUST
AIR
12 MIN.
(305)
Above Grade
5Ć1/2
(140)
GRADE
ÉÉÉÉÉÉÉÉÉ
INTAKE
AIR
EXHAUST
AIR
Side View
8 (203)
Minimum Inches (mm)
Front View
INTAKE
VENT
1/2 (13) Foam
Insulation in
Unconditioned Space
12
(305)
EXHAUST VENT
5
(127)
Side View
EXHAUST VENT
Inches (mm)
INTAKE VENT
OUTSIDE WALL
VENT TERMINATIONS
WALL TERMINATION KIT (30G28) WTK
FIGURE 16
Front View
Side View
EXHAUST
VENT
INTAKE VENT
5
(127)
5-1/2
(140)
12
(305)
18 MAX.
(457)
EXHAUST VENT
Inches (mm) INTAKE
VENT
OPTIONAL VENT TERMINATION FOR
MULTIPLE UNIT INSTALLATION
WALL TERMINATION KIT WTK
FIGURE 17
12 (305)
Minimum
ABOVE GRADE
GRADE
ÉÉÉÉÉÉÉÉÉÉÉ
VENT TERMINATIONS
MODEL WTK WALL TERMINATION KIT (30G28)
EXTENDED VENT FOR GRADE CLEARANCE
FIGURE 18
9
(229)
Front View
34
(864)
INTAKE
VENT
EXHAUST
VENT
NOTE-Enclosed exhaust pipe is insulated with 1/2 in. (13mm) foam insulation. If intake and exhaust pipes are reversed, slit and remove foam insulation and reapply to other vent. ExĆ haust vent must be insulated.
Side View
4
(102)
12
(305)
GRADE
EXHAUST VENT
8 MIN.
(203)
INTAKE
VENT
GRADE
VENT TERMINATIONS
MODEL WTKX (30G79)
EXTENSION RISER FOR GRADE CLEARANCE
FIGURE 19
Page 13
G26 VENTING IN EXISTING CHIMNEY
8 in. - 12 in.
(203mm - 305mm)
3 in. - 8 in.
(76mm-
203mm)
3 in. - 8 in.
(76mm-
203mm)
NOTE-Do not discharge exhaust gases directly into any chimney or vent stack. If vertiĆ cal discharge through an existing unused chimney or stack is required, insert piping inside chimney until the pipe open end is above top of chimney and terminate as illusĆ trated. In any exterior portion of chimney, the exhaust vent must be insulated. An alterĆ nate method is to fill the chimney with vermiculite or equal to take advantage of its acoustic and thermal properties.
FIGURE 20
Condensate Piping
This unit is designed for either right- or left-side exit of conĆ densate piping. Condensate drain line should be routed only within the conditioned space to avoid freezing of conĆ densate and blockage of drain line. An electric heat cable should be used where condition is exposed to uncondiĆ tioned areas.
CAUTION
Do not use copper tubing or existing copper condenĆ sate lines for drain line.
1 - Determine which side condensate will exit the unit.
2 - Connect a 1/2 inch (13mm) plastic pipe plug (provided) in the unused end of the condensate trap. Install plug so that it is sealed water tight yet able to be removed. Do not permanently seal the connection. Teflon tape is recĆ ommended to seal joint. See figure 21.
CONDENSATE ASSEMBLY
(For left or right installation)
COMBUSTION AIR
INDUCER BRACKET
COLD HEADER
BOX
3 - Use the provided adapter (1/2 inch PVC x 1/2 inch
MPT) and the nipple (1/2 inch PVC) to carry drainage outside the cabinet. If a field substitute is needed, 1/2 inch CPVC x 1/2 inch MPT adapter and 1/2 inch CPVC is acceptable for use.
4 - Glue nipple to the adapter using the procedures outlined in the Joint Cementing Procedures" section.
The nipple/adapter assembly should be connected in a non-permanent manner and must be water tight.
Teflon tape is recommended to seal the joint.
For Right-Hand Side Condensate Exit:
Install the nipple/adapter assembly from the outside of the cabinet and insert the adapter into the threaded opening in the condensate trap.
For Left-Hand Side Condensate Exit:
Insert nipple/adapter assembly from the left hand side of the cabinet and through the combustion air inducer mounting structure into the threaded openĆ ing in the condensate trap.
5 - Connect field supplied plumbing to nipple and route to open drain. Plumbing should be vented to a point higher than the condensing coil. See figure 22.
CONDENSATE PLUMBING
(Plumbing must be vented higher than coil.)
NIPPLE
ADAPTER
CONDENSATE TRAP
NIPPLE
ADAPTER
PLUG BOOT OR CAP
FIGURE 21
FIGURE 22
6 - Connect condensate drain line (1/2 inch [13mm] SDR
11 plastic pipe or tubing) to condensate connection on drip leg assembly and route to open drain. Condensate line must be sloped downward away from drip leg to drain. If drain level is above drip leg, condensate pump must be used to condensate line. Condensate drain line should be routed within the conditioned space to avoid freezing of condensate and blockage of drain line. If this is not possible, a heat cable kit may be
Page 14
used on the condensate drip leg and line. Heating cable kit is available from Lennox in various lengths;
6feet (1.8m) - kit no. 18K48; 24 feet (7.3m) - kit no.
18K49; and 50 feet (15.2m) - kit no. 18K50.
Gas Piping
1 - Gas piping may be routed into the unit through either the left- or right-hand side. Supply piping enters into the gas valve from the bottom of the valve as shown in figure 23.
LEFT SIDE PIPING
MANUAL
MAIN SHUT-
OFF
VALVE
1/8 IN. NPT
PLUGGED
TAP
GAS VALVE
RIGHT SIDE PIPING
(STANDARD)
MANUAL
MAIN SHUT-
OFF
VALVE
1/8 IN. NPT
PLUGGED
TAP
GAS VALVE
FIGURE 23
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 5 lists recommended pipe sizes for typical applications.
NOTE - Use two wrenches when connecting gas pipĆ ing to avoid transferring torque to the manifold.
3 - The gas piping must not run in or through air ducts, clothes chutes, gas vents or chimneys, dumb waiters or elevator shafts. Center gas line through piping hole.
Gas line should not touch side of unit.
When left-hand gas plumbing is required, gas line should be installed in the lower half of knockout so that piping will clear combustion air inducer. See figure 23.
4 - The piping should be sloped 1/4 inch (6.4 mm) per 15 feet (4.57 m) upward toward the meter from the furĆ nace. The piping must be supported at proper interĆ vals [every 8 to 10 feet (2.44 to 3.01 m)] using suitable hangers or straps. A drip leg should be installed in verĆ tical pipe runs to the unit.
