Lennox G40DF−36A−070, G40DX Series, G40DFX−36A−070, G40DF−36B−090, G40DF−48C−090 Installation Instructions Manual
...Page 1
INSTALLATION
E 2006 Lennox Industries Inc.
Dallas, Texas, USA
THIS MANUAL MUST BE LEFT WITH THE
HOMEOWNER FOR FUTURE REFERENCE
INSTRUCTIONS
G40DF(X) Series
GAS FURNACE
505,253M
10/2009
Supersedes 05/2009
Table of Contents
G40DF(X) Unit Dimensions 2. . . . . . . . . . . . . . . . . . . . . . .
G40DF(X) Parts Arrangement 3. . . . . . . . . . . . . . . . . . . . .
G40DF(X) Gas Furnace 4. . . . . . . . . . . . . . . . . . . . . . . . . .
Shipping and Packing List 4. . . . . . . . . . . . . . . . . . . . . . . .
Safety Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Use Furnace as a Construction Heater 5. . . . . . . . . . . . .
Combustion, Dilution, & Ventilation Air 6. . . . . . . . . . . . .
Downflow Installation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting Equipment 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filters 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Duct System 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Venting 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas Piping 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Start−Up 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas Pressure Adjustment 24. . . . . . . . . . . . . . . . . . . . . . .
High Altitude Information 25. . . . . . . . . . . . . . . . . . . . . . . .
Other Unit Adjustments 25. . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Performance 26. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Planned Service 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Parts List 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Control Board Diagnostic Codes 31. . . . . . . . . . .
Troubleshooting 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G40DF(X) Start−Up & Performance Check List 35. . . . . .
Litho U.S.A.
Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
Installation and service must be
performed by a qualified installer,
service agency or the gas supplier.
10/09
*2P1009*
WARNING
FIRE OR EXPLOSION HAZARD.
Failure to follow safety warnings exactly could result in serious injury, death,
or property damage.
WHAT TO DO IF YOU SMELL GAS:
D Do not try to light any appliance.
D Do not touch any electrical switch; do not
use any phone in your building.
D Leave the building immediately.
D Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s
instructions.
D If you cannot reach your gas supplier, call
the fire department.
Page 1
505,253M
*P505253M*
Page 2
G40DF(X) Unit Dimensions − inches (mm)
A
B
AIR FLOW
FLUE OUTLET
5/8
(16)
(Top)
3−3/4 (95)
D
5/8 (16)
RETURN AIR
OPENING
B
19−1/2
(495)
5/8 (16)
TOP VIEW
28−1/2
(724)
19−1/2
(495)
5/8
(16)
5/8
(16)
3/4
(19)
Model No.
G40DF(X)−24A−045,
G40DF(X)−36A−070
G40DF−36B−090
G40DF(X)−48C−090,
G40DF−48C−110,
G40DF(X)−60C−110
40
(1016)
ELECTRICAL INLET
(Either Side)
4−7/8 (124) Right
2−1/4 (57) Left
GAS PIPING INLET
(Either Side)
9−1/4
(235)
C
Supply
Air
3/4
(19)
19−1/4
(489)
FRONT VIEW SIDE VIEW
A B C D
in. mm in. mm in. mm in. mm
14−1/2 368 13−1/4 337 13 330 4−1/2 114
17−1/2 446 16−1/4 413 16 406 6 152
21 533 19−1/4 502 19−1/2 495 7−3/4 197
Supply
Air
3/4
(19)
G40DF−60D−135 24−1/2 622 23−1/4 591 23 584 9−1/2 241
Page 2
Page 3
G40DF(X) Parts Arrangement
Flue
Chase
Gasket
Internal Flue Pipe
Assembly
Blower Motor
Gasket
Transformer
Integrated Ignition
Control Board
Flue Box Gasket
Flue Collector Box
Capacitor
Door
Interlock Switch
Primary
Limit
Flame
Sensor
Blower Assembly
Flame Rollout
Switches
Heat Exchanger
Gasket
Combustion Air
Pressure Switch
Combustion Air Inducer
Gas Valve
Combustion
Air Orifice
Manifold
Gas
Orifices
FIGURE 1
Page 3
Burner
Igniter
Bracket
Igniter
Page 4
G40DF(X) Gas Furnace
The G40DF(X) gas furnace is shipped ready for installation in the downflow position fueled by natural gas. A
conversion kit (ordered separately) is required for use in
propane/LP gas applications.
Shipping and Packing List
Package 1 of 1 contains
1 − Assembled G40DF(X) unit
1 − Bag assembly containing the following:
3 − Wire nuts
1 − Snap bushing
1 − Snap plug
1 − Wire tie
1 − Vent warning label
1 − Owner’s manual and warranty card
The following items may be ordered separately:
1 − Thermostat
1 − Propane/LP changeover kit
Check equipment for shipping damage. If you find any
damage, immediately contact the last carrier.
DANGER
Danger of explosion.
There are circumstances in which odorant used with
LP/propane gas can lose its scent. In case of a leak,
LP/propane gas will settle close to the floor and may
be difficult to smell. An LP/propane leak detector
should be installed in all LP applications.
Safety Information
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 licensed professional installer (or
equivalent), service agency or the gas supplier.
CAUTION
As with any mechanical equipment, personal injury
can result from contact with sharp sheet metal
edges. Be careful when you handle this equipment.
G40DF(X) units are CSA International certified to ANSI
Z21.47 and CSA 2.3 standard.
In the USA, installation of gas furnaces must conform with
local building codes. In the absence of local codes, units
must be installed according to the current National Fuel
Gas Code (ANSI-Z223.1). The National Fuel Gas Code is
available from the following address:
American National Standards Institute, Inc.
11 West 42nd Street
New York, NY 10036
In Canada, installation must conform with current CSA
B149 Natural Gas and Propane Installation Codes, local
plumbing or waste water codes and other applicable local
codes.
Adequate clearance must be made around the air openings into the vestibule area. In order to ensure proper unit
operation, combustion and ventilation air supply must be
provided according to the current National Fuel Gas Code
or CSA B149 standards.
Vent installations must be consistent with the venting
tables (in this instruction) and applicable provisions of local
building codes.
This furnace is CSA International certified for installation
clearances to combustible material as listed on the unit
nameplate and in the table in figure 9. Accessibility and service clearances must take precedence over fire protection
clearances.
NOTE − For installation on combustible floors, the furnace
shall not be installed directly on carpeting, tile, or other
combustible material other than wood flooring.
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 according to recommended good practice requirements and current National Fuel Gas Code or CSA B149 standards.
NOTE − Furnace must be adjusted to obtain a temperature
rise within the range specified on the unit nameplate. Failure
to do so may cause erratic limit operation and premature heat
exchanger failure.
This G40DF(X) furnace must be installed so that its electrical components are protected from water.
When this 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 compartment.
With a parallel flow arrangement, a damper (or other
means to control the flow of air) must adequately prevent
chilled air from entering the furnace. If the damper 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.
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When installed, this furnace must be electrically grounded
according to local codes. In addition, in the United States,
installation must conform with the current National Electric Code, ANSI/NFPA No. 70. The National Electric Code
(ANSI/NFPA No. 70) is available from the following address:
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.
NOTE − This furnace is designed for a minimum continuous return air temperature of 60°F (16°C) or intermittent
operation down to 55°F (13°C) dry bulb in cases where a
night setback thermostat is used. Return air temperature
must not exceed 85°F (29°C) dry bulb.
NOTE − G40DF(X) series units should not be installed as a
unit heater.
The G40DF(X) furnace may be installed in alcoves, closets, attics, basements, garages, and utility rooms in the
downflow position.
This furnace design has not been CSA International certified for installation in mobile homes, recreational vehicles,
or outdoors.
Use of Furnace as Construction Heater
Lennox does not recommend the use of G40DF(X) units as
a construction heater during any phase of construction.
Very low return air temperatures, harmful vapors and operation of the unit with clogged or misplaced filters will damage the unit.
G40DF(X) units may be used for heating of buildings or
structures under construction, if the following conditions
are met:
D The vent system must be permanently installed per
these installation instructions.
D A room thermostat must control the furnace. The use of
fixed jumpers that will provide continuous heating is not
allowed.
D The return air duct must be provided and sealed to the
furnace.
D Return air temperature range between 60°F (16°C) and
80°F (27°C) must be maintained.
D Air filters must be installed in the system and must be
maintained during construction.
D Air filters must be replaced upon construction comple-
tion.
D The input rate and temperature rise must be set per the
furnace rating plate.
D One hundred percent (100%) outdoor air must be pro-
vided for combustion air requirements during construction. Temporary ducting may supply outdoor air to the
furnace. Do not connect duct directly to the furnace.
Size the temporary duct following these instructions in
section for Combustion, Dilution and Ventilation Air in a
confined space with air from outside.
D The furnace heat exchanger, components, duct system,
air filters and evaporator coils must be thoroughly
cleaned following final construction clean−up.
D All furnace operating conditions (including ignition, in-
put rate, temperature rise and venting) must be verified
according to these installation instructions.
NOTE − The Commonwealth of Massachusetts stipulates these additional requirements:
D Gas furnaces shall be installed by a licensed plumb-
er or gas fitter only.
D The gas cock must be T handle" type.
D When a furnace is installed in an attic, the passage-
way to and service area surrounding the equipment
shall be floored.
General
These instructions are intended as a general guide and do
not supersede local codes in any way. Consult authorities
having jurisdiction before installation.
WARNING
Product contains fiberglass wool.
Disturbing the insulation in this product during
installation, maintenance, or repair will expose you
to fiberglass wool. Breathing this may cause lung
cancer. (Fiberglass wool is known to the State of California to cause cancer.)
Fiberglass wool may also cause respiratory, skin,
and eye irritation.
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
In addition to the requirements outlined previously, the following general recommendations must be considered
when installing a G40DF(X) furnace:
D Place the furnace as close to the center of the air dis-
tribution system as possible. The furnace should also be
located close to the chimney or vent termination point.
D Do not install the furnace where drafts might blow direct-
ly into it. This could cause improper combustion and unsafe operation.
D Do not block the furnace combustion air openings with
clothing, boxes, doors, etc. Air is needed for proper
combustion and safe unit operation.
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D When the furnace is installed in an attic or other insu-
lated space, keep insulation away from the furnace.
Combustion, Dilution, & Ventilation Air
CAUTION
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 substances in the combustion air supply:
Permanent wave solutions
Chlorinated waxes and cleaners
Chlorine base swimming pool chemicals
Water softening chemicals
De-icing salts or chemicals
Carbon tetrachloride
Halogen type refrigerants
Cleaning solvents (such as perchloroethylene)
Printing inks, paint removers, varnishes, etc.
Hydrochloric acid
Cements and glues
Antistatic fabric softeners for clothes dryers
Masonry acid washing materials
In the past, there was no problem in bringing in sufficient outdoor air for combustion. Infiltration provided all the air that
was needed. In today’s homes, tight construction practices
make it necessary to bring in air from outside for combustion. Take into account that exhaust fans, appliance
vents, chimneys, and fireplaces force additional air that
could be used for combustion out of the house. Unless outside air is brought into the house for combustion, negative
pressure (outside pressure is greater than inside pressure)
will build to the point that a downdraft can occur in the furnace vent pipe or chimney. As a result, combustion gases
enter the living space creating a potentially dangerous situation.
In the absence of local codes concerning air for combustion and ventilation, use the guidelines and procedures in
this section to install G40DF(X) furnaces to ensure efficient
and safe operation. You must consider combustion air
needs and requirements for exhaust vents and gas piping.
A portion of this information has been reprinted with permission from the National Fuel Gas Code
(ANSI-Z223.1/NFPA 54). This reprinted material is not the
complete and official position of the ANSI on the referenced
subject, which is represented only by the standard in its entirety.
In Canada, refer to the CSA B149 installation codes.
CAUTION
Do not install the furnace in a corrosive or contaminated atmosphere. Meet all combustion and ventilation air requirements, as well as all local codes.
