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E2001 Lennox Industries Inc.
Dallas, Texas, USA
504,390M
7/2001
Supersedes 503,743M
G32
SERIES
GAS FURNACE
If the information in this manual is not
followed exactly, a fire or explosion
may result causing property damage,
personal injury or loss of life.
Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
Installation and service must be perĆ
formed by a qualified installer, service
agency or the gas supplier.
07/01
*2P0701*
Litho U.S.A.
WARNING
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 suppliĆ
er's instructions.
D If you cannot reach your gas supplier, call
the fire department.
504,390M
*P504390M*
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G32 Parts Identifications
FRESH AIR INTAKE
FLUE COLLAR
TOP CAP
FLAME SIGHT
GLASS
LOW HEAT
PRESSURE SWITCH
HIGH HEAT
PRESSURE SWITCH
(-75 models only)
HEAT
EXCHANGER
ASSEMBLY
CONNECTION
BURNERS
CABINET
GAS
MANIFOLD
UPPER ACCESS
PANEL
TWOĆSPEED
COMBUSTION AIR
BLOWER
DOOR
INTERLOCK
SWITCH
SURELIGHTt
INTEGRATED
CONTROL
TRANSFORMER
TWOĆSTAGE
CONTROL
BURNER
BOX
GAS
VALV E
CONDENSATE
TRAP
BLOWER
MOTOR
CAPACITOR
CIRCUIT
BREAKER
CONTROL
BOX
BLOWER ACCESS
DOOR
Figure 1
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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 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
WARNING
Do not set thermostat below 60_F (16_C) in heating
mode. Setting thermostat below 60_F (16_C) reĆ
duces the number of heating cycles. Damage to the
unit may occur that is not covered by the warranty.
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 combustible.
2 - DO NOT obstruct air flow to unit. Unit must receive
an unobstructed flow of combustion and ventilatĆ
ing air.
3 - DO NOT store chlorine or fluorine products near unit
or introduce these products into the combustion air.
These products can cause furnace corrosion.
4 - DO NOT draw the return air from a room where
another gas appliance (ie., a water heater) is
installed. Even though this furnace draws its comĆ
bustion 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 appliance is operating
in a room with negative pressure, the flue products
can be pulled back down the vent pipe and into the
room. This reverse flow of the flue gas may result in
incomplete combustion and the formation of carbon
monoxide gas. This toxic gas might then be distribĆ
uted through the house by the furnace duct system.
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.
WARNING
Do not use this furnace if any part has been underĆ
water. Immediately call a qualified service techniĆ
cian to inspect the furnace and to replace any part
of the control system and any gas control which
has been under water.
CAUTION
Before attempting to perform any service or mainteĆ
nance, turn the electrical power to unit OFF at disĆ
connect switch.
IMPORTANT
Any additions, changes, or conversions required in
order for the appliance to satisfactorily meet the apĆ
plication needs must be made by a Lennox service
technician using factory specified and approved
parts.
Your furnace is a gas appliance. It is critical that the gas
supplied to the unit be completely burned to avoid the proĆ
duction of carbon monoxide gas. Complete combustion
of the gas requires, but is not limited to, correct gas presĆ
sure and gas flow rate, adequate combustion, air, and
proper venting.
WARNING
Carbon monoxide gas is invisible, odorless, and
toxic.
Exposure to this gas can cause personal injury and even
death to all occupants, including pets. Any item that is
powered by or gives off heat from a combustion process
(including lawn mowers, automobiles, and fireplaces) has
the potential to produce carbon monoxide gas. Because
of this, Lennox recommends the use of a carbon monĆ
oxide detector in your home, even if you do not own
gas appliances. Reliable detectors are available at reaĆ
sonable retail prices. Contact your independent Lennox
dealer for more details about this investment in your safety.
Your furnace is designed to meet standards set by nationĆ
al agencies, and to operate safely when properly installed
and maintained. However, the unit's performance can be
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greatly impacted by the individual installation and the opĆ
erating environment. It is your responsibility to ensure
that this appliance is maintained. Proper maintenance is
critical for your safety and the satisfactory operation of the
product. Lennox strongly recommends annual inĆ
spection and maintenance of this appliance. Contact
your independent Lennox dealer for an inspection by a
qualified service technician.