5 - In some localities, codes may require installation of a manual main shut-off valve and union (furnished by inĆ staller) external to the unit. Union must be of the ground joint type.
IMPORTANT
Compounds used on threaded joints of gas piping must be resistant to the actions of liquified petroĆ leum gases.
MANUAL MAIN SHUT-OFF
NORMAL TEST PRESSURE
1/8 IN. (3.2mm) N.P.T.
PLUGGED TAP
CAP
FURNACE
FIGURE 24
NOTE - Install a 1/8 inch NPT plugged tap in the field pipĆ ing upstream of the gas supply connection to the unit.
The tap must be accessible for test gauge connection.
See figure 24.
Leak Check
After gas piping has been completed, carefully check all piping connections (factory and field) for gas leaks. Use a leak detecting solution or other preferred means.
CAUTION
Some soaps used for leak detection are corrosive to certain metals. Carefully rinse piping thoroughly afĆ ter leak test has been completed. Do not use matches, candles, flame or other sources of ignition to check for gas leaks.
Page 15
Nominal
Iron Pipe Size
-Inches(mm)
Internal
Diameter
-Inches(mm)
10
(3.048)
TABLE 5
GAS PIPE CAPACITY - FT 3 /HR (kL/HR)
20
(6.096)
30
(9.144)
40
(12.192)
Length of Pipe-Feet(m)
50
(15.240)
60
(18.288)
70
(21.336)
80
(24.384)
1/4
(6.35)
3/8
(9.53)
1/2
(12.7)
3/4
(19.05)
1
(25.4)
1-1/4
(31.75)
1-1/2
(38.1)
2
(50.8)
2-1/2
(63.5)
3
(76.2)
4
(101.6)
.364
(9.246)
.493
(12.522)
.622
(17.799)
.824
(20.930)
1.049
(26.645)
1.380
(35.052)
1.610
(40.894)
2.067
(52.502)
2.469
(67.713)
3.068
(77.927)
4.026
(102.260)
43
(1.13)
95
(2.69)
175
(4.96)
360
(10.19)
680
(19.25)
1400
(39.64)
2100
(59.46)
3950
(111.85)
6300
(178.39)
11000
(311.48)
23000
(651.27)
29
(.82)
65
(1.84)
120
(3.40)
250
(7.08)
465
(13.17)
950
(26.90)
460
(41.34)
2750
(77.87)
4350
(123.17)
7700
(218.03)
15800
(447.39)
24
(.68)
52
(1.47)
97
(2.75)
200
(5.66)
375
(10.62)
770
(21.80)
1180
(33.41)
2200
(62.30)
3520
(99.67)
6250
(176.98)
12800
(362.44)
20
(.57)
45
(1.27)
82
(2.32)
170
(4.81)
320
(9.06)
660
(18.69)
990
(28.03)
1900
(53.80)
3000
(84.95)
5300
(150.07)
10900
(308.64)
18
(.51)
40
(1.13)
73
(2.07)
151
(4.28)
285
(8.07)
580
(16.42)
900
(25.48)
1680
(47.57)
2650
(75.04)
4750
(134.50)
9700
(274.67)
16
(.45)
36
(1.02)
66
(1.87)
138
(3.91)
260
(7.36)
530
(15.01)
810
(22.94)
1520
(43.04)
2400
(67.96)
4300
(121.76)
8800
(249.18)
NOTE-Capacity given in cubic feet of gas per hour (kilo liters of gas per hour) and based on 0.60 specific gravity gas.
15
(.42)
33
(.73)
61
(1.73)
125
(3.54)
240
(6.80)
490
(13.87)
750
(21.24)
1400
(39.64)
2250
(63.71)
3900
(110.43)
8100
(229.36)
14
(.40)
31
(.88)
57
(1.61)
118
(3.34)
220
(6.23)
460
(13.03)
690
(19.54)
1300
(36.81)
2050
(58.05)
3700
(104.77)
7500
(212.37)
The furnace must be isolated from the gas supply system by closing its individual manual shutĆoff valve during any pressure testing of the gas supply system at pressures less than or equal to 1/2 psig (3.48 kPa, 14 inches w.c.).
90
(27.432)
13
(.37)
29
(.82)
53
(1.50)
110
(3.11)
205
(5.80)
430
(12.18)
650
(18.41)
1220
(34.55)
1950
(55.22)
3450
(97.69)
7200
(203.88) tion purposes. Refer to figure 29 for control box arrangeĆ ment, figure 30 for a detail of the Surelightt integrated control, figure 31 for schematic wiring diagram and trouĆ bleshooting, and figure 32 for point to point field wiring.
ELECTROSTATIC DISCHARGE (ESD)
Precautions and Procedures
100
(30.480)
12
(.34)
27
(.76)
50
(1.42)
103
(2.92)
195
(5.52)
400
(11.33)
620
(17.56)
1150
(32.56)
1850
(52.38)
3250
(92.03)
6700
(189.72)
IMPORTANT
When testing pressure of gas lines, gas valve must be disconnected and isolated. See figure 24. Gas valves can be damaged if subjected to pressures greater than 1/2 psig (3.48 kPa).
Electrical
A field make-up box is provided for line voltage wiring. Line voltage wiring to unit is done through the J69 jack from the field make-up box to plug P69 from the control box. See figĆ ures 25 and 26 for make-up box installation.
Figure 28 shows thermostat designations for identificaĆ
CAUTION
Electrostatic discharge can affect electronic comĆ ponents. Take precautions during furnace installaĆ tion and service to protect the furnace's electronic controls. Precautions will help to avoid control exĆ posure to electrostatic discharge by putting the furĆ nace, the control and the technician at the same electrostatic potential. Neutralize electrostatic charge by touching hand and all tools on an unĆ painted unit surface, such as the gas valve or blowĆ er deck, before performing any service procedure.
1 - Install field make-up box on either side, inside or out of the cabinet. Knockouts are provided in box and cabiĆ net to run wiring. See figures 25 and 26.
Page 16
INTERIOR MAKE-UP BOX INSTALLATION
MAKE-UP
BOX
BUSHING
J69
P69 from
Control Box
FIGURE 25
EXTERIOR MAKE-UP BOX INSTALLATION
MAKE-UP
BOX
BUSHING
J69
(Shown with accessory wire connected)
P69 from
Control Box
FIGURE 26
2 - Remove cap from knockout in blower deck on the same side as the installed make-up box.
