Lennox G32V, G32V5-100, G32V3-75, G32V5-125, G32V-100 L.P. Service Literature

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Service Literature

G32V SERIES UNITS

G32V series units are high−efficiency upflow gas furnaces manufactured with DuralokPlus aluminized steel clamshell-type heat exchangers. G32V units are available in heating capacities of 75,000 to 125,000 Btuh and cooling applications up to 5 tons. Refer to Engineering Handbook for proper sizing.

Units are factory equipped for use with natural gas. LP kits are available. All G32V−1 through −4 units feature the Lennox SureLight silicon nitride ignition system. G32V−5 and later units feature the two stage variable speed SureLight integrated control board.The G32V units meet the California Nitrogen Oxides

) Standards and California Seasonal Efficiency requirements without mod-

(NO

ification. All units use a two−stage gas valve along with a two−stage combustion air blower. The gas valve is redundant to assure safety shut−off as required by A.G.A. or C.G.A.

All G32V units are equipped with an electronic variable speed (VSM) fan motor. The VSM consists of an ICM2 motor and control module assembly. The VSM maintains a specified air volume throughout the entire external static range. Information contained in this manual is intended for use by qualified service technicians only. All specifications are subject to change. Procedures outlined

in this manual are presented as a recommendation only and do not supersede or replace local or state codes. In the absence of local or state codes, the guidelines and procedures outlined in this manual (except where noted) are recommended only.

G32V

Corp. 9816−L10

Revised 02−2004

G32V FURNACE

G32V HEAT EXCHANGE ASSEMBLY

Combustion Process:

1. A call for heat starts the combustion air blower.

2. Outdoor air is drawn through pipe into the burner compartment where it mixes with gas in a conventional style inshot burner.

3. The SureLight ignition system lights the burners.

4. Combustion products are drawn downward through the heat exchanger. Heat is extracted as indoor air passes across the outside surface of the metal.

5. Latent heat is removed from the combustion products as air passes through the coil. Condensate (water) is formed as the combustion products cool.

6. As the combustion products exit the coil, condensate is collected and drained away.

7. Combustion products are pulled from the heat exchanger and forced into the flue.

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Litho U.S.A.

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TABLE OF CONTENTS

Specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blower Data 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High Altitude 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Venting Table 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts Arrangement 8. . . . . . . . . . . . . . . . . . . . . . . . . . . .

I Unit Components 10. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Box 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SureLight Ignition System 11. . . . . . . . . . . . . . . . . . .

Two−Stage Ignition Control 13. . . . . . . . . . . . . . . . . .

VSP2−1 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VSP3−1 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SureLight Two Stage Variable Speed Control 22.

Blower Compartment 30. . . . . . . . . . . . . . . . . . . . . . .

Heating 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

III Start Up 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IV Heating System Service Checks 47. . . . . . . . . . . . . .

V Typical Operating Characteristics 49. . . . . . . . . . . . . .

VI Maintenance 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VII Wiring Diagrams and Operating Sequence 53. . . .

G32V−1 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G32V−3 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G32V−4 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G32V−5 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VSP2−1 Jumper Summary 70. . . . . . . . . . . . . . . . . .

VSP3−1 Jumper Summary 74. . . . . . . . . . . . . . . . . .

SureLight Jumper Summary 78. . . . . . . . . . . . . . . .

VIII Troubleshooting 81. . . . . . . . . . . . . . . . . . . . . . . . . . .

VSP2−1 Board 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VSP3−1 Board 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ICM2 Motor with VSP2−1 83. . . . . . . . . . . . . . . . . . .

ICM2 Motor with VSP3−1 84. . . . . . . . . . . . . . . . . . .

ICM2 Motor with SureLight Control 85. . . . . . . . . . .

SureLight Control 86. . . . . . . . . . . . . . . . . . . . . . . . .

II Placement and Installation 38. . . . . . . . . . . . . . . . . . . .

WARNING

Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Installation and service must be performed by a qualified installer or service agency.

WARNING

Electric shock hazard. Can cause injury or death. Before attempting to perform any service or maintenance, turn the electrical power to unit OFF at disconnect switch(es). Unit may have multiple power supplies.

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SPECIFICATIONS

Vent/Intake Air Roof

Model No. G32V3−75 G32V5−100 G32V5−125

Input Btuh (kW) − High 75,000 (22.0) 100,000 (29.3) 125,000 (36.6)

Input Btuh (kW) − Low 51,000 (14.9) 68,000 (19.9) 85,000 (24.9)

Output Btuh (kW) − High 67,500 (19.8) 90,000 (26.4) 112,500 (32.9)

Output Btuh (kW) − Low 45,900 (13.4) 61,200 (17.9) 76,500 (22.4)

A.F.U.E. 92.7% 93.2% 94.2%

California Seasonal Efficiency 89.4% 90.1% 91.1%

Exhaust pipe connection (PVC) diameter in. (mm) 2 (51)

Intake pipe connection (PVC) diameter in. (mm) 2 (51) 3 (76)

Condensate drain connection (PVC) in. (mm) 1/2 (12.7)

Temperature rise range  F (C)



High static certified by (A.G.A./C.G.A.)  in. wg. (Pa) .80 (200)

Gas Piping Size I.P.S. − Natural − in. (mm) 1/2 (12.7)

Blower wheel nominal diameter x width − in. (mm) 10 x 8 (254 x 203) 11−1/2 x 9 (292 x 229)

Blower motor output  hp (W) 1/2 1

Nominal cooling that can be added − Tons (kW) 2 to 3 (7 to 10.6) 3−1/2 to 5 (12.3 to 17.6)

No. & size of filters − in. (mm) (1) 14 x 25 x 1 (356 x 635 x 25) (1) 20 x 25 x 1 (508 x 635 x 25)

Shipping weight  lbs. (kg) 1 package 161 (73) 201 (91) 221 (100)

Electrical characteristics 120 volts  60 hertz  1 phase (less than 12 amps)

Concentric Vent/Intake Air/Roof Termination Kit 60G77  1/1/2 inch (38 mm)

Vent/Intake Air Roof

Termination Kit  vent size

Vent/Intake Air Wall

Termination Kit  vent size

Condensate Drain Heat Cable 26K68 6 ft. (1.8 m) − 26K69 24 ft. (7.3 m) − 26K70 50 ft. (15.2 m)

Heat Cable Tape

L.P. Kit 34L29 (−1, −2 models) 11M55 (−3 and later models)

Annual Fuel Utilization Efficiency based on U.S. DOE test procedures and FTC labeling regulations. Isolated combustion system rating for non−weatherized furnaces. Meets California Nitrogen Oxides (NO Determine from venting tables proper intake and exhaust pipe size and termination kit required. Polyurethane frame type filter.

NOTE − 2 inch x 3 inch (51 mm x 76 mm) adaptor is furnished with −100 and −125 furnaces for exhaust pipe connection.

Low Fire 30 − 60(16 − 33) 35 − 65 (19 − 36)



High Fire 40 − 70 (22 − 39) 50 − 80 (28 − 44)

OPTIONAL ACCESSORIES (Must Be Ordered Extra)

33K97  2 inch

(51 mm)

33K97− 2 inch (51 mm)

60L46 − 3 inch (76 mm)

2 inch (51 mm) 15F75

3 inch (76 mm) 44J41

2 inch (51 mm)

15F74 (ring kit)  22G44 (close couple) 30G28 (WTK close couple)

30G79 (WTKX close couple with extension riser)

3 inch (76 mm) 44J40 (close couple)  81J20 (WTK close couple)

Fiberglass − 1/2 in. (38 mm) 39G04

Aluminum foil − 2 in. (25 mm) 39G03

) Standard and California Seasonal Efficiency requirements.

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BLOWER PERFORMANCE

Jumper

Setting

ADJUST"

Jumper

Positions

Table 1

G32V3−75−1 through −3 Units

0 THROUGH 0.80 IN. W.G. (0 THROUGH 200 PA) EXTERNAL STATIC PRESSURE

VSP2-1 Blower Control Low Speed  3 Factory Settings High Speed  4

ADJUST"

Jumper

Setting

NORM 880 415 930 440 980 465 1040 490 1060 500 1105 520 1260 595 1330 630 1075 510 1150 545 1270 600 1350 635

− 15% 775 365 810 380 850 400 910 430 930 440 970 460 1070 505 1130 535 930 440 990 465 1080 510 1140 540

NOTE  The effect of static pressure and filter resistance is included in the air volumes listed.

(Cool, Low Heat Or Continuous Fan)

1 2 3 4 1 2 3 4 1 2 3 4

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

LOW" Speed

0 THROUGH 0.80 IN. W.G. (0 THROUGH 200 PA) EXTERNAL STATIC PRESSURE

VSP2-1 Blower Control G32V5−100 G32V5−125 Factory Settings Low Speed  2 Low Speed  3

ADJUST"

Jumper Settin

NORM 1140 540 1250 590 1440 680 1550 730 1620 765 1820 860 2000 945 2100 990 1560 735 1720 810 2030 960 2150 1015

NOTE  The effect of static pressure and filter resistance is included in the air volumes listed.  G32V5−125 unit only − do not place jumper on tap 1 ("") for high speed or tap 2 ("NORM" or "") for low speed.

LOW" Speed (Cool Or Continuous Fan) HIGH" Speed (Cool) HEAT" Speed

1 2 3 4 1 2 3 4 1 2 3 4

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

− 970 460 1060 500 1280 605 1320 625 1380 650 1550 730 1700 800 1780 840 1330 630 1460 690 1730 815 1830 865

Heat Speed  3

VSP2−1 Jumper Speed Positions

HIGH" Speed (Cool) HEAT" Speed

Table 2

G32V5−100/125−1 through −3 Units

High Speed  4 High Speed  4 Heat Speed  1 Heat Speed  2

VSP2 Jumper Speed Positions

Table 3

G32V3−75−4 Units

0 THROUGH 0.80 IN. W.G. (0 THROUGH 200 PA) EXTERNAL STATIC PRESSURE

VSP3−1 Blower Control Factory Settings ADJUST − NORM



Jumper

Positions

NORM (Normal) 880 415 930 440 980 465 1040 490 1075 510 1150 545 1270 600 1350 635

 " (Minus) 15% 775 365 810 380 850 400 910 430 930 440 990 460 1080 510 1140 540

ADJUST"

Jumper

Positions

NORM (Normal) 880 415 930 440 980 465 1040 490 1060 500 1105 520 1260 600 1350 635

 " (Minus) 15% 775 365 810 380 850 400 910 430 930 440 970 460 1080 510 1140 540

 15% lower motor speed than NORM jumper setting.

NOTE − The effect of static pressure and filter resistance is included in air volumes shown. NOTE − Continuous Fan only speed is approximately 800 cfm (380 L/s) − non adjustable. NOTE − Lennox Harmony II zone control applications − MAX CFM is determined by COOL jumper placement with a minimum of approximately 850 cfm (400 L/s) for all positions.

1 2 3 4 1 2 3 4

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

1 2 3 4 1 2 3 4

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

Heat Speed − 3 Cool Speed − 4

VSP Jumper Speed Positions

HEAT" Jumper

Low Speed High Speed

COOL" Jumper

Low Speed High Speed

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Table 4

ADJUST"

Jumper

Positions

Setti

G32V5−100/125−4 Units

0 THROUGH 0.80 IN. W.G. (0 THROUGH 200 PA) EXTERNAL STATIC PRESSURE

VSP3−1 Blower Control Factory Settings G32V5−100 ADJUST − NORM G32V5−125 ADJUST −  (minus)



Jumper

Positions

NORM (Normal) 1140 540 1250 590 1440 680 1550 730 1560 735 1720 810 2030 955 2150 1015

 " (Minus) 15% 970 455 1060 500 1280 605 1320 595 1330 625 1460 690 1730 815 1830 865

ADJUST"

Jumper

Positions

NORM (Normal) 1140 540 1250 590 1440 680 1550 730 1620 765 1820 860 2000 945 2100 990

 " (Minus) 15% 970 455 1060 500 1280 605 1320 595 1380 650 1550 730 1700 800 1780 840

 15% lower motor speed than NORM jumper setting.  G32V5−125 Models Only − Do not place jumper on position #1 (at NORM or " setting) or position #2 (at " setting) for HEAT speed.

NOTE − The effect of static pressure and filter resistance is included in air volumes shown. NOTE − Continuous Fan only speed is approximately 1150 cfm (545 L/s) − non adjustable. NOTE − Lennox Harmony II zone control applications − MAX CFM is determined by COOL jumper placement with a minimum of approximately 1140 cfm (540 L/s) for all positions.

1 2 3 4 1 2 3 4

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

1 2 3 4 1 2 3 4

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

Low Speed High Speed

Heat Speed − 2 Heat Speed − 4 Cool Speed − 4 Cool Speed − 4

VSP Jumper Speed Positions

HEAT" Jumper

COOL" Jumper

TABLE 5

G32V3−75−5 Units BLOWER MOTOR PERFORMANCE

0.0" to 0.8" w.g. (0 through 200 Pa) External Static Pressure Range

Blower Speed Adjustment Settings (Switches 5 and 6)

Cool

Adjust"

1 2 3 4 1 2 3 4

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

Low Speed High Speed

Norm 880 415 930 440 980 465 1040 490 1060 500 1105 520 1260 595 1330 630



–

775 365 810 380 850 400 910 430 930 440 970 460 1070 505 1130 535

Blower Speed Adjustment Settings (Switches 7 and 8)

Heat

Adjust"

Setting

1 2 3 4 1 2 3 4

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

Norm 945 446 1025 484 1125 531 1270 599 1080 510 1172 533 1286 607 1452 685



–

803 379 871 411 956 451 1080 510 918 433 996 470 1093 516 1234 582

15% lower motor speed than NORM switch setting.

NOTE − The effect of static pressure and filter resistance is included in air volumes shown. NOTE − Continuous Fan only speed is approximately 800 cfm (380 L/s) − non adjustable. NOTE − Lennox Harmony IIt zone control applications − MAX CFM is determined by COOL switch setting with a minimum of approximately 850 cfm (400 L/s) for all positions.

Low Speed High Speed

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TABLE 6

Setti

G32V5−100/125−5 Units BLOWER MOTOR PERFORMANCE

0.0" to 0.8" w.g. (0 through 200 Pa) External Static Pressure Range Blower Speed Adjustment Settings (Switches 5 and 6)

Cool

Adjust"



cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

Norm 1140 540 1250 590 1440 680 1550 730 1620 765 1820 860 2000 945 2100 990



–

970 455 1060 500 1280 605 1320 595 1380 650 1550 730 1700 800 1780 840

Low Speed High Speed



3 4 1



3 4

Blower Speed Adjustment Settings (Switches 7 and 8)

Heat

Adjust"

Setting

1 2 3 4 1 2 3 4

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

Norm 1140 540 1250 590 1440 680 1550 730 1560 735 1720 810 2030 960 2150 1015



–

15% lower motor speed than NORM switch setting. G32V5−125 Models Only − Do not set switches for position #1 (at NORM or –" setting) or position #2 (at −" setting) for HEAT speed.

NOTE − The effect of static pressure and filter resistance is included in air volumes shown. NOTE − Continuous Fan only speed is approximately 1150 cfm (545 L/s) − non adjustable. NOTE − Lennox Harmony IIt zone control applications − MAX CFM is determined by COOL switch setting with a minimum of approximately 1140 cfm (540 L/s) for all positions.

970 455 1060 500 1280 605 1320 595 1330 660 1460 690 1730 815 1830 865

Low Speed High Speed

FILTER AIR RESISTANCE

cfm (L/s) in. w.g. (Pa)

0 (0) 0.00 (0)

200 (95) 0.01 (0)

400 (190) 0.03 (5)

600 (285) 0.04 (10)

800 (380) 0.06 (15)

1000 (470) 0.09 (20)

1200 (565) 0.12 (30)

1400 (660) 0.15 (35)

1600 (755) 0.19 (45)

1800 (850) 0.23 (55)

2000 (945) 0.27 (65)

2200 (1040) 0.33 (80)

2400 (1130) 0.38 (95)

2600 (1225) 0.44 (110)

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No gas pressure adjustment is needed when operating from 0 to 4500 ft. (0 to 8 m). See below for correct manifold pressures for altitudes greater that 4500 ft. (1372 m) for natural and L.P. gas.

Manifold Absolute Pressure (outlet) in. w.g. (kPa)

Model No.

0 to 4500 ft. (0 to 1372 m)

above sea level

G32V−75 natural no adjustment

G32V−100 natural

G32V−125 natural

3.5 (0.88) 3.4 (0.85) 3.3 (0.82) 3.2 (0.80)

G32V−75 L.P. no adjustment

G32V−100 L.P. 7.5 (0.19) 7.3 (0.185) 7.1 (0.180) 7.0 (0.177)

G32V−125 L.P. 7.5 (0.19) 7.3 (0.185) 7.1 (0.180) 7.0 (0.177)

4501 to 5500 ft.

(1373 to 1676 m)

above sea level

5501 to 6500 ft.

(1677 to 1981 m)

above sea level

6501 to 7500 ft.

(1982 to 2286 m)

above sea level

INTAKE AND EXHAUST PIPE VENTING TABLE

HIGH ALTITUDE INFORMATION

Vent Pipe Maximum

Equivalent Length

75,000 Btuh (22.0 kW) 100,000 Btuh (29.3 kW) 125,000 Btuh (36.6 kW)

Feet Meters in. mm in. mm in. mm

15 4.6 2 51 2 51 2 51

20 6.1 2 51 2 51 3 76

25 7.6 2 51 2 51 3 76

30 9.1 2 51 3 51 3 76

40 12.2 2 51 3 51 3 76

50 15.2 2 51 3 51 3 76

55 16.8 2 51 3 76 3 76

60 18.3 3 76 3 76 3 76

70 21.3 3 76 3 76 3 76

80 24.4 3 76 3 76 3 76

90 27.4 3 76 3 76 3 76

100 30.5 3 76 3 76 3 76

110 33.5 3 76 3 76 3 76

120 36.6 3 76 3 76 3 76

130 39.6 3 76 3 76 − − − − − − − −

MINIMUM PIPE LENGTHS FOR FURNACES  G32V−75  5 feet (1.5 m) with two 90 elbows of 2 inch (51 mm) diameter pipe. (15 equivalent feet (4.6 m) total).

VENTING NOTES  One 90elbow is equivalent to 5 feet (1.5 m) of straight vent pipe.

Two 45 elbows are equal to one 90 elbow. One 45 elbow is equivalent to 2.5 feet (.75 m) of straight vent pipe. One foot (305 mm) length of 2 in. (51 mm) diameter pipe is equivalent to 8 feet (2.4 m) of 3 in. (76 mm) diameter pipe. Intake and Exhaust pipes must 2 inch x 3 inch (51 mm x 76 mm) adaptor is furnished with −100 and −125 furnaces for exhaust pipe connection. Exhaust pipe must terminate with 1−1/2 inch (38 mm) diameter pipe for furnaces using1−1/2 (38 mm) or 2 inch (51 mm) diameter pipe runs. Exhaust pipe must terminate with 2 inch (51 mm) diameter pipe for furnaces using 3 inch (76 mm) diameter pipe runs.

G32V−100  5 feet (1.5 m) with two 90 elbows of 2 inch (51 mm) diameter pipe. (15 equivalent feet (4.6 m) total). G32V−125  5 feet (1.5 m) with two 90 elbows of 2 inch (51 mm) diameter pipe. (15 equivalent feet (4.6 m) total).

be the same diameter.

Minimum Vent Pipe Diameter Required

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G32V PARTS ARRANGEMENT

FRESH AIR

INTAKE FITTING

BURNER BOX

ASSEMBLY

PATCH PLATE

FLAME SIGHT

BURNER

BOX

COVER

GLASS

TWO-STAGE

GAS VALVE AND

MANIFOLD

GLASS FIBER GASKET

LOW HEAT

DIFFERENTIAL

PRESSURE

SWITCH

HIGH HEAT

DIFFERENTIAL

PRESSURE

SWITCH

(−75 only)

WARM

HEADER

(COLLECTOR)

BOX

PATCH PLATE WITH

BARBED FITTING

AND FLAME

ROLL−OUT SWITCH

DuralokPlus

HEAT EXCHANGER

ASSEMBLY

FLUE COLLAR

TRANSITION

TOP CAP

CABINET

FLUE

SUPPLY

AIR

BLOWER

BURNER ACCESS

PANEL

BLOWER

ACCESS

DOOR

TWO−SPEED

COMBUSTION AIR

INDUCER

COMBUSTION

AIR

ORIFICE

COLD HEADER

(COLLECTOR)

BOX

SECONDARY COIL

PRIMARY LIMIT

(ALTERNATE STYLES)

TRANSFORMER

CONTROL VOLTAGE

CIRCUIT BREAKER

SURELIGHT TWO−STAGE,

VARIABLE−SPEED

INTEGRATED CONTROL BOARD

DOOR INTERLOCK SWITCH

FIGURE 1

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BURNER

ACCESS

COVER

BURNER BOX

MANIFOLD

GAS VALVE

FRESH AIR INTAKE

FITTING

G32V HEAT EXCHANGER

CORBEL ORIFICE

CUPS

SURELIGHT IGNITOR LENNOX DURALOKPLUS

HEAT EXCHANGER ASSEMBLY

COMBUSTION AIR

BLOWER MOTOR

COMBUSTION

AIR BLOWER

BURNER BOX

FLAME SIGHT GLASS

FLUE TRANSITION

LOW HEAT DIFFERENTIAL

PRESSURE SWITCH

HIGH HEAT DIFFERENTIAL

PRESSURE SWITCH

(G32V−75 ONLY)

COMBUSTION AIR BLOWER

DOOR INTERLOCK SWITCH

SURELIGHT CONTROL BOARD*

VSP BLOWER CONTROL BOARD*

BLOWER HOUSING

COLD HEADER

(COLLECTOR )

BOX

G32V GENERAL PARTS ORIENTATION

FIGURE 2

WARM HEADER

CONDENSER COIL

SUPPLY AIR DUCT FLANGE

UPPER VEST PANEL

GAS MANIFOLD

PRIMARY LIMIT

GAS VALVE

COLD HEADER BOX

HEADER BOX

CONDENSATE

LOWER VEST PANEL

CONTROL BOX

CIRCUIT BREAKER

TWO−STAGE CONTROL*

(COLLECTOR)

BOX

TRAP

BLOWER

COMPARTMENT

*NOTE−G32V−1 through −4 units only

BLOWER MOTOR

COIL CHOKE

FIGURE 3

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OUTSIDE INSTALLATION

MAKE-UP BOX

MAKE-UP BOX INSTALLATION

Box may be installed inside or outside cabinet and

may be installed on left side or right side of cabinet

STAR WASHERS

MUST BREAK

PAINT ON UNIT

CABINET FOR

PROPER GROUND.

UNIT

CABINET

INSIDE INSTALLATION

MAKE-UP BOX

Line Voltage Enters Through

Knockout In Make-Up Box.

J69 Passes Through Side

Knockout Into Side Of Unit.

JACK J69

BLOWER MULLION

PLUG P69

FIGURE 4

I−UNIT COMPONENTS

G32V unit components are shown in figures 1 and 2. General parts orientation is shown in figure 3. The gas valve, ignition control and burners can be accessed by removing the burner access panel. The blower and blower controls can be accessed by removing the blower access door.

G32V units are designed for bottom and side return air. The panels are designed to be knocked-out (bottom return) or cut-out (side return) as required for return air duct connection.

A−Make-Up Box (Figure 5)

The line voltage make-up box is shown in figure 5. The box may be installed inside or outside the unit and may be installed on the unit left or right side (figure 4).

MAKE-UP BOX

BOX

POWER ENTRY KNOCKOUT

120V LINE VOLTAGE

PIGTAIL CONNECTIONS

COVER

Line Voltage Enters Make-Up

Box Through Side Of Unit and

J69 Passes Through Bottom

Knockout in Make-Up Box.

BLOWER MULLION

An accessory (brown) output wire is provided with the make-up box. The wire provides a 120V connection for optional accessories such as electronic air cleaner or humidifier. If used, the wire is field installed in J69 jack plug by inserting the pin of the brown wire into the open socket of the jack. See figure 6. 120V

INSTALLING BROWN

ACCESSORY WIRE TO J69

accessories rated up to 4 amps total may be connected to this wire. The neutral leg of the accessory is connected to the

WHITE

NEUTRAL

BROWN

neutral white wire in the makeup box. The accessory terminal is energized whenever the blower is in operation.

B−Control Box Components

G32V−1 through −4 CONTROL BOX

DOOR

INTERLOCK

SWITCH

BLACK

J69

FIGURE 6

TRANSFORMER

UNIT

GROUND

JACK J69

to blower deck

Box may be installed inside or outside unit. See Figure 4.

TO BLOWER MULLION

FIGURE 5

SURELIGHT

Page 10

CONTROL

VSP

BOARD

TERMINAL STRIP

FIGURE 7

CIRCUIT

BREAKER

TWO− STAGE CONTROL BOARD

Page 11

Integrated ignition and blower control components (A92), unit transformer (T1) and 24V circuit breaker (CB8) are located in the control box. In addition, a door interlock switch (S51) is located in the control box. Jackplugs allow the control box to be easily removed for blower service.

1. Control Transformer (T1)

A transformer located in the control box provides power to the low voltage 24volt section of the unit. Transformers on all models are rated 50VA with a 120V primary and a 24V secondary.

2. Circuit Breaker (CB8)

A 24V circuit breaker is also located in the control box. The switch provides overcurrent protection to the transformer (T1). The breaker is rated 3A . If the current exceeds this limit the breaker will trip and all unit operation will shut-down. The breaker can be manually reset by pressing the button on the face.

3.Door Interlock Switch (S51)

A door interlock switch is located on the control box. The switch is wired in series with line voltage. When the blower door is removed the unit will shut down.

ELECTROSTATIC DISCHARGE (ESD)

Precautions and Procedures

NOTE − Do not remove blower access panel to read SureLight LED lights. A sight glass is provided on the access panel for viewing.

Tables 9 and 10 show jack plug terminal designations. Units equipped with the SureLight board can be used with either electronic or electro−mechanical thermostats without modification. The SureLight ignitor is made of durable silicon−nitride. Ignitor longevity is also enhanced by voltage ramping by the control board. The board finds the lowest ignitor temperature which will successfully light the burner, thus increasing the life of the ignitor.

SURELIGHT CONTROL BOARD

CAUTION

Electrostatic discharge can affect electronic components. Take precautions during furnace installation and service to protect the furnace’s electronic controls. Precautions will help to avoid control exposure to electrostatic discharge by putting the furnace, the control and the technician at the same electrostatic potential. Neutralize electrostatic charge by touching hand and all tools on an unpainted unit surface, such as the gas valve or blower deck, before performing any service procedure.

DANGER

Disconnect power before servicing. Control is not field repairable. If control is inoperable, simply replace entire control.

Can cause injury or death. Unsafe operation will result if repair is attempted.

4.SureLight Ignition System A92

G32V−1 through −4 units are equipped with the Lennox SureLight ignition system. The system consists of ignition control board (figure 8 with control terminal designations in table 1) and ignitor (figure 9). The board and ignitor work in combination to ensure furnace ignition and ignitor durability. The SureLight integrated board controls all major furnace operations. The board also features two LED lights for troubleshooting (and two accessory terminals rated at (4) four amps. See table 8 for troubleshooting diagnostic codes.

Page 11

13/32’

FIGURE 8

SURELIGHT IGNITOR

MEASUREMENT IS TO I.D.

5/8"

OF RETENTION RING

5/16 "

FIGURE 9

Page 12

TABLE 7

SURELIGHT CONTROL TERMINAL DESIGNATIONS

ACB COOL NOT USED

ACB HEAT NOT USED

PARK NOT USED

ACB LOW NOT USED

ACC ACCESSORY TERMINAL (LINE VOLT)

TX 120VAC TRANSFORMER

HOT 120VAC HOT INPUT

HTG ACC HEAT ONLY ACCESSORY (LINE VOLT)

NEUTRALS 120VAC NEUTRALS

24VAC HOT 24VAC HOT FROM TRANSFORMER

24VAC RTN 24VAC RETURN FROM TRANSFORMER

FLAME SENSE FLAME SENSE TERMINAL

TABLE 8

DIAGNOSTIC CODES

MAKE SURE TO ID LED’S CORRECTLY: REFER TO INSTALLATION INSTRUCTIONS FOR CONTROL BOARD LAYOUT.

LED #1 LED #2 DESCRIPTION

SIMULTANEOUS

SLOW FLASH

SIMULTANEOUS FAST

FLASH

SLOW FLASH ON

OFF SLOW FLASH

ALTERNATING SLOW

FLASH

SLOW FLASH OFF Flame sensed without gas valve energized.

