Lennox G51MP-24B-045, G51MP-36C-090, G51MP-36B-045, G51MP-36B-070, G51MP-48C-090 Installation Instructions Manual
...Page 1
INSTALLATION
E 2005 Lennox Industries Inc.
Dallas, Texas, USA
THIS MANUAL MUST BE LEFT WITH THE
HOMEOWNER FOR FUTURE REFERENCE
INSTRUCTIONS
G51MP SERIES UNITS
GAS UNITS
505,065M
05/2009
Supersedes 07/2007
Table of Contents
Unit Dimensions 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G51MP Parts Identification 3. . . . . . . . . . . . . . . . . . . . . .
Shipping and Packing List 4. . . . . . . . . . . . . . . . . . . . . .
Safety Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Use of Furnace as a Construction Heater 5. . . . . . . . .
General 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Combustion, Dilution & Ventilation Air 6. . . . . . . . . . . .
Installation − Setting Equipment 9. . . . . . . . . . . . . . . . . .
Filters 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Duct System 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pipe & Fittings Specifications 16. . . . . . . . . . . . . . . . . . . .
Vent Piping Guidelines 18. . . . . . . . . . . . . . . . . . . . . . . . .
Joint Cementing Procedure 19. . . . . . . . . . . . . . . . . . . . .
Venting Practices 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas Piping 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Start−Up 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas Pressure Adjustment 39. . . . . . . . . . . . . . . . . . . . . .
High Altitude Information 41. . . . . . . . . . . . . . . . . . . . . . .
Other Unit Adjustments 43. . . . . . . . . . . . . . . . . . . . . . . . .
Service 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Planned Service 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Parts List 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Control Board Diagnostic Codes 52. . . . . . . . . .
Vent Pipe Sizing Worksheet 53. . . . . . . . . . . . . . . . . . . . .
Start−Up & Performance Check List 53. . . . . . . . . . . . . .
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.
05/09
*2P0509*
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
505,065M
*P505065M*
Page 2
G51MP Unit Dimensions − inches (mm)
*NOTE − 60C and 60D size units installed in upflow applications that require air volumes over 1800 cfm (850 L/s) must
have one of the following:
1. Single side return air with transition, to accommodate
20 x 25 x 1 in. (508 x 635 x 25 mm) air filter.
Required to maintain proper air velocity.
2. Single side return air with optional RAB Return Air Base
3. Bottom return air.
4. Return air from both sides.
5. Bottom and
Refer to Engineering Handbook for additional information.
**Consider sizing requirements for optional IAQ equipment
before cutting side return opening.
1
Optional External Side Return Air Filter Kit is not for use
with the optional RAB Return Air Base.
3/4 (19)
one side return air.
A
B 9/16 (14)
11−5/8 (295)
Right
1
OPTIONAL
EXTERNAL
SIDE RETURN
AIR FILTER KIT
(Either Side)
9−3/4 (248)
Left
40
(1016)
14−3/4
(375)
16
(406)
AIR FLOW
5/8 (16)
C
*Bottom Return
Air Opening
3/4 (19)
FRONT VIEW SIDE VIEW
1
OPTIONAL
EXTERNAL
SIDE RETURN
AIR FILTER KIT
(Either Side)
5−1/2
(140)
6−1/2
(165)
4−1/8
(103)
6−3/4
(171)
4−7/8 (124) Right
2−1/4 (57) Left
2−1/2
(64)
18-3/4 (476)
6−1/2
(165)
3−1/8
(79)
4
(102)
4−1/4
(108)
SUPPLY AIR
OPENING
23-3/4 (603)
25 (635)
TOP VIEW
28−1/2
(724)
19−7/16
(378)
COMBUSTION AIR INTAKE
(Either Side)
EXHAUST AIR OUTLET
(Either Side)
GAS PIPING INLET
(Either Side)
CONDENSATE
TRAP CONNECTION
(Either Side)
ELECTRICAL INLET
(Either Side)
23
(584)
*OPTIONAL
RETURN CUTOUT
(Either Side)
1−15/16 (49)
23−1/2
(597)
*Bottom Return
Air Opening
9/16
(14)
14**
(356)
Model No.
G51MP−24B−045
G51MP−36B−045
G51MP−36B−070
G51MP−36C−090
G51MP−48C−090
G51MP−60C−090
G51MP−48C−110
G51MP−60C−110
G51MP−60D−135 24−1/2 622 23−3/8 546 23 584
in. mm in. mm in. mm
17−1/2 446 16−3/8 416 16 406
21 533 19−7/8 504 19−1/2 495
A B C
Page 2
Page 3
G51MP Parts Arrangement
G51MP PARTS IDENTIFICATION
TOP CAP
BURNER BOX
ASSEMBLY
GAS VALVE
AND MANIFOLD
FLUE
COLLAR
COMBUSTION
AIR PRESSURE
PROVE SWITCHES
COMBUSTION AIR
INDUCER
DuralokPlus
HEAT EXCHANGER
ASSEMBLY
TM
CABINET
WARM HEADER
(COLLECTOR)
BOX
CONDENSER COIL
BURNER
ACCESS
PANEL
BLOWER
ACCESS
DOOR
SIGHT
GLASS
INTERLOCK
DOOR
SWITCH
PRIMARY LIMIT
COLD HEADER
(COLLECTOR)
BOX
SECONDARY
LIMITS (2)
BLOWER
ASSEMBLY
CONTROL BOX
FIGURE 1
Page 3
Page 4
G51MP Gas Furnace
The G51MP Category IV gas furnace is shipped ready for
installation in the upflow, downflow, horizontal left air discharge or horizontal right air discharge position. The furnace is shipped with the bottom panel in place. The bottom panel must be removed if the unit is to be installed in
upflow applications with bottom return air. The bottom
panel must also be removed and discarded in all downflow
or horizontal applications.
The furnace is equipped for installation in natural gas applications. A conversion kit (ordered separately) is required for use in propane/LP gas applications.
The G51MP can be installed as either a Direct Vent or a
Non−Direct Vent gas central furnace.
NOTE − In Direct Vent installations, combustion air is taken
from outdoors and flue gases are discharged outdoors. In
Non−Direct Vent installations, combustion air is taken from
indoors and flue gases are discharged outdoors. See figure
2 for applications involving roof termination.
DIRECT VENT INSTALLATION NON−DIRECT VENT
COMBUSTION
AIR INTAKE
OUTSIDE OF
HOUSE
EXHAUST
OUTLET
INSTALLATION
EXHAUST
OUTLET
NOTE − G51MP−48C−110 and G51MP−60C−110 units also
include a 2" diameter PVC street elbow, which is shipped
on the blower deck in the heating compartment.
G51MP−60D−135 units are shipped with a 3" to 2" PVC reducing elbow.
Canadian Installations Only − Replace the provided 2"
street elbow shipped with the G51MP−48C−110 and
G51MP−60C−110 units with 2" street elbow Y0162. Replace the provided 3" X 2" reducing elbow shipped with the
G51MP−60D−135 units with 3" X 2" reducing elbow 40W22.
Y0162 and 40W22 meet B149 vent requirements.
Check equipment for shipping damage. If you find any
damage, immediately contact the last carrier.
The following items may also 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.
AIR INTAKE INSIDE
G51MP
CONDENSATE
DRAIN
FIGURE 2
Shipping and Packing List
Package 1 of 1 contains
1 − Assembled G51MP unit
1 − Bag assembly containing the following:
3 − Screws
3 − Wire nuts
1 − Snap bushing
1 − Snap plug
1 − Wire tie
1 − Condensate trap
1 − Condensate trap cap
2 − 2" diameter vent / intake plugs
1 − 3" diameter cabinet plug (intake)
1 − 2" diameter debris screen
COMBUSTION
OF HOUSE
G51MP
CONDENSATE
DRAIN
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.
Use only the type of gas approved for use with this furnace.
Refer to unit nameplate.
G51MP units are CSA International certified to ANSI
Z21.47 and CSA 2.3 standards.
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
Page 4
Page 5
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.
In order to ensure proper unit operation in non−direct vent
applications, combustion and ventilation air supply must be
provided according to the current National Fuel Gas Code
or CSA-B149 standard.
This furnace is CSA International certified for installation
clearances to combustible material as listed on the unit
nameplate and in the tables in figures 8, 13 and 17. Accessibility and service clearances must take precedence over fire
protection clearances.
NOTE − For installation on combustible floors, the furnace
shall not be installed directly on carpeting, tile, or other
combustible material other than wood flooring.
For installation in a residential garage, the furnace must
be installed so that the burner(s) and the ignition source
are located no less than 18 inches (457 mm) above the
floor. The furnace must be located or protected to avoid
physical damage by vehicles. When a furnace is installed
in a public garage, hangar, or other building that has a hazardous atmosphere, the furnace must be installed according to recommended good practice requirements and current National Fuel Gas Code or CSA B149 standards.
NOTE − Furnace must be adjusted to obtain a temperature
rise within the range specified on the unit nameplate. Failure
to do so may cause erratic limit operation and premature heat
exchanger failure.
This G51MP furnace may be used as a high−static unit
heater. The G51MP may also be installed in an aircraft hangar in accordance with the Standard for Aircraft Hangars
(ANSI/NFPA No. 408−1990).
Installation in parking structures must be in accordance
with the Standard for Parking Structures (ANSI/NFPA No.
88A−1991). Installation in repair garages must be in accordance with the Standard for Repair Garages (ANSI/NFPA
No. 88B−1991).
This G51MP 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.
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 an intermittent operation down to 55°F (13°C) dry bulb for cases
where a night setback thermostat is used. Return air temperature must not exceed 85°F (29°C) dry bulb.
The G51MP furnace may be installed in alcoves, closets,
attics, basements, garages, and utility rooms.
This furnace design has not been CSA certified for installation in mobile homes, recreational vehicles, or outdoors.
Never use an open flame to test for gas leaks. Check all
connections using a commercially available soap solution
made specifically for leak detection.
Use of Furnace as Construction Heater
Lennox does not recommend the use of G51MP 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.
G51MP 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.
Page 5
Page 6
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.
CAUTION
G51MP unit should not be installed in areas normally
subject to freezing temperatures.
Combustion, Dilution & Ventilation Air
If the G51MP is installed as a Non−Direct Vent Furnace, follow the guidelines in this section.
NOTE − In Non−Direct Vent installations, combustion air
is taken from indoors and flue gases are discharged out−
doors.
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 G51MP furnace:
• Place the furnace as close to the center of the air distribution system as possible. The furnace should also be
located close to the chimney or vent termination point.
• When the furnace is installed in non−direct vent applications, do not install the furnace where drafts might blow
directly into it. This could cause improper combustion
and unsafe operation.
• When the furnace is installed in non−direct vent applications, do not block the furnace combustion air opening
with clothing, boxes, doors, etc. Air is needed for proper
combustion and safe unit operation.
• When the furnace is installed in an attic or other insulated space, keep insulation away from the furnace.
• When the furnace is installed in an unconditioned
space, consider provisions required to prevent freezing
of condensate drain system.
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
WARNING
Insufficient combustion air can cause headaches,
nausea, dizziness or asphyxiation. It will also cause
excess water in the heat exchanger resulting in rusting and premature heat exchanger failure. Excessive
exposure to contaminated combustion air will result
in safety and performance related problems. Avoid
exposure to the following substances in the combustion air supply:
Permanent wave solutions
Chlorinated waxes and cleaners
Chlorine base swimming pool chemicals
Water softening chemicals
De−icing salts or chemicals
Carbon tetrachloride
Halogen type refrigerants
Cleaning solvents (such as perchloroethylene)
Printing inks, paint removers, varnishes, etc.
Hydrochloric acid
Cements and glues
Antistatic fabric softeners for clothes dryers
Masonry acid washing materials
In the past, there was no problem in bringing in sufficient
outdoor air for combustion. Infiltration provided all the air
that was needed. In today’s homes, tight construction
practices make it necessary to bring in air from outside
for combustion. Take into account that exhaust fans, appliance vents, chimneys, and fireplaces force additional
air that could be used for combustion out of the house.
Unless outside air is brought into the house for combustion, negative pressure (outside pressure is greater than
inside pressure) will build to the point that a downdraft
can occur in the furnace vent pipe or chimney. As a result,
combustion gases enter the living space creating a potentially dangerous situation.
Page 6
Page 7
In the absence of local codes concerning air for combus−
tion and ventilation, use the guidelines and procedures in
this section to install G51MP furnaces to ensure efficient
and safe operation. You must consider combustion air
needs and requirements for exhaust vents and gas piping. A portion of this information has been reprinted with
permission from the National Fuel Gas Code (ANSI−
Z223.1/NFPA 54). This reprinted material is not the complete and official position of the ANSI on the referenced
subject, which is represented only by the standard in its
entirety.
In Canada, refer to the CSA B149 installation codes.
CAUTION
Do not install the furnace in a corrosive or contaminated atmosphere. Meet all combustion and ventilation air requirements, as well as all local codes.
All gas-fired appliances require air for the combustion process. If sufficient combustion air is not available, the furnace or other appliance 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 required 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.
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 com−
bined 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.
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
(64516 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 3.
EQUIPMENT IN CONFINED SPACE − ALL AIR FROM INSIDE
ROOF TERMINATED
EXHAUST PIPE
Unconfined Space
An unconfined space is an area such as a basement or
large equipment room with a volume greater than 50 cubic
feet (1.42 m3) per 1,000 Btu (.29 kW) per hour of the combined input rating of all appliances installed in that space.
This space also includes adjacent rooms which are not
separated by a door. Though an area may appear to be unconfined, it might be necessary to bring in outdoor air for
combustion if the structure does not provide enough air by
infiltration. If the furnace is located in a building of tight
Page 7
OPENINGS
SIDE WALL
TERMINATED EX-
HAUST PIPE (ALTER-
NATE LOCATION)
NOTE − Each opening shall have a free area of at least one square
inch per 1,000 Btu (645mm
rating of all equipment in the enclosure, but not less than 100 square
inches (64516mm.
G51MP
2
2).
(To Adjacent
Unconfined
Space)
per .29kW) per hour of the total input
FIGURE 3
Page 8
Air from Outside
If air from outside is brought in for combustion and ventilation, the confined space shall be provided with two
permanent openings. One opening shall be within 12"
(305mm) of the top of the enclosure and one within 12"
(305mm) 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 per 4,000 Btu
(645mm2 per 1.17kW) per hour of total input rating of all
equipment in the enclosure. When communicating with
the outdoors through horizontal ducts, each opening shall
have a minimum free area of 1 square inch per 2,000 Btu
(645mm2 per .59kW) per total input rating of all equipment
in the enclosure (See figure 4).
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.
EQUIPMENT IN CONFINED SPACE − ALL AIR FROM OUTSIDE
(All Air Through Ventilated Attic)
EQUIPMENT IN CONFINED SPACE − ALL AIR FROM OUTSIDE
(Inlet Air from Crawl Space and Outlet Air to Ventilated Attic)
VENTILATION LOUVERS
OUTLET
AIR
(Each end of attic)
VENTILATION
LOUVERS
(For unheated
crawl space)
2
per 1.17kW) per
ROOF TERMINATED
EXHAUST PIPE
SIDE WALL
TERMINATED
EXHAUST PIPE
(ALTERNATE
LOCATION)
G51MP
INLET
AIR
NOTE−The inlet and outlet air openings shall each have a free area
of at least one square inch per 4,000 Btu (645mm
hour of the total input rating of all equipment in the enclosure.
FIGURE 4
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 4 and 5. 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 6.
ROOF TERMINATED
EXHAUST PIPE
OUTLET
AIR
SIDE WALL
TERMINATED
EXHAUST PIPE
(ALTERNATE
LOCATION)
G51MP
NOTE−The inlet and outlet air openings shall each have a free area of
at least one square inch per 4,000 Btu (645mm
VENTILATION LOUVERS
(Each end of attic)
INLET AIR
(Ends 12" above
bottom)
2
per 1.17kW) per hour
of the total input rating of all equipment in the enclosure.
FIGURE 5
EQUIPMENT IN CONFINED SPACE −
ALL AIR FROM OUTSIDE
ROOF TERMINATED
EXHAUST PIPE
OUTLET AIR
SIDE WALL
TERMINATED
EXHAUST PIPE
(ALTERNATE
LOCATION)
NOTE−Each air duct opening shall have a free area of at least one
square inch per 2,000 Btu (645mm
G51MP
2
per .59kW) per hour of the total
INLET AIR
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 1 square inch per 4,000 Btu (645mm
2
per 1.17kW) per
hour of the total input rating of all other equipment in the enclosure.
FIGURE 6
Page 8
Page 9
Installation − 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.
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,
condensate trap and drain connections, and installation
and service clearances [24 inches (610 mm) at unit
front]. The unit must be level from front to back and side
to side. The unit may be tilted slightly (maximum 1/2 in.)
from back to front to aid in the draining of the heat exchanger. See figure 7.
SETTING EQUIPMENT
UPFLOW APPLICATION DOWNFLOW APPLICATION
UNIT MUST BE LEVEL SIDE−TO−SIDE IN ALL APPLICATIONS.