Lighting and Operating Information
WARNING
If you do not follow these instructions exactly, a fire
or explosion may result causing property damage,
personal injury or loss of life.
BEFORE LIGHTING smell all around the appliance area
for gas. Be sure to smell next to the floor because some
gas is heavier than air and will settle on the floor.
The unit is equipped with a gas control knob. Use only
your hand to move the gas control knob. Never use tools.
If the knob will not move by hand, do not try to repair it. Call
a qualified service technician. Force or attempted repair
may result in a fire or explosion.
To place G32 furnace into operation:
G32 units are equipped with a SureLightt ignition sysĆ
tem. Do not attempt to manually light these furnaces.
Each time thermostat calls for heat, the burners will be auĆ
tomatically lit by the ignitor. The ignitor does not get hot
when there is no call for heat.
Operating the Gas Valve (Figure 3)
1 - STOP! Read the safety information at the beginning
of this section.
2 - Set thermostat to lowest setting. See figure 2.
6 - Turn the gas valve knob to OFF. See figure 3.
HONEYWELL VR8205 Series Gas Valve
high fire adjusting screw
(under cap)
manifold
pressure
tap
low fire
adjusting screw
(under cap)
inlet pressure tap
Gas Valve Shown In OFF Position
Figure 3
7 - Wait five (5) minutes to clear out any gas. If you then
smell gas, STOP! Immediately call your gas supplier
from a neighbor's phone. Follow the gas supplier's
instructions. If you do not smell gas go to next step.
8 - Turn the gas valve knob to ON. Do not force the knob.
9 - Replace the unit access panel.
10 - Turn on all electrical power to the unit.
11 - Set thermostat to desired setting.
NOTE - When the unit is first started, steps 1 through
11 may need to be repeated to purge air from pilot
line.
12 - If the appliance still will not operate, follow the inĆ
structions Turning Off Gas to the Unit" and call your
service technician or gas supplier.
Turning Off Gas to the Unit
1 - Set thermostat to lowest setting.
2 - Turn off all the electrical power to unit if service is to
be performed.
3 - Remove the upper access panel.
4 - Turn the gas valve knob to OFF. Do not force the
knob.
5 - Replace the upper access panel.
Filters
THERMOSTATS
Figure 2
3 - Turn OFF all electrical power to appliance.
4 - This appliance is equipped with an ignition device
which automatically lights the burners. Do not try to
light the burners by hand.
5 - Remove upper access panel.
A filter must be in place any time the unit is operating.
Ask your dealer to show you where the filter is located.
The filter should be inspected monthly and cleaned
when necessary to assure proper furnace operation.
Foam filters may be cleaned for reuse. If replacement is
necessary, order Lennox part no. 31J81 for 14 X 25 inch
filter used in G32-75 units or P-8-7831 for 20 X 25 inch
filter used in G32-100 and -125 units. Use the following
procedure to clean filter.
Bottom Return Air Filter Installation (Figure 4)
1 - Turn off electric power to furnace.
2 - Remove blower access panel.
3 - Remove filter by pressing side filter clips and pulling
filter up and out. See figure 4.
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BOTTOM RETURN FILTER INSTALLATION
REAR FILTER CLIP
FURNACE
BACK
SIDE FILTER CLIPS (2)
RETURN AIR OPENING
REMOVING / REPLACING FILTER DOOR
FILTER DOOR
PIN
FILTER DOOR
TAB
FILTER
FURNACE
FRONT
FURNACE
BASE BOTTOM
Figure 4
4 - Clean filter with cold water and a mild soap. Direct
water through filter in the opposite direction of air
flow. Remove all soap residue.
5 - Allow filter to dry then spray with filter handicoater
prior to reinstallation. Filter handicoater is available
from your Lennox dealer as P-8-5069.
6 - 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.
7 - Replace blower access panel.
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.
Side Return Air Filter Installation (Figure 5)
1 - Turn off electric power to furnace.
2 - Locate the filter door of the filter rack assembly.
3 - Using the filter door pins, pull filter door, with filter atĆ
tached, out of filter rack assembly. Remove filter door
from filter by pulling up on securing tabs.