IMPORTANT
Ignition control will not operate unless unit is properĆ ly grounded. 120V supply must be installed with corĆ rect polarity.
3 - Electrically ground unit in accordance with local codes or, in the absence of local codes, in accordance with the current National Electric Code (ANSI/NFPA No.
70) and in Canada with the current Canadian Electric
Code part 1 (CSA standard C22.1). The ground wire is pro-vided in the field make-up box.
To ensure proper grounding of the furnace, two star washers are included in the electrical make-up box bag assembly. Place the star washer on securing screw before installing the make-up box. Make sure the star washer breaks the paint on the cabinet so that the washer is touching metal. Unit is not properly grounded if paint has not been removed by star washer.
4 - An optional 120 volt accessory wire is provided with
G26 units. Install brown accessory wire into J69 jack plug by inserting the pin of the brown wire into the open socket of the jack. See fig-
INSTALLING BROWN
ACCESSORY WIRE TO J69 ure 27. Any accessory rated up to 4 amps can be connected to this wire. Connect the neutral leg of the accesĆ sory to the neutral white wire in the make-up box. The acĆ cessory terminal is enerĆ gized whenever the blower is in operation.
5 - Insert the three-pin (P69)
WHITE
NEUTRAL
BLACK
J69
BROWN plug from the control box
FIGURE 27 into the knockout provided in the blower deck.
6 - Connect jack (J69) from make-up box to jack plug in blower deck.
7 - Select wire size according to the blower motor amps.
8 - Snaphole bushing is provided for the wiring entry hole in the cabinet. A snaphole plug is provided to seal the unused wire entry hole.
9 - Install room thermostat according to instructions provided with thermostat. See figure 28 for thermostat desĆ ignations. If furnace is being used with heat pump refer to FM21 installation instruction.
10 - Install a separate fused disconnect switch near the unit so power can be turned off for servicing.
G26 and CONDENSING UNIT
THERMOSTAT DESIGNATIONS
(Refer to specific thermostat and outdoor unit.)
Thermostat G26
Furnace
Condensing Unit
Y
COOLING
Y
COMPRESSORā
HS UNIT
COMPRESSOR
INDOOR BLOWER
HEAT
W W
POWER
COMMON COMMON
HS UNIT
COMMON
FIGURE 28
11 - Complete wiring connections to equipment using wirĆ ing diagrams provided with unit and in figures 31 and
32. Use 18-gauge wire or larger for thermostat conĆ nections.
Page 17
Indoor Blower Speeds (Refer to Figure 31)
1 - When the thermostat is set to FAN ON," the indoor blower will run continuously on low speed when there is no cooling or heating demand.
2 - When there is a cooling demand, the indoor blower will run on the cooling speed.
3 - When there is a heating demand, the indoor blower will run on the heating speed.
G26 CONTROL BOX
TRANSFORMER
CIRCUIT
BREAKER
DOOR
INTERLOCK
SWITCH
SURELIGHT
CONTROL
FIGURE 29
DETACHABLE
TERMINAL STRIP
2
SURELIGHT INTEGRATED CONTROL BOARD
ACB COOL
ACB HEAT
PARK
ACB LOW
ACC
TX
HOT
HTG ACC
NEUTRALS
24VAC HOT
24VAC RTN
FLAME SENSE
TERMINAL DESIGNATIONS
Blower - Cooling Speed (Line Volt)
Blower - Heating Speed (Line Volt)
Alternate Blower Speeds (Dead)
Continuous Low Speed Blower
Accessory Terminal (Line Volt)
120VAC Hot to Transformer
120VAC Hot Input
Heat Only Accessory (Line Volt)
120VAC Neutrals
24VAC Hot from Transformer
24VAC Return from Transformer
Flame Sense Terminal
FIGURE 30
Page 18
OUTDOOR
UNIT
TYPICAL G26 WIRING DIAGRAM
B6
COMBUSTION
AIR INDUCER
MOTOR
FIGURE 31
Page 19
THERMOSTAT
W R Y G
TYPICAL G26 FIELD WIRING DIAGRAM
FLAME
ROLLOUT
SWITCH
COMBUSTION
AIR PROVE
SWITCH
LIMIT IGNITION
CONTROL
FIELD
MAKE-UP
BOX
GAS
VALVE
COMBUSTION
AIR INDUCER
J69
BLACK
WHITE
BROWN
TRANSFORMER
L1 N GND
Y G W R
SURELIGHT CONTROL
C
CONTROL
BOX
DOOR
INTERLOCK
SWITCH
TO ACCESSORY IF USED.
(ELECTRONIC AIR CLEANER)
IF NOT NEEDED, DO NOT INSTALL
ACCESSORY WIRE IN J69.
TO COMPRESSOR
CONTACTOR
FIELD INSTALLED CLASS II 24V VOLTAGE
FIELD INSTALLED LINE VOLTAGE
Unit Start-Up
FOR YOUR SAFETY READ BEFORE LIGHTING
WARNING
Do not use this furnace if any part has been underwaĆ ter. 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.
FIGURE 32
Gas valve may be equipped with either a gas control knob or lever. Use only your hand to push in or turn the gas conĆ trol knob or move the gas control lever. Never use tools. If the knob will not push in or turn or if lever will not move by hand, do not try to repair it, call a qualified service techniĆ cian. Force or attempted repair may result in a fire or exploĆ sion.
G26 units are equipped with a SureLightt ignition sysĆ tem. Do not attempt to manually light burners on this furĆ nace. Each time the 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 SureLightt ignition system.
Gas Valve Operation (Figure 33) WARNING
If overheating occurs, or if gas supply fails to shut off, shut off the manual gas valve to the appliance beĆ fore shutting off electrical supply.
WARNING
If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or death.
CAUTION
Before attempting to perform any service or mainteĆ nance, turn the electrical power to unit OFF at disĆ connect switch.
BEFORE OPERATING 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.
1 - STOP! Read the safety information at the beginning of this section.
2 - Set thermostat to lowest setting.
3 - Turn off all electrical power to furnace.
4 - This furnace is equipped with an ignition device which automatically lights the burner. Do not try to light the burners by hand.
5 - Remove the unit access panel.
Page 20
HONEYWELL VR8205 SERIES GAS VALVE
ON
OFF
GAS VALVE SHOWN IN OFF POSITION
WHITE RODGERS
36E GAS VALVE
GAS VALVE
SHOWN
IN OFF
POSITION
FIGURE 33
6 - White Rodgers 36E Gas Valve - Switch gas valve leĆ ver to OFF. See figure 33.