HORIZONTAL APPLICATION
NOTE − 1/3 hp blower motors are equipped with four flexible mounting legs, and 1/2 hp blower motors are equipped
with three flexible legs and one rigid leg. The rigid leg is
equipped with a shipping bolt and a flat white plastic washer (rather than the rubber mounting grommet used with a
flexible mounting leg). The bolt and washer must be re-
moved before the furnace is placed into operation. After the bolt and washer have been removed, the rigid leg
will not touch the blower housing.
NOTE − The G51MP−60D−135 units are equipped with a
shipping pad under the blower housing. Remove the shipping pad prior to opertion.
Allow for clearances to combustible materials as indicated
on the unit nameplate. Minimum clearances for closet or alcove installations are shown in figures 8, 13 and 17.
AIR FLOW
UNIT
FRONT
AIR FLOW
FRONT VIEW
AIR FLOW
SIDE VIEW
AIR FLOW
FRONT VIEW
UNIT
FRONT
1/2"
max.
1/2"
max.
UNIT SHOULD BE LEVEL FROM LEFT TO RIGHT BUT MAY BE
TILTED SLIGHTLY (MAX. 1/2") FROM BACK TO FRONT
TO AID IN THE DRAINING OF THE HEAT EXCHANGER.
END VIEW
FIGURE 7
UNIT
FRONT
FRONT VIEW
AIR FLOW
SIDE VIEW
1/2"
max.
Page 9
Page 10
WARNING
Blower access panel must be securely in place when
blower and burners are operating. Gas fumes, which
could contain carbon monoxide, can be drawn into
living space resulting in personal injury or death.
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 air in the living space. Use sheet metal screws and
joint tape to seal return air system to furnace.
In platform installations with furnace return, the furnace should be sealed airtight to the return air 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.
For no reason should return and supply air duct systems ever 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.
Upflow Applications
The G51MP gas furnace can be installed as shipped in
the upflow position. Refer to figure 8 for clearances.
Installation Clearances
Top
Return Air −− Upflow Units
Return air can be brought in through the bottom or either
side of the furnace installed in an upflow application. If the
furnace is installed on a platform with bottom return, make
an airtight seal between the bottom of the furnace and the
platform to ensure that the furnace operates properly and
safely. The furnace is equipped with a removable bottom
panel to facilitate installation.
Markings are provided on both sides of the furnace cabinet
for installations that require side return air. Cut the furnace
cabinet at the maximum dimensions shown on page 2.
NOTE − When air volumes over 1800 cfm (850 L/s) are
required with 60C or 60D models in an upflow application, the following return air options are available:
1 − Return air from single side with transition which will
accommodate 20 x 25 x 1 in. (508 x 635 x 25 mm) air filter.
(Required to maintain proper air velocity.) See figure 9.
2 − Return air from single side with optional RAB Return
Air Base. See figure 11.
3 − Return air from bottom.
4 − Return air from both sides.
5 − Return air from bottom and
one side.
Refer to Engineering Handbook for additional information.
G51MP applications which include side return air and
a condensate trap installed on the same side of the
cabinet require either a return air base or field−fabricated transition to accommodate an optional IAQ accessory taller than 14.2".
Side Return Air
(with transition and filter)
Left Side
Bottom (Floor)
Top/Plenum 1 in. (25 mm)
*Front 0
Back 0
Sides 0†
Vent 0
Floor 0‡
*Front clearance in alcove installation must be 24 in. (610 mm).
Maintain a minimum of 24 in. (610 mm) for front service access.
†Allow proper clearances to accommodate condensate trap and
vent pipe installation.
‡For installations on a combustible floor, do not install the furnace
directly on carpeting, tile or other combustible materials other
than wood flooring.
Right Side
FIGURE 8
20" X 25" X 1"
(508mm X635mm X 25mm)
Air Filter
Return
Air
Plenum
Transition
FIGURE 9
Removing the Bottom Panel
Remove the two screws that secure the bottom cap to the
furnace. Pivot the bottom cap down to release the bottom
panel. Once the bottom panel has been removed, reinstall
the bottom cap. See figure 10.
Page 10
Page 11
Removing the Bottom Panel
Screw
Bottom Panel
FIGURE 10
(Upflow Applications Only −− For use with B, C and D cabinets only)
Bottom Cap
Optional Return Air Base
Setting an Upflow Unit
When the side return air inlets are used in an upflow application, it may be necessary to install leveling bolts on the
bottom of the furnace. Use field−supplied corrosion−resistant 5/16 inch machine bolts (4) and nuts (8). See figure 12.
NOTE − The maximum length of the bolt is 1−1/2 inches.
1 − Lie the furnace on its back and drill a 5/16 inch diame-
ter hole in each corner of the furnace’s bottom. See figure 12 for the correct location of the holes. Drill through
the bottom panel and the bottom flange of the cabinet.
2 − Install one bolt and two nuts into each hole. Screw the
first nut onto a bolt and then insert the bolt into a hole. A
flat washer may be added between the nut and the bottom of the unit.
3 − Screw another nut onto the bolt on the inside of the fur-
nace base. A flat washer may be added between the
nut and the bottom of the unit.
1
23 (584)
Overall
(Maximum)
1
Unit side return air
Opening
5−5/8
(143)
SIDE RETURN
AIR OPENINGS
(Either Side)
23 (584)
27−5/8 (702)
SIDE VIEW
1
Minimum
11 (279)
2
Maximum
14 (356)
1
22−7−16
(570)
Overall
(Maximum)
AIR FLOW
17−1/2 (446) RAB−B (98M60)
21 (533) RAB−C (98M58)
24−1/2 (622) RAB−D (98M59)
FURNACE
FRONT
7−1/4 (184)
OPTIONAL RAB
RETURN AIR BASE
4
(102)
14
(356)
7/8
(22)
FRONT VIEW
NOTE− Optional Side Return Air Filter Kits are not for use with RAB Return Air Base.
1
Both the unit return air opening and the base return air opening must be covered by a single plenum or IAQ cabinet.
Minimum unit side return air opening dimensions for units requiring 1800 cfm or more of air (W x H): 23 x 11 in.
(584 x 279 mm).
The opening can be cut as needed to accommodate plenum or IAQ cabinet while maintaining dimensions shown.
Side return air openings must be cut in the field. There are cutting guides stenciled on the cabinet for the side return
air opening. The size of the opening must not extend beyond the markings on the furnace cabinet..
2
To minimize pressure drop, the largest opening height possible (up to 14 inches) is preferred.
NOTE− Optional Side Return Air Filter Kits are not for use with RAB Return Air Base.
FIGURE 11
3/4
(19)
Page 11
Page 12
4 − Adjust the outside nut to the appropriate height and
tighten the inside nut to secure the arrangement.
NOTE − The unit may be tilted back−to−front a maximum of
1/2". This will ensure proper draining of the heat exchanger.
Downflow Application Installation Clearances
Top
Leveling Bolt Installation
Inches (mm)
3/8
(10)
Furnace Front
3/8
(10)
1−3/4
(44)
Furnace
1−3/4
(44)
Leveling Bolt
Locations
Bottom
Leveling Bolt
Locations
3/8
(10)
1−3/4
(44)
1−3/4 (44)
3/8
(10)
FIGURE 12
Downflow Applications
The unit may be installed three ways in downflow applications: 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 in the down-
flow position. Flange damage will result.
Refer to figure 13 for clearances in downflow applications.
Left Side
Bottom
Top 0
*Front 0
Back 0
Sides 0†
Vent 0
Floor NC‡
*Front clearance in alcove installation must be 24 in. (610 mm).
Maintain a minimum of 24 in. (610 mm) for front service access.
†Allow proper clearances to accommodate condensate trap and
vent pipe installation.
‡The furnace may be installed on a combustible wood floor if an optional additive base is installed between the furnace and the combustible floor.
Right Side
FIGURE 13
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
Cabinet Width
Front to Rear Side to Side
in. mm in. mm
B Cabinet (17.5") 19 − 3/4 502 16 − 5/8 422
C Cabinet (21") 19 − 3/4 502 20−1/8 511
D Cabinet (24.5") 19 − 3/4 502 23 − 5/8 600
Page 12
Page 13
Installation on Combustible Flooring
(Using an Additive Base)
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. 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.
TABLE 2
ADDITIVE BASE FLOOR OPENING SIZE
Cabinet
Width
B Cabinet
(17.5")
C Cabinet
(21")
Catalog
Number
11M60
11M61
Front to Rear Side to Side
in. mm in. mm
22 559 18 − 3/4 476
22 559 22 − 3/4 578
Installation on Cooling Cabinet
1 − Refer to reverse−flow coil installation instructions for
correctly sized opening in floor and installation of cabinet.
2 − When cooling cabinet is in place, set and secure the
furnace according to the instructions that are provided
with the cooling coil. Secure the furnace to the cabinet.
3 − Seal the cabinet and check for air leaks.
Return Air Opening −− Downflow Units
The following steps should be taken when installing plenum:
1 − Bottom edge of plenum should be flanged with a
hemmed edge (See figure 15 or 16).
2 − Sealing strips should be used to ensure an airtight seal
between the cabinet and the plenum.
3 − In all cases, plenum should be secured to top of fur-
nace using sheet metal screws.
4 − Make certain that an adequate seal is made.
D Cabinet
(24.5")
11M62
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.
G51MP UNIT
SUPPLY AIR PLENUM
PROPERLY
SIZED FLOOR
OPENING
ADDITIVE BASE
PLENUM
(Field Provided)
SEALING STRIP
(Field Provided)
PLENUM
(Field Provided)
SECURE FROM
INSIDE CABINET
SECURE FROM
OUTSIDE CABINET
CABINET
SIDE PANEL
Side View
FIGURE 15
SEALING STRIP
(Field Provided)
CABINET
SIDE PANEL
Side View
FIGURE 16
FIGURE 14
Page 13
Page 14
Horizontal Applications
The G51MP furnace can be installed in horizontal applications with either right− or left−hand air discharge.
Horizontal Application
Installation Clearances
Right−Hand Discharge
Top
Left End
Bottom (Floor)**
Left−Hand Discharge
Top
Left End
Bottom (Floor)**
Top 0
Front* 0
Back 0
Ends 0
Vent 0
Floor 0‡
*Front clearance in alcove installation must be 24 in. (610 mm).
Maintain a minimum of 24 in. (610 mm) for front service access.
**A 5−1/2 service clearance must be maintained below the unit to
provide for servicing of the condensate trap.
‡For installations on a combustible floor, do not install the furnace
directly on carpeting, tile or other combustible materials other
than wood flooring.
FIGURE 17
The G51MP may also be installed as a unit heater. Either
suspend the furnace as shown in figure 18, or install the
furnace on a field−fabricated raised platform. The unit
must be supported at both ends and beneath the blower
deck to prevent sagging.
Refer to figure 17 for clearances in horizontal applications.
Right End
Right End
Suspended Installation of Horizontal Unit
NOTE − If unit is suspended, horizontal support kit (Cat No.
56J18 ordered separately) or equivalent is recommended
to ensure proper unit support and coil drainage.
1 − Select location for unit keeping in mind service and
other necessary clearances. See figure 17.
2 − Provide service platform in front of unit.
3 − If unit is installed above finished space, fabricate a
drain pan fitted with a 1/2 inch or 3/4 inch N.P.T. fitting.
4 − Using 3/8 inch rods and support frame kit (ordered
separately), fabricate suspension hangers for unit
keeping in mind front service access clearances.
5 − Mount unit on support frame as shown in figure 18.
6 − Continue with exhaust, condensate and intake line
piping instructions.
BLOWER ACCESS PANEL 3/8 in. RODS
INTAKE/EXHAUST
CONNECTION
SUPPORT FRAME
DRAIN PAN
(to protect finished space)
FIGURE 18
7 − If unit is suspended above finished space, hang the
field−provided drain pan below the support frame as
shown in figure 18. Leave 5−1/2 inches for service
clearance below unit for condensate trap.
8 − Route auxiliary drain line so that water draining from
this outlet will be easily noticed by the homeowner. If
necessary, run the condensate line into a condensate
pump to meet drain line slope requirements. The
pump must be rated for use with condensing furnaces.
Protect the condensate discharge line from the pump
to the outside to avoid freezing.
Platform Installation of Horizontal Unit
1 − Select location for unit keeping in mind service and
other necessary clearances. See figure 17.
2 − Construct a raised wooden frame and cover frame
with a plywood sheet. Provide a service platform in
front of unit. If unit is installed above finished space,
fabricate a drain pan to be installed under unit.
When installing the unit in a crawl space, a proper sup-
port platform may be created using cement blocks and
the horizontal support frame kit (ordered separately,
Page 14
Page 15
Lennox part number 56J18). Position the support
frame on top of the blocks and install the unit on the
frame. Leave 5−1/2 inches for service clearance for
condensate trap.
EXHAUST PIPE
INTAKE PIPE
*Gas connector may be
used for Canadian
installation if acceptable by local authority
having jurisdiction.
*GAS
CONNECTOR
Unit Heater Discharge Duct Guidelines
A field−fabricated and installed discharge air duct and grille
cabinet is suitable for use with the G51MP heater. See figure 20. Keep the following items in mind when constructing
the cabinet.
1 − Outer dimensions of cabinet should match those of the
unit heater, so the duct/grille cabinet installs flush with
the unit heater cabinet. See figure 20.
2 − Flange both ends of duct/grille cabinet so that screws
can be used to secure cabinet to discharge end of unit
heater.
3 − To ensure proper operation, the duct/grille cabinet
must be at least 18 inches long.
RAISED
PLATFORM
CONDENSATE LINE
SERVICE PLATFORM
FIGURE 19
3 − Route auxiliary drain line so that water draining from
this outlet will be easily noticed by the homeowner. If
necessary, run the condensate line into a condensate
pump to meet drain line slope requirements. The
pump must be rated for use with condensing furnaces.
Protect the condensate discharge line from the pump
to the outside to avoid freezing.
4 − Set unit in drain pan as shown in figure 19. Leave 5−1/2
inches for service clearance below unit for condensate
trap.
5 − Continue with exhaust, condensate and intake piping
installation according to instructions.
G51MP Installed in Unit Heater Applications
Horizontal unit heaters may be installed either suspended
from the ceiling using the support frame kit or mounted on a
field−fabricated raised platform. The condensate trap must
be installed where it can be serviced at a later date.
The G51MP may also be installed as a unit heater. Either
suspend the furnace from roof rafters or floor joists, as
shown in figure 18, or install the furnace on a field−fabricated raised platform, as shown in figure 19. The unit must
be supported at both ends and beneath the blower deck to
prevent sagging.
4 − Use #10−16 x 1/2 inch sheet metal screws to secure
duct/grille cabinet to unit, taking care not to damage internal components of unit heater when drilling holes or
installing screws. See figure 20.
5 − Use adjustable, double−deflection grille(s) to distribute
discharge air. Adjust static pressure to be in the 0.06
inch to 0.10 inch w.c. range.
18 in.
MIN.
DRAIN PAN
(to protect
finished
space)
NOTE − When installing duct/grille cabinet, take care not to damage internal unit
heater components when drilling holes or installing screws.
FIGURE 20
Return Air −− Horizontal Applications
Return air may be brought in only through the end of a furnace installed in the horizontal position. The furnace is
equipped with a removable bottom panel to facilitate
installation. See figure 10.
Page 15
Page 16
Filters
This unit is not equipped with a filter or rack. A field−provided filter is required for the unit to operate properly. Table
3 lists recommended filter sizes.
A filter must be in place whenever the unit is operating.
TABLE 3
Furnace
Cabinet Width
17−1/2" 16 X 25 X 1 (1) 16 X 25 X 1 (1)
21" 16 X 25 X 1 (1) 20 X 25 X 1 (1)
24−1/2" 16 X 25 X 1 (2) 24 X 25 X 1 (1)
Side Return Bottom Return
Filter Size
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.
NOTE − Operation of this furnace in heating mode (indoor
blower operating at selected heating speed) with an external static pressure which exceeds 0.5 inches w.c. may result in erratic limit operation.
Supply Air Plenum
If the furnace is installed without a cooling coil, a removable
access panel should be installed in the supply air duct. The
access panel should be large enough to permit inspection
(by reflected light) of the heat exchanger for leaks after the
furnace is installed. The furnace access panel must always
be in place when the furnace is operating and it must not
allow leaks into the supply air duct system.
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 pres-
sure 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.
Return air can be brought in through the bottom or either
side of the furnace. If a furnace with bottom return air is
installed on a platform, make an airtight seal between the
bottom of the furnace and the platform to ensure that the
unit operates properly and safely. Use fiberglass sealing
strips, caulking, or equivalent sealing method between the
plenum and the furnace cabinet to ensure a tight seal. If a
filter is installed, size the return air duct to fit the filter frame.
Pipe & Fittings Specifications
All pipe, fittings, primer and solvent cement must conform
with American National Standard Institute and the American Society for Testing and Materials (ANSI/ASTM) standards. The solvent shall be free flowing and contain no
lumps, undissolved particles or any foreign matter that adversely affects the joint strength or chemical resistance of
the cement. The cement shall show no gelation, stratification, or separation that cannot be removed by stirring. Refer to the table 4 below for approved piping and fitting materials.
