Lennox G50DF(X)?24A?045, G50DF(X)?48C?090, G50DF?60C?110, G50DF?60D?135, G50DF(X)?36A?070 Installation Instructions Manual

...

Download

Page 1

INSTALLATION

E 2006 Lennox Industries Inc.

Dallas, Texas, USA

THIS MANUAL MUST BE LEFT WITH THE

HOMEOWNER FOR FUTURE REFERENCE

INSTRUCTIONS

G50DF(X) Series

GAS FURNACE

505,255M 10/2009 Supersedes 05/2009

Table of Contents

G50DF(X) Unit Dimensions 2. . . . . . . . . . . . . . . . . . . . . . .

G50DF(X) Parts Arrangement 3. . . . . . . . . . . . . . . . . . . . .

G50DF(X) Gas Furnace 4. . . . . . . . . . . . . . . . . . . . . . . . . .

Shipping and Packing List 4. . . . . . . . . . . . . . . . . . . . . . . .

Safety Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Use of Furnace as a Construction Heater 5. . . . . . . . . . .

Combustion, Dilution, & Ventilation Air 6. . . . . . . . . . . . .

Downflow Installation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting Equipment 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filters 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Duct System 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Venting 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gas Piping 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unit Start−Up 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gas Pressure Adjustment 25. . . . . . . . . . . . . . . . . . . . . . .

High Altitude Information 26. . . . . . . . . . . . . . . . . . . . . . . .

Other Unit Adjustments 26. . . . . . . . . . . . . . . . . . . . . . . . . .

Blower Performance 27. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair Parts List 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Planned Service 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SureLight SureLight

G50DF(X) Start−Up & Performance Check List 35. . . . . .

Integrated Control Diagnostic Codes 31. . . .

Control Troubleshooting 32. . . . . . . . . . . . . . .

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

505,255M

*P505255M*

Page 2

G50DF(X) Unit Dimensions − inches (mm)

AIR FLOW

FLUE OUTLET

5/8

(16)

(Top)

3−3/4 (95)

5/8 (16)

RETURN AIR

OPENING

19−1/2

(495)

5/8 (16)

TOP VIEW

28−1/2

(724)

19−1/2

(495)

5/8

(16)

5/8

(16)

(1016)

ELECTRICAL INLET

(Either Side)

4−7/8 (124) Right

2−1/4 (57) Left

GAS PIPING INLET

(Either Side)

9−1/4 (235)

3/4

(19)

Supply

Air

3/4

(19)

19−1/4

(489)

Supply

Air

3/4

(19)

FRONT VIEW SIDE VIEW

Model No.

G50DF(X)−24A−045, G50DF(X)−36A−070

G50DF−36B−090 17−1/2 446 16−1/4 413 16 406 6 152 G50DF(X)−48C−090,

G50DF−48C−110, G50DF−60C−110

G50DF−60D−135 24−1/2 622 23−1/4 591 23 584 9−1/2 241

14−1/2 368 13−1/4 337 13 330 4−1/2 114

A B C D

in. mm in. mm in. mm in. mm

21 533 19−1/4 502 19−1/2 495 7−3/4 197

Page 2

Page 3

G50DF(X) Parts Arrangement

Internal Flue

Pipe

Assembly

Blower Motor

Gasket

Blower Assembly

Flue

Chase

Gasket

Transformer

Integrated Ignition

Control Board

Flue Box Gasket

Flue Collector Box

Gasket

Capacitor

Interlock Switch

Gas Valve

Combustion

Air Orifice

Door

Flame

Sensor

Primary

Limit

Burner

Flame Rollout

Switches

Bracket

Heat Exchanger

Ignitor

Combustion Air

Pressure Switch

Combustion Air Inducer

Gas

Orifices

FIGURE 1

Page 3

Ignitor

Manifold

Page 4

G50DF(X) Gas Furnace

The G50DF(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 G50DF(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

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.

Check equipment for shipping damage. If you find any damage, immediately contact the last carrier.

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.

G50DF(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/NFPA 54). 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 National Standard of Canada 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.

This G50DF(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.

Page 4

Page 5

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.

The G50DF(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 G50DF(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.

G50DF(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.

In addition to the requirements outlined previously, the following general recommendations must be considered when installing a G50DF(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.

