Lennox G32V3-75, G32V5-100, G32V5-125 Installation Instructions Manual
INSTALLATION
2002 Lennox Industries Inc.
Dallas, Texas, USA
RETAIN THESE INSTRUCTIONS
FOR FUTURE REFERENCE
INSTRUCTIONS
G32V SERIES UNITS
GAS UNITS
504,564M
5/2002
Supersedes 504,468M
Table of Contents
G32V Unit Dimensions- inches (mm) 2. . . . . . . . . . . .
G32V Parts Arrangement 3. . . . . . . . . . . . . . . . . . . . . .
Safety Instructions 4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation - Setting Equipment 5. . . . . . . . . . . . . . . .
Return Air Opening Guidelines 5. . . . . . . . . . . . . . . . .
Filter & Filter Assembly 6. . . . . . . . . . . . . . . . . . . . . . .
Duct System 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pipe & Fittings Specifications 7. . . . . . . . . . . . . . . . . .
Vent Piping Guidelines 8. . . . . . . . . . . . . . . . . . . . . . . .
Joint Cementing Procedure 9. . . . . . . . . . . . . . . . . . . .
Venting Practices 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas Piping 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Integrated Control Board Settings 23. . . . . . . . . . . . .
Unit Start-Up 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heating Sequence of Operation 27. . . . . . . . . . . . . . .
Gas Pressure Adjustment 31. . . . . . . . . . . . . . . . . . . .
High Altitude Information 32. . . . . . . . . . . . . . . . . . . . .
Other Unit Adjustments 32. . . . . . . . . . . . . . . . . . . . . .
Service 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Parts List 35. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Integrated Control Board Diagnostic Codes 35. . . . .
Troubleshooting 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start-Up & Performance Check List 42. . . . . . . . . . . .
Litho U.S.A.
Do not store or use gasoline or other flamĆ
mable vapors and liquids in the vicinity of
this or any other appliance.
Installation and service must be performed
by a qualified installer, service agency or
the gas supplier.
05/02
*2P0502*
WARNING
If the information in this manual is not
followed exactly, a fire or explosion
may result causing property damage,
personal injury or death.
WHAT TO DO IF YOU SMELL GAS:
Do not try to light any appliance.
Extinguish any open flames.
Do not touch any electrical switch; do not use any
phone in your building.
Leave the building immediately.
Immediately call your gas supplier from a neighbor's
phone. Follow the gas supplier's instructions.
If you cannot reach your gas supplier, call the
fire department.
Page 1
504,564M
*P504564M*
G32V Unit Dimensions - inches (mm)
1 1/16
(41)
5/8
(16)
1 1/16
(41)
18 7/8
(479)
B
SUPPLY
AIR
OPENING
23 3/4 (603)
25 (635)
TOP VIEW
28 1/2
(724)
CONDENSATE
DRAIN
(Both Sides)
ELECTRICAL
INLETS
(Both Sides)
3 5/8
(92)
7 3/8
(187)
2
(51)
2 1/2 (64)
21 3/4
(552)
4 1/2
(114)
GAS PIPING
(Both Sides)
F
COMBUSTION
EXHAUST
AIR OUTLET
23
(584)
INLET
AIR INTAKE
46
(1168)
EXTERNAL
SIDE RETURN
AIR FILTER KIT
(Either Side)
A
(Optional)
23 (584)
C
RETURN AIR
KNOCKOUT
(Either Side)
1-15/16 (49)
23 (584)
Return Air
Knockout (Bottom)
4 (102)
4 (102)
G
5/8 (16)
H
E
AIR FLOW
D
Return Air
Knockout (Bottom)
FRONT VIEWSIDE VIEW
Model No.
G32V3-75 16-1/4 413 14-1/8 359 12 305 12 305 2-1/8 54 7-5/8 194 14 356 12-3/4 324
G32V5–100 21-1/4 540 19-1/8 486 18 457 18 457 1-5/8 41 10-1/8 257 20 508 18-3/4 476
G32V5–125 26-1/4 667 24-1/8 613 18 457 18 457 4-1/8 105 12-5/8 321 20 508 18-3/4 476
A B C D E F G H
in. mm in. mm in. mm in. mm in. mm in. mm in. mm in. mm
Page 2
G32V Parts Arrangement
FRESH AIR
INTAKE FITTING
BURNER BOX
ASSEMBLY
PATCH
PLATE
FLAME SIGHT
BURNER BOX
COVER
GLASS
TWOĆSTAGE
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
TM
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
Page 3
Safety Instructions
To combustible
Lennox G32V units are Category IV CSA International
certified to ANSI Z21.47 and CSA 2.3 standards.
