Lennox GHR32Q, GHR32V Unit Information

Page 1

Service Literature

GHR32Q/V SERIES UNITS

This manual contains information pertaining to GHR32−1 through −6 model units. GHR32 series units are high−efficiency horizontal or down flow gas furnaces manufactured with Lennox DuralokPlust aluminized and stainless steel clamshell-type heat exchangers. GHR32Q units are available in heating input capacities of 50,000 to 120,000 Btuh (14.7 to 35.2 kW) and cooling applications from 2 through 5 tons (7.0 through 17.6 kW). GHR32V units are available in heating capacities of 75,000 and 100,000 Btuh (22.0 and 29.3 kW) and 3 and 5 tons (10.5 and 17.5) for cooling. Refer to Engineering Handbook for proper sizing.

Units are factory equipped for use with natural gas. A kit is available for conversion to LPG operation. GHR32−1 through −4 units are equipped with the Lennox SureLight silicon nitride ignition system. GHR32−5 units are equipped with the two stage (V models will have the variable speed control) integrated control board. Each GHR32 unit meets the California Nitrogen Oxides (NOx) Standards and California Seasonal Efficiency requirements. The gas valve is redundant to assure safety shut−off as required by A.G.A. and C.G.A.

The heat exchanger, burners and manifold assembly can be removed for inspection and service. The maintenance section gives a detailed description on how this is done.

Information contained in this manual is intended for use by qualified service technicians only. All specifica-

tions are subject to change. Procedures outlined in this manual are presented as a recommendation only and do not supersede or replace local or state codes.

TABLE OF CONTENTS

General 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications Q Models 2. . . . . . . . . . . . . . . . . . . . . . . .

Blower performance Q Models 3. . . . . . . . . . . . . . . . . .

Specifications V Models 4. . . . . . . . . . . . . . . . . . . . . . . .

Blower performance V Models 5. . . . . . . . . . . . . . . . . . .

Parts Arrangement 7. . . . . . . . . . . . . . . . . . . . . . . . . . . .

I Unit Components 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

II Placement and Installation 41. . . . . . . . . . . . . . . . . . . .

III Start Up 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IV Heating System Service Checks 47. . . . . . . . . . . . . .

V Typical Operating Characteristics 49. . . . . . . . . . . . . .

VI Maintenance 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GHR32Q/V

Corp. 0001−L2

Revised 08−2004

DOWN FLOW

POSITION

GHR32Q MODEL SHOWN

VII Wiring Diagram and Sequence of Operation 54. . . .

GHR32Q−1 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GHR32Q−3 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GHR32Q−5 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GHR32V−1 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GHR32V−3 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GHR32V−4 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GHR32V−5 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VIII Operating Flow Charts 65. . . . . . . . . . . . . . . . . . . . . .

IX Troubleshooting 76. . . . . . . . . . . . . . . . . . . . . . . . . . . .

X Blower Control Board Jumper Summary 87. . . . . . . .

Page 1

Litho U.S.A.

Page 2

SPECIFICATIONS GHR32Q MODELS

(kW)

Temperature rise

Blower wheel nominal

Nominal cooling

Intake

Kit

()

10.0 (2.49)

Kit #67K27

Model No. GHR32Q2/3-50 GHR32Q3-75 GHR32Q4/5-100 GHR32Q4/5-120

nput  Btuh

utput  Btuh

A.F.U.E. 90.0%

California Seasonal Efficiency 83.7% 83.9% 85.3% 84.0%

Exhaust pipe connection (PVC) diameter  in. (mm) 2 (51)

Intake pipe connection (PVC) diameter  in. (mm) 2 (51)

Condensate drain connection (PVC)  in. (mm) 1/2 (12.7)

Temperature rise range  _F (_C)

High static certified by (A.G.A./C.G.A.)  in wg. (Pa) .50 (125)

Gas Piping Size I.P.S.  in. (mm) 1/2 (12.7)

Blower wheel nominal

diameter x width

Number and size of filters − in. (mm) (1) 14 x 25 x 1 (356 x 635 x 25) (1) 20 x 25 x 1 (508 x 635 x 25)

Blower motor output  hp (W) 1/3 (249) 1/2 (373) 3/4 (560)

Nominal cooling

that can be added

Shipping weight  lbs. (kg) 1 package 147 (67) 155 (70) 196 (89) 205 (93)

Electrical characteristics 120 volts  60 hertz  1 phase (less than 12 amps)

High Fire 50,000 (14.7) 72,000 (21.1) 100,000 (29.3) 118,000 (34.6)

Low Fire 34,000 (10.0) 51,000 (14.9) 68,000 (19.9) 81,600 (23.9)

High Fire 47,000 (13.8) 67,000 (19.6) 93,000 (27.2) 111,000 (32.5)

Low Fire 31,600 (9.3) 47,000 (13.8) 63,000 (18.4) 75,900 (22.2)

High Fire 30 − 60 (17 − 33) 40 − 70 (22 − 39) 45 − 75 (25 − 42)

Low Fire 25 − 55 (14 − 31) 35 − 65 (20 − 36) 40 − 70 (22 − 39)

in. 10 x 8 11-1/2 x 9

mm 254 x 203 292 x 229

Tons 2 to 3 2 to 3.5 3.5 to 5

kW 7.0 to 10.6 7.0 to 12.3 12.3 to 17.6

Optional Accessories (Must Be Ordered Extra)

LPG/Propane kit 59L81 (−1 and −2 models) 11M57 (−3 and later models)

Down-Flow Additive Base 32K52 32K53

Horizontal Support Frame Kit  Ship. Wt. − lbs. (kg.) 56J18  18 lbs. (8 kg)

Concentric Roof/Wall Termination Kits 60G77 − For 1 1/2 inch (38 mm) venting

Roof

Vent/

Intake

Kits

Twinning Kit 15L38 (all models)

Condensate Drain Heat Cable 26K68 6 ft. (1.8 m)  26K69 24 ft. (7.3 m)  26K70 50 ft. (15.2 m)

Heat Cable Tape 39G04 1/2 inch (13 mm) wide or 39G03 2 inch (51 mm) wide

Annual Fuel Utilization Efficiency based on U.S. DOE test procedures and FTC labeling regulations. Isolated combustion system rating for non-weatherized furnaces. Determine from venting tables proper intake and exhaust pipe size and termination kit required. Cleanable polyurethane frame type filter.

Termination

Kits

Wall

Termination

For 2 inch (51 mm) venting 15F75 Not Available

For 3 inch (76 mm) venting Not Available 44J41

For 2 inch (51 mm) venting

15F74 (ring kit) − 22G44 (close couple) − 30G28 (WTK Close Cou-

30G79 (WTKX close couple with extension riser)

For 3 inch (76 mm) venting Not Available 44J40 (close couple)  81J20 (WTK close couple)

ple)

33K97 − For 2 inch

(51 mm) venting

60L46 − For 3 inch

(76 mm) venting

Not Available

HIGH ALTITUDE

No gas pressure adjustment is needed when operating from 0 to 4500 ft. (0 to 1372m). See table below for correct manifold pressure and prove switch for altitudes greater than 4500 ft. (1372m).