TABLE 4
PIPING AND FITTINGS SPECIFICATIONS
PIPE & FITTING MATERIAL
Schedule 40 PVC (Pipe) D1785
Schedule 40 PVC (Cellular Core Pipe) F891
Schedule 40 PVC (Fittings) D2466
Schedule 40 CPVC (Pipe) F441
Schedule 40 CPVC (Fittings) F438
SDR−21 PVC or SDR−26 PVC (Pipe) D2241
SDR−21 CPVC or SDR−26 CPVC (Pipe) F442
Schedule 40 ABS Cellular Core DWV (Pipe) F628
Schedule 40 ABS (Pipe) D1527
Schedule 40 ABS (Fittings) D2468
ABS−DWV (Drain Waste & Vent)
(Pipe & Fittings)
PVC−DWV (Drain Waste & Vent)
Pipe & Fittings)
PRIMER & SOLVENT CEMENT
PVC & CPVC Primer F656
PVC Solvent Cement D2564
CPVC Solvent Cement F493
ABS Solvent Cement D2235
PVC/CPVC/ABS All Purpose Cement For Fittings & Pipe of the same material
ABS to PVC or CPVC Transition Solvent
Cement
CANADA PIPE & FITTING & SOLVENT
CEMENT
PVC & CPVC Pipe and Fittings
PVC & CPVC Solvent Cement
ABS to PVC or CPVC Transition Cement
ASTM
SPECIFICATION
D2661
D2665
ASTM
SPECIFICATION
D2564, D2235,
F493
D3138
MARKING
ULCS636
CAUTION
Solvent cements for plastic pipe are flammable liquids and should be kept away from all sources of
ignition. Do not use excessive amounts of solvent
cement when making joints. Good ventilation should
be maintained to reduce fire hazard and to minimize
breathing of solvent vapors. Avoid contact of cement
with skin and eyes.
Page 16
Page 17
Use PVC primer and solvent cement or ABS solvent cement
meeting ASTM specifications, refer to Table 4. As an alternate, use all purpose cement, to bond ABS, PVC, or CPVC
pipe when using fittings and pipe made of the same materials. Use transition solvent cement when bonding ABS to either PVC or CPVC.
Low temperature solvent cement is recommended. Metal or
plastic strapping may be used for vent pipe hangers. Uniformly apply a liberal coat of PVC primer for PVC or use a
clean dry cloth for ABS to clean inside socket surface of fitting and male end of pipe to depth of fitting socket.
TABLE 5
OUTDOOR TERMINATION KITS AND CORRESPONDING EQUIVALENCIES
Vent Pipe Length Equivalency (feet)
Outdoor Ex-
haust Accel-
erator
(Dia. X
Length)
1−1/2"
Concentric
Kit
UNIT
MODEL
VENT
PIPE
DIA.
(in.)
Outdoor Ex-
haust Accel-
erator
(Dia. X
Length)
Canadian Applications Only − Pipe, fittings, primer
and solvent cement used to vent (exhaust) this appliance must be certified to ULC S636 and supplied by a
single manufacturer as part of an approved vent (exhaust) system. When bonding the vent system to the furnace, use ULC S636 approved One−Step Transition Cement to bond the pipe to the flue collar, or to bond the 90°
elbow or reducing 90° elbow to the flue collar. In addition, the first three feet of vent pipe from the furnace flue
collar must be accessible for inspection.
Table 5 lists the available exhaust termination kits, as well
as vent pipe equivalencies which must be used when sizing vent pipe. All Lennox vent terminations are PVC.
2" Con-
centric Kit
3" Con-
centric Kit
2" Wall Plate
Kit
3" Wall Plate
Kit
Ring Kit
2" Wall
1−1/2" X 12"
2 4
24B−045
36B−045
36B−070
36C−090
48C−090
60C−090
48C−110
60C−110
60D−135
*Requires field−provided and installed 1−1/2" exhaust accelerator.
**Requires field−provided and installed 2" exhaust accelerator.
***For use only in non−direct vent applications, when snow riser is not required. Requires field−provided and installed 2" exhaustaccelerator.
2−1/2 5
3 7
4 14
2 4
2−1/2 5
3 8
4 14
2
2−1/2
3
4
2
2−1/2
3
4
3
4
Not
Allowed
Not
Allowed
Not
Allowed
Not
Allowed
Not
Allowed
Not
Allowed
Not
Allowed
Not
Allowed
Not
Allowed
Not
Allowed
2" X 12"
Not
Allowed
Not
Allowed
Not
Allowed
Not
Allowed
Not
Allowed
Not
Allowed
Not
Allowed
Not
Allowed
1
2
2
4
1
2
2
4
6
10
71M80
or 44W92
12
15
21
42
12
15
24
42
Not
Allowed
Not
Allowed
Not
Allowed
Not
Allowed
Not
Allowed
Not
Allowed
Not
Allowed
Not
Allowed
Not
Allowed
Not
Allowed
69M29
or 44W92
Not
Allowed
Not
Allowed
Not
Allowed
Not
Allowed
Not
Allowed
Not
Allowed
Not
Allowed
Not
Allowed
3 3
6 6
6 6
12 12
3 3
6 6
6 6
12 12
Not
Allowed
Not
Allowed
Termination kits 44W92 (includes 1−1/2" reducer), 44W93, 30G28 and
81J20 approved for use in Canadian installations.
60L46
or 44W93
Not
Allowed
Not
Allowed
Not
Allowed
Not
Allowed
Not
Allowed
Not
Allowed
Not
Allowed
Not
Allowed
15
25
22G44
or 30G28
4 4* 4
5 5* 5
7 7* 7
14 14* 14
4 4* 4
5 5* 5
8 8* 8
14 14* 14
Not
Allowed
Not
Allowed
Not
Allowed
Not
Allowed
Not
Allowed
Not
Allowed
Not
Allowed
Not
Allowed
Not
Allowed
Not
Allowed
44J40
or 81J20
1 1**
2 2**
2 2**
4 4**
1 1**
2 2***
2 2***
4 4***
6 6***
10 10***
15F74
Page 17
Page 18
Vent Piping Guidelines
The G51MP can be installed as either a Non−Direct Vent
or a Direct Vent gas central furnace.
NOTE − In Non-Direct Vent installations, combustion air is
taken from indoors and flue gases are discharged outdoors.
In Direct Vent installations, combustion air is taken from outdoors and flue gases are discharged outdoors.
Intake and exhaust pipe sizing in Direct Vent applications
and exhaust pipe sizing in Non-Direct Vent applications −−
Size pipe according to tables 6 and 7. Table 6 lists the minimum equivalent vent pipe lengths permitted. Table 7 lists
the maximum equivalent pipe lengths permitted.
Maximum vent length is defined as:
Total length (linear feet) of pipe,
Plus Equivalent length (feet) of fittings,
Plus Equivalent length (feet) of termination.
NOTE − Include ALL pipe and ALL fittings, both in
doors and outdoors.
Regardless of the diameter of pipe used, the standard roof
and wall terminations described in section Exhaust Piping
Terminations should be used. Exhaust vent termination
pipe is sized to optimize the velocity of the exhaust gas as
it exits the termination. Refer to table 8.
*NOTE − The exhaust pipe should be offset a minimum of
12 inches to avoid the possibility of water droplets being released from the exhaust termination. The minimum exhaust vent length is 15 ft. Shorter exhaust vent lengths may
result in the discharge of water droplets from the exhaust
termination, in spite of the 12−inch vertical offset. See figure
21.
Each 90° elbow (including those provided with the furnace)
of any diameter is equivalent to 5 feet (1.52m) of vent pipe
of the same diameter. Two 45° elbows are equivalent to
one 90° elbow of the same diameter. One 45° elbow is
equal to 2.5 feet (.76m) of vent pipe of the same diameter.
In some applications which permit the use of several different sizes of vent pipe, a combination vent pipe may be
used. Contact Lennox’ Application Department for assistance in sizing vent pipe in these applications.
NOTE − The flue collar on all models is sized to accommodate 2" Schedule 40 flue pipe. When vent pipe which is
larger than 2" must be used in an upflow application, a 2"
elbow must be applied at the flue collar in order to properly transition to the larger diameter flue pipe. This elbow
must be added to the elbow count used to determine acceptable vent lengths. Assign an equivalent feet value to
this elbow according to the larger size pipe being used.
Contact the Application Department for more information
concerning sizing of vent systems which include multiple
pipe sizes.
Use the following steps to correctly size vent pipe diameter.
Refer to Vent Pipe Size Determination Worksheet on
Page 53.
1 − Determine the vent termination and its corresponding
equivalent feet value according to table 5.
2 − Determine the number of 90° elbows required for both
indoor and outdoor (e.g. snow riser) use. Calculate the
corresponding equivalent feet of vent pipe.
3 − Determine the number of 45° elbows required for both
indoor and outdoor use. Calculate the corresponding
equivalent feet of vent pipe.
4 − Determine the length of straight pipe required.
5 − Add the total equivalent feet calculated in steps 1
through 4 and compare that length to the maximum
values given in table 7 for the proposed vent pipe di-
ameter. If the total equivalent length required exceeds
the maximum equivalent length listed in the appropri-
ate table, evaluate the next larger size pipe.
12" Min.*
Upflow Application
Rooftop Termination
12" Min.*
Horizontal Application
Rooftop Termination
*A minimum of 1/4" (6mm) drop for each 12" (305mm) of horizontal run is mandatory for drainage.
Exhaust Pipe Offset
12" Min.
Upflow Application
Side Wall Termination
12" Min.*
Horizontal Application
Side Wall Termination
FIGURE 21
Page 18
Page 19
IMPORTANT
Do not use screens or perforated metal in exhaust
terminations. Doing so will cause freeze−ups and
may block the terminations.
MINIMUM VENT PIPE LENGTHS
G51MP
MODEL
045, 070,
090
110**
135***
*Any approved termination may be added to the minimum equivalent length
listed.
**G51MP−48C−110 and G51MP−60C−110 must have 90° street ell (supplied or
field replacement Canadian kit) installed directly into unit flue collar.
***G51MP−60D−135 must have 3" to 2" reducing ell (supplied or field replacement Canadian kit) installed directly into unit flue collar.
DIRECT (2 PIPE) AND NON−DIRECT (1 PIPE) APPLICATIONS
ALTITUDE
0 − 2000
(0 − 609 m)
2001 − 4500
(610 − 1371 m)
4501−7500
(1372−2286 m)
7501 − 10000
(2287 − 3048 m)
n/a −− Not allowed.
*G51MP−48C−110 and G51MP−60C−110 must have 90° street ell (supplied or
field replacement Canadian kit) installed directly into unit flue collar.
**G51MP−60D−135 must have 3" to 2" reducing ell (supplied or field replace-
ment Canadian kit) installed directly into unit flue collar.
***90° elbows used in configuration of G51MP−60D−135 vent, must be lim-
ited to 3" sweep elbows.
MIN. EQUIV.
VENT LENGTH
15 ft.*
MAXIMUM VENT PIPE LENGTHS
G51MP
MODEL
135** n/a n/a ***125 180
135** n/a n/a ***90 180
135** n/a n/a ***90 180
135** n/a n/a ***90 180
Joint Cementing Procedure
All cementing of joints should be done according to the
specifications outlined in ASTM D 2855.
TABLE 6
EXAMPLE
5 ft. plus 2 elbows of 2", 2−1/2", 3"
or 4" diameter pipe
5 ft. plus 2 elbows of 2", 2−1/2", 3" or
4" diameter pipe
5 ft. plus 2 elbows of 3" or 4"
diameter pipe
TABLE 7
MAXIMUM EQUIVALENT VENT
LENGTH FEET
2" dia. 2−1/2" dia. 3" dia. 4" dia.
045 110 135 160 250
070 70 135 160 250
090 50 100 125 225
110* 30 70 125 200
045 110 135 160 250
070 70 135 160 250
090 50 100 125 225
110* 20 70 125 200
045 110 135 160 250
070 70 135 160 250
090 30 100 125 225
110* n/a 70 125 200
045 110 135 160 250
070 70 135 160 250
090 n/a 100 125 225
110* n/a 70 125 200
WARNING
DANGER OF EXPLOSION!
Fumes from PVC glue may ignite during system
check. Allow fumes to dissipate for at least 5 minutes
before placing unit into operation.
1 − Measure and cut vent pipe to desired length.
2 − Debur and chamfer end of pipe, removing any ridges
or rough edges. If end is not chamfered, edge of pipe
may remove cement from fitting socket and result in a
leaking joint.
3 − Clean and dry surfaces to be joined.
4 − Test fit joint and mark depth of fitting on outside of pipe.
5 − Uniformly apply a liberal coat of PVC primer for PVC or
use a clean dry cloth for ABS to clean inside socket
surface of fitting and male end of pipe to depth of fitting
socket.
NOTE − Furnace flue collar and air inlet fitting are both
made of ABS material. Use transition solvent cement
when joining ABS fittings to PVC pipe.
6 − Promptly apply solvent cement to end of pipe and in-
side socket surface of fitting. Cement should be applied lightly but uniformly to inside of socket. Take
care to keep excess cement out of socket. Apply second coat to end of pipe.
NOTE − Time is critical at this stage. Do not allow primer to dry before applying cement.
7 − Immediately after applying last coat of cement to pipe,
and while both inside socket surface and end of pipe
are wet with cement, forcefully insert end of pipe into
socket until it bottoms out. Turn PVC pipe 1/4 turn during assembly (but not after pipe is fully inserted) to distribute cement evenly. DO NOT turn ABS or cellular
core pipe.
NOTE − Assembly should be completed within 20 seconds after last application of cement. Hammer blows
should not be used when inserting pipe.
8 − After assembly, wipe excess cement from pipe at end
of fitting socket. A properly made joint will show a
bead around its entire perimeter. Any gaps may indicate a defective assembly due to insufficient solvent.
9 − Handle joints carefully until completely set.
Venting Practices
The thickness of construction through which vent pipes
may be installed is 24" (610mm) maximum and 3/4"
(19mm) minimum.
1 − Use recommended piping materials for exhaust pip-
ing.
2 − Secure all joints, including drip leg, gas-tight using ap-
proved cement.
Page 19
Page 20
Suspend piping using hangers at a minimum of every 5
feet (1.52m) for schedule
40 PVC and every 3 feet
(.91m) for ABS−DWV, PVC−
DWV, SPR−21 PVC, and
STRAPPING
(metal, plastic
or large wire
ties)
SDR−26 PVC piping. A suitable hanger can be fabricated by using metal or
plastic strapping or a large
FIGURE 22
wire tie.
3 − In areas where piping penetrates joists or interior
walls, hole must be large enough to allow clearance on
all sides of pipe through center of hole using a hanger.
4 − Secure piping at the point where it exits the outside
wall or roof in order to prevent transmission of vibration to the structure.
5 − When furnace is installed in a residence where unit is
shut down for an extended period of time, such as a
vacation home, make provisions for draining condensate collection trap and lines.
Exhaust Piping
NOTE − A 2" diameter PVC street ell is located on the
blower deck of the 48C−110 and 60C−110 units. In upflow
or downflow applications, the street ell must be glued
using transition solvent cement directly into the unit flue
collar. See figure 23. A 3" to 2" PVC reducing ell is located
on the blower deck of the 60D−135 units. In upflow or
downflow applications, the reducing ell must be glued
using transition solvent cement directly into the unit flue
collar.
1 − Choose the appropriate side for venting in upflow or
downflow positions. Exhaust piping exits from the top
of the unit in horizontal air discharge applications.
Glue the field−provided exhaust vent pipe (or provided
street ell or reducing ell in upflow or downflow applications) to the flue collar. All PVC cement joints should
be made according to the specifications outlined in
ASTM D 2855. Refer to pipe and fittings specifications
and gluing procedures.
TYPICAL EXHAUST PIPE CONNECTIONS AND CONDENSATE TRAP INSTALLATION
IN UPFLOW OR DOWNFLOW DIRECT OR NON−DIRECT VENT APPLICATIONS
(Right−Hand Exit in Upflow Application Shown)
PLUG
VENT PLUG
(Must be
glued in
place)
PLUG
*2" diameter street elbow provided.
** Street elbow may be used on −045, −070 and −090.
PLUG
2"
CONDENSATE
TRAP
(Must be installed
on same side as
exhaust piping)
45°
2−1/2",
3", OR
4"
2"
2"
2"
TRANSITION
−045, −070, or
−090 with
2−1/2", 3", or 4"
vent pipe
TRANSITION
(use only if 4"
pipe is
required)
3" OR 4" vent pipe
or
2"
**2"
2"
2−1/2",
3", OR
4"
TRANSITION
−110 with
2−1/2", 3", OR 4"
vent pipe
*2"
MAX
SIDE VIEW
4"
2"
3" to 2" REDUCING ELBOW
−135 with
45°
MAX
(provided)
FIGURE 23
Page 20
Page 21
TYPICAL EXHAUST PIPE CONNECTIONS
HORIZONTAL DIRECT OR
NON−DIRECT VENT APPLICATIONS
(Horizontal Right−Hand Air Discharge Application Shown)
4 − Route piping to outside of structure. Continue with
installation following instructions given in piping termination section.
*Limit pipe length to 2"
in −135 applications.
TRANSITION
DO NOT transition from
smaller to larger pipe
size in horizontal runs.