ON SLOW FLASH Rollout switch open. OR: 9 pin connector improperly attached. ON

OFF

FAST FLASH SLOW FLASH Main power polarity reversed. Switch line and neutral.

SLOW FLASH FAST FLASH Low flame signal. Measures below .61 microAmps. Replace flame sense rod.

ALTERNATING FAST

FLASH

NOTE − Slow flash equals 1 Hz (one flash per second). Fast flash equals 3 Hz (three flashes per second). Drop out flame sense current < 0.20 microAmps

SIMULTANEOUS

SLOW FLASH

SIMULTANEOUS FAST

FLASH

ALTERNATING SLOW

FLASH

OFF

ALTERNATING FAST

FLASH

Also signaled during cooling and continues fan.

Power − Normal operation

Normal operation − signaled when heating demand initiated at thermostat.

Primary or Secondary limit open. Units with board 63K89 or 24L85: Limit must close within 5

trials for ignition or board goes into one hour limit Watchguard. Units with board 56L83 or

97L48: Limit must close within 3 minutes or board goes into one hour limit Watchguard.

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 blower.

Watchguard − burners fail to ignite.

Circuit board failure or control wired incorrectly.

Improper main ground or line voltage below 75 volts; OR: Broken ignitor; OR: Open ignitor

circuit.

TABLE 9

SureLight BOARD J156 TERMINAL

DESIGNATIONS

PIN # FUNCTION

1 Ignitor

Combustion Air Blower Line Voltage

Combustion Air Blower Neutral

Not Used

Ignitor Neutral

Not Used

Page 12

TABLE 10

SureLight BOARD J58 TERMINAL

DESIGNATIONS

PIN # FUNCTION

1 Primary Limit In

Pressure Switch and Primary Limit Out

Gas Valve Common

Roll Out Switch Out

Gas Valve 24V

Pressure Switch In

Not Used

Roll Out Switch In

Ground

Page 13

Electronic Ignition (See Ignition Sequence Below)

On a call for heat the SureLight control monitors the combustion air blower pressure switch. The control will not begin the heating cycle if the pressure switch is closed (by− passed). Once the pressure switch is determined to be open, the combustion air blower is energized. When the differential in the pressure switch is great enough, the pressure switch closes and a 15−second pre−purge begins. If the pressure switch is not proven within 2−1/2 minutes, the control goes into Watchguard−Pressure Switch mode for a 5−minute re−set period. After the 15−second pre−purge period, the SureLight ignitor warms up for 20 seconds after which the gas valve opens for a 4−second trial for ignition. G32V units with board 24L85, 56L83 or 63K89: the ignitor energizes for the first second of the 4−second trial. Units equipped with board 97L48: ignitor energizes during the trial until flame is sensed. If ignition is not proved during the 4−second period, the control will try four more times with an inter purge and warm−up time between trials of 35 seconds. After a total of five trials for ignition (including the initial trial), the control goes into Watchguard−Flame Failure mode. After a 60−minute reset period, the control will begin the ignition sequence again. The SureLight control board has an added feature that prolongs the life of the ignitor. After a successful ignition, the SureLight control utilizes less power to energize the ignitor on successive calls for heat. The control continues to ramp down the voltage to the ignitor until it finds the lowest amount of power that will provide a successful ignition. This amount of power is used for 255 cycles. On the 256th call for heat, the control will again ramp down until the lowest power is determined and the cycle begins again.

5. Two−Stage Control (A86) G32V−1 through −4 units

G32V−1 through −4 units are equipped with a two−stage control (figure 10). The two−stage board acts as a go between from the indoor thermostat to the SureLight ignition board. The board can be utilized in three modes: with a SINGLE−STAGE thermostat, a TWO−STAGE thermostat or with a second−stage (high fire) delay called W2 TIMED. The two−stage board is equipped with a jumper (see figure 10) which changes operating modes and a jumper which adjusts second−stage heat delay during W2 TIMED mode. While in the single−stage thermostat mode (one−stage jumper setting), the unit will always operate on second− stage heat. The combustion air blower (B6) will operate on high speed and indoor blower (B3) will operate on heating speed. While in the two−stage thermostat mode the unit will operate on first−stage heat (low fire). The combustion air blower (B6) and indoor blower will operate on low speed. The unit will switch to second−stage heat (high fire) on call from the indoor thermostat W2. While in the W2 TIMED mode (factory setting 8 minutes) the unit will fire on first− stage heat (low fire) with the combustion air blower (B6) and indoor blower (B3) operating on low speed. After a set time delay the unit switches to second−stage heat (high fire). The combustion air blower and indoor blower also switch to second−stage heat mode.

Ignition Sequence Board: 63K89, 24L85 and 56L8301

Blower On"

Delay

5 SEC80

Post

Purge

OFF

DEMAND

CAB IGNITOR GAS VALVE INDOOR BLOWER

Pre −Purge Ignitor Warmup Trial for

Ignition

Ignition Sequence Board 97L4801

OFF

DEMAND

CAB IGNITOR GAS VALVE INDOOR BLOWER

*All controls: blower on time will be 45 seconds after gas valve is energized. Blower off time will depend on OFF TIME" Setting.

Pre −Purge Ignitor Warmup

Trial for Ignition

Blower On"

Delay

5 SEC80

Post

Purge

Page 13

Page 14

MODE OF

OPERATION

JUMPER

TWO−STAGE CONTROL BOARD

W2 TIMED ON DELAY JUMPER

FIGURE 10

6.VSP2−1 Blower Control Board (A24) G32V −1 / −3 units

G32V units are equipped with a variable speed motor that is capable of maintaining a specified CFM throughout the external static range. The unit uses the VSP2−1 variable speed control board, located in the blower compartment, which controls the blower speed and provides diagnostic LE Ds. The control has bot h a non−adjustable, factory preset ON" fan timing delay and an adjustable OFF" fan timing delay (see figure 13).

The VSP2−1 also senses limit trip condition and turns on the blower. The G32V limit switch is located in the middle of the vestibule wall. When excess heat is sensed in t h e h e a t exchanger, the limit switch will open and interrupt the current to the gas valve, while at the same time the VSP2−1 energizes the blower on heating speed. The limit automatically resets when the unit temperature returns to normal and the blower is de−energized.

Diagnostic LEDs located on the VSP2−1 control board are provided to aid in identifying the unit’s mode of operation. Certain scenarios will arise depending on the jumper positions. Refer to figure 11 for identification.

HIGH SPEED SELECTOR PINS (COOLING ONLY)

LOW SPEED

SELECTOR PINS

(COOLING, HEATING and

CONTINUOUS FAN)

HEATING STAGE

JUMPER SELECTOR PINS

JP73

15 PIN PLUG (BOARD TO VARIOUS POINTS IN FURNACE)

VSP2−1 VARIABLE SPEED CONTROL BOARD SELECTIONS

JP2

HIGH LOW ADJUST HEAT

TEST

−

NORM

DS3

ON/OFF

HI/LOW

DS1

270

DS4

CFM

210

150

JP1

HTG.

BLOWER

HEAT

DS2

FIGURE 11

JP46

13 PIN PLUG

(BOARD TO MOTOR)

HEATING SPEED SELECTOR PINS

See table 11 for VSP2

factory settings

OPERATIONAL

SELECTOR PINS

(Affects both heating

and cooling modes)

DIAGNOSTIC

DS LEDS

FAN OFF"

TIMING PINS

Page 14

Page 15

VSP2−1 BLOWER CONTROL BOARD (A24)

J46

HIGH LOW ADJUST HEAT

DS3

TEST

− + NORM

HI/LOW

1 2 3 4

DS4

1 2 3 4

HTG.

BLOWER

1 2 3 4

HEAT

IMPORTANT

24 VAC half wave rectified (DC pulse), when measured with a meter, may appear as a lower or higher voltage depending on the make of the meter. Rather than attempting to measure the output voltage of A24, see G32V BLOWER & VSP2 BLOWER CONTROL BOARD TROUBLESHOOTING FLOW CHART in the TROUBLESHOOTING section of this manual.

DS2

J73

PIN 2 - G - Input signal from thermostat’s fan signal.

PIN 3 - W2 - Input signal for second stage heat from the thermostat.

PIN 4 - DS - Input signal for the blower speed regulation.

PIN 11 - HT - Input signal from the fan limit control.

PIN 13 - 24V - Input 24 VAC power for the VSP2-1. PIN 14 - 24V - Input 24 VAC power for the VSP2-1.

PIN 1 - Heat - Heat speed input signal to the ICM2 motor.

PIN 4 - High Tap - High Speed programming input.

PIN 6 - On / Off - On / off output signal to the ICM2 motor.

PIN 8 - Hi / Low - Speed regulate input signal to the ICM2 motor.

PIN 9 - Hi / Low - Speed regulate input signal to the ICM2 motor.

PIN 11 - Heat Tap - Heating blower speed programming.

PIN 1 - C - 24 VAC common.

PIN 5 - Limit - Input signal from the external limit.

PIN 6 - R - 24 VAC power to the thermostat.

PIN 7 - C - 24 VAC common.

PIN 9 - CI - Input signal from the fan limit control. PIN 10 - CO - Output signal to the burner control.

PIN 5 - Low Tap - Low speed programming input.

Pin 8 - C - 24 VAC common.

PIN 12 - ACC - 24 VAC accessory output.

PIN 15 - V - Input signal from the gas line.

PIN 2 - C - 24 VAC common. PIN 3 - C - 24 VAC common.

PIN 7 - Adjust Tap - ICM2 mode selection.

PIN 10 - Ref. V - ICM2 reference voltage.

PIN 12 - C - 24 VAC common.

PIN 13 - cfm - Motor speed diagnostic signal.

ON/OFF

J73

J46

DS1

270

CFM

210

150

VOLTAGES INTO VSP2−1

Voltage across J73 pins 13 to 1 and 6 to 1 is 24VAC as shown here.

34 volts

volts

−34 volts

Voltage across J73 pins 4 to 1 is approximately 15-20VDC (straight voltage) if CCB is used. If Harmony is used a voltage of 0−25VDC should be present.

If CCB or Harmony is not used, pin 4 to 1 voltage is 21VAC.

Refer to unit wiring diagram.

24VAC @ 60Hz.

VOLTAGES FROM VSP2−1 TO ELECTRONICALLY

CONTROLLED BLOWER MOTOR

Voltage across J46 pins 6 to 3 and 1 to 3 is half-rectified AC as shown here.

Approx. 34 volts

volts

Voltage across J46 pins 8 and 9 to 3, is approximately 15-20VDC if CCB is used. If

CCB or Harmony is not used, pins 8 and 9 to 3 voltage is approximately 21VAC. If

Harmony is used a voltage of 0−25VDC should be present.

Refer to unit wiring diagram.

24VAC Half-Rectified (DC

Pulse)

@ 60Hz.

FIGURE 12

Diagnostic LED Lights

a − DS3 ON/OFF"

ON/OFF−DS3 indicates there is a demand for the blower motor

to run. When the ON/OFF LED−DS3 is lit, a demand is being sent to the motor. In heating mode only, there is a 45 sec o nd fan ON" delay in energizing ON/OFF LED−DS3. The light will not go off until adjustable fan OFF" delay has expired.

If ON/OFF LED−DS3 is on and both HIGH/LOW LED−DS1 & HEAT LED−DS2 are off, the motor will operate in low speed.

b − DS2 HEAT"

If HEAT LED−DS2 is on, the blower is running in the heat speed according to the HEAT" jumper setting. The HEAT LED−DS2 comes on instantaneous and switches off when the call for heat is satisfied.

NOTE−When the blower is in OFF" delay mode, the motor runs at low speed, therefore the HEAT LED−DS2 is off. It switches off when the call for heat is satisfied.

c − DS1 HI/LOW"

HIGH/LOW LED−DS1 indicates whether the blower is oper-

ating in high or low speed. When the light is off, the blower is running in low speed according to the LOW" jumper setting. When HIGH/LOW LED−DS1 is on, the blower is operating in high speed according to the HIGH" jumper setting.

d − DS4 CFM"

CFM LED−DS4 indicates the CFM the unit is operating, ac-

cording to the jumper settings. The light flashes once for approximately every 100 CFM. For example, if the unit is operating at 1000 CFM, CFM LED−DS4 will flash 10 times. If the CFM is 2050, CFM LED−DS4 will flash 20 full times plus one fast or half flash. At times the light may appear to flicker or glow. This takes place when the control is communicating with the motor between cycles. This is normal operation.

The appropriate speed according to application and CFM need is selected by moving jumper pins.

Page 15

Page 16

NOTE−On Harmony II zoning applications in the heating mode, the highest speed obtainable is the same as the highest cooling speed selection. Also, the heating speed (heat jumper position) is only used when the primary limit has been tripped. In non−zoning applications, refer to the section on the VSP2−1 control.

When W1 is energized, the LOW jumper selections are activated. The HEAT jumper selections are activated when W2 is energized.

NOTE−In Harmony II zoning applications, HEATING BLOWER jumper must be in position #2.

c−HEAT"

Jumper Settings

The HEAT jumper is used to set the blower speed to ob- tain the required CFM as outlined in HEAT SPEED section of the tables on page 3.

IMPORTANT

Before changing jumper setting, make sure the motor has completely stopped. Any jumper setting change will not take place while the motor is running.

To change jumper positions, gently pull the jumper off the pins and place it on the desired set of pins. The following section outlines the different jumper selections available and conditions associated with each one. Refer to figure 11 for identification.

After the CFM for each application has been determined, the jumper settings must be adjusted to reflect those given in the tables on page 3. Using the tables, determine w h i ch r o w of CFM volumes most closely matches the desired CFM. Once a specific row has been chosen (NORMAL or −), CFM volumes from other rows cannot be used. Below are the descriptions of each of the jumper selections.

Refer to table 11 for factory settings. Refer to the tables on page 3 for the approximate air volume for each setting.

TABLE 11

VSP2−1 FACTORY SETTINGS

MODEL

NUMBER

G32V3-75

G32V5-100 241

G32V5-120

HIGH LOW HEAT

ADJUST

NORM

a−ADJUST"

The ADJUST pins allow the motor to run at normal speed or approximately 15% lower than normal speed. The tables on page 2 give two rows (NORMAL and −) with their respective CFM volumes. The + adjustment setting is not operab le. Notice that the normal adjustment setting for heat speed position #3 is 2000 CFM (944 L/s). After the adjustment setting has been determined, cho s e th e re m a ining speed jumper settings from those offered in the table.

The HEAT jumper selections are activated with a call for second-stage heating (W2).

Before changing jumper setting, make sure the motor has completely stopped. Any jumper setting change will not take place while the motor is running.

d−HIGH"

The HIGH jumper is used to determine the CFM during cooling speed. These jumper selections are activated when G and DS terminals are energized.

e−LOW"

The LOW jumper is used to determine CFM during low speed cooling. These jumper selections are activated when G is energized. The LOW jumper may also be used for low speed heating. See the HEAT" section for details.

f−FAN OFF"

Fan OFF" timings (time that the blower operates after the heat demand has been satisfied) are determined by the arrangement of a jumper on the VSP2−1 board. See figure 13. To adjust fan OFF" timings, gently disconnect the jumper and reposition it across pins corresponding with the new timing. Fan OFF" time is adjustable from 90 to 330 seconds. The control has a non−adjustable, factory preset on" fan timing (45 seconds).

WARNING − MAKE SURE TO DISCONNECT POWER BEFORE CHANGING FAN OFF" TIMINGS.

TIMING

JUMPER

IMPORTANT

FAN-OFF TIME ADJUSTMENT

To adjust fan−off timings:

Remove jumper from VSP2−1 and

select one of the other pin combinations to achieve the desired

time.

The TEST pin is available to bypass the VSP2−1 control and run the motor at approximately 70% to test that the m o tor i s operational. This is beneficial primarily in troubleshooting. G must be energized for motor to run.

b−HEATING BLOWER"

For G32V units, place the HEATING BLOWER jumper across the second and third pins (position #2).

Page 16

270

150 90

FIGURE 13

210

Leave jumper off to achieve

330 second fan−off timing.

TIMING PINS (seconds)

Fan-off timing is factory

set at 90 seconds

Page 17

NOTEIf fan OFF" time is too low, residual heat in heat exchanger may cause primary limit S10 to trip resulting in frequent cycling of blower. If this occurs, adjust blower to longer time setting.

in relation to specific modes of operation. Some information has been repeated from the previous section to provide an example. Refer to each diagnostic LED or jumper settings section for more information.

Table 12 outlines the operation of the variable speed motor

TABLE 12

VSP2−1 G32V−1 / −3 units OPERATION

HEATING MODE

UNITS WITH

SINGLE−STAGE HEATING

NON−ZONED

APPLICATIONS

Using a single−stage thermostat with one−stage" heating, the HEAT LED− DS2 is lit when the thermostat calls for heat. The ON/OFF LED−DS3 is lit after 110 seconds (65 seconds pre−purge and 45 seconds fan ON" time) from the time a call for heat is made. This indicates the blower is operating in heating speed.

Using a single−stage thermostat with W2 TIMED," and W1 calling, the ON/ OFF LED−DS3 is lit to indicate the blower is operating on low speed.

When the HEAT LED−DS2 is lit, the blower is operating in heating speed, and second−stage (W2) heating is calling.

HARMONY ZONED

APPLICATIONS

The blower speed is controlled by the PWM (pulse width modulation) signal sent from the control center of the zoning system to the terminal strip’s DS terminal. HI/LOW LED−DS1 and ON/ OFF LED−DS3 are lit to indicate the blower is operating.

NOTE−In Harmony II zoning applications, HTG. BLOWER jumper must be in position #2.

NOTE: For zone applications with Harmony, remove the wire from the pin #3 of the J73 terminal on the VSP control board, insulate the end, and secure it to prevent from shorting.

Using a two−stage thermostat with first− stage (W1) calling, the ON/OFF LED− DS3 is lit to indicate the blower is operating in low speed.

When the ON/OFF LED−DS3 and HEAT LED−DS2 are lit, the blower is operating in heating speed and second−stage (W2) heating is calling.

HEAT LED−DS2 is lit with a call for heat from the thermostat. ON/OFF LED− DS3 is lit after 110 seconds from the time a call for heat is made.

NOTE−In Harmony II zoning applications, HTG. BLOWER jumper must be in position #2.

UNITS WITH

TWO−STAGE HEATING

NON−ZONED

APPLICATIONS

HARMONY ZONED

APPLICATIONS

UNITS WITH SINGLE−SPEED

COMPRESSOR

NON−ZONED

APPLICATIONS

The terminals DS and Y must be jumpered together. With a call for cooling, terminals G, Y and DS on the unit control board are energized from the thermostat. HI/LOW LED−DS1 and ON/ OFF LED−DS3 are lit to indicate the blower is operating on high speed.

NOTEY and DS are factory jumpered for single−stage cooling, non− zoned.

NOTEFor low speed during single− stage cooling remove jumper from Y and Ds.

HARMONY ZONED

APPLICATIONS

COOLING MODE

UNITS WITH TWO−SPEED

The ON/OFF LED−DS3 is lit to indicate the blower is operating in first stage cooling. This LED is energized on when a 24VAC thermostat demand is supplied to the control (terminal G" on the control board terminal strip).

In second stage, the ON/OFF LED− DS3 and HI/LOW LED−DS1 are lit to indicate the blower is operating on high speed (24VAC is supplied to the unit terminal strip Y2 from Y2 on the thermostat).

NOTE Jumper must be moved from Y1 to Y2 In two−speed, non−zoned applications.

HARMONY ZONED

COMPRESSOR

NON−ZONED

APPLICATIONS

Page 17

Page 18

7.VSP3−1 Blower Control Board (A24) G32V−4 Units

G32V−4 units are equipped with a variable speed motor that is capable of maintaining a specified CFM throughout the external static range. The unit uses the VSP3−1 variable speed control board, located in the blower compartment, which controls the blower speed and provides diagnostic LE Ds. The control has bot h a non−adjustable, factory preset ON" fan timing delay and an adjustable OFF" fan timing delay (see figure 13).

Diagnostic LEDs located on the VSP3−1 control board are provided to aid in identifying the unit’s mode of operation. Certain scenarios will arise depending on the jumper positions. Refer to figure 14 for identification.

IMPORTANT

The VSP3−1 also senses limit trip condition and turns on the blower. The G32V limit switch is located in the middle of the vestibule wall. When excess heat is sensed in t h e h e a t exchanger, the limit switch will open and interrupt the current to the gas valve, while at the same time the VSP3−1 energizes the blower on heating speed. The limit automatically resets when the unit temperature returns to normal and the blower is de−energized.

VSP3−1 VARIABLE SPEED CONTROL BOARD SELECTIONS

JP2

DELAY PROFILE

SELECTOR PINS

(COOLING ONLY)

COOL SPEED

SELECTOR PINS

(COOLING, HEATING and

CONTINUOUS FAN)

HEATING STAGE

JUMPER SELECTOR PINS

DELAY COOL ADJUST HEAT

HTG.

BLOWER

HEAT

DS2

24 VAC half wave rectified (DC pulse), when measured with a meter, may appear as a lower or higher voltage depending on the make of the meter. Rather than attempting to measure the output voltage of A24, see G32V BLOWER & VSP3 BLOWER CONTROL BOARD TROUBLESHOOTING FLOW CHART in the TROUBLESHOOTING section of this manual.

JP46

13 PIN PLUG

(BOARD TO MOTOR)

TEST

−

NORM

DS3

ON/OFF

HI/LOW

DS1

DS4

CFM

210

HEATING SPEED SELECTOR PINS

See table 13 for VSP3−1

factory settings

OPERATIONAL

SELECTOR PINS

(Affects both heating

and cooling modes)

DIAGNOSTIC

DS LEDS

JP73

15 PIN PLUG (BOARD TO VARIOUS POINTS IN FURNACE)

JP1

270

150

FAN OFF"

TIMING PINS

FIGURE 14

Page 18

Page 19

VSP3−1 BLOWER CONTROL BOARD (A24)

J46

DELAY COOL ADJUST HEAT

J73

J46

TEST

− + NORM

DS3

ON/OFF

HI/LOW

DS1

270

210

150

1 2 3 4

DS4

CFM

1 2 3 4

HTG.

BLOWER

J73

PIN 2 - G - Input signal from thermostat’s fan signal.

PIN 3 - W2 - Input signal for second stage heat from the thermostat.

PIN 4 - DS - Input signal for the blower speed regulation.

PIN 5 - Limit - Input signal from the external limit.

PIN 6 - R - 24 VAC power to the thermostat.

PIN 9 - CI - Input signal from the fan limit control. PIN 10 - CO - Output signal to the burner control.

PIN 11 - HT - Input signal from the fan limit control.

PIN 12 - ACC - 24 VAC accessory output. PIN 13 - 24V - Input 24 VAC power for the VSP2-1. PIN 14 - 24V - Input 24 VAC power for the VSP2-1.

PIN 15 - V - Input signal from the gas line.

PIN 4 - Delay Tap - Delay profile programming input.

PIN 5 - Cool Tap - Cooling blower programming input.

PIN 6 - On / Off - On / off output signal to the ICM2 motor.

PIN 7 - Adjust Tap - ICM2 mode selection.

PIN 9 - Hi / Low - Speed regulate input signal to the ICM2 motor with CCB1 and

PIN 10 - Ref. V - ICM2 reference voltage.

PIN 11 - Heat Tap - Heating blower speed programming.

PIN 13 - cfm - Motor speed diagnostic signal.

1 2 3 4

HEAT

DS2

PIN 1 - C - 24 VAC common.

PIN 7 - C - 24 VAC common.

Pin 8 - C - 24 VAC common.

PIN 1 - Not Used. PIN 2 - C - 24 VAC common. PIN 3 - C - 24 VAC common.

PIN 8 - NOT USED

HARMONY only

PIN 12 - C - 24 VAC common.

Diagnostic LED Lights

DS3 ON/OFF

ON/OFF−DS3 indicates there is a demand for the blower

motor to run. When the ON/OFF LED−DS3 is lit, a demand is being sent to the motor. In heating mode only, there is a 45−second fan ON" delay in energizing ON/OFF LED−DS3. Light will not go off until adjustable fan OFF" delay has expired.

If ON/OFF LED−DS3 is on and both HIGH/LOW LED−DS1

& HEAT LED−DS2 are off, the motor will operate in low

speed (heating).

DS2 HEAT

If HEAT LED−DS2 is on, the blower is running in second− stage heat speed according to the HEAT" jumper setting. In heating mode only, there is a 45 second delay in energizing HEAT LED−DS2. Light will not go off until adjustable fan OFF" delay has expired.

DS1 HI/LOW

HIGH/LOW LED−DS1 indicates the blower is operating in

the cooling mode.

DS4 CFM

CFM LED−DS4 indicates the CFM the blower is providing,

according to the jumper settings.

Jumper Settings

IMPORTANT

Before changing jumper setting, make sure the motor has completely stopped. Any jumper setting change will not take place while the motor is running.

VOLTAGES INTO VSP3−1

Voltage across J73 pins 13 to 1 and 6 to 1 is 24VAC as shown here.

34 volts

volts

−34 volts

Voltage across J73 pins 4 to 1 is approximately 15-20VDC (straight voltage) if CCB is used. If Harmony is used a voltage of 0−25VDC should be present.

If CCB or Harmony is not used, pin 4 to 1 voltage is 21VAC.

Refer to unit wiring diagram.

24VAC @ 60Hz.

VOLTAGES FROM VSP3−1 TO ELECTRONICALLY

CONTROLLED BLOWER MOTOR

Voltage across J46 pins 6 to 3 and 1 to 3 is half-rectified AC as shown here.

Approx. 34 volts

volts

Voltage across J46 pin 9 to 3 is approximately 15-20VDC if CCB is used. If CCB or

Harmony is not used, pin 9 to 3 voltage is approximately 21VAC. If Harmony is used

Refer to unit wiring diagram.

a voltage of 0−25VDC should be present.

24VAC Half-Rectified (DC

Pulse)

@ 60Hz.

FIGURE 15

After the CFM for each application has been determined, the

jumper settings must be adjusted to reflect those given in

the tables on page 3 and 4. Using the tables, determine wh i ch

row of CFM volumes most closely matches the desired

CFM. Once a specific row has been chosen (NORMAL or

−), CFM volumes from other rows cannot be used. Below

are the descriptions of each of the jumper selections. Re-

fer to table 13 for factory settings. Refer to CFM tables for

approximate air volume for each setting.

Page 19

Page 20

TABLE 13

VSP FACTORY SETTINGS FOR G32V−4 UNITS

MODEL

NUMBER

G32V3−75 4 4 NORM 3

G32V5−100 4 4 NORM 2

G32V5−125 4 4 " 4

NOTE − In Harmony II zoning applications in the heating mode, the highest cooling speed selected is the highest blower speed obtainable. Also, the fan−only speed is used when the primary limit has been tripped. In non−zoning applications, refer to the section on the VSP3−1 control.

DELAY COOL ADJUST HEAT

ADJUST

The ADJUST pins allow the motor to run at normal speed or approximately 15% lower than normal speed. Blower tables and the front of this manualgive two rows (NORMAL and −) with their respective CFM volumes. The + adjustment setting is not operable. Notice that the normal adjustment setting for heat speed position #3 is 2030 CFM (955 L/s) in table 4. After the adjustment setting has been determined, choose the remainder speed jumper settings from those in the table.

The TEST pin is available to bypass the VSP3−1 control and run the motor at approximately 70% to test that the motor is operational. This is beneficial primarily in troubleshooting. G must be energized for motor to run.

HTG. BLOWER

For G32V−4 units only, place the HTG. BLOWER jumper across the second and third pins (position #2).

NOTE − In Harmony II zoning applications, HTG. BLOWER jumper must be in position #2.

HEAT

The HEAT jumper is used to set the blower speed to obtain the required CFM as outlined in HEAT SPEED section of tables 3 and 4.

The HEAT jumper selections are activated with a call for first−stage heating (W1) and second−stage heating (W2).

DELAY

The DELAY jumper is used to set the specific motor fan mode of operation during cooling. Depending on the application, one of four fan options may be chosen by moving the jumper to the appropriate set of pins.

Options 1, 2, 3, or 4 will have an increased dehumidification effect on the system. Option 1 will have the least effect and option 4 will have the greatest effect.

#1 PIN JUMPERED

A − Motor runs at 100% until demand is satisfied. B − Once demand is met, motor ramps down to off.

A B

100% CFM

COOLING DEMAND

OFFOFF

#2 PIN JUMPERED

A − Motor runs at 82% for approximately 7−1/2 minutes. B − If demand has not been satisfied after 7−1/2 minutes,

the motor runs at 100% until demand is satisfied.

C − Once demand is met, motor ramps down to off.

OFF

7 1/2 MIN

82%CFM

100% CFM

COOLING DEMAND

#3 PIN JUMPERED A − Motor runs at 50% for 1/2 minute. B − Motor then runs at 82% for approximately 7−1/2 min-

utes.