D When the furnace is installed in an attic or other insu-

lated space, keep insulation away from the furnace.

Page 5

Page 6

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

Combustion, Dilution, & Ventilation Air

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 G50DF(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.

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

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

Page 6

Page 7

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 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.

Page 7

Page 8

CHIMNEY OR

GAS VENT

FURNACE

(Inlet Air from Crawlspace and Outlet Air to Ventilated Attic)

VENTILATION LOUVERS

(Each end of attic)

EQUIPMENT IN CONFINED SPACE

ALL AIR FROM OUTSIDE

OUTLET

AIR

WATER

HEATER

CHIMNEY

OR GAS

VENT

FURNACE

VENTILATION

LOUVERS

(For unheated crawl space)

INLET

AIR

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.

FIGURE 3

EQUIPMENT IN CONFINED SPACE

ALL AIR FROM OUTSIDE

(All Air Through Ventilated Attic)

VENTILATION LOUVERS

(Each end of attic)

OUTLET

AIR

above bottom)

INLET AIR

(Ends 12 in.

FURNACE

CHIMNEY

OR GAS

VENT

CONFINED SPACE

WATER

HEATER

OUTLET AIR

EQUIPMENT IN

ALL AIR FROM

OUTSIDE

FIGURE 4

WATER

HEATER

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

Page 8

Page 9

Downflow Installation

Downflow unit installs in three ways: on non−combustible flooring, on combustible flooring using an additive base, or on a reverse−flow cooling cabinet. Do not drag the unit across the floor.

Installation on Non−Combustible 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

NON−COMBUSTIBLE 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

Front to Rear Side to Side

in. mm in. mm

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.

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

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.

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.

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.

CAUTION

The furnace and additive base shall not be installed directly on carpeting, tile, or other combustible material other than wood flooring.

G50DF(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.

Page 9

Page 10

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).

PLENUM

SECURE FROM

OUTSIDE CABINET

Side View

HEMMED EDGE

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.

FIBERGLASS SEALING

STRIP

(Field Provided)

CABINET SIDE PANEL

FIGURE 7

2 − Fiberglass sealing strips should be used. 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 G50DF(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 − G50DF−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.

Downflow Application Installation Clearances

Top

Left Side

Bottom

Type of Vent

Connector

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.

Type C Type B1

Right Side

FIGURE 9

Page 10

Page 11

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.

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)

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 Filter Size (inches)

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 G50DF(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 Codes 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.

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.

Page 11

Page 12

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 Codes 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 in 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 12

Page 13

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 G50DF(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 G50DF(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 7 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 7 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 13

Page 14

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% (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/NFPA 54).

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%, 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 Code for Canada. If the existing venting system does not meet these requirements, it must be resized.

Page 14

Page 15

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

(feet)

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

(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 15

Page 16

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

(feet)

Lateral

(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 16

Page 17

Vent

Height

(feet)

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

(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

(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 17

Page 18

TABLE 9

Vent Connector Capacity

Type B Double−Wall Vents with Single−Wall Metal Connectors

Serving Two or More Category I Appliances

Vent

Height

(feet)

Connector

Rise

(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

(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 18

Page 19

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)

(25.4)

1−1/4

(31.75)

1−1/2

(38.1)

(50.8)

2−1/2

(63.5)

(76.2)

Internal

Diameter

inches

(mm)

.493

(12.522)95(2.69)

.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)

(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)

(1.84)

120

(3.40)

250

(7.08)

465

(13.17)

950

(26.90)

460

(41.34)

2750

(77.87)

4350

(123.17)

7700

(218.03)

(1.47)

(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)

(1.27)

(2.32)

170

(4.81)

320

(9.06)

660

990

1900

3000

5300

(1.13)

(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

(1.02)

(1.87)

138

(3.91)

260

(7.36)

530

810

1520

2400

4300

(.73)

(1.73)

125

(3.54)

240

(6.80)

490

(13.87)

750

(21.24)

1400

(39.64)

2250

(63.71)

3900

(110.43)

(.88)

(1.61)

118

(3.34)

220

(6.23)

460

(13.03)

690

(19.54)

1300

(36.81)

2050

(58.05)

3700

(104.77)

(.82)

(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)

(.76)

(1.42)

103

(2.92)

195

(5.52)

400

(11.33)

620

(17.56)

1150

(32.56)

1850

(52.38)

3250

(92.03)

Page 19

Page 20

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 20

Page 21

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 G50DF(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.