2−1/2",
3", OR
4"
*2"
2"
2"
−24B−045
−36B−045
−36B−070
−36C−090
−48C−090
−60C−090
−48C−110
−60C−110
−60D−135*
2"
−24B−045
−36B−045
−36B−070
−36C−090
−48C−090
−48C−110
−60C−090
−60D−110
FIGURE 24
IMPORTANT
Exhaust piping and condensate trap must be
installed on the same side of the unit in upflow and
dowflow applications or use alternate drain kit
76M20.
2 − All horizontal runs of exhaust pipe must slope back to-
ward unit. A minimum of 1/4" (6mm) drop for each 12"
(305mm) of horizontal run is mandatory for drainage.
Horizontal runs of exhaust piping must be supported every 5 feet (1.52m) using hangers.
NOTE − Exhaust piping should be checked carefully to
make sure there are no sags or low spots.
3 − On the opposite side of the cabinet, glue the provided
2" ABS vent plug into the unused ABS flue collar with
ABS or all purpose solvent cement.
CAUTION
Do not discharge exhaust into an existing stack or
stack that also serves another gas appliance. If vertical discharge through an existing unused stack is required, insert PVC pipe inside the stack until the end
is even with the top or outlet end of the metal stack.
CAUTION
The exhaust vent pipe operates under positive pressure and must be completely sealed to prevent leakage of combustion products into the living space.
Intake Piping
The G51MP furnace may be installed in either direct vent
or non−direct vent applications. In non−direct vent applica-
tions, when intake air will be drawn into the furnace from the
surrounding space, the indoor air quality must be considered and guidelines listed in Combustion, Dilution and Ventilation Air section must be followed.
The G51MP unit is designed for either left−side or right−side
air intake connections in either upflow or downflow applications. In horizontal applications, air intake must be brought
in through the top. Intake air piping is independent of exhaust piping.
Follow the next four steps when installing the unit in Direct
Vent applications, where combustion air is taken from outdoors and flue gases are discharged outdoors. The pro-
vided air intake screen must not be used in direct vent applications.
1 − Use transition solvent cement to connect PVC pipe to
the ABS slip connector located on the side of the burner box.
2 − Use a sheet metal screw to secure the intake pipe to the
connector, if desired. A pilot indentation is provided in the
slip connector to assist in locating and starting the fastener.
3 − Glue the provided 2" ABS plug into the unused ABS air
intake connector on the opposite side of the cabinet with
ABS or all pupose solvent cement.
4 − Route piping to outside of structure. Continue with instal-
lation following instructions given in general guide lines for
piping terminations and in intake and exhaust piping terminations for direct vent sections. Refer to figure 25 for
pipe sizes.
Page 21
Page 22
TYPICAL AIR INTAKE PIPE CONNECTIONS
UPFLOW OR DOWNFLOW DIRECT VENT APPLICATIONS
(Right−Hand Exit in Upflow Application Shown)
2
2
2
PLUG
(Must be
glued in
place)
−24B−045
−36B−045
−36B−070
−36C−090
−48C−090
−48C−110
−60C−090
−60C−110
TYPICAL AIR INTAKE PIPE CONNECTIONS
HORIZONTAL DIRECT VENT APPLICATIONS
(Horizontal Right−Hand Air Discharge Application Shown)
FIGURE 25
Follow the next three steps when installing the unit in NonDirect Vent applications where combustion air is taken
from indoors and flue gases are discharged outdoors.
2−1/2",
3" OR
4
TRANSITION
2
−24B−045
−36B−045
−36B−070
−36C−090
−48C−090
−60C−090
−48C−110
−60C−110
2
TRANSITION
2
*2"
*Limit pipe length to 4"
in −135 applications.
2−1/2",
3" OR
4
−24B−045
−36B−045
−36B−070
−36C−090
−48C−090
−60C−090
−48C−110
60C−110
−60D−135*
*Limit pipe
length to 4" in
−135 applications.
−24B−045
−36B−045
−36B−070
−36C−090
−48C−090
−60C−090
48C−110
−60C−110
−24B−045
−36B−045
−36B−070
−36C−090
−48C−090
48C−110
−60C−090
60C−110
−24B−045
−36B−045
−36B−070
−36C−090
−48C−090
−60C−090
48C−110
−60C−110
−60D−135*
2”
2”
2”
2”
2−1/2”,
3” OR 4”
TRANSITION
*2”
2”
TRANSITION
2−1/2”,
3” OR 4”
2”
TYPICAL AIR INTAKE PIPE CONNECTIONS
UPFLOW OR HORIZONTAL NON−DIRECT
(Right−Hand Exit in Upflow Application Shown)
PLUG
(Must be
glued in
place)
NOTE − Debris screen and elbow may be rotated, so that
screen may be positioned to face forward, backward or
downward.
VENT APPLICATIONS
6 in. Max.
INTAKE
DEBRIS
SCREEN
(Provided)
FIGURE 26
FIGURE 27
Page 22
Page 23
TYPICAL AIR INTAKE PIPE CONNECTIONS
DOWNFLOW NON−DIRECT VENT APPLICATIONS
(Right−Hand Exit in Downflow Applications Shown)
2" SWEEP
ELL
INTAKE
DEBRIS
SCREEN
(Provided)
PLUG
(Must be
glued in
place)
6 in. Max.
INTAKE DEBRIS
SCREEN
(Provided)
Downflow
Evaporator
Coil
FIGURE 28
1 − Use field−provided materials and the factory−provided
air intake screen to route the intake piping as shown in
figures 27 and 28. Maintain a minimum clearance of 3"
(76mm) around the air intake opening. The air intake
opening (with the protective screen) should always be
directed either downward or straight out. Use 2" pipe
and fittings only and make sure that the air intake does
not extend more than 6" beyond the G51MP cabinet.
The air intake connector must not be located near
the floor. To avoid this complication in downflow
applications which do not include a downflow
evaporator coil, the intake air routing should be modi-
fied as shown in figure 28.
PLUG
(Must be
glued in
place)
Downflow Additive Flloor Base
2"
2" SWEEP ELL
18 in.
NOTE − Debris screen and sweep ell may be rotated, so that
screen may be positioned to face forward, backward or to the side.
2 − Use a sheet metal screw to secure the intake pipe to the
connector, if desired. A pilot indentation is provided in the
slip connector to assist in locating and starting the fastener.
3 − Glue the provided 2" ABS plug into the unused ABS air
intake connector on the opposite side of the cabinet with
ABS or all purpose solvent cement.
Page 23
Page 24
General Guidelines for Vent Terminations
In Non-Direct Vent applications, combustion air is taken
from indoors and the flue gases are discharged to the outdoors. The G51MP is then classified as a non-direct vent,
Category IV gas furnace.
In Direct Vent applications, combustion air is taken from
outdoors and the flue gases are discharged to the outdoors. The G51MP is then classified as a direct vent,
Category IV gas furnace.
In both Non-Direct Vent and Direct Vent applications, the
vent termination is limited by local building codes. In the
absence of local codes, refer to the current National Fuel
Gas Code ANSI Z223−1/NFPA 54 in U.S.A., and current
CSA−B149 Natural Gas and Propane Installation Codes in
Canada for details.
Position termination according to location given in figure 29
or 30. In addition, position termination so it is free from any
obstructions and 12" above the average snow accumulation.
At vent termination, care must be taken to maintain
protective coatings over building materials (prolonged
exposure to exhaust condensate can destroy protective
coatings). It is recommended that the exhaust outlet not be
located within 6 feet (1.8m) of a condensing unit because
the condensate can damage the painted coating.
NOTE − If winter design temperature is below 32°F (0°C),
exhaust piping should be insulated with 1/2" (13mm), Armaflex or equivalent when run through unheated space.
Do not leave any surface area of exhaust pipe open to outside air; exterior exhaust pipe should be insulated with 1/2"
(13mm) Armaflex or equivalent. In extreme cold climate
areas, 3/4" (19mm) Armaflex or equivalent may be necessary. Insulation on outside runs of exhaust pipe must be
painted or wrapped to protect insulation from deterioration.
Exhaust pipe insulation may not be necessary in some
specific applications.
NOTE − During extremely cold temperatures, below
approximately 20°F (6.7°C), units with long runs of vent
pipe through unconditioned space, even when insulated,
may form ice in the exhaust termination that prevents the
unit from operating properly. Longer run times of at least 5
minutes will alleviate most icing problems. Also, a heating
cable may be installed on exhaust piping and termination to
prevent freeze−ups. Heating cable installation kit is available from Lennox. See Condensate Piping section for part
numbers.
IMPORTANT
Do not use screens or perforated metal in exhaust
terminations. Doing so will cause freeze−ups and
may block the terminations.
IMPORTANT
For Canadian Installations Only:
In accordance to CSA International B149 installation
codes, the minimum allowed distance between the
combustion air intake inlet and the exhaust outlet of
other appliances shall not be less than 12 inches
(305mm).
Page 24
Page 25
VENT TERMINATION CLEARANCES
FOR NON−DIRECT VENT INSTALLATIONS IN THE USA AND CANADA
INSIDE CORNER
DETAIL
G
D
A
E
B
L
C
Fixed
F
Closed
Operable
B
B
B
VENT TERMINAL
AIR SUPPLY INLET
US Installations
A =
B =
C =
Clearance above grade, veranda,
porch, deck or balcony
Clearance to window or
door that may be opened
Clearance to permanently
12 inches (305mm) or 12 in. 305mm)
above average snow accumulation.
4 feet (1.2 m) below or to side of opening;
1 foot (30 cm) above opening
closed window
D =
Vertical clearance to ventilated soffit
located above the terminal within a
* Equal to or greater than soffit depth.
horizontal distance of 2 feet (mm)
from the center line of the terminal
E =
F =
G =
H =
I =
J =
Clearance to unventilated soffit
Clearance to outside corner
Clearance to inside corner
Clearance to each side of center line ex-
tended above meter / regulator assembly
Clearance to service regulator
vent outlet
Clearance to non−mechanical air
supply inlet to building or the com-
bustion air inlet to any other ap-
* Equal to or greater than soffit depth.
* No minimum to outside corner * No minimum to outside corner
* 3 feet (.9m) * 3 feet (.9m)
3 feet (.9m) within a height 15 feet (4.5m)
*
above the meter / regulator assembly
* 3 feet (.9m)
4 feet (1.2 m) below or to side of opening;
1 foot (30 cm) above opening
pliance
K =
L =
Clearance to mechanical air sup-
ply inlet
Clearance above paved sidewalk or
3 feet (.9m) above if within 10 feet
(3m) horizontally
7 feet (2.1m)
paved driveway located on public property
M =
1
2
A vent shall not terminate directly above a sidewalk or paved driveway that is located
between two single family dwellings and serves both dwellings.
Permitted only if veranda, porch, deck or balcony is fully open on a minimum of two
sides beneath the floor. Lennox recommends avoiding this location if possible.
Clearance under veranda, porch,
deck or balcony
In accordance with the current ANSI Z223.1/NFPA 54 Natural Fuel Gas Code
In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code
*12 inches (305mm)
FIGURE 29
Operable
A
* 12"
H
Fixed
Closed
J
B
I
M
K
AREA WHERE TERMINAL
IS NOT PERMITTED
1
Canadian Installations
2
12 inches (305mm) or 12 in. 305mm)
above average snow accumulation.
6 inches (152mm) for appliances <10,000
Btuh (3kw), 12 inches (305mm) for
appliances > 10,000 Btuh (3kw) and
<100,000 Btuh (30kw), 36 inches (.9m)
for appliances > 100,000 Btuh (30kw)
* 12"
* Equal to or greater than soffit depth.
* Equal to or greater than soffit depth.
3 feet (.9m) within a height 15 feet (4.5m)
above the meter / regulator assembly
3 feet (.9m)
6 inches (152mm) for appliances <10,000
Btuh (3kw), 12 inches (305mm) for
appliances > 10,000 Btuh (3kw) and
<100,000 Btuh (30kw), 36 inches (.9m)
for appliances > 100,000 Btuh (30kw)
6 feet (1.8m)
7 feet (2.1m)
12 inches (305mm)
*For clearances not specified in ANSI Z223.1/NFPA 54 or CSA B149.1, clearance will be in accordance with local installation codes and the requirements
of the gas supplier and these installation instructions."
Page 25
Page 26
VENT TERMINATION CLEARANCES
FOR DIRECT VENT INSTALLATIONS IN THE USA AND CANADA
INSIDE CORNER
DETAIL
G
D
A
E
B
L
C
Fixed
F
Closed
Operable
B
B
B
VENT TERMINAL
AIR SUPPLY INLET
US Installations
A =
B =
Clearance above grade, veranda,
porch, deck or balcony
Clearance to window or
door that may be opened
12 inches (305mm) or 12 in. 305mm)
above average snow accumulation.
6 inches (152mm) for appliances <10,000
Btuh (3kw), 9 inches (mm) for appliances
> 10,000 Btuh (3kw) and <50,000 Btuh
(15 kw), 12 inches (305mm) for ap-
pliances > 50,000 Btuh (15kw)
C =
Clearance to permanently
closed window
D =
Vertical clearance to ventilated soffit
located above the terminal within a
* Equal to or greater than soffit depth
horizontal distance of 2 feet (mm)
from the center line of the terminal
E =
F =
G =
H =
Clearance to unventilated soffit
Clearance to outside corner
Clearance to inside corner
Clearance to each side of center line ex-
tended above meter / regulator assembly
I =
Clearance to service regulator
vent outlet
J =
Clearance to non−mechanical air
supply inlet to building or the com-
bustion air inlet to any other ap-
pliance
* Equal to or greater than soffit depth * Equal to or greater than soffit depth
* No minimum to outside corner
* 3 feet (.9m)
3 feet (.9m) within a height 15 feet (4.5m)
above the meter / regulator assembly
*
3 feet (.9m)
6 inches (152mm) for appliances <10,000
Btuh (3kw), 9 inches (mm) for appliances
> 10,000 Btuh (3kw) and <50,000 Btuh
(15 kw), 12 inches (305mm) for ap-
pliances > 50,000 Btuh (15kw)
K =
L =
M =
1
2
A vent shall not terminate directly above a sidewalk or paved driveway that is located
between two single family dwellings and serves both dwellings.
Permitted only if veranda, porch, deck or balcony is fully open on a minimum of two
sides beneath the floor. Lennox recommends avoiding this location if possible.
Clearance to mechanical air sup-
ply inlet
Clearance above paved sidewalk or
paved driveway located on public property
Clearance under veranda, porch,
deck or balcony
In accordance with the current ANSI Z223.1/NFPA 54 Natural Fuel Gas Code
In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code
3 feet (.9m) above if within 10 feet
(3m) horizontally
* 7 feet (2.1m)
*12 inches (305mm)
FIGURE 30
H
Operable
A
Fixed
Closed
J
B
I
M
AREA WHERE TERMINAL
IS NOT PERMITTED
1
Canadian Installations
12 inches (305mm) or 12 in. 305mm)
above average snow accumulation.
6 inches (152mm) for appliances <10,000
Btuh (3kw), 12 inches (305mm) for
appliances > 10,000 Btuh (3kw) and
<100,000 Btuh (30kw), 36 inches (.9m)
for appliances > 100,000 Btuh (30kw)
* 12"
* 12"
* Equal to or greater than soffit depth* Equal to or greater than soffit depth
* No minimum to outside corner
* 3 feet (.9m)
3 feet (.9m) within a height 15 feet (4.5m)
above the meter / regulator assembly
3 feet (.9m)
6 inches (152mm) for appliances <10,000
Btuh (3kw), 12 inches (305mm) for
appliances > 10,000 Btuh (3kw) and
<100,000 Btuh (30kw), 36 inches (.9m)
for appliances > 100,000 Btuh (30kw)
6 feet (1.8m)
7 feet (2.1m)
12 inches (305mm)
*For clearances not specified in ANSI Z223.1/NFPA 54 or CSA B149.1, clearances will be in accordance with local installation codes and the requirements
of the gas supplier and these installation instructions."
K
2
Page 26
Page 27
Details of Intake and Exhaust Piping Terminations for
Direct Vent Installations (Figure 30)
NOTE − In Direct Vent installations, combustion air is taken
from outdoors and flue gases are discharged to outdoors.
Intake and exhaust pipes may be routed either horizontally
through an outside wall or vertically through the roof. In attic or closet installations, vertical termination through the
roof is preferred. Figures 31 through 39 show typical terminations.
1 − Exhaust and intake exits must be in same pressure
zone. Do not exit one through the roof and one on the
side. Also, do not exit the intake on one side and the
exhaust on another side of the house or structure.
2 − Intake and exhaust pipes should be placed as close
together as possible at termination end (refer to illustrations). Maximum separation is 3" (76mm) on roof
terminations and 6" (152mm) on side wall terminations.
3 − If necessary, install a field−provided reducer to adapt
larger vent pipe size to termination pipe size.
4 − On roof terminations, the intake piping should termi-
nate straight down using two 90° elbows (See figure
31).
5 − Exhaust piping must terminate straight out or up as
shown. In rooftop applications, a reducer may be required on the exhaust piping at the point where it exits
the structure to improve the velocity of exhaust away
from the intake piping. See table 8.
NOTE − Care must be taken to avoid recirculation of
exhaust back into intake pipe.
TABLE 8
EXHAUST PIPE TERMINATION SIZE REDUCTION
G51MP
MODEL
045 and 070 2", 2−1/2", 3" or 4" 1−1/2"
090 2", 2−1/2", 3" or 4" 2"
110 2", 2−1/2", 3" or 4" *2"
135 3" or 4" *2"
*Approved 3" concentric termination kit terminates with 2−5/8" ID pipe.