C − If demand has not been satisfied after 7−1/2 minutes,

motor runs at 100% until demand is satisfied.

D − Once demand is met, motor ramps down to off.

C D

100% CFM

OFF

1/2 MIN 50% CFM

7 1/2 MIN 82% CFM

COOLING DEMAND

#4 PIN JUMPERED A − Motor runs at 50% for 1/2 minute. B − Motor then runs at 82% for approximately 7−1/2 min-

utes.

C − If demand has not been satisfied after 7−1/2 minutes,

motor runs at 100% until demand is satisfied.

D − Once demand is met, motor runs at 50% for 1/2 min-

ute.

E − Motor ramps down to off.

C D

100% CFM

1/2 MIN 50% CFM

OFF

1/2 MIN 50% CFM

7 1/2 MIN 82% CFM

COOLING DEMAND

COOL

The cool jumper is used to set the blower speed to obtain the required CFM as outlined in tables 3 and 4.

VSP Operation

Table 14 and 15 outline the operation of the variable speed motor in relation to specific modes of operation. Some information has been repeated from the previous section to provide an example. Refer to each diagnostic LED or jumper settings section for more information.

Page 20

Page 21

TABLE 14

Normal operation

blower speed follow thermostat

removal during 1st

ifi

ill i

When humidity demand is satisfied

satisfied during

gp p

Call f

idit

Call for 1st stage

Call for 2nd stage

Reduced blower speed (dehumidifi-

)

mostat demand), slide switch is

G32V−4 UNITS WITH CCB1, & TWO−SPEED OUTDOOR UNIT OPERATING SEQUENCE

Operating Sequence System Demand System Response

System

Condition

Step

Thermostat

Demand

*Relative Humidity

(EfficiencyPlus Lights)

***Compressor

Speed

Blower CFM

(COOL)

Comments

Normal operation

Call for humidity

removal during 1st

stage thermostat

demand

Significant increase

in humidity during

thermostat demand.

Humidity demand

satisfied during

thermostat demand.

or hum

removal during 2nd

stage thermostat

demand

*Call for 1st stage

cooling after call for

humidity removal.

Call for 2nd stage

cooling after call for

humidity removal

Call for cooling after significant increase

in humidity

Humidity demand

satisfied between

thermostat demands

(unit off cycle).

1 Y1 Acceptable (None) Low

2 Y2 Acceptable (None) High HIGH COOL

1 Y1 Acceptable (None) Low

2 Y1

Demand

satisfied

4 Y1 Slightly over setpoint (1) High

1 Y1 Acceptable (None) Low

2 Y1

1 Y1 Over Setpoint High

2 Y1

3 None Acceptable (None) Off Off

4 Y1 Acceptable (None) Low

1 Y2 Acceptable (None) High HIGH COOL

2 Y2

3 Y2 Acceptable (None) High HIGH COOL

1 None Slightly over setpoint (1) Off Off Dehumidification mode (high speed

2 Y1 Slightly over setpoint (1) Low

1 None Slightly over setpoint (1) Off Off

2 Y2 Slightly over setpoint (1) High

1 None

2 Y1 or Y2

1 None Over setpoint (1 or more) Off Off

2 Y1 or Y2

Change to slightly

over setpoint (1)

Slightly over setpoint (1) Off Off

Change to significantly

over setpoint (2 or more)

Change to Acceptable

(None)

Change to slightly

over setpoint (1)

Significantly over setpoint

(2 or more)

Significantly over

setpoint (2 or more

Change to

acceptable (None)

Low

High

High HIGH COOL

High

Off Off

High

High HIGH COOL

55% of

HIGH COOL

55% of

HIGH COOL

55% of

HIGH COOL

**77%/74% of

HIGH COOL

55% of

HIGH COOL

**77%/74% of

HIGH COOL

**77%/74% of

HIGH COOL

55% of

HIGH COOL

**77%/74% of

HIGH COOL

55% of

HIGH COOL

**77%/74% of

HIGH COOL

**77%/74% of

HIGH COOL

Compressor demand and indoor

blower s

Dehumidification mode begins with

next thermostat demand, after initial

thermostat demand is satisfied.

If humidity increases significantly

over setpoint, or if slide switch is

moved sign

ately go into dehumidification mode

(in presence of thermostat demand).

When humidity demand is satisfied

blower immediately shifts to the

HIGH COOL CFM in order to hasten

e end of the cycle. Unit can only

shift out of high speed compressor

operation at beginning of next cycle.

Blower immediately changes speed

in response to thermostat demand.

compressor) begins with next ther-

mostat demand after initial demand is

Reduced blower speed (dehumidifi-

cation speed) begins immediately

If humidity increases significantly

over setpoint, or if slide switch is

moved, unit immediately goes into

dehumidification mode (in presence

While unit is not operating (no ther-

mostat demand

moved down and back up. Blower

and compressor operate at high

speed until next thermostat demand.

eed follow thermostat

demand

cantly, unit w

satisfied.

with thermostat demand

of thermostat demand).

, slide switch is

mmedi-

Note − When changing unit mode of operation from cooling to heating, indicating lights that are on will stay on until the first thermostat heating demand.

*IMPORTANT - If power to unit is turned on with CCB1 calling for humidity removal, outdoor unit may be locked into high speed indefinitely. To reset, move humidity slide switch all the way down then back up to desired setpoint (with unit running) ** Reduced blower speed is 77% of COOL for the V3 units; 74% of COOL for V5. ***If the two−speed control on a two−speed outdoor unit is set for LATCH 2 (15 minutes) or LATCH 3 (30 minutes), the compressor will latch into high speed after a Y1 demand has occurred for that period of time.

Page 21

Page 22

Heating Mode Cooling Mode

Units With

Single−Stage Heating

Non−Zoned Applications

Using a single−stage thermostat with "one−stage" heating, the HEAT LED−DS2 is lit when the thermostat calls for heat. The ON/OFF LED− DS3 is lit after 110 seconds (65 seconds prepurge and 45 seconds fan "ON" time) from the time a call for heat is made. This indicates the blower is operating in high speed heat.

Using a single−stage thermostat with "W2 TIMED" and W1 calling, the ON/OFF LED−DS3 is lit to indicate the blower is operating on low speed heat.

When HEAT LED−DS2 is lit, the blower is operating in high speed heat and second−stage (W2) is calling.

G32V−4 Units with VSP3−1

TABLE 15

Units With

Two−Stage Heating

Non−Zoned Applications

Using a two−stage thermostat with first−stage (W1) calling, the ON/ OFF LED−DS3 is lit to indicate the blower is operating in low speed heat.

When the ON/OFF LED−DS3 and HEAT LED−DS2 are lit, the blower is operating in high speed heat and second−stage (W2) is calling.

HEAT LED−DS2 is lit with a call for heat from the thermostat. ON/OFF LED−DS3 is after 110 seconds from the time a call for heat is made.

Units With

Single−speed Compressor

Non−Zoned Applications

Y1−DS and Y1−Y2 must be jumpered together. With a call for cooling, G, Y1, Y2 and DS on the unit control board are energized from the thermostat. HI/LOW LED−DS1 and ON/OFF LED−DS3 are lit to indicate a call for cooling.

Note − Y1 to DS and Y1 to Y2 are factory jumpered for single−stage cooling, non−zoned applications.

Units With

Two−speed Compressor

Non−Zoned Applications

Y1−DS must be jumpered together. With a call for single−stage cooling, G, Y1, and DS on the unit control board are energized from the Thermostat. With a call for second−stage cooling, G, Y1, Y2, and DS on the unit control board are energized from the thermostat. In both cases, HI/LOW LED−DS1 and ON/OFF LED−DS3 are lit to indicate a call for cooling.

Note − Jumper Y1−Y2 must be removed for units with two−speed compressor.

Harmony Zoned Applications

The blower speed is controlled by the PWM (pulse width modulation) signal sent from the control center of the zoning system to the terminal strip’s DS terminal. HI/LOW LED− DS1 and ON/OFF LED−DS3 are lit to indicate the blower is operating.

Note − In Harmony II zoning applications, HTG BLOWER jumper must be in position #2.

Harmony Zoned Application

The blower speed is controlled by the PWM (pulse width modulation) signal sent from the control center of the zoning system to the terminal strip’s DS terminal. HI/LOW LED− DS1 and ON/OFF LED−DS3 are lit to indicate the blower is operating.

Note − In Harmony II zoning applications, HTG BLOWER jumper must be in position #2.

Harmony Zoned Application

The blower speed is controlled by the PWM (pulse width modulation) signal sent from the control center of the zoning system to the terminal strip’s DS terminal. HI/LOW LED− DS1 and ON/OFF LED−DS3 are lit to indicate the blower is operating.

Harmony Zoned Application

The blower speed is controlled by the PWM (pulse width modulation) signal sent from the control center of the zoning system to the terminal strip’s DS terminal. HI/LOW LED− DS1 and ON/OFF LED−DS3 are lit to indicate the blower is operating.

NOTE − For zone applications with Harmony, remove the wire from pin #2 and pin #13 of the J49 terminal at the motor and the wire from pin #3 of the J73 terminal on the VSP control board, insulate the ends and secure to prevent shorting.

8.Two Stage Variable Speed Control (A24) G32V−5 and later Units

(DS3, DS6, DS7 and DS8) to show furnace status. The board also has two accessory terminals rated at (1) one amp each. See table 20 for status code and table 21 for troubleshooting diagnostic codes.

WARNING

Shock hazard. Disconnect power before servicing. Integrated

Control Board is not field repairable. If control is inoperable, simply replace entire control.

Can cause injury or death. Unsafe operation will result if repair is attempted.

G32V−5 and later units are equipped with the Lennox two− stage, variable speed integrated SureLight control board. The system consists of a ignition / blower control board (figure 16 with control terminal designations in tables 16 through 19) and ignitor (figure 9). The board and ignitor work in combination to ensure furnace ignition and ignitor durability. The SureLight integrated board controls all major furnace operations. The board features two LED lights, DS1 and DS2 for troubleshooting and four LED lights

Electronic Ignition

At the beginning of the heat cycle the SureLight control monitors the combustion air inducer prove switch. The control will not begin the heating cycle if the prove switch is closed (by−passed). Once the prove switch is determined to be open, the combustion air inducer is energized on low (first stage) heat speed.

G32V−75 Only

At the beginning of the heat cycle the SureLight control monitors the first and second stage combustion air inducer prove switches. The control will not begin the heating cycle if the first stage prove switch is closed (by−passed). Like wise the control will not begin second stage heat if the second stage prove switch is closed and will allow first stage heat only. However, if the second stage prove switch closes DURING first stage pre−purge, the control will still respond to second stage heat.

Page 22

Page 23

Once the prove switch (first stage prove switch for G32V−75) is determined to be open, the combustion air inducer is energized on low (first stage) heat speed. When the differential in the prove switch is great enough, the prove switch closes and a 15−second pre−purge begins. If the switch is not proven within 2−1/2 minutes, the control goes into Watchguard−Pressure Switch mode for a 5−minute re−set period. After the 15−second pre−purge period, the SureLight ignitor warms up for 20 seconds after which the gas valve opens for a 4−second trial for ignition. The ignitor energizes during the trial until flame is sensed. If ignition is not proved during the 4−second period, the control will try four more times with an inter purge and warm−up time between trials of 35 seconds. After a total of five trials for ignition (including the initial trial), the control goes into Watchguard−Flame Failure mode. After a 60−minute reset period, the control will begin the ignition sequence again. The SureLight control board has an added feature that prolongs the life of the ignitor. After a successful ignition, the SureLight control utilizes less power to energize the ignitor on successive calls for heat. The control continues to ramp down the voltage to the ignitor until it finds the lowest amount of power that will provide a successful ignition. This amount of power is used for 255 cycles. On the 256th call for heat, the control will again ramp down until the lowest power is determined and the cycle begins again.

TW0−STAGE, VARIABLE SPEED INTEGRATED

CONTROL BOARD

DIAGNOSTIC

LEDs

DIP

SWITCHES

1 − 3

LEDs

DIP

SWITCHES

5 − 12

LED

Two Stage Operation / Thermostat Selection Jumper

The control can be utilized in two modes: SINGLE−STAGE thermostat or TWO−STAGE thermostat. The thermostat selection jumper E20, located just below dip switches 1 through 3 (figure 16), must be positioned for the particular application. The jumper is factory set on TWO" for use with a two−stage thermostat with two stage heat. Re−position jumper to SINGLE" for use with a single stage thermostat with two stage heat. While in the single−stage thermostat mode (single jumper setting), the burners will always fire on first−stage heat. The combustion air inducer will operate on low speed and indoor blower will operate on low heat speed. After a 10 minute recognition period, the unit will switch to second stage heat. While in the two−stage thermostat mode (two jumper setting) the burners will fire on first−stage heat. The combustion air inducer will operate on low speed and indoor blower will operate on low heat speed. The unit will switch to second−stage heat on call from the indoor thermostat. If there is a simultaneous call for first and second stage heat, the unit will fire an first stage heat and switch to second stage heat after 30 seconds of operation. See Sequence of Operation flow charts in the back of this manual for more detail.

ON−BOARD

JUMPER W914

(cut when CCB1 or

Harmony II are used)

THERMOSTAT CONNECTIONS (TB1)

DIP SWITCH FUNCTIONS

DIP SWITCH(ES) FUNCTION

1 and 2 Blower Off Delay

3 Second Stage ON Delay (Single−stage t’stat)

4 Not used 5 and 6 Cooling Mode Blower Speed 7 and 8 Blower Speed Adjustment

9 and 10 Cooling Mode Blower Ramping Profile

11 and 12 Heating Mode Blower Speed

ON−BOARD

JUMPER W915

(cut when two−stage

cooling is used)

JUMPER W951

(cut when heat pump is

used with FM21)

FIGURE 16

Page 23

Page 24

TABLE 16

Two Stage Ignition / Blower Control Terminals

LINE Line 120VAC Neutral

XFMR Transformer 120VAC Neutral

EAC Electronic Air Cleaner 120VAC Neutral

CIRC Indoor Blower 120VAC Neutral

HUM Humidifier 120VAC Neutral

HUM Humidifier 120VAC Hot

XMFR Transformer 120VAC Hot

LINE Line 120VAC Hot

CIRC Indoor Blower 120VAC Hot

EAC Electronic Air Cleaner 120VAC Hot

TABLE 17

SureLight Board 5 Pin Terminal Designation

PIN # Function

1 Ignitor

2 Combustion Air Inducer High Speed

3 Combustion Air Inducer Low Speed

4 Combustion Air Inducer Neutral

5 Ignitor Neutral

TABLE 18

SureLight Board 12Pin Terminal Designation

PIN # Function

1 Gas Valve High Fire

2 Second Stage Prove Switch (G32V−75)

3 Not Used

4 Ground

5 24V Hot

6 Primary Limit In

7 Gas Valve Low Stage

8 Gas Valve Common

9 24V Neutral

10 Ground

11 Primary Limit Out

12 1st Stage Prove Switch

TABLE 19

SureLight Board 16 Pin Blower Control Terminals

PIN # Function

1 Ground

2 Low Heat Speed

3 Ground

4 DELAY" Dip Switch Selection

5 COOL" Dip Switch Selection

6 Y1" Signal

7 ADJUST" Dip Switch Selection

8 Ground

9 0" From Thermostat

10 DS" Output Signal

11 HEAT" Dip Switch Selection

12 24 VAC

13 HIGH HEAT Speed

14 Y2" Signal

15 G"

16 CFM LED

Page 24

Page 25

TABLE 20

ONONON

Circuit board failure or control wired incorrectly. Check 24 and 115 volts to board.

STATUS CODES

STATUS LED COLOR FUNCTION

DS3

ON / OFF ’

DS6

CFM"

DS7

HI / LO"

DS8

HEAT"

GREEN

YELLOW

YELLOW DS8−ON indicates the system is in HEAT mode.

DS3−ON indicates that the motor has a demand to operate. (This LED must be on in all modes).

DS6−blinking indicates the airflow (CFM) demand in the motor. The air flow is determine by counting blinks between two (2) second pauses. One blink equals roughly 100 CFM.

DS7−ON indicaties the DS to R" jumper has not been cut. When the jumper is cut the system will be operating with LENNOX HARMONY II (See Harmony Installation Instructions) or with the CCB1 Efficiency Plus control. CCB1: When ON, a 24 VAC is being applied and when OFF, it has been removed. This on/off operation varies the indoor blower’s performance so dehumidification can be enhanced.

TABLE 21

DIAGNOSTIC CODES

Diagnostic LEDs are labeled DS1 and DS2. See figure 16 for location of diagnostic LEDs.

DS1 DS2 DESCRIPTION

SIMULTANEOUS

SLOW FLASH

SIMULTANEOUS

FAST FLASH

SLOW FLASH ON

OFF SLOW FLASH

OFF FAST FLASH

ALTERNATING

SLOW FLASH

SLOW FLASH OFF Flame sensed without gas valve energized.

ON ON

OFF ON

FAST FLASH SLOW FLASH Main power polarity reversed. Switch line and neutral.

SLOW FLASH FAST FLASH Low flame signal. Measures below 0.23 microAmps. Replace flame sense rod.

ALTERNATING

FAST FLASH

SIMULTANEOUS

SLOW FLASH

SIMULTANEOUS

FAST FLASH

ALTERNATING

SLOW FLASH

OFF

ALTERNATING

FAST FLASH

Power on − Normal operation. Also signaled during cooling and continuous fan.

Normal operation − signaled when heating demand initiated at thermostat.

Primary, secondary or rollout limit switch open. Limits must close within 3 minutes or unit goes into 1 hour Watchguard. Low pressure switch open; (G32V−75 only) OR: Blocked inlet/exhaust vent; OR: Low pressure switch closed prior to activation of combustion air inducer.

High pressure switch open; OR: Blocked inlet/exhaust vent; OR: High pressure switch closed prior to activation of combustion air inducer.

Watchguard −− burners failed to ignite; OR limit open more than 3 minutes; OR lost flame sense 5 times in one heating cycle; OR pressure switch opened 5 times in one heating cycle.

Circuit board failure or control wired incorrectly. Check 24 and 115 volts to board.

The following conditions are sensed during the ignitor warm−up period only:

1) Improper main ground;

2) Broken ignitor; OR: Open ignitor circuit;

3) Line voltage below 75 volts. (If voltage lower than 75 volts prior to ignitor warm-up, control will signal waiting on call from thermostat, and will not respond.

NOTE − Slow flash rate equals 1 Hz (one flash per second). Fast flash rate equals 3 Hz (three flashes per second). Minimum flame sense current = 0.17−0.22 microAmps.

Page 25

Page 26

Dip Switch Settings Switches 1 and 2 −− Blower Off Delay −− The blower−on

delay of 45 seconds is not adjustable. The blower−off delay (time that the blower operates after the heating demand has been satisfied) can be adjusted by moving switches 1 and 2 on the integrated control board. The unit is shipped from the factory with a blower−off delay of 90 seconds. The blower off delay affects comfort and is adjustable to satisfy individual applications. Adjust the blower off delay to achieve a supply air temperature between 90° and 110°F at the exact moment that the blower is de−energized. Longer off delay settings provide lower supply air temperatures; shorter settings provide higher supply air temperatures.The table below provides the blower off timings that will result from different switch settings.

TABLE 22

Blower Off Delay Switch Settings

Blower Off Delay

(Seconds)

Switch 1 Switch 2

60 Off Off

90 Off On 120 On Off 180 On On

Switch 3 −− Second Stage Delay (Used with Single− Stage Thermostat Only) −− This switch is used to deter-

mine the second stage on delay when a single−stage thermostat is being used. The switch is factory−set in the ON position, which provides a 10−minute delay before second− stage heat is initiated. If the switch is toggled to the OFF position, it will provide a 15−minute delay before second− stage heat is initiated. This switch is only activated when the thermostat selector jumper is positioned for SINGLE−stage thermostat use.

Switch 4 −− Not used. Switches 5 and 6 −− Cooling Mode Blower Speed −−

Switches 5 and 6 are used to select cooling blower motor speed. The unit is shipped from the factory with the dip switches positioned for high speed (4) indoor blower motor operation during the cooling mode. The table below provides the cooling mode blower speeds that will result from different switch settings. Refer to blower data tables at the front of this manual for corresponding cfm values.

TABLE 23

Cooling Mode Blower Speeds

Speed

Switch 5 Switch 6

1 − Low On On

2 − Medium Low Off On

3 − Medium High On Off

4 − High (Factory) Off Off

Switches 7 and 8 −− Blower Speed Adjustment −−

Switches 7 and 8 are used to select blower speed adjustment settings. The unit is shipped from the factory with the dip switches positioned for NORMAL (no) adjustment. The dip switches may be positioned to adjust the blower speed by +10% or −10% to better suit the application. The table below provides blower speed adjustments that will result from different switch settings. Refer to blower data tables at the front of this manual for corresponding cfm values.

TABLE 24

Blower Speed Adjustment

Adjustment

Switch 7 Switch 8

+10% (approx.) On Off

NORMAL (Factory) Off Off

−10% (approx.) Off On

Switches 9 and 10 −− Cooling Mode Blower Speed Ramping −− Switches 9 and 10 are used to select cooling

mode blower speed ramping options. Blower speed ramping may be used to enhance dehumidification performance. The switches are factory set at option A which has the greatest effect on blower motor performance. The table below provides the cooling mode blower speed ramping options that will result from different switch settings. The cooling mode blower speed ramping options are detailed on the next page. See unit nameplate for manufacturing date.

TABLE 25

Cooling Mode Blower Speed Ramping

Ramping Option

Switch 9 Switch 10

A (Factory) Off Off

B On Off C Off On

D* On On

*Only option for CCB1

Page 26

Page 27

G32V units manufactured before April 2003

Ramping Option A (Factory Selection)

 Motor runs at 50% for 1/2 minute.  Motor then runs at 82% for approximately 7−1/2 min-

utes.

 If demand has not been satisfied after 7−1/2 minutes,

motor runs at 100% until demand is satisfied.

 Once demand is met, motor runs at 50% for 1/2 min-

ute.

 Motor ramps down to off.

G32V units manufactured April 2003 and later

Ramping Option A (Factory Selection)

S Motor runs at 50% for 30 seconds. S Motor then runs at 82% for approximately 7−1/2 min-

utes. If demand has not been satisfied after 7−1/2 minutes.

S Motor runs at 100% until demand is satisfied. S Once demand is met, motor runs at 50% for 30 seconds

then −

S ramps down to stop.

OFF

1/2 MIN 50% CFM

7−1/2 MIN 82% CFM

COOLING DEMAND

100% CFM

1/2 MIN 50% CFM

OFF

Ramping Option B

 Motor runs at 50% for 1/2 minute.  Motor then runs at 82% for approximately 7−1/2 min-

utes.

 If demand has not been satisfied after 7−1/2 minutes,

motor runs at 100% until demand is satisfied.

 Once demand is met, motor ramps down to off.

OFF

1/2 MIN 50% CFM

7−1/2 MIN 82% CFM

COOLING DEMAND

100% CFM

OFF

Ramping Option C

 Motor runs at 82% for approximately 7−1/2 minutes.  If demand has not been satisfied after 7−1/2 minutes,

the motor runs at 100% until demand is satisfied.

 Once demand is met, motor ramps down to off.

OFF

7−1/2 MIN

82%CFM

COOLING DEMAND

100% CFM

OFF

1/2 MIN 50% CFM

7 1/2 MIN 82% CFM

COOLING DEMAND

100% CFM

1/2 MIN 50% CFM

OFF

Ramping Option B

S Motor runs at 82% for approximately 7−1/2 minutes. If

demand has not been satisfied after 7−1/2 minutes −

S motor runs at 100% until demand is satisfied. S Once demand is met, motor ramps down to stop.

OFF

7 1/2 MIN

82%CFM

COOLING DEMAND

100% CFM

OFF

Ramping Option C

S Motor runs at 100% until demand is satisfied.

S Once demand is met, motor runs at 100% for 60 sec-

onds. Then,

S ramps down to stop.

OFF

100% CFM

COOLING DEMAND

100% CFM

OFF

Ramping Option D

 Motor runs at 100% until demand is satisfied.  Once demand is met, motor ramps down to off.

100% CFM

COOLING DEMAND

OFFOFF

Page 27

Ramping Option D

S− Motor runs at 100% until demand is satisfied.

S− Once demand is met, motor ramps down to stop.

100% CFM

COOLING DEMAND

OFFOFF

Page 28

Switches 11 and 12 −− Heating Mode Blower Speed −−

idit

Dehumidification mode begins when rela

satisfied between

lid

Switches 11 and 12 are used to select heating mode blower motor speed. The unit is shipped from the factory with the dip switches positioned for medium low (2) speed indoor blower motor operation during the heating mode. The table below provides the heating mode blower speeds that will result from different switch settings. Refer to blower data tables at the front of this manual for corresponding cfm values.

TABLE 26

Heating Mode Blower Speeds

Speed

Switch 11 Switch 12

1 − Low On On

2 − Medium Low

(Factory)

Off On

3 − Medium High On Off

4 − High Off Off

On−Board Jumper W914

On−board jumper W914, which connects terminals DS and R on the integrated control board, must be cut when the furnace is installed with either the Harmony II zone control board or the CCB1 EfficiencyPlus humidity control. Refer to table 27 for operation sequence in applications including a G32V, CCB1 and single−speed outdoor unit. Table 28 gives the operation sequence in applications with a two−speed outdoor unit.

On−Board Jumper W951

On−board jumper W951, which connects terminals R and O on the integrated control board, must be cut when the furnace is installed in applications which include a heat pump unit and the FM21 FuelMaster control board.

On−Board Jumper W915

On board jumper W915, which connects Y1 to Y2 terminals on the integrated control board terminal strip must be cut if two−stage cooling will be used.

On−Board Jumper W6

On board jumper W6 is an external measuring device for indoor blower CFM. If by chance W6 is cut, the CFM LED will not operate but the furnace will operate as normal. The jumper has no affect on furnace operation.

Diagnostic LEDs (DS1 and DS2)

Two diagnostic LEDs are located on the two−stage, variable speed integrated control just to the left of the first bank of dip switches. These lights’ flashes correspond with diagnostic codes detailed on in table 21.

Status LEDs (HEAT, HI/LO, ON/OFF and CFM)

The integrated control includes four LEDs which indicate operating status. The green ON/OFF LED is lit any time the blower is operating. The green CFM LED indicates the blower motor speed. Count the number of blinks between the two−second pauses to determine the CFM. Each blink represents approximately 100 CFM. The yellow HI/LO LED is lit when the W914 (DS to R) jumper has not

been clipped for CCB1 or Harmony operation. The yellow HEAT LED is lit when the indoor blower is operating at the HEATING speed.

G32V−5, CCB1 and Single−Speed Outdoor Unit

TABLE 27

OPERATING MODE SYSTEM DEMAND SYSTEM RESPONSE

System Condition

Normal operation Y1

*Call for humidity

removal during

cooling demand

Dehumidification demand satisfied

during cooling demand.

Call for cooling after

call for hum

removal.

Humidity demand satisfied between

thermostat demands

(unit off cycle).

NOTE − When changing unit mode of operation from cooling to heating, indicating lights that are on will stay on until the first thermostat heating demand. * Reduced blower speed is 77% of COOL for V3 units and 74% of COOL for the V5 units.

Thermostat

Demand

None

None Over setpoint (1 or more) Off

Y1 Change to acceptable COOL

*Relative Humidity

(EfficiencyPlus Lights)

No demand. Humidity

level is acceptable

Humidity level rises

above setpoint. Demand

initiated.

Humidity level falls below

setpoint. No demand

Humidity level above set-

point. Demand initiated.

Humidity level above set-

point. Demand initiated.

Blower

CFM

(COOL)

COOL

77%/74% of COOL

COOL

Off

77%/74%

of COOL

Comments

Compressor demand and indoor blower speed controlled by thermostat demand.

Call for dehumidification initiated by CCB1 control. Indoor blower speed reduced by CCB1 control.

When humidity demand is satisfied, blower speed immediately increases to the COOL CFM to hasten the end of the cycle.

Dehumidification mode begins when relative humidity is greater than setpoint.

While unit is not operating (no thermostat

emand), s

back up. Blower operates at COOL CFM.

e switch is moved down an

Page 28

Page 29

TABLE 28

Normal operation

blower speed controlled by

removal during

until after initial thermostat demand is

humidity duri

point, or if slide switch is moved signifi

When humidity demand is satisfied,

satisfied during

speed compressor operation at begin

compressor) begins with next thermo

satisfied between

G32V−5, CCB1 and Two−Speed Outdoor Unit

OPERATING MODE SYSTEM DEMAND SYSTEM RESPONSE

System

Condition

Normal operation

Call for humidity

1st−stage cooling

demand

Significant increase in

thermostat cooling

demand.

Humidity demand

satisfied durin

thermostat demand.