Honeywell VR8205 Gas Valve - Turn knob on gas valve clockwise to OFF. Do not force. See figure
33.
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 instrucĆ tions. If you do not smell gas go to next step.
8 - White Rodgers 36E Gas Valve - Switch gas valve lever to ON.
Honeywell VR8205 Gas Valve - Turn knob on gas valve counterclockwise to ON. Do not force.
9 - Replace unit access panel.
10- Turn on all electrical power to unit.
11- Set thermostat to desired setting.
NOTE - When unit is initially started, steps 1 through 11 may need to be repeated to purge air from line.
NOTE - On initial start-up and when condensate trap is dry, unit may turn itself off and on to allow condensate trap to fill. This is normal operation.
12- If the furnace will not operate, follow the instructions
To Turn Off Gas To Unit" and call your service techniĆ cian or gas supplier.
To Turn Off Gas To Unit
1 - Set thermostat to lowest setting.
2 - Turn off all electrical power to unit if service is to be perĆ formed.
3 - Remove heat section access panel.
4 - On Honeywell VR8205 gas valves, turn knob on gas valve clockwise to OFF. For White Rodgers 36E gas valves, move switch to OFF. Do not force.
5 - Replace the unit access panel.
Gas Pressure Adjustment
Gas Line Pressure
Check gas line pressure with unit firing at maximum rate. A minimum of 4.5 inches w.c. (1.12kPa) for natural gas or 8.5
inches w.c. (2.11kPa) for LP/propane gas should be mainĆ tained.
Gas Manifold Pressure
After line pressure has been checked and adjusted, check regulator pressure. See table 6 for correct manifold presĆ sures for LP/propane and natural gas at altitudes in a range of 0 to 7500 feet (0 to 2248m).
TABLE 6
Unit (Fuel)
Manifold Pressure (outlet) from 0 to 7500 ft. (0 to 2248m) above sea level
Natural
L.P./Propane
3.5" w.c. (.87 kPa)
7.5" w.c. (1.86 kPa)
WARNING
Do not set manifold pressure for LP/propane higher than 7.5 inches w.c. (1.8kPa).
HONEYWELL GAS VALVE
GAS VALVE
CONTROL KNOB
WIRING
TERMINALS
INLET
PRESSURE
TAP
OUTLET
PRESSURE
TAP
OUTLET
FIGURE 34
BARBED
FITTING FOR
PRESSURE
SWITCH
HOSE
PRESSURE
REGULATOR
(UNDER CAP SCREW)
Page 21
WHITE RODGERS 36E GAS VALVE
REGULATOR ADJUSTMENT SCREW LOCATION
FIGURE 35
REGULATOR
COVER SCREW
ADJUSTING
SCREW
Manifold Pressure Measurement & Adjustment
NOTE - Pressure test adaptor kit (10L34) is available from
Lennox to facilitate manifold pressure measurement.
1 - Connect test gauge to outlet tap on gas valve.
2 - Disconnect pressure sensing hose from gas valve and plug hose by covering opening with tape or equivalent.
Leave barbed fitting on valve open to atmosphere.
See figure 36.
DIFFERENTIAL PRESSURE SWITCH CIRCUITRY
TEE
BURNER
BOX
DIFFERENTIAL
PRESSURE
SWITCH
HOSE
BARB
COMBUSTION
AIR PRESSURE
SENSING HOSE
BURNER
BOX
SENSING
HOSE
GAS
VALVE
SENSING
HOSE
GAS
VALVE
COMBUSTION
AIR INDUCER PRESSURE
SWITCH
SENSING
HOSE
LEFT SIDE OF PRESSURE SWITCH = MORE NEGATIVE
RIGHT SIDE OF PRESSURE SWITCH = LESS NEGATIVE (Closer to Zero)
FIGURE 36
3 - Start unit and allow 5 minutes for unit to reach steady state.
4 - Examine the burner flame. The flame should be stable and should not lift from the burner. Natural gas should burn blue. L.P./propane gas should burn mostly blue with some orange streaks.
5 - After allowing unit to stabilize for 5 minutes, record manifold pressure and compare to values given in table 6.
Page 22
NOTE - Shut unit off and remove manometer as soon as an accurate reading has been obtained. Take care to replace pressure tap plug.
NOTE - During this test procedure, the unit unit will be overfiring:
D
Operate unit only long enough to obtain accurate reading to prevent overheating heat exchanger.
D
Attempts to clock gas valve during this procedure will be inaccurate. Measure gas flow rate only during nor-mal unit operation.
6 - When test is complete remove obstruction from hose and return hose to gas valve barbed fitting.
Gas Flow
To check for proper gas flow to the combustion chamber, deĆ termine the Btu (kW) input from the unit rating plate. Divide this input rating by the Btu (kW) per cubic foot (cubic meter) of available gas. The result is the required number of cubic feet (cubic meter) per hour. Determine the flow of gas through the gas meter for two minutes and multiply by 30 to get the hourly flow of gas.
High Altitude Information
Unit does not need gas pressure adjustment when operating from 0 to 7500 feet (0 to 2248m). See table 6 for correct manĆ ifold pressures for LP/propane and natural gases.
Other Unit Adjustments
Natural to LP/Propane Changeover
A natural gas to LP/propane gas changeover kit is required to convert unit. Refer to installation instructions supplied with kit for conversion procedure.
Heat Anticipation Settings
Thermostat anticipator setting (if adjustable) should be set according to amps listed on wiring diagram on unit.
Flame Rollout Switch
Factory set: No adjustment necessary.
Limit Control
Factory set: No adjustment necessary.
Pressure Switch
Factory set: No adjustment is necessary.
Fan Control
The fan-on delay of 45 seconds is not adjustable. The fanoff delay (time that the blower operates after the heating demand has been satisfied) can be adjusted by moving the jumper on the SureLightt integrated control. The unit is shipped with a factory fan-off delay of 90 seconds. The fanoff delay will affect comfort and is adjustable to satisfy indiĆ vidual applications. See figure 37.
60sec.
FANĆOFF TIME ADJUSTMENT
90sec.
120sec.
180sec.
To adjust fan-off timing, flip dip switch to desired setting.
FIGURE 37
Temperature Rise
Check temperature rise and, if necessary, adjust blower speed to maintain temperature rise within range shown on unit rating plate.
Electrical
1 - Check all wiring for loose connections.
2 - Check circuit breaker located on unit control box.
3 - Check for correct voltage at the furnace (furnace operĆ ating).
4 - Check amp-draw on blower motor.
Motor Nameplate __________Actual__________.