In the USA, installation of Lennox gas central furnaces
must conform with local building codes. In the absence of
local codes, units must be installed according to the curĆ
rent National Fuel Gas Code (ANSI-Z223.1/NFPA 54) in
the United States. The National Fuel Gas Code is availĆ
able from the following address:
American National Standards Institute, Inc.
11 West 42nd Street
New York, NY 10036
In Canada, installation must conform with current NationĆ
al Standard of Canada CAN/CGAĆB149.1 Installation
Code for Natural Gas Burning Appliances and EquipĆ
ment" and CAN/CGA-B149.2 Installation Code for ProĆ
pane Gas Burning Appliances and Equipment," local
plumbing or waste water codes and other applicable local
codes.
This furnace is CSA International certified for installation
clearances to combustible material as listed on the unit
rating plate and in table 1.
TABLE 1
Clearances Location Inches (mm)
Front 24 (610)
Service access
To combustible
materials
Condensate side
To p 1 (25)
Exhaust 0
Side, rear, and front 0
3 (76)
(from side of unit)
When the furnace is used with cooling units, it shall be
installed in parallel with, or on the upstream side of, cooling units to avoid condensation in the heating compartĆ
ment. With a parallel flow arrangement, a damper (or othĆ
er means to control the flow of air) must adequately
prevent chilled air from entering the furnace. If the dampĆ
er is manually operated, it must be equipped to prevent
operation of either the heating or the cooling unit, unless it
is in the full HEAT" or COOL" setting.
When installed, the furnace must be electrically grounded
according to local codes. In addition, in the United States,
installation must conform with the current National ElecĆ
tric Code, ANSI/NFPA No. 70. The National Electric Code
(ANSI/NFPA No. 70) is available from the following adĆ
dress:
National Fire Protection Association
1 Battery March Park
Quincy, MA 02269
In Canada, all electrical wiring and grounding for the unit
must be installed according to the current regulations of
the Canadian Electrical Code Part I (CSA Standard
C22.1) and/or local codes.
Field wiring connections must meet or exceed specificaĆ
tions of type T wire and withstand a maximum temperaĆ
ture rise of 180°F (82°C).
G32V unit must be installed so that electrical components
are protected from water.
When the furnace is installed so that supply ducts carry
air circulated by the furnace to areas outside of the space
containing the furnace, return air shall be handled by a
duct(s) sealed to the furnace casing and terminating outĆ
side space containing furnace.
Floor 0
NOTE - For installation on combustible floors, the furnace
shall not be installed directly on carpeting, tile, or other
combustible material other than wood flooring.
Accessibility and service clearances must take preceĆ
dence over fire protection clearances.
For installation in a residential garage, the furnace must
be installed so that the burner(s) and the ignition source
are located no less than 18 inches (457 mm) above the
floor. The furnace must be located or protected to avoid
physical damage by vehicles. When a furnace is installed
in a public garage, hangar, or other building that has a
hazardous atmosphere, the furnace must be installed acĆ
cording to recommended good practice requirements
and current National Fuel Gas Code or CAN/CGA B149.1
and B149.2 standards.
WARNING
Product contains fiberglass wool.
Disturbing the insulation in this product during
installation, maintenance, or repair will expose you
to fiberglass wool dust. Breathing this may cause
lung cancer. (Fiberglass wool is known to the State
of California to cause cancer.)
Fiberglass wool may also cause respiratory, skin,
and eye irritation.
To reduce exposure to this substance or for further
information, consult material safety data sheets
available from address shown below, or contact
your supervisor.
Lennox Industries Inc.
P.O. Box 799900
Dallas, TX 75379-9900
Page 4
NOTE - G32V series units must not be used as a
construction heater during any phase of construction.
Very low return air temperatures, harmful vapors and misĆ
placement of the filters will damage the unit and lower its
efficiency.
The G32V furnace may be installed in alcoves, closĆ
ets, attics, basements, garages and utility rooms in
the upflow position.
General
The G32V is an upflow gas furnace which is factoryequipped for use with natural gas. A changeover kit is
necessary if the furnace is to be used with L.P. gas. These
instructions are intended as a general guide and do not
supersede local codes in any way. Consult authorities
having jurisdiction before installation.
Shipping and Packing List
1 - Assembled G32V furnace
1 - 3 inch x 2 inch vent transition piece (-100, -125
units only)
1 - Bag assembly containing:
1 - Filter
1 - External filter rack for side return air application
1 - Bag assembly containing:
1 - Electrical make-up box with cover and
grounding screw
4 - Thread-forming make-up box screws
1 - Green ground wire
1 - Wiring harness
1 - Snap bushing
2 - Filter clips
1 - Condensate drain pipe adapter
1 - Condensate plug
4 - Wire nuts
2 - Lockwashers and screws
8 - Self-tapping screws
2 - Filter door pins
1 - Grounding label
1 - Wire tie
Shipping Damage
Check equipment for shipping damage. If you find any
damage, immediately contact the last carrier.
