PRODUCT LITERATURE
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1992 Lennox Industries Inc.
Dallas, Texas
502,754M
9/98
Supersedes 4/95
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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
vicinityofthisorany other appliance.
Installation and service must be performed by a qualified installer, service agency or the gas supplier.
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- Do not try to light any appliance.
- Extinguish any open flames.
- Do not touch any electrical switch; do not
use any phone in your building.
- Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s
instructions.
- If you cannot reach your gas supplier, call
the fire department.
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G20E / G20X PARTS IDENTIFICATION
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UPPER ACCESS
PANEL
GAS
MANIFOLD
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TOP STRIP
DRAFT
HOOD
IGNITION
CONTROL
ROLL-OUT
SWITCH
BLOCKED VENT
SHUT-OFF
SWITCH
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HEAT
EXCHANGER
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PILOT/ELECTRODE
ASSEMBLY
BURNER BOX
DAMPER ASSEMBLY
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REMOVABLE
BURNER
BOX TOP
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CONTROL
BURNER
BOX
LIMIT
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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.
Toreduce 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
WARNING
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.
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.
IMPORTANT
Any additions, changes, or conversions required
in order for the appliance to satisfactory meet the
application needs must be made by a Lennox service technician using factory specified and approved parts.
CAUTION
Before attempting to perform any service or maintenance, turn the electrical power to unit OFF at
disconnect switch.
holes, corrosion, or blockage. Inspect 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.
DO NOT
2-
unobstructed flow of combustion and ventilating air.
DO NOT
3-
introduce these products into the combustion air.
These products can cause furnace corrosion.
DO NOT draw return air from a room where this
4-
furnace, or any other gas appliance (ie., a water
heater), is installed.
aroom,anegativepressureiscreatedintheroom.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
andtheformation ofcarbon monoxidegas.This toxic
gas might then be distributed throughout the house
by the furnace duct system.
Yourfurnace is agas appliance.
suppliedto theunit becompletely burned to avoidtheproduction 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.
obstruct air flow to unit. Unit must receive an
store chlorine or fluorine products near unit or
When return air is drawn from
Itis criticalthat the gas
WARNING
Carbon monoxide gas is invisible, odorless, and
toxic.
Exposure to this gas can cause personal injury and
even death to all oc cupant s, including pets. Any item
that is powered by or gives off heat from a combustion
process(includinglawnm owers ,automobiles,andfireplaces) has the potential to produce carbon monox ide
gas. Because of this,
of acarbon monoxidedetectorin your home,even
ifyo u do not own gas applian ces.
are available at reasonable retail prices . Contac t your
independent Lennox dealer for more details about this
investment in your safety.
Lennox recommends the use
Reliabledetector s
IMPORTANT DIRECTIONS
1- Keep the furnace area clear and free of combustible
material, gasoline, and other flammable vapors and liquids. If installed in an insulated area, furnace must be
kept free of insulating material. Insulating material may
be combu sti b l e. Inspect furnace venting system to
make sure it is in place, physically sound, and without
Yourfurnace isdesignedto meet standards set bynationalagencies,andto operate safely whenproperlyinstalled
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
criticalfor your safety andthe satisfactory operationof the
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product. Lennox strongly recommends annual inspection and maintenance of this appliance. Contact
your independent Lennox dealer for an inspection by a
qualified service technician.
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LIGHTING INFORMATION AND OPERATION
WARNING
Ifyou do not follow these instructions exactly,afire
or explosion may result causing property damage,
personal injury or death.
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.
Useonly your hand to push inor turn the gas control knob
or lever.Never use tools. If the knob or lever will not push
inorturnby hand,do nottry to repairit,calla qualifiedservice technician. Force or attempted repair may result in a
fire or explosion.
To place G20E or G20X furnace into operation:
G20E or G20X units are equipped with an intermittent pilotignitionsystem. Do not
on these furnaces. Each time thermostat calls for heat,
the pilot will automatically light. The pilot does not burn
when there is no call for heaton units with electronic ignitions.
Gas Valve Operation (Figures 3 and 4)
1- STOP! Read the safety information at the beginning
of this section.
2- Set thermostat to lowest setting. See figure 2.
THERMOSTATS
3- Turn off all electrical power to appliance.
4- This appliance is equipped with an ignition device
whichautomatically lights the pilot. Donot try to light
the pilot by hand.
5- Remove control access panel.
HoneywellVR8204 Gas Valve
6-
gas valve clockwise
Robertshaw 7200Gas Valve
move to OFF position. Do not force. See figure 4.
attempt to manually light pilots
FIGURE 2
-Turn the knobonthe
to OFF. See figure 3.
-Depress theleverand
ON
OFF
GAS VALVE SHOWN IN OFF POSITION
FIGURE 3
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GAS VALVE
SELECTOR
ARM
IN OFF
POSITION
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7- Waitfive (5) minutes toclear out any gas. If youthen
smell gas, STOP! Immediately callyour gassupplier
from a neighbor’s phone. Follow the gas supplier’s
instructions. If you do not smell gas go to next step.
Honeywell VR8204 Gas Valves
8-
the gas valve counterclockwise
Robertshaw 7200Gas Valve
- Turn the knob on
to ON.