NOTE - Do not secure electrical conduit directly to ducting or structure.
Blower Speeds
Refer to blower speed selection chart on unit wiring diagram.
NOTE - CFM readings are taken external to unit with a dry evaporator coil, filter installed and without any other accesĆ sories.
Electronic Ignition
The SureLightt integrated control has an added internal watchguard feature. The feature serves as an automatic reset device for ignition controls locked out because the burner has failed to light. This type of nuisance lockout is usually attributed to low gas line pressure. After one hour of continuous thermostat demand for heat, the watchguard will break and remake thermostat demand to the furnace and automatically reset the control to relight the furnace.
Burner Flame
Burner Flame -- Start burner and allow to operate for a few minutes to establish normal burning conditions. Check burner flame by observation. Flame should be predomiĆ nantly blue and strong in appearance.
Check burner flame periodically to ensure proper operation.
Service
WARNING
Disconnect power before servicing unit.
CAUTION
Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.
Annual Service
At the beginning of each heating season, system should be checked as follows by a qualified service technician:
Electrical
1 - Check all wiring for loose connections.
2 - Check circuit breaker located on unit control box.
3 - Check for correct voltage at unit (unit operating).
4 - Check amp-draw on blower motor.
Motor Nameplate_________Actual_________
5 - Check to see that heat (if applicable) is operating.
Blower
Check the blower wheels for debris and clean if necessary.
The blower motors are prelubricated for ex-tended bearing life. No further lubrication is needed.
Filters
1 - Filters must be cleaned or replaced when dirty to assure proper furnace operation.
2 - Reusable foam filters used with G26 can be washed with water and mild detergent. When dry, they should be sprayed with filter handicoater prior to reinstallaĆ tion. Filter handicoater is RP Products coating no. 418 and is available as Lennox part no. P-8-5069.
3 - If replacement is necessary, order Lennox part no.
31J81 for 14 inch x 25 inch (356 x 635mm) filter for
G26-50 and -75 units and P-8-7831 for 20 inch x 25 inch (508 x 635mm) filter for G26Q4/5-75, G26-100 and -125 units.
Intake and Exhaust Lines
Check intake and exhaust lines and all connections for tightness and make sure there is no blockage. Also check condensate line for free flow during operation.
Insulation
Outdoor piping insulation should be inspected yearly for deterioration. If necessary, replace with same materials.
Winterizing and Condensate Trap Care
1 - Turn off power to unit.
2 - Have a shallow pan ready to empty condensate water.
Avoid spilling water into the control box.
3 - Remove clamp from flue assembly and remove boot or cap. Empty water from cap. Visually inspect bottom of flue assembly. Replace boot and clamp.
4 - Remove boot from condensate trap and empty water.
Inspect trap then replace boot.
Cleaning DuralokPlus TM Heat Exchanger
If it is necessary to clean the heat exchanger, follow the proĆ cedure below and refer to figure 1 when disassembling the unit. Use papers or protective covering in front of furnace while removing heat exchanger assembly.
1 - Turn off electrical and gas power supplies to furnace.
2 - Remove upper and lower furnace access panels.
3 - Remove four screws around air intake fitting and lift inĆ take pipe up and away.
4 - Loosen hose clamp securing top of flue transition to bottom of flue collar. Remove screw securing flue colĆ lar to top cap and lift exhaust pipe and flue collar up and away.
5 - If electrical field makeĆup box is located inside the unit, it must be removed.
6 - Remove gas supply line connected to gas valve.
Page 23
7 - Mark all gas valve wires and disconnect them from valve. Mark and remove wires from flame rollĆout switch.
8 - Remove top cap of unit.
9 - Remove sensor wire from SureLightt control. DisĆ connect 2Ćpin plug from the ignitor.
10- Mark and disconnect pressure switch tubing from both sides of the pressure switch.
11 - Loosen two screws holding gas manifold support at vestibule panel.
12 - Remove four burner box screws at the vestibule panel and remove burner box and gas valve/manifold asĆ sembly with bracket.
13 - Drain condensate trap. Disconnect condensate line from the outside of unit. Remove condensate line from condensate trap by turning the adapter fitting counterĆ clockwise. The fitting has standard right-hand threads.
14 - Disconnect the drain hose from the flue transition to the elbow on the cold header (collector) box trap.
15 - Disconnect the 2Ćpin plug from the combustion air inĆ ducer at the blower deck. Remove four screws from combustion air inducer and remove flue transition and inducer assembly from cabinet. Take care not to lose the combustion air orifice.
16 - Disconnect 9Ćpin plug from the blower compartment at the blower deck.
17 - Remove 9Ćpin plug above the blower deck.
18 - Remove the limit switch and the pressure switch from the vestibule panel.
19 - Remove two screws from the front cabinet flange at the blower deck. Remove front screws from cabinet at blower deck on left and right sides. Cabinet sides must be slightly spread to clear heat exchanger passage.
20 - Remove screws along vestibule sides and bottom which secure vestibule panel and heat exchanger asĆ sembly to cabinet. Remove heat exchanger.
21- Back wash heat exchanger with soapy water solution or steam. If steam is used it must be below 275°F
(135°C) .
22 - Thoroughly rinse and drain the heat exchanger. Soap solution can be corrosive so take care that entire asĆ sembly is completely rinsed.
23 - Re-install heat exchanger into cabinet making sure that the clamshells of the heat exchanger assembly are resting in the notches of the support located at the rear of the cabinet. This can be viewed by removing the indoor blower and examining through the blower opening.
24 - ReĆsecure the supporting screws along the vestibule sides and bottom to the cabinet.
25 - ReĆinstall cabinet screws on sides and front flange at blower deck.
26 - ReĆinstall the limit switch and pressure switch on the vestibule panel.
27 - ReĆinstall 9Ćpin plug to blower deck and connect it to the 9Ćpin plug from below the blower deck.
28 - ReĆinstall the combustion air inducer. Check the plasĆ tic orifice in the inducer inlet to make sure it has not fallen out. See figure 1. Reconnect the 2Ćpin plug to the wire harness. ReĆinstall the flue transition in the cabinet and reĆattach the drain tube. Route the drain tube below the combustion air inducer housing and to the elbow on the cold header (collector) box trap. See figure 36.
29 - ReĆinstall condensate line with adapter to condensate trap. Use fresh Teflon tape to ensure a leak-free joint.
ReĆconnect to condensate line outside of the unit.
30 - ReĆinstall the burner box. Tighten the screws holding the support bracket. It is important that the glass fiber gasket not be damaged so it will provide a continuous seal between the burner box and the vestibule panel.