Model No. Prove Switch

GHR32−50 nat no change 3.5 (0.87) 3.5 (0.87) 3.5 (0.87)

GHR32−75 nat

GHR32−100 nat

GHR32−120 L.P.

GHR32−50 L.P.

GHR32−75 L.P.

GHR32−100 L.P.

HGR32−120 L.P.

Kit #67K27 3.4 (0.85) 3.3 (0.82) 3.2 (0.80)

no change

Manifold Pressure (outlet) in. w.g. (kPa)

4501 to 5500 ft.

(1373 to 1676m)

10.0 (2.49) 10.0 (2.49) 10.0 (2.49)

9.6 (2.39) 9.3 (2.31) 9.0 (2.24)

5501 to 6500 ft.

(1677 to 1981m)

6501 to 7500 ft.

(1982 to 2286m)

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Page 3

BLOWER PERFORMANCE DATA Q MODELS

External Static

GHR32Q2/3-50 BLOWER PERFORMANCE

External Static

Pressure

in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts

0 0 1480 700 640 1330 630 520 1070 505 435 900 425 355 .10 25 1430 675 615 1290 610 500 1050 495 420 880 415 346 .20 50 1380 650 595 1240 585 480 1040 490 400 870 410 330 .30 75 1320 625 570 1200 565 455 1010 475 380 850 400 320 .40 100 1260 595 545 1140 540 430 980 460 370 820 385 300 .50 125 1200 565 520 1080 510 410 930 440 320 790 375 280 .60 150 1100 520 500 1000 470 385 860 405 300 740 350 265 .70 175 1000 470 470 890 420 370 750 355 290 660 310 250 .80 200 800 380 440 700 330 340 590 280 280 550 260 240

NOTE  All air data is measured external to unit with air filter in place.

High Medium-High Medium-Low Low

GHR32Q3-75 BLOWER PERFORMANCE

External Static

Pressure

in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts

0 0 1650 780 720 1540 725 585 1450 685 540 1230 580 450 .10 25 1590 750 660 1490 705 550 1400 660 505 1200 565 420 .20 50 1520 715 645 1430 675 520 1350 635 485 1170 550 405 .30 75 1440 680 630 1370 645 490 1300 615 450 1130 535 390 .40 100 1370 645 610 1300 615 470 1240 585 430 1090 515 370 .50 125 1300 615 590 1240 585 450 1170 550 410 1040 490 330 .60 150 1210 570 560 1170 550 430 1100 520 375 970 460 320 .70 175 1120 530 540 1080 510 410 1020 480 350 890 420 280 .80 200 1020 480 515 980 460 380 900 425 325 750 355 260 .90 225 880 415 500 820 385 350 750 355 300 600 285 240

NOTE  All air data is measured external to unit with air filter in place.

High Medium-High Medium-Low Low

GHR32Q4/5-100 BLOWER PERFORMANCE

External Static

Pressure

in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts

0 0 2530 1195 1360 2300 1085 1210 2030 960 1050 1780 840 885 1540 725 745 .10 25 2460 1160 1290 2250 1060 1140 2010 950 1010 1760 830 850 1530 720 730 .20 50 2380 1125 1270 2200 1040 1100 1990 940 990 1740 820 830 1520 715 720 .30 75 2310 1090 1250 2150 1015 1080 1950 920 970 1720 810 805 1510 715 710 .40 100 2250 1060 1200 2090 985 1060 1910 900 950 1690 800 790 1500 710 690 .50 125 2180 1030 1150 2020 955 1020 1870 880 910 1660 785 780 1480 700 670 .60 150 2100 990 1100 1960 925 980 1810 855 870 1620 765 760 1430 675 650 .70 175 2010 950 1070 1880 885 940 1750 825 855 1570 740 730 1380 650 630 .80 200 1910 900 1040 1800 850 920 1680 795 840 1500 710 710 1320 625 615 .90 225 1800 850 1010 1700 800 890 1580 745 800 1420 670 690 1240 585 600

1.00 250 1700 800 980 1600 755 870 1500 710 780 1320 625 670 1120 530 590

NOTE  All air data is measured external to unit with air filter in place.

High Medium-High Medium Medium-Low Low

Air Volume and Motor Watts at Specific Blower Taps

GHR32Q4/5-120 BLOWER PERFORMANCE

External Static

Pressure

in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts

0 0 2400 1135 1250 2270 1070 1140 2060 970 1010 1800 850 860 1560 735 720 .10 25 2350 111 0 1220 2220 1050 1100 2040 965 980 1780 840 830 1550 730 705 .20 50 2290 1080 1200 2170 1025 1080 2000 945 960 1750 825 815 1540 725 685 .30 75 2220 1050 1180 2120 1000 1060 1960 925 940 1720 810 800 1520 715 675 .40 100 2150 1015 1130 2050 965 1020 1900 895 920 1680 795 770 1500 710 660 .50 125 2080 980 1100 1980 935 980 1850 875 880 1640 775 750 1460 690 650 .60 150 2000 945 1050 1910 900 940 1780 840 840 1590 750 720 1420 670 630 .70 175 1900 895 1010 1830 865 920 1710 805 810 1530 720 690 1380 650 610 .80 200 1800 850 980 1740 820 900 1630 770 790 1460 690 675 1320 625 595 .90 225 1700 800 960 1630 770 860 1540 725 770 1380 650 660 1250 590 580

1.00 250 1600 755 940 1530 720 840 1430 675 750 1300 615 640 1150 545 560

NOTE  All air data is measured external to unit with air filter in place.

High Medium-High Medium Medium-Low Low

Air Volume and Motor Watts at Specific Blower Taps

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SPECIFICATIONS GHR32V MODELS

Temperature rise

Blower wheel nominal

Nominal cooling

Vent/

Kits

Model No. GHR32V3-75 GHR32V5-100

High Fire 72,000 (21.1) 100,000 (29.3)

Input  Btuh (kW)

Output  Btuh (kW)

A.F.U.E. 90.0% 90.0%

California Seasonal Efficiency 83.9 85.3

Exhaust pipe connection (PVC) diameter  in. (mm) 2 (51)

Intake pipe connection (PVC) diameter  in. (mm) 2 (51)

Condensate drain connection (PVC)  in. (mm) 1/2 (12.7)

Low Fire 51,000 (14.9) 68,000 (19.9)

High Fire 67,000 (19.6) 93,000 (27.2)

Low Fire 47,000 (13.8) 63,000 (18.4)

Te mperature rise range  _F (_C)

High static certified by (A.G.A./C.G.A.)  in wg. (Pa) .80 (200)

Gas Piping Size I.P.S.  in. (mm) 1/2 (12.7)

Blower wheel nominal

diameter x width

Blower motor output  hp (W) 1/2 (373) 1 (746)

Number and size of filters − in. (mm) (1) 14 x 25 x 1 (356 x 635 x 25) (1) 20 x 25 x 1 ( 508 x 635 x 25)

Nominal coolin

that can be added

Shipping weight  lbs. (kg) 1 package 160 (73) 201 (91)

Electrical characteristics 120 volts  60 hertz  1 phase (less than 12 amps)

High Fire 40 − 70 (22 − 39)

Low Fire 35 − 65 (19 − 36)

in. 10 x 8 11-1/2 x 9

mm 254 x 203 292 x 229

Tons 2 to 3.5 3.5 to 5

kW 7.0 to 12.3 12.3 to 17.6

Optional Accessories (Must Be Ordered Extra)