Inches(mm)
8" (203) MIN
12" (305) ABOVE
AVERAGE SNOW
ACCUMULATION
3" (76) OR
2" (51) PVC
PROVIDE SUPPORT
FOR INTAKE AND
EXHAUST LINES
Exhaust Pipe Size Termination Pipe Size
3(76) MAX.
DIRECT VENT ROOF TERMINATION KIT
(15F75 or 44J41)
SIZE TERMINATION
PIPE PER TABLE 8.
UNCONDITIONED
ATTIC SPACE
1/2" (13) FOAM
INSULATION IN
UNCONDITIONED
SPACE
FIGURE 31
1/2 (13) ARMAFLEX
INSULATION IN
UNCONDITIONED SPACE
FIELD−
PROVIDED
REDUCER MAY
BE REQUIRED
TO ADAPT
LARGER VENT
PIPE SIZE TO
TERMINATION
OUTSIDE
WALL
Inches (mm)
TOP VIEW WALL RING KIT WITH STRAIGHT INTAKE
1/2 (13) ARMAFLEX
INSULATION IN
UNCONDITIONED SPACE
FIELD−
PROVIDED
REDUCER MAY
BE REQUIRED
TO ADAPT
LARGER VENT
PIPE SIZE TO
TERMINATION
Inches (mm)
OUTSIDE
WALL
TOP VIEW WALL RING KIT WITH 90° ELBOW ON INTAKE
(15F74)
(15F74)
12 (305) MAX.
6 (152)
MAXIMUM
8 (203)
MINIMUM
12 (305) MAX.
6 (152)
MAXIMUM
4 (102)
MINIMUM
1/2" (13)
ARMAFLEX
INSULATION
TERMINATION
PIPE PER
TABLE 8.
2 (51) PVC
COUPLING
TERMINATION
SIZE
1/2" (13)
ARMAFLEX
INSULATION
SIZE
PIPE PER
TABLE 8.
FIGURE 32
6 − On field supplied terminations for side wall exits, ex-
haust piping should extend a maximum of 12 inches
(305mm) beyond the outside wall. Intake piping
should be as short as possible. See figure 32.
7 − On field supplied terminations, a minimum separation
distance between the end of the exhaust pipe and the
end of the intake pipe is 8 inches (203mm).
8 − If intake and exhaust piping must be run up a side wall
to position above snow accumulation or other obstructions, piping must be supported every 3 ft. (.9m) as
shown in figure 22. Refer to figure 35 for proper piping
method. In addition, WTK wall termination kit must be
extended for use in this application. See figure 38.
When exhaust and intake piping must be run up an
outside wall, the exhaust piping must be terminated
with pipe sized per table 8. The intake piping may be
equipped with a 90° elbow turndown. Using turndown
will add 5 feet (1.5m) to the equivalent length of the
pipe.
9 − Based on the recommendation of the manufacturer, a
multiple furnace installation may use a group of up to
four termination kits WTK assembled together horizontally, as shown in figure 37.
Page 27
Page 28
EXHAUST
TERMINATION
INTAKE
TERMINATION
EXHAUST
12" (305) ABOVE
AVERAGE SNOW
ACCUMULATION
FIELD−PROVIDED
REDUCER MAY BE REQUIRED
TO ADAPT LARGER VENT
PIPE SIZE TO TERMINATION
INTAKE
Inches (mm)
DIRECT VENT CONCENTRIC ROOFTOP TERMINATION
(71M80, 69M29 or 60L46)
FIGURE 33
Inches (mm)
EXHAUST
FIELD−PROVIDED
REDUCER MAY
BE REQUIRED TO
ADAPT LARGER
VENT PIPE SIZE
TO TERMINATION
INTAKE
INTAKE
TERMINATION
EXHAUST
TERMINATION
12" (305) Min.
above grade or
average snow
accumulation
INTAKE
VENT
1/2" (13) Foam Insulation
in Unconditioned Space
FIELD−
PROVIDED
REDUCER MAY
BE REQUIRED
TO ADAPT
LARGER VENT
PIPE SIZE TO
TERMINATION
Inches (mm)
DIRECT VENT WALL TERMINATION KIT
(22G44, 44J40, 30G28 or 81J20)
EXHAUST
VENT
INTAKE
VENT
FIGURE 36
5"
(127)
18" MAX.
(457)
EXHAUST VENT
Front View
Top View
EXHAUST VENT
INTAKE VENT
OUTSIDE WALL
12"
(305)
5−1/2"
(140)
Front View
EXHAUST VENT
DIRECT VENT CONCENTRIC WALL TERMINATION
(71M80, 69M29 or 60L46)
FIGURE 34
Inches(mm)
UNCONDITIONED
SPACE
OUTSIDE WALL
PROVIDE SUPPORT
FOR INTAKE AND
EXHAUST LINES EVERY
36" (914)
FIELD−PROVIDED
REDUCER MAY
BE REQUIRED TO
ADAPT LARGER
VENT PIPE SIZE
TO TERMINATION
1/2" (13) FOAM
INSULATION IN
UNCONDITIONED
SPACE
DIRECT VENT WALL RING TERMINATION
See venting table 7 for maximum venting lengths with this arrangement.
12" (305) MAX. for 2" (51)
SIDE VIEW
(15F74)
8 (203)
MIN.
SIZE
TERMINATION
PIPE PER
TABLE 8.
12" (305) ABOVE
AVERAGE SNOW
ACCUMULATION
1/2" (13) FOAM
INSULATION
FIGURE 35
Inches (mm)
INTAKE
VENT
Side View
OPTIONAL VENT TERMINATION FOR MULTIPLE UNIT
INSTALLATION OF DIRECT VENT WALL TERMINATION KIT
(22G44, 44J40, 30G28 or 81J20)
FIGURE 37
Page 28
Page 29
INTAKE
AIR
GRADE
12" (305) MAX. for 2" (51)
20" (508) MAX. for 3" (76)
8" (203)
Minimum
Side View
Inches (mm)
EXHAUST
AIR
12" MIN.
(305)
Above Grade or
average snow
accumulation
INTAKE
AIR
5"
(127)
12"
(305)
5-1/2"
(140)
COVER EXHAUST
VENT WITH
1/2" (13)
FOAM
INSULATION
EXHAUST
AIR
12" MIN.
(305)
Above Grade or
average snow
accumulation
GRADE
DIRECT VENT TERMINATION
WALL TERMINATION KIT (22G44, 44J40, 30G28 or 81J20) EXTENDED VENT FOR GRADE CLEARANCE
FIGURE 38
Front View
G51MP DIRECT VENT APPLICATION
USING EXISTING CHIMNEY
3" − 8"
8" − 12"
(203mm − 305mm)
INTAKE PIPE
SNOW
INSULATION (optional)
SHEET
METAL TOP
PLATE
INSULATE
TO FORM
SEAL
MINIMUM 12"
(305mm) ABOVE
ROOF OR AVERAGE
ACCUMULATION
*SIZE TERMINATION
PIPE PER TABLE 8.
NOTE − Do not discharge exhaust gases directly into any chimney or vent stack. If ver-
tical discharge through an existing unused chimney or stack is required, insert piping
inside chimney until the pipe open end is above top of chimney and terminate as illustrated. In any exterior portion of chimney, the exhaust vent must be insulated.
(76mm−
203mm)
STRAIGHT−CUT OR
ANGLE−CUT IN DIRECTION
OF ROOF SLOPE *
EXHAUST VENT
1/2" (13mm)
WEATHERPROOF
INSULATION
SHOULDER OF FITTINGS
PROVIDE SUPPORT
OF PIPE ON TOP PLATE
3" − 8"
(76mm−
203mm)
ALTERNATE
INTAKE PIPE
EXTERIOR
PORTION OF
CHIMNEY
FIGURE 39
Details of Exhaust Piping Terminations for Non-Direct
Vent Applications
Exhaust pipes may be routed either horizontally through an
outside wall or vertically through the roof. In attic or closet
installations, vertical termination through the roof is preferred. Figures 40 through 43 show typical terminations.
1 − Exhaust piping must terminate straight out or up as
shown. The termination pipe must be sized as listed in
table 8.The specified pipe size ensures proper velocity required to move the exhaust gases away from the
building.
2 − On field supplied terminations for side wall exits, ex-
haust piping should extend a maximum of 12 inches
(305mm) beyond the outside wall. See figure 41.
Inches(mm)
12" (305mm)
ABOVE AVE.
SNOW
ACCUMULATION
3" (76) OR
2" (51) PVC
PROVIDE SUPPORT
FOR EXHAUST LINES
NON−DIRECT VENT ROOF TERMINATION KIT
1/2" (13) ARMAFLEX
INSULATION IN
UNCONDITIONED SPACE
FIELD−PROVIDED
REDUCER MAY
BE REQUIRED TO
ADAPT LARGER
VENT PIPE SIZE
TO TERMINATION
Inches (mm)
NON−DIRECT VENT WALL RING KIT
(15F75 or 44J41)
FIGURE 40
12" (305) Max. for 2" (51)
TOP VIEW
(15F74)
FIGURE 41
SIZE TERMINATION
PIPE PER TABLE 8.
UNCONDITIONED
ATTIC SPACE
1/2" (13)
ARMAFLEX
INSULATION
PVC REDUCER
SIZE TERMINATION
PIPE PER TABLE 8.
Page 29
Page 30
3 − If exhaust piping must be run up a side wall to position
above snow accumulation or other obstructions, piping must be supported every 3 feet (.9m) as shown in
figure 22. Refer to figure 42 for proper piping method.
When exhaust piping must be run up an outside wall,
any reduction in exhaust pipe size must be done after
the final elbow.
Condensate Piping
This unit is designed for either right- or left-side exit of condensate piping in either upflow or downflow applications;
however, it must be installed on the same side of the unit as
the exhaust piping. In horizontal applications, the condensate trap should extend below the unit. A 5−1/2" service
clearance is required for the condensate trap. Refer to figure for condensate trap locations.
Inches(mm)
UNCONDITIONED
SPACE
OUTSIDE WALL
PROVIDE SUPPORT
FOR EXHAUST LINES
EVERY 36" (914)
FIELD−PROVIDED
REDUCER MAY BE
REQUIRED TO
ADAPT LARGER
VENT PIPE SIZE TO
TERMINATION
1/2" (13) FOAM
INSULATION IN
UNCONDITIONED
SPACE
12" (305) Max. for 2" (51)
12" (305) ABOVE
AVERAGE SNOW
ACCUMULATION
1/2" (13) FOAM
INSULATION
SIZE TERMINATION
PIPE PER
TABLE 8.
SIDE VIEW
NON−DIRECT VENT WALL RING TERMINATION
(15F74)
FIGURE 42
G51MP NON−DIRECT VENT APPLICATION
USING EXISTING CHIMNEY
SIZE TERMINATION
PIPE PER TABLE 8.
3" − 8"
(76mm−
203mm)
MINIMUM 12" (305mm)
ABOVE ROOF OR AVERAGE SNOW ACCU-
MULATION
SHEET
METAL TOP
PLATE
INSULATE
TO FORM
SEAL
NOTE − Do not discharge exhaust gases directly into any chimney or vent stack. If vertical discharge through an existing unused chimney or stack is required, insert piping
inside chimney until the pipe open end is above top of chimney and terminate as illustrated. In any exterior portion of chimney, the exhaust vent must be insulated.
STRAIGHT−CUT OR
ANGLE−CUT IN DIRECTION
OF ROOF SLOPE
EXHAUST VENT
1/2" (13mm)
WEATHERPROOF
INSULATION
SHOULDER OF FITTINGS
PROVIDE SUPPORT
OF PIPE ON TOP PLATE
3" − 8"
(76mm−
203mm)
EXTERIOR
PORTION OF
CHIMNEY
FIGURE 43
CONDENSATE TRAP LOCATIONS
(Unit shown in upflow position)
Horizontal
left and
optional
downflow
Optional
upflow
Horizontal
right and
optional
downflow
Optional
upflow
NOTE − In upflow applications where side return
air filter is installed on same side as the condensate trap, filter rack must be installed beyond
condensate trap to avoid interference.
FIGURE 44
1 − Determine which side condensate piping will exit the
unit. Remove plugs from the condensate collar at the
appropriate location on the side of the unit.
NOTE − The condensate trap is factory−shipped with
two rubber O−rings and two rubber clean−out caps
installed. Check to make sure that these items are in
place before installing the trap assembly.
2 − Install condensate trap onto the condensate collar.
Use provided HI/LO screws to secure two upper
flanges of the trap to the collar. Use provided sheet
metal screw to secure bottom trap flange to side of
unit. DO NOT apply glue to secure condensate trap
to cabinet. All other joints must be glued. See figure
45.
NOTE − In upflow and downflow applications, condensate trap must be installed on the same side as
exhaust piping.
Page 30
Page 31
CAUTION
DO NOT use a power driver to tighten screws which
secure condensate trap to cabinet. Screws should
be hand−tightened using a screw driver to avoid the
possibility of damage to the trap assembly.
O−RINGS
CONDENSATE ASSEMBLY
HI/LO SCREWS
(DO NOT use power
driver. Hand−tighten
using screw driver.)
VENT
NIPPLE
3 − The condensate trap provided with the unit is
manufactured using ABS material. Use ABS to PVC
transition solvent cement to glue a field−provided PVC
coupling or PVC pipe to the trap. Install a tee and vent
pipe near the trap.
NOTE − The condensate trap drain stubs (both sides)
have an outer diameter which will accept a standard
3/4" PVC coupling. The inner diameter of each stub
will accept standard 1/2" diameter PVC pipe.
NOTE − Vinyl tubing may be used for condensate
drain. Tubing must be 1−1/4" OD X 1" ID and should be
attached to the drain stubs on the trap using a hose
clamp.
4 − Glue the field−provided drain line to the tee. Route the
drain line to an open drain. As an alternate, clear vinyl
tubing may be used to drain condensate away from
the trap. Secure the vinyl tubing to the drain stubs on
the trap using a hose clamp. Do not overtighten the
hose clamp.
Condensate line must be sloped downward away from
condensate trap to drain. If drain level is above condensate trap, condensate pump must be used. Condensate drain line should be routed within the conditioned space to avoid freezing of condensate and
blockage of drain line. If this is not possible, a heat
cable kit may be used on the condensate trap and line.
Heating cable kit is available from Lennox in various
lengths; 6 ft. (1.8m) − kit no. 26K68; 24 ft. (7.3m) − kit
no. 26K69; and 50 ft. (15.2m) − kit no. 26K70.
CAUTION
Do not use copper tubing or existing copper
condensate lines for drain line.
5 − If unit will be started immediately upon completion of
installation, prime trap per procedure outlined in Unit
Start−Up section.
6 − Glue the provided cap onto the unused condensate
drain line stub.
TEE
CAP
COUPLING
CONDENSATE
SCREW
NOTE − Use screws to secure condensate trap to cabinet. DO
NOT apply glue to this joint. All other joints must be glued.
FIGURE 45
NIPPLE
CLEAN−OUT ACCESS
(both sides)
TRAP
Gas Piping
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.
WARNING
Do not exceed 600 in−lbs (50 ft−lbs) torque when attaching the gas piping to the gas valve.
1 − Gas piping may be routed into the unit through either
the left- or right-hand side. Supply piping enters into
the gas valve from the side of the valve as shown in
figure 48 or 48.
IMPORTANT
The Honeywell VR8205 gas valve requires a low inlet
pressure switch in LP/propane applications. A 4" BIP
nipple must be installed in the gas valve inlet when
right−side gas entry is used in LP/propane applications. See figure 47 or 48.
2 − When connecting gas supply, factors such as length of
run, number of fittings and furnace rating must be considered to avoid excessive pressure drop. Table 9 lists
recommended pipe sizes for typical applications.
NOTE − Use two wrenches when connecting gas piping to avoid transferring torque to the manifold.
Page 31
Page 32
3 − Gas piping must not run in or through air ducts, clothes
chutes, chimneys or gas vents, dumb waiters or elevator shafts. Center gas line through piping hole. Gas
line should not touch side of unit. See figure 48 or 48.
4 − Piping should be sloped 1/4 inch per 15 feet (6mm per
5.6m) upward toward the gas meter from the furnace.
The piping must be supported at proper intervals, every 8 to 10 feet (2.44 to 3.05m), using suitable hangers
or straps. Install a drip leg in vertical pipe runs to serve as
a trap for sediment or condensate.
5 − A 1/8" N.P.T. plugged tap or pressure post is located
on the gas valve to facilitate test gauge connection.
See figures 55 and 56.
6 − In some localities, codes may require installation of a
manual main shut-off valve and union (furnished by installer) external to the unit. Union must be of the
ground joint type.
IMPORTANT
Compounds used on threaded joints of gas piping
must be resistant to the actions of liquified petroleum gases.
MANUAL MAIN SHUT−OFF
VALVE WILL NOT HOLD
NORMAL TEST PRESSURE
FURNACE
ISOLATE
GAS VALVE
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.
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 46. Gas
valves can be damaged if subjected to pressures
greater than 1/2 psig (3.48 kPa).
WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warnings exactly could
result in serious injury, death, or property damage.