WARNING
Improper installation, adjustment, alteration, serĆ
vice or maintenance can cause property damage,
personal injury or loss of life. Installation and serĆ
vice must be performed by a qualified installer, serĆ
vice agency or the gas supplier.
CAUTION
As with any mechanical equipment, personal injuĆ
ry can result from contact with sharp sheet metal
edges. Be careful when you handle this equipment.
Installation - Setting Equipment
Select a location that allows for required clearances listed
on the unit rating plate. Also consider gas supply connecĆ
tions, electrical supply, vent connection and installation
and service clearances [24 inches (610 mm) at unit front].
The furnace must be level.
CAUTION
G32V unit should not be installed in areas normally
subject to freezing temperatures.
Return Air Opening Guidelines
WARNING
Improper installation of unit can result in personal
injury or death. Combustion and flue products
must never be allowed to enter the return air sysĆ
tem or air in the living space. Use sheet metal
screws and joint tape to seal return air system to
furnace.
In platform installations with furnace return, the
furnace should be sealed airtight to the return air
plenu m . A doo r mu s t never be us e d as a portion of
the return air duct system. The base must provide
a stable support and an airtight seal to the furnace.
Allow absolutely no sagging, cracks, gaps, etc.
For no reason should return and supply air duct
systems ever be connected to or from other heatin g devices such as a fireplace or stove, etc. Fire,
explosion, carbon monoxide poisoning, personal
injury and/or property damage could result.
WARNING
The blower access panel must be securely in place
when the blower and burners are operating. Gas
fumes, which could contain carbon monoxide, can
be drawn into living space resulting in personal inĆ
jury or death.
Return air can be brought in either side or at the bottom of
the unit. Scribe lines show the outline of each side and the
bottom return air opening.
Page 5
Bottom Return Air Applications
If return air is to terminate through the floor under the furĆ
nace, a direct, airtight and sealed connection must be
made to the bottom of the furnace.
1 - Cut opening in floor or platform. Using knockouts
provided, cut bottom of base panel. See figure 2.
KNOCKOUT PATTERN FOR BOTTOM
RETURN AIR APPLICATION
FIGURE 2
BOTTOM RETURN AIR APPLICATION
FILTER SIZE REQUIREMENTS
TABLE 2
UNIT MODEL
NUMBER
G32V-75 31J81
G32V-100
G32V-125
FILTER PART
NUMBER
P-8-7831
FILTER SIZE
14 inches x 25 inches
(356 x 635 mm)
20 inches x 25 inches
(508 x 635 mm)
Bottom Return Air Applications
1 - Remove blower access panel.
2 - Install filter clips, provided with unit, by slipping
folded section of clip on edge of bottom opening. See
figure 4.
BOTTOM RETURN FILTER INSTALLATION
REAR FILTER CLIP
FURNACE
SIDE FILTER CLIPS (2)
RETURN AIR OPENING
BACK
G32V UNIT
RETURN AIR
PLENUM
PROPERLY
SIZED FLOOR
OPENING
FIGURE 3
2 - Bend a flange on return air plenum and lower into
floor or platform opening. See figure 3.
3 - Position unit over return air opening. Seal unit air
tight with return air plenum.
NOTE - Be careful not to damage insulation. Check for
tight seal.
Side Return Air Applications
For installations where the return air is taken from a return
air drop, unit may be installed using either the left or right
side of furnace.
For side return air applications, cut the furnace cabinet at
the dimensions given in the unit dimensions graphic. EmĆ
bossed corners are pro-vided on both cabinet sides for reĆ
turn air opening location.
FURNACE
FRONT
FURNACE
BASE BOTTOM
FIGURE 4
3 - Place filter in bottom of blower compartment beneath
rear filter clip. Press down on filter sides. Filter clips
flex allowing filter to snap into place.
4 - To remove filter, press clip and pull filter up and out.
Side Return Air Applications
1 - Align filter rack opening with the inside edge of the
side return opening. Bottom of rack should be
approximately 1 inch (25 mm) from the bottom and 3
inches (76 mm) from the front of the unit.
2 - Screw filter rack into place with the eight self drill, self
tap screws provided. See figure 5.
3 - Push filter door pins through the two holes in filter
door from the inside of the uĆchannel. See figure 6.
SIDE RETURN FILTER INSTALLATION
in. (mm)
BLOWER DECK
RETURN AIR
RETURN
AIR
OPENING
12 in. (305) for
14 in. (356) Filter
18 in. (457) for
20 in. (508) Filter
PLENUM SIZE
12-3/4 in X 23-1/2 in (324 X
597) for 14 in (356) Filter
18-3/4 in. x 23-1/2 in.