LPG/Propane kit 59L81

Down-Flow Additive Base 32K52 32K53

Horizontal Support Frame Kit  Ship. Wt. − lbs. (kg.) 56J18  18 lbs. (8 kg)

Concentric Roof/Wall Termination Kits 60G77 − For 1 1/2 inch (38 mm) venting 33K97 − For 2 inch (51 mm) venting

Roof

Termination

Vent/

Intake

Kits

Condensate Drain Heat Cable 26K68 6 ft. (1.8 m)  26K69 24 ft. (7.3 m)  26K70 50 ft. (15.2 m)

Heat Cable Tape 39G04 1/2 inch (13 mm) wide or 39G03 2 inch (51 mm) wide

Kits

Wall

Termination

Kits

For 2 inch (51 mm) venting 15F75

For 3 inch (76 mm) venting 44J41

15F74 (ring kit)

For 2 inch (51 mm) venting

30G79 (WTKX close couple w/ extension riser)

For 3 inch (76 mm) venting 44J40 (close couple)  81J20 (WTK close couple)

22G44 (close couple)

30G28 (WTK Close Couple)

22G44 (close couple)

Page 4

15F74 (ring kit)

Page 5

BLOWER PERFORMANCE DATA −1 through −3 V MODELS

Jumper

Setting

ADJUST

Jumper

Positions

ADJUST

Jumper

Positions

GHR32V3-75 BLOWER PERFORMANCE

0 through 0.80 in. w.g. (0 Through 200 Pa) External Static Pressure Range

VSP2−1 Blower Control Low Speed  3 Factory Settings High Speed  4

ADJUST"

Jum

Setting

NORM 875 415 940 445 985 465

minus 15%

less motor

speed

NOTE  The effect of static pressure and filter resistance is included in the air volumes listed.

(Cool, Low Heat Or Continuous Fan)

1 2 3 4 1 2 3 4 1 2 3 4

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

750 355 795 375 850 400 915 430 900 425 940 445

LOW" Speed

GHR32V5-100 BLOWER PERFORMANCE

0 through 0.80 in. w.g. (0 Through 200 Pa) External Static Pressure Range

VSP2−1 Blower Control Low Speed  2 Factory Settings High Speed  4

ADJUST"

Jumper

Settin

NORM 1100 520 1260 595 1445 680 1635 770 1670 790 1960 925 2165 1020 2285 1075 1640 775 1825 860 2150 1015 2315 1090

minus 15%

less motor

speed

NOTE  The effect of static pressure and filter resistance is included in the air volumes listed.

LOW" Speed (Cool Or Continuous Fan) HIGH" Speed (Cool) HEAT" Speed

1 2 3 4 1 2 3 4 1 2 3 4

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

935 440 1015 480 1195 565 1355 640 1335 630 1495 705 1690 800 1800 850 1360 640 1465 690 1770 835 1905 900

GHR32V3-75 BLOWER PERFORMANCE

0 through 0.80 in. w.g. (0 Through 200 Pa) External Static Pressure Range

VSP3−1 Blower Control Factory Settings ADJUST − NORM

ADJUST"

Jumper

Positions

1 2 3 4 1 2 3 4

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

NORM (Normal) 875 415 940 445 985 465 1060 500 1090 515 1175 555 1285 605 1330 630

 " (Minus) 15% 750 355 795 375 850 400 915 430 940 445 995 470 1095 515 1180 555

ADJUST"

Jumper

Position

1 2 3 4 1 2 3 4

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

NORM (Normal) 875 415 940 445 985 465 1060 500 1070 505 1130 535 1270 600 1290 610

 " (Minus) 15% 750 355 795 375 850 400 915 430 900 425 940 445 1055 500 1120 530

 15% lower motor speed than NORM jumper setting.

NOTE − The effect of static pressure and filter resistance is included in air volumes shown. NOTE − Continuous Fan only speed is approximately 825 cfm (390 L/s) − non adjustable. NOTE − Lennox Harmony IIt zone control applications − MAX CFM is determined by COOL jumper placement with a minimum of approximately 875 cfm (415 L/s) for all positions.

GHR32V5−100 BLOWER PERFORMANCE

0 through 0.80 in. w.g. (0 Through 200 Pa) External Static Pressure Range

VSP3−1 Blower Control Factory Settings ADJUST − NORM

ADJUST"

Jumper

Positions

NORM (Normal) 1100 520 1260 595 1445 680 1635 770 1640 775 1825 860 2150 1015 2315 1090

 " (Minus) 15% 935 440 1015 480 1195 565 1355 640 1360 640 1465 690 1770 835 1905 900

ADJUST"

Jumper

Position

NORM (Normal) 1100 520 1260 595 1445 680 1635 770 1670 790 1960 925 2165 1020 2285 1075

 " (Minus) 15% 935 440 1015 480 1195 565 1355 640 1335 630 1495 705 1690 800 1800 850

 15% lower motor speed than NORM jumper setting.

NOTE − The effect of static pressure and filter resistance is included in air volumes shown. NOTE − Continuous Fan only speed is approximately 1050 cfm (495 L/s) − non adjustable. NOTE − Lennox Harmony IIt zone control applications − MAX CFM is determined by COOL jumper placement with a minimum of approximately 1100 cfm (520 L/s) for all positions.

1 2 3 4 1 2 3 4

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

1 2 3 4 1 2 3 4

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

Heat Speed  3

VSP Jumper Speed Positions

HIGH" Speed (Cool) HEAT" Speed

106

500

107

505 113 0 535

127

105

129

600

500 112 0 530 940 445 995 470

610

109

515 117 5 555

Heat Speed  1

VSP Jumper Speed Positions

BLOWER PERFORMANCE DATA −4 V MODELS

Heat Speed − 3 Cool Speed − 4

VSP Jumper Speed Positions

HEAT"

Low Speed High Speed

COOL"

Low Speed High Speed

Heat Speed − 2 Cool Speed − 4

VSP Jumper Speed Positions

HEAT"

Low Speed High Speed

COOL"

Low Speed High Speed

Page 5

128

605

109

515 118 0 555

133

630

Page 6

GHR32V3−75−5 Blower Motor Performance

Adjust

Jumper

Adjust"

Jumper

Adj

Jumper

(For Static Pressure 0.0" to 0.8" w.g.)

Blower Speed Adjustment Settings (Switches 5 and 6)



Jumper

Setting

Norm 875 415 940 445 985 465 1060 500 1070 505 1130 535 1270 600 1290 610



–

1 2 3 4 1 2 3 4

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

750 355 795 375 850 400 915 430 900 425 940 445 1055 500 1120 530

Low High

Cooling

Blower Speed Adjustment Settings (Switches 7 and 8)

 Jumper

Setting

1 2 3 4 1 2 3 4

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

Low High

Norm 945 446 1025 484 1125 531 1270 599 1080 510 1172 533 1286 607 1452 685



–

803 379 871 411 956 451 1080 510 918 433 996 470 1093 516 1234 582

15% lower motor speed than NORM switch setting.