Never use an open flame to test for gas leaks. Check
all connections using a commercially available soap
solution made specifically for leak detection.Some
soaps used for leak detection are corrosive to certain
metals. Carefully rinse piping thoroughly after leak
test has been completed.
CAP
Upflow Application
Left Side Piping
(Standard)
MANUAL
MAIN SHUT−OFF
VALV E
GROUND
JOINT
UNION
FIGURE 46
DRIP LEG
AUTOMATIC
GAS VALVE
(with manual
shut−off valve)
FIELD
PROVIDED
AND INSTALLED
FIGURE 47
Upflow Application
Right Side Piping
(Alternate)
MANUAL
MAIN SHUT−OFF
VALV E
GROUND
JOINT
UNION
DRIP LEG
In LP/propane applications using a Honeywell
VR8205 gas valve, a 4" BIP nipple must be installed
to accommodate the low inlet pressure switch.
Page 32
Page 33
MANUAL
MAIN SHUT−OFF
VALV E
GROUND
JOINT
UNION
DRIP LEG
Horizontal Application
Right−Side Air Discharge
Horizontal Applications
Possible Gas Piping Configurations
MANUAL
MAIN SHUT−OFF
VALV E
GROUND
JOINT
UNION
DRIP LEG
In LP/propane applications using a
Honeywell VR8205 gas valve, a 4" BIP
nipple must be installed to accommodate
the low inlet pressure switch.
Horizontal Application
Left−Side Air Discharge
MANUAL
MAIN SHUT−OFF
VALV E
(With 1/8 in. NPT
Plugged Tap
Shown)
GROUND
JOINT
UNION
DRIP LEG
FIGURE 48
TABLE 9
GAS PIPE CAPACITY − FT3/HR (kL/HR)
Nominal
Iron Pipe Size
−Inches(mm)
1/4
(6.35)
3/8
(9.53)
1/2
(12.7)
3/4
(19.05)
1
(25.4)
1−1/4
(31.75)
1−1/2
(38.1)
2
(50.8)
2−1/2
(63.5)
3
(76.2)
4
(101.6)
Internal
Diameter
−Inches(mm)
.364
(9.246)
.493
(12.522)
.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)
4.026
(102.260)
10
(3.048)20(6.096)30(9.144)40(12.192)50(15.240)60(18.288)70(21.336)80(24.384)90(27.432)
43
(1.13)
95
(2.69)
175
(4.96)
360
(10.19)
680
(19.25)
1400
(39.64)
2100
(59.46)
3950
(111.85)
6300
(178.39)
11000
(311.48)
23000
(651.27)
29
(.82)
65
(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)
15800
(447.39)
24
(.68)
52
(1.47)
97
(2.75)
200
(5.66)
375
(10.62)
770
(21.80)
1180
(33.41)
2200
(62.30)
3520
(99.67)
6250
(176.98)
12800
(362.44)
NOTE − Capacity given in cubic feet of gas per hour (kilo liters of gas per hour) and based on 0.60 specific gravity gas.
Length of Pipe−Feet(m)
20
(.57)
45
(1.27)
82
(2.32)
170
(4.81)
320
(9.06)
660
(18.69)
990
(28.03)
1900
(53.80)
3000
(84.95)
5300
(150.07)
10900
(308.64)
18
(.51)
40
(1.13)
73
(2.07)
151
(4.28)
285
(8.07)
580
(16.42)
900
(25.48)
1680
(47.57)
2650
(75.04)
4750
(134.50)
9700
(274.67)
16
(.45)
36
(1.02)
66
(1.87)
138
(3.91)
260
(7.36)
530
(15.01)
810
(22.94)
1520
(43.04)
2400
(67.96)
4300
(121.76)
8800
(249.18)
15
(.42)
33
(.73)
61
(1.73)
125
(3.54)
240
(6.80)
490
(13.87)
750
(21.24)
1400
(39.64)
2250
(63.71)
3900
(110.43)
8100
(229.36)
14
(.40)
31
(.88)
57
(1.61)
118
(3.34)
220
(6.23)
460
(13.03)
690
(19.54)
1300
(36.81)
2050
(58.05)
3700
(104.77)
7500
(212.37)
13
(.37)
29
(.82)
53
(1.50)
110
(3.11)
205
(5.80)
430
(12.18)
650
(18.41)
1220
(34.55)
1950
(55.22)
3450
(97.69)
7200
(203.88)
100
(30.480)
12
(.34)
27
(.76)
50
(1.42)
103
(2.92)
195
(5.52)
400
(11.33)
620
(17.56)
1150
(32.56)
1850
(52.38)
3250
(92.03)
6700
(189.72)
Page 33
Page 34
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.
INTERIOR MAKE−UP BOX INSTALLATION
MAKE−UP
BOX
Right Side
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. If the make−up box is moved to the right
side, the excess wire must be pulled into the blower
compartment. Secure the excess wire to the existing harness to protect it from damage.
Refer to figure 52 for field wiring and figure 54 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 52. Use 18−gauge wire or
larger that is suitable for Class II rating for thermostat
connections.
FIGURE 49
INTERIOR MAKE−UP BOX INSTALLATION
Left side
MAKE−UP
BOX
FIGURE 50
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 G51MP furnace contains electronic components that are polarity sensitive. Make sure that the
furnace is wired correctly and is properly grounded.
One line voltage EAC" accessory terminal is provided
on the furnace 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 the
any of the NEUTRAL" terminals. See figure 53 for control board configuration. This terminal is energized
whenever the blower is operating.
One line voltage HUM" accessory terminal is provided
on the furnace 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 53 for control board
configuration. This terminal is energized in the heating
mode whenever the combustion air inducer is operating.
Page 34
Page 35
G51MP and CONDENSING UNIT
(Refer to specific thermostat and outdoor unit.)
Thermostat
R
W1
Y
G
C
THERMOSTAT DESIGNATIONS
G51MP
Furnace
POWER
HEAT
COOLING
INDOOR BLOWER
COMMON
R
W
Y
G
C
Condensing
Unit
CONDENSING
UNIT
CONDENSING
UNIT COMMON
FIGURE 51
One 24 volt 24V HUM" terminal is provided on the
furnace control board. Any humidifier rated up to 0.5
amp can be connected to this terminal with the com-
TYPICAL G51MP FIELD WIRING DIAGRAM
mon leg of the circuit being connected to the C" terminal of the thermostat terminal block, which is located on the control board.
Install the room thermostat according to the instruc-
tions provided with the thermostat. See figure 51 for
thermostat designations. If the furnace is being
matched with a heat pump, refer to the FM21 installation instruction.
Indoor Blower Speeds
When the thermostat is set to FAN ON," the indoor
blower will run continuously on the continuous low
speed (FAN) when there is no cooling or heating demand.
When the G51MP 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.
FIGURE 52
Page 35
Page 36
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 53
Page 36
Page 37
TYPICAL G51MP WIRING DIAGRAM
FIGURE 54
Page 37
Page 38
Unit Start−Up
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING
Do not use this furnace if any part has been underwater. A flood−damaged furnace is extremely dangerous. Attempts to use the furnace can result in
fire or explosion. Immediately call a qualified service technician to inspect the furnace and to replace
all gas controls, control system parts, and electrical
parts that have been wet or to replace the furnace,
if deemed necessary.
WARNING
Danger of explosion. Can cause injury
or product or property damage. Should
the gas supply fail to shut off or if
overheating occurs, shut off the gas
valve to the furnace before shutting off
the electrical supply.
CAUTION
Before attempting to perform any service or maintenance, turn the electrical power to unit OFF at disconnect switch.
Priming Condensate Trap
The condensate trap should be primed with water prior to
start−up to ensure proper condensate drainage. Either
pour 10 fl. oz. (300 ml) of water into the trap, or follow
these steps to prime the trap:
1 − Follow the lighting instructions to place the unit into op-
eration.
2 − Set the thermostat to initiate a heating demand.
3 − Allow the burners to fire for approximately 3 minutes.
4 − Adjust the thermostat to deactivate the heating de-
mand.
5 − Wait for the combustion air inducer to stop. Set the
thermostat to initiate a heating demand and again al-
low the burners to fire for approximately 3 minutes.
6 − Adjust the thermostat to deactivate the heating de-
mand and again wait for the combustion air inducer to
stop. At this point, the trap should be primed with suffi-
cient water to ensure proper condensate drain opera-
tion.
BEFORE LIGHTING the unit, smell all around the furnace 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 G51MP is equipped with a gas control switch (lever). Use only your hand to move the switch.
Never use tools. If the the switch 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:
G51MP units are equipped with a SureLight® ignition
system. Do not attempt to manually light burners on this
furnace. Each time the thermostat calls for heat, the
burners will automatically light. The ignitor does not get
hot when there is no call for heat on units with SureLight
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 55 and 56)
1 − STOP! Read the safety information at the beginning of
this section.
2 − Set the thermostat to the lowest setting.
3 − Turn off all electrical power to the unit.
4 − This furnace is equipped with an ignition device which
automatically lights the burners. Do not try to light the
burners by hand.
5 − Remove the upper access panel.
6 − White Rodgers 36G Gas Valve − Move gas valve
switch to OFF. See figure 55 for the White Rodgers
36G valve.
Honeywell VR8205 Gas Valve − Move gas valve
switch to OFF. See figure 56 for Honeywell VR8205
valve.
7 − Wait five minutes to clear out any gas. If you then smell
gas, STOP! Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s instructions. If you do not smell gas go to next step.
®
Page 38
Page 39
White Rodgers 36G Series Gas Valve
OUTLET
PRESSURE
POST
INLET
PRESSURE
POST
GAS VALVE SHOWN IN OFF POSITION
MANIFOLD
PRESSURE
ADJUSTMENT
SCREW
FIGURE 55
Honeywell VR8205 Gas Valve with ON/OFF Switch
MANIFOLD
PRESSURE
ADJUSTMENT
SCREW
(under
barbed
fitting)
INLET
PRESSURE
PORT
GAS VALVE SHOWN IN ON POSITION
MANIFOLD
PRESSURE
OUTLET
FIGURE 56
8 − White Rodgers 36G Gas Valve − Move gas valve
switch to ON. See figure 55 for the White Rodgers
36G valve
Honeywell VR8205 Gas Valve − Move gas valve
switch to ON. See figure 56 for Honeywell VR8205
valve.
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 − White Rodgers 36G Gas Valve − Move gas valve
switch to OFF.
Honeywell VR8205 Gas Valve − Move gas valve
switch to OFF.
5 − Replace the upper access panel.
Heating Sequence Of Operation
When thermostat calls for heat, combustion air inducer
starts.
Combustion air pressure switch proves blower opera-
tion. 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 10 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.
Page 39
Page 40
TABLE 10
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
Gas Supply Pressure Measurement
A threaded plug on the inlet side of the gas valve provides
access to the supply pressure tap. Remove the threaded
plug, install a field−provided barbed fitting and connect a
manometer to measure supply pressure. Replace the
threaded plug after measurements have been taken.
Manifold Pressure Measurement
To correctly measure manifold pressure, the differential
pressure between the positive gas manifold and the negative burner box must be considered. Use pressure test
adapter kit (available as Lennox part 10L34) to assist in
measurement.
1/2 cu ft Dial 1 cu ft Dial
Gas Meter Size
1 − Remove the threaded plug from the outlet side of the
gas valve and install a field−provided barbed fitting.
Connect test gauge +" connection to barbed fitting to
measure manifold pressure.
2 − Tee into the gas valve regulator vent hose and connect
test gauge −" connection.
3 − Start unit and allow 5 minutes for unit to reach steady
state.
4 − While waiting for the unit to stabilize, notice the flame.
Flame should be stable and should not lift from burner.
Natural gas should burn blue.
5 − After allowing unit to stabilize for 5 minutes, record
manifold pressure and compare to value given in table
11.
NOTE − Shut unit off and remove manometer as soon as an
accurate reading has been obtained. Take care to remove
barbed fitting and replace threaded plug.
IMPORTANT
The White Rodgers 36G gas valve (figure 55) is
equipped with pressure posts for measuring supply
and manifold pressures. The posts provide built−in
hose connections and have an integral 3/32" Allen−
head screw. Rotate the screw counterclockwise one
full turn to permit pressure measurement. Reseat the
screw (rotate one full turn clockwise) after measurements have been taken to prevent gas leakage.
Page 40
Page 41
High Altitude Information
NOTE − In Canada, certification for installations at elevations over 4500 feet (1372 m) is the jurisdiction of local authorities.
The manifold pressure may require adjustment to ensure
proper operation at higher altitudes. Refer to table 11 for
proper manifold pressure settings at varying altitudes.
Table 12 lists required pressure switch changes and conversion kits at varying altitudes.
The combustion air pressure switches are factory−set and
require no adjustment.
TABLE 12
Conversion Kit and Pressure Switch Requirements at Varying Altitudes
TABLE 11
Manifold Pressure (Outlet) inches w.c.
Model
Fuel
Nat.
Gas
L.P.
Gas
*Conversion kit required for applications at altitudes above 7501
ft. above sea level.
**Conversion kit required for applications at all altitudes.
Input
Sizes
All
sizes
All
sizes
0−
4500
3.5 3.5 3.5 3.5 3.5*
10.0** 10.0** 10.0** 10.0** 10.0**
Altitude (feet)
4501−
5500
5501−
6500
6501−
7500
7501−
10,000
NOTE − A natural to L.P. propane gas changeover kit is necessary to convert this unit. Refer to the changeover kit
installation instruction for the conversion procedure.
High Altitude
Input
−045 44W51 − − − 95M22 83M74 83M75
−070 44W51 56M05 56M06 83M74 83M75
−090 44W51 75M20 56M07 83M74 83M75
−110 44W51 75M20 56M07 83M74 83M75
−135 44W51 56M04 60M35 83M74 83M75
Pressure switch is factory set. No adjustment necessary. All models use the factory installed pressure switch from 0−4500 feet (0−1370 m).
Orifice Kit
Natural Gas Only
7501−10,000 ft. 4501−7500 ft. 7501−10,000 ft. 0−7500 ft. 7501−10,000 ft.
High Altitude Pressure
Switch Kit
LPG/Propane Kit
Page 41
Page 42
Testing for Proper Venting and Sufficient Combustion Air for Non−Direct Vent Applications
horizontal pitch. Determine there is no blockage or re-
WARNING
CARBON MONOXIDE POISONING HAZARD!
Failure to follow the steps outlined below for each
appliance connected to the venting system being
placed into operation could result in carbon monoxide poisoning or death.
The following steps shall be followed for each appliance connected to the venting system being
placed into operation, while all other appliances connected to the venting system are not in operation.
After the G51MP gas furnace has been started, the following test should be conducted to ensure proper venting and
sufficient combustion air has been provided to the G51MP,
as well as to other gas-fired appliances which are separately vented.
If a G51MP furnace replaces a Category I furnace which
was commonly vented with another gas appliance, the size
of the existing vent pipe for that gas appliance must be
checked. Without the heat of the original furnace flue products, the existing vent pipe is probably oversized for the
single water heater or other appliance. The vent should be
checked for proper draw with the remaining appliance.
The test should be conducted while all appliances (both in
operation and those not in operation) are connected to the
venting system being tested. If the venting system has
been installed improperly, or if provisions have not been
made for sufficient amounts of combustion air, corrections
must be made as outlined in the previous section.
1 − Seal any unused openings in the venting system.
2 − Visually inspect the venting system for proper size and
striction, leakage, corrosion, or other deficiencies
which could cause an unsafe condition.
3 − To the extent that it is practical, close all building doors
and windows and all doors between the space in which
the appliances connected to the venting system are lo-
cated and other spaces of the building.
4 − Close fireplace dampers.
5 − Turn on clothes dryers and any appliances not con-
nected to the 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.
6 − Follow the lighting instruction to place the appliance
being inspected into operation. Adjust thermostat so
appliance will operate continuously.
7 − Use the flame of match or candle to test for spillage of
flue gases at the draft hood relief opening after 5 min-
utes of main burner operation.
8 − If improper venting is observed during any of the
above tests, the venting system must be corrected or
sufficient combustion/make-up air must be provided.
The venting system should be re-sized to approach
the minimum size as determined by using the ap-
propriate tables in appendix G in the current standards
of the National Fuel Gas Code ANSI−Z223.1/NPFA 54
in the U.S.A., and the appropriate Natural Gas and
Propane appliances venting sizing tables in the cur-
rent standard of the CSA−B149 Natural Gas and Pro-
pane Installation Codes in Canada.
9 − After determining that each appliance remaining
connected to the common venting system properly
vents when tested as indicated in step 3, return
doors, windows, exhaust fans, fireplace dampers
and any other gas-burning appliance to their previous
condition of use.
Page 42
Page 43
Other Unit Adjustments
Primary and Secondary Limits
The primary limit is located on the heating compartment
vestibule panel. The secondary limits are 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 Switches (Two)
The pressure switches are located in the heating compartment on the combustion air inducer. These switches check
for proper combustion air inducer operation before allowing ignition trial. The switches are factory−set and require
no adjustment.
Temperature Rise
After the furnace has been started and supply and return air
temperatures have been allowed to stabilize, 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 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 SureLight® 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 53.
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 SureLight® 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 53.
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.
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
insulated.