All gas-fired appliances require air for the combustion process. If sufficient combustion air is not available, the furnace or other appliances will operate inefficiently and unsafely. Enough air must be provided to meet the needs of all
fuel-burning appliances and appliances such as exhaust
fans which force air out of the house. When fireplaces, exhaust fans, or clothes dryers are used at the same time as
the furnace, much more air is necessary to ensure proper
combustion and to prevent a downdraft. Insufficient air
causes incomplete combustion which can result in carbon
monoxide.
In addition to providing combustion air, fresh outdoor air
dilutes contaminants in the indoor air. These contaminants may include bleaches, adhesives, detergents, solvents and other contaminants which can corrode furnace
components.
The requirements for providing air for combustion and ventilation depend largely on whether the furnace is installed in
an unconfined or a confined space.
Unconfined Space
An unconfined space is an area such as a basement or
large equipment room with a volume greater than 50 cubic
feet (1.42 m3) per 1,000 Btu (.29 kW) per hour of the combined input rating of all appliances installed in that space.
This space also includes adjacent rooms which are not
separated by a door. Though an area may appear to be unconfined, it might be necessary to bring in outdoor air for
combustion if the structure does not provide enough air by
infiltration. If the furnace is located in a building of tight
construction with weather stripping and caulking around
the windows and doors, follow the procedures in the air
from outside section.
Confined Space
A confined space is an area with a volume less than 50 cubic feet (1.42 m3) per 1,000 Btu (.29 kW) per hour of the
combined input rating of all appliances installed in that
space. This definition includes furnace closets or small
equipment rooms.
When the furnace is installed so that supply ducts carry air
circulated by the furnace to areas outside the space containing the furnace, the return air must be handled by ducts
which are sealed to the furnace casing and which terminate
outside the space containing the furnace. This is especially
important when the furnace is mounted on a platform in a
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confined space such as a closet or small equipment room.
Even a small leak around the base of the unit at the platform
or at the return air duct connection can cause a potentially
dangerous negative pressure condition. Air for combustion
and ventilation can be brought into the confined space either
from inside the building or from outside.
EQUIPMENT IN CONFINED
CHIMNEY
OR GAS
VENT
FURNACE
NOTE−Each opening shall have a free area of at least one square
inch (645 mm2) per 1,000 Btu (.29 kW) per hour of the total input rating of all equipment in the enclosure, but not less than 100 square
inches (64516 mm2).
SPACE ALL AIR FROM INSIDE
WATER
HEATER
OPENINGS
(To Adjacent
Room)
FIGURE 2
Air from Inside
If the confined space that houses the furnace adjoins a
space categorized as unconfined, air can be brought in by
providing two permanent openings between the two
spaces. Each opening must have a minimum free area of 1
square inch (645 mm2) per 1,000 Btu (.29 kW) per hour of
total input rating of all gas−fired equipment in the confined
space. Each opening must be at least 100 square inches
(64,516 mm2). One opening shall be within 12 inches (305
mm) of the top of the enclosure and one opening within 12
inches (305 mm) of the bottom. See figure 2.
Air from Outside
If air from outside is brought in for combustion and ventilation, the confined space must have two permanent openings. One opening shall be within 12 inches (305 mm) of the
top of the enclosure and one opening within 12 inches (305
mm) of the bottom. These openings must communicate directly or by ducts with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors or indirectly
through vertical ducts. Each opening shall have a minimum
free area of 1 square inch (645 mm2) per 4,000 Btu (1.17
kW) per hour of total input rating of all equipment in the enclosure. See figures 3 and 4. When communicating with
the outdoors through horizontal ducts, each opening shall
have a minimum free area of 1 square inch (645 mm2) per
2,000 Btu (.56 kW) per total input rating of all equipment in
the enclosure. See figure 5.
When ducts are used, they shall be of the same cross−sectional area as the free area of the openings to which they
connect. The minimum dimension of rectangular air ducts
shall be no less than 3 inches (75 mm). In calculating free
area, the blocking effect of louvers, grilles, or screens must
be considered. If the design and free area of protective covering is not known for calculating the size opening required,
it may be assumed that wood louvers will have 20 to 25 percent free area and metal louvers and grilles will have 60 to
75 percent free area. Louvers and grilles must be fixed in the
open position or interlocked with the equipment so that they
are opened automatically during equipment operation.
CHIMNEY OR
GAS VENT
VENTILATION LOUVERS
(Each end of attic)
FURNACE
VENTILATION
LOUVERS
(For unheated crawl space)
NOTE−The inlet and outlet air openings shall each have a free area of at least one square inch (645
mm2) per 4,000 Btu (1.17 kW) per hour of the total input rating of all equipment in the enclosure.
(Inlet Air from Crawlspace and Outlet Air to Ventilated Attic)
OUTLET
AIR
EQUIPMENT IN CONFINED SPACE
ALL AIR FROM OUTSIDE
WATER
HEATER
INLET
AIR
FIGURE 3
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Page 8
EQUIPMENT IN CONFINED SPACE
ALL AIR FROM OUTSIDE
CHIMNEY
OR GAS
VENT
FURNACE
NOTE−The inlet and outlet air openings shall each have a
free area of at least one square inch (645 mm2) per 4,000
Btu (1.17 kW) per hour of the total input rating of all equipment in the enclosure.
(All Air Through Ventilated Attic)
VENTILATION LOUVERS
(Each end of attic)
OUTLET
AIR
above bottom)
INLET AIR
(Ends 12 in.
WATER
HEATER
FIGURE 4
EQUIPMENT IN
CONFINED SPACE
ALL AIR FROM
OUTSIDE
OUTLET AIR
FURNACE
CHIMNEY
OR GAS
VENT
WATER
HEATER
Installation on Noncombustible Flooring
1 − Cut floor opening keeping in mind clearances listed on
unit rating plate. Also keep in mind gas supply connections, electrical supply, flue and air intake connections
and sufficient installation and servicing clearances.
See table 1 for correct floor opening size.
2 − Flange warm air plenum and lower the plenum into the
opening.
3 − Set the unit over the plenum and seal the plenum to
the unit.
3 − Ensure that the seal is adequate.
TABLE 1
NONCOMBUSTIBLE FLOOR OPENING SIZE
Model No.
A Cabinet (14.5") 19 − 3/4 502 13 − 1/4 337
B Cabinet (17.5") 19 − 3/4 502 16 − 1/4 413
C Cabinet (21") 19 − 3/4 502 19 − 3/4 502
D Cabinet (24.5") 19 − 3/4 502 23 − 1/4 591
NOTE − Floor opening dimensions listed are 1/4 inch (6 mm) larger than
the unit opening. See figure 1.
Front to Rear Side to Side
in. mm in. mm
Installation on Combustible Flooring
1 − When unit is installed on a combustible floor, an addi-
tive base must be installed between the furnace and
the floor. The base must be ordered separately for the
following cabinet sizes:
D A cabinet 14.5" − # 11M59
D B cabinet 17.5" − # 11M60
D C cabinet 21" − # 11M61
D D cabinet 24.5" − # 11M62
See table 2 for opening size to cut in floor.
INLET AIR
NOTE − Each air duct opening shall have a free area of at least
one square inch (645 mm2) per 2,000 Btu (.59 kW) per hour of
the total input rating of all equipment in the enclosure. If the
equipment room is located against an outside wall and the air
openings communicate directly with the outdoors, each opening shall have a free area of at least one square inch (645 mm2)
per 4,000 Btu (1.17 kW) per hour of the total input rating of all
other equipment in the enclosure.
FIGURE 5
Downflow Installation
Downflow unit installs in three ways: on noncombustible
flooring, on combustible flooring using an additive base, or
on a reverse−flow cooling cabinet. Do not drag the unit
across the floor.
CAUTION
The furnace and additive base shall not be installed
directly on carpeting, tile, or other combustible material other than wood flooring.
The furnace and additive base shall not be installed
directly on carpeting, tile, or other combustible material other than wood flooring.
TABLE 2
ADDITIVE BASE FLOOR OPENING SIZE
Model No.
A Cabinet (14.5")
B Cabinet (17.5")
C Cabinet (21")
D Cabinet (24.5")
NOTE − Floor opening dimensions listed are 1/4 inch (6 mm) larger than
unit opening. See figure 1.
Page 8
Front to Rear Side to Side
in. mm in. mm
22 559 15 − 3/4 400
22 559 18 − 3/4 476
22 559 22 − 3/4 578
22 559 25 − 3/4 654
Page 9
2 − After opening is cut, set additive base into opening.
3 − Check fiberglass strips on additive base to make sure
they are properly glued and positioned.
4 − Lower supply air plenum into additive base until ple-
num flanges seal against fiberglass strips.
NOTE − Be careful not to damage fiberglass strips.
Check for a tight seal.
5 − Set the furnace over the plenum.
6 − Ensure that the seal between the furnace and plenum
is adequate.
G40DF(X)UNIT
SUPPLY AIR PLENUM
PROPERLY
SIZED FLOOR
OPENING
ADDITIVE BASE
FIGURE 6
Installation on Cooling Cabinet
1 − Refer to reverse−flow coil installation instructions for
correctly sized opening in floor and installation of cabinet.
2 − When cooling cabinet is in place, set and secure the
furnace according to the instructions that are provided
with the cooling coil. Secure the furnace to the cabinet.
3 − Seal the cabinet and check for air leaks.
Return Air Opening −− Downflow Units
The following steps should be taken when installing plenum:
1 − Bottom edge of plenum should be flanged with a
hemmed edge (See figure 7).
2 − Fiberglass sealing strips should be used.
PLENUM
SECURE FROM
OUTSIDE CABINET
Side View
HEMMED EDGE
FIBERGLASS SEALING
STRIP
(Field Provided)
CABINET SIDE PANEL
FIGURE 7
3 − In all cases, plenum should be secured to top flanges
of furnace with sheet metal screws.
4 − In closet installations, it may be impossible to install
sheet metal screws from the outside. In this case,
make plenum with a removable front and install
screws from the inside (See figure 8).
5 − Make certain that an adequate seal is made.
SECURE FROM
INSIDE CABINET
FIBERGLASS
SEALING STRIP
(Field Provided)
CABINET SIDE
PLENUM
Side View
HEMMED EDGE
PANEL
FIGURE 8
Setting Equipment
WARNING
Do not install the furnace on its front or its back. Do
not connect the return air ducts to the back of the furnace. Doing so will adversely affect the operation of
the safety control devices, which could result in personal injury or death.
Install the G40DF(X) gas furnace as shipped. Do not
install the furnace horizontally.
Select a location that allows for the required clearances
that are listed on the unit nameplate. Also consider gas
supply connections, electrical supply, vent connection,
and installation and service clearances [24 inches (610
mm) at unit front]. The unit must be level.
NOTE − 1/3 hp blower motors are equipped with four flexible mounting legs, and 1/2 hp blower motors are equipped
with three flexible legs and one rigid leg. The rigid leg is
equipped with a shipping bolt and a flat white plastic washer (rather than the rubber mounting grommet used with a
flexible mounting leg). The bolt and washer must be re-
moved before the furnace is placed into operation. After the bolt and washer have been removed, the rigid leg
will not touch the blower housing.
NOTE − G40DF−36C−110 units include a bracket which stabilizes the blower motor during shipping. The bracket is secured to the blower housing by two screws. This bracket
must be removed prior to placing the unit into operation. See figure 1.
Downflow Application
Allow for clearances to combustible materials as indicated on the unit nameplate. Minimum clearances for
closet or alcove installations are shown in figure 9.
Page 9
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Downflow Application Installation Clearances
Top
Left Side
Type of Vent
Connector
Bottom
Type C Type B1
Right Side
Filters
This unit is not equipped with a filter or rack. A field−provided high−velocity filter is required for the unit to operate
properly. Table 3 lists the recommended minimum filter
sizes.
A filter must be in place any time the unit is operating.
TABLE 3
Furnace
Cabinet Size
14−1/2" 14 X 25 X 1 (1)
17−1/2" 16 X 25 X 1 (1)
21" 20 X 25 X 1 (1)
24−1/2" 24 X 25 X 1 (1)
Return Air Filter Size (inches)
Top 1 in. (25 mm) 1 in. (25 mm)
*Front 3 in. (76 mm) 3 in. (76 mm)
Back 0 0
Sides 0† 0
Vent 6 in. (152 mm) 1 in. (25 mm)
Floor NC†† NC††
*Front clearance in alcove installation must be 24 in. (610 mm).