31 - With the pressure switch mechanism oriented on the right, reconnect pressure switch tubing by connecting the tubing from the burner box to the barbed fitting on the bottom. Connect the tubing from the combustion air inducer to the barbed fitting on the top. See figure
36.
32 - Reconnect the sensor and ignitor wires.
33 - ReĆinstall top cap to unit.
34 - ReĆinstall electrical connections to gas valve. Orange wire to M1 and yellow wire to C2. Reconnect wires to flame rollĆout switch.
NOTE - Unit is polarityĆsensitive. 120V supply wiring must be installed correctly.
35 - Reconnect main gas line to gas valve.
36 - ReĆinstall field makeĆup box if removed.
37 - ReĆinstall exhaust pipe/flue collar and secure flue colĆ lar to the unit top cap using existing screw. Insert the bottom of the flue collar into the top of the flue transiĆ tion and tighten hose clamp.
38 - ReĆinstall intake pipe fitting to burner box with screws.
39 - Replace both upper and lower access panels.
40 - Refer to instruction on verifying gas and electrical conĆ nections when reĆestablishing supply.
41 - Following lighting instructions from installation manuĆ al, light and run unit for 5 minutes to ensure heat exĆ changer is clean, dry and operating safely.
Cleaning the Burner Assembly
1 - Turn off electrical and gas power supplies to furnace.
Remove upper and lower furnace access panels.
2 - Disconnect the gas supply line to gas valve. DependĆ ing on gas plumbing installation, the gas manifold may move aside enough that breaking the union may not be necessary.
3 - Remove five screws from edges of burner box cover.
G26-50 units have only four screws.
4 - Loosen two screws on bottom of burner box front. The cover is key holed at these screw point so screws do not need to be removed. Pull off cover and set aside.
6 - Mark all gas valve wires and disconnect them from valve.
7 - Mark and disconnect sensor wires from the burner box at the ignition control. Disconnect 2Ćpin plug from the ignitor at the burner box.
Page 24
8 - Loosen two screws at the gas manifold support brackĆ et.
9 - Pull on the left side of the gas manifold and follow with tension to the right side. The manifold support bracket will be free of the mounting screws on the vestibule panel. Set the gas manifold/gas valve assembly aside.
Take care not to damage foam gaskets on each end of the gas manifold.
10 - Using a 1/4 inch nut driver, remove the burner mountĆ ing screws from underneath the burners.
11 - While supporting ignitor and sensor lines at the gromĆ met, grasp burners and simultaneously pull burners and grommet out of the burner box.
12 - Remove ignitor and sensor bracket assemblies from burners using a 1/4 inch nut driver to remove two screws from each bracket.
13 - Clean burner by running a vacuum with a soft brush atĆ tachment over face of burners. Visually inspect inside of burners and crossovers for any blockage caused by forĆ eign matter. Remove any blockage.
14 - ReĆinstall ignitor and sensor bracket assemblies on burners.
NOTE - Ignitor must be installed on the opposite side of the burner from the metal button protrusions. Screws which attached the ignitor bracket must be installed from the same side as the ignitor and through the brackĆ et to engage in the smaller holes located in the burner.
The correct burner orientation is with metal button proĆ trusions always pointing up.
15 - Replace burner ignitor assembly back into burner box so that grommet groove fits back into sheet metal notch and makes a good seal. The burners sit on top of the burner box flanges. Make certain that the screws from the underneath the box pass through the larger holes in the flange and engage in the smaller holes in the burner. ReĆinstall the two screws.
16 - ReĆinstall the gas manifold/gas valve assembly by first inserting the right hand side of the gas manifold into the burner box. Swing left side of manifold into box while engaging support bracket to vestibule panel screws. Check that foam gaskets are providing a seal around each end of the gas manifold. All gas orifices should be engaged. If at this point the burners were mounted in the wrong holes, this needs to be corĆ rected. The saddle brackets on the gas manifold should be flush with the front surfaces on the burner box sides.
17 - Inspect the dual layered metal pieces at the front lip of the cover. These pieces must sandwich around the metal. ReĆinstall burner box cover.
18 - ReĆinstall the screws to secure the burner box cover.
Make sure screws are tight to ensure a leak tight burnĆ er box. Tighten the two screws underneath the box.
Again, inspect the grommet to ensure a tight seal.
19 - Tighten the two screws holding the manifold bracket to the vestibule panel.
20 - ReĆinstall the electrical connections to the gas valve.
Orange wire to M1 and yellow wire to C2.
21 - ReĆinstall the 2Ćpin ignitor plug at the burner box. ReĆ install sensor line to ignition control spade connector.
22 - Reconnect gas line to gas valve.
23 - Replace lower access panel.
24 - Following lighting instructions and gas line connection test procedures from installation manual.
25 - Replace upper access panel.
Page 25
Repair Parts List
The following repair parts are available through Lennox dealers. When ordering parts, include the complete furnace model number listed on the unit rating plate. Example: G26Q3-75.
CABINET PARTS
Cabinet cap
Blower panel
Upper access panel
CONTROL PANEL PARTS
Surelightt integrated control
Transformer
Circuit breaker
Door interlock switch
BLOWER PARTS
Blower wheel
Motor
Motor mounting frame
Motor capacitor
Blower housing cutĆoff plate
Blower housing
HEATING PARTS
Heat exchanger/coil assembly
Gas manifold
Main burner orifices
Main burners
Gas valve
Ignitor
Primary limit control
Flame rollout switch
Filter and filter rack assembly
Flue transition
Pressure switch
Flame sensor
Sight glass and grommet
Rubber boot trap
Foam manifold gaskets
Combustion air inducer
Condensate pipe plug and adapter
Cold end header (collector) box
Troubleshooting
DIAGNOSTIC CODES
LED #1
SIMULTANEOUS
SLOW FLASH
SIMULTANEOUS
FAST FLASH
SLOW FLASH
OFF
LED #2
SIMULTANEOUS
SLOW FLASH
SIMULTANEOUS
FAST FLASH
ON
SLOW FLASH
DESCRIPTION
Power on -- Normal operation.
Also signaled during cooling and continuous fan.
Normal operation - signaled when heating demand initiated at thermostat.
Primary or secondary limit switch open.
Pressure switch open or has opened 5 times during a single call for heat;
OR: Blocked inlet/exhaust vent; OR: Condensate line blocked;
OR: Pressure switch closed prior to activation of combustion air inducer.