Refer to blower speed selection chart on unit wiring dia-
gram for desired heating or cooling speed. See blower
performance data beginning on Page 44.
Connect selected speed tap at control board speed
terminal.
Resecure blower access panel.
Turn on electrical power to furnace.
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. This type of lockout is usually due to low gas
line pressure. 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.
Exhaust and Air Intake Pipe
1 − Check exhaust and air intake connections for tightness
and to make sure there is no blockage.
2 − Are pressure switches closed? Obstructed exhaust
pipe will cause unit to shut off at pressure switches.
Check termination for blockages.
3 − 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.
Page 43
Page 44
Blower Motor Performance
G51MP−24B−045 PERFORMANCE (Less Filter)
External
Static
Pressure
in. w.g.
0.00 1125 425 900 360 745 295 690 265
0.10 1115 410 905 350 760 285 695 260
0.20 1090 395 895 335 755 280 685 255
0.30 1060 380 880 325 740 270 675 250
0.40 1020 365 860 315 720 260 665 240
0.50 970 345 835 300 700 255 640 230
0.60 920 335 795 290 665 240 600 220
0.70 860 315 730 270 620 230 565 215
0.80 760 295 665 250 560 215 510 200
0.90 675 275 585 230 495 200 465 175
NOTES − Air volume based on bottom return air. Actual air volume may vary on side return air applications.
Air Volume / Watts at Different Blower Speeds
High
Medium−
High
Medium−
Low
Low
cfm Watts cfm Watts cfm Watts cfm Watts
G51MP−36B−045 PERFORMANCE (Less Filter)
External
Static
Pressure
in. w.g.
0.00 1555 630 1410 585 1190 520 1030 435
0.10 1515 605 1385 555 1190 485 1020 415
0.20 1470 580 1345 520 1170 455 1010 400
0.30 1410 555 1310 495 1155 440 1000 385
0.40 1350 535 1250 465 1120 410 980 360
0.50 1290 505 1205 450 1080 390 950 345
0.60 1220 485 1145 420 1020 365 905 320
0.70 1145 460 1080 400 975 345 860 300
0.80 1050 425 985 365 870 320 785 285
0.90 945 410 900 345 825 305 730 270
Air Volume / Watts at Different Blower Speeds
High
Medium−
High
Medium−
Low
Low
cfm Watts cfm Watts cfm Watts cfm Watts
G51MP−36B−070 PERFORMANCE (Less Filter)
External
Static
Pressure
in. w.g.
0.00 1640 660 1415 575 1160 485 1005 410
0.10 1600 635 1395 550 1160 460 1000 385
0.20 1540 605 1370 525 1160 445 995 375
0.30 1495 580 1345 505 1145 425 990 365
0.40 1420 545 1275 480 1125 395 965 345
0.50 1360 525 1245 450 1080 375 945 325
0.60 1275 490 1165 410 1025 350 900 305
0.70 1170 465 1085 385 965 335 860 295
0.80 1080 440 1010 360 865 310 775 270
0.90 945 400 840 320 765 275 710 245
NOTES − Air volume based on bottom return air. Actual air volume may vary on side return air applications.
Air Volume / Watts at Different Blower Speeds
High
Medium−
High
Medium−
Low
Low
cfm Watts cfm Watts cfm Watts cfm Watts
G51MP−48C−090 PERFORMANCE (Less Filter)
External
Static
Pressure
in. w.g.
Air Volume / Watts at Different Blower Speeds
High
Medium−
High
Medium−
Low
Low
cfm Watts cfm Watts cfm Watts cfm Watts
0.00 2180 930 1835 790 1520 630 1280 510
0.10 2135 885 1825 750 1510 610 1275 495
0.20 2085
0.30
0.40 1940 760 1735 650 1480 535 1250 440
0.50 1865
0.60
0.70 1645 640 1475 520 1290 450 1105 375
0.80 1540
0.90
840 1810 720 1505 580 1270 475
2030 800 1775 685 1500 565 1265 460
725 1660 600 1430 505 1215 425
1740 670 1590 575 1380 475 1175 410
600 1340 465 1175 405 1020 355
1335 540 1170 440 1070 375 950 330
G51MP−36C−090 PERFORMANCE (Less Filter)
External
Static
Pressure
in. w.g.
0.00 1630 745 1360 635 1125 540 975 440
0.10 1620 715 1365 610 1160 515 1000 430
0.20 1590 680 1365 580 1160 495 990 405
0.30 1550 655 1355 565 1170 475 985 395
0.40 1520 630 1330 545 1160 460 980 380
0.50 1465 605 1300 515 1140 440 960 360
0.60 1415 570 1250 490 1095 420 940 350
0.70 1350 545 1215 470 1065 400 905 335
0.80 1260 510 1140 440 1005 375 850 310
0.90 1165 475 1035 395 900 335 730 285
G51MP−48C−110 PERFORMANCE (Less Filter)
External
Static
Pressure
in. w.g.
0.00 2160 880 1880 755 1490 602 1235 485
0.10 2100 850 1855 730 1480 585 1230 475
0.20 2035
0.30
0.40 1885 725 1715 625 1465 510 1215 430
0.50 1780
0.60
0.70 1575 620 1410 505 1210 405 1035 350
0.80 1375
0.90
Air Volume / Watts at Different Blower Speeds
High
Medium−
High
Medium−
Low
Low
cfm Watts cfm Watts cfm Watts cfm Watts
Air Volume / Watts at Different Blower Speeds
High
Medium−
High
Medium−
Low
Low
cfm Watts cfm Watts cfm Watts cfm Watts
805 1815 690 1475 560 1225 460
1965 750 1755 650 1475 545 1220 445
680 1630 580 1420 490 1150 400
1690 660 1550 550 1360 460 111 0 380
550 1230 450 1125 380 970 325
1225 520 1120 415 1050 365 885 310
Page 44
Page 45
G51MP−60C−090 PERFORMANCE (Less Filter)
Air Volume / Watts at Different Blower Speeds
External
Static
Pressure −
in. w.g.
0.00
0.10 2765 1415 2365 1080 1950 885 1580 700 2785 1475 2345 1135 1805 865 1515 690
0.20 2695 1385 2345 1050 1985 870 1620 695 2715 1435 2275 1080 1825 845 1560 685
0.30 2605 1335 2315 1030 1990 850 1645 690 2620 1380 2260 1035 1840 825 1600 680
0.40 2530 1300 2265 990 1990 825 1665 675 2550 1350 2230 1015 1845 815 1620 670
0.50 2420 1260 2210 955 1970 800 1675 665 2450 1305 2175 990 1850 790 1615 655
0.60 2330 1220 2145 925 1930 775 1665 650 2365 1270 2130 940 1830 775 1615 640
0.70 2250 1190 2050 885 1875 745 1645 630 2240 1205 2070 915 1815 760 1595 620
0.80 2135
0.90 2030 1090 1885 830 1720 685 1560 590 2015 1150 1820 820 1690 715 1440 580
G51MP−60C−110 PERFORMANCE (Less Filter)
External
Static
Pressure
in. w.g.
0.00 2720 1385 2410 1090 2055 935 1620 710 2625 1350 2310 1080 1885 885 1515 700
0.10 2665 1355 2385 1075 2025 885 1730 735 2570 1330 2325 1060 1910 865 1575 700
0.20 2585 1315 2350 1015 2030 865 1680 690 2410 1305 2285 1035 1930 845 1620 690
0.30 2505 1275 2290 990 2025 840 1695 675 2425 1265 2230 990 1925 825 1635 675
0.40 2435 1250 2235 940 2030 830 1695 660 2335 1220 2175 950 1910 810 1640 660
0.50 2350 1205 2170 930 1975 790 1735 665 2270 1195 2120 935 1895 785 1640 640
0.60 2255 1185 2100 895 1915 765 1720 650 2170 1155 2045 885 1860 765 1630 630
0.70 2160 1150 2005 840 1865 730 1680 635 2110 1130 1950 855 1795 730 1590 610
0.80 2020
0.90 1910 1050 1820 795 1705 675 1540 590 1900 1055 1760 780 1665 680 1470 565
Bottom Return Air, Side Return Air with Optional RAB
Return Air Base, Return Air from Both Sides or Return
Air from Bottom and One Side.
High Medium−High Medium−Low Low High Medium−High Medium−Low Low
cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts
2840 1450 2345 1105 1895 900 1515 700 2835 1495 2340 1155 1800 895 1440 695
1140 2000 865 1810 715 1620 615 2185 1190 1965 865 1775 745 1555 605
Air Volume / Watts at Different Blower Speeds
Bottom Return Air, Side Return Air with Optional RAB
Return Air Base, Return Air from Both Sides or Return
Air from Bottom and One Side.
High Medium−High Medium−Low Low High Medium−High Medium−Low Low
cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts
1090 1905 825 1810 710 1625 610 2035 1090 1885 820 1745 705 1540 580
Single Side Return Air − Air volumes in bold require field
fabricated transition to accommodate 20 x 25 x 1 in. air
filter in order to maintain proper air velocity.
Single Side Return Air − Air volumes in bold require field
fabricated transition to accommodate 20 x 25 x 1 in. air
filter in order to maintain proper air velocity.
G51MP−60D−135 PERFORMANCE (Less Filter)
External
Static
Pressure
in. w.g.
0.00 2730 1465 2425 1125 2055 915 1560 680 2665 1440 2325 1100 1865 890 1410 690
0.10 2670 1440 2400 1100 2065 890 1590 675 2615 1405 2310 1065 1915 865 1465 685
0.20 2600 1400 2365 1070 2045 865 1620 665 2530 1370 2280 1055 1925 850 1570 675
0.30 2525 1360 2315 1045 2035 845 1615 655 2470 1330 2235 1015 1920 825 1590 670
0.40 2445 1325 2260 1015 2020 820 1615 645 2380 1290 2175 985 1910 805 1590 655
0.50 2360 1280 2195 985 1960 790 1610 635 2310 1265 2120 965 1890 790 1595 645
0.60 2290 1255 2130 965 1900 755 1600 615 2200 1230 2055 935 1835 765 1580 630
0.70 2205 1220 2035 910 1825 730 1570 600 2120 1190 1970 900 1790 740 1545 605
0.80 2110 1195 1945 880 1765 710 1540 580 2025 1160 1890 875 1720 710 1515 590
0.90
Bottom Return Air, Side Return Air with Optional RAB
Return Air Base, Return Air from Both Sides or Return
Air from Bottom and One Side.
High Medium−High Medium−Low Low High Medium−High Medium−Low Low
cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts
1970 1120 1835 830 1680 690 1540 545 1930 1110 1800 835 1655 685 1440 570
Air Volume / Watts at Different Blower Speeds
Single Side Return Air − Air volumes in bold require field
fabricated transition to accommodate 20 x 25 x 1 in. air
filter in order to maintain proper air velocity.
Page 45
Page 46
Service
WARNING
ELECTRICAL SHOCK, FIRE,
OR EXPLOSION HAZARD.
Failure to follow safety warnings exactly could result
in dangerous operation, serious injury, death or
property damage.
Improper servicing could result in dangerous operation, serious injury, death, or property damage.
Before servicing, disconnect all electrical power to
furnace.
When servicing controls, label all wires prior to disconnecting. Take care to reconnect wires correctly.
Verify proper operation after servicing.
At the beginning of each heating season, system should be
checked as follows by a qualified service technician:
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
The blower access panel must be securely in place
when the blower and burners are operating. Gas
fumes, which could contain carbon monoxide, can
be drawn into living space resulting in personal injury or death.
Filters
All G51MP filters are installed external to the unit. Filters
should be inspected monthly. Clean or replace the filters
when necessary to ensure proper furnace operation.
Table 3 lists recommended filter sizes.
Exhaust and air intake pipes
Check the exhaust and air intake pipes and all connections
for tightness and to make sure there is no blockage.
NOTE − After any heavy snow, ice or frozen fog event the
furnace vent pipes may become restricted. Always check
the vent system and remove any snow or ice that may be
obstructing the plastic intake or exhaust pipes.
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__________
Winterizing and Condensate Trap Care
1 − Turn off power to the unit.
2 − Have a shallow pan ready to empty condensate water.
3 − Remove the drain plug from the condensate trap and
empty water. Inspect the trap then reinstall the drain
plug.
Cleaning Heat Exchanger
If cleaning the heat exchanger becomes necessary, follow
the below procedures and refer to figure 1 when disassembling unit. Use papers or protective covering in front of furnace while removing heat exchanger assembly.
1 − Turn off electrical and gas supplies to the furnace.
2 − Remove the upper and lower furnace access panels.
3 − Mark all gas valve wires and disconnect them from
valve.
4 − Remove gas supply line connected to gas valve. Re-
move gas valve/manifold assembly.
5 − Remove sensor wire from sensor. Disconnect 2-pin or
3−pin plug from the ignitor.
6 − Disconnect wires from flame roll−out switches.
7 − Remove burner box cover and remove four burner box
screws at the vestibule panel and remove burner box.
Set burner box assembly aside.
NOTE − If necessary, clean burners at this time. Follow
procedures outlined in Burner Cleaning section.
8 − Loosen three clamps and remove flexible exhaust tee.
9 − Remove 3/8 inch rubber cap from condensate drain
plug and drain. Replace cap after draining.
10 − Disconnect condensate drain line from the conden-
sate trap. Remove condensate trap (it may be neces-
sary to cut drain pipe). Remove screws that secure
condensate collars to either side of the furnace and re-
move collars. Remove drain tubes from cold end
header collector box.
11 − Disconnect condensate drain tubing from flue collar.
Remove screws that secure both flue collars into
place. Remove flue collars. It may be necessary to cut
the exiting exhaust pipe for removal of the fittings.
12 − Disconnect the 2-pin plug from the combustion air in-
ducer. Disconnect the two wires to the secondary limit,
if applicable. Remove four screws which secure com-
bustion air inducer to collector box Remove combus-
tion air inducer assembly. Remove ground wire from
vest panel.
13 − Mark and disconnect all combustion air pressure tub-
ing from cold end header collector box.
14 − Mark and remove wires from pressure switches. Re-
move pressure switches. Keep tubing attached to
pressure switches.
15 − Remove electrical junction box from the side of the fur-
nace.
16 − Mark and disconnect any remaining wiring to heating
compartment components. Disengage strain relief
bushing and pull wiring and bushing through the hole in
the blower deck.
Page 46
Page 47
17 − Remove the primary limit from the vestibule panel.
18 − Remove two screws from the front cabinet flange at
the blower deck. Spread cabinet sides slightly to allow
clearance for removal of heat exchanger.
19 − Remove screws along vestibule sides and bottom
which secure vestibule panel and heat exchanger assembly to cabinet. Remove two screws from blower
rail which secure bottom heat exchanger flange. Remove heat exchanger from furnace cabinet.
20 − Back wash heat exchanger with soapy water solution
or steam. If steam is used it must be below 275°F
(135°C) .
21 − Thoroughly rinse and drain the heat exchanger. Soap
solutions can be corrosive. Take care to rinse entire
assembly.
22 − Reinstall heat exchanger into cabinet making sure that
the clamshells of the heat exchanger assembly are
resting on the support located at the rear of the cabinet. Remove the indoor blower to view this area
through the blower opening.
23 − Re-secure the supporting screws along the vestibule
sides and bottom to the cabinet.
24 − Reinstall cabinet screws on front flange at blower
deck.
25 − Reinstall the primary limit on the vestibule panel.
26 − Route heating component wiring through hole in blow-
er deck and reinsert strain relief bushing.
27 − Reinstall pressure switches and reconnect pressure
switch wiring.
28 − Carefully connect combustion air pressure switch
hosing from pressure switches to proper stubs on
cold end header collector box.
29 − Reinstall condensate collars on each side of the fur-
nace. Reconnect drain tubing to collector box.
30 − Reinstall condensate trap on same side as exhaust
pipe. Reconnect condensate drain line to the conden-
sate trap.
31 − Reinstall electrical junction box.
32 − Reinstall the combustion air inducer. Reconnect the
2−pin or 3−pin plug to the wire harness. Reconnect the
two wires to the secondary limit, if applicable.
33 − Use securing screws to reinstall flue collars to either
side of the furnace. Reconnect exhaust piping and ex-
haust drain tubing.
34 − Replace flexible exhaust tee on combustion air induc-
er and flue collars. Secure using three existing hose
clamps.
35 − Reinstall burner box assembly in vestibule area.
36 − Reconnect flame roll−out switch wires.
37 − Reconnect sensor wire and reconnect 2−pin plug from
ignitor.
38 − Secure burner box assembly to vestibule panel using
four existing screws. Make sure burners line up in
center of burner ports.
39 − Reinstall gas valve manifold assembly. Reconnect
gas supply line to gas valve.
40 − Reinstall burner box cover.
41 − Reconnect wires to gas valve.
42 − Replace the blower compartment access panel.
43 − Refer to instruction on verifying gas and electrical con-
nections when re−establishing supplies.
44 − Follow lighting instructions to light and operate fur-
nace for 5 minutes to ensure that heat exchanger is
clean and dry and that furnace is operating properly.
45 − Replace heating compartment access panel.
Cleaning the Burner Assembly
1 − Turn off electrical and gas power supplies to furnace.
Remove upper and lower furnace access panels.
2 − Mark all gas valve wires and disconnect them from the
valve.