(476 x 597)
for 20 in. (508) Filter
Filter & Filter Assembly
A filter and an external filter rack for use in side return air
applications are shipped with the unit. A filter must be in
place anytime the unit is in operation.
Page 6
1-15/16 in.
(49)
CABINET BASE BOTTOM
FIGURE 5
15/16 in
(24)
4 - Position filter door on end of filter so that the thumb
tab side of the filter door is away from the furnace.
Squeeze thumb tabs to secure filter to door.
5 - Guide filter and filter door into the filter rack installed
on side of furnace. Push door into filter rack until secure.
6 - To remove filter, pull filter door pins until door is re-
leased from filter rack.
FILTER DOOR ASSEMBLY
FILTER DOOR
PIN
FILTER DOOR
TAB
FILTER
NO TE - For bot to m re tu r n air, ret ur n ai r du ct should be seĆ
cured to the unit using rivets or S-locks. For side return
air, secure return air duct to filter rack using screws. When
using screws, take care to avoid interference with the filĆ
ter which may cause improper filtration.
The ret urn ai r mu s t no t be draw n fro m a room where
another gas appliance (ie., a water heater) is
installed. Even though this furnace draws its combusĆ
tion air from outside of the structure, other gas apĆ
pliances that share a utility room may not. When return
air is drawn from a room, a negative pressure is created
in the room. If a gas appliance is operating in a room
with negative pressure, the flue products can be pulled
back down the vent pipe and into the room. This reverse
flow of the flue gas may result in incomplete combustion
and the formation of carbon monoxide gas. This toxic
gas might then be distributed through the house by the
furnace duct system.
FILTER DOOR
PIN
TAB
FIGURE 6
Duct System
Use industry-approved standards to size and install the
supply and return air duct system. This will result in a quiet
and low-static system that has uniform air distribution. If
the G32V unit is being installed as a replacement for an
existing furnace, the existing supply and return air duct
system should be evaluated to make sure that it is approĆ
priately sized.
The total external static pressure (ESP) should not exĆ
ceed 0.8" w.c. The ESP calculation should include presĆ
sure losses caused by electronic air cleaners, filters,
cooling coils, the duct system, registers and grilles. A
properly sized duct system will help to optimize efficiency
and reliability and to minimize sound levels. Operation of
a G32V unit outside of its specified static pressure range
will result in poor performance and will reduce the useful
life-expectancy of the product and its components.
Supply Air Plenum
Furnaces installed without a cooling coil require the installaĆ
tion of a removable access panel in the supply air duct. The
access panel should be large enough to permit inspection
(either by smoke or reflected light) of the heat exchanger for
leaks after installation. The furnace access panel must alĆ
ways be in place when the furnace is operating and it must
not allow leaks into the supply air duct system.
Return Air Plenum
See dimension illustration for proper return air duct size.
Pipe & Fittings Specifications
All pipe, fittings, primer and solvent cement must conform
with American National Standard Institute and the AmeriĆ
can Society for Testing and Materials (ANSI/ASTM) stanĆ
dards. The solvent shall be free flowing and contain no
lumps, undissolved particles or any foreign matter that
adversely affects the joint strength or chemical resistance
of the cement. The cement shall show no gelation, stratifiĆ
cation, or separation that cannot be removed by stirring.
Refer to table 3 for approved piping and fitting materials.
Primers and solvents must meet ASTM specifications.
PVC primer is specified in ASTM F 656. Use PVC solvent
cement as specified in ASTM D 2564 and ABS solvent
cement as specified in ASTM D 2235. Low temperature
solvent cement is recommended. Metal or plastic strapĆ
ping may be used for vent pipe hangers.
Table 4 lists the available exhaust termination kits. All
Lennox vent terminations are PVC.
TABLE 3
PIPING AND FITTINGS SPECIFICATIONS
PIPE & FITTING MATERIAL
Schedule 40 PVC (Pipe) D1785
Schedule 40 PVC (Cellular Core Pipe) F891
Schedule 40 PVC (Fittings) D2466
Schedule 40 CPVC (Pipe) F441
Schedule 40 CPVC (Fittings) F438
SDR-21 PVC (Pipe) or SDR-26 PVC (Pipe) D2241
SDR-21 CPVC (Pipe) or SDR-26 CPVC (Pipe) F442
Schedule 40 ABS (Pipe) D1527
Schedule 40 ABS (Fittings) D2468
ABS-DWV (Drain Waste & Vent)
(Pipe & Fittings)
PVC-DWV (Drain Waste & Vent Pipe & Fittings)
ASTM
SPECIFICATION
D2661
D2665
Page 7
TABLE 4
TERMINATION KITS
Lennox Part
No.