Call for humidity

removal during 2nd

stage thermostat

eman

*Call for 1st stage

cooling after call for

humidity removal.

Call for 2nd stage

cooling after call for

humidity removal

Call for cooling after

significant increase in

humidity

Humidity demand

satisfied between

thermostat demands

(unit off cycle).

Note − During mode of operation change from cooling to heating, indicating lights will not change until the first thermostat heating demand.

Thermostat

Demand

Y1 No demand. Acceptable Low

Y2 No demand. Acceptable High HIGH COOL

Y1 No demand. Acceptable Low

Demand

satisfied

None

Y1 or Y2

None

Y1 or Y2

*Relative Humidity

(EfficiencyPlus Lights)

Humidity level rises slightly

(1) above setpoint. Demand

initiated.

Humidity level remains

slightly (1) above setpoint.

Demand continues.

Humidity level remains

slightly (1) above setpoint.

Demand continues.

No demand. Acceptable

Humidity level rises signifi-

cantly (2 or more) above

setpoint. Demand initiated.

Humidity level

above setpoint.

Humidity level falls below

setpoint. No demand.

No demand. Acceptable

Humidity level rises slightly

(1) above setpoint. Demand

initiated.

No demand. Acceptable

Humidity level is slightly (1)

above setpoint.

Humidity level is slightly (1)

above setpoint.

Humidity level is slightly (1)

above setpoint.

Humidity level is slightly (1)

above setpoint.

Humidity level is significantly

above setpoint (2 or more).

Humidity level is significantly

above setpoint (2 or more).

Humidity level is slightly (1)

above setpoint.

Humidity level falls below

setpoint. No demand.

****Compressor

Speed

Low

Off

High

Low

High

Off

Low

High

Off

Low

Off

High

Off

High

Off

High

Blower CFM

HIGH COOL

**77%/74% of

HIGH COOL

**77%/74% of

HIGH COOL

**77%/74% of

HIGH COOL

**77%/74% of

HIGH COOL

**77%/74% of

HIGH COOL

**77%/74% of

HIGH COOL

(COOL)

55% of

Off

55% of

Off

55% of

Off

55% of

Off

Comments

Compressor demand and indoor

blower s

Dehumidification mode does not begin

satisfied and new cooling demand is

If humidity rises significantly above setpoint, or if slide switch is moved signifi-

cantly, unit will immediately go into de-

humidification mode (in presence of

When humidity demand is satisfied,

blower immediately shifts to the COOL

CFM in order to hasten the end of the

cycle. Unit can only shift out of high

speed compressor operation at begin-

Blower immediately changes speed in

response to thermostat demand.

Dehumidification mode (high speed

compressor) begins with next thermo-

stat demand after initial demand is sat-

Reduced blower speed (dehumidifica-

tion speed) begins immediately with

If humidity increases significantly over

setpoint, or if slide switch is moved,

unit immediately goes into dehumidifi-

cation mode (in presence of thermostat

While unit is not operating (no thermo-

stat demand), slide switch is moved

down and back up. Blower and com-

pressor operate at high speed until

next thermostat demand.

eed controlled by

thermostat demand

initiated.

thermostat demand).

ning of next cycle.

isfied.

thermostat demand

demand).

*IMPORTANT - If power to unit is turned on with CCB1 calling for humidity removal, outdoor unit may be locked into high speed indefinitely. To reset, move the humidity slide switch all the way down then back up to desired setpoint while the unit is running. ** Reduced blower speed is 77% of COOL for the V3 units; 74% of COOL for V5. ***If the two−speed control on a two−speed outdoor unit is set for LATCH 2 (15 minutes) or LATCH 3 (30 minutes), the compressor will latch into high speed after a Y1 demand has occurred for that period of time.

Page 29

Page 30

C−Blower Compartment (Figure 17)

Located inside the blower compartment are the variable speed blower motor (B3), coil choke (L13), and the secondary limit switches [(1)S21 and (2)S21]. To access the blower compartment follow the steps outlined below:

1. Blower Motor (B3)

G32V units use a three-phase, electronically controlled D.C. brushless motor (controller converts single phase a.c. to three phase D.C.), with a permanent-magnet-type rotor (figure 18). Because this motor has a permanent magnet rotor it does not need brushes like conventional D.C. motors. Internal components are shown in figure 19. The stator windings are split into three poles which are electrically connected to the controller. This arrangement al l o ws mo tor windi n g s to tu r n on an d off in sequence by the controller.

SUPPLY AIR BLOWER

AND SECONDARY LIMITS

G32V BLOWER MOTOR B3

J48

SHAFT

MOTOR

CONTROLLER

J49

FIGURE 18

G32V BLOWER MOTOR COMPONENTS

STATOR

(WINDINGS)

BEARING

OUTPUT

SHAFT

ROTOR

FIGURE 19

A solid-state controller is permanently attached to the motor. The controller is primarily an A.C. to D.C. converter. Converted D.C. power is used to drive the motor. The controller contains a microprocessor which monitors varying conditions inside the motor (such as motor workload).

COIL

CHOKE

(L13)

To Remove Blower From Unit: Remove Bolts and

Wiring Jackplugs. Then Slide Out Front of Unit.

BLOWER

WHEEL

FIGURE 17

To Remove Blower:

1. Turn off line voltage power. Unplug J69 from P69 located on blower deck.

2. Disconnect thermostat wiring connections at the terminal strip.

3. Disconnect J58/P58 and located on blower deck.

4. Disconnect J43/P43 and J49/P49 from blower motor.

5. Disconnect wires from power choke.

6. Remove screw from control panel bracket at the blower.

7. Loosen screws (2) and remove control box assembly from unit. Holes are slotted so screws do not need to be removed.

8. Remove screws (2) and remove blower from unit.

BLOWER

MOTOR (B6)

FIGURE 20

The controller uses sensing devices to sense what position the rotor is in at any given time. By sensing the position of the rotor and then switching the motor windings on and off in sequence, the rotor shaft turns the blower.

G32V series blower motor ratings are listed in table 29. All G32V blower motors use single phase power. An external run capacitor is not used. The motor uses permanently lubricated ball-type bearings.

434

Page 30

Page 31

TABLE 29

ELECTRONICALLY CONTROLLED BLOWER MOTOR

Unit Volts Phase HP

G32V3 120 1

CCW ROTATION

1/2

1G32V5 120

Internal Operation

Each time the controller switches a stator winding (figure 19) on and off, it is called a pulse." The length of time each pulse stays on is called the pulse width." By varying the pulse width (figure 21), the controller varies motor speed (called pulsewidth modulation"). This allows for precise control of motor speed and allows the motor to compensate for varying load conditions as sensed by the controller. In this case, the controller monitors the static workload on the motor and varies motor rpm in order to maintain constant airflow (cfm).

The motor is equipped with 11 incremental taps which are driven by the integral controller. The controller is capable of controlling three of the 11 taps.

The motor controller is driven by the VSP2−1, VSP3−1 or two−stage variable speed SureLight control. The control receives its demand (PWM signal or fixed 24 VAC or VDC signal) from optional controls such as the Harmony zone control system, Efficiency Plus Humidity Control (CCB1) or a conventional thermostat.

Motor rpm is continually adjusted internally to maintain constant static pressure against the blower wheel. The controller monitors the static work load on the motor and motor ampdraw to determine the amount of rpm adjustment. Blower rpm may be adjusted any amount in order to maintain a constant cfm as shown in Blower Ratings Tables. The amount of adjustment is determined by the incremental taps which are used and the amount of motor loading sensed internally. The cfm remains relatively stable over a broad range of static pressure. Since the blower constantly adjusts rpm to maintain a specified cfm, motor rpm is not rated. Hence, the terms blower speed" and speed tap" in this manual, on the unit wiring diagram and on blower B3 refer to blower cfm regardless of motor rpm.

When Harmony is used, speed taps are overridden and a PWM signal generated by the Harmony controller continuously varies motor speed based upon zone demands.

Initial Power Up

When line voltage is applied to B3, there will be a large inrush of power lasting less than 1/4 second. This inrush charges a bank of DC filter capacitors inside the controller. If the disconnect switch is bounced when the disconnect is closed, the disconnect contacts may become welded. Try not to bounce the disconnect switch when applying power to the unit.

Motor Start-Up

When B3 begins start-up, the motor gently vibrates back and forth for a moment. This is normal. During this time the electronic controller is determining the exact position of the rotor. Once the motor begins turning, the controller slowly eases the motor up to speed (this is called soft-start"). The motor may take as long as 10-15 seconds to reach full speed. If the motor does not reach 200rpm within 13 seconds, the motor shuts down. Then the motor will immediately attempt a restart. The shutdown feature provides protection in case of a frozen bearing or blocked blower wheel. The motor may attempt to start eight times. If the motor does not start after the eighth try, the controller locks out. Reset controller by momentarily turning off power to unit.

The DC filter capacitors inside the controller are connected electrically to the speed tap wires. The capacitors take approximately 5 minutes to discharge when the disconnect is opened. For this reason it is necessary to wait at least 5 minutes after turning off power to the unit before attempting to change speed taps.

DANGER

Disconnect power from unit and wait at least five minutes to allow capacitors to discharge before attempting to adjust motor speed tap settings. Failure to wait may cause personal injury or death.

Page 31

Page 32

MOTOR SPEED CONTROL WITH D.C. PULSE-WIDTH MODULATION

Motor speed is determined by the size of the electrical pulse sent to

the motor windings. The longer the pulse, the faster the motor.

OUTPUT FROM CONTROLLER TO MOTOR WINDINGS

WINDINGS TURNED OFF

The frequency of the pulses to the windings is 20KHz.

DO NOT ATTEMPT TO MEASURE THESE VOLTAGES.

LOW SPEED HEAT/COOL (output from controller to motor windings)

One

Pulse

One revolution

325VDC

O volts

WINDING #1

325VDC

O volts

WINDING #2

325VDC

O volts

WINDING #3

HIGH SPEED HEAT (output from controller to motor windings)

One revolution

325VDC

O volts

WINDING #1

325VDC

O volts

WINDING #2

325VDC

O volts

WINDING #3

WINDINGS TURNED ON

ON PULSE

OFF PULSE

HIGH SPEED COOL (output from controller to motor windings)

One revolution

325VDC

O volts

WINDING #1

325VDC

O volts

WINDING #2

325VDC

O volts

WINDING #3

FIGURE 21

Page 32

Page 33

External Operation (Speed Tap Priority)

Figure 22 shows the two quick-connect jacks (J48 and J49) which connect the motor to the G32V. Jack J48 is the power plug and jack J49 connects the unit controls to the motor.

Line voltage must be applied to J48 pin 5 in order for the motor to operate. When using 120VAC pins 1 and 2 must be jumpered. When control voltage is applied to J49 pin 3 and 15 (single stage heating and cooling), the motor is energized on the low speed heat/cool tap.

When voltage is applied to J49 pin 2 in addition to pin 3 and 15 (second stage heating), the blower is energized on the high speed heating tap. When voltage is applied to J49 pin 10 in addition to pin 3 and 15 (second stage cooling), the blower is energized on the high speed cooling tap. The motor assigns priority to J49 pin 2 so that if a call for cooling and a call for heating are concurrent, heating call overrides and the blower operates on high speed heating tap.

ICM2 with VSP3 and Two Stage Variable Speed

Control

The ICM2 operates slightly different than stated above when matched with the VSP3 control. When control voltage is applied to J49 pin 3 and 15, the motor is energized on continuous fan. When voltage is applied to J49 pin 2 in addition to pin 3 and 15 (first stage heating), the blower is energized on the low speed heating tap. When voltage is applied to J49 pin 13 in addition to pin 3 and 15 (second stage heating), the blower is energized on the high speed heating tap. The motor assigns priority to J49 pin 2 so that if a call for cooling and a call for heating are concurrent, heating call overrides and the blower operates on high speed heating tap.

DANGER

Do not attempt to repair electronically controlled blower motor or VSP. There are no field serviceable parts. If either component appears to be faulty after following checkout procedure, replace entire component then recheck for proper operation.

2−Choke Coil (L13)

A choke coil is used on all G32V units. The choke is located on the blower housing and is used to block radio frequency interference.

Precautions

If the G32V or its electronically controlled blower motor is improperly or inadequately grounded, it may cause television interference (commonly known as RFI or radio frequency interference).

This interference is caused by internal switching frequencies of the motor controller. TV interference may show up a s sm a l l s p e cks o r l i n es which randomly appear on the TV screen accompanied by pops or clicks in the sound. Before attempting any service, make sure the indoor unit is causing the interference. To check, disconnect power to indoor unit then check TV for continued signs of interference.

TV interference may be stopped by making sure the motor is solidly grounded to the cabinet (metal to metal) and by making sure the cabinet is solidly grounded. If TV interfe r ence pe r s ists, make su r e the television (and all affected RF appliances) are moved away from the G32V. Also make sure affected appliances are connected to a separate electrical circuit.

BLOWER B3 HARNESS CONNECTORS

POWER

CONNECTOR J48

J48 PIN 1 - Jumper PIN 1 to PIN2 for 120VAC line input only. PIN 2 - Jumper PIN 1 to PIN2 for 120VAC line input only. PIN 3 - Ground PIN 4 - AC Line PIN 5 - AC Line

CONTROL

CONNECTOR J49

J49 PIN 1 - C1 PIN 2 - W / W1 PIN 3 - C2 PIN 4 − Delay

PIN 5 - Cool PIN 6 - Y1 PIN 7 - Adjust PIN 8 - 0ut PIN 9 - 0 PIN 10 - BK / PWM PIN 11 - Heat PIN 12 - R PIN 13 - EM / W2 PIN 14 - Y / Y2 PIN 15 - G PIN 16 - Out +

FIGURE 22

Page 33

Page 34

D−Heating Components

1.Flame Sensor

A flame sensor is located on the left side of the burner support. See figure 23. The sensor is mounted on a bracket in the burner support and the tip protrudes into the flame envelope of the left−most burner. The sensor is fastened to burner supports and can be removed for service without removing any part of the burners. During operation, flame is sensed by current passed through the flame and sensing electrode. The SureLight control allows the gas valve to remain open as long as flame signal is sensed.

SENSOR

3/8"

IGNITOR

SPADE CONNECTORS

G32V SERIES UNITS AND ALTERNATE STYLE

LIMIT CONTROL (S10) FOR

Units may be equipped with either style limit.

LIMIT

INSULATING COVER (s)

FIGURE 24

4.Flame Rollout Switch (S47)

Flame rollout switch S47 is a SPST N.C. high temperature limit

located on the right side of the burner box assembly (see figure

25). S47 is wired to the burner ignition control A92. When

S47 senses flame rollout (indicating a blockage in the

combustion passages), the flame rollout switch trips,

and the ignition control immediately closes the gas

va lve. Switch S47 in all G32V units is factory preset to open

at 200F +

flame rollout switches are manually reset.

12F (93C + 6.7C) on a temperature rise. All

FLAME ROLLOUT SWITCH (S47)

FIGURE 23

NOTE − The G32V furnace contains electronic components that are polarity sensitive. Make sure that the furnace is wired correctly and is properly grounded.

2.Combustion Air Inducer (B6)

All G32V units use a two−stage combustion air inducer to move air through the burners and heat exchanger during heating operation. The blower uses a 120VAC motor. The motor operates during all heating operation and is controlled by the SureLight integrated control A92 and the two−stage control board A86. The combustion air inducer operates for 15 seconds before burner ignition (pre-purge) and for 5 seconds after the gas valve closes (post-purge). The combustion air inducer operates on low speed during first−stage heat (low fire), then switches to high speed for second−stage heat (high fire).

3.Primary Limit Control (S10) Figure 24

The primary limit (S10) on G32V units is located in the middle of the heating vestibule panel. When excess heat is sensed in the heat exchanger, the limit will open. If the limit is tripped, the furnace control energizes the supply air blower and de−energizes the gas valve. The limit automatically resets when unit temperature returns to normal. The switch is factory set and cannot be adjusted. The switch may have a different setpoint for each unit model number. However, the setpoint will be printed on the outside face of the limit.

FLAME ROLLOUT

SWITCH (S47)

RE 2

5.Burners

All units use inshot burners (see figure 26). Burners are factory set and do not require adjustment. A sight glas s is furn i s hed in the burner box assembly for flame viewing. Always operate the unit with the b urner box cover in place. Burners can be removed as an assembly for service. Burner maintenance and service is detailed in the MAINTENANCE section of this manual. Each burner uses an orifice which is precisely matched to the burner input (see nameplate for orifice size). The orifice is threaded into the burner manifold. The burner is supported by the orifice and will easily slide off for service. Each orifice and burner are sized specifically to the unit. Refer to Lennox Repair Parts Listing for correct sizing information. A flame retention ring in the end of each burner maintains correct flame length and shape and keeps the flame from lifting off the burner head. In addition, the burner entrance to each clamshell (Figure 2) is fitted with a corbel cup (orifice) used to direct the flow of combustion products.

TYPICAL BURNER ASSEMBLY

FIGURE 26

Page 34

Page 35

6.Gas Valve

The G32V uses gas valves manufactured by White Rodg-

ers or Honeywell. The valves are two-stage internally re-

dundant to assure safety shut−off. If the gas valve must be

replaced, the same type valve must be used. The Honey-

well valve (figure 27) is adjustable on low fire and high fire

and is field convertible for LP. WhiteRodgers supplies two

separate valves for natural and LP (figures 28 and 29) .

White Rodgers valves are not adjustable on low fire.

WHITE RODGERS 36E SERIES GAS VALVE

PROPANE GAS

HIGH HEAT MANIFOLD

PRESSURE

ADJUSTMENT

ON SIDE

(under cap)

MANIFOLD

PRESSURE

OUTLET ON

SIDE

24VAC terminals and gas control knob are located on top of the

valve. Terminals on the gas valve are connected to wires from

the SureLight integrated control and the two−stage control. 24V

applied to the terminals energizes the valve.

IMPORTANT

WhiteRodgers valve is NOT adjustable on low fire. Do not attempt to adjust low fire on WhiteRodgers valve.

HONEYWELL VR8205 Series Gas Valve

HIGH FIRE

ADJUSTMENT

SCREW

(under cap)

lOW FIRE

ADJUSTMENT

SCREW

(under cap)

GAS VALVE SHOWN IN OFF POSITION

INLET PRESSURE TAP

FIGURE 27

MANIFOLD PRESSURE

TAP

FIGURE 29

100% Sealed Combustion

The burner box is completely sealed and operates under a negative pressure. A pressure hose is connected from the burner box to the gas valve regulator and differential pressure switch. The gas valve senses the pressure in the burner box and changes gas valve output based on changes in burner box pressure. The intent is to compensate for different vent configurations which can greatly affect the rate of the unit.

Figure 30 show how gas valve output changes as burner box pressure changes. Generally, a lower burner box pressure produces a leaner gas/air mixture and a higher burner box pressure produces a richer mixture. Burner box pressure pressure will be between 0" and −1.0". Manifold pressure for natural units should be 3.5" W.C. + or − .30" and 7.0" W.C. + or − .30" for propane units. A procedure showing how to check manifold pressure is shown on page 32.

NORMAL OPERATION

3.5

3.4

3.3

3.2

3.1

3.0

OPERATION AT THIS EXTREME

MAY INDICATE A BLOCKED

INLET OR OTHER PROBLEM"

WHITE RODGERS 36E SERIES GAS VALVE

NATURAL GAS

HIGH HEAT

MANIFOLD

PRESSURE

ADJUSTMENT

ON SIDE

(under cap)

MANIFOLD PRESSURE

OUTLET ON

SIDE

FIGURE 28

Page 35

2.9

2.8

GAS VALVE OUTPUT

2.7

AOPERATION AT THIS EXTREME

2.6

MANIFOLD PRESSURE (positive inches water column)

2.5

−1.0 −0.2 0−0.4−0.6−0.8

Gray area indicates normal operating range + 10% of manifold pressure.The purpose of this chart is to explain unit operation . Each unit may vary depending on installation, altitude, intake/exhaust configuration and other factors.

measured on right side of burner box)

MAY INDICATE A BLOCKED

OUTLET OR OTHER PROBLEM

BURNER BOX PRESSURE

(Negative inches water gauge

FIGURE 30

Page 36

7.Differential Pressure Switch (S102) all

75,000

units, (S128) G32V−75 units only (Combustion Air Prove Switch)

All G32V series units are equipped with a proving switch S102 located on the vestibule panel.The G32V−75 unit only, is equipped with a second prove switch S128. The switches are connected to the combustion air inducer housing by means of a flexible silicon hose. A separate hose connects the prove switch to the burner box and the gas valve regulator. The silicon hose on S128 will tee into S102. See figure31. The switch monitors air pressure in the combustion air inducer housing and burner box.

Both switches are a single-pole single-throw normally open pressure switch electrically connected in series with the ignition control. The purpose of the switch is to prevent burner operation if the combustion air inducer is not operating. The switch also guards against insufficient combustion air, due to restrictions in the intake and exhaust piping.

On start-up, the switch senses that the combustion air inducer is operating. It closes a circuit to the ignition control when the difference in pressure across the prove switch increases above a particular setting. See table 30. The pressure sensed by the switch is relative to the pressure in the burner box. In order for the furnace to operate, the larger nega-

tive must always be on the combustion air inducer side of the switch. If the flue or air inlet become obstructed dur-

ing operation, the switch senses a loss of pressure differential (drops below set point) and opens the circuit to the ignition control.

The switch is factory set and is not adjustable. It is a safety shut-down control and MUST not be bypassed.

Figure 32 shows an example of the pressure differential (.25" W.C.. shown) required to obtain unit operation. If the switch does not successfully sense the required differential, the switch cannot close and the furnace cannot operate.

When measuring the pressure differential, readings should be taken at the prove switch.

TABLE 30

G32V

model

75,000

btuh

100,000

btuh

125,000

btuh

TEE

S102 PROVE

SWITCH

TEE

S128 PROVE

SWITCH

(G32V3−75

ONLY)

COMBUSTION

AIR BLOWER

Pressure

Switch

S102 .40 $ .05

S128 .20 $ .05

S102 .25 $ .05

S102 .20 $ .05

DIFFERENTIAL PRESSURE SWITCH CIRCUITRY

Pressure Switch Setting

in. negative W.C..

(G32V3−75 SHOWN)

PRESSURE SWITCH

HOSE

FIGURE 31

BURNER

BOX

HOSE BARB

BURNER

BOX

SENSING

HOSE

GAS

VALV E

SENSING

HOSE

GAS

VALV E

Page 36

Page 37

−1.2

CHART REPESENTS NORMAL OPERATING

CHARACTERISTICS OF THE PRESSURE SWITCH ONLY

AND SHOULD NOT BE USED FOR TROUBLSHOOTING

−1.0

−0.8

−0.6

−0.4

−0.2

COMBUSTION AIR BLOWER STATIC PRESSURE

DIFFERENTIAL SWITCH CLOSED

−0.4 −0.6 −0.8 −1.2

BURNER BOX STATIC PRESSURE

FIGURE 32

Temporarily jumpering the pressure switch when troubleshooting will determine if the pressure switch and furnace are operating properly. However, this may not indicate if the sealed combustion system is operating properly. If the unit cannot attain the required inches differential (see table 30) , the unit will not operate. Be sure to remove jumper when finished. See Warning this page.

DIFFERENTIAL SWITCH OPEN

(Furnace will not operate)

−1.0−0.20

Measuring pressure differential

The differential pressure is the difference in pressure measured on either side of the pressure switch: 1 − Remove thermostat demand and allow to cycle off. 2 − Disconnect hose from left side of pressure switch and

install Tee as shown in figure 33.

TEE AND 1/4"i.d. RUBBER HOSE FIELD PROVIDED

WARNING

Safety Hazard. Turn off gas supply before jumpering switch or testing switch differential. If switch is operating properly and sealed combustion system is operating improperly, a potentially lethal situation will be created when switch is bypassed. DO NOT ALLOW UNIT TO OPERATE WITH SAFETY SYSTEMS BYPASSED.

Checks of pressure differential can be made as an aid in troubleshooting. It is important to remember that the switch must see the required differential in order for the furnace to operate. Lack of differential usually indicates problems in the intake or exhaust piping but may indicate problems in the heat exchanger, condenser coil, header boxes, combustion blower or other components. Generally, if both readings are closer to zero (figure 32) the unit may have a restricted flue outlet or other problem. If both readings are farther from zero (figure 32) the unit may have a restricted flue inlet or other problem.

USED FOR MEASURING PRESSURE

ACROSS BURNER BOX AND COM-

BUSTION AIR BLOWER

TO PRESSURE

SWITCH

TO PRESSURE

SENSING HOSE

TO DRAFT GAUGE

FIGURE 33

3 − Install draft gauge to open end of Tee. 4 − Operate unit and observe draft gauge reading. Read-

ings will change as heat exchanger warms.

a. Take one reading immediately after startup. b. Take a second reading after unit has reached steady

state (approximately 5 minutes). 5 − Remove thermostat demand and allow to cycle off. 6 − Remove draft gauge and Tee. Reinstall combustion air

sensing hose to left side of pressure switch. 7 − Disconnect hose from right side of pressure switch and

install Tee as shown in figure 33. 8 − Install draft gauge to open end of Tee.

Page 37

Page 38

9 − Operate unit and observe draft gauge reading. Read-

ings will change as heat exchanger warms.

a. Take one reading immediately after startup. b. Take a second reading after unit has reached steady state (approximately 5 minutes). Both readings should fall above the line shown in figure 32.

10− Compare readings to figure 32. Be sure to compare

only like readings (compare startup reading to startup reading, then compare steady state reading to steady state reading). Subtract the absolute steady state readings from one another. This will be the pressure differential. In order for the furnace to operate, the larger

negative must always be on the combustion air blower side of the switch.

Example − one side of the pressure switch reads .60" and the other side of the pressure switch reads .10". Pressure differential is .60" − .10"= .50"

The pressure differential should be greater than the settings in table 30.

11− When test is complete, remove thermostat demand

and allow unit to cycle off.

12− Remove draft gauge and Tee. Reinstall pressure

switch sensing hose to left side of pressure switch.

If pressure switch does not close at start up or differential is less than set point the following should be checked.

1 − Restriction in exhaust and or intake vent. 2 − Pressure switch lines are routed correctly and for dam-

age. 3 − Condensate in pressure switch lines. 4 − Wiring of pressure switch to furnace. 5 − Blocked heat exchanger or leak in heat exchanger.

II−PLACEMENT AND INSTALLATION

Make sure unit is installed in accordance with installation instructions and applicable codes.

A−PVC Joint Cementing Procedure

6 − Promptly apply solvent cement to end of pipe and in-

side 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.

NOTE−Time is critical at this stage. Do not allow primer 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 assembly (but not after pipe is fully inserted) to distribute cement evenly. Once joint is made, PVC may swell. Hold joint together until bonded (approximately 20 seconds).

NOTE−Assembly should be completed within 20 seconds 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 indicate a defective assembly due to insufficient solvent.

9 − Handle joints carefully and support properly until com-

pletely set.

B−Venting Considerations

The thickness of construction through which vent/air intake pipes may be installed is 24" (610mm) maximum and 3" (76mm) minimum. If a G32V 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 may be oversized for the single water heater or other appliance. The vent should be checked for proper draw with the remaining appliance.

WARNING

DANGER OF EXPLOSION! Fumes from PVC glue may ignite during system check. Remove spark plug wire from ignition control before 120V 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 leak-

ing 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 for at least 5 to 15 seconds to inside

socket surface of fitting and male end of pipe to depth of

fitting socket. Remove puddles of primer before applying

cement.

CAUTION

Insufficient combustion air can cause headaches, nausea, dizziness or asphyxiation. Excessive exposure to contaminated combustion air will result in safety and performance related problems. Avoid exposure to the following substances in the combustion 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; and Masonry acid washing materials.

Page 38

Page 39

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 to-

ward unit. A minimum of 1/4" (6mm) drop for each 12" (305mm) of horizontal run is mandatory for drainage. Horizontal runs of exhaust piping must be supported every 5 ft. (1.52m) using hangers for schedule 40 pipe. All other pipe must be supported every 3 ft. (.91m).

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" (13mm) Armaflex or equivalent when run through unheated space. Do not leave any area of exhaust pipe open to outside air; exterior exhaust must be insulated with 1/2" (13mm) Armaflex or equivalent.

1 − Seal any unused openings in the common venting sys-

tem.

2 − Visually inspect the venting system for proper size and

horizontal pitch and determine there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition.

3 − Insofar as is practical, close all building doors and win-

dows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers 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 operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

4 − Follow the lighting instruction. Place the appliance be-

ing inspected in operation. Adjust thermostat so appliance will operate continuously.

5 − Test for spillage at the draft hood relief opening after 5

minutes of main burner operation. Use a draft gauge or the flame of match or candle, or smoke from a cigarette, cigar.