Maintain a minimum of 24 in. (610 mm) for front service access.
†Left side requires 3 in. if a single wall vent is used on 14 −1/2 in. cabinets, or 2 in. if a single wall vent is used on 17 − 1/2 in. cabinets.
††The furnace may be installed on a combustible wood floor if an
optional additive base is installed between the furnace and the
combustible floor.
FIGURE 9
WARNING
Improper installation of the furnace can result in personal injury or death. Combustion and flue products
must never be allowed to enter the return air system
or the living space. Use screws and joint tape to seal
the return air system to the furnace.
In platform installations with bottom return air, the
furnace should be sealed airtight to the return air plenum. A door must never be used 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.
The return and supply air duct systems must never
be connected to or from other heating 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 injury or death.
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.
Ensure that you have made a seal between the supply air
plenum and the furnace and between the furnace and the
return air plenum.
NOTE − Do not operate the furnace with an external static
pressure that exceeds 0.5 inches w.c. Higher external static pressures may cause erratic limit operation.
Return Air Plenum
NOTE − Return air must not be drawn from a room
where this furnace, or any other gas−fueled appliance (i.e., water heater), or carbon monoxide−
producing device (i.e., wood fireplace) is installed.
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 throughout the house
by the furnace duct system.
Venting
A 4−inch diameter flue transition is factory-installed on all
models. Modifying or removing the flue transition will
cause the unit to operate unsafely and will void the unit
certification. The vent connector does not require insula-
tion.
The G40DF(X) series units are classified as fan−assisted
Category I furnaces when vertically vented according to
the latest edition of National Fuel Gas Code (ANSI
Z223.1/NFPA 54) in the USA and the current standards of
CSA B149 Natural Gas and Propane Installation Code in
Canada. A fan−assisted Category I furnace is an appliance
equipped with an integral mechanical means to either draw
or force combustion products through the combustion
chamber and/or heat exchanger.
Page 10
Page 11
NOTE − Use these instructions as a guide. They do not supersede local codes. This furnace must be vented according to all local codes, these installation instructions, and the
provided venting tables (5 through 10) in these instructions.
The venting tables in this manual were extracted from the
National Fuel Gas Code (ANSI Z223.1/NFPA 54) and are
provided as a guide for proper vent installation. Proper application, termination, construction and location of vents
must conform to local codes having jurisdiction. In the absence of local codes, the NFGC serves as the defining document.
Refer to the tables and the venting information contained in
these instructions to properly size and install the venting
system.
IMPORTANT
Once the venting system is installed, attach the Disconnected Vent" warning sticker to a visible area of
the plenum near the vent pipe. The warning sticker
is provided in the bag assembly.
WARNING
Asphyxiation hazard. The exhaust vent for this furnace must be securely connected to the furnace flue
transition at all times.
VENT CONNECTION
VENT
PIPE
FLUE TRANSITION
COLLAR
FURNACE
FIGURE 10
Use self−drilling sheet metal screws or a mechanical fastener to firmly secure the vent pipe to the round collar of the
flue transition. If self−drilling screws are used to attach the
vent pipe, it is recommended that three be used. Drive one
self−drilling screw through the front and one through each
side of the vent pipe and collar. See figure 10.
Install the first vent connector elbow at a minimum of six
inches (152 mm) from the furnace vent outlet.
Venting Using a Masonry Chimney
The following additional requirements apply when a lined
masonry chimney is used to vent this furnace.
Masonry chimneys used to vent Category I central furnaces must be either tile-lined or lined with a listed metal
lining system or dedicated gas vent. Unlined masonry
chimneys are prohibited. See figures 11 and 12 for common venting.
A chimney with one or more sides exposed to the outside of
the structure is considered to be an exterior chimney.
An exterior masonry chimney that is not tile−lined must be
lined with B1 vent or a listed insulated flexible metal vent.
An exterior tile−lined chimney that is sealed and capped
may be lined with a listed uninsulated flexible metal vent.
If the existing chimney will not accommodate a B1 vent or
an insulated flexible vent pipe liner, either the chimney
must be rebuilt to accommodate one of these liners or an
alternate approved venting method must be found.
Insulation for the flexible vent pipe must be an encapsulated fiberglass sleeve recommended by the flexible vent
pipe manufacturer. See figure 11.
DO NOT insulate the space between the liner and the
chimney wall with puffed mica or any other loose granular insulating material
A fan−assisted furnace may be commonly vented into an
existing lined masonry chimney if the following conditions
are met:
S The chimney is currently serving at least one drafthood
equipped appliance
S The vent connectors and chimney are sized according
to the provided venting tables for the USA, and the appropriate venting tables in the standards of CSA B149
Natural Gas and Propane Installation Code in Canada
Common Venting Using Metal−Lined Masonry Chimney
SEALED
MAX. LENGTH
− SEE NOTE 1
5 ft. (1.5 m)
minimum
VENT CONNECTOR
SEE NOTE 2
4 in. (102 mm)
minimum
OTHER
APPLIANCE
NOTE 1 − Refer to the provided venting tables for installations in the USA
and the venting tables in CSA−B149 for installations Canada.
NOTE 2 − Either single-walled or double-walled vent connector may be
used. Refer to the capacity requirements shown in the provided venting
tables for installations in USA and the venting tables in current CSA−
B149 for installations in Canada.
BELOW.
MIN. LENGTH − AS
SHORT AS PRACTICAL
FURNACE
EXTERIOR
CHIMNEY WITH
METAL LINER
PERMANENTLY
SEALED FIREPLACE
OPENING
FIGURE 11
Page 11
Page 12
Common Venting Using Tile−Lined Interior Masonry Chimney and Combined Vent Connector
MINIMUM LENGTH = AS SHORT AS PRACTICAL.
FOR MAXIMUM LENGTH SEE NOTE TO LEFT
NOTE− Refer to provided venting tables
for installations in the USA and the
venting tables in current CSA−B149 for
installations in Canada.
FURNACE
OTHER
APPLIANCE
NOTE − Either single-walled or double-walled vent connector may be used. Refer to the capacity requirements as shown in the provided venting tables for installations in USA and the venting tables in current CSA−B149 for installations in Canada.
VENT
CONNECTOR
SEE NOTE 1 BELOW
INTERIOR TILE−LINED
MASONRY CHIMNEY
NOTE − the chimney must be properly
sized per provided venting tables or
lined with listed metal lining system.
PERMANENTLY
SEALED FIREPLACE
OPENING
FIGURE 12
General Venting Requirements
IMPORTANT
SINGLE appliance venting of a fan-assisted furnace
into a tile-lined masonry chimney (interior or outside
wall) is PROHIBITED. The chimney must first be lined
with either type B1 vent or an insulated single wall
flexible vent lining system which has been sized according to the provided venting tables and the vent
pipe manufacturer’s instructions.
If type B1 double-wall vent is used inside a chimney, no other appliance can be vented into the chimney. The outer wall
of type B1 vent pipe must not be exposed to flue products.
A type B1 vent or masonry chimney liner shall terminate
above the roof surface with a listed cap or a listed roof assembly according to the terms of their respective listings
and the vent manufacturer’s instructions.
When inspection reveals that an existing chimney is not
safe for the intended purpose, it shall be rebuilt to conform
to nationally recognized standards, lined or relined with
suitable materials, or replaced with a gas vent or chimney
suitable for venting G40DF(X) series units. The chimney
passageway must be checked periodically to ensure that it
is clear and free of obstructions.
Do not install a manual damper, barometric draft regulator,
or flue restrictor between the furnace and the chimney.
Never connect a Category I appliance to a chimney that is
servicing a solid−fuel appliance. If a fireplace chimney flue
is used to vent this appliance, the fireplace opening must
be permanently sealed.
A type B or listed chimney lining system that passes
through an unused masonry chimney flue is not considered
to be exposed to the outdoors.
Vent all G40DF(X) furnaces according to these instructions:
1 − Vent diameter recommendations and maximum allow-
able piping runs are found in the provided venting tables
for the USA, and the appropriate venting tables in the
standards of CSA B149 Natural Gas and Propane
Installation Codes for Canada.
2 − In no case should the vent or vent connector diameter
be less than the diameter specified in the provided
venting tables for the USA, and the appropriate venting
tables in the standards of CSA B149 Natural Gas and
Propane Installation Codes for Canada.
3 − Single appliance vents − If the vertical vent or tile-lined
chimney has a larger diameter or flow area than the
vent connector, use the vertical vent diameter to determine the minimum vent capacity and the vent
connector diameter to determine the maximum vent
capacity. The flow area of the vertical vent, however,
shall not exceed seven times the flow area of the listed
appliance categorized vent area, drafthood outlet area
or flue collar area unless designed according to approved engineering methods.
4 − Multiple appliance vents − The flow area of the largest
section of vertical vent or chimney shall not exceed
seven times the smallest listed appliance categorized
vent area, drafthood outlet area or flue collar area unless designed according to approved engineering
methods.
5 − The entire length of single wall metal vent connector
shall be readily accessible for inspection, cleaning,
and replacement.
Page 12
Page 13
6 − Single appliance venting configurations with zero lat-
eral lengths (tables 5 and 6), are assumed to have no
elbows in the vent system. For all other vent configurations, the vent system is assumed to have two 90° elbows. For each additional 90° elbow or equivalent (for
example two 45° elbows equal one 90° elbow) beyond
two, the maximum capacity listed in the venting table
should be reduced by 10 percent (0.90 x maximum
listed capacity).
7 − The common venting tables (7, 8, 9, and 10) were gen-
erated using a maximum horizontal vent connector
length of 1−1/2 feet (.46 m) for each inch (25 mm) of
connector diameter as follows:
TABLE 4
Connector Diameter
inches (mm)
3 (76) 4−1/2 (1.37)
4 (102) 6 (1.83)
5 (127) 7−1/2 (2.29)
6 (152) 9 (2.74)
7 (178) 10−1/2 (3.20)
Maximum Horizontal
Connector Length −− feet (m)
8 − If the common vertical vent is offset, the maximum
common vent capacity listed in the common venting
tables should be reduced by 20%, the equivalent of two
90° elbows (0.80 x maximum common vent capacity).
The horizontal length of the offset shall not exceed
1-1/2 feet (.46 m) for each inch (25 mm) of common
vent diameter.
9 − The vent pipe should be as short as possible with the
least number of elbows and angles required to complete the job. Route the vent connector to the vent using the shortest possible route.
10 − A vent connector shall be supported without any dips
or sags and shall slope a minimum of 1/4 inch (6.4 mm)
per linear foot (305 mm) of connector, back toward the
appliance.
11 − Vent connectors shall be firmly attached to the furnace
flue collars by screws or other approved means, except vent connectors of listed type B vent material
which shall be assembled according to the manufac-
turer’s instructions. Joints between sections of single
wall connector piping shall be fastened by screws or
other approved means.
12 − When the vent connector used for Category I ap-
pliances must be located in or pass through a crawlspace or other areas which may be cold, that portion of
the vent connector shall be constructed of listed
double-wall type B vent material or material having
equivalent insulation qualities.
13 − All venting pipe passing through floors, walls, and ceil-
ings must be installed with the listed clearance to combustible materials and be fire stopped according to local codes. In absence of local codes, refer to NFGC
(Z223.1).
14 − No portion of the venting system can extend into, or pass
through any circulation air duct or plenum.
15 − Vent connectors serving Category I appliances shall
not be connected to any portion of mechanical draft
systems operating under positive pressure such as
Category III or IV venting systems.
16 − If vent connectors are combined prior to entering the
common vent, the maximum common vent capacity
listed in the common venting tables must be reduced by
10 percent, the equivalent of one 90° elbow (0.90 x
maximum common vent capacity).
17 − The common vent diameter must always be at least as
large as the largest vent connector diameter.