60G77 LB-49107CE
33K97 LB-87942
15F75 LB-49107CC
22G44 LB-49107CD
15F74 LB-49107CB 2" (50.8) Wall Ring Kit
44J41 LB-65678A
44J40 LB-65701A
30G28 WTK
30G79 WTKX
Kit LB# Description-Inches (mm)
1-1/2" (50.8) Concentric
Termination Kit
3" (50.8) Low Pressure Drop ConĆ
centric Term. Kit
2" (50.8) Roof
Termination Kit
2" (50.8) Wall
Assembly Termination Kit
3" (76.2) Roof
Termination Kit
3" (76.2) Wall
Assembly Termination Kit
2" (50.8) Wall
Termination Extended Vent
2" (50.8) Wall
Termination Extension Riser
CAUTION
Solvent cements for plastic pipe are flammable liqĆ
uids and should be kept away from all sources of
ignition. Do not use excessive amounts of solvent
cement when making joints. Good ventilation
should be maintained to reduce fire hazard and to
minimize breathing of solvent vapors. Avoid conĆ
tact of cement with skin and eyes.
When making ABS joints, pieces can be prepared with a
cleaner. When joining ABS to PVC materials, use PVC
solvent cement. Refer to this procedure as specified in
ASTM D3138.
Vent Piping Guidelines
Pipe used for exhaust and intake lines should be sized acĆ
cording to table 5. Note that maximum length of vent pipe
is for one run; either intake or exhaust. Maximum vent
length given is not the total length of intake plus exhaust
vents.
Each 90° elbow is equivalent to 5 feet (1.52 m) of vent
pipe. Two 45° elbows are equivalent to one 90° elbow.
One 45° elbow is equal to 2.5 feet (.76 m) of vent pipe. If
intake and exhaust piping runs are not equal in length and
number of elbows, the larger diameter pipe must be used
for both runs.
TABLE 5
VENT PIPE SIZING TABLE FOR G32V FURNACES
MINIMUM DIAMETER OF INTAKE/EXHAUST PIPE
Vent Pipe
Equivalent Length
Max. Feet (Meters)
15 (4.57) 2" 2" 2"
20 (6.10) 2" 2" 3"
25 (7.62) 2" 2" 3"
30 (9.14) 2" 3" 3"
40 (12.19) 2" 3" 3"
50 (15.24) 2" 3" 3"
55 (16.76) 2" 3" 3"
60 (18.29) 3" 3" 3"
70 (21.34) 3" 3" 3"
80 (24.38) 3" 3" 3"
90 (27.43) 3" 3" 3"
100 (30.48) 3" 3" 3"
110 (33.53) 3" 3" 3"
120 (36.58) 3" 3" 3"
130 (39.62) 3" 3" --
NOTE - Minimum vent pipe for G32V-75, G32V-100, and G32V-125 is 5
feet with 2 elbows of 2-inch diameter pipe.
G32V-75
75,000
BTU
G32V-100
100,000
BTU
G32V-125
125,000
BTU
NOTE - When you install a WTKX termination kit as part
of the intake and exhaust piping, the two 2-inch diameter
90° elbows and the 27 inch pipe (in the kit) should be inĆ
cluded in the maximum vent pipe length for each run.
For 75 kBtuh units, connections are provided for 2-inch
diameter vent pipe which should satisfy most venting reĆ
quirements. No transition pieces are provided or needed
for use with 2-inch vent pipe.
For -100 and -125 kBtuh units, the intake connection is
sized for 3-inch diameter pipe. The exhaust connection
ha s a 2- inc h ni pp le . A pipe transition piece is shipped with
the unit for use with 3-inch pipe. See figure 7 for 2-inch
and 3-inch vent pipe applications.
Most venting applications will require 3-inch vent pipe for
proper unit operation. The intake and exhaust pipe
must never be constructed of different diameter
pipes. Regardless of the diameter of pipe used, the stanĆ
dard roof and wall terminations described in section InĆ
take and Exhaust Piping Terminations should be used.
Exhaust piping must terminate with 1-1/2 inch pipe for
1-1/2 inch or 2 inch vents and 2-inch vent pipe for 3-inch
vents.
Page 8
G32V-100 OR -125 WITH 2 IN. VENTING
2 IN. VENT PIPE
2 IN.
OUT
3 IN. X 2 IN.
REDUCER
3 IN.
IN
G32V-100 OR -125 WITH 3 IN. VENTING
3 IN. X 2 IN. REDUCER
2 IN. FIELD
PROVIDED
NIPPLE
2 IN.
OUT
3 IN.
IN
3 IN. FIELD
PROVIDED
NIPPLE
3 IN. VENT PIPE
into socket until it bottoms out. Turn pipe 1/4 turn durĆ
ing assembly (but not after pipe is fully inserted) to
distribute cement evenly.
NOTE - Assembly should be completed within 20 seĆ
conds after last application of cement. Hammer
blows should not be used when inserting pipe.