One 24 volt terminal 24V HUM" is provided on the fur-

nace control board. Any humidifier rated up to 0.5 amp can be connected to this terminal with the common leg of the circuit being connected to the C" terminal of the thermostat terminal block located on the control board.

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.

G50DF(X) and CONDENSING UNIT

(Refer to specific thermostat and outdoor unit.)

Thermostat

THERMOSTAT DESIGNATIONS

G50DF(X)

Furnace

POWER

HEAT

COOLING

INDOOR BLOWER

COMMON

Condensing

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 low speed when there is no cooling or heating demand.

When the G50DF(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 21

Page 22

TYPICAL G50DF(X) FIELD WIRING DIAGRAM

FIELD INSTALLED CLASS II 24V FIELD INSTALLED LINE VOLTAGE

FIGURE 19

SURELIGHT® INTEGRATED CONTROL BOARD

COOL HEAT PARK FAN EAC XFMR LINE HUM 5 Terminals FS 24V HUM

1/4" FEMALE

QUICK

CONNECT

TERMINAL DESIGNATIONS

Blower − Cooling Speed (120VAC) Blower − Heating Speed (120VAC) Unused Blower (Not energized) Continuous Low Blower Speed Accessory Terminal (120VAC) Transformer (120VAC) Input (120VAC) Heat Only Accessory (120VAC) 120 Volt Neutral Flame Sensor Heat Only Accessory (24VAC)

*Factory setting

FIGURE 20

Page 22

Page 23

G50DF(X) Schematic Wiring Diagram

FIGURE 21

Page 23

Page 24

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.

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 instruc-

tions. If you do not smell gas go to next step.

Honeywell VR8205 Series Gas Valve

MANIFOLD

PRESSURE

ADJUSTMENT

SCREW

(under cap)

(With On/Off Switch)

MANIFOLD

PRESSURE

OUTLET

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 G50DF(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:

G50DF(X) units are equipped with an automatic hot surface ignition system. Do not attempt to manually light burners on these furnaces. Each time the thermostat calls for heat, the burners will automatically light. The ignitor does not get hot when there is no call for heat on units with this ignition system.

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.

GAS VALVE ON/OFF SWITCH SHOWN IN OFF POSITION

FIGURE 22

Honeywell VR8205 Series Gas Valve

with Gas Control Knob

MANIFOLD PRESSURE

ADJUSTMENT

SCREW

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

Page 24

Page 25

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.

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 ignitor en-

ergizes.

After a 20 second ignitor 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 automatically 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.

Page 25

Page 26

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.

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 switches are factory−set and require no adjustment. The factory−installed pressure switch is acceptable for use with 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

Heating Mode −− The fan on delay of 45 seconds is not adjustable. The fan off delay (amount of time that the blower operates after the heat demand has been satisfied) may be adjusted by setting S1 switches 1 and 2 located 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 20. Cooling Mode −− The cooling mode fan off delay (amount

of time that the blower operates after the cooling demand has been satisfied) may be adjusted by setting S1 switch 3 located on the integrated control. In the off position, the cooling fan off delay is 2 seconds. In the on position, the cooling fan off delay is 45 seconds. See figure 20.

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 performance data Page 27.

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.

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.

G50DF−24A−045 PERFORMANCE

External

Static

Pressure

in. w.g.