18 − In no case, shall the vent connector be sized more than
two consecutive table size diameters over the size of
the draft hood outlet or flue collar outlet.
19 − Do not install a manual damper, barometric draft regu-
lator or flue restrictor between the furnace and the
chimney.
20 − When connecting this appliance to an existing dedi-
cated or common venting system, you must inspect the
venting system’s general condition and look for signs
of corrosion. The existing vent pipe size must conform
to these instructions and the provided venting tables
for the USA, and the appropriate venting tables in the
standards of CSA B149 Natural Gas and Propane
Installation Codes for Canada. If the existing venting
system does not meet these requirements, it must be
resized.
Page 13
Page 14
TABLE 5
Capacity of Type B Double−Wall Vents with Type B Double−Wall Connectors
Serving a Single Category I Appliance
Vent and Connector Diameter − D (inches)
Height
H
(feet)
6
8
10
15
20
30
NOTE − Single appliance venting configurations with zero lateral lengths are assumed to have no elbows in the vent system. For all other
vent configurations, the vent system is assumed to have two 90° elbows. For each additional 90° elbow or equivalent (for example two 45°
elbows equal one 90° elbow) beyond two, the maximum capacity listed in the venting table should be reduced by 10 percent (0.90 x maximum listed capacity).
Lateral
L
(feet)
0 0 78 0 152 0 251 0 375
2 13 51 18 97 27 157 32 232
4 21 49 30 94 39 153 50 227
6 25 46 36 91 47 149 59 223
0 0 84 0 165 0 276 0 415
2 12 57 16 109 25 178 28 263
5 23 53 32 103 42 171 53 255
8 28 49 39 98 51 164 64 247
0 0 88 0 175 0 295 0 447
2 12 61 17 11 8 23 194 26 289
5 23 57 32 11 3 41 187 52 280
10 30 51 41 104 54 176 67 267
0 0 94 0 191 0 327 0 502
2 11 69 15 136 20 226 22 339
5 22 65 30 130 39 219 49 330
10 29 59 40 121 51 206 64 315
15 35 53 48 11 2 61 195 76 301
0 0 97 0 202 0 349 0 540
2 10 75 14 149 18 250 20 377
5 21 71 29 143 38 242 47 367
10 28 64 38 133 50 229 62 351
15 34 58 46 124 59 217 73 337
20 48 52 55 11 6 69 206 84 322
0 0 100 0 213 0 374 0 587
2 9 81 13 166 14 283 18 432
5 21 77 28 160 36 275 45 421
10 27 70 37 150 48 262 59 405
15 33 64 44 141 57 249 70 389
20 56 58 53 132 66 237 80 374
30 NR NR 73 113 88 214 104 346
3 Inch 4 Inch 5 Inch 6 Inch
Appliance Input Rating in Thousands of Btu Per Hour
MIN MAX MIN MAX MIN MAX MIN MAX
Page 14
Page 15
TABLE 6
Capacity of Type B Double−Wall Vents with Single−Wall Metal Connectors
Serving a Single Category I Appliance
Vent and Connector Diameter − D (inches)
Height
H
(feet)
6
8
10
15
20
30
NOTE − Single appliance venting configurations with zero lateral lengths are assumed to have no elbows in the vent system. For all other
vent configurations, the vent system is assumed to have two 90° elbows. For each additional 90° elbow or equivalent (for example two 45°
elbows equal one 90° elbow) beyond two, the maximum capacity listed in the venting table should be reduced by 10 percent (0.90 x maximum listed capacity).
Lateral
L
(feet)
0 38 77 59 151 85 249 126 373
2 39 51 60 96 85 156 123 231
4 NR NR 74 92 102 152 146 225
6 NR NR 83 89 114 147 163 220
0 37 83 58 164 83 273 123 412
2 39 56 59 108 83 176 121 261
5 NR NR 77 102 107 168 151 252
8 NR NR 90 95 122 161 175 243
0 37 87 57 174 82 293 120 444
2 39 61 59 117 82 193 11 9 287
5 52 56 76 111 105 185 148 277
10 NR NR 97 100 132 171 188 261
0 36 93 56 190 80 325 11 6 499
2 38 69 57 136 80 225 11 5 337
5 51 63 75 128 102 216 144 326
10 NR NR 95 116 128 201 182 308
15 NR NR NR NR 158 186 220 290
0 35 96 54 200 78 346 11 4 537
2 37 74 56 148 78 248 11 3 375
5 50 68 73 140 100 239 141 363
10 NR NR 93 129 125 223 177 344
15 NR NR NR NR 155 208 216 325
20 NR NR NR NR 186 192 254 306
0 34 99 53 211 76 372 110 584
2 37 80 55 164 76 281 109 429
5 49 74 72 157 98 271 136 417
10 NR NR 91 144 122 255 171 397
15 NR NR 11 5 131 151 239 208 377
20 NR NR NR NR 181 223 246 357
30 NR NR NR NR NR NR NR NR
3 Inch 4 Inch 5 Inch 6 Inch
Appliance Input Rating in Thousands of Btu Per Hour
MIN MAX MIN MAX MIN MAX MIN MAX
Page 15
Page 16
Vent
Height
H
(feet)
6
8
10
15
20
30
TABLE 7
Vent Connector Capacity
Type B Double−Wall Vents with Type B Double−Wall Connectors
Serving Two or More Category I Appliances
Connector
Rise
R
(feet)
1 22 37 35 66 46 106 58 164
2 23 41 37 75 48 121 60 183
3 24 44 38 81 49 132 62 199
1 22 40 35 72 49 11 4 64 176
2 23 44 36 80 51 128 66 195
3 24 47 37 87 53 139 67 210
1 22 43 34 78 49 123 65 189
2 23 47 36 86 51 136 67 206
3 24 50 37 92 52 146 69 220
1 21 50 33 89 47 142 64 220
2 22 53 35 96 49 153 66 235
3 24 55 36 102 51 163 68 248
1 21 54 33 99 46 157 62 246
2 22 57 34 105 48 167 64 259
3 23 60 35 110 50 176 66 271
1 20 62 31 113 45 181 60 288
2 21 64 33 118 47 190 62 299
3 22 66 34 123 48 198 64 309
3 Inch 4 Inch 5 Inch 6 Inch
MIN MAX MIN MAX MIN MAX MIN MAX
Vent and Connector Diameter − D (inches)
Appliance Input Rating in Thousands of Btu Per Hour
TABLE 8
Common Vent Capacity
Type B Double−Wall Vents with Type B Double−Wall Connectors
Serving Two or More Category I Appliances
Vent
Height
H
(feet)
6 92 81 140 11 6 204 161 309 248
8 101 90 155 129 224 178 339 275
10 110 97 169 141 243 194 367 299
15 125 112 195 164 283 228 427 352
20 136 123 215 183 314 255 475 394
30 152 138 244 210 361 297 547 459
FAN + FAN FAN + NAT FAN + FAN FAN + NAT FAN + FAN FAN + NAT FAN + FAN FAN + NAT
4 Inch 5 Inch 6 Inch 7 Inch
Appliance Input Rating in Thousands of Btu Per Hour
Common Vent Diameter − D (inches)
Page 16
Page 17
TABLE 9
Vent Connector Capacity
Type B Double−Wall Vents with Single−Wall Metal Connectors
Serving Two or More Category I Appliances
Vent
Height
H
(feet)
6
15
30
Connector
Rise
R
(feet)
1 NR NR NR NR NR NR NR NR
2 NR NR NR NR NR NR 168 182
3 NR NR NR NR 121 131 174 198
1 NR NR 79 87 116 138 177 214
2 NR NR 83 94 121 150 185 230
3 NR NR 87 100 127 160 193 243
1 47 60 77 110 113 175 169 278
2 50 62 81 115 117 185 177 290
3 54 64 85 119 122 193 185 300
3 Inch 4 Inch 5 Inch 6 Inch
MIN MAX MIN MAX MIN MAX MIN MAX
Vent and Connector Diameter − D (inches)
Appliance Input Rating in Thousands of Btu Per Hour
TABLE 10
Common Vent Capacity
Type B Double−Wall Vents with Single−Wall Metal Connectors
Serving Two or More Category I Appliances
Vent
Height
H
(feet)
6 89 78 136 11 3 200 158 304 244
8 98 87 151 126 218 173 331 269
10 106 94 163 137 237 189 357 292
15 121 108 189 159 275 221 416 343
20 131 118 208 177 305 247 463 383
30 145 132 236 202 350 286 533 446
FAN + FAN FAN + NAT FAN + FAN FAN + NAT FAN + FAN FAN + NAT FAN + FAN FAN + NAT
4 Inch 5 Inch 6 Inch 7 Inch
Appliance Input Rating in Thousands of Btu Per Hour
Common Vent Diameter − D (inches)
Removal of the Furnace from Common Vent
In the event that an existing furnace is removed from a
venting system commonly run with separate gas appliances, the venting system is likely to be too large to
properly vent the remaining attached appliances.
Conduct the following test while each appliance is operating and the other appliances (which are not operating) remain connected to the common venting system. If the
venting system has been installed improperly, you must
correct the system as indicated in the general venting requirements section.
1 − Seal any unused openings in the common venting sys-
tem.
2 − Inspect the venting system for proper size and horizontal
pitch. Determine that there is no blockage, restriction,
leakage, corrosion, or other deficiencies which could
cause an unsafe condition.
3 − Close all building doors and windows and all doors be-
tween the space in which the appliances remaining
connected to the common venting system are located
and other spaces of the building. Turn on clothes dryers and any appliances not connected to the common
venting system. Turn on any exhaust fans, such as
range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.
4 − Follow the lighting instructions. Turn on the appliance
that is being inspected. Adjust the thermostat so that
the appliance operates continuously.
5 − After the main burner has operated for 5 minutes, test
for leaks of flue gases at the draft hood relief opening.
Use the flame of a match or candle, or smoke from a
cigarette, cigar, or pipe.
6 − After determining that each appliance connected to the
common venting system is venting properly, (step 3)
return all doors, widows, exhaust fans, fireplace dampers, and any other gas−burning appliances to their previous mode of operation.
7 − If a venting problem is found during any of the preced-
ing tests, the common venting system must be modified to correct the problem.
Page 17
Page 18
Resize the common venting system to the minimum
vent pipe size determined by using the appropriate
tables in appendix G. (These are in the current standards of the National Fuel Gas Code ANSI Z223.1 in
the USA, and the appropriate Category 1 Natural Gas
and Propane appliances venting sizing tables in the
current standards of the CSA B149 Natural Gas and
Propane Installation Codes in Canada.)
Gas Piping
3 − The gas piping must not run in or through air ducts,
clothes chutes, gas vents or chimneys, dumb waiters,
or elevator shafts.
4 − The piping should be sloped 1/4 inch (6.4 mm) per 15
feet (4.57 m) upward toward the meter from the furnace. The piping must be supported at proper intervals
[every 8 to 10 feet (2.44 to 3.01 m)] with suitable hangers or straps. Install a drip leg inside vertical pipe runs
to the unit.
5 − In some localities, codes may require the installation of
a manual main shut-off valve and union (furnished by
the installer) external to the unit. The union must be of
the ground joint type.
CAUTION
If a flexible gas connector is required or allowed by
the authority that has jurisdiction, black iron pipe
shall be installed at the gas valve and extend outside
the furnace cabinet.
Compounds used on threaded joints of gas piping
must be resistant to the actions of liquified petro-
Gas Supply
1 − This unit is shipped standard for left or right side instal-
lation of gas piping. Connect the gas supply to the piping assembly.
2 − When connecting the gas supply piping, consider fac-
tors such as length of run, number of fittings, and furnace rating to avoid excessive pressure drop. Table 11
lists recommended pipe sizes for typical applications.
leum gases.
NOTE − Install a 1/8 inch NPT plugged tap in the field piping
upstream of the gas supply connection to the unit. The tap
must be accessible for test gauge connection. See figure 13.
NOTE − If emergency shutoff is necessary, shut off the main
manual gas valve and disconnect the main power to the
furnace. The installer should properly label these devices.