4 - Clean filter with cold water and a mild soap. Direct
water through filter in the opposite direction of air
flow. Allow filter to dry, then spray with filter handiĆ
coater prior to reinstallation. Filter handicoater is
available from your Lennox dealer as P-8-5069.
5 - Position filter door on end of filter so that the thumb
tab side of the filter door is away from the furnace.
Check for correct air flow position. Squeeze thumb
tabs to secure filter to door.
6 - Guide filter and filter door into the filter rack
installed on side of furnace. Push door into filter
rack until secure.
FILTER DOOR
PIN
TAB
Figure 5
Seasonal Inspections
A qualified service technician should inspect the comĆ
plete system each season (heating and cooling). The folĆ
lowing maintenance procedures should be conducted by
a qualified service technician. Do not attempt to service
the unit in any way.
During a seasonal check the service technician will inĆ
spect the indoor blower, the burner flame and the venting
system.
Venting System
Annually (before heating season) inspect furnace ventĆ
ing system, heat exchanger and burners for corrosion,
deterioration, or deposits of debris. Remove any obĆ
structions.
Inspect furnace venting system to make sure it is in place,
physically sound, and without holes, corrosion, or blockĆ
age. Vent connector must be in correct position, sloped
upward and be physically sound without holes or excesĆ
sive corrosion.
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.
Inspect and clean the condensate traps and drain.
Blower
Check and clean blower wheel for any debris. Blower moĆ
tor is preĆlubricated for extended bearing life. No further
lubrication is needed.
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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 in color and strong in appearance.
CAUTION
Periodically look through the flame sight glass to
check the burner flame.
Contact your Lennox dealer for a periodic unit inspection
by a qualified service technician.
D If you experience headache, nausea, fatigue, or dizziĆ
ness, the cause could be exposure to carbon monoxĆ
ide gas. This is often misdiagnosed as the flu because
symptoms are similar. If you suffer from flu-like sympĆ
toms that are exaggerated at home, but seem to subĆ
side while you are away from the house, exposure to
carbon monoxide could be the cause.
Your vigilance may pay off in early detection of a problem
before either personal injury or property damage occurs.
Do not hesitate to contact a qualified service technician as
an investment in your well being.
Service Reminder
Call your Lennox service technician if unit is inoperative.
Before calling, always check the following to be sure serĆ
vice is required.
1 - Check that electrical disconnect switches are ON.
2 - Check room thermostat for proper setting.
3 - Replace any blown fuses or reset circuit breakers. InĆ
vestigate reason for blown fuses or tripped breakers.
4 - Make sure gas valve is in ON position.
5 - Air filter should not be plugged limiting air flow.
6 - Is gas turned on at meter?
7 - Is manual main shutĆoff valve open?
Safety Precautions
If you discover any of the following, shut down your
unit, and contact an independent Lennox dealer for
an inspection by a qualified technician.
D If you repeatedly hear any new or unfamiliar sounds
while your unit is operating, there may be a problem.
For example, poorly performing burners can produce
unfamiliar noises.
D If you smell any unusual odors, your unit may be operĆ
ating improperly. For example, units can give off unfaĆ
miliar odors if components are required to operate in
abnormal conditions.
D Look for visible signs of a malfunctioning unit. ExamĆ
ples include unusual amounts of condensate on winĆ
dows inside your house, visibly burnt components, or
unusual accumulation of rust in the unit.
Planned Service
You should expect a service technician to check the folĆ
lowing items during an annual inspection. Power to the
unit must be shut off for the service technician's safety.
Burners- Must be inspected for rust, dirt, or signs of waĆ
ter.
Vent pipe - Must be inspected for dirt, damaged or sagĆ
ging unsupported pipe, or disconnected joints.
Unit appearance - Must be inspected for rust, dirt, signs
of water, and burnt or damaged wires components.
Blower access door - Must be properly in place and proĆ
vide a seal between the return air and the room where the
furnace is installed.
Return air duct - Must be properly attached and provide
an airtight 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 beĆ
tween annual furnace inspections that may result in unĆ
safe operation. For instance, items innocently stored next
to the air inlet may obstruct the combustion air supply.
This could cause incomplete combustion and the producĆ
tion of carbon monoxide gas.
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