CAUTION

Do not discharge exhaust into an existing stack or stack that also serves another gas appliance. If vertical discharge through an existing unused stack is required, insert PVC pipe inside the stack until the end is beyond the top or outlet end of the metal stack.

CAUTION

The exhaust vent pipe operates under positive pressure and must be completely sealed to prevent leakage 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 appliances, the venting system may be too large to properly vent the remaining attached appliances. The following test should be conducted while all appliances (both in operation 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.

6 − After it has been determined that each appliance re-

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 condition of use.

7 − If improper venting is observed during any of the above

tests, the common venting system must be corrected. The common venting system should be re−sized 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 34 through 46 show typical terminations.

1 − Use recommended piping materials for both intake

and exhaust piping.

Page 39

Page 40

2 − Secure all joints, including drain leg, gas tight using ap-

proved primer and cement.

3 − Piping diameters should be determined according to

length of pipe run. See vent pipe specifications on page 6. 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.

4 − Intake and exhaust pipes should be placed as close to-

gether as possible at termination end (refer to illustrations). Maximum separation is 3" (76mm) on roof terminations and 6" (152mm) on side wall terminations.

5 − Exhaust piping must terminate straight out or up as

shown. In rooftop applications, a 2" X 1−1/2" reducer for 2" venting, 3" x 2" reducer for 3" venting must be used on the exhaust piping after it exits the structure to improve the velocity of exhaust away from the intake piping.

On roof terminations, the intake piping should termi-

nate straight down using two 90 elbows (See figure

34).

Inches(mm)

3(76) MAX.

3 x 2 (76 x 51) OR 2 x 1−1/2 (51 x 38)

PVC REDUCER

IMPORTANT

Do not use screens or perforated metal in intake and exhaust terminations. Doing so will cause freeze−ups and may block the terminations.

NOTE − If winter design temperature is below 32 F (0C), ex- haust piping must be insulated with 1/2" (13mm), Armaflex or equivalent when run through unheated space. Do not leave any surface area of exhaust pipe open to outside air; exterior exhaust pipe must be insulated with 1/2" (13mm) Armaflex or equivalent. In extreme cold climate areas, 3/4" (19mm) Armaflex or equivalent is recommended. Insulation on outside runs of exhaust pipe must be painted or wrapped to protect insulation from deterioration.

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 help to 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 re−circulation of exhaust back into intake pipe.

6 − On field supplied terminations for side wall exits, ex-

haust piping should extend a minimum of 12" (305mm) beyond the outside wall. Intake piping should be as short as possible. See figure 35.

8 (203) MIN

12 (305) ABOVE AVERAGE SNOW ACCUMULATION

3 (76) OR

2 (51) PVC

PROVIDE SUPPORT

FOR INTAKE AND

EXHAUST LINES

(15F75) LB−49107CC for 2 (51) Venting

(44J41) LB−65678A for 3 (76) Venting

ROOF TERMINATION KIT

FIGURE 34

1/2 (13) FOAM

INSULATION IN

UNCONDITIONED

SPACE

UNCONDITIONED

ATTIC SPACE

1/2 (13) ARMAFLEX

INSULATION IN

UNCONDITIONED SPACE

2 (51) PVC 1−1/2 (38) PVC

1/2 (13) ARMAFLEX

INSULATION

OUTSIDE

WALL

Inches (mm)

(15J74) LB−49107CB for 2 (50.8) Venting

TOP VIEW

WALL RING KIT

12 (305) MIN.

PVC REDUCER

FIGURE 35

2 X 1−1/2 (51 x 38)

6 (152)

MAXIMUM

8 (203)

MINIMUM

2 (51) PVC

COUPLING

Page 40

Page 41

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" (203mm).

8 − If intake and exhaust piping must be run up a side wall

to position above snow accumulation or other obstruc-

tions, piping must be supported every 3 ft. (.91m) as

IMPORTANT

For Canadian Installations Only: In accordance to CAN/CGA−B149.1 and .2, the minimum allowed distance between the combustion air intake inlet and the exhaust outlet of other appliances shall not be less than 12" (305mm).

shown in figure 41. Refer to figures 39 and 40 for prop-

er piping method. WTK wall termination kit must be ex-

tended for use in this application. See figure 44 or use

kit WTKX shown in figure 45. When exhaust and intake

piping must be run up an outside wall, the exhaust pip-

ing is reduced to 1−1/2" (38mm) after the final elbow.

The intake piping may be equipped with a 90 elbow

turndown. Using turndown will add 5ft. (1.5m) to the

equivalent length of the pipe.

1/2 (12.7) FOAM INSULATION

IN UNCONDITIONED SPACE

TOP VIEW

WALL TERMINATION

(22G44) LB−49107CD for 2 (50.8) Venting

(44J40) LB−65701A for 3 (76.2) Venting

Inches(mm)

OUTSIDE WALL

Optional Turndown

Shown

(Intake Only)

FIGURE 36

EXHAUST

TERMINATION

EXHAUST

INTAKE

TERMINATION

INTAKE

Inches

(mm)

CONCENTRIC WALL TERMINATION

(60G77) LB−49107CE for G32V−75 Units Only

(33K97) LB−87942 for G32V−100 & −125 Units Only

FIGURE 38

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)

ACCUMULATION

12 (305) Min.

above grade.

8 (203)

MIN.

12 (305) ABOVE

AVERAGE

SNOW

EXHAUST

TERMINATION

INTAKE

TERMINATION

EXHAUST

CONCENTRIC ROOFTOP TERMINATION

(60G77) LB−49107CE for G32V−75 Units Only

(33K97) LB−87942 for G32V−100 & −125 Units Only

12 (305) ABOVE

AVERAGE SNOW

ACCUMULATION

Inches (mm)

INTAKE

FIGURE 37

Page 41

1/2 (13) FOAM

INSULATION IN

UNCONDITIONED

SPACE

SIDE VIEW

WALL RING TERMINATION

(15F74) LB−49107CB for 2" (51) Venting

1/2 (13) FOAM

INSULATION

FIGURE 39

9 − Position termination ends so they are free from any ob-

structions and above the level of snow accumulation (where applicable). Termination ends must be a minimum of 12" (305mm) above grade level. Do not point into window wells, stairwells, alcoves, courtyard areas or other recessed areas. Do not position termination ends closer than 12" below roof eaves or above a walkway. Since the G32V is a certified direct vent, Category IV gas furnace, the location of the termination is limited by 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

Page 42

the Natural Gas and Propane Installation Instructions in Canada for details. The termination should be at least 12" (305mm) from any opening through which flue products could enter the building.

When horizontally vented, minimum clearance for termination from electric meters, gas meters, regulators and relief equipment is 4 ft. (1.2m) for US installations. 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 (prolonged exposure to exhaust condensate can destroy protective coatings). It is recommended that the exhaust outlet not be located within 6 feet (1.8m) of a condensing unit because the condensate can damage the painted coating.

IMPORTANT

Combustion air intake inlet and exhaust outlet should not be located within 6 ft. (1.8m) of dryer vent or combustion air inlet or outlet of another appliance. Piping should not exit less than 3 ft. (.91m) from opening into another building.

Inches(mm)

3 (76) OR

2 (51) 90_ ELBOW

1/2 (13)

FOAM

INSULATION

3 x 2 (76 x 51) OR 2 x 1−1/2 (51 x 38)

REDUCER BUSHING LOCATION

FOR OFFSET TERMINATION

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 fabricated 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.

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 condensate 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 43.

Front View

INTAKE

VENT

1/2 (13) Foam

Insulation in

Unconditioned Space

(305)

EXHAUST VENT

(127)

Side View

EXHAUST VENT

Optional Turn-

down

(Not Shown)

May Be Used on

Intake Only

(22G44) LB−49107CD for 2(51) Venting

(44J40) LB−65701A for 3(76) Venting

METAL OR PLASTIC

STRAPPING

OR LARGE

WIRE TIES

2 (51) 90_ ELBOW

FRONT VIEW

WALL TERMINATION

FIGURE 40

FIGURE 41

3 (76) OR

Inches

(mm)

Inches (mm)

INTAKE VENT

OUTSIDE WALL

VENT TERMINATIONS

WALL TERMINATION KIT (30G28) WTK

FIGURE 42

Page 42

Page 43

Front View

INTAKE VENT

Side View

Inches (mm)

Front View

INTAKE

AIR

(127)

Inches (mm)

EXHAUST

VENT

18 MAX.

(457)

(127)

5−1/2 (140)

(305)

EXHAUST VENT

INTAKE

VENT

OPTIONAL VENT TERMINATION FOR

MULTIPLE UNIT INSTALLATION

WALL TERMINATION KIT WTK

FIGURE 43

(305)

5-1/2 (140)

COVER EXHAUST

Above Grade

GRADE

VENT WITH

1/2 (13)

FOAM

INSULATION

EXHAUST

AIR

12 MIN.

(305)

Front View

(229)

EXHAUST

VENT

NOTE−Enclosed exhaust pipe is insulated with 1/2" (13mm) foam insulation. If intake and exhaust pipes are reversed, slit and remove foam insulation and reapply to other vent. Exhaust vent must be insulated.

GRADE

EXHAUST VENT

8 MIN.

(203)

Inches (mm)

Side View

(864)

INTAKE

VENT

(305)

(102)

INTAKE

VENT

OUTSIDE WALL

GRADE

VENT TERMINATIONS

MODEL WTKX (30G79)

EXTENSION RISER FOR GRADE CLEARANCE

FIGURE 45

G32V VENTING IN EXISTING CHIMNEY

INTAKE

AIR

EXHAUST

AIR

8 (203)

Minimum

Side View

Inches (mm)

GRADE

VENT TERMINATIONS

MODEL WTK WALL TERMINATION KIT (30G28)

EXTENDED VENT FOR GRADE CLEARANCE

FIGURE 44

12 (305)

Minimum

ABOVE GRADE

3" − 8"

8" − 12"

(203mm − 305mm)

NOTE−Do not discharge exhaust gases directly into any chimney or vent stack. If vertical 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 illustrated. In any exterior portion of chimney, the exhaust vent must be insulated. An alternate method is to fill the chimney with vermiculite or equal to take advantage of its acoustic and thermal properties.

(76mm− 203mm)

3" − 8"

(76mm−

203mm)

FIGURE 46

Page 43

Page 44

Condensate Piping

This unit is designed for either right- or left-side exit of condensate piping. Condensate drain line should be routed only within the conditioned space to avoid freezing of condensate and blockage of drain line. An electric heat cable should be used where condensate drain is exposed to unconditioned areas. The following procedure is for all G32V units.

1 − Determine which side condensate will exit the unit.

2 − Connect 1/2" (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 recommended to seal joint. See figure 47.

CONDENSATE ASSEMBLY

(For left or right installation)

For Left-Hand Side Condensate Exit:

Insert nipple/adapter assembly from the left hand side of the cabinet and through the combustion air blower mounting structure into the threaded opening 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 48.

CAUTION

Do not use copper tubing or existing copper condensate lines for drain line.

CONDENSATE PLUMBING

(Plumbing must be vented higher than coil.)

COMBUSTION AIR

BLOWER BRACK-

NIPPLE

ADAPTER

PLUG

BOOT OR CAP

COLD HEAD-

BOX

NIPPLE

ADAPTER

CONDENSATE TRAP

FIGURE 47

3 − Use the provided adapter (1/2" PVC x 1/2" MPT) and

the nipple (1/2" PVC) to carry drainage outside the

cabinet. If a field substitute is needed, 1/2" CPVC x 1/2"

MPT adapter and 1/2" CPVC is acceptable for use.

4 − Glue nipple to the adapter using the procedures out-

lined 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.

FIGURE 48

6 − Connect condensate drain line (1/2" [13mm] SDR 11

plastic pipe or tubing) to condensate connection on condensate trap assembly and route to open drain. Condensate line must be sloped downward away from condensate trap to thedrain. If drain level is above condensate outlet, use a condensate pump to pump condensate to the higher level. 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 used on the condensate trap and condensate line. Heating cable kit is available from Lennox in various lengths; 6ft. (1.8m) − kit no. 18K48; 24ft. (7.3m) − kit no. 18K49; and 50ft. (15.2m) − kit no. 18K50.

Page 44

Page 45

DETAIL OF

FLUE TRAPB

FLUE TRAP

HOSE BARB

G32V CONDENSATE

REMOVAL PROCESSB

COLD

HEADER

BOX

VENT

Condensate Removal Process:

1. Condensate mixed with flue products exits the coil and enters the cold header box.

2. Condensate and flue products are separated. Flue products are drawn into the combustion air blower while condensate is drained into the header box condensate trap.

3. Flue products are expelled into the flue. As flue products travel up and out, they cool and more condensate is produced.

4. Condensate travels down the walls of the flue pipe and into drain hose.

5. Water drains down through the flue drain hose and is emptied into the header box condensate trap.

6. When the cold header box condensate trap is full, water begins draining out the condensate drain pipe.

7. An external condensate trap is not required, but a vent is required. The vent must extend above the height of the condenser coil (approx. 1 inch above the top of the cold header box).

CONDENSATE

FROM COIL

CONDENSATION TRAP

SIDE DETAIL OF

HEADER BOX

FLUE

DRAIN

HOSE

COMBUSTION

AIR BLOWER

HEADER BOX

CONDENSATE TRAP

DETAIL OF COLD HEADER CONDENSATE TRAP

COLD HEADER BOX

HOSE BARB

COIL OPENING BEHIND

COLD HEADER BOX

1/2"MPT PLUG

RUBBER BOOT OR CAP

FLUE DRAIN HOSE

FRONT DETAIL OF

HEADER BOX

CONDENSATION TRAP

1/2"PVC

1/2"MPT TO FEMALE

PVC PIPE ADAPTER

FIGURE 49

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III−START-UP

A−Preliminary and Seasonal Checks

1 − Inspect electrical wiring, both field and factory installed for

loose connections. Tighten as required.

2 − Check voltage at disconnect switch. Voltage must be

within range listed on the nameplate. If not, consult the power company and have voltage condition corrected before starting unit.

3 − Inspect condition of condensate traps and drain as-

sembly. Disassemble and clean seasonally.

B−Heating Start-Up

FOR YOUR SAFETY READ BEFORE LIGHTING

CAUTION

Shock and burn hazard. G32V units are equipped with the SureLight ignition system. Do not attempt to light manually.

WARNING

Do not use this furnace if any part has been underwater. Inspect the furnace and replace any part of the control system and any gas control which has been under water.

How To Operate Gas Valve (Figure 50)

WARNING

If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

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 appliance is equipped with an ignition device

which automatically lights the burner. Do not try to light the burner by hand.

5 − Remove unit access panel.

6 − WhiteRodgers natural valve, move lever to OFF.

WhiteRodgers propane and Honeywell valve, turn knob to OFF. Do not force. See figure 50.

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.

White Rodgers

Natural Gas Valve

WARNING

If overheating occurs or if gas supply fails to shut off, shut off the manual gas valve to the appliance before shutting off electrical supply.

CAUTION

Before attempting to perform any service or maintenance, turn the electrical power to unit OFF at disconnect switch.

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.

Use only your hand to turn the gas control switch. Never use tools. If the switch will not turn by hand, do not try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

G32V units are equipped with the SureLight ignition system. DO NOT attempt to manually light burners on this furnace. Each time thermostat calls for heat, burners will be automatically lit. The ignitor does not get hot when there is no call for heat on units with SureLight ignition system.

White Rodgers

LP Gas Valve

VALVES SHOWN IN

OFF POSITION

Honeywell Nat / LP Gas Valve

8 − WhiteRodgers natural valve, move lever to ON. WhiteR-

odgers propane and Honeywell valve, turn knob to ON. Do not force.

9 − Replace access panel.

10− Turn on all electrical power to unit.

11− Set thermostat to desired setting.

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12− If the appliance will not operate, follow the instructions

G32VUnit

To Turn Off Gas To Unit" and call your service technician or gas supplier.

Turning Off Gas To Unit

1 − Set thermostat to lowest setting.

2 − Turn off all electrical power to unit if service is to be per-

formed.

3 − Remove access panel.

4 − WhiteRodgers natural valve, move lever to OFF. White-

Rodgers propane and Honeywell valve, turn knob to OFF. Do not force.

5 − Replace access panel.

NOTE−On initial start−ups and when condensate trap is dry, unit may turn itself off and on to allow condensate trap to fill. This is normal operation.

C−Safety or Emergency Shutdown

Turn off unit power. Close manual and main gas valves.

D−Extended Period Shutdown

Turn off thermostat or set to UNOCCUPIED" mode. Close all gas valves (both internal and external to unit) to guarantee no gas leak into combustion chamber. Turn off power to unit. All access panels, covers and vent caps must be in place and secured.

Refer to Maintenance" section of this manual for instructions on how to prepare condensate assembly for extended period shutdown.

IV−HEATING SYSTEM SERVICE CHECKS

A−A.G.A./C.G.A. Certification

All units are A.G.A. and C.G.A. design certified without modifications. Refer to the G32V Operation and Installation Instruction Manual Information.

B−Exhaust CO2 and CO content

Carbon Dioxide is a colorless and odorless gas produced in small amounts by all furnaces, including the G32V, during combustion process. See table 31 or 32 for CO when the unit is properly installed and operating normally. If unit appears to be operating normally at or beyond the upper limit of the CO

range, the unit should be checked for

abnormally high CO. CO content will be less than 0.04% (400 PPM) in an air free

sample regardless of the firing rate used.

TABLE 31

Natural Gas

Hi Fire CO

Min Vent Max Vent Min Vent Max Vent

75,000 7.4−8.4 7.8−8.8 5.0−6.0 5.4−6.4

100,000 6.9−7.9 7.3−8.3 4.5−5.5 5.6−6.0

125,000 6.9−7.9 7.7−8.7 5.0−6.0 54.−6.4

Low Fire CO

levels

TABLE 32

Propane Gas

Hi Fire CO

Min Vent Max Vent Min Vent Max Vent

75,000 7.5−8.5 8.2−9.2 5.5−6.5 5.9−6.9

100,000 8.0−9.0 8.5−9.5 5.2−6.2 5.6−6.6

125,000 7.9−8.9 8.4−9.4 5.3−6.3 6.0−7.0

Low Fire CO

Testing for abnormally high CO2 and CO.

One method for testing the CO ach CO of testing CO

test with the Fyrite CO2 indicator. Other methods

/CO are available. Closely follow the instruc-

/CO content is the Bachar-

tions included in the test kit you choose. Follow the procedure below in order to check CO

/CO on the G32V furnace.

1 − Drill size "R" or 11/32 in. on the exhaust vent, just exit-

ing the cabinet and tap 1/8−27 NPT. This hole will be used to draw your CO

/CO sample. 2 − Install a hose barb connector into test hole. 3 − Attach one end of Fyrite sampling tube to hose barb. 4 − Set thermostat to highest setting and allow unit to run

15 minutes.

5 − When CO

/CO testing is complete, turn off unit, re-

move hose barb from exhaust vent and use a1/8" plas-

tic plug (46F4801) to close off port.

C−Gas Piping

Gas supply piping should not allow more than 0.5"W.C. drop in pressure between gas meter and unit. Supply gas pipe must not be smaller than unit gas connection.

D−Testing Gas Piping

When pressure testing gas lines, the gas valve must be disconnected and isolated. Gas valves can be damaged if subjected to more than 0.5psig (14" W.C.). See figure 51. If the pressure is equal to or less than 0.5psig (14"W.C.), use the manual shut−off valve before pressure testing to isolate furnace from gas supply.

GAS PIPING TEST PROCEDURE (TYPICAL)

MANUAL MAIN SHUT−OFF

VALVE WILL NOT HOLD

NORMAL TEST PRESSURE

CAP

GAS VALVE WILL NOT HOLD TEST PRESSURE IN

EXCESS OF 0.5 PSIG (14"W.C.)

FURNACE

ISOLATE

GAS VALVE

FIGURE 51

IMPORTANT

In case emergency shutdown is required, turn off the main shut-off valve and disconnect the main power to unit. These controls should be properly labeled by the installer.

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When checking piping connections for gas leaks, use preferred means. Kitchen detergents can cause harmful corrosion on various metals used in gas piping. Use of a specialty Gas Leak Detector is strongly recommended. It is available through Lennox under part number 31B2001.

Do not use matches, candles, flame or any other source of ignition to check for gas leaks.

E−Testing Gas Supply Pressure

When testing supply gas pressure, connect test gauge to inlet pressure tap (field provided). Check gas line pressure with unit firing at maximum rate or high fire. Low pressure may result in erratic operation or underfire. High pressure can result in permanent damage to gas valve or overfire. For G32V units, operating pressure at unit gas connection must be between 4.5" W.C. and 13.0" W.C.

On multiple unit installations, each unit should be checked separately, with and without units operating. Supply pressure must fall within range listed in previous paragraph.

F−Check Manifold Pressure

IMPORTANT

WhiteRodgers valve is NOT adjustable on low fire. Do not attempt to adjust low fire on WhiteRodgers valve.

Manifold Operating Pressure is the manifold pressure mea- sured during normal operation (sensing burner box pressure). Manifold Absolute Pressure is the manifold pressure measured when the gas valve regulator is operating at factory preset level (sensing atmospheric pressure).

After line pressure has been checked and adjusted, check manifold absolute pressure. Move pressure gauge to outlet pressure tap located on unit gas valve (GV1). Checks of manifold absolute pressure are made as verification of proper regulator adjustment.

Manifold operating pressure for the G32V can be measured at any time the gas valve is open and is supplying gas to the unit. For natural gas units, normal manifold absolute pressure for high fire is 3.5 in. W.C. (see figure 30 for changes due to burner box pressure). and 1.7 in. W.C. for low fire. For propane units, normal manifold absolute pressure for high fire is

7.5 in. W.C. and 3.5 in. W.C for low fire. See tale below.

MANIFOLD CHECK

(G32V−75 SHOWN)

CONNECT C.A.B. HOSE TO +" SIDE OF SWITCH.

CONNECT BURNER BOX HOSE TO −" SIDE OF SWITCH.

HOSE BARB

BURNER

BOX

SENSING

HOSE

GAS

VALV E

SENSING

HOSE

GAS VALVE

FIGURE 52

4 − While waiting for the unit to stabilize, notice the flame.

Flame should be stable and should not lift from burner. Natural gas should burn blue.

5 − After allowing unit to stabilize for 5 minutes, record

manifold pressure. Manifold pressure should read

3.5"W.C. + or − 0.3 W.C. for natural gas units and 7.5" W.C + or − 0.3" W.C for propane gas units. Regulator cap must be installed when reading pressures.

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 will be overfiring:

 Operate unit only long enough to obtain accurate read-

ing to prevent overheating heat exchanger.

 Attempts to clock gas valve during this procedure will

be inaccurate. Measure gas flow rate only during normal unit operation.

6 − When test is complete remove obstruction from hose

and return hose to gas valve barb.

IMPORTANT

For safety, connect a shut-off valve between the manometer and the gas tap to permit shut off of gas pressure to the manometer.

The gas valve is factory set and should not require adjustment. Also, gas valve regulation varies with burner box pressure (figure 30).

*Manifold Absolute Pressure Measurement and Adjustment

1 − Connect test gauge to outlet tap on gas valve. 2 − Disconnect pressure sensing hose from gas valve

and plug hose. Leave hose barb on valve open to atmosphere. See figure 52.

3 − Start unit on high fire and allow 5 minutes for unit to

reach steady state.

WARNING

Fire and explosion hazard. These instructions MUST be followed exactly. Can cause a fire or explosion resulting in property

damage, personal injury or loss of life.

G− Proper Gas Flow (Approximate)

Furnace should operate at least 5 minutes before checking gas flow. Determine time in seconds for two revolutions of gas through the meter. (Two revolutions assures a more accurate time.) Divide by two and compare to time in table 33 below.

NOTE−To obtain accurate reading, shutoff all other gas appliances connected to meter.

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Page 49

TABLE 33

18M34

63K89

GAS METER CLOCKING CHART

Seconds for One Revolution

G32V

Unit

Natural LP

1 cu ft

Dial

2 cu ft

Dial

1 cu ft

Dial

2 cu ft

DIAL

−75 48 96 120 240

−100 36 72 90 180

−125 29 58 72 144

Natural−1000 btu/cu ft LP−2500 btu/cu ft

H−High Altitude Derate

See specifications section in this manual for manifold pressure settings for installations at altitudes from 0 to 7500ft. (0 to 2286m).

IMPORTANT

For safety, shut unit off and remove manometer as soon as an accurate reading has been obtained. Take care to replace pressure tap plug.

I−Flame Signal

A microamp DC meter is needed to check the flame signal on the SureLight control. Use a flame signal transducer (part number 78H5401) available from Lennox to measure the flame signal, if meter used will not read microamp signal.

Flame (microamp) signal is an electrical current which passes from the ignition control through the sensor electrode during unit operation. Current passes from the sensor through the flame to ground to complete a safety circuit.

To Measure Flame Signal:

1 − Set the volt meter to the DC voltage scale. Insert trans-

ducer into the VDC and common inputs. Observe correct polarities. Failure to do so results in negative (−)

values. 2 − Turn off supply voltage to control. 3 − Disconnect flame sensor lead from terminal of ignition

control. 4 − Connect (+) lead of transducer to ignition control sen-

sor connection. 5 − Connect (−) lead of the transducer to sensor wire. 6 − Turn supply voltage on and close thermostat contacts

to cycle system. 7 − When unit lights, read voltage on meter display. Re-

member 1 DC volt = 1 DC microamp.

TABLE 34

FLAME SIGNAL MICROAMPS

Boards

46M99 18M99 49M59

Boards

24L85 56L83 97L48

Normal u0.23

Low 0.17 to 0.22

Drop Out 0.16

Normal u0.61

Low 0.21 to 0.60

Drop Out 0.20

V−TYPICAL OPERATING CHARACTERISTICS A−Blower Operation and Adjustment

NOTE− The following is a generalized procedure and does not apply to all thermostat controls.

1 − Blower operation is dependent on thermostat control

system.

2 − Generally, blower operation is set at thermostat sub-

base fan switch. With fan switch in ON position, blower operates continuously. With fan switch in AUTO position, blower cycles with demand or runs continuously while heating or cooling circuit cycles.

3 − In all cases, blower and entire unit will be off when the

system switch is in OFF position.

B−Temperature Rise

Temperature rise for G32V units depends on unit input, blower speed, blower horsepower and static pressure as marked on the unit rating plate. The blower speed must be set for unit operation within the range of AIR TEMP. RISE °F" listed on the unit rating plate.

To Measure Temperature Rise:

1 − Place plenum thermometers in the supply and return air

plenums. Locate supply air thermometer in the first horizontal run of the plenum where it will not pick up radiant heat from the heat exchanger.

2 − Set thermostat to highest setting. 3 − After plenum thermometers have reached their highest

and steadiest readings, subtract the two readings. The difference should be in the range listed on the unit rating plate. If the temperature is too low, decrease blower speed. If temperature is too high, first check the firing rate. Provided the firing rate is acceptable, increase blower speed to reduce temperature. To change blower speed taps see the Blower Speed Taps section in this manual.

C−External Static Pressure

1 − Measure tap locations as shown in figure 53.

2 − Punch a 1/4" diameter hole

in supply upstream of evaporator and return air plenums. Insert manometer hose flush with inside edge of hole or insulation. Seal around the hose with permagum. Connect the zero end of the manometer to the discharge (supply) side of the system. On ducted systems, connect the other end of manometer to the return duct as above. For systems with non− ducted returns, leave the other end of the manometer open to the atmosphere.

3 − With only the blower motor running and the evaporator

coil dry, observe the manometer reading. Adjust blower motor speed to deliver the air desired according to the job requirements.

4 − Pressure drop must not exceed 0.8" W.C.

5 − Seal around the hole when the check is complete.

STATIC PRESSURE

TEST

MANOMETER

G32V UNIT

FIGURE 53

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Page 50

VI−MAINTENANCE

Retainers for factory supplied return air filter are shown in figure 54.

BOTTOM RETURN FILTER

REAR FILTER CLIP

SIDE FILTER CLIPS (2)

FURNACE

FRONT

RETURN AIR

OPENING

FURNACE

BASE BOTTOM

FURNACE

BACK

FIGURE 54

A−Filters

At the beginning of each heating season, the system should be checked as follows: 1 − Filters should be inspected monthly and must be

cleaned or replaced when dirty to ensure proper furnace operation.

2 − Reusable foam filters used with the G32V can be

washed with water and mild detergent. When dry, they should be sprayed with filter handicoater prior to reinstallation. 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" x 25" (356 x 635mm) filter for G32VQ3−75 units and P-8-7831 for 20" x 25" (508 x 635mm) filter for G32V−100 and -125 units.

B−Cleaning Heat Exchanger and Burners

If cleaning the heat exchanger becomes necessary, follow the below procedures and refer to figure 1 when disassembling 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 (4) screws around air intake fitting and lift

intake pipe up and away.