TABLE 11
Gas Pipe Capacity − ft3/hr (m3/hr)
Nominal
Iron Pipe
Size
inches
(mm)
3/8
(9.53)
1/2
(12.7)
3/4
(19.05)
1
(25.4)
1−1/4
(31.75)
1−1/2
(38.1)
2
(50.8)
2−1/2
(63.5)
3
(76.2)
Internal
Diameter
inches
(mm)
.493
(12.522)95(2.69)65(1.84)
.622
(17.799)
.824
(20.930)
1.049
(26.645)
1.380
(35.052)
1.610
(40.894)
2.067
(52.502)
2.469
(67.713)
3.068
(77.927)
10
(3.048)20(6.096)30(9.144)40(12.192)50(15.240)60(18.288)70(21.336)80(24.384)90(27.432)
175
(4.96)
360
(10.19)
680
(919.25)
1400
(39.64)
2100
(59.46)
3950
(111.85)
6300
(178.39)
11000
(311.48)
120
(3.40)
250
(7.08)
465
(13.17)
950
(26.90)
460
(41.34)
2750
(77.87)
4350
(123.17)
7700
(218.03)
52
(1.47)
97
(2.75)
200
(5.66)
375
(10.62)
770
(21.80)
1180
(33.41)
2200
(62.30)
3520
(99.67)
6250
(176.98)
(18.69)
(28.03)
(53.80)
(84.95
(150.07)
NOTE − Capacity given in cubic feet (m3 ) of gas per hour and based on 0.60 specific gravity gas.
Length of Pipe − feet (m)
45
(1.27)
82
(2.32)
170
(4.81)
320
(9.06)
660
990
1900
3000
5300
40
(1.13)
73
(2.07)
151
(4.28)
285
(8.07)
580
(16.42)
900
(25.48)
1680
(47.57)
2650
(75.04)
4750
(134.50)
(15.01)
(22.94)
(43.04)
(67.96)
(121.76)
IMPORTANT
36
(1.02)
66
(1.87)
138
(3.91)
260
(7.36)
530
810
1520
2400
4300
33
(.73)
61
(1.73)
125
(3.54)
240
(6.80)
490
(13.87)
750
(21.24)
1400
(39.64)
2250
(63.71)
3900
(110.43)
31
(.88)
57
(1.61)
118
(3.34)
220
(6.23)
460
(13.03)
690
(19.54)
1300
(36.81)
2050
(58.05)
3700
(104.77)
29
(.82)
53
(1.50)
110
(3.11)
205
(5.80)
430
(12.18)
650
(18.41)
1220
(34.55)
1950
(55.22)
3450
(97.69)
100
(30.480)
27
(.76)
50
(1.42)
103
(2.92)
195
(5.52)
400
(11.33)
620
(17.56)
1150
(32.56)
1850
(52.38)
3250
(92.03)
Page 18
Page 19
MANUAL
MAIN SHUT−OFF
VALV E
(With 1/8 in. NPT
Plugged Tap Shown)
GROUND
JOINT
UNION
Left Side Piping
(Standard)
AUTOMATIC
GAS VALVE
(with manual
shut−off valve)
AUTOMATIC
GAS VALVE
(with manual
shut−off valve)
MANUAL
MAIN SHUT−OFF
VALV E
(With 1/8 in. NPT
Plugged Tap
Shown)
GROUND
JOINT
UNION
DRIP LEG
FIELD
PROVIDED
DRIP LEG
AND INSTALLED
FIGURE 13
Leak Check
After gas piping is completed, carefully check all piping
connections (factory− and field−installed) for gas leaks. Use
a leak detecting solution or other preferred means.
CAUTION
Some soaps used for leak detection are corrosive to
certain metals. Carefully rinse piping thoroughly after leak test has been completed. Do not use
matches, candles, flame or other sources of ignition
to check for gas leaks.
The furnace must be isolated from the gas supply system
by closing its individual manual shut-off valve during any
pressure testing of the gas supply system at pressures less
than or equal to 1/2 psig (3.48 kPa, 14 inches w.c.).
IMPORTANT
When testing pressure of gas lines, gas valve must
be disconnected and isolated. See figure 15. Gas
valves can be damaged if subjected to pressures
greater than 1/2 psig (3.48 kPa, 14 inches w.c.).
MANUAL MAIN
SHUT−OFF VALVE
WILL NOT HOLD
NORMAL TEST
PRESSURE
ISOLATE
GAS VALVE
FURNACE
Right Side Piping
(Alternate)
Electrical
ELECTROSTATIC DISCHARGE (ESD)
Precautions and Procedures
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.
The unit is equipped with a field make−up box. The make−
up box may be moved to the right side of the furnace to facilitate installation. Secure the excess wire to the existing
harness to protect it from damage.
INTERIOR MAKE−UP BOX INSTALLATION
CAP
FIGURE 14
MANUAL MAIN
SHUT−OFF VALVE
WILL NOT HOLD
NORMAL TEST
PRESSURE
CAP
ISOLATE
GAS VALVE
FIGURE 15
MAKE−UP
BOX
FURNACE
FIGURE 16
Page 19
Page 20
INTERIOR MAKE−UP BOX INSTALLATION
MAKE−UP
BOX
FIGURE 17
Refer to figure 19 for field wiring and figure 21 for schematic
wiring diagram and troubleshooting.
Select circuit protection and wire size according to the
unit nameplate. The power supply wiring must meet
Class I restrictions.
Holes are on both sides of the furnace cabinet to facili-
tate wiring.
Install a separate disconnect switch (protected by ei-
ther fuse or circuit breaker) near the furnace so that
power can be turned off for servicing.
Before connecting the thermostat or the power wiring,
check to make sure the wires will be long enough for
servicing at a later date. Remove the blower access
panel to check the length of the wire.
Complete the wiring connections to the equipment.
Use the provided unit wiring diagram and the field wiring diagram shown in figure 19. Use 18−gauge wire or
larger that is suitable for Class II rating for thermostat
connections.
Electrically ground the unit according to local codes or,
in the absence of local codes, according to the current
National Electric Code (ANSI/NFPA No. 70) for the
USA and current Canadian Electric Code part 1 (CSA
standard C22.1) for Canada. A green ground wire is
provided in the field make−up box.
NOTE − The G40DF(X) furnace contains electronic
components that are polarity sensitive. Make sure
that the furnace is wired correctly and is properly
grounded.
One line voltage EAC" terminal is provided on the fur-
nace control board. Any electronic air cleaner rated up
to one amp can be connected to this terminal with the
neutral leg of the circuit being connected to any of the
NEUTRAL" terminals. See figure 20 for control board
configuration. This terminal is energized when the
blower is operating.
One line voltage HUM" terminal is provided on the fur-
nace control board. Any humidifier rated up to one amp
can be connected to this terminal with the neutral leg
of the circuit being connected to any of the NEUTRAL"
terminals. See figure 20 for control board configuration. This terminal is energized in the heating mode
whenever the combustion air inducer is operating.
Install the room thermostat according to the instruc-
tions provided with the thermostat. See figure 18 for
thermostat designations. If the furnace is being
matched with a heat pump, refer to the FM21 installation instruction.
G40DF(X) and CONDENSING UNIT
(Refer to specific thermostat and outdoor unit.)
Thermostat
R
W1
Y
G
C
THERMOSTAT DESIGNATIONS
G40DF(X)
Furnace
POWER
HEAT
COOLING
INDOOR BLOWER
COMMON
R
W
Y
G
C
Condensing
Unit
A/C UNIT
A/C UNIT
COMMON
FIGURE 18
Indoor Blower Speeds
When the thermostat is set to FAN ON," the indoor
blower will run continuously on the heat speed when
there is no cooling or heating demand.
When the G40DF(X) is running in the heating mode,
the indoor blower will run on the heating speed.
When there is a cooling demand, the indoor blower will
run on the cooling speed.
Page 20
Page 21
TYPICAL G40DF(X) FIELD WIRING DIAGRAM
FIGURE 19
INTEGRATED CONTROL BOARD
(Automatic Hot Surface Ignition System)
TERMINAL DESIGNATIONS
HUM
LINE
XFMR
EAC
COOL
HEAT
PARK
FLAME
NEUTRALS
3 AMP, 32 VAC FUSE
Humidifier (120VAC)
Input (120VAC)
Transformer (120VAC)
Electronic Air Cleaner (120VAC)
Blower − Cooling Speed (120VAC)
Blower − Heating Speed (120VAC)
Dead terminals to park alternate spd taps
Flame senser
Neutral terminals (120VAC)
BLOWER OFF
DELAY JUMPER
FIGURE 20
Page 21
Page 22
G40DF(X) Typical Schematic Wiring Diagram
FIGURE 21
Page 22
Page 23
Unit Start−Up
FOR YOUR SAFETY READ BEFORE LIGHTING
WARNING
Do not use this furnace if any part has been underwater. Immediately call a qualified service technician to
inspect the furnace and to replace any part of the
control system and any gas control which has been
under water.
WARNING
If overheating occurs or if gas supply fails to shut off,
shut off the manual gas valve to the appliance before
shutting off electrical supply.
CAUTION
Before attempting to perform any service or maintenance, turn the electrical power to unit OFF at disconnect switch.
BEFORE LIGHTING smell all around the appliance area for
gas. Be sure to smell next to the floor because some gas is
heavier than air and will settle on the floor.
The gas valve on the G40DF(X) unit may be equipped with
either a gas control knob or gas control lever. Use only your
hand to push the lever or to turn the gas control knob. Never
use tools. If the knob will not turn or if the lever will not move
by hand, do not try to repair it. Force or attempted repair
may result in a fire or explosion.
Placing the furnace into operation:
G40DF(X) units are equipped with an automatic hot surface ignition system. Do not attempt to manually light
burners on this furnace. Each time the thermostat calls
for heat, the burners will automatically light. The igniter
does not get hot when there is no call for heat on these
units.
WARNING
If you do not follow these instructions exactly, a fire
or explosion may result causing property damage,
personal injury or death.
Gas Valve Operation (Figures 22, 23, and 24)
1 − STOP! Read the safety information at the beginning of
this section.
2 − Set the thermostat to the lowest setting.
3 − Turn off all electrical power to the unit.
4 − This furnace is equipped with an ignition device which
automatically lights the burners. Do not try to light the
burners by hand.
5 − Remove the upper access panel.
6 − Honeywell VR8205 Gas Valve with ON/OFF Switch
− Move gas valve switch to OFF. See figure 22.
Honeywell VR8205 Gas Valve with Control Knob −
Turn knob on gas valve clockwise
to OFF. Do not
force. See figure 23.
White Rodgers 36G Gas Valve − Move gas valve
switch to OFF. See figure 24.
7 − Wait five minutes to clear out any gas. If you then smell
gas, STOP! Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s instructions. If you do not smell gas go to next step.
Honeywell VR8205 Series Gas Valve
MANIFOLD
PRESSURE
ADJUSTMENT
SCREW
(under cap)
GAS VALVE ON/OFF SWITCH SHOWN IN OFF POSITION
(With On/Off Switch)
MANIFOLD
PRESSURE
OUTLET
FIGURE 22
Honeywell VR8205 Series Gas Valve
with Gas Control Knob
MANIFOLD
PRESSURE
ADJUSTMENT
SCREW
ON
OFF
GAS VALVE SHOWN IN OFF POSITION
MANIFOLD
PRESSURE
OUTLET
FIGURE 23
White Rodgers 36G Series Gas Valve
OUTLET
PRESSURE
POST
INLET
PRESSURE
POST
GAS VALVE SHOWN IN OFF POSITION
MANIFOLD
PRESSURE
ADJUSTMENT
SCREW
(Under cover
screw)
FIGURE 24
8 − Honeywell VR8205 Gas Valve with ON/OFF Switch
− Move gas valve switch to ON. See figure 22.
Honeywell VR8205 Gas Valve with Control Knob −
Turn knob on gas valve counterclockwise to ON.
Do not force. See figure 23.
White Rodgers 36G Gas Valve − Move gas valve
switch to ON. See figure 24.
9 − Replace the upper access panel.
Page 23
Page 24
10− Turn on all electrical power to to the unit.