0.00 1200 417 1060 367 830 278

0.05 1185 410 1040 360 820 274

0.10 1165 402 1025 353 810 270

0.15 1145 396 1010 346 795 265

0.20 1125 390 990 338 775 260

0.25 1105 382 980 335 765 257

0.30 1080 374 965 331 750 254

0.40 1020 357 920 319 710 244

0.50 960 342 875 306 650 234

0.60 900 330 810 290 620 231

0.70 815 313 690 272 565 221

0.80 685 289 620 259 465 203

0.90 560 271 510 238 395 190

Air Volume / Watts at Different Blower Speeds

High Medium Low

cfm Watts cfm Watts cfm Watts

G50DF−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

0.20 1375 574 1255 510 1105 437 965 381

0.25 1345

0.30

0.40 1250 528 1150 455 1040 395 920 346

0.50 1200

0.60

0.70 1030 455 970 390 855 338 720 280

0.80 960 434 875 359 735 299 665 266

0.90

Air Volume / Watts at Different Blower Speeds

High

cfm Watts cfm Watts cfm Watts cfm Watts

1475 616 1345 554 1150 495 990 415

1395 585 1275 521 1115 452 970 390

1320 552 1205 478 1075 418 945 360

1110 475 1035 409 950 354 830 313

770 389 715 321 665 278 590 244

Medium−

High

595 1300 532 1125 466 975 398

563 1230 494 1090 428 955 371

508 1095 432 1000 374 880 331

Medium−

Low

G50DF−36B−090 PERFORMANCE

External

Static

Pressure

in. w.g.

0.00

0.05 1580 599 1400 518 1165 428 965 351

0.10 1560 589 1390 509 1160 420 970 346

0.15 1530 573 1370 497 1155 413 965 341

0.20 1495 556 1350 485 1150 406 965 335

0.25 1465 544 1325 473 1135 398 955 329

0.30 1430 532 1300 460 1125 389 945 323

0.40 1370 509 1250 438 1095 373 935 313

0.50 1295 482 1200 420 1055 355 900 302

0.60 1215 456 1140 397 1010 343 860 285

0.70 1140 437 1055 371 915 313 800 272

0.80 1000 401 950 342 850 295 730 251

0.90 900 374 820 313 740 272 − − − − − −

Air Volume / Watts at Different Blower Speeds

High

cfm Watts cfm Watts cfm Watts cfm Watts

1600 608 1410 526 1165 436 965 355

Medium−

High

Medium−

Low

G50DF−48C−090 PERFORMANCE

External

Static

Pressure

in. w.g.

0.00

0.05 2000 727 1825 638 1575 547 1340 460

0.10 1955 704 1800 619 1555 532 1350 453

0.15 1920 692 1770 602 1540 518 1340 441

0.20 1885 679 1740 585 1525 503 1330 428

0.25 1845 662 1700 568 1500 488 1300 414

0.30 1800 645 1665 551 1475 473 1270 399

0.40 1695 606 1585 517 1415 448 1225 378

0.50 1600 570 1490 485 1335 414 1170 360

0.60 1495 540 1405 457 1250 389 1110 337

0.70 1380 509 1300 426 1165 367 1025 316

0.80 1250 478 1160 390 1025 331 − − − − − −

0.90 1095 439 1030 360 925 307 − − − − − −

Air Volume / Watts at Different Blower Speeds

High

cfm Watts cfm Watts cfm Watts cfm Watts

2040 749 1850 657 1595 562 1325 466

Medium−

High

Medium−

Low

Page 27

Page 28

Blower Performance

G50DF−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

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 502 1065 406 955 348 815 296

0.90 1010

G50DF−60C−110 PERFORMANCE

External

Static

Pressure

in. w.g.

.00 2475 1276 2280 987 1995 845 1690 698

.10 2390 1248 2235 955 1990 829 1675 690

.20 2330 1223 2180 945 1975 809 1665 675

.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 2020 1129 1880 815 1750 695 1580 599

.70 1920 1094 1775 785 1660 669 1525 579

.80 1785

.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

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

Air Volume / Watts at Different Blower Speeds

High

cfm Watts cfm Watts cfm Watts cfm Watts

Medium−

High

803 1730 675 1475 567 1220 463

736 1655 618 1440 528 1200 437

630 1445 524 1280 447 1065 371

472 930 372 840 320 690 265

Medium−

High

1052 1685 762 1585 645 1440 556

Medium−

Low

Medium−

Low

G50DF−60D−135 PERFORMANCE

External

Static

Pressure

in. w.g. cfm Watts cfm Watts cfm Watts cfm Watts

.00

.10 2560 1353 2310 1030 1945 840 1640 667

.20 2490 1325 2280 1000 1940 824 1630 661

.30

.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 1112 1865 828 1680 683 1515 584

.90 1865 1096 1760 797 1605 656 1465 567

Air Volume / Watts at Different Blower Speeds

High

2660 1379 2325 1059 1960 864 1655 684

2415 1293 2225 972 1930 801 1625 649

Medium−

High

Medium−

Low

Page 28

Page 29

Electronic Ignition

The SureLight® integrated 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.

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.

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.

WARNING

Filters

All G50DF(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.