-Depress theleverand
move to ON position. Do not force.
9- Replace control 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 pilot line.
12- If the furnace still will not operate, follow the instruc-
tions “ToTurn Off Gas ToUnit” and call your service
technician 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
performed.
3- Remove control access panel.
Honeywell VR8204 Gas Valves
4-
gas valve clockwise
Robertshaw 7200 Gas Valve-De
- Turn the knob on the
to OFF.
press the lever and
move to OFF position. Do not force.
5- Replace control access panel.
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Filters
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g
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G20E and G20X series units are equipped with reusable
filters which should be inspected monthly and cleaned
whennecessary to assure proper furnace operation.See
table 1 for filter sizes. Use the following procedure to
clean filter.
1- Turn off electric power to furnace.
2- Remove blower access panel. Wait for blower to stop.
3- Remove filter by sliding up and out of filter brackets.
4- Wash filter with water and a mild detergent. For in-
creased efficiency, filter media should be sprayed
withfilter Handicoater when dry.Filter Handicoateris
RP products no. 418and is available as Lennox part
no. P-8-5069.
NOTE-If filter media must be replaced, order Lennox
part no.P-9-7831 for 20”x 25” filter,P-8-7822 for 16”
x 25” filter, 97H0601 for 18” x 25” filter, 97H0701 for
25” x25” filter, and 97H0801 for 24” x 30” filter.
5- Reinstall filter. Slide filter into top bracket and drop
into lower bracket.
NOTE-Do not replace reusable foam filters with
throw-away filters.
6- Replace blower access panel.
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Q2-50, Q3-50, Q2-75,
Q3-75,
Q4-75, Q3/4-100 16X25X1 18X25X1
Q5/6-100, Q3/4-125,
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16 X 25 X 1
20 X 25 X 1
20 X 25 X 1
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16 X 25 X 1
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Blower
Checkandclean blower wheel foranydebris. Blower motoris prelubricated forextended bearin
life.No further lu-
brication is needed.
Pilot and Burner Flame
PILOT FLAME
BURNER
PILOT GAS
LINE
(Side View)
FLAME SENSOR
ELECTRODE
(G20E & G20X)
FIGURE 7
Burner Flame
2-
a few minutes to establish normal burnin
--Start burner and allow to operate for
condi-
tions. Check burner flame by observation. Flame
should be predominantly blue in color, stron
in appearance and should rise directly from the burner
ports in the heat exchan
is burnin
from all continuous ribbon ports and that
flame does not impin
chan
er. See figure 8.
BURNER FLAME
NOTE-VIEW BURNER FLAME
THROUGH OBSERVATION PORT ON
BURNER BOX OR DAMPER OPENING
(Not Shown)
er.Check to see that flame
e on the sides of the heat ex-
FIGURE 8
VENTING SYSTEM INSPECTION
Annually (before heatingseason)inspectfurnaceventin
system, draft hood, vent cap, heat exchanger, burners
and pilot for corrosion, deterioration, or deposits of debris. Remove any obstructions.
Contact your Lennox dealer for a periodic unit inspection
by a qualified service technician.
CAUTION
Check pilot flame and burner flame periodically to
ensure proper operation.
Pilot Flame
1-
flame sensor for proper operation of pilot safety circuit. See fi
-- Pilot flame must surround the end of
ure 7.
BLOCKED VENT SHUT-OFF SYSTEM
Your Lennox furnace is equipped with a blocked vent
shut-off switch and a flame roll-out switch. The blocked
ventshut-offswitch shuts offthe
in the event of flue or vent blocka
switch shuts off the
as supply to the furnace if there is a
assupply tothe furnace
e. The flame roll-out
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blockage of the heat exchanger.If the furnace fails to operate due to the functioning of either of these switches,
DONOT attempt to placethe furnaceinto operation.Contact a qualified service person.
SERVICE REMINDER
Call your Lennox service technician if unit is inoperative.
Before calling, always check the following to be sure service is required.
ness, the cause could be exposure to carbon monoxidegas. 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.
Yourvigilance 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.
1- Check to see 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 limiting air flow.
6- Is gas turned on at meter?
7- Is manual main shut-off valve open?
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Tokeep yourLennox gas heating system in peak operating condition year after year, contact your independent
Lennox dealer about a planned service program.
If you discover any of the following, shut down your
unit, and contact an independent Lennox dealer for
an inspection by a qualified technician.
-
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.
-
If you smell any unusual odors, your unit may beoperating improperly.For example, units can give offunfamiliar odors if components are required to operate in
abnormal conditions.
-
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.
-
If you experience headache, nausea, fatigue, or dizzi-
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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, dam-
aged or sagging pipe, or disconnected joints.
Unit appearance - Must beinspected for rust, dirt, signs
of water, burnt or damaged wires, or components.
Blower access door -Must beproperlyinplace and providea seal between the return air andthe room where the
furnace is installed.
Return air duct - Must be properly attached and provide
an air seal to 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 unsafeoperation. For instance, itemsinnocently storednext
to the furnace may obstruct the combustion air supply.
This couldcauseincomplete combustion and theproduction of carbon monoxide gas.
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