ALTERNATING
SLOW FLASH
SLOW FLASH
ON
ON
ON
OFF
FAST FLASH
ALTERNATING
SLOW FLASH
OFF
SLOW FLASH
ON
OFF
ON
SLOW FLASH
Watchguard -- burners failed to ignite.
Flame sensed without gas valve energized.
Rollout switch open. OR: 9Ćpin connector improperly attached.
Circuit board failure or control wired incorrectly.
Main power polarity reversed. Switch line and neutral.
SLOW FLASH
ALTERNATING
FAST FLASH
FAST FLASH
ALTERNATING
FAST FLASH
Low flame signal. Measures below .7 microAmps. Replace flame sense rod.
Improper main ground or line voltage below 75 volts;
OR: Broken ignitor; OR: Open ignitor circuit.
NOTE - Slow flash equals 1 Hz (one flash per second). Fast flash equals 3 Hz (three flashes per second).
Minimum flame sense current = 0.15 microAmps.
Page 26
Troubleshooting
SURELIGHT CONTROL
HEATING SEQUENCE OF OPERATION
NORMAL HEATING MODE
POWER ON
CONTROL SELF-CHECK OKAY?
COMBUSTION AIR INDUCER ON FOR 1 SECOND.
NO
LED#1 AND LED#2
ALTERNATING FAST
FLASH. SIGNAL
HOLDS UNTIL UNIT IS
PROPERLY GROUND.
TURN INDUCER ON FOR 1 SECOND.
IS POLARITY REVERSED?
NO
NO
IS THERE
PROPER GROUND?
YES
YES
IS VOLTAGE
ABOVE 75 VOLTS?
ABNORMAL HEATING MODE
GAS VALVE OFF. COMBUSTION AIR INDUCER ON.
INDOOR BLOWER ON.
LED #1 ALTERNATING FAST FLASH
LED#2 ALTERNATING FAST FLASH
CHECK FOR BROKEN IGNITOR OR
OPEN IGNITOR CIRCUIT
GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.
INDOOR BLOWER DELAY OFF.
LED #1 ON
LED #2 ON
(RESET CONTROL BY TURNING MAIN POWER OFF.)
NO
POLARITY REVERSED.
LED #1 -- FAST FLASH
LED #2 -- SLOW FLASH
ROLLOUT SWITCH CLOSED?
YES
YES
NO
LED#1 AND LED#2 ALTERNATING FAST
FLASH. SIGNAL HOLDS UNTIL VOLTAGE
RISES ABOVE 75 VOLTS.
NO
GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.
INDOOR BLOWER OFF WITH DELAY.
LED #1 -- ON. LED #2 -- SLOW FLASH.
SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES.
BURNER OFF?
(CONTINUOUS FLAME CHECK)
YES
NORMAL OPERATION:
LED #1 -- SLOW FLASH
LED #2 -- SLOW FLASH
GAS VALVE OFF. COMBUSTION AIR INDUCER ON.
INDOOR BLOWER ON HEATING SPEED.
LED #1 -- SLOW FLASH
LED #2 -- OFF
THERMOSTAT CALLS FOR HEAT:
LED #1 -- FAST FLASH
LED #2 -- FAST FLASH
YES
IS COMBUSTION AIR
PRESSURE SWITCH OPEN?
YES
IS COMBUSTION AIR INDUCER ENERGIZED?
(HTG ACC TERMINAL IS ENERGIZED WITH C.A.B.)
YES
HAS COMBUSTION AIR PRESSURE
SWITCH CLOSED IN 2.5 MINUTES?
YES
15ĆSECOND COMBUSTION AIR INDUCER PREPURGE
INITIATED BY CLOSED PRESSURE SWITCH.
YES
CONTINUED NEXT PAGE
NO
NO
GAS VALVE OFF.
COMBUSTION AIR INDUCER OFF.
INDOOR BLOWER OFF WITH DELAY.
LED #1 OFF
LED #2 SLOW FLASH
(Sequence holds until pressure switch closes or thermostat resets control.)
PRESSURE SWITCH IS IN WATCHGUARD MODE.
GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.
INDOOR BLOWER OFF WITH DELAY.
LED #1 -- OFF. LED #2 -- SLOW FLASH.
IS 5ĆMINUTE RESET PERIOD COMPLETE?
Page 27
Troubleshooting
NORMAL HEATING MODE
15ĆSECOND COMBUSTION AIR INDUCER PREPURGE
INITIATED BY CLOSED PRESSURE SWITCH.
YES
IGNITOR WARMĆUP -- 20 SECONDS.
YES
4ĆSECOND TRIAL FOR IGNITION.
GAS VALVE OPENS. IGNITOR IS ENERGIZED
YES
FLAME STABILIZATION PERIOD.
4 SECONDS
FLAME RECTIFICATION CURRENT
CHECK. CAN FLAME BE PROVEN WITHIN
4 SECONDS AFTER GAS VALVE OPENS?
(u0.15 microamps)
YES
FLAME PRESENT?
YES
FLAME SIGNAL ABOVE 0.7 MICROAMPS?
YES
INDOOR BLOWER ON DELAY BEGINS
(45 seconds.)
YES
PRIMARY AND SECONDARY LIMIT
SWITCHES CLOSED?
YES
ABNORMAL HEATING MODE
NO
YES
IS VOLTAGE ABOVE 75 VOLTS?
YES
IS THERE A PROPER GROUND?
NO
NO
YES
IS IGNITOR INTACT AND CONNECTED?
NO
LEDS SIGNAL
ALTERNATING
FAST FLASH
NO
GAS VALVE OFF. COMBUSTION AIR INDUCER ON.
INDOOR BLOWER OFF.
HAS CONTROL FAILED TO SENSE FLAME FOR
FIVE CONSECUTIVE TRIES DURING A SINGLE
HEAT DEMAND?
NO
NO
IGNITION WATCHGUARD MODE. GAS VALVE OFF.
COMBUSTION AIR INDUCER OFF.
INDOOR BLOWER OFF WITH DELAY
LED 1 ALT. SLOW FLASH LED 2 ALT SLOW FLASH
IS 60ĆMINUTE RESET PERIOD COMPLETE?
YES
HAS CONTROL RESET IGNITION
SEQUENCE FOUR TIMES?
YES
NO
NO LOW FLAME SIGNAL
(Does not affect operation of control)
LED #1 -- SLOW FLASH
LED #2 -- FAST FLASH
NO
GAS VALVE DE-ENERGIZED.
COMBUSTION AIR INDUCER
DE-ENERGIZED. INDOOR BLOWER
ON UNTIL SWITCH CLOSES.LED #1
-- SLOW FLASH. LED #2 -- ON.