NOTE − The effect of static pressure and filter resistance is included in air volumes shown. NOTE − Continuous Fan only speed is approximately 825 cfm (390 L/s) − non adjustable. NOTE − Lennox Harmony IIt zone control applications − MAX CFM is determined by COOL switch setting with a minimum of approximately 875 cfm (415 L/s) for all positions.

Heating

GHR32V5−100/125−5 Blower Motor Performance

(For Static Pressure 0.0" to 0.8" w.g.)

Blower Speed Adjustment Settings (Switches 5 and 6)



ust

Jumper

Setting

Norm 1100 520 1260 595 1445 680 1635 770 1670 790 1960 925 2165 1020 2285 1075



–

1 2 3 4 1 2 3 4

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

935 440 1015 480 1195 565 1355 640 1335 630 1495 705 1690 800 1800 850

Low High

Cooling

Blower Speed Adjustment Settings (Switches 7 and 8)



Adjust"

Setting

Norm 1100 520 1260 595 1445 680 1635 770 1640 775 1825 860 2150 1015 2315 1090



–

1* 2 3 4 1* 2 3 4

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

935 440 1015 480 1195 565 1355 640 1360 640 1465 690 1770 835 1905 900

Low High

15% lower motor speed than NORM switch setting.

NOTE − The effect of static pressure and filter resistance is included in air volumes shown. NOTE − Continuous Fan only speed is approximately 1050 cfm (495 L/s) − non adjustable. NOTE − Lennox Harmony IIt zone control applications − MAX CFM is determined by COOL switch setting with a minimum of approximately 1100 cfm (520 L/s) for all positions.

Heating

Page 6

Page 7

GHR32Q−5 PARTS IDENTIFICATION

(Downflow Application Shown)

CONTROL VOLTAGE

CIRCUIT BREAKER

CONTROL TRANSFORMER

CONTROL BOX COVER

DOOR INTERLOCK SWITCH

COLD END HEADER

(COLLECTOR) BOX

COMBUSTION AIR

BLOWER MOUNTING

COMBUSTION

AIR INDUCER

EXHAUST TEE

PATCH PLATE

WITH BARBED

FITTING

BURNER BOX

COVER

FLAME SIGHT

GLASS

FLAME SENSOR

INTAKE AIR

GASKET

BRACKET

FRESH AIR

INTAKE FITTING

IGNITOR

SURELIGHT TWO−STAGE

INTEGRATED CONTROL

CORBELS

BURNER BOX

TOP

BURNER BOX

ASSEMBLY

ORIFICE

GAS VALVE

AND MANIFOLD

FIGURE 1

SUPPLY AIR

BLOWER

TOP CAP

CONTROL

BOX

GASKET

PRIMARY LIMIT

AUTO−RESET

(ALTERNATE STYLES)

BURNER BOX

GASKET

FLAME ROLL−OUT SWITCH

(MANUAL RESET)

SECONDARY LIMIT

AUTO−RESET

(Located on Backside

of Blower Wrapper)

CABINET

COMBUSTION AIR

PROVING (PRES-

SURE) SWITCH

HOT END HEADER

(COLLECTOR) BOX

CONDENSER

COIL

DuralokPlus

HEAT EXCHANGER

ASSEMBLY

CONDENSATE

TRAP

BACK FILTER

CLIP

FLUE

COLLAR

CONDENSATE

COLLAR

Page 7

Page 8

I−UNIT COMPONENTS

GHR32 unit components are shown in figure 1. The combustion air blower, gas valve and burners can be accessed by removing the burner access panel. The blower and control box can be accessed by removing the blower access door.

INTERIOR MAKE−UP BOX INSTALLATION

MAKE−UP

BOX

WARNING

Before attempting to perform any service or maintenance, turn the electrical power to unit OFF at disconnect switch

A−Make-Up Box (Figure 2)

WARNING

Unit must be grounded in accordance with national and local codes. Electric Shock Hazaed. Can cause injury or death.

A field make−up box (see figure 2) is provided for line voltage wiring. Line voltage wiring to unit is done through the J96 jack from the field make−up box to plug P96 from the control box. The box may be installed inside or outside the unit (see figures 3 and 4) and may be installed on the unit left or right side.

MAKE-UP BOX

POWER ENTRY KNOCKOUT

BOX

UNIT

GROUND

JACK J96

Box may be installed inside or outside unit.

FIGURE 2

120V LINE VOLTAGE

PIGTAIL CONNECTIONS

COVER

J96

BUSHING

P96

FIGURE 3

EXTERIOR MAKE−UP BOX INSTALLATION

MAKE−UP

BOX

BUSHING

J96

(Shown with

accessory

wire connected)

P96

FIGURE 4

An accessory (brown) output wire is provided with the makeup box. The wire provides a 120V connection for optional accessories such as electronic air cleaner or humidifier. If used, the wire is field installed in J96 jack plug by inserting the pin of the brown wire into the open socket of the jack. See figure 5. 120V accessories rated up to 4 amps total may be connected to this wire. The neutral leg of the accessory is connected to the neutral white wire in the make-up box. The acces-

INSTALLING BROWN

ACCESSORY WIRE TO J96

WHITE

NEUTRAL

BROWN

sory terminal is energized whenever the indoor blower is in operation.

BLACK

J96

FIGURE 5

Page 8

Page 9

B−Control Box (Figure 6)

ELECTROSTATIC DISCHARGE (ESD)

Precautions and Procedures

CIRCUIT BREAKER CB8

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.

GHR32−1 through −4 CONTROL BOX

TWO−STAGE

CONTROL

CIRCUIT

BREAKER

TRANSFORMER

FIGURE 6

Unit transformer (T1), circuit breaker (CB8), SureLight control (A92), VSP−2 control (A24) and Two−stage control (A86) are located in the control box. In addition, a door interlock switch (S51) is located in the control box. Jackplugs and a snap-off" terminal strip allow the control box to be easily removed for blower service.

1. Control Transformer (T1)

A transformer located in the control box provides power to the low voltage 24 volt section of the unit. Transformers on all models are rated 40VA with a 120V primary and a 24V secondary.

2. Circuit Breaker (CB8)

A 24V circuit breaker is also located in the control box. The switch provides overcurrent protection to the transformer (T1). The breaker is rated 3 amps at 32V. If the current exceeds this limit the breaker will trip and all unit operation will shut down. The breaker can be manually reset by pressing the button on the face (figure 7).

VSP−2

CONTROL

(v models only)

SURELIGHT

CONTROL

DOOR INTERLOCK

SWITCH

PRESS TO RESET

FIGURE 7

3.Door Interlock Switch (S51)

A door interlock switch rated 14 amps at 125VAC is located on the control box. The switch is wired in series with line voltage. When the blower door is removed the unit will shut down.

DANGER

Shock hazard.

Disconnect power before servicing. Control is not field repairable. If control is inoperable, simply replace entire control.

Can cause injury or death. Unsafe operation will result if repair is attempted.

4. SureLight Ignition System A92

All GHR32−1 through −4 units are equipped with the Lennox SureLight ignition system. The system consists of ignitor (figure 8) and ignition control board (figure 9 and table 3 ). The board and ignitor work in combination to ensure furnace ignition and ignitor durability. The SureLight integrated board controls all major furnace operations. Table 1 and 2 show jack plug terminal designations. shows control board terminations. The board also features two LED lights for troubleshooting and two accessory terminals rated at (1) one amp. See table 4 for troubleshooting diagnostic codes. Units equipped with the SureLight board can be used with either electronic or electro−mechanical thermostats without modification. The SureLight ignitor is made of durable silicon nitride. Ignitor longevity is also enhanced by voltage ramping by the control board. The board finds the lowest ignitor temperature which will successfully light the burner, thus increasing the life of the ignitor.