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 25.

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. 6 − Label and disconnect the pressure switch wires. 7 −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 26.

Page 29

Page 30

G50DF(X) Internal Flue Pipe and Chase

Unit Top Cap

Internal Flue

with Adaptor

Screw (1)

Internal

Flue Pipe

RTV Silicone Sealant

Pipe

Flue Chase

with Gaskets

Combustion

Air Inducer

FIGURE 25

G50DF(X) CAI & Burner Box Removal

Heat Exchanger

Combustion

Air Inducer

Burner Box Assembly

FIGURE 26

8 −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.

9 −Label the wires from gas valve and rollout switches,

then disconnect them.

10 −Disconnect gas supply piping. Remove four screws

securing the burner manifold assembly to the vestibule panel and remove the assembly from the unit.

11 −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 27.

INSERTS

(X models only)

NOx INSERT

FIGURE 27

12 −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. 13 −Repeat procedure for each heat exchanger section. 14 −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. 15 −Remove the cable from the heat exchanger. Use a

vacuum cleaner to remove debris knocked loose dur-

ing cleaning. 16 −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. 17 −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. 18 −To clean the burner, run a vacuum cleaner with a soft

brush attachment over the face of burners. Inspect in-

side the burners and crossovers for any blockage.

Clean the inside of the burner if necessary. 19 −NOx Units − Reattach the NOx inserts to the corbels at

the entrance to each heat exchanger opening. See fig-

ure 27. 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.

Page 30

Page 31

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.

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.

CAUTION

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: G50DF(X)−24A−045−9. 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 SureLight® integrated 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 Ignitor Primary limit control Flame rollout switches Secondary limit Combustion Air Inducer Gaskets Flue Box Gaskets Flue Chase Gasket Set

Internal Flue Pipe Assembly

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.

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.

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.

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.

Page 31

Page 32

SureLight® Integrated Control Diagnostic Codes

DIAGNOSTIC CODES

Make sure to Identify LED’S Correctly.

Refer to figure 20 for control board layout.

LED #1 LED #2 DESCRIPTION

SIMULTANEOUS

SLOW FLASH

SIMULTANEOUS

FAST FLASH

SLOW FLASH ON

OFF SLOW FLASH

ALTERNATING

SLOW FLASH

SLOW FLASH OFF Flame sensed without gas valve energized.

ON SLOW FLASH Rollout switch open.

ON ON

OFF

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

SLOW FLASH FAST FLASH Low flame signal. Measures below .31 microAmps. Replace flame sense rod.

ALTERNATING

FAST FLASH

NOTE − Slow flash rate equals 1 Hz (one flash per second). Fast flash rate equals 3 Hz (three flashes per second). Drop out = 0.24 microAmps or below.

SIMULTANEOUS

SLOW FLASH

SIMULTANEOUS

FAST FLASH

ALTERNATING

SLOW FLASH

OFF

ALTERNATING

FAST FLASH

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

Normal operation − signaled when heating demand initiated at thermostat.

Primary or secondary limit switch open. Limit must close within 3 minutes or unit goes into 1 hour Watchguard.

Pressure switch open or has opened 5 times during a single call for heat; OR: Blocked inlet/exhaust vent; OR: Pressure switch closed prior to activation of combustion air inducer.

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

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

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

1) Improper main ground;

2) Broken ignitor; OR: Open ignitor circuit;

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

Page 32

Page 33

SureLight® Control Troubleshooting: Heating Sequence of Operation

SURELIGHT® CONTROL

HEATING SEQUENCE OF OPERATION

NORMAL HEATING MODE ABNORMAL HEATING MODE

LED#1 AND LED#2 ALTERNATING FAST FLASH. SIGNAL HOLDS UNTIL UNIT IS PROPERLY GROUND.

POWER ON

CONTROL SELF−CHECK OKAY?

IS POLARITY REVERSED?

ROLLOUT SWITCH CLOSED?

IS THERE

PROPER GROUND?

YES

GAS VALVE

DE−ENERGIZED?

YES

NORMAL OPERATION:

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

YES

IS VOLTAGE

ABOVE 75 VOLTS?

YES

GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

(RESET CONTROL BY TURNING MAIN POWER OFF.)

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF WITH DELAY.

LED #1 −− ON. LED #2 −− SLOW FLASH.

SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES.