11− Set the thermostat to desired setting.
NOTE − When unit is initially started, steps 1 through 11
may need to be repeated to purge air from gas line.
12− If the appliance will not operate, follow the instructions
Turning Off Gas to Unit" and call the gas supplier.
Turning Off Gas to Unit
1 − Set the thermostat to the lowest setting.
2 − Turn off all electrical power to the unit if service is to be
performed.
3 − Remove the upper access panel.
4 − Honeywell VR8205 Gas Valve with ON/OFF Switch
− Move gas valve switch to OFF. See figure 22.
Honeywell VR8205 Gas Valve with Control Knob −
Turn knob on gas valve clockwise to OFF. Do not
force. See figure 23.
White Rodgers 36G Gas Valve − Move gas valve
switch to OFF. See figure 24.
5 − Replace the upper access panel.
Heating Sequence Of Operation
When thermostat calls for heat, combustion air inducer
starts.
Combustion air pressure switch proves combustion air
inducer operation. Switch is factory set and requires no
adjustment.
After a 15 second prepurge, the hot surface igniter en-
ergizes.
After a 20 second igniter warm−up period, the gas valve
solenoid opens.
Gas is ignited, flame sensor proves the flame, and the
combustion process continues.
If flame is not detected after first ignition trial, the igni-
tion control will repeat steps 3 and 4 four more times
before locking out the gas valve (WATCHGUARD"
flame failure mode). The ignition control will then auto-
matically repeat steps 1 through 6 after 60 minutes.
To interrupt the 60−minute WATCHGUARD" period,
move thermostat from Heat" to OFF" then back to
Heat." Heating sequence then restarts at step 1.
Gas Pressure Adjustment
Gas Flow (Approximate)
1 − Operate unit at least 15 minutes before checking gas
flow. Determine the time in seconds for one revolutions of gas through the meter. A portable LP gas meter (17Y44) is available for LP applications.
2 − Compare the number of seconds and the gas meter
size in table 12 to determine the gas flow rate. Multiply
the gas flow rate by the heating value to determine the
unit input rate. If manifold pressure is correct and the
unit input rate is incorrect, check gas orifices for proper
size and restriction.
3 − Remove temporary gas meter if installed.
NOTE − To obtain accurate reading, shut off all other gas
appliances connected to meter.
TABLE 12
Gas Flow Rate (Ft.3/Hr.)
Seconds for 1
Revolution
10 180 360
12 150 300
14 129 257
16 113 225
18 100 200
20 90 180
22 82 164
24 75 150
26 69 138
28 64 129
30 60 120
32 56 113
34 53 106
36 50 100
38 47 95
40 45 90
42 43 86
44 41 82
46 39 78
48 38 75
50 36 72
52 35 69
54 33 67
56 32 64
58 31 62
60 30 60
1/2 cu ft Dial 1 cu ft Dial
Gas Meter Size
IMPORTANT
For safety, shut unit off and remove manometer as
soon as an accurate reading has been obtained.
Take care to replace pressure tap plug.
Gas Pressure
1 − Check the gas line pressure with the unit firing at maxi-
mum rate. A minimum of 4.5 in. w.c. for natural gas or
11.0 in. w.c. for LP/propane gas should be maintained.
2 − After the line pressure has been checked and ad-
justed, check the manifold pressure. A natural gas to
LP/propane gas changeover kit is required to convert
the unit. Manifold pressure for all units fueled by natural gas at all altitudes is 3.5" w.c. Manifold pressure for
all units fueled by L.P./propane gas at all altitudes is
10.0" w.c. See figures 22, 23 and 24 for the location of
the manifold pressure adjustment screws.
Page 24
Page 25
High Altitude Information
NOTE − In Canada, certification for installations at elevations over 4500 feet (1372 m) is the jurisdiction of local authorities.
Manifold pressure for all units fueled by natural gas at all
altitudes is 3.5" w.c. Manifold pressure for all units fueled
by L.P./propane gas at all altitudes is 10.0" w.c.
NOTE − A natural to L.P. propane gas changeover kit is
necessary to convert this unit. L.P. conversion kit 25W20
is used with all units installed at altitudes up to 7,500 feet.
L.P. conversion kit 25W21 is used with all units installed at
altitudes from 7,501 to 10,000 feet above sea level. Refer
to the changeover kit installation instruction for the
conversion procedure.
NOTE − Units fueled by natural gas and installed at altitudes of 7501−10,000 feet above sea level require installation of a high altitude orifice kit (59M17).
The combustion air pressure switch is factory−set and requires no adjustment. The factory−installed pressure
switch is acceptable for use in units installed at altitudes up
to 10,000 feet above sea level.
Other Unit Adjustments
Primary and Secondary Limits
The primary limit is located on the heating compartment
vestibule panel. The secondary limit is located in the blower
compartment, attached to the back side of the blower.
These limits are factory set and require no adjustment.
Flame Rollout Switches (Two)
These manually reset switches are located on the burner
box. If tripped, check for adequate combustion air before
resetting.
Pressure Switch
The pressure switch is located in the heating compartment
adjacent to the combustion air inducer. This switch checks
for proper combustion air inducer operation before allowing ignition trial. The switch is factory−set and requires no
adjustment.
Temperature Rise
Place the unit into operation with a heating demand. After
supply and return air temperatures have stabilized, check
the temperature rise. If necessary, adjust the blower speed
to maintain the temperature rise within the range shown on
the unit nameplate. Increase the blower speed to decrease
the temperature. Decrease the blower speed to increase
the temperature rise. Failure to do adjust the temperature
rise may cause erratic limit operation.
Fan Control
There is no cooling mode fan on delay; however, there is a
cooling fan off delay of 45 seconds. This delay is not adjustable.
The heating mode fan on time of 45 seconds is not adjustable. The heating mode fan off delay(amount of time that
the blower operates after the heat demand has been satisfied) may be adjusted by changing the jumper position
across the five pins on the integrated control. The unit is
shipped with a factory fan off setting of 90 seconds. The fan
off delay affects comfort and is adjustable to satisfy individual applications. Adjust the fan 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 return air temperatures; shorter settings provide higher return air temperatures. See figure 25.
FAN-OFF TIME ADJUSTMENT
To adjust fan−off timing, reposition jumper across pins to
achieve desired setting.
FIGURE 25
Thermostat Heat Anticipation
Set the heat anticipator setting (if adjustable) according to
the amp draw listed on the wiring diagram that is attached
to the unit.
Electrical
1 − Check all wiring for loose connections.
2 − Check for the correct voltage at the furnace (furnace
operating).
3 − Check amp-draw on the blower motor.
Motor Nameplate__________Actual__________
NOTE − Do not secure the electrical conduit directly to the
air ducts or structure.
Blower Speeds
NOTE − CFM readings are taken external to unit with a dry
evaporator coil and without accessories. See blower performace data beginning on Page 26.
Turn off electrical power to furnace.
Remove blower access panel.
Disconnect existing speed tap at control board speed
terminal.
NOTE − Termination of any unused motor leads must be
connected to the park terminals on the control board.
Refer to blower speed selection chart on unit wiring dia-
gram for desired heating or cooling speed.
Connect selected speed tap at control board speed
terminal.
Resecure blower access panel.
Turn on electrical power to furnace.
Electronic Ignition
The integrated ignition control has an added feature of an
internal Watchguard control. The feature serves as an automatic reset device for ignition control lockout caused by
ignition failure. After one hour of continuous thermostat demand for heat, the Watchguard will break and remake thermostat demand to the furnace and automatically reset the
control to begin the ignition sequence.
Page 25
Page 26
Flue And Chimney
1 − Check flue pipe, chimney and all connections for tight-
ness and to make sure there is no blockage.
2 − Check unit for proper draft.
3 − Is pressure switch closed? Obstructed flue will cause
unit to shut off at pressure switch. Check flue and outlet
for blockages.
4 − Reset manual flame rollout switches on burner box
cover.
Failure To Operate
If the unit fails to operate, check the following:
1 − Is the thermostat calling for heat?
2 − Are access panels securely in place?
3 − Is the main disconnect switch closed?
4 − Is there a blown fuse?
5 − Is the filter dirty or plugged? Dirty or plugged filters will
cause the limit control to shut the unit off.
6 − Is gas turned on at the meter?
7 − Is the manual main shut-off valve open?
8 − Is the internal manual shut-off valve open?
9 − Is the unit ignition system in lock out? If the unit locks out
again, inspect the unit for blockages.
Blower Performance
NOTE − All air data is measured external to unit with 1 in. cleanable filter (not furnished − field provided) in place.
G40DF−24A−045 PERFORMANCE
External
Static
Pressure
in. w.g.
0.00
0.05 1185 410 1040 360 820 274
0.10 1165
0.15
0.20 1125 390 990 338 775 260
0.25 1105
0.30 1080 374 965 331 750 254
0.40 1020 357 920 319 710 244
0.50 960
0.60 900 330 810 290 620 231
0.70 815 313 690 272 565 221
0.80 685 289 620 259 465 203
0.90
G40DF−36A−070 PERFORMANCE
External
Static
Pressure
in. w.g.
0.00
0.05 1450 606 1320 543 1140 481 985 407
0.10 1425
0.15 1395 585 1275 521 111 5 452 970 390
0.20 1375 574 1255 510 1105 437 965 381
0.25 1345 563 1230 494 1090 428 955 371
0.30 1320 552 1205 478 1075 418 945 360
0.40 1250 528 1150 455 1040 395 920 346
0.50 1200 508 1095 432 1000 374 880 331
0.60 1110 475 1035 409 950 354 830 313
0.70 1030 455 970 390 855 338 720 280
0.80 960
0.90 770 389 715 321 665 278 590 244
Air Volume / Watts at Different Blower Speeds
High Medium Low
cfm Watts cfm Watts cfm Watts
1200 417 1060 367 830 278
402 1025 353 810 270
1145 396 1010 346 795 265
382 980 335 765 257
342 875 306 650 234
560 271 510 238 395 190
Air Volume / Watts at Different Blower Speeds
High
cfm Watts cfm Watts cfm Watts cfm Watts
1475 616 1345 554 1150 495 990 415
Medium−
High
595 1300 532 1125 466 975 398
434 875 359 735 299 665 266
Medium−
Low
Low
G40DF−36B−090 PERFORMANCE
External
Static
Pressure
in. w.g.
0.00
0.05 1580 599 1400 518 1165 428 965 351
0.10 1560
0.15
0.20 1495 556 1350 485 1150 406 965 335
0.25 1465 544 1325 473 1135 398 955 329
0.30
0.40 1370 509 1250 438 1095 373 935 313
0.50 1295
0.60
0.70 1140 437 1055 371 915 313 800 272
0.80 1000
0.90
G40DF−48C−090 PERFORMANCE
External
Static
Pressure
in. w.g.
0.00 2040 749 1850 657 1595 562 1325 466
0.05 2000 727 1825 638 1575 547 1340 460
0.10 1955
0.15
0.20 1885 679 1740 585 1525 503 1330 428
0.25 1845
0.30
0.40 1695 606 1585 517 1415 448 1225 378
0.50 1600
0.60
0.70 1380 509 1300 426 1165 367 1025 316
0.80 1250 478 1160 390 1025 331 − − − − − −
0.90
Air Volume / Watts at Different Blower Speeds
High
cfm Watts cfm Watts cfm Watts cfm Watts
1600 608 1410 526 1165 436 965 355
1530 573 1370 497 1155 413 965 341
1430 532 1300 460 1125 389 945 323
1215 456 1140 397 1010 343 860 285
900 374 820 313 740 272 − − − − − −
Air Volume / Watts at Different Blower Speeds
High
cfm Watts cfm Watts cfm Watts cfm Watts
1920 692 1770 602 1540 518 1340 441
1800 645 1665 551 1475 473 1270 399
1495 540 1405 457 1250 389 111 0 337
1095 439 1030 360 925 307 − − − − − −
Medium−
High
589 1390 509 1160 420 970 346
482 1200 420 1055 355 900 302
401 950 342 850 295 730 251
Medium−
High
704 1800 619 1555 532 1350 453
662 1700 568 1500 488 1300 414
570 1490 485 1335 414 1170 360
Medium−
Low
Medium−
Low
Low
Low
Page 26
Page 27
Blower Performance
NOTE − All air data is measured external to unit with 1 in. cleanable filter (not furnished − field provided) in place.
