Lennox G32V Series, 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.

Page 1

Litho U.S.A.

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.

Page 2

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.

Page 3

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

Page 4

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

Page 5

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)

Page 6

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

Page 7

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

Page 8

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

Page 9

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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