8 - After assembly, wipe excess cement from pipe at
end of fitting socket. A properly made joint will show a
bead around its entire perimeter. Any gaps may indiĆ
cate a defective assembly due to insufficient solvent.
9 - Handle joints carefully until completely set.
Venting Practices
FIGURE 7
Joint Cementing Procedure
All cementing of joints should be done according to the
specifications outlined in ASTM D 2855.
WARNING
DANGER OF EXPLOSION! Fumes from PVC glue
may ignite during system check. Disconnect wire
from pressure switch terminal before 115 volt powĆ
er is applied to unit. Reconnect wire after two minĆ
utes of combustion air blower operation.
1 - Measure and cut vent pipe to desired length.
2 - Debur and chamfer end of pipe, removing any ridges
or rough edges. If end is not chamfered, edge of pipe
may remove cement from fitting socket and result in
a leaking joint.
3 - Clean and dry surfaces to be joined.
4 - Test fit joint and mark depth of fitting on outside of
pipe.
5 - Uniformly apply liberal coat of PVC primer for PVC or
ABS cleaner for ABS to inside socket surface of fitĆ
ting and male end of pipe to depth of fitting socket.
6 - Promptly apply solvent cement to end of pipe and inĆ
side socket surface of fitting. Cement should be apĆ
plied 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
WARNING
Insufficient combustion air can cause headaches,
nausea, dizziness or asphyxiation. It will also
cause excess water in the heat exchanger resulting
in rusting and premature heat exchanger failure.
Excessive exposure to contaminated combustion
air will result in safety and performance related
problems. Avoid exposure to the following subĆ
stances 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
Masonry acid washing materials
The thickness of construction through which vent/air inĆ
take pipes may be installed is a minimum of 3 inches (76
mm) and a maximum of 24 inches (610 mm). 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 is probably oversized for the single water heater or
other appliance. The vent should be checked for proper
draw with the remaining appliance.
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.
Page 9
Exhaust Piping
1 - Cement exhaust piping into flue collar socket located
on the left side of the top cap.
2 - All horizontal runs of exhaust pipe must slope back
toward the unit. A minimum of 1/4 inch (6 mm) drop
for each 12 inches (305 mm) of horizontal run is manĆ
datory for drainage. Horizontal runs of exhaust pipĆ
ing must be supported every 5 feet (1.52 m) using
hangers.
NOTE - Exhaust piping should be checked carefully
to make sure there are no sags or low spots.
NOTE - Exhaust piping must be insulated with 1/2
inch (13 mm) 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 inch (13 mm) Armaflex or
equivalent.
CAUTION
Do not discharge exhaust into an existing stack or
stack that also serves another gas appliance. If verĆ
tical discharge through an existing unused stack is
required, insert PVC pipe inside the stack until the
end is even with the top or outlet end of the metal
stack.
CAUTION
The exhaust vent pipe operates under positive
pressure and must be completely sealed to prevent leakage of combustion products into the livĆ
ing space.
Removal of Unit from Common Venting System
In the event that an existing furnace is removed from a
venting system commonly run with separate gas apĆ
pliances, the venting system may be too large to properly
vent the remaining attached appliances. The following
test should be conducted while all appliances (both in opĆ
eration and those not in operation) are connected to the
common venting system. If the venting system has been
installed improperly, corrections must be made as outĆ
lined in the previous section.
1 - Seal any unused openings in the common venting
system.
2 - Visually inspect the venting system for proper size
and horizontal pitch and determine there is no blockĆ
age or restriction, leakage, corrosion or other defiĆ
ciencies which could cause an unsafe condition.
3 - Close all building doors and windows, and all doors
between the space in which the appliances remainĆ
ing connected to the common venting system are loĆ
cated 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 operĆ
ate a summer exhaust fan. Close fireplace dampers.
4 - Follow the lighting instructions. Place the appliance
being 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 the flame of
match or candle, or smoke from a cigarette or cigar,
or a draft gauge.
6 - After determining that each appliance remaining
connected to the common venting system properly
vents when tested as indicated in step 3, return
doors, windows, exhaust fans, fireplace dampers
and any other gasĆburning appliance to their preĆ
vious 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
resized to approach the minimum size as deterĆ
mined by using the appropriate tables in appendix G
in the current standards of the National Fuel Gas
Code ANSI Z223-1 in the USA, and the appropriate
Category 1 Natural Gas appliances venting sizing
tables in the current standard of the CAN/
CGA-B149.1 in the Natural Gas Installation Code in
Canada.
Intake and Exhaust Piping Terminations
Intake and exhaust pipes may be routed either horizontalĆ
ly through an outside wall or vertically through the roof. In
attic or closet installations, vertical termination through
the roof is preferred. Figures 8 through 20 show typical
terminations.