4 − Loosen hose clamp securing top of flue transition to

bottom of flue collar. Remove screw securing flue collar to top cap and lift exhaust pipe and flue collar up and away.

5 − If electrical field make up box is located inside the unit,

it must be removed.

6 − Remove gas supply line to connected to gas valve.

7 − Mark all gas valve wires and disconnect them from

valve. Mark and remove wires from flame roll-out switch.

8 − Remove top cap of unit.

9 − Remove sensor wire from SureLight control. Discon-

nect 2-pin plug from the ignitor.

10− Mark and disconnect pressure switch tubing from both

sides of the pressure switch.

11− Loosen two (2) screws holding gas manifold support at

vestibule panel.

12− Remove four (4) burner box screws at the vestibule

panel and remove burner box and gas valve/manifold assembly 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 counterclockwise. 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 3-pin plug from the combustion air

blower at the blower deck. Remove four (4) screws from combustion air blower and remove flue transition and blower assembly from cabinet. Take care not to lose the combustion air orifice.

BURNER ACCESS/REMOVAL

BURNER MOUNTING

BRACKET

BARBED PRESSURE

SWITCH FITTINGS

PATCH PLATE

Simplified Burner Removal:

1− Remove cover by loosening bot-

tom screws (2) and removing cover front screws (5).

2− Remove ignitor wire and sensor

wire. Remove gas valve and manifold assembly.

3− Remove burner assembly.

ROLLOUT SWITCH

UNIT VEST PANEL

FIGURE 55

Page 50

Page 51

16− Disconnect 9-pin plug from the blower compartment at

the blower deck.

17− Remove 9-pin plug above the blower deck.

18− Remove the limit switch and the pressure switch from

the vestibule panel.

19− Remove two (2) 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 assembly to cabinet. Remove heat exchanger then remove cold end header box.

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 assembly 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− Re-secure the supporting screws along the vestibule

sides and bottom to the cabinet.

25− Re-install cabinet screws on sides and front flange at

blower deck.

26− Re-install the limit switch and pressure switch (−75 unit

will have a second switch) on the vestibule panel.

27− Re-install 9-pin plug to blower deck and connect it to

the 9-pin plug from below the blower deck.

28− Re-install the combustion air blower. Be careful that

the plastic orifice on the blower inlet has not fallen out. See figure 1. Reconnect the 3-pin plug to the wire harness. Re-install the flue transition in the cabinet and reattach the drain tube. Route the drain tube below the combustion air blower housing and to the elbow on the cold header (collector) box trap. See figure 31.

29− Re-install condensate line with adapter to condensate

trap. Use fresh Teflon tape to ensure a leak−free joint. Re-connect to condensate line outside of the unit.

30− Re-install 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− Reconnect pressure switch tubing by connecting the

tubing from the burner box to the barb on the bottom and the tubing from the combustion air blower to the barb on the top. See figure 31.

Note−G32V−75 units will have two pressure switches.

32− Reconnect the sensor and ignitor wires.

33− Re-install top cap to unit.

Page 51

34− Re-install electrical connections to gas valve. Brown

wire to H1, yellow wire to C2 and orange wire to M. Reconnect wires to flame roll-out switch.

NOTE − Unit is polarity-sensitive. 120V supply wiring must be installed correctly.

35− Reconnect main gas line to gas valve. 36− Re-install field make-up box if removed. 37− Re-install exhaust pipe/flue collar and secure flue col-

lar to the unit top cap using existing screw. Insert the bottom of the flue collar into the top of the flue transition

and tighten hose clamp. 38− Re-install 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 con-

nections when re-establishing supply. 41− Following lighting instructions from installation manu-

al, light and run unit for 5 minutes to ensure heat ex-

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. Depend-

ing on gas plumbing installation, the gas manifold may

move aside enough that breaking the union may not be

necessary. 3 − Remove five (5) screws from edges of burner box cov-

er. 4 − Loosen two (2) 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 gas valve wires and disconnect them from valve. 7 − Mark and disconnect sensor wire from the burner box

at the SureLight control. Disconnect 2-pin plug from

the ignitor at the burner box. 8 − Loosen two (2) screws at the gas manifold support

bracket. 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" nut driver, remove the burner mounting

screws from underneath the burners. 11− While supporting ignitor and sensor lines at the grom-

met, grasp burners and simultaneously pull burners

and grommet out of the burner box. 12− Remove ignitor and sensor assemblies from burners

using a 1/4" nut driver to remove two screws from each

bracket. 13− Clean burner by running a vacuum with a soft brush at-

tachment over face of burners. Visually inspect inside of

burners and crossovers for any blockage caused by for-

eign matter. Remove any blockage. 14− Re-install ignitor and sensor bracket assemblies on

burners.

Page 52

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 bracket to engage in the smaller holes located in the burner. The correct burner orientation is with metal button protrusions 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 underneath the box pass through the larger holes in the flange and engage in the smaller holes in the burner. Re-install the two screws.

16− Re-install 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 corrected. 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. Re-install burner box cover.

18− Re-install the screws to secure the burner box cover.

Make sure screws are tight to ensure a leak tight burner 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− Re-install the electrical connections to the gas valve.

Brown wire to H1, yellow wire to C2 and orange wire to M.

21− Re−install the sensor wire to the spade connector on

the SureLight control. Re-install the 2-pin ignitor plug

at the burner box. 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.

C−Supply Air Blower

1 − Check and clean blower housing and blower wheel. 2 − Motors are prelubricated for extended life; no further lu-

brication is required.

D−Electrical

1 − Check all wiring for loose connections. 2 − Check circuit breaker located in unit control box. 3 − Check for correct voltage at unit (unit operating). 4 − Check amp-draw on blower motor.

Motor Nameplate_________Actual_________

E−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.

F−Insulation

Outdoor piping insulation should be inspected yearly for deterioration. If necessary, replace with same materials.

G−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.

Page 52

Page 53

VII−WIRING DIAGRAM & SEQUENCE OF OPERATION

G32V −1 UNITS SCHEMATIC WIRING DIAGRAM

Page 53

Page 54

G32V −3 UNITS SCHEMATIC WIRING DIAGRAM

Page 54

Page 55

G32V −4 UNITS SCHEMATIC WIRING DIAGRAM

Page 55

Page 56

A−Sequence of Operation

Ignitor operation will vary between SureLight boards. Board 63K89, 56L83 and 24L85 will energize ignitor for the first second of the 4 second ignition trial. Board 97L48, will energize ignitor during the entire trial until flame is sense.

1 − When there is a call for heat, W1 of the thermostat en-

ergizes W of the furnace control with 24VAC. 2 − SureLight control runs self−check for S10 primary limit

switch normally closed contacts. The control also

checks S128 combustion air prove switch and S102

high fire prove switch normally open contacts. Follow

steps 4 through 8 per respective thermostat.

Single−stage Mode, Single−stage Thermostat

3 − SureLight control energizes combustion air inducer B6

on high speed. Combustion air blower runs until S102

high fire prove switch closes (switch will close within

2−1/2 minutes or control goes into Watchguard−

PROVE Switch mode). A 15−second pre−purge follows

after S102 closes. 4 − SureLight control energizes ignitor. A 20−second

warm−up period begins. 5 − Gas valve is energized on first stage heat (low). Gas

valve opens for a 4 second trial for ignition.

6 − Flame is sensed. After 8 seconds from when gas valve

opens, valve energizes on second stage (high heat).

7 − After 45−second delay, indoor blower B3 is energized

on heating speed.

Two−stage Mode, Single−stage Thermostat

1 − SureLight control energizes combustion air inducer B6

on low speed. Combustion air inducer runs until com-

bustion air prove switch S102 (or S128 onG32V3−75

units) closes (switch will close within 2−1/2 minutes or

control goes into Watchguard−PROVE Switch mode).

A 15−second pre−purge follows once S102 closes.

2 − SureLight control energizes ignitor. A 20−second

warm−up period begins.

3 − Gas valve is energized on first stage. Gas valve opens

for a 4−second trial for ignition. Signal is sent from control module to two−stage control board to begin W2 (second−stage) ON delay.

4 − Flame is sensed, gas valve remains open for the heat

call.

5 − After 45−second delay, indoor blower B3 is energized

on low speed.

6 − Second stage time on delay complete (8, 12, or 15 min-

utes). Combustion air inducer B6 switches to high speed, indoor blower B3 switches to heating speed and gas valve opens on high fire (second stage.)

Two−stage Mode, Two−stage Thermostat

1 − SureLight control energizes combustion air inducer B6

on low speed. Combustion air inducer runs until combustion air prove switch S102 closes (or S128 on G32V3−75 units. Switch will close within 2−1/2 minutes or control goes into Watchguard−PROVE Switch mode). A 15−second pre−purge follows once S102 closes.

2 − SureLight control energizes ignitor. A 20−second

warm−up period begins.

3 − Gas valve is energized on first stage only. Gas valve

opens for a 4−second trial for ignition.

4 − Flame is sensed, gas valve remains open for the heat

call.

5 − After 45−second delay, indoor blower B3 is energized

on low speed.

6 − Call for second stage heat comes from indoor thermo-

stat (W2).

Page 56

Page 57

HEATING SEQUENCE OF OPERATION

NOTE: LED REFERS TO SURELIGHT CONTROL . LED−DS REFERS TO VSP CONTROL.

NORMAL HEATING MODE ABNORMAL HEATING MODE

POWER ON

CONTROL SELF−CHECK OKAY?

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER DELAY OFF.

LED #1 ON LED #2 ON

(RESET CONTROL BY TURNING MAIN POWER OFF.)

COMBUSTION AIR INDUCER ON FOR 1 SECOND.

LED #1 −− SIMULTANEOUS SLOW FLASH LED #2 −− SIMULTANEOUS SLOW FLASH

ENERGIZE COMBUSTION AIR INDUCER.

IS LINE VOLTAGE ABOVE 75 VOLTS?

TWO−STAGE MODE

CALL FOR 1ST STAGE HEAT

POLARITY OKAY?

YES

ROLLOUT SWITCH CLOSED?

YES

BURNER OFF?

(CONTINUOUS FLAME CHECK)

YES

NORMAL OPERATION:

THERMOSTAT CALLS FOR HEAT:

LED #1 −− FAST FLASH LED #2 −− FAST FLASH

YES

PRIMARY LIMIT SWITCH CLOSED?

YES

PROVE SWITCH CONTACTS OPEN?

(HIGH AND LOW HEAT)

YES

ENERGIZE HTG ACC. TERM.

YES

IS UNIT PROPERLY GROUNDED?

YES

W2 TIMED MODE

SINGLE STAGE T’STAT

SINGLE−STAGE MODE

HIGH HEAT ONLY

POLARITY REVERSED.

LED #1 −− FAST FLASH

LED #2 −− SLOW FLASH

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF DELAY.

LED #1 −− ON

LED #2 −− SLOW FLASH

GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

INDOOR BLOWER ON.

LED #1 −− SLOW FLASH

LED #2 −− OFF

COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER ON.

LED #1 −− SLOW FLASH

LED #2 −− ON

GAS VALVE OFF.

COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF DELAY.

LED #1 OFF

LED #2 SLOW FLASH

(Sequence holds until PROVE switch

closes or thermostat resets control.)

COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF. LED #1 −− ALTERNATING FAST FLASHES LED #2 −− ALTERNATING FAST FLASHES

COMBUSTION AIR INDUCER

ON LOW SPEED (t 2.5 MINUTES)

LOW−HEAT PROVE

SWITCH CLOSED?

YES YES

CONTINUED ON NEXT PAGE

PREPURGE

15 SECONDS

COMBUSTION AIR INDUCER

ON HIGH SPEED (t 2.5 MINUTES)

HIGH−HEAT PROVE

SWITCH CLOSED?

Page 57

PROVE SWITCH WATCHGUARD

(5 MINUTES)

COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF.

LED #1 OFF

LED #2 SLOW FLASH

WATCHGUARD 60-MINUTE DELAY

(SIGNAL LIMIT OR IGNITION FAILURE)

GAS VALVE OFF. COMBUSTION AIR

AND INDOOR BLOWER OFF.

LED #1 AND LED #2

ALTERNATING SLOW FLASHES

Page 58

TWO−STAGE MODE

CALL FOR 1st STAGE HEAT

HEATING SEQUENCE CONTINUED

NORMAL HEATING MODE ABNORMAL HEATING MODE

PREPURGE

15 SECONDS

IGNITION SEQUENCE BEGINS

(Ignition trial counter initiated.)

IGNITOR WARM−UP

(20 SECONDS)

W2 TIMED MODE

SINGLE STAGE T’STAT

SINGLE−STAGE MODE

HIGH HEAT ONLY

WATCHGUARD 60-MINUTE DELAY

(SIGNAL LIMIT OR IGNITION FAILURE)

GAS VALVE OFF. COMBUSTION AIR

AND INDOOR BLOWER OFF.

LED #1 AND LED #2

ALTERNATING SLOW FLASHES

WATCHGUARD −− FLAME FAILURE.

GAS VALVE OFF.

COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF.

LED #1 & LED #2 ALTERNATE FLASH.

NO YES

MAIN GAS VALVE OPEN

LOW HEAT ONLY

FLAME RECTIFICATION CURRENT CHECK

(Response time −− 2 seconds maximum.)

"HEAT" LED−DS2 LIT INDOOR BLOWER ON DELAY BEGINS

TWO−STAGE MODE

CALL FOR 1st STAGE HEAT

CFM" LED−DS4 BLINKS ONCE FOR EVERY 100CFM. INDOOR

BLOWER ON LOW SPEED

MAIN GAS VALVE OPEN

LOW HEAT ONLY

SECOND STAGE

TIME ON BEGINS

4 SECONDS

(u0.20 microamps)

FLAME PRESENT?

(45 seconds.)

W2 TIMED MODE

SINGLE STAGE T’STAT

FLAME PRESENT?

(Continuous flame check)

FLAME SIGNAL

(u0.61 microamps)

GAS VALVE OPEN

HIGH AND LOW HEAT

SINGLE−STAGE MODE

HIGH HEAT ONLY

CFM" LED−DS4 BLINKS ONCE FOR EVERY 100CFM. INDOOR BLOWER

ON HIGH HEATING SPEED

CONTROL CHECKS RETRY

FOR IGNITION COUNT. HAVE FOUR RE-TRIES

BEEN COMPLETED?

GAS VALVE

DE−ENERGIZED

YES

WATCHGUARD 60-MINUTE DELAY

LIMIT SWITCH. GAS VALVE OFF. COMBUSTION AIR AND INDOOR

BLOWER OFF. LED #1 SLOW FLASH

AND LED #2 ON. IS 60 MINUTE RESET

PERIOD COMPLETE?

LOW FLAME SIGNAL

LED #1 −− SLOW FLASH

LED #2 −− FAST FLASH

PRIMARY LIMIT SWITCH CLOSED?

ROLLOUT SWITCH CLOSED?

PROVE SWITCH CLOSED?

(CONTINUED ON NEXT PAGE)

CONTINUED ON NEXT PAGE

COMBUSTION AIR INDUCER DE−ENERGIZED.

GAS VALVE DE−ENERGIZED.

INDOOR BLOWER ON.

LED #1 − SLOW FLASH; LED #2 − ON.

HAS LIMIT RESET?

(See table 8 DIAGNOSTIC CODES for limit reset operation)

GAS VALVE DE−ENERGIZED.

COMBUSTION AIR INDUCER DE−ENERGIZED.

INDOOR BLOWER OFF DELAY (Selected time)

LED #1 −− ON

LED #2 −− SLOW FLASH

Page 58

YES

Page 59

HEATING SEQUENCE CONTINUED

NORMAL HEATING MODE ABNORMAL HEATING MODE

PREPURGE

PROVE SWITCH CLOSED?

(See top of previous page.)

TWO−STAGE MODE

CALL FOR 1st STAGE HEAT

CALL FOR 2nd STAGE

HEAT (HIGH HEAT)

FROM THERMOSTAT

INDOOR BLOWER SWITCHES TO HEATING SPEED.

CFM" LED−DS4 BLINKS ONCE FOR EVERY 100 CFM.

COMBUSTION AIR INDUCER SWITCHES TO

HIGH HEAT PROVE SWITCH CLOSED?

HIGH HEAT GAS VALVE OPEN? (8 SEC. DELAY)

TWO−STAGE MODE

CALL FOR 1st STAGE HEAT

CONTROL CHECKS: FLAME PRESENCE, CLOSED

PRIMARY LIMIT, CLOSED PROVE SWITCHES,

CONTINUOUSLY CLOSED ROLLOUT SWITCH (during

SEE PREVIOUS SEQUENCES FOR FAILURE MODES.

COMBUSTION AIR INDUCER POST−PURGE 5 SECONDS. HTG ACC. TERM. DE−ENERGIZED

YES YES

W2 TIMED MODE

SINGLE STAGE T’STAT

2nd STAGE ON DELAY ON CONTROL BOARD

COMPLETE

(8, 12 OR 15 MIN.)

HIGH SPEED?

YES

W2 TIMED MODE

SINGLE STAGE T’STAT

heating cycle).

DEMAND FOR HEAT SATISFIED.

THERMOSTAT OPENS.

GAS VALVE DE−ENERGIZED.

INDOOR BLOWER

SELECTED TIME OFF DELAY.

COMBUSTION AIR INDUCER ON FOR 2.5 MINUTES.

¦ 2.5

MINUTES

SINGLE−STAGE MODE

HIGH HEAT ONLY

LED #1 LED #2 DESCRIPTION

SLOW FLASH

FAST FLASH

SLOW FLASH

ALTERNATING SLOW FLASH

ALTERNATING FAST FLASH

GAS VALVE DE−ENERGIZED.

INDOOR BLOWER DE−ENERGIZED.

PROVE SWITCH

CLOSED?

PROVE SWITCH WATCHGUARD

COMBUSTION AIR INDUCER

DE−ENERGIZED.

5−MINUTE DELAY

COMBUSTION AIR

INDUCER ON.

DIAGNOSTIC CODES

Primary or secondary limit open

Rollout switch open

Flame sensed without gas valve energized

PROVE switch open

Power on

Heating demand

Polarity reversed

Low flame signal

Circuit board failure

Watchguard −− burners failed to ignite

Watchguard −− low voltage, below 75V or improper main ground.

OFF

SLOW FLASH

OFF

SLOW FLASH

FAST FLASH

SLOW FLASH

FAST FLASH

Page 59

Page 60

COOLING SEQUENCE OF OPERATION

NORMAL COOLING MODE ABNORMAL COOLING MODE

POWER ON

IGNITION CONTROL MAIN POWER ON.

SIGNAL IMPROPER

GROUND AT LED.

SIGNAL HOLDS

UNTIL UNIT IS

PROPERLY

GROUNDED.

ROLLOUT SWITCH MONITORED CONTINUOUSLY.

CHECK FOR MAIN BURNER FLAME SENSE.

LED: SLOW FLASH RATE REMAINS UNCHANGED

CONTROL SELF DIAGNOSTIC CHECK.

IS CONTROL OPERATING NORMALLY?

YES

TURN INDUCER ON FOR 1 SECOND.

IS POLARITY REVERSED?

IS ROLLOUT SWITCH CLOSED?

IS MAIN BURNER FLAME OFF?

THROUGHOUT COOLING CYCLE.

THERMOSTAT CALLS FOR COOLING.

IS THERE

PROPER GROUND?

YES

IS VOLTAGE

ABOVE 75 VOLTS?

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.

SIGNAL POLARITY REVERSED AT LED.

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.

LOW VOLTAGE SIGNAL AT LET HOLDS

UNTIL VOLTAGE RISES ABOVE 75 VOLTS.

COMPRESSOR CONTACTOR AND BLOWER

ENERGIZED WITH 0-SECOND DELAY

(COOLING SPEED). ACC. TERM. ENERGIZED.

ON/OFF" LED−DS3 LIT. CFM" LED−DS4 BLINKS

ONCE FOR EVERY 100CFM.

THERMOSTAT OPENS.

COMPRESSOR OFF.

INDOOR BLOWER AND ACC. TERM. OFF

WITH 0-SECOND DELAY.

Page 60

Page 61

SURELIGHT CONTROL

CONTINUOUS LOW SPEED FAN SEQUENCE OF OPERATION

LED: SLOW FLASH RATE REMAINS

UNCHANGED THROUGHOUT SEQUENCE.

MANUAL FAN SELECTION MADE AT THERMOSTAT.

CONTROL (G) ENERGIZES SYSTEM FAN AT ACB

LOW SPEED. ACC. TERMINAL IS ENERGIZED.

THERMOSTAT CALLS FOR HEAT (W).

NO YES

THERMOSTAT CALLS FOR COOLING.

YES

SYSTEM FAN SWITCHED TO ACB COOL

SPEED. ACC. TERM. REMAINS ON.

THERMOSTAT OPENS.

HTG ACC. TERM. ENERGIZES

WITH COMB. AIR BLOWER.

BOARD NO. 63K8901

SYSTEM FAN DE−ENERGIZED. SYSTEM FAN

ENERGIZES ON ACB HEAT SPEED AFTER

NORMAL DELAY.

BOARD NO. 24L85, 56L83, 97L48

SYSTEM FAN SWITCHES TO ACB HEAT SPEED

AFTER NORMAL DELAY (fan remains energized)

THERMOSTAT OPENS. COMBUSTION AIR

AND HTG ACC TERMINAL DE−ENERGIZE.

BOARD 63K89: SYSTEM FAN OFF. ACC. TERM.

OFF. (AFTER OFF DELAY COMPLETED).

BOARDS 24L85, 56L83 AND 97L48:

SYSTEM FAN SWITCHES TO

LOW SPEED AFTER NORMAL DELAY.

(fan remains energized)

MANUAL FAN SELECTION MADE AT THERMOSTAT.

CONTROL (G) ENERGIZES SYSTEM FAN AT ACB

LOW SPEED. ACC. TERM. ENERGIZED.

Page 61

Page 62

G32V −5, −6 UNITS SCHEMATIC WIRING DIAGRAM

Page 62

Page 63

B−Sequence of Operation.

Sequence depends on type thermostat used. Units are applicable for single stage or two stage thermostats. Both type thermostats are described below. Thermostat jumper E20 dictates which mode unit will operate in. See flow chart for more sequence detail.

SureLight Control Self Check

When there is a call for heat, the SureLight integrated control runs a self check. The control checks for S10 primary limit, S21 secondary limit (s) and S47 rollout switch normally closed contacts. The control also checks for prove switch S102 and low heat prove switch S128 (G32V−75 only) normally open contacts. Once self check is complete and all safety switches are operational, heat call can continue.

Two−Stage Thermostat, Two Stage Heat. Jumper E20

set at TWO".

1− SureLight control energizes combustion air inducer B6

on low heat speed. Combustion air inducer runs until S102 prove switch contacts close (switch must close within 2 1/2 minutes or control goes into Watchguard PROVE Switch mode. G32V−75 ONLY − Combustion air inducer runs until S128 prove switch contacts close (switch must close within 2 1/2 minutes or control goes into Watchguard PROVE Switch mode. Prove switch S102 may also close). A 15 second pre−purge follows once S128 closes.

2− SureLight control begins 20 second ignitor warm up pe-

riod.

3− Gas valve opens on first stage for a 4 second trial for

ignition. Ignitor stays energized during the trial or until flame sensed.

4− Flame is sensed, gas valve remains on first stage heat,

ignitor de−energizes.

5− After 45 second delay, indoor blower B3 is energized

on low heat speed.

The furnace will stay in this mode until first stage demand is satisfied OR a second stage heat demand is initiated.

6− Second stage heat demand initiated. A 30 second sec-

ond stage recognition period begins.

7− The combustion air inducer ramps up to high heat

speed.

G32V−75 − S102 high heat prove switch closes. 8− Gas valve energizes second stage heat. 9− B3 indoor blower ramps up to high heat speed.

Single−Stage Thermostat, Two Stage Heat. Jumper

E20 set at SINGLE"

1− SureLight control energizes combustion air inducer B6

2− SureLight control begins 20 second ignitor warm up pe-

riod.

3− Gas valve opens on first stage for a 4 second trial for

ignition. Ignitor stays energized during the trial or until flame sensed.

4− Flame is sensed, gas valve remains on first stage heat,

ignitor de−energizes.

5− After 45 second delay, indoor blower B3 is energized

on low heat speed.

6− A 10 minute (factory set) or 15 minute (field set) second

stage heat delay period begins.

7− The combustion air inducer ramps up to high heat

speed.

G32V−75 − S102 high heat prove switch closes. 8− Gas valve energizes second stage heat. 9− B3 indoor blower ramps up to high heat speed.

Page 63

Page 64

HEATING SEQUENCE OF OPERATION

NORMAL AND ABNORMAL HEATING MODE

POWER ON

CONTROL SELF−CHECK OKAY?

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF. INDOOR BLOWER OFF. CHECK FOR BROKEN IGNITOR OR OPEN IGNITER CIRCUIT. DS 1 AND DS 2 ALTERNATING FAST FLASH.

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF. (RESET CONTROL BY

TURNING MAIN POWER OFF.) DS1 ON, DS2 ON

POLARITY OKAY?

YES

IS THERE A

PROPER GROUND?

YES

IS VOLTAGE

ABOVE 75 VOLTS?

YES

BURNER OFF?

(CONTINUOUS FLAME CHECK)

YES

NORMAL OPERATION:

DS 1 −− SIMULTANEOUS SLOW FLASH DS 2 −− SIMULTANEOUS SLOW FLASH

THERMOSTAT CALLS FOR HEAT:

DS 1 −− SIMULTANEOUS FAST FLASH DS 2 −− SIMULTANEOUS FAST FLASH

YES

PRIMARY LIMIT

SWITCH CLOSED?

YES

ROLLOUT SWITCH CLOSED?

YES

FIRST (LOW) STAGE PRESSURE SWITCH

CONTACTS OPEN?

YES

SECOND (HIGH) STAGE PRESSURE SWITCH

CONTACTS OPEN?

SIGNAL HOLDS UNTIL UNIT IS PROPERLY GROUNDED.

DS1 AND DS2 ALTERNATING FAST FLASH.

SIGNAL HOLDS UNTIL VOLTAGE RISES ABOVE 75 VOLTS.

DS1 AND DS2 ALTERNATING FAST FLASH.

GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

INDOOR BLOWER ON HEATING SPEED.

INDOOR BLOWER ON. HAS PRIMARY LIMIT

60−MINUTE LIMIT WATCHGUARD MODE.

GAS VALVE OFF, COMBUSTION AIR INDUCER

OFF, INDOOR BLOWER OFF WITH DELAY.

DS1 AND DS2 ALTERNATING SLOW FLASH,

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

HAS MANUAL ROLLOUT SWITCH(ES) BEEN

RESET (CLOSED) WITHIN 3 MINUTES?

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF. CONTROL REMAINS UNTIL

PRESSURE SWITCH IS DETECTED OPEN.

ON/OFF LED OFF, HEAT LED OFF.

POLARITY REVERSED.

DS 1 −− FAST FLASH

DS 2 −− SLOW FLASH

DS1 SLOW FLASH, DS2 OFF,

ON/OFF LED OFF

COMBUSTION AIR INDUCER OFF.

RESET WITHIN 3 MINUTES? DS1 SLOW FLASH, DS2 ON,

ON/OFF LED ON, HEAT LED ON.

ON/OFF LED OFF, HEAT LED ON.

DS1 SLOW FLASH, DS2 ON,

ON/OFF LED ON, HEAT LED ON.

DS1 OFF, DS2 SLOW FLASH,

YES

TWO−STAGE OR SINGLE−STAGE THERMOSTAT

CALL FOR HEAT

COMBUSTION AIR INDUCER ON LOW SPEED.

DS1 AND DS2 SIMULTANEOUS FAST FLASH

CONTINUED ON NEXT PAGE

COMBUSTION AIR INDUCER OFF.

GAS VALVE OFF.

INDOOR BLOWER OFF.

CONTROL WILL NOT ATTEMPT SECOND−STAGE

OPERATION DURING THIS HEAT DEMAND.

FIRST−STAGE OPERATION WILL BE ATTEMPTED.

DS1 OFF, DS2 FAST FLASH,

ON/OFF LED OFF, HEAT LED ON.

Page 64

Page 65

CONTINUED

HEATING SEQUENCE OF OPERATION

THERMOSTAT CALLS FOR HEAT

DS1 AND DS2 SIMULTANEOUS FAST FLASH

(Refer to box A on previous page)

FIRST−STAGE (LOW−FIRE) PRESSURE

SWITCH CLOSED WITHIN 2.5 MINUTES?

YES

15−SECOND COMBUSTION AIR INDUCER

PRE−PURGE INITIATED BY CLOSED FIRST−STAGE

PRESSURE SWITCH (or 15 SECOND

INTER−PURGE PERIOD.)