3 − Disconnect the gas supply line from the gas valve. Re-
move gas valve/manifold assembly.
4 − Mark and disconnect sensor wire from the sensor. Dis-
connect 2-pin plug from the ignitor at the burner box.
5 − Remove burner box cover and remove four screws
which secure burner box assembly to vest panel. Re-
move burner box from the unit.
6 − Use the soft brush attachment on a vacuum cleaner to
gently clean the face of the burners. Visually inspect
the inside of the burners and crossovers for any block-
age caused by foreign matter. Remove any blockage.
7 − Reconnect the sensor wire and reconnect the 2−pin
plug to the ignitor wiring harness.
8 − Reinstall the burner box assembly using the existing
four screws. Make sure that the burners line up in the
center of the burner ports.
9 − Reinstall the gas valve manifold assembly. Reconnect
the gas supply line to the gas valve. Reinstall the burn-
er box cover.
10 − Reconnect the gas valve wires to the gas valve.
11 − Replace the blower compartment access panel.
12 − Refer to instruction on verifying gas and electrical con-
nections when re−establishing supplies.
13 − Follow lighting instructions to light and operate fur-
nace for 5 minutes to ensure that heat exchanger is
clean and dry and that furnace is operating properly.
14 − Replace heating compartment access panel.
Page 47
Page 48
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.
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.
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.
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.
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 nameplate −− Example: G51MP−24B−045−1. All service must be performed by a licensed pro-
fessional installer (or equivalent), service agency, or gas supplier.
Cabinet Parts
Upper access panel
Blower access 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 cutoff plate
Heating Parts
Flame Sensor
Heat exchanger assembly
Gas manifold
Combustion air inducer
Gas valve
Main burner cluster
Main burner orifices
Pressure switches
Ignitor
Primary limit control
Secondary limit control
Flame rollout switches
Combustion air inducer auxiliary limit
Page 48
Page 49
SureLight® Troubleshooting: Heating Sequence of Operation
SURELIGHT CONTROL
HEATING SEQUENCE OF OPERATION
NORMAL HEATING MODE ABNORMAL HEATING MODE
POWER ON
CONTROL SELF−CHECK OKAY?
IS POLARITY REVERSED?
NO
IS VOLTAGE
ABOVE 75 VOLTS?
YES
ROLLOUT SWITCHES CLOSED?
YES
BURNER OFF?
(CONTINUOUS FLAME CHECK)
YES
NORMAL OPERATION:
DS1 −− SLOW FLASH
DS2 −− SLOW FLASH
THERMOSTAT CALLS FOR HEAT:
DS1 −− FAST FLASH
DS2 −− FAST FLASH
YES
ARE COMBUSTION AIR
PRESSURE SWITCHES OPEN?
YES
IS COMBUSTION AIR INDUCER ENERGIZED?
(HUM TERMINALS ARE ENERGIZED WITH CAI)
YES
HAVE COMBUSTION AIR PRESSURE
SWITCHES CLOSED IN 2.5 MINUTES?
YES
CONTINUED NEXT PAGE
NO
NO
YES
NO
NO
NO
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.
SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES.
GAS VALVE OFF. COMBUSTION AIR INDUCER ON.
INDOOR BLOWER ON HEATING SPEED.
NO
PRESSURE SWITCHES IN WATCHGUARD MODE.
GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.
INDOOR BLOWER OFF WITH DELAY.
DS1 −− OFF. DS2 −− SLOW FLASH.
IS 5-MINUTE RESET PERIOD COMPLETE?
INDOOR BLOWER ON.
DS1 ALTERNATING FAST FLASH
DS2 ALTERNATING FAST FLASH
CHECK FOR BROKEN IGNITOR OR
OPEN IGNITOR CIRCUIT
INDOOR BLOWER DELAY OFF.
DS1 ON
DS2 ON
POLARITY REVERSED.
DS1 −− FAST FLASH
DS2 −− SLOW FLASH
DS1 AND DS2 ALTERNATING FAST
FLASH. SIGNAL HOLDS UNTIL VOLTAGE
RISES ABOVE 75 VOLTS.
DS1 −− ON. DS2 −− SLOW FLASH.
DS1 −− SLOW FLASH
DS2 −− OFF
GAS VALVE OFF.
COMBUSTION AIR INDUCER OFF.
INDOOR BLOWER OFF WITH DELAY.
DS1 OFF
DS2 SLOW FLASH
(Sequence holds until pressure switch
closes or thermostat resets control.)
Page 49
Page 50
SureLight® 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 0.34 MICROAMPS?
YES
INDOOR BLOWER ON DELAY BEGINS
(45 seconds.)
YES
PRIMARY AND SECONDARY LIMIT
SWITCHES CLOSED?
COMBUSTION AIR INDUCER
AUXILIARY LIMIT SWITCH CLOSED?
YES
IS VOLTAGE ABOVE 75 VOLTS?
NO
IS THERE A PROPER GROUND?
YES
IS IGNITOR INTACT AND CONNECTED?
GAS VALVE OFF. COMBUSTION AIR INDUCER ON.
NO
HAS CONTROL FAILED TO SENSE FLAME FOR
FIVE CONSECUTIVE TRIES DURING A SINGLE
IGNITION WATCHGUARD MODE. GAS VALVE OFF.
DS1 ALT. SLOW FLASH DS2 ALT. SLOW FLASH
IS 60-MINUTE RESET PERIOD COMPLETE?
NO
NO
(Does not affect operation of control)
GAS VALVE DE−ENERGIZED.
COMBUSTION AIR INDUCER
DE−ENERGIZED.INDOOR BLOWER
NO
ON UNTIL SWITCHES CLOSE. DS1
−− SLOW FLASH. DS2 −− ON.
IS LIMIT SWITCH CLOSED?
HAVE PRIMARY/SECONDARY/CAI
YES
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
DS1 −− SLOW FLASH
DS2 −− FAST FLASH
YES
AUX. LIMITS RESET (CLOSED)
WITHIN 3 MINUTES?
NO
NO
DS1 & DS2
SIGNAL
ALTERNATING
NO
FAST FLASH.
NO
YES
YES
YES
LIMIT SWITCH WATCH-
GUARD MODE. GAS
VALVE OFF. COMB. AIR
INDUCER OFF. INDOOR
BLOWER OFF WITH
DELAY. DS1 − SLOW
FLASH DS2 − ON. IS
60MINUTE RESET
PERIOD COMPLETE?
NO
YES
NO
ROLLOUT SWITCHES CLOSED?
YES
COMBUSTION AIR PRESSURE
SWITCH CLOSED?
YES
THERMOSTAT DEMAND SATISFIED.
YES
DS1 & DS2 SIMULTANEOUS SLOW FLASHES.
YES
COMB. AIR INDUCER CONTINUES 5-SECOND
POST PURGE AFTER T’STAT DEMAND IS SATISFIED.
INDOOR AIR BLOWER COMPLETES SELECTED OFF"
DELAY BEFORE SHUTTING OFF.
NO
SEQUENCE HOLDS UNTIL ROLLOUT SWITCH AND
NO
GAS VALVE DE−ENERGIZED.
COMBUSTION AIR INDUCER ON.
INDOOR BLOWER OFF WITH DELAY
DS1 −− OFF. DS2 −− SLOW FLASH.
HAS CAB SWITCH CLOSED IN 2.5 MINUTES?
5-MINUTE PRESSURE SWITCH
GAS VALVE POWER OFF.
COMBUSTION AIR INDUCER POWER ON.
INDOOR BLOWER ON WITH DELAY
DS1 −− ON. DS2 −− SLOW FLASH.
THERMOSTAT IS RESET.
NO
WATCHGUARD MODE.
Page 50
YES
YES
YES
Page 51
SureLight® Troubleshooting: Cooling Sequence of Operation
SURELIGHT CONTROL
COOLING SEQUENCE OF OPERATION
NORMAL COOLING MODE ABNORMAL COOLING MODE
POWER ON.
IGNITION CONTROL MAIN POWER ON.
CONTROL SELF DIAGNOSTIC CHECK.
IS CONTROL OPERATING NORMALLY?
YES
IS POLARITY REVERSED?
NO
IS VOLTAGE
ABOVE 75 VOLTS?
YES
ROLLOUT SWITCHES MONITORED CONTINUOUSLY.
ARE ROLLOUT SWITCHES CLOSED?
YES
DS1 & DS2: SLOW FLASH RATE REMAINS
UNCHANGED THROUGHOUT COOLING CYCLE.
THERMOSTAT CALLS FOR COOLING.
COMPRESSOR CONTACTOR AND SYSTEM FAN
ENERGIZED WITH 2-SECOND DELAY. COOL
SPEED TERMINAL IS ENERGIZED. EAC
TERMINAL IS ENERGIZED.
NO
NO
YES
NO
GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.
INDOOR BLOWER OFF WITH NORMAL DELAY.
SIGNAL CIRCUIT BOARD FAILURE AT DS1 & DS2.
INTERRUPT MAIN POWER TO RESET CONTROL.
DS1 FAST FLASH DS2 SLOW FLASH.
DS1 AND DS2 ALTERNATING FAST
FLASH. SIGNAL HOLDS UNTIL VOLTAGE
RISES ABOVE 75 VOLTS.
GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.
INDOOR BLOWER OFF WITH NORMAL DELAY.
SIGNAL CIRCUIT BOARD FAILURE AT DS1 & DS2.
SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES.
THERMOSTAT OPENS.
COMPRESSOR OFF.
SYSTEM FAN AND EAC TERM. OFF
WITH 2− OR 45-SECOND DELAY.
Page 51
Page 52
SureLight® Troubleshooting: Continuous Fan Sequence of Operation
SURELIGHT CONTROL
CONTINUOUS FAN SEQUENCE OF OPERATION
DS1 & DS2: 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.
HUM (120 VAC & 24VAC)
THERMOSTAT CALLS FOR HEAT (W).
NO
THERMOSTAT CALLS FOR COOLING.
YES
INDOOR BLOWER SWITCHES TO COOL SPEED.
THERMOSTAT OPENS.
YES
NO
INDOOR BLOWER SWITCHES TO HEAT SPEED
AFTER NORMAL DELAY.
THERMOSTAT OPENS. COMBUSTION AIR INDUCER
AND HUM TERMINALS ARE DE−ENERGIZED
FOLLOWING 5−SECOND POST−PURGE.
INDOOR BLOWER SELECTED TIME OFF DELAY BEGINS.
AFTER DELAY, HEAT SPEED DE−ENERGIZED.
(Blower remains energized during continuous fan mode).
TERMINALS ENERGIZED
WITH COMB. AIR INDUCER.
INDOOR BLOWER SWITCHES TO SELECTED
BLOWER SPEED. EAC TERM. REMAINS
ENERGIZED.
Ignition Control Board Diagnostic Codes
DIAGNOSTIC CODES
Refer to Installation Instructions for control board layout.
DS1
(Red or Green)
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. Improper main ground.
SLOW FLASH FAST FLASH Low flame signal. Check flame sensor.
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 flame sense current = 0.15 − 0.24 microAmps.
DS2
(Green)
SIMULTANEOUS
SLOW FLASH
SIMULTANEOUS
FAST FLASH
ALTERNATING
SLOW FLASH
ON
OFF
ON
ALTERNATING
FAST FLASH
Make sure to Identify LED’S Correctly.
DESCRIPTION
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: Blocked inlet/exhaust vent;
OR: Condensate line blocked;
OR: Pressure switch closed prior to activation of combustion air inducer.
Watchguard −− Burners failed to ignite, limit open longer than 3 minutes, or flame sense lost 5
times in one heating cycle.
Circuit board failure or control wired incorrectly. Check 24−volt and 115−volt connections 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.
Page 52
Page 53
Vent Pipe Sizing Worksheet
Step 1
Step 2
Proposed vent pipe size : ______
Termination kit catalog number : _____________
Equivalent Feet
Vent pipe equivalency value from table 5 : ______
Step 3
Total number of 90° elbows required (indoors and outdoors)
______ X 5 = ______ equivalent feet of pipe
Step 4
Total number of 45° elbows required (indoors and outdoors)
______ X 2.5 = ______ equivalent feet of pipe
Step 5
Step 6
Linear feet of straight pipe required : ______
Add equivalent feet of vent pipe listed in
TOTAL
steps 2 through 5.
If the total is equal to, or less than, the allowable maximum given in table 7, the proposed pipe size is acceptable. If the
total exceeds the maximum allowed vent pipe length, repeat the process above using the next larger diameter pipe until
an acceptable total is achieved.
NOTE − In Direct Vent systems, total the equivalent length of either the exhaust OR intake piping run, depending upon which
will be LONGER. Intake and exhaust pipe diameter must be the same size and must be terminated in the same pressure
zone. Intake and exhaust pipe should be roughly the same length.
G51MP Start−Up & Performance Check List
Job Name
Job Location
Installer
Unit Model No.
Serial No.
Job No.
City
City
Technician
Date
State
State
Heating Section
Electrical Connections Tight?
Supply Voltage
Blower Motor Amps
Fuel Type: Natural Gas?
Furnace Btu Input
Line Pressure
Regulator Pressure
Flue Connections Tight?
Condensate Connections Tight?
Combustion Gas Tested?
Fan Control Setting
(45 Seconds Fixed On)
Fan Control Off Setting
Filter Clean & Secure?
w.c. − Nat.:
CO
LP/Propane Gas?
2
Blower Motor H.P.
Gas Piping Connections
Tight & Leak−Tested?
w.c. − LP/Propane
Proper Draft?
CO
Temperature Rise
Vent Clear?
Thermostat
Calibrated? Heat Anticipator Properly Set? Level?
Page 53
Page 54
Requirements for Commonwealth of Massachusetts
Modifications to NFPA−54, Chapter 10
Revise NFPA−54 section 10.8.3 to add the following requirements:
For all side wall, horizontally vented, gas−fueled equipment
installed in every dwelling, building or structure used in
whole or in part for residential purposes, including those
owned or operated by the Commonwealth and where the
side wall exhaust vent termination is less than seven (7)
feet above the finished grade in the area of the venting, including but not limited to decks and porches, the following
requirements shall be satisfied:
1 − INSTALLATION OF CARBON MONOXIDE DETEC-
TORS. At the time of installation of the side wall, horizontally vented, gas−fueled equipment, the installing
plumber or gasfitter shall observe that a hard−wired
carbon monoxide detector with an alarm and battery
backup is installed on the floor level where the gas
equipment is to be installed. In addition, the installing
plumber or gasfitter shall observe that a battery−operated or hard−wired carbon monoxide detector with an
alarm is installed on each additional level of the dwelling, building or structure served by the side wall, horizontally vented, gas−fueled equipment. It shall be the
responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard−wired carbon monoxide detectors.
a − In the event that the side wall, horizontally vented,
gas−fueled equipment is installed in a crawl space
or an attic, the hard−wired carbon monoxide detector with alarm and battery back−up may be installed
on the next adjacent floor level.
b − In the event that the requirements of this subdivi-
sion cannot be met at the time of completion of
installation, the owner shall have a period of thirty
(30) days to comply with the above requirements;
provided, however, that during said thirty (30) day
period, a battery−operated carbon monoxide detector with an alarm shall be installed.
2 − APPROVED CARBON MONOXIDE DETECTORS.
Each carbon monoxide detector as required in accordance with the above provisions shall comply with
NFPA 720 and be ANSI/UL 2034 listed and IAS certified.
3 − SIGNAGE. A metal or plastic identification plate shall
be permanently mounted to the exterior of the building
at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented, gas−fueled heating appliance or
equipment. The sign shall read, in print size no less
than one−half (1/2) inch in size, GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS."
4 − INSPECTION. The state or local gas inspector of the
side wall, horizontally vented, gas−fueled equipment
shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a) 1 through 4.
EXEMPTIONS: The following equipment is exempt
from 24 CMR 5.08(2)(a) 1 through 4:
1 − The equipment listed in Chapter 10 entitled Equip-
ment Not Required to Be Vented" in the most current
edition of NFPA 54 as adopted by the Board; and
2 − Product Approved side wall, horizontally vented, gas−
fueled equipment installed in a room or structure separate from the dwelling, building or structure used in
whole or in part for residential purposes.
MANUFACTURER REQUIREMENTS −
GAS EQUIPMENT VENTING SYSTEM PROVIDED.
When the manufacturer of Product Approved side wall,
horizontally vented, gas−fueled equipment provides a venting system design or venting system components with the
equipment, the instructions provided by the manufacturer
for installation of the equipment and the venting system
shall include:
1 − Detailed instructions for the installation of the venting
system design or the venting system components:
and
2 − A complete parts list for the venting system design or
venting system.
MANUFACTURER REQUIREMENTS −
GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED.
When the manufacturer of Product Approved side wall,
horizontally vented, gas−fueled equipment does not provide the parts for venting the flue gases, but identifies special venting systems," the following requirements shall be
satisfied by the manufacturer:
1 − The referenced special venting system" instructions
shall be included with the appliance or equipment
installation instructions; and
2 The special venting systems" shall be Product Ap-
proved by the Board, and the instructions for that system shall include a parts list and detailed installation
instructions.
A copy of all installation instructions for all Product
Approved side wall, horizontally vented, gas−fueled
equipment, all venting instructions, all parts lists for
venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at
the completion of the installation.
Page 54
Loading...