1 - Use recommended piping materials for both intake
and exhaust piping.
2 - Secure all joints, including drain leg, gas-tight using
approved cement.
3 - Piping diameters should be determined according
to length of pipe run. See table 5. Locate intake pipĆ
ing upwind (prevailing wind) from exhaust piping.
To avoid recirculation of exhaust gas on roof terĆ
minations, end of exhaust pipe must be higher than
intake pipe.
Exhaust and intake exits must be in same pressure
zone. Do not exit one through the roof and one on the
side. Also, do not exit the intake on one side and the
exhaust on another side of the house or structure.
Page 10
4 - Intake and exhaust pipes should be placed as close
together as possible at termination end (refer to ilĆ
lustrations). Maximum separation is 3 inches (76
mm) on roof terminations and 6 inches (152 mm) on
side wall terminations.
5 - Exhaust piping must terminate straight out or up as
shown. In rooftop applications, a 2 inch X 1-1/2 inch
reducer for 2 inch venting, 3 inch x 2 inch reducer for
3 inch venting must be used on the exhaust piping at
the point where it exits the structure to improve the
velocity of exhaust away from the intake piping.
On roof terminations, the intake piping should termiĆ
nate straight down using two 90° elbows. See figure 8.
Inches (mm)
8 (203) MIN
12 (305) ABOVE
AVERAGE SNOW
ACCUMULATION
3 (76) MAX.
3 x 2 (76 x 51) OR
2 x 1-1/2 (51 x 38)
PVC REDUCER
1/2 (13) FOAM
INSULATION IN
UNCONDITIONED
SPACE
NOTE - During extremely cold temperatures, below
approximately 20°F (6.67°C), units with long runs of
vent pipe through unconditioned space, even when inĆ
sulated, may form ice in the exhaust termination that
prevents the unit from operating properly. Longer run
times of at least 5 minutes will alleviat e mos t icing probĆ
lems. Also, a heatin g cable may be installed on exhaust
piping and termination to prevent freezeĆups. Heating
cable installation kit is available from Lennox. See ConĆ
densate Piping section for part numbers.
NOTE - Avoid recirculation of exhaust back into the inĆ
take pipe.
6 - On field-supplied terminations for side wall exits, exĆ
haust piping should extend a maximum of 12 inches
(305 mm) beyond the outside wall. Intake piping
should be as short as possible. See figure 9.
1/2 (13) ARMAFLEX
INSULATION IN
UNCONDITIONED SPACE
2 (51) PVC 1-1/2 (38) PVC
12 (305) MIN.
2 X 1-1/2
(51 x 38)
PVC REDUCER
3 (76) OR
2 (51) PVC
PROVIDE SUPPORT
FOR INTAKE AND
EXHAUST LINES
ROOF TERMINATION KIT
(15F75) LB-49107CC for 2 (51) Venting
(44J41) LB-65678A for 3 (76) Venting
UNCONDITIONED
ATTIC SPACE
FIGURE 8
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),
exhaust piping must be insulated with 1/2 inch (13 mm),
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 insuĆ
lated with 1/2 inch (13 mm) Armaflex or equivalent. In exĆ
treme cold climate areas, 3/4 inch (19 mm) Armaflex or
equivalent is recommended. Insulation on outside runs of
exhaust pipe must be painted or wrapped to protect inĆ
sulation from deterioration.
1/2 (13) ARMAFLEX
Inches (mm)
INSULATION
OUTSIDE
WALL
TOP VIEW
(15J74) LB-49107CB for 2 (50.8) Venting
WALL RING KIT
6 (152)
MAXIMUM
8 (203)
MINIMUM
2 (51) PVC
COUPLING
FIGURE 9
7 - On field-supplied terminations, a minimum separaĆ
tion distance between the end of the exhaust pipe
and the end of the intake pipe is 8 inches (203 mm).
8 - If intake and exhaust piping must be run up a side
wall to position above snow accumulation or other
obstructions, the piping must be supported every 3
fee t (.91 m) as shown in figure 14. Refer to figures 13
and 15 for proper piping method. WTK wall terminaĆ
tion kit must be extended for use in this application.
See figure 18 or use kit WTKX shown in figure 19.
When exhaust and intake piping must be run up an
outside wall, the exhaust piping is reduced to 1 1/2
inches (38 mm) after the final elbow. The intake pipĆ
ing may be equ i p ped wit h a 90° elbow turndown. UsĆ
in g tu rn- do wn wi ll ad d 5 fe et (1 . 5 m) to th e eq ui va len t
length of the pipe.
Page 11
1/2 (12.7) FOAM INSULATION
IN UNCONDITIONED SPACE
Inches (mm)
OUTSIDE WALL
Inches(mm)
UNCONDITIONED
SPACE
OUTSIDE WALL
12 (305) MIN. for 2 (51)
20 (508) MAX. for 3 (76)
8 (203)
MIN.