G40DF−48C−110 PERFORMANCE
External
Static
Pressure
in. w.g.
0.00
0.05 2000 825 1760 694 1495 581 1225 470
0.10 1970
0.15
0.20 1880 758 1685 638 1465 542 1215 447
0.25 1835 736 1655 618 1440 528 1200 437
0.30
0.40 1680 669 1550 564 1360 483 1135 400
0.50 1620
0.60
0.70 1290 545 1180 434 1055 369 905 319
0.80 1155
0.90
Air Volume / Watts at Different Blower Speeds
High
cfm Watts cfm Watts cfm Watts cfm Watts
2035 846 1790 712 1510 595 1225 477
1925 781 1710 657 1475 555 1220 455
1795 714 1625 597 1420 514 1185 427
1445 592 1310 479 1165 404 1000 343
1010 472 930 372 840 320 690 265
Medium−
High
803 1730 675 1475 567 1220 463
630 1445 524 1280 447 1065 371
502 1065 406 955 348 815 296
Medium−
Low
Low
G40DF−60C−110 PERFORMANCE
External
Static
Pressure
in. w.g.
.00
.10 2390 1248 2235 955 1990 829 1675 690
.20 2330
.30 2245 1192 2125 911 1940 786 1660 657
.40 2175 1187 2050 880 1895 757 1650 636
.50 2085 1145 1970 849 1835 734 1625 619
.60
.70 1920 1094 1775 785 1660 669 1525 579
.80 1785 1052 1685 762 1585 645 1440 556
.90 1670 1020 1600 741 1520 633 1370 538
Air Volume / Watts at Different Blower Speeds
High
cfm Watts cfm Watts cfm Watts cfm Watts
2475 1276 2280 987 1995 845 1690 698
1223 2180 945 1975 809 1665 675
2020 1129 1880 815 1750 695 1580 599
Medium−
High
Medium−
Low
Low
G40DF−60D−135 PERFORMANCE
External
Static
Pressure
in. w.g.
.00
.10 2560 1353 2310 1030 1945 840 1640 667
.20 2490 1325 2280 1000 1940 824 1630 661
.30 2415 1293 2225 972 1930 801 1625 649
.40 2345 1264 2170 941 1910 779 1620 638
.50 2265 1235 2115 918 1870 754 1615 624
.60 2165 1199 2020 880 1830 733 1585 604
.70 2050 1160 1940 854 1755 705 1570 604
.80 1955
.90 1865 1096 1760 797 1605 656 1465 567
cfm Watts cfm Watts cfm Watts cfm Watts
2660 1379 2325 1059 1960 864 1655 684
Air Volume / Watts at Different Blower Speeds
High Medium−High Medium−Low Low
1112 1865 828 1680 683 1515 584
Page 27
Page 28
Service
WARNING
Disconnect power before servicing unit.
CAUTION
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.
At the beginning of each heating season, a qualified technician should check the system as follows:
Blower
Check the blower wheel for debris and clean if necessary.
The blower motors are prelubricated for extended bearing
life. No further lubrication is needed.
2 − Remove the three screws that secure the vent pipe to
the flue collar. See figure 10.
3 − Remove the screw that secures the internal flue pipe to
the combustion air inducer. See figure 26.
4 −Scrape away the silicone sealant that is between the
internal flue pipe and the combustion air inducer.
5 − Pull the internal flue pipe into the chase.
G40DF(X) Internal Flue Pipe and Chase
Unit Top Cap
Internal Flue
Pipe
with Adaptor
Flue Chase
with Gaskets
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 injury or death.
Filters
All G40DF(X) filters are installed external to the unit. Filters
should be inspected monthly. Clean or replace the filters
when necessary to ensure that the furnace operates properly. Replacement filters must be rated for high velocity airflow. Table 3 lists recommended filter sizes.
Flue And Chimney
Check the flue pipe, chimney and all connections for tightness and to make sure there is no blockage.
Electrical
1 − Check all wiring for loose connections.
2 − Check for the correct voltage at the furnace (furnace
operating).
3 − Check amp−draw on the blower motor.
Motor Nameplate__________Actual__________
Cleaning the Heat Exchanger and Burners
NOTE − Use papers or protective covering in front of the furnace during cleaning.
Cleaning the heat exchanger requires a steel spring
snake," a reversible drill and a vacuum cleaner. The steel
spring snake may be constructed using a 4 ft. long by 1/4
inch diameter steel wire cable and a 1/4 inch diameter wire
brush. These items are available at a hardware store. Insert wire end of brush into the open end of the spring cable.
Crimp the cable around the brush so that the brush is secured and will not come off during cleaning. Attach the other end of the cable to the reversible drill to complete the tool
for cleaning the heat exchanger.
1 − Turn off both electrical and gas supplies to the furnace.
Remove the furnace access panels.
Screw (1)
Internal
Flue Pipe
RTV
Silicone
Sealant
Combustion
Air Inducer
FIGURE 26
G40DF(X) CAI & Burner Box Removal
Heat Exchanger
Combustion Air Inducer
Burner Box Assembly
FIGURE 27
6 − Remove the collector box located behind the combus-
tion air inducer. Be careful with the collector box gasket. If the gasket is damaged, it must be replaced to
prevent leakage.
7 − Label the wires from gas valve and rollout switches,
then disconnect them.
Page 28
Page 29
8 −Disconnect gas supply piping. Remove four screws se-
curing the burner manifold assembly to the vestibule
panel and remove the assembly from the unit.
NOx INSERTS
(X models only)
NOx INSERT
FIGURE 28
9 −NOx units only − Remove the three screws that attach
the NOx insert to the corbel at the entrance to each
heat exchanger section. Carefully remove the NOx insert from each section. See figure 28.
10 −Insert the brush end of cable snake into the top of one
of the heat exchanger openings. Do not force the
cable into the heat exchanger. Insert the cable and
operate the drill on slow speed. Move the cable in and
out of the heat exchanger section three or four times or
until sufficient cleaning is accomplished. Reverse drill
and slowly work the cable out of opening.
11 −Repeat procedure for each heat exchanger section.
12 −After each of the top heat exchanger sections has
been cleaned, insert the brush end of the cable snake
into the bottom openings of each of the heat exchanger
sections and clean as described in step 8.
13 −Remove the cable from the heat exchanger. Use a
vacuum cleaner to remove debris knocked loose dur-
ing cleaning.
14 −Attach the exhaust end (positive pressure) of the vacu-
um cleaner to the top of the heat exchanger section.
Any loose debris will be forced to the bottom of the heat
exchanger section. Vacuum debris from bottom open-
ings.
15 −Replace collector box and combustion air inducer.
Check gaskets for damage. Damaged gaskets must
be replaced to avoid heat exchanger leaks. Replace all
screws to the collector box and combustion air inducer.
Failure to replace all screws may cause leaks.
16 −To clean the burner, run a vacuum cleaner with a soft
brush attachment over the face of burners. Inspect inside the burners and crossovers for any blockage.
Clean the inside of the burner if necessary.
17 −Label and disconnect the pressure switch wires.
18 −Remove the four screws that secure the combustion
air inducer. Carefully remove the combustion air induc-
er to avoid damaging the blower gasket. If the gasket is
damaged, it must be replaced to prevent leakage. See
figure 27.
19 −NOx Units − Reattach the NOx inserts to the corbels at
the entrance to each heat exchanger opening. See fig-
ure 28.
20 −Reinstall the burner/manifold assembly on the vesti-
bule panel.
21 −Reconnect wires to pressure switch, roll−out switches,
gas valve and combustion air inducer. Refer to unit wir-
ing diagram.
22 −Use screws to resecure the junction box to the cabinet.
23 −Apply RTV/high temperature silicone sealant between
the internal flue pipe and the combustion air inducer.
24 −Use one screw to resecure the internal flue pipe to the
combustion air inducer.
25 −Use three screws to resecure the vent pipe to the flue
collar. See figure 10.
26 −Reconnect the gas supply piping.
27 −Turn on power and gas supply to the unit.
28 −Set thermostat and check for proper operation.
29 −Check all piping connections, factory and field, for gas
leaks. Use a leak detecting solution or other preferred
means.
CAUTION
Some soaps used for leak detection are corrosive to
certain metals. Carefully rinse piping thoroughly after leak test has been completed. Do not use
matches, candles, flame or other sources of ignition
to check for gas leaks.
30 −If a leak is detected, shut gas and electricity off and re-
pair leak.
31 −Repeat steps 35 and 36 until no leaks are detected.
32 −Replace front access panels.
Page 29
Page 30
Planned Service
A service technician should check the following items during an annual inspection. Power to the unit must be shut off
for safety.
Fresh air grilles and louvers (on the unit and in the room
where the furnace is installed) − Must be open and unobstructed to provide combustion air.
Burners − Must be inspected for rust, dirt, or signs of water.
Vent pipe − Must be inspected for signs of water, damaged,
cracked or sagging pipe, or disconnected joints.
Return air duct − Must be properly attached and provide
an air seal to the unit.
Operating performance − Unit must be observed during
operation to monitor proper performance of the unit and the
vent system.
Combustion gases − Flue products must be analyzed and
compared to the unit specifications.
Problems detected during the inspection may make it necessary to temporarily shut down the furnace until the items
can be repaired or replaced.
Unit appearance − Must be inspected for rust, dirt, signs
of water, burnt or damaged wires, or components.
Blower access door − Must be properly in place and provide a seal between the return air and the room where the
furnace is installed.
Instruct the homeowners to pay attention to their
furnace. Situations can arise between annual furnace in-
spections that may result in unsafe operation. For instance,
items innocently stored next to the furnace may obstruct
the combustion air supply. This could cause incomplete
combustion and the production of carbon monoxide gas.
Repair Parts List
The following repair parts are available through Lennox dealers. When ordering parts, include the complete furnace model
number listed on the CSA International nameplate −− Example: G40DF(X)−24A−045−15.All service must be performed by
a licensed professional installer (or equivalent), service agency, or gas supplier.
Cabinet Parts
Upper access panel
Blower panel
Top cap
Control Panel Parts
Transformer
Integrated ignition control board
Door interlock switch
Circuit breaker
Blower Parts
Blower wheel
Motor
Motor mounting frame
Motor capacitor
Blower housing cut−off plate
Heating Parts
Flame Sensor
Heat exchanger assembly
Gas manifold
Combustion air inducer
Gas valve
Main burner cluster
Main burner orifices
Pressure switch
Igniter
Primary limit control
Flame rollout switches
Secondary limit
Combustion air inducer gaskets
Flue box gaskets
Flue chase gaskets
Internal flue pipe assembly
Page 30
Page 31
Ignition Control Board Diagnostic Codes
DIAGNOSTIC CODES
Make sure to Identify LED’S Correctly.
Refer to figure 20 for control board layout.
LED #1 (Red) LED #2 (Green) 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: 12-pin connector improperly attached.
SIMULTANEOUS
SLOW FLASH
SIMULTANEOUS
FAST FLASH
ALTERNATING
SLOW FLASH
Power on − Normal operation.
Also signaled during cooling and continuous fan.
Normal operation − signaled when heating demand initiated at thermostat.
Primary or secondary limit switch open. Limit must close within 3 minutes or unit
goes into 1 hour Watchguard.
Pressure prove switch open.
OR: Blocked inlet/exhaust vent;
OR: Pressure switch closed prior to activation of combustion air inducer.
Watchguard −− burners failed to ignite or lost flame 5 times during single heating
demand.
ON
ON
OFF
ON
OFF
ON
Circuit board failure or control wired incorrectly.
FAST FLASH SLOW FLASH Main power polarity reversed. Switch line and neutral.
SLOW FLASH FAST FLASH Low flame signal. Measures below 1.5 microamps. Replace flame sense rod.
ALTERNATING
FAST FLASH
ALTERNATING
FAST FLASH
Improper main ground.