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

IGNITOR WARM−UP (20 SECONDS)

DS1 AND DS2 SIMULTANEOUS FAST FLASH

IS VOLTAGE ABOVE 75 VOLTS?

YES

IS THERE A PROPER GROUND?

IS IGNITOR INTACT AND CONNECTED?

YES

AT END OF IGNITOR 20 SECOND WARM UP

PERIOD, 4−SECOND TRIAL FOR IGNITION.

GAS VALVE OPENS, IGNITOR ENERGIZED DURING

4−SECOND TRIAL UNTIL FLAME SENSED.

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

YES

GAS VALVE OFF. COMBUSTION AIR INDUCER

OFF. INDOOR BLOWER OFF. UNIT WILL RETRY

AFTER 5−MINUTE WAIT PERIOD.

DS1 OFF, DS2 SLOW FLASH,

ON/OFF LED OFF, HEAT LED OFF.

COMBUSTION AIR INDUCER OFF, IGNITER OFF.

SIGNAL HOLDS UNTIL VOLTAGE RISES ABOVE 75 VOLTS.

DS1 AND DS2 ALTERNATING FAST FLASH.

COMBUSTION AIR INDUCER OFF, IGNITER OFF.

SIGNAL HOLDS UNTIL UNIT IS PROPERLY GROUNDED.

DS1 AND DS2 ALTERNATING FAST FLASH.

COMBUSTION AIR INDUCER OFF, IGNITOR OFF.

SIGNAL HOLDS UNTIL IGNITOR IS REPLACED

OR RECONNECTED.

DS1 AND DS2 ALTERNATING FAST FLASH.

4−SECOND FLAME STABILIZATION PERIOD.

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

FLAME RECTIFICATION CURRENT CHECK

CAN FLAME BE PROVEN WITHIN 4

SECONDS AFTER GAS VALVE OPENS?

(u0.16 microamps)

FLAME PRESENT?

YES

CONTINUED ON NEXT PAGE

GAS VALVE OFF. COMBUSTION AIR

INDUCER ON. INDOOR BLOWER OFF.

HAS CONTROL RESET IGNITION SEQUENCE

DS1 SLOW FLASH, DS2 FAST FLASH,

ON/OFF LED OFF, HEAT LED 0N.

HAS CONTROL FAILED TO SENSE

FLAME FOR FIVE CONSECUTIVE TRIES

DURING A SINGLE HEAT DEMAND?

YES

WATCHGUARD MODE. GAS VALVE OFF,

COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF.

DS1 AND DS2 ALTERNATING SLOW FLASH.

ON/OFF LED 0FF, HEAT LED OFF.

IS 60−MINUTE RESET PERIOD COMPLETE?

YES

FOUR (4) TIMES?

DS1 SLOW FLASH, DS2 FAST FLASH,

ON/OFF LED OFF, HEAT LED ON .

YES

Page 65

Page 66

CONTINUED

FLAME SIGNAL ABOVE

0.23 microamps)

YES

HEATING SEQUENCE OF OPERATION

THERMOSTAT CALLS FOR HEAT.

YES

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

(Does not affect control operation)

DS1 SLOW FLASH, DS2 FAST FLASH.

SEE BOX A.

LOW FLAME SIGNAL

SINGLE−STAGE THERMOSTAT MODE

(E20 SET AT SINGLE")

YES

START SECOND−STAGE RECOGNITION

ON DELAY (10 OR 15 MINUTES).

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

FIRST−STAGE (LOW FIRE)

PRESSURE SWITCH CLOSED?

YES

FIRST−STAGE HEAT DEMAND SATISFIED?

DS1 AND DS2 SIMULTANEOUS SLOW FLASH.

GAS VALVE OFF, COMBUSTION AIR INDUCER

OFF FOLLOWING POST PURGE.

INDOOR BLOWER OFF WITH DELAY

DS1 AND DS2 SIMULTANEOUS SLOW FLASH

SECOND−STAGE HEAT DEMAND. SECOND−STAGE HEAT DEMAND REQUIRED? DS1 AND DS2 SIMULTANEOUS SLOW FLASH.

SECOND STAGE PRESSURE SWITCH CLOSED?

ABNORMAL FLASH CODE.

NOTE − IF SECOND−STAGE PRESSURE SWITCH

WAS ORIGINALLY FOUND CLOSED,

ABNORMAL CODE WILL FLASH.

SECOND−STAGE 30−SECOND DELAY ON BEGINS.

DS1 AND DS2 SIMULTANEOUS FAST FLASH

SECOND−STAGE COMBUSTION AIR INDUCER

ON. SECOND−STAGE GAS VALVE ON. HIGH

HEAT INDOOR BLOWER SPEED ON.

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

SECOND−STAGE PRESSURE SWITCH CLOSED

IN LESS THAN TEN (10) SECONDS?

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

YES

ON/OFF LED ON.

YES

CONTINUED ON NEXT PAGE

YES

TWO STAGE THERMOSTAT MODE

(E20 SET AT TWO")

YES

45−SECOND INDOOR BLOWER ON DELAY BEGINS.

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

YES

GAS VALVE OFF, COMBUSTION AIR INDUCER OFF, INDOOR BLOWER ON. DS1 SLOW FLASH, DS2 ON,

(Indoor blower on low speed during 3−minute period)

GAS VALVE OFF, COMBUSTION AIR INDUCER OFF,

DS1 AND DS2 ALTERNATING SLOW FLASH,

IS 60−MINUTE RESET PERIOD COMPLETE?

GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

SECOND−STAGE PRESSURE SWITCH CLOSED

DS1 AND DS2 SIMULTANEOUS SLOW FLASH.

RETURNS TO FIRST−STAGE HEAT MODE WHICH CONTINUES UNTIL SECOND−STAGE PRESSURE

SWITCH CAN BE PROVEN or HEAT DEMAND IS

SATISFIED. FIVE (5) MINUTE WAIT PERIOD

INITIATED BEFORE RETRY. WERE 5 ATTEMPTS

DS1 AND DS2 SIMULTANEOUS SLOW FLASH.

YES

PRIMARY LIMIT AND

ROLLOUT SWITCH CLOSED?

ON/OFF LED ON, HEAT LED ON.

HAS PRIMARY LIMIT OR ROLLOUT

SWITCH CLOSED WITHIN 3 MINUTES?

LIMIT SWITCH WATCHGUARD MODE.

INDOOR BLOWER OFF WITH DELAY.

ON/OFF LED OFF, HEAT LED OFF.

INDOOR BLOWER OFF AFTER DELAY.

DS1 OFF, DS 2 SLOW FLASH,

ON/OFF LED OFF, HEAT LED ON.

AT BEGINNING OF HEAT DEMAND?

DS1 OFF, DS2 SLOW FLASH,

ON/OFF LED ON, HEAT LED ON.

SECOND STAGE HEAT DEMAND

MADE FOR SECOND−STAGE HEAT?

YES

NORMAL OPERATION.

YES

Page 66

Page 67

CONTINUED

HEATING SEQUENCE OF OPERATION

SEE BOX A

NORMAL OPERATION

DS1 AND DS2 SIMULTANEOUS SLOW FLASH.

ARE PRIMARY LIMIT AND ROLLOUT

SECOND−STAGE (HIGH FIRE) HEAT

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

SWITCH CLOSED?

YES

FIRST−STAGE (LOW FIRE) HEAT

PRESSURE SWITCH CLOSED?

YES

HEAT DEMAND SATISFIED?

YES

THERMOSTAT CALLS FOR HEAT

SEE BOX B

DS 1 AND DS 2 SIMULTANEOUS FAST

FLASH.

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER ON.

DS1 SLOW FLASH, DS2 ON,

ON/OFF LED ON, HEAT LED 0N.

HAS PRIMARY LIMIT OR ROLLOUT SWITCH

CLOSED WITHIN 3 MINUTES?

LIMIT SWITCH WATCHGUARD MODE. GAS VALVE

OFF. COMBUSTION AIR INDUCER OFF. INDOOR BLOWER OFF WITH DELAY. IS 60−MINUTE RESET PERIOD COMPLETE? DS SLOW FLASH, DS2 ON,

ON/OFF LED OFF, HEAT LED OFF.

GAS VALVE OFF, COMBUSTION AIR INDUCER

OFF AFTER 15 SECOND POST PURGE, INDOOR

BLOWER OFF AFTER DELAY.

DS1 OFF, DS2 FAST FLASH,

ON/OFF LED ON, HEAT LED ON.

RETURN TO HEAT DEMAND?

RETURN TO FIRST−STAGE HEAT MODE.

FIRST−STAGE CONTINUES UNTIL SECOND−

STAGE PRESSURE SWITCH CAN BE PROVEN

or HEAT DEMAND IS SATISFIED. A FIVE (5)

MINUTE WAIT PERIOD IS INITIATED BEFORE

RETRY. WERE 5 ATTEMPTS MADE FOR

SECOND−STAGE HEAT?

SEE BOX C

FIRST−STAGE HEAT DEMAND SATISFIED?

YES

SINGLE−STAGE THERMOSTAT MODE

(E20 SET AT SINGLE")

YES

HEAT DEMAND SATISFIED?

DS1 AND DS2

SIMULTANEOUS FAST FLASH.

YES

GAS VALVE OFF, COMBUSTION AIR

INDUCER OFF AFTER 5−SECOND

LOW SPEED POST PURGE PERIOD,

INDOOR BLOWER OFF DELAY

INITIATED ON LOW HEAT SPEED.

DS1 AND DS2

SIMULTANEOUS FAST FLASH

DEMAND FOR HEAT SATISFIED.

POWER ON STAND BY.

DS1 AND DS2

SIMULTANEOUS SLOW FLASH

TWO STAGE THERMOSTAT MODE?

(E20 SET AT TWO")

YES

FIRST AND SECOND STAGE HEAT

DEMAND SATISFIED SIMULTANEOUSLY.

DS1 & DS2 SIMULTANEOUS FAST FLASH.

YES

GAS VALVE, COMBUSTION AIR INDUCER

AND INDOOR BLOWER RETURN TO FIRST−

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

FIRST STAGE HEAT DEMAND SATISFIED?

GAS VALVE OFF. COMBUSTION AIR INDUCER

OFF AFTER 5−SECOND LOW SPEED POST−

PURGE PERIOD. INDOOR BLOWER OFF. DELAY INITIATED ON LOW HEAT SPEED.

DS1 & DS2 SIMULTANEOUS FAST FLASH.

SECOND STAGE HEAT

DEMAND SATISFIED?

DS1 AND DS2

SIMULTANEOUS FAST FLASH.

YES

STAGE OPERATION.

YES

Page 67

Page 68

COOLING SEQUENCE OF OPERATION

POWER ON

SIGNAL IMPROPER

GROUND AT DS.

SIGNAL HOLDS

UNTIL UNIT IS

PROPERLY

GROUNDED.

THERMOSTAT CALLS FOR FIRST−STAGE COOL.

INDOOR BLOWER ENERGIZED ON FIRST STAGE

FIRST−STAGE DEMAND FOR COOL SATISFIED?

THERMOSTAT CALLS FOR SECOND−STAGE COOL.

IS POLARITY REVERSED?

COMPRESSOR AND CONDENSER FAN

COOL SPEED AFTER 2 SECOND DELAY.

IS THERE

PROPER GROUND?

ENERGIZED.

YES

IS VOLTAGE

ABOVE 75 VOLTS?

YES

SIGNAL POLARITY REVERSED.

DS1 FAST FLASH, DS2 SLOW FLASH.

COMPRESSOR AND CONDENSER FAN DE−ENERGIZED.

LOW VOLTAGE SIGNAL AT DS HOLDS

UNTIL VOLTAGE RISES ABOVE 75 VOLTS.

INDOOR BLOWER DE−ENEGIZED.

INDOOR BLOWER RAMPS UP TO SECOND−STAGE COOL SPEED.

SECOND−STAGE DEMAND FOR COOL SATISFIED?

YES

UNIT RETURNS TO FIRST STAGE COOL

Page 68

Page 69

CONTINUOUS LOW SPEED FAN SEQUENCE OF OPERATION

MANUAL FAN SELECTION MADE AT THERMOSTAT.

AFTER 2 SECOND DELAY, INDOOR BLOWER IS

ENERGIZED ON CONTINUOUS FAN SPEED.

YES YES

YES

INDOOR BLOWER RAMPS TO FIRST STAGE

COOLING SPEED AFTER A 2−SECOND DELAY.

THERMOSTAT CALLS FOR FIRST−STAGE HEAT.THERMOSTAT CALLS FOR FIRST STAGE COOL.

YES

AFTER 45−SECOND DELAY, INDOOR BLOWER

SWITCHES TO LOW HEAT SPEED.

YES

FIRST−STAGE COOL DEMAND SATISFIED?

SECOND STAGE COOL DEMAND

INDOOR BLOWER RAMPS TO SECOND

STAGE COOL SPEED

SECOND STAGE COOL DEMAND SATISFIED?

YES

INDOOR BLOWER RAMPS DOWN TO FIRST STAGE

COOL SPEED.

FIRST−STAGE HEAT DEMAND SATISFIED.

THERMOSTAT CALLS FOR SECOND−STAGE HEAT.

YES

INDOOR BLOWER SWITCHES TO HIGH HEAT SPEED

AFTER 30−SECOND RECOGNITION PERIOD.

YES

SECOND−STAGE HEAT DEMAND SATISFIED.

YES

INDOOR BLOWER RAMPS DOWN TO LOW

HEAT SPEED.

YES

Page 69

Page 70

G32V−1 / −3 OPERATION SEQUENCE AND JUMPERS SUMMARY WITH VSP2 (HEATING)

MATCH UP COMMENTS OR SEQUENCE

T−Strip Jumper

Mode of

Operation

Jumper

FOR COOLING JUMPERS

SEE COOLING SECTION

BELOW

TABLE 35

Page 70

Single-Stage Heating

with Single−Stage

Jumpers

Thermostat

Two-Stage Heating

With Single−Stage

Jumpers

Thermostat

Harmony Heating No

Jumpers

One−Stage

W2 Timed

Two−Stage

Blower operates on the high

speed heat tap during the

heating mode.

Blower operates on the low

speed heat/cool tap during the

first stage of heating. Blower

operates on the high speed

heat tap during second stage

heating.

Remove pin #3 of the J73

plug on the VSP control.

See figure 12. Insulate end

to prevent it from shorting.

Blower operates on PWM

signal generated by Har-

mony. Harmony overrides blower speed taps. Blower

speed varies according to

zone demand.

(continued on following page)

Low and high fire controlled by temperature modulating switch.

Page 71

(continued from previous page)

G32V−1 / −3 OPERATION SEQUENCE AND JUMPERS SUMMARY WITH VSP2 (HEATING CONTINUED)

MATCH UP COMMENTS OR SEQUENCE

T−Strip Jumper

Mode of Operation

Jumper

Page 71

Two−Stage Heating

With Two−Stage

Thermostat

MATCH UP

FOR HEATING JUMPERS

SEE HEATING SECTION

ABOVE

Single-Speed Com-

pressor, no CCB1,

no Harmony

Jumpers

Two−Stage Blower operates on the low

speed heat/cool tap during first

stage heating. Blower operates

on high speed heat tap during

second stage heating.

G32V−1 / −3 OPERATION SEQUENCE AND JUMPERS SUMMARY WITH VSP2 (COOLING)

T−STRIP JUMPER

DS to Y1"

(factory wired)

Remove Jumper

DS to Y1"

COMMENTS OR SEQUENCE

Blower operates on high speed

cool tap during cooling.

Blower operates on low speed

heat/cool tap during cooling

Two-Speed Compressor,

no CCB1, no Harmony

wired jumper from

(continued on following page)

DS" to Y2"

Move factory

Y1 to Y2".

Blower operates on low

speed heat/cool tap when

compressor is in first

stage cooling. Blower op-

erates on high speed cool

tap when compressor is in

second stage cooling.

Page 72

(continued from previous page)

MATCH UP COMMENTS OR SEQUENCE

FOR HEATING JUMPERS

SEE HEATING SECTION

ABOVE

CCB1 with Single-Speed

Compressor, no Harmony

Page 72

CCB1 with Two-Speed

Compressor, no Harmony

G32V−1 / −3 OPERATION SEQUENCE AND JUMPERS SUMMARY WITH VSP2 (COOLING CONTINUED)

T−STRIP JUMPER

Blower speed is controlled by

the DC signal from CCB1.

No Jumpers

(Remove jumper

from Y1 to DS")

Blower operates on low speed heat/cool tap during dehumidification. Otherwise, blower oper-

ates on high speed cool tap

during cooling cycle.

Blower speed is controlled by

the DC signal from CCB1.

No Jumpers

(Remove jumper

from Y1 to DS")

Blower operates on low speed heat/cool tap during dehumidi-

fication. Otherwise, blower op-

erates on high speed cool tap

during high speed compressor

operation and low speed heat/

cool tap during low speed

compressor operation.

(continued on following page)

Page 73

(continued from previous page)

G32V−1 / −3 OPERATION SEQUENCE AND JUMPERS SUMMARY WITH VSP2 (COOLING CONTINUED)

MATCH UP COMMENTS OR SEQUENCE WIRING CONNECTIONS

FOR HEATING JUMPERS

SEE SEE HEATING SECTION

ABOVE

T−STRIP JUMPER

Harmony and Single-

Speed Compressor

No Jumpers

(Remove

jumper from

Y1 to DS").

Remove pin #3 of the J73

terminal on the VSP con-

trol. Insulate end to prevent shorting. Blower operates on PWM signal generated by Harmony. Harmony

overrides blower speed

taps. Blower speed varies

according to zone demand.

Page 73

Harmony and Two-

Speed Compressor

No Jumpers

(Remove

jumper from

Y1 to DS").

Remove pin #3 of the J73

terminal on the VSP con-

trol. Insulate end to pre-

vent shorting. Blower oper-

ates on PWM signal gener-

ated by Harmony. Harmony

overrides blower speed

taps. Blower speed varies

according to zone demand.

Page 74

MATCH UP

FOR COOLING JUMPERS

SEE COOLING SECTION

BELOW

Single-Stage Heating

with Single−Stage

Thermostat

TABLE 36

G32V−4 OPERATION SEQUENCE AND JUMPERS SUMMARY WITH VSP3 (HEATING)

T−Strip Jumper

Mode of

Operation

COMMENTS OR SEQUENCE

WIRING CONNECTIONS

Jumper

Jumpers

One−Stage

Blower operates on

high speed during the

heating mode.

Page 74

Two-Stage Heating

With Single−Stage

Thermostat

Harmony Heating No

(continued on following page)

Jumpers

W2 Timed

Two−Stage

Blower operates on low

speed during the first stage

of heating. Blower operates

on high speed during

second−stage heating.

Remove pin #3 of the J73 plug on

the VSP control, and pins #2 and 13 of the J49 plug at the

motor. See figure 15 and 22. Insulate

ends to prevent them from shorting.

Blower operates on PWM signal

generated by Harmony. Harmo-

ny overrides blower speed taps.

Blower speed varies according

to zone demand.

Low and high fire controlled by

temperature modulating switch.

TEMPERATURE

MODULATING

SWITCH

Page 75

(continued from previous page)

G32V−4 OPERATION SEQUENCE AND JUMPERS SUMMARY WITH VSP3 (HEATING CONTINUED)

MATCH UP

T−Strip Jumper

Mode of Operation

Jumper

COMMENTS OR SEQUENCE

WIRING CONNECTIONS

Page 75

Two−Stage Heating

With Two−Stage

Thermostat

MATCH UP

FOR HEATING JUMPERS

SEE HEATING SECTION

ABOVE

Single-Speed Com-

pressor, no CCB1,

no Harmony

Jumpers

Two−Stage

Blower operates on low speed during first stage

heating. Blower operates on

high speed during second

stage heating.

G32V−4 OPERATION SEQUENCE AND JUMPERS SUMMARY WITH VSP3 (COOLING)

T−STRIP JUMPER

DS to Y1

and Y1 to Y2

and O to R

COMMENTS OR SEQUENCE

Blower operates on high speed

during cooling.

WIRING CONNECTIONS

(factory wired)

Remove jumper

DS to Y1

Blower operates on low speed

during cooling.

Two-Speed Compressor,

no CCB1, no Harmony

Remove factory−wired

jumper Y1 to Y2.

(continued on following page)

DS to Y1

and

O to R

Blower operates on low speed

cool when compressor is in

first stage cooling.

Blower operates on high

speed cool when compressor

is in second stage cooling.

Page 76

(continued from previous page)

G32V−4 OPERATION SEQUENCE AND JUMPERS SUMMARY WITH VSP3 (COOLING CONTINUED)

MATCH UP COMMENTS OR SEQUENCE

T−STRIP JUMPER

WIRING CONNECTIONS

FOR HEATING JUMPERS

SEE HEATING SECTION

ABOVE

CCB1 with Single-Speed

Compressor, no Harmony

Page 76

CCB1 with Two-Speed

Compressor, no Harmony

(continued on following page)

Y1 to Y2

and

O to R

Remove the

factory−wired

jumper

Y1 to DS.

O to R

Remove jumper

from Y1 to DS

and

Y1 to Y2.

Blower speed is controlled

by the DC signal from

CCB1. Blower operates on

low speed during dehumidification.

Otherwise, blower operates

on high speed during

cooling cycle.

See table 14.

Page 77

(continued from previous page)

MATCH UP COMMENTS OR SEQUENCE

FOR HEATING JUMPERS

SEE SEE HEATING SECTION

ABOVE

Harmony and

Single-Speed

Compressor

Page 77

Harmony and

Two-Speed Compressor

G32V−4 OPERATION SEQUENCE AND JUMPERS SUMMARY WITH VSP3 (COOLING CONTINUED)

T−STRIP JUMPER

WIRING

CONNECTIONS

Remove the wire from Pin #2 and

Pin #13 of the J49 harness connec-

Y1 to Y2

and

O to R

(Remove

jumper from

Y1 to DS.)

tor at the motor and the wire from

Pin #3 of the J73 harness connec-

tor on the VSP control board.

Insulate the wire ends and secure

them to prevent shorting. Blower

operates on PWM signal generated

by the Harmony control board con-

trol board. The Harmony control

board overrides blower speed taps.

Blower speed varies according to

the zone’s demand.

Remove the wire from Pin #2 and Pin

#13 of the J49 harness connector at

the motor and the wire from Pin #3 of

O to R

(Remove jumper

from Y1 to DS

and Y1 to Y2.)

the J73 harness connector on the

VSP control board.

Insulate the wire ends and secure

them to prevent shorting. Blower op-

erates on PWM signal generated by

the Harmony control board.

The Harmony control board overrides

blower speed taps. Blower speed

varies according to zone’s demand.

Page 78

G32V−5 Units with Two Stage Variable Speed Control

TABLE 37

Field Wiring Applications

Thermostat

1 Heat / 1 Cool

NOTE − Use dip switch 3 to set second−stage heat ON delay. ON−10 minutes. OFF−15 minutes.

1 Heat / 1 Cool with CCB1

NOTE − Use dip switch 3 to set second−stage heat ON delay. ON−10 minutes. OFF−15 minutes.

Jumper Settings (See figure 16)

E20 W915 W914 W951

SINGLE Ye s Intact Intact

SINGLE Ye s Cut Intact

Wiring Connections

T’STAT

TERM. STRIP

CCB1

CONTROL

TERM. STRIP

OUTDOOR

UNIT

OUTDOOR

UNIT

Page 78

Page 79

TABLE 37

Field Wiring Applications (Continued)

Thermostat

1 Heat / 2 Cool

NOTE − Use dip switch 3 to set second−stage heat ON delay. ON−10 minutes. OFF−15 minutes.

1 Heat / 2 Cool with CCB1

NOTE − Use dip switch 3 to set second−stage heat ON delay. ON−10 minutes. OFF−15 minutes.

Jumper Settings (See figure 16)

E20 W915 W914 W951

SINGLE No Intact Intact

SINGLE No Cut Intact

Wiring Connections

T’STAT

CONTROL

TERM. STRIP

CCB1

CONTROL

TERM. STRIP

OUTDOOR

UNIT

OUTDOOR

UNIT

2 Heat / 2 Cool TWO No Intact Intact

2 Heat / 2 Cool

TWO No Cut Intact

with CCB1

T’STAT

CONTROL

TERM. STRIP

CCB1

CONTROL

TERM. STRIP

OUTDOOR

UNIT

OUTDOOR

UNIT

Page 79

Page 80

TABLE 37

Field Wiring Applications (Continued)

Thermostat

E20 W915 W914 W951

Jumper Settings (See figure 16)

2 Heat / 1 Cool TWO Ye s Intact Intact

FM21 Heat

SINGLE Ye s Intact Cut

Pump / 1 Cool

Harmony

TWO Yes Cut Intact Application* 2 Heat / 1 Cool

Wiring Connections

T’STAT

*Disconnect existing furnace transformer and replace with 75VA, 24V transformer if defrost option to be used.

75VA, 24V

TRANSFORMER*

NOTE − Wiring connections to outdoor unit and thermostat made at FM21 control board per FM21 instructions.

TEMP.

MOD.

SWITCH

FAN LO

FAN LINE

CONTROL

TERM. STRIP

HARMONY

CONTROL

TERM. STRIP

CONTROL

TERM. STRIP

OUTDOOR

UNIT

FM21

NOTE − Remove Y1/Y2 jumper for two−stage cooling.

OUT-

DOOR

UNIT

Harmony Application* 2 Heat / 2 Cool

TWO No Cut Intact

TEMP.

MOD.

SWITCH

FAN LO

FAN LINE

HARMONY

CONTROL

TERM. STRIP

OUT-

DOOR

UNIT

*Cut wires at pin positions 2 and 13 of J/P46. Insulate ends to prevent a short. Blower operates on PWM signal generated by Harmony. Harmony overrides blower speed taps. Blower speed varies according to zone demand. Low and high−fire controlled by temperature modulating switch.

Page 80

Page 81

VIII− Troubleshooting 1− VSP2−1 Blower Control Board G32V−1 / −3 Units

DOES UNIT OPERATE?

R AND C?

YES

COOLING MODE

YES

IS 24VAC ACROSS

PLACE JUMPER ACROSS R AND G.

IS BLOWER ON LOW SPEED AND IS

ON/OFF" LED−DS3 LIT? CFM" LED−DS4

LIGHT SHOULD BLINK ONCE FOR EV-

ERY 100 CFM SELECTED IN THE

TABLES ON PAGE 2.

IS 24 VOLTS PRESENT AT J73

PIN 12 ON VSP2 BOARD?

IN ADDITION TO R AND G,

JUMPER R AND DS.

CHECK: 1−UNIT POWER 2−INTERLOCK SWITCH 3−TRANSFORMER 4−LIMIT SWITCH

CHECK UNIT WIRING

AND IF CORRECT, REPLACE VSP2−1.

REPLACE VSP2−1.

END OF COOLING TEST

HEATING MODE

YES

IS BLOWER ON HIGH SPEED AND ARE DS1 AND

DS3 LIT? DOES THE CFM" LED−DS4 LIGHT BLINK

ONCE FOR EVERY 100 CFM SELECTED IN THE

YES

PLACE HTG. BLOWER" JUMPER IN POSITION #2.

PLACE JUMPER ACROSS R AND W1. WAIT 75

SECOND FOR PREPURGE AND FANON" DELAY.

IS BLOWER ON LOW SPEED AND IS ON/OFF" LED−

DS3 LIT? CFM" LED−DS4 LIGHT SHOULD BLINK

ONCE FOR EVERY 100 CFM SELECTED IN THE

TABLES ON PAGE 2?

DOES UNIT OPERATE?

IS 24VAC ACROSS

R AND C?

YES

TABLES ON PAGE 2.

YES

IS 24 VOLTS PRESENT AT J73

PIN 12 ON VSP2 BOARD?

PLACE HTG. BLOWER"

JUMPER IN POSITION #1.

R AND W1 REMAIN JUMPERED.

YES

CHECK UNIT WIRING

AND IF CORRECT

REPLACE THE

VSP2−1.

CHECK: 1−UNIT POWER 2−INTERLOCK SWITCH 3−TRANSFORMER 4−LIMIT SWITCH

1−CHECK UNIT WIRING AND IF

CORRECT, REPLACE VSP2−1.

2−BREAK AND REMAKE JUMPER

(R TO W1).

3−AFTER 30−35 SECOND

PURGE, IS 24VAC PRESENT AT GAS VALVE?

REPLACE VSP2−1.

END OF TEST

DOES BLOWER SHIFT TO HEAT SPEED

AND IS HEAT" LED−DS2 ON? DOES THE

CFM" LED−DS4 LIGHT BLINK ONCE FOR EVERY 100 CFM SELECTED IN

THE TABLES ON PAGE 2?