INDOOR BLOWER ON.

LED #1 ALTERNATING FAST FLASH

LED#2 ALTERNATING FAST FLASH

CHECK FOR BROKEN IGNITOR OR

OPEN IGNITOR CIRCUIT

INDOOR BLOWER DELAY OFF.

LED #1 ON LED #2 ON

POLARITY REVERSED.

LED #1 −− FAST FLASH

LED #2 −− SLOW FLASH

LED#1 AND LED#2 ALTERNATING FAST

FLASH. SIGNAL HOLDS UNTIL VOLTAGE

RISES ABOVE 75 VOLTS.

THERMOSTAT CALLS FOR HEAT:

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

YES

IS COMBUSTION AIR

PRESSURE SWITCH OPEN?

YES

IS COMBUSTION AIR INDUCER ENERGIZED?

(HUM TERMINAL IS ENERGIZED WITH C.A.I.)

YES

HAS COMBUSTION AIR PRESSURE

SWITCH CLOSED IN 2.5 MINUTES?

YES

15-SECOND COMBUSTION AIR INDUCER PREPURGE

INITIATED BY CLOSED PRESSURE SWITCH.

YES

CONTINUED NEXT PAGE

PRESSURE SWITCH IS IN WATCHGUARD MODE.

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

IS 5-MINUTE RESET PERIOD COMPLETE?

COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF WITH DELAY.

(Sequence holds until pressure switch

closes or thermostat resets control.)

INDOOR BLOWER OFF WITH DELAY.

LED #1 −− OFF. LED #2 −− SLOW FLASH.

GAS VALVE OFF.

LED #1 OFF

LED #2 SLOW FLASH

Page 33

Page 34

SureLight® Control Troubleshooting: Heating Sequence of Operation (Continued)

NORMAL HEATING MODE ABNORMAL HEATING MODE

15-SECOND COMBUSTION AIR INDUCER PREPURGE

INITIATED BY CLOSED PRESSURE SWITCH.

YES

IGNITOR WARM-UP −− 20 SECONDS.

YES

4-SECOND TRIAL FOR IGNITION.

GAS VALVE OPENS. IGNITOR 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?

(u0.24 microamps)

YES

FLAME PRESENT?

YES

FLAME SIGNAL ABOVE 0.31 MICROAMPS?

YES

INDOOR BLOWER ON DELAY BEGINS

(45 seconds.)

YES

PRIMARY AND SECONDARY LIMIT

SWITCHES CLOSED?

YES

IS VOLTAGE ABOVE 75 VOLTS?

IS THERE A PROPER GROUND?

YES

IS IGNITOR INTACT AND CONNECTED?

GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

HAS CONTROL FAILED TO SENSE FLAME FOR

FIVE CONSECUTIVE TRIES DURING A SINGLE

IGNITION WATCHGUARD MODE. GAS VALVE OFF.

LED 1 ALT. SLOW FLASH LED 2 ALT SLOW FLASH

IS 60-MINUTE RESET PERIOD COMPLETE?

(Does not affect operation of control)

GAS VALVE DE−ENERGIZED. COMBUSTION AIR INDUCER

DE−ENERGIZED.INDOOR BLOWER

ON UNTIL SWITCH CLOSES.LED #1

−− SLOW FLASH. LED #2 −− ON. IS LIMIT SWITCH CLOSED?

HAS PRIMARY/SECONDARY LIMIT

YES

INDOOR BLOWER OFF.

HEAT DEMAND?

COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF WITH DELAY

HAS CONTROL RESET IGNITION

SEQUENCE FOUR TIMES?

LOW FLAME SIGNAL

LED #1 −− SLOW FLASH

LED #2 −− FAST FLASH

YES

RESET (CLOSED) WITHIN 3

MINUTES?

LEDS SIGNAL ALTERNATING

FAST FLASH

YES

LIMIT SWITCH WATCH-

GUARD MODE. GAS

VALVE OFF. COMB. AIR

INDUCER OFF. INDOOR

BLOWER OFF WITH

DELAY. LED#1−SLOW

FLASH LED#2 − ON. IS

60MINUTE RESET

PERIOD COMPLETE?

YES

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.

LED #1 −− OFF. LED #2 −− SLOW FLASH.

HAS CAB SWITCH CLOSED IN 2.5 MINUTES?