IS LIMIT SWITCH CLOSED?
YES
HAS PRIMARY/SECONDARY LIMIT
RESET (CLOSED) WITHIN 3
MINUTES?
YES
LIMIT SWITCH WATCHĆ
GUARD MODE. GAS
VALVE OFF. COMB. AIR
INDUCER OFF. INDOOR
BLOWER OFF WITH
DELAY. LED#1-SLOW
FLASH LED#2 - ON. IS
60MINUTE RESET
PERIOD COMPLETE?
NO
YES
ROLLOUT SWITCH CLOSED?
YES
NO GAS VALVE POWER OFF.
COMBUSTION AIR INDUCER POWER OFF.
INDOOR BLOWER OFF WITH DELAY
LED #1 -- ON. LED #2 -- SLOW FLASH.
SEQUENCE HOLDS UNTIL ROLLOUT SWITCH IS RESET
COMBUSTION AIR PRESSURE
SWITCH CLOSED?
YES
THERMOSTAT DEMAND SATISFIED.
YES
LED #1 & #2 SIMULTANEOUS SLOW FLASHES.
YES
COMB. AIR INDUCER CONTINUES 5ĆSECOND
POST PURGE AFTER T'STAT DEMAND IS SATISFIED.
INDOOR AIR BLOWER COMPLETES SELECTED OFF"
DELAY BEFORE SHUTTING OFF.
NO
GAS VALVE DE-ENERGIZED.
COMBUSTION AIR INDUCER ON.
INDOOR BLOWER OFF WITH DELAY
LED #1 -- OFF. LED #2 -- SLOW FLASH.
HAS CAB SWITCH CLOSED IN 2.5 MINUTES?
NO
5ĆMINUTE PRESSURE SWITCH
WATCHGUARD MODE.
YES
YES
Page 28
Troubleshooting
SURELIGHT CONTROL
COOLING SEQUENCE OF OPERATION
NORMAL COOLING MODE ABNORMAL COOLING MODE
POWER ON
IGNITION CONTROL MAIN POWER ON.
LED#1 AND LED#2
ALTERNATING FAST
FLASH. SIGNAL
HOLDS UNTIL UNIT IS
PROPERLY GROUND.
CONTROL SELF DIAGNOSTIC CHECK.
IS CONTROL OPERATING NORMALLY?
YES
TURN INDUCER ON FOR 1 SECOND.
NO
GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.
INDOOR BLOWER OFF WITH NORMAL DELAY.
SIGNAL CIRCUIT BOARD FAILURE AT LED.
INTERRUPT MAIN POWER TO RESET CONTROL.
YES
NO
IS POLARITY REVERSED?
NO
IS THERE
PROPER GROUND?
YES IS VOLTAGE
ABOVE 75 VOLTS?
LED#1 FAST FLASH LED#2 SLOW FLASH
NO
LED#1 AND LED#2 ALTERNATING FAST
FLASH. SIGNAL HOLDS UNTIL VOLTAGE
RISES ABOVE 75 VOLTS.
ROLLOUT SWITCH MONITORED CONTINUOUSLY.
IS ROLLOUT SWITCH CLOSED?
YES
CHECK FOR MAIN BURNER FLAME SENSE.
IS MAIN BURNER FLAME OFF?
NO
NO
GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.
INDOOR BLOWER OFF WITH NORMAL DELAY.
SIGNAL CIRCUIT BOARD FAILURE AT LED.
SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES.
GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.
INDOOR BLOWER OFF WITH NORMAL DELAY.
SIGNAL CIRCUIT BOARD FAILURE AT LED.
SEQUENCE HOLDS UNTIL FLAME IS NOT SENSED.
LED: SLOW FLASH RATE REMAINS UNCHANGED
THROUGHOUT COOLING CYCLE.
THERMOSTAT CALLS FOR COOLING.
COMPRESSOR CONTACTOR AND SYSTEM FAN
ENERGIZED WITH 0ĆSECOND DELAY. ACB
COOL SPEED TERMINAL IS ENERGIZED. ACC.
TERMINAL IS ENERGIZED.
THERMOSTAT OPENS.
COMPRESSOR OFF.
SYSTEM FAN AND ACC. TERM. OFF
WITH 0ĆSECOND DELAY.
Page 29
Troubleshooting
SURELIGHT CONTROL
CONTINUOUS FAN SEQUENCE OF OPERATION
LED: SLOW FLASH RATE REMAINS
UNCHANGED THROUGHOUT SEQUENCE.
MANUAL FAN SELECTION MADE AT THERMOSTAT.
CONTROL (G) ENERGIZES INDOOR BLOWER AT
ACB LOW SPEED. ACC. TERM. IS ENERGIZED.
NO
THERMOSTAT CALLS FOR HEAT (W).
YES
NO
THERMOSTAT CALLS FOR COOLING.
YES
HTG ACC. TERM. ENERGIZES
WITH COMB. AIR INDUCER.
INDOOR BLOWER SWITCHES TO ACB HEAT
SPEED AFTER NORMAL DELAY.
INDOOR BLOWER SWITCHES TO ACB COOL SPEED.
THERMOSTAT OPENS. COMBUSTION AIR INDUCER
AND HTG ACC. TERMINAL ARE DE-ENERGIZED.
THERMOSTAT OPENS.
INDOOR BLOWER SELECTED TIME OFF DELAY BEGINS.
AFTER DELAY ACB HEAT SPEED DE-ENERGIZED.
(blower remains energized during continuous fan mode).
INDOOR BLOWER SWITCHES TO ACB LOW
SPEED. ACC. TERM. REMAINS ENERGIZED.
Page 30
G26 Start-Up & Performance Check List
Job Name
Job Location
Installer
START-UP AND PERFORMANCE CHECK LIST
Job No.
City
City
Technician Unit Model No.
Serial No.
HEATING SECTION
Electrical Connections Tight?
Supply Voltage
Blower Motor Amps
Blower Motor H.P.
Gas Piping Connections
Tight & Leak-Tested?
Fuel Type: Natural Gas? LP/Propane Gas?
Furnace Btu Input
Line Pressure
Regulator Pressure: w.c. Ċ Nat.; w.c. Ċ LP/Propane
Flue Connections Tight?
Fan Control Setting (45 Seconds Fixed On)
Fan Control Off Setting
Filter Clean & Secure?
Temperature Rise
Vent Clear?
THERMOSTAT
Heat Anticipator Properly Set?
Level?
Date
State
State
Page 31
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