EXHAUST
INTAKE
PIPE
PIPE
Optional Turndown
TOP VIEW
WALL TERMINATION
(22G44) LB-49107CD for 2 (50.8) Venting
(44J40) LB-65701A for 3 (76.2) Venting
(Intake Only)
FIGURE 10
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
INTAKE
Inches (mm)
FIGURE 11
OUTSIDE WALL
EXHAUST
INTAKE
Inches (mm)
CONCENTRIC WALL TERMINATION
(60G77) LB-49107CE for G32V-75 Units Only
(33K97) LB-87942 for G32V-100 & -125 Units Only
EXHAUST
TERMINATION
INTAKE
TERMINATION
12 (305) Min.
above grade.
Shown
PROVIDE SUPPORT
FOR INTAKE AND
EXHAUST LINES EVERY
36 (914)
1/2 (13) FOAM
INSULATION IN
UNCONDITIONED
SPACE
WALL RING TERMINATION
(15F74) LB-49107CB for 2 in. (51) Venting
See venting table 5 for maximum venting lengths with
SIDE VIEW
this arrangement.
12 (305) ABOVE
AVERAGE SNOW
ACCUMULATION
1/2 (13) FOAM
INSULATION
FIGURE 13
9 - Position termination ends so they are free from any
obstructions and above the level of snow accumulaĆ
tion (where applicable). Termination ends must be a
minimum of 12 inches (305 mm) above grade level.
Do not point into window wells, stairwells, alcoves,
courtyard areas or other recessed areas. Do not
position termination ends directly below roof eaves
or above a walkway. Since the G32V is a certified diĆ
rect vent, Category IV gas furnace, the location of
the termination is limited by local building codes. In
the absence of local codes, refer to the current NaĆ
tional Fuel Gas Code ANSI Z223-1 in USA, and curĆ
rent standard CAN/CGA-B149.1 of the Natural Gas
Installation Instructions in Canada for details. The
termination should be at least 12 inches (305 mm)
from any opening through which flue products could
enter the building.
When horizontally vented, minimum clearance for
termination from electric meters, gas meters, regulaĆ
tors and relief equipment is 4 feet (1.2 m) for US
installations. Refer to the current CAN/CGA-B149.1
for installations in Canada or with authorities having
local jurisdiction.
FIGURE 12
Page 12
At vent termination, care must be taken to maintain
protective coatings over building materials (proĆ
longed exposure to exhaust condensate can destroy
protective coatings). It is recommended that the exĆ
haust outlet not be located within 6 feet (1.8 m) of a
condensing unit because the condensate can damĆ
age the painted coating.
METAL OR PLASTIC
STRAPPING
OR LARGE
WIRE TIES
FIGURE 14
IMPORTANT
Combustion air intake inlet and exhaust outlet
should not be located within 6 feet (1.8 m) of dryer
vent or combustion air inlet or outlet of another apĆ
pliance. Piping should not exit less than 3 feet (.91 m)
from opening into another building.
IMPORTANT
For Canadian Installations Only:
In accordance to CAN/CGA-B149.1 and .2, the miniĆ
mum allowed distance between the combustion air
intake inlet and the exhaust outlet of other apĆ
pliances shall not be less than 12 inches (305 mm).
10 - Suspend piping using hangers at a minimum of every
5 feet (1.52 m) for schedule 40 PVC and every 3 feet
(.91 m) for ABS-DWV, PVC-DWV, SDR-21 PVC,
and SDRĆ26 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 as it passes through the center of
the hole.
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 conĆ
densate collection trap and lines.
14 - Based on the recommendation of the manufacturer,
a multiple furnace installation may use a group of up
to four termination kits WTK assembled together
horizontally, as shown in figure 17.
Inches(mm)
3 (76) OR
2 (51) 90_ ELBOW
Optional Turndown
(Not Shown)
May Be Used on
Intake Only
(22G44) LB-49107CD for 2(51) Venting
(44J40) LB-65701A for 3(76) Venting
Front View
INTAKE
VENT
1/2 (13) Foam
Insulation in
Unconditioned Space
Inches (mm)
WALL TERMINATION KIT (30G28) WTK
1/2 (13)
FOAM
INSULATION
FRONT VIEW
WALL TERMINATION
FIGURE 15
12
(305)
VENT TERMINATIONS
FIGURE 16
3 x 2 (76 x 51) OR
2 x 1-1/2 (51 x 38)
REDUCER BUSHING LOCAĆ
FOR OFFSET TERMINATION
TION
3 (76) OR
2 (51) 90_ ELBOW
EXHAUST VENT
5
(127)
Side View
EXHAUST VENT
INTAKE VENT
OUTSIDE WALL
Page 13
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