COMBUSTION AIR INDUCER POWER OFF.

SEQUENCE HOLDS UNTIL ROLLOUT SWITCH IS RESET

GAS VALVE DE−ENERGIZED.

COMBUSTION AIR INDUCER ON.

INDOOR BLOWER OFF WITH DELAY

5-MINUTE PRESSURE SWITCH

WATCHGUARD MODE.

GAS VALVE POWER OFF.

INDOOR BLOWER OFF WITH DELAY

LED #1 −− ON. LED #2 −− SLOW FLASH.

Page 34

YES

Page 35

SureLight® Control Troubleshooting: Cooling Sequence of Operation

SURELIGHT® CONTROL

COOLING SEQUENCE OF OPERATION

NORMAL COOLING MODE ABNORMAL COOLING MODE

POWER ON

IGNITION CONTROL MAIN POWER ON.

LED#1 AND LED#2 ALTERNATING FAST FLASH. SIGNAL HOLDS UNTIL UNIT IS PROPERLY GROUND.

ROLLOUT SWITCH MONITORED CONTINUOUSLY.

CHECK TO ENSURE GAS VALVE IS DE−ENERGIZED.

LED: SLOW FLASH RATE REMAINS UNCHANGED

CONTROL SELF DIAGNOSTIC CHECK.

IS CONTROL OPERATING NORMALLY?

YES

IS POLARITY REVERSED?

IS ROLLOUT SWITCH CLOSED?

THROUGHOUT COOLING CYCLE.

THERMOSTAT CALLS FOR COOLING.

IS THERE

PROPER GROUND?

YES

IS GAS VALVE OFF?

YES

IS VOLTAGE

ABOVE 75 VOLTS?

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF WITH NORMAL DELAY.

SIGNAL CIRCUIT BOARD FAILURE AT LED.

INTERRUPT MAIN POWER TO RESET CONTROL.

LED#1 FAST FLASH LED#2 SLOW FLASH

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF WITH NORMAL DELAY.

SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES.

LED#1 AND LED#2 ALTERNATING FAST

FLASH. SIGNAL HOLDS UNTIL VOLTAGE

RISES ABOVE 75 VOLTS.

SIGNAL CIRCUIT BOARD FAILURE AT LED.

COMPRESSOR CONTACTOR IS ENERGIZED.

INDOOR BLOWER ON COOL SPEED AND EAC

TERMINAL IS ENERGIZED AFTER 2-SECOND DELAY.

THERMOSTAT OPENS.

COMPRESSOR OFF.

SYSTEM FAN AND EAC TERM. OFF

WITH 2 OR 45-SECOND DELAY.

Page 35

Page 36

SureLight® Control Troubleshooting: Continuous Fan Sequence of Operation

SURELIGHT® CONTROL

CONTINUOUS FAN SEQUENCE OF OPERATION

LED: SLOW FLASH RATE REMAINS

UNCHANGED THROUGHOUT SEQUENCE.

MANUAL FAN SELECTION MADE AT THERMOSTAT.

CONTROL (G) ENERGIZES INDOOR BLOWER AT

FAN SPEED. EAC TERM. IS ENERGIZED.

THERMOSTAT CALLS FOR HEAT (W).

THERMOSTAT CALLS FOR COOLING.

YES

INDOOR BLOWER SWITCHES TO COOL SPEED.

THERMOSTAT OPENS.

INDOOR BLOWER SWITCHES TO FAN

SPEED. EAC TERM. REMAINS ENERGIZED.

YES

INDOOR BLOWER SWITCHES TO HEAT SPEED

AFTER NORMAL DELAY.

THERMOSTAT OPENS. COMBUSTION AIR INDUCER

AND HUM TERMINAL ARE DE−ENERGIZED.

INDOOR BLOWER SELECTED TIME OFF DELAY BEGINS.

AFTER DELAY HEAT SPEED DE−ENERGIZED.

(blower remains energized during continuous fan mode).

HUM TERM. ENERGIZES

WITH COMB. AIR INDUCER.

G50DF(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

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?

Temperature Rise

Vent Clear?

Thermostat

Date State State

Page 36

Lennox G50DF(X)?24A?045, G50DF(X)?48C?090, G50DF?60C?110, G50DF?60D?135, G50DF(X)?36A?070 Installation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual