.
2000 Lennox Industries Inc.
Dallas, Texas,USA
503,991M
6/2000
£
G40UH(X)
SERIES
GAS FURNACE
Ifthe informationin thismanual isnot followed
exactly, a fire or explosion may result causing
property damage, personal injury or loss of
life.
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of
this or any other appliance.
Installation and service must be performed by
a qualified installer, service agency or the gas
supplier.
06/00
$
Litho U.S.A.
WARNING
WHAT TO DO IF YOU SMELL GAS:
-
Do not try to light any appliance.
-
Extinguish any open flames.
-
Do not touch any electrical switch; do not use any
phone in your building.
-
Immediatelycallyour gassupplierfroma neighbor’s
phone. Follow the gas supplier’s instructions.
-
Ifyou cannotreach your gassupplier,callthefire department.
503,991M
$!
G40UH(X) Parts Identification
TOP CAP
FLUE
COLLAR
DURALOKTMHEAT
EXCHANGER
ASSEMBLY
COMBUSTION AIR
PROVING
(PRESSURE) SWITCH
COMBUSTION AIR
INDUCER
UPPER ACCESS
PANEL
BURNERS
SURELIGHT
CONTROL BOARD
BLOWER ACCESS
PANEL
Z
Z
CABINET
GAS
VALVE
GAS
MANIFOLD
NAMEPLATE
BLOWER
MOTOR
CONTROL BOX
FIGURE 1
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.(Fiberglasswoolis known tothe Stateof 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
availablefromaddressshownbelow,orcontactyour
supervisor.
Lennox Industries Inc.
P.O. Box 799900
Dallas, TX 75379-9900
NOTE - This manual must be left with the equipment
user.
Page 2
WARNING
Do not set thermostat below 60°F (16°C) in heating
mode. Setting thermostat below 60°F (16°C)reduces
the number of heating cycles. Damage to the unit
may occur that is not covered by the warranty.
WARNING
Ifoverheatingoccursorif gassupplyfailsto shut off,
shutoff themanual g as valveto theappliancebefore
shutting off electrical supply.
CAUTION
Before attempting to perform any service or maintenance, turn the electrical power to unit OFF at the
disconnect switch.
WARNING
Do not use this furnace if any part has been under
water.Immediatelycall aqualified servicetechnician
to inspect the furnace and to replace any part of the
control system and any gas control which has been
under water.
Your furnace is a gas appliance.
supplied to the unit be completely burned to avoid the production of carbon monoxide gas. Complete combustion of
the gas requires, but is not limited to, correct gas pressure
and gas flow rate, adequate combustion, air, and proper
venting.
It is critical that the gas
IMPORTANT
Any additions, changes, or conversions required in
order for the appliance to satisfactorily meet the application needs must be made by a Lennox service
technician using factory specified and approved
parts.
WARNING
Improperinstallation,adjustment,alteration,service
ormaintenancecancausepropertydamage,personal injury or loss of life. Installation and service must
be performed by a qualified installer, service agency
or the gas supplier.
Important Directions
1 - Keep the furnace area clear and free of combustible
material, gasoline, and other flammable vapors and
liquids.If itis installedin aninsulatedarea, thefurnace
mustbe keptfree ofinsulatingmaterial.Insulatingmaterial may be combustible.
DO NOT
2-
unobstructed flow of combustion and ventilating air.
DO NOT
3-
or introduce these products into the combustion air.
These products can cause furnace corrosion.
DONOTdraw return air fromaroomwherethisfur-
4-
nace, orany other gas appliance (ie., a water heater),isinstalled.
anegative pressure iscreatedin theroom. If agas 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 thehouse by the
furnace duct system.
The blower door must be securely in place when the
blowerand burners areoperating. Gas fumes, which
could contain carbon monoxide, can be drawn into
the living space resulting in personal injury ordeath.
obstruct air flow to unit. Unit must receive an
store chlorine or fluorine products near unit
Whenreturnairis drawnfromaroom,
WARNING
WARNING
Carbon monoxide gas is invisible, odorless and
toxic.
Exposure to carbon monoxide gas can cause personal injury and even death to all occupants, including pets. Any item
that is powered by or gives off heat from a combustion process (including lawn mowers, automobiles, and fireplaces)
hasthe potentialtoproducecarbon monoxidegas. Because
Lennoxrecommendsthe useof a carbonmonox-
ofthis,
ide detector in your home, even if you do not own gas
appliances.
retail prices. Contact your Lennox dealer for more details
about this investment in your safety.
Yourfurnace isdesigned tomeet standards setby nationalagencies, andto operatesafely whenproperly installed
and maintained. However,the unit’s performance can be
greatly impacted by the individual installation and the operatingenvironment.Itis yourresponsibilitytoensurethat
this appliance is maintained. Proper maintenance is critical for your safety and the satisfactory operation of the
product.
spection and maintenance of this appliance.
yourLennoxdealerfor aninspectionbyaqualifiedserv ice
technician.
Reliable detectors are available at reasonable
Lennox strongly recommends annual in-
Contact
Lighting Information & Operation
WARNING
If you do not follow these instructions exactly, a fire
or explosion may result causing property damage,
personal injury or death.
BEFORE LIGHTING
forgas.Besuretosmell nexttothe floorbecausesomegas
is heavier than air and will settle on the floor.
smell all around the appliance area
Page 3
The gas valv e on the G40UH(X) will be equipped with eitheragas controlknobor lever.U se onlyyour handtoturn
the gas control knob or pus h the gas lever. Never us e
tools. If thek nob or lever will not moveby hand, do not try
torepair it. Calla qualifiedserv ice technician. Force orattempted repair may result in a fire o r explosion.
Placing the G40UH(X) furnace into operation:
G40UH(X) units are equipped with a SureLightZignition
system.Do
not
attempt to manually light burners on these
furnaces. Each time thermostat calls for heat, the burners
will automatically light. The ignitor does not get hot when
thereisno callforheatonunitswiththe SureLightZignition
system.
Operating the Gas Valve (Figures 3, 4 and 5)
STOP
1-
!Read the safety information at the beginningof
this section.
2 - Set the thermostat to the lowest setting. See figure 2.
3 - Turn off all electrical power to the unit.
White Rodgers 36E Series Gas Valve
MANIFOLD
PRESSURE
ADJUSTMENT
SCREW
MANIFOLD
PRESSURE
OUTLET
GAS VALVE SHOWN IN OFF POSITION
FIGURE 3
White Rodgers 36F Series Gas Valve
MANIFOLD
PRESSURE
ADJUSTMENT
SCREW
MANIFOLD
PRESSURE
OUTLET
THERMOSTATS
FIGURE 2
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-
White Rodgers 36E/36F Gas Valve -
valve lev er t o
OFF
.
Honeywell VR8205 G as Valve -
valvecloc kwi se
to
OFF
.D onotforce.Seefigur e
Switch gas
Turn knob on gas
5.
7 - Waitfiveminutes toclear out anygas. If youthen smell
STOP
gas,
! 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.
WhiteRodgers36E/36F Gas Valve-
8-
Switch gasvalvelever toON. See figur e 3 for the White Rodgers 36E
valveandfigure4fort heWhiteRodgers 36Fv alve.
Honeywell VR8205 Gas Valve -
counterclockwise
toON. Do not force.
Turn knob on gas valve
GAS VALVE SHOWN IN OFF POSITION
FIGURE 4
Honeywell VR8205 Series Gas Valve
MANIFOLD
PRESSURE
ADJUSTMENT
SCREW
ON
OFF
GAS VALVE SHOWN IN OFF POSITION
MANIFOLD
PRESSURE
OUTLET
FIGURE 5
9 - Replace the upper access panel.
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 section
“TurningOffGas tothe Unit”andcallyour servicetechnician or gas supplier.
Turning Off Gas to the Unit
1 - Set the thermostat to the lowest setting.
2 - Turn offall electrical power totheunit if service is to be
performed.
3 - Remove the upper access panel.
Page 4
4-
White Rodgers 36E/36F Gas Valve -
valve lev er t o
OFF
.
Honeywell VR8205 G as Valve -
valve clockwis e
5 - Replace the upper access panel.
to
OFF
.Donotforce.
Switch gas
Turn knob on gas
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.
A filter must be in place whenever the unit is operating.
Seasonal Inspections
A qualified service technician should inspect the complete
system each season (heating and cooling). The following
maintenance procedures should only be conducted by a
qualified service technician.
the unit in any way.