NOTE − Do not remove blower access panel to read Surelight LED lights. A sight glass is provided on the access panel for viewing.

Page 9

Page 10

13/32’

SURELIGHT IGNITOR

MEASUREMENT IS TO I.D.

5/8"

OF RETENTION RING

FRONT VIEW

TABLE 1

SureLight BOARD J156 (J2) TERMINAL

DESIGNATIONS

PIN # FUNCTION

1 Ignitor

Combustion Air Blower Line Voltage

Combustion Air Blower Neutral

Not Used

Ignitor Neutral

Not Used

TABLE 2

SureLight BOARD J58 (J1) TERMINAL

DESIGNATIONS

5/16"

TOP VIEW

FIGURE 8

SURELIGHT INTEGRATED CONTROL BOARD

GHR32−1 through −4 units

PIN # FUNCTION

1 Primary Limit In

Pressure Switch and Primary Limit Out

Gas Valve Common

Roll Out Switch Out

Gas Valve 24V

Pressure Switch In

Not Used

Roll Out Switch In

Ground

TABLE 3

ACB COOL ACB HEAT PARK ACB LOW ACC TX HOT HTG ACC NEUTRALS 24VAC HOT 24VAC RTN FLAME SENSE

TERMINAL DESIGNATIONS

Blower − Cooling Speed (Line Volt) Blower − Heating Speed (Line Volt) Alternate Blower Speeds (Dead) Continuous Low Speed Blower Accessory Terminal (Line Volt) 120VAC Hot to Transformer 120VAC Hot Input Heat Only Accessory (Line Volt) 120VAC Neutrals 24VAC Hot from Transformer 24VAC Return from Transformer Flame Sense Terminal

FIGURE 9

Page 10

Page 11

TABLE 4

DIAGNOSTIC CODES

MAKE SURE TO ID LED’S CORRECTLY: REFER TO INSTALLATION INSTRUCTIONS FOR CONTROL BOARD LAYOUT.

LED #1 LED #2 DESCRIPTION

SIMULTANEOUS

SLOW FLASH

SIMULTANEOUS FAST

FLASH

SLOW FLASH ON

OFF SLOW FLASH

ALTERNATING SLOW

FLASH

SLOW FLASH OFF

ON SLOW FLASH

ON ON

OFF

FAST FLASH SLOW FLASH

SLOW FLASH FAST FLASH

ALTERNATING FAST

FLASH

SIMULTANEOUS

SLOW FLASH

SIMULTANEOUS FAST

ALTERNATING SLOW

ALTERNATING FAST

FLASH

OFF

FLASH

Also signaled during cooling and continuous fan.

Normal operation − signaled when heating demand initiated at thermostat.

Primary or Secondary limit open. Limit must close within 3 minutes or board goes

Watchguard pressure switch − 5 minutes. Pressure switch open or has opened 5 times during a single call for heat; OR: Blocked inlet/exhaust vent; OR: Conden-

sate line blocked; OR: Pressure switch closed prior to activation of combustion

Watchguard 60 minute delay − burners fail to ignite.

Flame sensed without gas valve energized.

Rollout switch open. OR: 9 pin connector improperly attached.

Circuit board failure or control wired incorrectly.

Main power polarity reversed. Switch line and neutral.

Low flame signal. Measures below .61 microAmps. Replace flame sense rod.

Improper main ground or line voltage below 75 volts; OR: Broken ignitor; OR:

Power − Normal operation

into one hour limit Watchguard.

air blower.

Open ignitor circuit.

NOTE − Slow flash equals 1 Hz (one flash per second). Fast flash equals 3 Hz (three flashes per second). Drop out flame sense current < 0.21 microAmps

a−Electronic Ignition Figures 12 and 13

On a call for heat the SureLight control monitors the combustion air blower pressure switch. The control will not begin the heating cycle if the pressure switch is closed (by− passed). Once the pressure switch is determined to be open, the combustion air blower is energized. When the differential in the pressure switch is great enough, the pressure switch closes and a 15−second pre−purge begins. If the pressure switch is not proven within 2−1/2 minutes, the control goes into Watchguard−Pressure Switch mode for a 5−minute re−set period. After the 15−second pre−purge period, the SureLight ignitor warms up for 20 seconds after which the gas valve opens for a 4−second trial for ignition. Units with control 97L48: ignitor stays energized during the trial or until flame is sensed. Units with control 56L83: ignitor stays energized for the first second of the 4−second trial. If ignition is not

The SureLight control board has an added feature that prolongs the life of the ignitor. After a successful ignition, the SureLight control utilizes less power to energize the ignitor on successive calls for heat. The control continues to ramp down the voltage to the ignitor until it finds the lowest amount of power that will provide a successful ignition. This amount of power is used for 255 cycles. On the 256th call for heat, the control will again ramp down until the lowest power is determined and the cycle begins again.

b−Fan Time Control Q Models Only

The fan on time of 45 seconds is not adjustable. Fan off time (time that the blower operates after the heat demand has been satisfied) can be adjusted by flipping the dip switches located on the SureLight integrated control. The unit is shipped with a factory fan off setting of 90 seconds. Fan off time will affect comfort and is adjustable to satisfy individual applications. See figure 10.

proved during the 4−second period, the control (97L48 or 56L83) will try four more times with an inter purge and warm−up time between trials of 35 seconds. After a total of five trials for ignition (including the initial trial), the control

FAN-OFF TIME ADJUSTMENT

60sec. 90sec. 120sec. 180sec.

goes into Watchguard−Flame Failure mode. After a 60−minute reset period, the control will begin the ignition sequence again.

To adjust fan−off timing, flip dip switch to desired setting.

FIGURE 10

Page 11

Page 12

c−Flame Sensor

ЙЙЙЙЙЙЙЙЙ

A flame sensor is located on the left side of the burner support. See figure 11. The sensor is mounted on a bracket in the burner support and the tip protrudes into the flame envelope of the left−most burner. The sensor is fastened to burner supports and can be removed for service without removing any part of the burners. During operation, flame is sensed by current passed through the flame and sensing electrode. The SureLight control allows the gas valve to remain open as long as flame signal is sensed.

SENSOR

3/8"

IGNITOR

FIGURE 11

NOTE − The GHR32 furnace contains electronic components that are polarity sensitive. Make sure that the furnace is wired correctly and is properly grounded.

5. Two−Stage Control (A86)

All GHR32−1 through −4 units are equipped with a two− stage control board. Two different boards have been used. Boards 43K9001 and 29M9201 (figure 14) are identical, except the 9 pin connector on 43K9001 is replaced by two relays with quick connect terminals on board 29M9201. The two−stage board acts as a go between from the indoor thermostat to the SureLight ignition board. The board can be utilized in three modes: with a SINGLE−STAGE thermostat, a TWO−STAGE thermostat or with a second−stage (high fire) delay called W2 TIMED. The two−stage board is equipped with a jumper (see figure 14) which changes operating modes and a jumper which adjusts second−stage heat delay during W2 TIMED mode.

NOTE−The mode of operation jumper on the two−stage control board is factory set in the TWO−STAGE" position.

While in the single−stage thermostat mode (one−stage jumper setting), the unit will always operate on second− stage heat. The combustion air blower (B6) will operate on high speed and indoor blower (B3) will operate on heating speed. While in the two−stage thermostat mode the unit will operate on first−stage heat (low fire). The combustion air blower (B6) and indoor blower will operate on low speed. The unit will switch to second−stage heat (high fire) on call from the indoor thermostat W2. While in the W2 TIMED mode (factory setting 8 minutes) the unit will fire on first− stage heat (low fire) with the combustion air blower (B6) and indoor blower (B3) operating on low speed. After a set time delay the unit switches to second−stage heat (high fire). The combustion air blower and indoor blower also switch to second−stage heat mode.

SureLight Control Ignition Sequence Board 56L8301

OFF

DEMAND

CAB IGNITOR GAS VALVE INDOOR BLOWER

*Blower on time will be 45 seconds after gas valve is energized. Blower off time will depend on OFF TIME" Setting.

Pre −Purge Ignitor Warmup Trial for

341

Ignition

Blower On"

Delay

FIGURE 12

SureLight Control Ignition Sequence Board 97L4801

OFF

DEMAND

CAB IGNITOR GAS VALVE INDOOR BLOWER

*Blower on time will be 45 seconds after gas valve is energized. Blower off time will depend on OFF TIME" Setting.

Pre −Purge Ignitor Warmup

341

Trial for Ignition

Blower On"

Delay

FIGURE 13

5 SEC80

Post

Purge

5 SEC80

Post

Purge

Page 12

Page 13

MODE OF

OPERATION

JUMPER

TWO−STAGE CONTROL BOARD

G32(V) −1 through −4 units

W2 TIMED DELAY JUMPER

6.VSP2−1 Blower Control Board (A24)

−1 through −3 V Models only

GHR32V−1 through −3 units are equipped with a variable speed motor that is capable of maintaining a specified CFM throughout the external static range. The unit uses the VSP2−1 variable speed control board, located in the blower compartment, which controls the blower speed and provides diagnostic LEDs. The control has a non−adjustable, factory preset ON" fan timing delay and an adjustable OFF" fan timing delay (see figure 17).

The VSP2−1 also senses limit trip condition and turns on the blower. The GHR32 primary limit switch is located in the middle of the vestibule wall and the secondary limit switch is located int ehblower compartment. When excess heat is sensed in the heat exchanger, or blower compartment, the respective switch will open and interrupt the current to the gas valve, while at the same time the VSP2−1 energizes the blower on heating speed. The limit automatically resets when the unit temperature returns to normal and the blower is de−energized.

FIGURE 14

HIGH SPEED

SELECTOR PINS

(COOLING ONLY)

LOW SPEED

SELECTOR PINS

(COOLING, HEATING and

CONTINUOUS FAN)

HEATING STAGE

JUMPER SELECTOR PINS

JP73

15 PIN PLUG (BOARD TO VARIOUS POINTS IN FURNACE)

Diagnostic LEDs located on the VSP2−1 control board are provided to aid in identifying the unit’s mode of operation. Certain scenarios will arise depending on the jumper positions. Refer to figure 15 for identification.

VSP2−1 VARIABLE SPEED CONTROL BOARD SELECTIONS

JP 2

HIGH LOW ADJUST HEAT

270

DS4

CFM

210

150

JP 1

HTG.

BLOWER

HEAT

DS2

TEST

−

NORM

DS3

ON/OFF

HI/LOW

DS1

JP46

13 PIN PLUG

(BOARD TO MOTOR)

HEATING SPEED

SELECTOR PINS

See table 5 for VSP2

factory settings

OPERATIONAL

SELECTOR PINS

(Affects both heating and

cooling modes)

DIAGNOSTIC

DS LEDS

FAN OFF"

TIMING PINS

FIGURE 15

Page 13

Page 14

IMPORTANT

24 VAC half wave rectified (DC pulse), when measured with a meter, may appear as a lower or higher voltage depending on the make of the meter. Rather than attempting to measure the output voltage of the VSP2 board, see GHR32 BLOWER & VSP2 BLOWER CONTROL BOARD TROUBLESHOOTING FLOW CHART in the TROUBLESHOOTING section of this manual.

VSP2−1 BLOWER CONTROL BOARD (A24)

J46

HIGH LOW ADJUST HEAT

1 2 3 4

HTG.

BLOWER

1 2 3 4

HEAT

DS3

TEST

− + NORM

HI/LOW

1 2 3 4

DS4

Diagnostic LED Lights

a − DS3 ON/OFF"

ON/OFF−DS3 indicates there is a demand for the blower mo-

tor to run. When the ON/OFF LED−DS3 is lit, a demand is being sent to the motor. In heating mode only, there is a 45 second fan ON" delay in energizing ON/OFF LED−DS3. The light will not go off until adjustable fan OFF" delay has expired.

If ON/OFF LED−DS3 is on and both HIGH/LOW LED−DS1 & HEAT LED−DS2 are off, the motor will operate in low speed.

b − DS2 HEAT"

If HEAT LED−DS2 is on, the blower is running in the heat speed according to the HEAT" jumper setting. The HEAT LED−DS2 comes on instantaneous and switches off when the call for heat is satisfied.

NOTE−When the blower is in OFF" delay mode, the motor runs at low speed, therefore the HEAT LED−DS2 is off. It switches off when the call for heat is satisfied.

c − DS1 HI/LOW"

ON/OFF

J73

PIN 2 - G - Input signal from thermostat’s fan signal.

PIN 3 - W2 - Input signal for second stage heat from the thermostat.

PIN 4 - DS - Input signal for the blower speed regulation.

PIN 5 - Limit - Input signal from the external limit.

PIN 6 - R - 24 VAC power to the thermostat.

PIN 9 - CI - Input signal from the fan limit control. PIN 10 - CO - Output signal to the burner control.

PIN 11 - HT - Input signal from the fan limit control.

PIN 12 - ACC - 24 VAC accessory output. PIN 13 - 24V - Input 24 VAC power for the VSP2-1. PIN 14 - 24V - Input 24 VAC power for the VSP2-1.

PIN 15 - V - Input signal from the gas line.

PIN 1 - Heat - Heat speed input signal to the ICM2 motor.

PIN 4 - High Tap - High Speed programming input.

PIN 5 - Low Tap - Low speed programming input.

PIN 6 - On / Off - On / off output signal to the ICM2 motor.

PIN 7 - Adjust Tap - ICM2 mode selection.

PIN 8 - Hi / Low - Speed regulate input signal to the ICM2 motor.

PIN 9 - Hi / Low - Speed regulate input signal to the ICM2 motor.

PIN 10 - Ref. V - ICM2 reference voltage.

PIN 11 - Heat Tap - Heating blower speed programming.

PIN 13 - cfm - Motor speed diagnostic signal.

DS2

PIN 1 - C - 24 VAC common.

PIN 7 - C - 24 VAC common.

Pin 8 - C - 24 VAC common.