OR: Line voltage below 90 volts.
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 = 0.5 microAmps.
Page 31
Page 32
Troubleshooting: Heating Sequence of Operation
HEATING SEQUENCE OF OPERATION
NORMAL HEATING MODE
POWER ON
CONTROL SELF−CHECK OKAY?
YES
IS POLARITY CORRECT?
YES
IS THERE A PROPER GROUND?
YES
IS VOLTAGE
ABOVE 90 VOLTS?
YES
ROLLOUT SWITCH CLOSED?
YES
NO
NO
NO
ABNORMAL HEATING MODE
GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.
(RESET CONTROL BY TURNING MAIN POWER OFF.)
NO
NO
CONTROL WILL NOT RESPOND TO A CALL FOR
HEATING UNTIL VOLTAGE RISES ABOVE 95 VOLTS.
GAS VALVE OFF. COMBUSTION AIR INDUCER ON.
SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES
AND POWER IS RESET OR T’STAT IS INTERRUPTED
INDOOR BLOWER DELAY OFF.
LED #1 ON
LED #2 ON
POLARITY REVERSED.
LED #1 −− FAST FLASH
LED #2 −− SLOW FLASH
IMPROPER GROUND.
LED #1 −− ALTERNATING FAST FLASH
LED #2 −− ALTERNATING FAST FLASH
LEDs SIGNAL FAST ALTERNATING FLASH.
INDOOR BLOWER ON.
LED #1 −− ON. LED #2 −− SLOW FLASH.
FOR MINIMUM OF 1 SECOND.
NO
(CONTINUOUS FLAME CHECK)
BURNER OFF?
YES
NORMAL OPERATION:
LED #1 −− SLOW FLASH
LED #2 −− SLOW FLASH
YES
THERMOSTAT CALLS FOR HEAT:
LED #1 −− FAST FLASH
LED #2 −− FAST FLASH
YES
PRIMARY AND SECONDARY LIMIT SWITCH.
CLOSED?
YES
IS COMBUSTION AIR
PRESSURE SWITCH OPEN?
YES
IS COMBUSTION AIR INDUCER
ENERGIZED?
YES
HAS COMBUSTION AIR PRESSURE
SWITCH CLOSED IN 2.5 MINUTES?
YES
NO
NO
GAS VALVE OFF. COMBUSTION AIR INDUCER ON.
INDOOR BLOWER ON HEATING SPEED.
NO
NO
PRESSURE SWITCH IS IN WATCHGUARD MODE.
GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.
INDOOR BLOWER OFF WITH DELAY.
LED #1 −− OFF. LED #2 −− SLOW FLASH.
IS 5-MINUTE RESET PERIOD COMPLETE?
LED #1 −− SLOW FLASH
LED #2 −− OFF
COMBUSTION AIR INDUCER OFF.
INDOOR BLOWER ON
LED #1 SLOW FLASH RATE
LED #2 −− ON
GAS VALVE OFF.
COMBUSTION AIR INDUCER OFF.
INDOOR BLOWER OFF WITH DELAY.
LED #1 OFF
LED #2 SLOW FLASH
(Sequence holds until pressure switch
opens or thermostat resets control.)
YES
CONTINUED NEXT PAGE
Page 32
Page 33
Troubleshooting: Heating Sequence of Operation (Continued)
HEATING SEQUENCE CONTINUED
NORMAL HEATING MODE ABNORMAL HEATING MODE
15-SECOND COMBUSTION AIR INDUCER PREPURGE
INITIATED BY CLOSED PRESSURE SWITCH.
YES
IGNITER WARM-UP −− 20 SECONDS.
YES
4-SECOND TRIAL FOR IGNITION.
GAS VALVE OPENS. IGNITER ENERGIZED FOR
UP TO 4 SECONDS.
YES
FLAME STABILIZATION PERIOD.
4 SECONDS
FLAME RECTIFICATION CURRENT
CHECK. CAN FLAME BE PROVEN WITHIN
4 SECONDS AFTER GAS VALVE OPENS?
(0.5 microamps)
YES
FLAME PRESENT?
YES
FLAME SIGNAL 1.5 MICROAMPS OR GREATER?
YES
INDOOR BLOWER ON
AFTER 45−SECOND DELAY
YES
PRIMARY AND SECONDARY LIMIT
SWITCHES CLOSED?
YES
NO
IS VOLTAGE ABOVE 90 VOLTS?
YES
GAS VALVE OFF. COMBUSTION AIR INDUCER ON.
NO
HAS CONTROL FAILED TO SENSE FLAME FOR
FIVE CONSECUTIVE TRIES DURING A SINGLE
WATCHGUARD MODE. GAS VALVE OFF.
LEDs SIGNAL WATCHGUARD FAILURE CODE.
IS 60-MINUTE RESET PERIOD COMPLETE?
NO
NO
(Does not affect operation of control)
LED #1 −− SLOW FLASH
LED #2 −− FAST FLASH
COMBUSTION AIR INDUCER DE−ENERGIZED.
INDOOR BLOWER ON UNTIL SWITCH CLOSES.
NO
LED #1 −− SLOW FLASH. LED #2 −− ON.
HAS PRIMARY / SECONDARY
EXCEEDED 3 MINUTES?
INDOOR BLOWER OFF.
HEAT DEMAND?
COMBUSTION AIR INDUCER OFF.
INDOOR BLOWER OFF WITH DELAY
HAS CONTROL RESET IGNITION
SEQUENCE FOUR TIMES?
LOW FLAME SIGNAL
GAS VALVE DE−ENERGIZED.
IS LIMIT SWITCH CLOSED?
YES
LIMIT RESET TIME
LEDS SIGNAL
NO
LIMIT SWITCH WATCHGUARD
MODE. GAS VALVE, COMB. AIR
INDUCER AND INDOOR BLOW-
ER OFF. LEDs SIGNAL LIMIT
SWITCH OPEN UNTIL MAIN
YES
ALTERNATING
FAST FLASH UNTIL
VOLTAGE IS ABOVE
95 VOLTS, THEN
RESTARTS HEATING
SEQUENCE.
NO
YES
YES
NO
YES
POWER IS
INTERRUPTED OR
T’STAT IS CYCLED
OFF/ON FOR 1
SEC. MINIMUM.
60−MINUTE WATCH-
GUARD PERIOD
STARTS AT TIME
LIMIT CLOSES.
IS 60−MIN. PERIOD
COMPLETE?
NO
ROLLOUT SWITCH CLOSED?
YES
COMBUSTION AIR PRESSURE
SWITCH CLOSED?
YES
THERMOSTAT DEMAND SATISFIED.
YES
LED #1 & #2 SIMULTANEOUS SLOW FLASHES.
YES
COMB. AIR INDUCER CONTINUES 5-SECOND
POST PURGE AFTER T’STAT DEMAND IS SATISFIED.
INDOOR AIR BLOWER COMPLETES SELECTED
OFF" DELAY BEFORE SHUTTING OFF.
NO
SEQUENCE HOLDS UNTIL ROLLOUT SWITCH IS RESET
NO
THERMOSTAT IS CYCLED OFF/ON FOR 1 SEC. MINIMUM.
GAS VALVE DE−ENERGIZED.
COMBUSTION AIR INDUCER ON.
INDOOR BLOWER OFF WITH DELAY
LED #1 −− OFF. LED #2 −− SLOW FLASH.
HAS CAB SWITCH CLOSED IN 2.5 MINUTES?
5-MINUTE PRESSURE SWITCH
GAS VALVE POWER OFF.
COMBUSTION AIR INDUCER POWER ON.
INDOOR BLOWER ON
LED #1 −− ON. LED #2 −− SLOW FLASH.
AND MAIN POWER IS INTERRUPTED OR
NO
WATCHGUARD MODE.
Page 33
YES
Page 34
Troubleshooting: Cooling Sequence of Operation
COOLING SEQUENCE OF OPERATION
NORMAL COOLING MODE ABNORMAL COOLING MODE
POWER ON
IGNITION CONTROL MAIN POWER ON.
CONTROL SELF DIAGNOSTIC CHECK.
IS CONTROL OPERATING NORMALLY?
YES
IS THERE A PROPER GROUND?
YES
IS POLARITY CORRECT?
YES
IS VOLTAGE
ABOVE 90 VOLTS?
YES
ROLLOUT SWITCH MONITORED CONTINUOUSLY.
IS ROLLOUT SWITCH CLOSED?
YES
NO
NO
NO
NO
NO
GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.
INDOOR BLOWER OFF WITH NORMAL DELAY.
SIGNAL CIRCUIT BOARD FAILURE AT LED.
INTERRUPT MAIN POWER TO RESET CONTROL.
SIGNAL IMPROPER GROUND AT LED.
CONTROL WILL CONTINUE TO CALL FOR COOLING
IN THIS CONDITION.
SIGNAL POLARITY REVERSED AT LED. CONTROL
WILL CONTINUE TO CALL FOR COOLING IN THIS
CONDITION.
LED SIGNALS LOW VOLTAGE. CONTROL WILL
CONTINUE TO CALL FOR COOLING
IN THIS CONDITION.
GAS VALVE OFF. COMBUSTION AIR INDUCER ON.
INDOOR BLOWER ON.
SIGNAL ROLL-OUT SWITCH OPEN AT LED.
SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES
AND MAIN POWER IS INTERRUPTED OR THERMOSTAT
IS CYCLED OFF/ON FOR 1 SEC. MINIMUM.
LED: SLOW FLASH RATE REMAINS UNCHANGED
THROUGHOUT COOLING CYCLE.
THERMOSTAT CALLS FOR COOLING.
COMPRESSOR CONTACTOR AND SYSTEM FAN
ENERGIZED WITH 2-SECOND DELAY
(COOLING SPEED). EAC TERM. ENERGIZED.
THERMOSTAT OPENS.
COMPRESSOR OFF.
SYSTEM FAN AND EAC TERM. OFF
WITH 45-SECOND DELAY.
Page 34
Page 35
Troubleshooting: Continuous Fan Sequence of Operation
CONTINUOUS HEAT SPEED FAN SEQUENCE OF OPERATION
LED: SLOW FLASH RATE REMAINS
UNCHANGED THROUGHOUT SEQUENCE.
MANUAL FAN SELECTION MADE AT THERMOSTAT.
CONTROL (G) ENERGIZES SYSTEM FAN AT HEAT
SPEED. EAC TERMINAL IS ENERGIZED.
THERMOSTAT CALLS FOR HEAT (W).
NO
THERMOSTAT CALLS FOR COOLING.
YES
SYSTEM FAN SWITCHED TO COOL SPEED.
EAC TERM. REMAINS ON.
THERMOSTAT OPENS.
MANUAL FAN SELECTION MADE AT THERMOSTAT.
CONTROL (G) ENERGIZES SYSTEM FAN AT HEAT
SPEED. EAC TERM. ENERGIZED.
NO
YES
SYSTEM FAN REMAINS ON
HEATING SPEED.
THERMOSTAT OPENS.
HUM TERM. DE−ENERGIZES
WITH COMB. AIR INDUCER
SYSTEM FAN REMAINS ON
HEATING SPEED.
G40DF(X) Start−Up & Performance Check List
Job Name
Job Location
Installer
Unit Model No.
Serial No.
Electrical Connections Tight?
Supply Voltage
Blower Motor Amps
Fuel Type: Natural Gas?
Furnace Btu Input Line Pressure
Regulator Pressure w.c. − Nat.:
Flue Connections Tight?
Combustion Gas Tested? CO
2
Fan Control Setting (45 Seconds Fixed On)
Fan Control Off Setting
Filter Clean & Secure?
Calibrated? Heat Anticipator Properly Set? Level?
Job No.
City
City
Technician
Heating Section
Blower Motor H.P.
Gas Piping Connections Tight & Leak−Tested?
LP/Propane Gas?
w.c. − LP/Propane
Proper Draft?
CO
Temperature Rise
Vent Clear?
Thermostat
HUM TERM. ENERGIZES
WITH COMB. AIR INDUCER.
Date
State
State
Page 35
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