Venting System
Do not attempt to service
WARNING
Asphyxiation Hazard
The exhaust vent for this furnace must be securely
connected to the furnace flue collar at all times.
For your safety and to fulfill the terms of the limited
warranty,aqualified servicetechnicianmust annually inspect this furnace and its vent system.
Annually (before heating season) inspect furnace venting
system, vent cap, heat exchanger, and burners for corrosion, deterioration, or deposits of debris. Remove any obstructions.
Inspect the furnace venting system to make sure it is in
place, physically sound, and without holes, corrosion, or
blockage. Vent connector must be in correct position,
sloped upward and be physically sound without holes or
excessive corrosion.
Inspect the furnace return air duct connection to ensure
duct is sealed to the furnace and terminates outside the
space containing the furnace.
Inspect the physical support of the furnace to guarantee
that it is sound without sagging, cracks or gaps around
base and it maintains seal between base and support.
Duringa seasonal check theservice technician willinspect
the indoor blower and the burner flames along with the
venting system.
Blower
Check blowerwheel for anydebris and clean,if necessary.
Blowermotoris pre-lubricatedfor extendedbearinglife. No
further lubrication is needed.
Burner Flame
CAUTION
To ensure proper operation, a qualified technician
should annually check the burner flame.
Service Reminder
CallyourLennoxservice technicianif the unit willnot operate. Before calling, always check the following to be sure
service is required:
1 - Check that electrical disconnect switches are
2 - Check room thermostat for proper setting.
3 - Replace any blown fuses or reset circuit breakers.
4 - Gas valve should beON.
5 - Air filter shouldnot be plugged,whichwilllimit air flow.
6 - Is gas turned on at meter?
7 - Is manual main shut-off valve open?
Record themodel and serialnumber of the furnace. These
numbersareon theunit nameplate, whichis located below
the burners.
Serial Number __________________
Model Number __________________
Safety Precautions
If you discover any of the following, shut down your
unit, and contact a Lennox dealer for an inspection by
a qualified technician.
-
If you repeatedly hear any new or unfamiliar sounds
whileyourunitisoperating,theremaybe aproblem.For
example, poorly performing burners can produce unfamiliar noises.
-
Ifyou smellany unusualodors, your unitmaybeoperating improperly.For example, units can give off unfamiliar odors if components are required to operate in abnormal conditions.
-
Lookforvisiblesigns ofamalfunctioningunit.Examples
includeunusual amounts ofcondensateon windows inside your house, visibly burnt components or unusual
dirt or rust accumulations on the vent pipeor in the unit.
-
If you experience headache, nausea, fatigue, or dizziness, thecause couldbe exposure to carbon monoxide
gas. This is often misdiagnosed as the flu because
symptoms are similar. If you suffer from flu-like symptoms that are exaggerated at home, but seem to subside while you are away from the house, exposure to
carbon monoxide could be the cause.
Your vigilance may pay off in early detection of a problem
before either personal injury or property damage occurs.
Do not hesitate to contact a qualified service technician as
an investment in your well being.
ON.
Page 5
Planned Service
Youshould expectaservicetechnicianto check thefollowing items during an annual inspection. Power to the unit
must be shut off for the service technician’s safety.
Fresh air grilles and louvers
where the furnace is installed) - Must be open and unobstructed to provide combustion air.
(on the unit and in the room
Return air duct
an air seal to the unit.
Operating performance
operationtomonitor properperformanceof theunitand the
vent system.
Combustion gases
compared to the unit specifications.
- Must be properly attached and provide
- Unit must be observed during
-Flue products mustbe analyzed and
Burners
Vent pipe
or sagging pipe, or disconnected joints.
Unit appearance
of water, burnt or damaged wires, or components.
Blower access door
vide a seal between the return air and the room where the
furnace is installed.
- Must be inspected for rust, dirt, or signs of water.
-Mustbe inspected for signsof water,damaged
- Must be inspected for rust, dirt, signs
- Must be properly in place and pro-
Problems detected during the inspection may make it necessary to temporarily shut down the furnaceuntilthe items
can be repaired or replaced.
Pay attention to your furnace.
tweenannualfurnaceinspections thatmay result inunsafe
operation.For instance, itemsinnocently stored next tothe
furnacemay obstruct thecombustionair supply.This could
cause incomplete combustion and the production of carbon monoxide gas.
Situations can arise be-
Page 6
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