YES

REMOVE JUMPERS

YES

AFTER THE SELECTED

TIME, DOES BLOWER

TURN OFF?

Page 81

CHECK UNIT WIRING

AND IF CORRECT, REPLACE VSP2−1.

REPLACE THE VSP2−1.

Page 82

2− VSP3−1 Blower Control Board G32V−4 Units

DOES UNIT OPERATE?

YES

IS 24VAC ACROSS

COOLING MODE

PLACE JUMPER ACROSS R, G, AND Y1.

IS BLOWER ON LOW SPEED AND IS ON/

OFF LED−DS3 AND HI/LOW LED−DS1 LIT?

CFM LED−DS4 LIGHT SHOULD BLINK

ONCE FOR EVERY 100 CFM SELECTED IN

THE TABLES ON PAGE 2.

R AND C?

YES

CHECK: 1−UNIT POWER 2−INTERLOCK SWITCH 3−TRANSFORMER 4−LIMIT SWITCH

CHECK UNIT WIRING AND IF

CORRECT, REPLACE VSP3−1.

END OF COOLING TEST

HEATING MODE

IS 24 VOLTS PRESENT AT J73

PIN 12 ON VSP3 BOARD?

YES

IN ADDITION TO R G, AND Y1

JUMPER R AND Y2.

YES

IS BLOWER ON HIGH SPEED AND ARE DS1 AND

DS3 LIT? DOES THE CFM LED−DS4 LIGHT BLINK

ONCE FOR EVERY 100 CFM SELECTED IN THE

TABLES ON PAGE 2?

DOES UNIT OPERATE?

YES

IS 24VAC ACROSS

R AND C?

YES

PLACE HTG. BLOWER JUMPER IN POSITION #2.

PLACE JUMPER ACROSS R AND W1. WAIT 75

SECOND FOR PREPURGE AND FAN ON DELAY.

IS BLOWER ON LOW SPEED AND IS ON/OFF" LED−DS3 LIT? CFM" LED−DS4 LIGHT SHOULD

BLINK ONCE FOR EVERY 100 CFM SELECTED IN

THE TABLES ON PAGE 2.

YES

IS 24 VOLTS PRESENT AT J73

PIN 12 ON VSP3 BOARD?

REPLACE VSP3−1.

CHECK UNIT WIRING

AND IF CORRECT

REPLACE THE

VSP3−1.

CHECK: 1−UNIT POWER 2−INTERLOCK SWITCH 3−TRANSFORMER 4−LIMIT SWITCH

1−CHECK UNIT WIRING AND IF

CORRECT, REPLACE

2−BREAK AND REMAKE JUMPER

VSP3−1. (R TO W1).

3−AFTER 30−35 SECOND PURGE,

IS 24VAC PRESENT AT GAS VALVE?

REPLACE VSP3−1.

END OF TEST

PLACE HTG. BLOWER

JUMPER IN POSITION #1.

R AND W1 REMAIN JUMPERED.

DOES BLOWER SHIFT TO HIGH SPEED

AND IS HEAT" LED−DS2 ON? DOES THE

CFM" LED−DS4 LIGHT BLINK ONCE

FOR EVERY 100 CFM SELECTED IN

THE TABLES ON PAGE 2?

REMOVE JUMPERS

YES

AFTER THE SELECTED

TIME, DOES BLOWER

YES

TURN OFF?

Page 82

CHECK UNIT WIRING

AND IF CORRECT, REPLACE VSP3−1.

REPLACE THE VSP3−1.

Page 83

3− Variable Speed Blower Motor

To check−out the VSM blower and the blower control board, begin with the ICM2 motorand follow the check−out procedure as outlined. The ICM2 consist of a control module and motor. The control module can be replaced separately from the motor

ICM−2 WITH VSP2

120V to the motor must not be interrupted. All connections for check out will be from the voltage source below (battery or 24V) to plug J46, after disconnecting from blower control board.

J46

if necessary. However, if the motor fails the motor/module assembly must be replaced. To verify proper operation of the blower control board, check the board as outlined in the troubleshooting flowcharts on the previous page.

CHECK−OUT PROCEDURE USING BATTERY

An ordinary 9 volt battery with maximum DC 20volts is recommended. A 9 volt battery will last for about one day of normal operation.

LOW SPEED CHECK−OUT

12345678 910111213

J46

1− Disconnect power to unit. 2− Disconnect plug J46 from P46 located on the

blower control board. 3− Connect voltage source as shown above. 4− Turn on power to unit. Blower should operate

at low speed.

HIGH SPEED CHECK−OUT

12345678 910111213

J46

6− Disconnect power to unit. 7− Connect voltage source as shown above. 8− Turn on power to unit. Blower should operate

at high speed.

CHECK−OUT PROCEDURE USING 24V SOURCE

Unit transformer T1 with a maximum AC 30 volts may be used in lieu of a battery. If transformer T1 is used, double check all wiring connections before placing unit back in operation.

LOW SPEED CHECK−OUT

12345678910111213

J46

1− Disconnect power to unit. 2− Disconnect plug J46 from P46 located on the

blower control board. 3− Disconnect C and R from control board. 4− Connect voltage source as shown above. 5− Turn on power to unit. Blower should operate

at low speed.

HIGH SPEED CHECK−OUT

12345678910111213

J46

6− Disconnect power to unit. 7− Connect voltage source as shown above. 8− Turn on power to unit. Blower should operate

at high speed.

HEATING SPEED CHECK−OUT

12345678910111213

J46

9− Disconnect power to unit. 10−Connect voltage source as shown above.

11−Turn on power to unit. Blower should operate

at heating speed.

HEATING SPEED CHECK−OUT

12345678910111213

J46

9− Disconnect power to unit. 10− Connect voltage source as shown above. 11− Turn on power to unit. Blower should operate

at heating speed.

A kit is available from the Lennox parts center to use in testing the variable speed motor. The kit 70J11 includes a test plug harness to facilitate ICM−2 check−out. Follow testing procedures outlined in the instructions provided with the kit.

The testing procedures are different than those listed above.

Page 83

Page 84

ICM−2 WITH VSP3

120V to the motor must not be interrupted. All connections for check out will be from the voltage source below (battery or 24V) to plug J46, after disconnecting from blower control board.

CHECK−OUT PROCEDURE USING BATTERY

An ordinary 9 volt battery with maximum DC 20volts is recommended. A 9 volt battery will last for about one day of normal operation.

LOW COOL SPEED

1 2 3 4 5 6 7 8 9 10111213

J46

1 Disconnect power to unit. 2 Disconnect plug J46 from P46 located on the

blower control board. 3 Connect voltage source as shown above. 4 Turn on power to unit. Blower should operate

at low cool speed.

HIGH COOL SPEED

12345678 910111213

5 Disconnect power to unit. 6 Connect voltage source as shown above.

7 Disconnect Y" on ignition control AND re-

move connection from Y2" on TB1 in control box. Connect a separate wire between the − side of the battery and BOTH Y" on the ignition control and Y2" on TB1.

8 Turn on power to unit. Blower should operate

at high cool speed.

To Y2" on TB1.!

To Y" on ignition control. !

LOW HEAT SPEED

12345678910111213

J46

To W" on ignition control board. !

9 Disconnect power to unit. 10 Connect voltage source as shown above. 11 Disconnect W" terminal on ignition control

board and connect a separate wire between

W" and + side of battery. 12 Turn on power to unit. Blower should operate

at low heat speed.

CHECK−OUT PROCEDURE USING 24V SOURCE

Unit transformer T1 with a maximum AC 30 volts may be used in lieu of a battery. If transformer T1 is used, double check all wiring connections before placing unit back in operation.

LOW COOL SPEED

12345678 910111213

J46

1− Disconnect power to unit.

2− Disconnect plug J46 from P46 located on the

blower control board.

3− Disconnect C and R from ignition control

board.

4− Disconnect Y" from ignition control and con-

nect a separate wire between R" on the

transformer and Y" on the ignition control. 5− Connect voltage source as shown above. 6− Turn on power to unit. Blower should operate

at low cool speed.

To Y" on ignition control. !

HIGH COOL SPEED

1 2 3 4 5 6 7 8 9 1011 1213

J46

7− Disconnect power to unit. 8− Connect voltage source as shown above. 9− Disconnect Y2" on TB1 in control box and

connect a separate wire between R" on transformer and Y2" on TB1.

10− Turn on power to unit. Blower should oper-

ate at high cool speed.

LOW HEAT SPEED

12345678 910111213

J46

11− Disconnect power to unit. 12− Connect voltage source as shown above. 13− Disconnect W" from ignition control and

connect a separate wire between R" on transformer and W" on the ignition control.

14− Turn on power to unit. Blower should operate

at low heat speed.

To W" on on ignition control. !

To Y2" on TB1.!

HIGH HEAT SPEED

12345678 910111213

J46

To W2" on TB1 !

13 Disconnect power to unit. 14 Connect voltage source as shown above.

15 Disconnect W2" on TB1 in control box and

connect a separate wire between W2" and + side of battery.

16 Turn on power to unit. Blower should operate

at high heat speed.

Page 84

HIGH HEAT SPEED

12345678 910111213

J46

15− Disconnect power to unit. 16− Connect voltage source as shown above. 17− Disconnect W2" from TB1and connect a

separate wire between R" on transformer and W2" on TB1.

18− Turn on power to unit. Blower should operate

at low heat speed.

To W2" on TB1 !

Page 85

ICM−2 WITH TWO STAGE VARIABLE SPEED CONTROL BOARD

120V to the motor must not be interrupted. All connections for check out will be from the voltage source below (battery or 24V) to plug J46, after disconnecting from blower control board.

REMOVE PLUG FROM BOARD

CHECK−OUT PROCEDURE USING BATTERY

An ordinary 9 volt battery with maximum DC 20volts is recommended. A 9 volt battery will last for about one day of normal operation.

LOW

COOL

J46

SPEED

1 Disconnect power to unit. 2 Disconnect plug J46 from P46 located on the blower control board. 3 Connect voltage source as shown above. 4 Turn on power to unit. Blower should operate at low cool speed.

HIGH

COOL

SPEED

J46

CHECK−OUT PROCEDURE USING 24V SOURCE

Unit transformer T1 with a maximum AC 30 volts may be used in lieu of a battery. If transformer T1 is used, double check all wiring connections before placing unit back in operation.

LOW

COOL

J46

SPEED

HIGH

COOL

SPEED

J46

5 Disconnect power to unit. 6 Connect voltage source as shown above.

7 Turn on power to unit. Blower should operate at high cool speed.

LOW

HEAT

J46

SPEED

8 Disconnect power to unit. 9 Connect voltage source as shown above.

10 Turn on power to unit. Blower should operate at low heat speed.

HIGH

HEAT

SPEED

11 Disconnect power to unit. 12 Connect voltage source as shown above.

13 Turn on power to unit. Blower should operate at high heat speed.

5 Disconnect power to unit. 6 Connect voltage source as shown above.

7 Turn on power to unit. Blower should operate at high cool speed.

LOW

HEAT

J46

SPEED

8 Disconnect power to unit. 9 Connect voltage source as shown above.

10 Turn on power to unit. Blower should operate at low heat speed.

HIGH

HEAT

SPEED

11 Disconnect power to unit. 12 Connect voltage source as shown above.

13 Turn on power to unit. Blower should operate at high heat speed.

J46J46

Page 85

Page 86

4− SureLight Control Board

Diagnostic lights flash the roll out

LED#1−On

ACTION 1

blower does not energize

120V field connection

UPON INITIAL POWER UP, REMOVE ALL THERMOSTAT DEMANDS TO THE UNIT Unless otherwise noted, condition applies to all G32V units.

PROBLEM: 1 UNIT FAILS TO OPERATE IN THE COOLING, HEATING, OR CONTINUOUS FAN MODE

Condition Possible Cause Corrective Action / Comments

1.1

− Both diagnostic lights fail to light up.

Main voltage 120V not supplied to unit.

1.1.1

ACTION 1 − Check 120V main voltage.

Determine cause of main power failure.

LED#1−Off LED#2−Off

1.2

G32V−1 through −4 Units Only

− Diagnostic lights flash the roll−out

code.

−

LED#2−Slow Flash

1.3

− On initial power−up the comb. air .

− Diagnostic lights flash the reverse

polarity code.

1.1.2

Miswiring of furnace or improper connections.

1.1.3

Circuit breaker tripped or fails to close.

1.1.4

Door interlock switch failure.

1.1.5

Transformer Failure.

1.1.6

Failed control board.

1.2.1

Roll−out switch open.

1.2.2

Roll−out switch failure.

1.2.3

Miswiring or improper connections at roll−out switch.

1.2.4

Nine pin connector failure

1.3.1

120V main power polarity reversed.

ACTION 1 − Check for correct wiring of 120V to power make up box and transformer.

ACTION 2 − Check 24V wiring to control board.

ACTION 1 − Replace circuit breaker if it is reset

but does not have continuity. ACTION 2 − If circuit breaker still trips, check for short.

ACTION 1 − Check that door switch is activated when door is closed. ACTION 2 − Check wire connections to switch, replace loose connectors. ACTION 3 − Check continuity of switch in closed position. Replace if malfunctioning

ACTION 1 − Check that transformer output is 24V. Replace if malfunctioning

ACTION 1 − If all the above items have been checked, replace board.

ACTION 1 − Manually reset the roll−out switch by pushing the top button. ACTION 2 − Determine the cause of the roll−out switch activation before leaving furnace.

ACTION 1 − Check continuity across roll−out switch. Replace roll−out switch if switch is reset but does not have continuity.

− Check wiring connections to switch.

ACTION 1 − Check 9−pin connector for proper

connection to control board. ACTION 2 − Check continuity of the multi plug pin.

ACTION 1 − Check the 120V has line and neutral correctly input into control. ACTION 2 − Reverse the line and neutral at the 120V field connection.

LED#1−Fast Flash, LED#2−Slow Flash.

1.4

G32V−1 through −4 Units Only

− On initial power up the combustion air

blower does not energize.

− Diagnostic lights flash normal power

on operation.

LED#1−Slow Flash LED#2−Slow Flash

1.4.1

Open combustion air blower motor circuit.

1.4.2

Failed combustion air blower motor.

Page 86

ACTION 1 − Check for 120V to combustion air blower. If no power, check wire and connections.

ACTION 1 − If power is present at blower, replace blower.

Page 87

PROBLEM 1: UNIT FAILS TO OPERATE IN THE COOLING, HEATING, OR CONTINUOUS FAN MODE

Diagnostic lights flash the pressure

Condition Possible Cause Corrective Action / Comments

1.5

− On initial power−up the combustion

air blower remains energized.

− Diagnostic lights flash the improper main ground.

LED#1−Alternating Fast Flash LED#2−Alternating Fast Flash

1.5.1

Improper ground to the unit.

1.5.2

6−Pin connector is improperly at-

tached to the circuit board.

1.5.3

Line voltage is below 75V.

ACTION 1 − Check that the unit is properly grounded. ACTION 2 − Install a proper main ground to the unit

ACTION 1 − Check 6−pin connector for proper installation. Correctly insert connector into control.

ACTION 1 − Check that the line voltage is above 75V. Determine cause of voltage drop and supply correct voltage to the control.

PROBLEM 2: UNIT FAILS TO OPERATE IN THE COOLING OR HEATING MODE, BUT COMBUSTION AIR BLOWER OPERATES CONTINUOUS. G32V−1 through −4 UNITS WITH CONTROL BOARDS DATE CODED AFTER NOV.1 1997, WILL OPERATE IN COOLING WITH COMBUSTION AIR BLOWER CYCL-

ING 5 SECONDS ON 55 SECONDS OFF, BUT NOT IN THE HEATING MODE.

Condition Possible Cause Corrective Action / Comments

2.1

− On initial power−up the combustion

air blower remains energized.

− Diagnostic lights flash the improper main ground.

− G32V−1 to −4 Units with control boards date coded after Nov.1 1997; combustion air blower will cycle 5 seconds on 55 seconds off.

LED#1−Alternating Fast Flash LED#2−Alternating Fast Flash

2.1.1

Open ignitor circuit.

2.1.2

Broken or failed ignitor.

ACTION 1 − Check for correct wiring and loose connections in the ignitor circuit. Check multi − plug connections for correct installation.

ACTION 1 − Unplug ignitor and read resistance across ignitor. If resistance does not read between 10.9 and 19.7 ohms, replace the ignitor.

PROBLEM 3: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR BLOWER DOES NOT

ENERGIZE

Condition Possible Cause Corrective Action / Comments

3.1

− Unit operates with a cooling or contin-

uous fan demand.

− Combustion air blower will not start with a Heating demand.

− Diagnostic lights flash the limit failure mode.

LED#1−Slow Flash, LED#2−On

3.2

− Unit operates with a cooling and continuous fan demand.

− Combustion air blower will not start with a Heating demand.

− Diagnostic lights flash the pressure

−

switch failure code.

LED#1−Off, LED#2−Slow Flash

3.1.1

Primary or secondary (if equipped) or

rollout limit switch open.

3.1.2

Miswiring of furnace or improper con-

nections at limit switch(es).

3.2.1

Miswiring of furnace or improper con-

nections to combustion air blower.

3.2.2

Pressure switch stuck closed.

ACTION 1 − Check continuity across switch(es). Switches reset automatically upon cool down.

Rollout switch must be reset manually. ACTION 2 − Check for restrictions on blower inlet

air (including filter) and outlet air. Determine cause for limit activation before placing unit back in operation.

ACTION 1 − Check for correct wiring and loose connections. Correct wiring and/or replace any loose connections.

ACTION 1 − Check that the pressure switch is open without the combustion air blower operating. Replace if malfunctioning

Page 87

Page 88

PROBLEM 3: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR BLOWER DOES NOT

LED#1 Off

ENERGIZE (CONT.).

Condition Possible Cause Corrective Action/Comments

3.3

− Unit operates with a cooling and continuous fan demand.

− Combustion air blower will not start with a Heating demand.

Miswiring of furnace or improper con-

nections to combustion air blower.

3.3.1

ACTION 1 − Check for correct wiring and loose

connections. Correct wiring and/or replace any loose connections.

− Diagnostic lights flash the pressure switch failure code 2.5 minutes after heating demand.

ACTION 1 − If there is 120V to combustion air blower and it does not operate, replace combustion air blower.

LED#1−Off,

3.3.2

Combustion air blower failure.

LED#2−Slow Flash

PROBLEM 4: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR BLOWER

ENERGIZES, IGNITOR IS NOT ENERGIZED.

Condition Possible Cause Corrective Action/Comments

4.1

− Unit operates with a cooling and

continuous fan demand.

− Combustion air blower energizes with a heating demand.

− Diagnostic lights flash the pressure switch failure code 2.5 minutes after heating demand.

LED#1−Off LED#2−Slow Flash

Pressure switch does not close due to

incorrect routing of the pressure

Pressure switch does not close due to

obstructions in the pressure tubing.

Pressure switch tubing damaged

Condensate in pressure switch tub-

Pressure switch does not close due to

a low differential pressure across the

Wrong pressure switch installed in the

unit, or pressure switch is out of cal-

Miswiring of furnace or improper con-

nections at pressure switch.

Pressure switch failure.

4.1.1

switch tubing.

4.1.2

4.1.3

4.1.4

ing.

4.1.5

pressure switch.

4.1.6

ibration.

4.1.7

4.1.8

ACTION 1 − Check that the pressure switch tub-

ing is correctly routed. Correctly route pressure switch tubing.

ACTION 1 − Remove any obstructions from the pressure tubing and/or taps.

ACTION 1 − Check pressure switch tubing for leaks. Replace any broken tubing.

ACTION 1 − Check pressure switch tubing for condensate. Remove condensate from tubing. Check that the condensate tubing is located correctly.

ACTION 1 − Check the differential pressure across the pressure switch. This pressure should exceed the set point listed on the switch. ACTION 2 − Check for restricted inlet and exhaust vent. Remove all blockage. ACTION 3 − Check for proper vent sizing and run length. See installation instructions.

ACTION 1 − Check that the proper pressure switch is installed in the unit. Replace pressure switch if necessary.

ACTION 1 − Check for correct wiring and loose connections. Correct wiring and/or replace any loose connections.

ACTION 1 − If all the above modes of failure have been checked, the pressure switch may have failed. Replace pressure switch and determine if unit will operate.

Page 88

Page 89

PROBLEM 5: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR BLOWER

rners light but unit shuts off prior

ignite code.

ENERGIZES, IGNITOR IS ENERGIZED. (CONT.)

Condition Possible Cause Corrective Action/Comments

5.1

− Unit operates with a cooling and continuous fan demand.

− Combustion air blower energizes with Heating demand.

− Ignitor is energized but unit fails to light.

LED#1−Alternating Slow Flash LED#2−Alternating Slow Flash

PROBLEM 6: BURNERS LIGHT WITH A HEATING DEMAND BUT UNIT SHUTS DOWN

Condition Possible Cause Corrective Action/Comments

6.1

− Burners fire with a heating demand.

−

− Bu to satisfying T−stat demand.

− Diagnostic lights flash the pressure switch code.

LED#1−Off LED#2−Slow Flash

6.2

− Combustion air blower energizes with a heating demand.

− Burners light but fail to stay lit.

− After 5 tries the control diagnostics flash the watchguard burners failed to ignite code.

LED#1−Alternating Slow Flash LED#2−Alternating Slow Flash

5.1.1

Check that gas is being supplied to

the unit.

5.1.2

Miswiring of gas valve or loose con-

nections at multi−pin control amp

plugs or valve.

5.1.3

Malfunctioning gas valve or ignition

control.

PREMATURELY

6.1.1

Wrong concentric vent kit used for ter-

minating the unit.

6.1.2

Condensate drain line is not draining

properly.

6.1.3

Low pressure differential at the pres-

sure switch.

6.2.1

Sensor or sense wire is improperly

installed.

6.2.2

Sensor or sense wire is broken.

6.2.3

Sensor or sensor wire is grounded to

the unit.

6.2.4

Control does not sense flame.

ACTION 1 − Check line pressure at the gas valve. Pressure should not exceed 13" WC for both natural and propane. Line pressure should read a minimum 4.5" WC for natural and 8.0"WC for propane.

ACTION 1 − Check for correct wiring and loose connections. Correct wiring and/or replace any loose connections.

ACTION 1 − Check that 24V is supplied to the gas valve approximately 35 seconds after heat demand is initiated. ACTION 2 − Replace the valve if 24V is supplied but valve does not open (check for excessive gas line pressure before replacing gas valve). ACTION 3 − Replace the control board if 24V is not supplied to valve.

ACTION 1 − Check vent termination kit installed. 1−1/2" dia. concentric vent (kit60G77) for 50 and 75 inputs and 2" dia. concentric vent (kit 33K97) for 100 &125 inputs.

ACTION 1 − Check condensate line for proper vent slope, and any blockage. Condensate should flow freely during operation of furnace. Repair or replace any improperly installed condensate lines.

ACTION 1 − Check for restricted vent inlet or exhaust. Remove all blockage. ACTION 2: Check for proper vent sizing. See installation instructions.

ACTION 1 − Check that sensor is properly located (page 10) and that the sense wire is properly attached to both the sensor and the control.

ACTION 1 − Check for a broken sensor. ACTION 2 − Test continuity across the sense

wire. If wire or sensor are damaged replace the component.

ACTION 1 − Check for resistance between the sensor rod and the unit ground. ACTION 2 − Check for resistance between the sensor wire and the unit ground.

ACTION 3 − Correct any shorts found in circuit.

ACTION 1 − Check the microamp signal from

the burner flame. If the microamp signal is below 0.70 microamps, check the sense rod for proper location or contamination. ACTION 2 − Replace, clean, or relocate flame sense rod. If rod is to be cleaned, use steel wool or replace sensor. DO NOT CLEAN ROD WITH SAND PAPER. SAND PAPER WILL CONTRIBUTE TO THE CONTAMINATION PROBLEM. NOTE: Do not attempt to bend sense rod.

Page 89

Page 90

PROBLEM 6: BURNERS LIGHT WITH HEATING DEMAND BUT UNIT SHUTS DOWN

ure.

LED#2−Sl

flame failure

Condition Possible Cause Corrective Action/Comments

6.3

− Combustion air blower energizes with a heating demand.

− Burners light.

− Roll−out switch trips during the heating demand.

− Diagnostic lights flash roll−out failure.

G32V−1 through −4 Units Only

LED#1−On

ow Flas

G32V−5 Units

LED#1−Slow Flash LED#2−On

6.4

− Combustion air blower energizes

with a heating demand.

− Burners light roughly and the unit fails to stay lit.

− Diagnostic lights flash watchguard flame failure.

PREMATURELY (CONT.)

6.3.1

Unit is firing above 100% of the

nameplate input.

6.3.2

Gas orifices leak at the manifold con-

nection.

6.3.3

Air leakage at the connections be-

tween the primary heat exchanger,

secondary heat exchanger, and com-

bustion air blower.

6.3.4

Insufficient flow through the heat ex-

changer caused by a sooted or re-

stricted heat exchanger.

6.3.5

Burners are not properly located in

the burner box.

6.4.1

Recirculation of flue gases. This con-

dition causes rough ignitions and op-

eration. Problem is characterized by

nuisance flame failures.

ACTION 1 − Check that the manifold pressure matches value listed on nameplate. See installation instructions for proper procedure. ACTION 2 − Verify that the installed orifice size match the size listed on the nameplate or installation instructions. ACTION 3 − Check gas valve sensing hose to insure no leaks are present. ACTION 4 − Check the input rate to verify rate matches value listed on nameplate.

ACTION 1 − Tighten orifice until leak is sealed. NOTE: Be careful not to strip orifice threads. ACTION 2 − Check for gas leakage at the

threaded orifice connection. Use approved method for leak detection (see unit instructions).

ACTION 1 − Check for air leakage at all joints in the heat exchanger assembly. Condition may cause high CO2 with high CO. ACTION 2 − Seal leakage if possible (high temperature silicon is recommended), replace heat exchanger if necessary, tag and return heat exchanger to proper Lennox personnel.

ACTION 1 − Check for sooting deposits or other restrictions in the heat exchanger assembly. Clean assembly as outlined in instruction manual. ACTION 2 − For G32V gas furnaces, check for proper combustion and flow. CO2 should measure between 7.9% and 8.5% for high fire and between 5.5% and 6.3% for low fire. CO should measure below .04% (400PPM) in an air−free sample of flue gases.

ACTION 1 − Check that the burners are firing into the center of the heat exchanger openings. Correct the location of the burners if necessary.

ACTION 1 − Check for proper flow of exhaust gases away from intake vent. Remove any obstacles in front of the intake and exhaust vent which would cause recirculation. ACTION 2 − Check for correct intake and exhaust vent installation.

LED#1−Alternating Slow Flash LED#2−Alternating Slow Flash

6.4.2

Improper burner cross−overs

ACTION 1 − Remove burner and inspect the cross−overs for burrs, or any restriction or if crossover is warped. Remove restriction or replace burners.

Page 90

Page 91

PROBLEM 6: BURNERS LIGHT WITH HEATING DEMAND BUT UNIT SHUTS DOWN

code

6.5

− Combustion air blower energizes with a heating demand.

− Burners light.

− Diagnostic lights flash watch guard flame failure.

− NOTE" Unit might go into 60 minute Watchguard mode depending on intermittent nature of sensor signal.

LED#1−Alternating Slow Flash LED#2−Alternating Slow Flash

PROBLEM 7: CONTROL SIGNALS LOW FLAME SENSE DURING HEATING MODE

Condition Possible Cause Corrective Action/Comments

7.0

− Unit operates correctly but the diagnostic lights flash low flame sense

LED#1−Slow Flash LED#2−Fast Flash

PREMATURELY (CONT.)

6.5.1

Loose sensor wire connection causes

intermittent loss of flame signal.

7.1.1

Sense rod is improperly located on

the burner.

7.1.2

Sense rod is contaminated.

ACTION 1 − Check that the sensor is properly located. ACTION 2 − Check that the sense wire is properly attached to both the sensor and the control. Pay extra attention to the pin connectors.

ACTION 1 − Check the sense rod for proper location on the burner. Properly locate the sense rod or replace if rod cannot be located correctly.

ACTION 1 − Check sense rod for contamination or coated surface. Clean the sense rod with steel wool or replace sensor. DO NOT USE SAND PAPER TO CLEAN ROD. SAND PAPER WILL CONTRIBUTE TO THE CONTAMINATION PROBLEM.

PROBLEM 8: RF STATIC DURING TIME FOR IGNITION

Condition Possible Cause Corrective Action/Comments

8.0

− AM radio interference

8.1.1

Ignitor operation

ACTION 1− Call Technical Support, Dallas

Page 91

Lennox G32V, G32V5-100, G32V3-75, G32V5-125, G32V-100 L.P. Service Literature

Specifications and Main Features

Frequently Asked Questions

User Manual

SPECIFICATIONS

BLOWER PERFORMANCE