PIN 2 - C - 24 VAC common. PIN 3 - C - 24 VAC common.

PIN 12 - C - 24 VAC common.

J73

J46

DS1

270

CFM

210

150

HIGH/LOW LED−DS1 indicates whether the blower is operating in high or low speed. When the light is off, the blower is running in low speed according to the LOW" jumper setting. When HIGH/LOW LED−DS1 is on, the blower is op- erating in high speed according to the HIGH" jumper setting.

d − DS4 CFM"

CFM LED−DS4 indicates the CFM the unit is operating,

according to the jumper settings. The light flashes once for approximately every 100 CFM. For example, if the unit is operating at 1000 CFM, CFM LED−DS4 will flash 10 times. If the CFM is 2050, CFM LED−DS4 will flash 20 full times plus one fast or half flash. At times the light may appear to flicker or glow. This takes place when the control is communicating with the motor between cycles. This is normal operation.

The appropriate speed according to application and CFM need is selected by moving jumper pins.

Page 14

VOLTAGES INTO VSP2−1

Voltage across J73 pins 13 to 1 and 6 to 1 is 24VAC as shown here.

34 volts

0 volts

−34 volts

Voltage across J73 pins 4 to 1 is approximately 15-20VDC (straight voltage) if CCB

is used. If Harmony is used a voltage of 0−25VDC should be present.

If CCB or Harmony is not used, pin 4 to 1 voltage is 21VAC.

Refer to unit wiring diagram.

24VAC @ 60Hz.

VOLTAGES FROM VSP2−1 TO ELECTRONICALLY

CONTROLLED BLOWER MOTOR

Voltage across J46 pins 6 to 3 and 1 to 3 is half-rectified AC as shown here.

Approx.

34 volts

0 volts

Voltage across J46 pins 8 and 9 to 3, is approximately 15-20VDC if CCB is used. If CCB or

Harmony is not used, pins 8 and 9 to 3 voltage is approximately 21VAC. If Harmony is used

Refer to unit wiring diagram.

24VAC Half-Rectified (DC Pulse)

a voltage of 0−25VDC should be present.

@ 60Hz.

FIGURE 16

Page 15

NOTE−On Harmony II zoning applications in the heating mode, the highest speed obtainable is the same as the highest cooling speed selection. Also, the heating speed (heat jumper position) is only used when the primary limit has been tripped. In non−zoning applications, refer to the section on the VSP2−1 control.

Jumper Settings

SEE BLOWER PERFORMANCE TABLES AT FRONT

OF MANUAL FOR ANY REFERENCE TO CFM.

not operable. Notice in the GHR32V5−100 table, that the normal adjustment setting for heat speed position #3 is 2150 CFM (1015L/s). After the adjustment setting has been determined, c hose th e re main ing speed jumper settings from those offered in the table.

The TEST pin is available to bypass the VSP2−1 control and run the motor at approximately 70% to test that the moto r i s operational. This is beneficial primarily in troubleshooting. G must be energized for motor to run.

b−HEATING BLOWER"

IMPORTANT

Before changing jumper setting, make sure the motor has completely stopped. Any jumper setting change will not take place while the motor is running.

To change jumper positions, gently pull the jumper off the pins and place it on the desired set of pins. The following section outlines the different jumper selections available and conditions associated with each one. Refer to figure 15 for identification.

After the CFM for each application has been determined, the jumper settings must be adjusted to reflect those given in the tables in the blower performance section. Using the tables, determine which row of CFM volumes most closely matches the desired CFM. Once a specific row has been chosen (NORMAL or −), CFM volumes from other rows cannot be used. Below are the descriptions of each of the jumper selections.

Refer to table 5 for factory settings. Refer to the blower performance tables for the approximate air volume for each setting.

VSP2−1 FACTORY SETTINGS

MODEL HIGH LOW ADJUST HEAT

GHR32V−75−

1, −2, −3 units

GHR32V−100

−1, −2, −3 units

a−ADJUST"

The ADJUST pins allow the motor to run at normal speed or approximately 15% lower than normal speed. The blower performance tables give two rows (NORMAL and −) with their respective CFM volumes. The + adjustment setting i s

TABLE 5

4 3 NORM 2

4 2 NORM 1

For GHRV32 units, place the HEATING BLOWER jumper across the second and third pins (position #2).

When W1 is energized, the LOW jumper selections are activated. The HEAT jumper selections are activated when W2 is energized.

NOTE−In Harmony II zoning applications, HEATING BLOWER jumper must be in position #2.

c−HEAT"

The HEAT jumper is used to set the blower speed to ob- tain the required CFM as outlined in HEAT SPEED in the blower performance tables.

The HEAT jumper selections are activated with a call for second-stage heating (W2).

d−HIGH"

The HIGH jumper is used to determine the CFM during cooling speed. These jumper selections are activated when G and DS terminals are energized.

e−LOW"

The LOW jumper is used to determine CFM during low speed cooling. These jumper selections are activated when G is energized. The LOW jumper may also be used for low speed heating. See the HEAT" section for details.

f−FAN OFF"

Fan OFF" timings (time that the blower operates after the heat demand has been satisfied) are determined by the arrangement of a jumper on the VSP2−1 board. See figure

17. To adjust fan OFF" timings, gently disconnect the jumper and reposition it across pins corresponding with the new timing. Fan OFF" time is adjustable from 90 to 330 seconds. The control has a non−adjustable, factory preset on" fan timing (45 seconds).

WARNING − MAKE SURE TO DISCONNECT POWER BEFORE CHANGING FAN OFF" TIMINGS.

Page 15

Page 16

FAN-OFF TIME ADJUSTMENT

NOTEIf fan OFF" time is too low, residual heat in heat exchanger may cause primary limit S10 to trip resulting

TIMING

JUMPER

To adjust fan−off timings:

Remove jumper from VSP2−1 and select

one of the other pin combinations to

achieve the desired time.

in frequent cycling of blower. If this occurs, adjust blower to longer time setting.

Table 6 outlines the operation of the variable speed motor in relation to specific modes of operation. Some informa-

270

150 90

210

Leave jumper off to achieve

330 second fan−off timing.

TIMING PINS (seconds)

Fan-off timing is factory

set at 90 seconds

tion has been repeated from the previous section to provide an example. Refer to each diagnostic LED or jumper settings section for more information.

FIGURE 17

TABLE 6

VSP2−1 GHR32−1 through −3 units OPERATION

HEATING MODE COOLING MODE

UNITS WITH

SINGLE−STAGE HEATING

NON−ZONED

APPLICATIONS

Using a single−stage thermostat with one−stage" heating, the HEAT LED− DS2 is lit when the thermostat calls for heat. The ON/OFF LED−DS3 is lit after 110 seconds (65 seconds pre−purge and 45 seconds fan ON" time) from the time a call for heat is made. This indicates the blower is operating in heating speed.

Using a single−stage thermostat with W2 TIMED," and W1 calling, the ON/ OFF LED−DS3 is lit to indicate the blower is operating on low speed.

When the HEAT LED−DS2 is lit, the blower is operating in heating speed, and second−stage (W2) heating is calling.

HARMONY ZONED

APPLICATIONS

The blower speed is controlled by the PWM (pulse width modulation) signal sent from the control center of the zoning system to the terminal strip’s DS terminal. HI/LOW LED−DS1 and ON/ OFF LED−DS3 are lit to indicate the blower is operating.

NOTE−In Harmony II zoning applications, HTG. BLOWER jumper must be in position #2.

NOTE: For zone applications with Harmony, remove the wire from the pin #3 of the J73 terminal on the VSP control board, insulate the end, and secure it to prevent from shorting.

Using a two−stage thermostat with first−stage (W1) calling, the ON/OFF LED−DS3 is lit to indicate the blower is operating in low speed.

When the ON/OFF LED−DS3 and HEAT LED−DS2 are lit, the blower is operating in heating speed and second−stage (W2) heating is calling.

HEAT LED−DS2 is lit with a call for heat from the thermostat. ON/OFF LED− DS3 is lit after 110 seconds from the time a call for heat is made.

NOTE−In Harmony II zoning applications, HTG. BLOWER jumper must be in position #2.

UNITS WITH

TWO−STAGE HEATING

NON−ZONED

APPLICATIONS

HARMONY ZONED

APPLICATIONS

UNITS WITH SINGLE−

SPEED COMPRESSOR

NON−ZONED

APPLICATIONS

The terminals DS and Y must be jumpered together. With a call for cooling, terminals G, Y and DS on the unit control board are energized from the thermostat. HI/LOW LED−DS1 and ON/OFF LED−DS3 are lit to indicate the blower is operating on high speed.

NOTEY and DS are factory jumpered for single−stage cooling, non− zoned applications.

NOTEFor low speed during single− stage cooling remove jumper from Y to DS.

HARMONY ZONED

APPLICATIONS

The blower speed is controlled by the PWM (pulse width modulation) signal sent from the control center of the zoning system to the terminal strip’s DS terminal. HI/LOW LED−DS1 and ON/OFF LED−DS3 are lit to indicate the blower is operating.

UNITS WITH TWO−SPEED

COMPRESSOR

NON−ZONED

APPLICATIONS

The ON/OFF LED−DS3 is lit to indicate the blower is operating in first stage cooling. This LED is energized on when a 24VAC thermostat demand is supplied to the control (terminal G" on the control board terminal strip).

In second stage, the ON/OFF LED− DS3 and HI/LOW LED−DS1 are lit to indicate the blower is operating on high speed (24VAC is supplied to the unit terminal strip Y2 from Y2 on the thermostat).

NOTE Jumper must be moved from Y1 to Y2 In two−speed, non−zoned applications.

HARMONY ZONED

APPLICATIONS

Page 16

Page 17

7.VSP3−1 Blower Control Board (A24) GHR32V−4 Units

GHR32V−4 units are equipped with a variable speed motor that is capable of maintaining a specified CFM throughout the external static range. The unit uses the VSP3−1 variable speed control board, located in the blower compartment, which controls the blower speed and provides diagnostic LEDs. The control has both a non−adjustable, factory preset ON" fan timing delay and an adjustable OFF" fan timing delay (see figure 17).

VSP3−1 VARIABLE SPEED CONTROL BOARD SELECTIONS

JP2

DELAY PROFILE SELECTOR PINS

(COOLING ONLY)

DELAY COOL ADJUST HEAT

The VSP3−1 also senses limit trip condition and turns on the blower. The GHR32V limit switch is located in the middle of the vestibule wall. When excess heat is sensed in the hea t exchanger, the limit switch will open and interrupt the current to the gas valve, while at the same time the VSP3−1 energizes the blower on heating speed. The limit automatically resets when the unit temperature returns to normal and the blower is de−energized.

Diagnostic LEDs located on the VSP3−1 control board are provided to aid in identifying the unit’s mode of operation. Certain scenarios will arise depending on the jumper positions. Refer to figure 18 for identification.

JP46

13 PIN PLUG

(BOARD TO MOTOR)

TEST

−

NORM

HEATING SPEED SELECTOR PINS

See table 7 for VSP3−1

factory settings

COOL SPEED

SELECTOR PINS

(COOLING, HEATING and

CONTINUOUS FAN)

HEATING STAGE

JUMPER SELECTOR PINS

JP73

15 PIN PLUG (BOARD TO VARIOUS POINTS IN FURNACE)

JP1

HTG.

BLOWER

HEAT

DS2

ON/OFF

FIGURE 18

DS3

HI/LOW

DS1

270

210

150

DS4

CFM

OPERATIONAL

SELECTOR PINS

(Affects both heating

and cooling modes)

DIAGNOSTIC

DS LEDS

FAN OFF"

TIMING PINS

Page 17

Page 18

VSP3−1 BLOWER CONTROL BOARD (A24)

J46

DELAY COOL ADJUST HEAT

1 2 3 4

HTG.

BLOWER

1 2 3 4

HEAT

DS3

TEST

− + NORM

HI/LOW

1 2 3 4

DS4

IMPORTANT

24 VAC half wave rectified (DC pulse), when measured with a meter, may appear as a lower or higher voltage depending on the make of the meter. Rather than attempting to measure the output voltage of A24, see GHR32V BLOWER & VSP3 BLOWER CONTROL BOARD TROUBLESHOOTING FLOW CHART in the TROUBLESHOOTING section of this manual.

ON/OFF

J73

PIN 2 - G - Input signal from thermostat’s fan signal.

PIN 3 - W2 - Input signal for second stage heat from the thermostat.

PIN 4 - DS - Input signal for the blower speed regulation.

PIN 5 - Limit - Input signal from the external limit.

PIN 6 - R - 24 VAC power to the thermostat.

PIN 9 - CI - Input signal from the fan limit control. PIN 10 - CO - Output signal to the burner control.

PIN 11 - HT - Input signal from the fan limit control.

PIN 12 - ACC - 24 VAC accessory output. PIN 13 - 24V - Input 24 VAC power for the VSP2-1. PIN 14 - 24V - Input 24 VAC power for the VSP2-1.

PIN 15 - V - Input signal from the gas line.

PIN 4 - Delay Tap - Delay profile programming input.

PIN 5 - Cooling blower speed programming input.

PIN 6 - On / Off - On / off output signal to the ICM2 motor.

PIN 7 - Adjust Tap - ICM2 mode selection.

PIN 9 - Hi / Low - Speed regulate input signal to the ICM2 motor with CCB1 and

PIN 10 - Ref. V - ICM2 reference voltage.

PIN 11 - Heat Tap - Heating blower speed programming.

PIN 13 - cfm - Motor speed diagnostic signal.

DS2

PIN 1 - C - 24 VAC common.

PIN 7 - C - 24 VAC common.

Pin 8 - C - 24 VAC common.

PIN 2 - C - 24 VAC common. PIN 3 - C - 24 VAC common.

PIN 12 - C - 24 VAC common.

J73

J46

PIN 1 - Not Used.

PIN 8 - NOT USED

HARMONY only

DS1

270

CFM

210

150

Diagnostic LED Lights

DS3 ON/OFF

ON/OFF−DS3 indicates there is a demand for the blower

motor to run. When the ON/OFF LED−DS3 is lit, a demand is being sent to the motor. In heating mode only, there is a 45−second fan ON" delay in energizing ON/OFF LED− DS3. Light will not go off until adjustable fan OFF" delay has expired.

If ON/OFF LED−DS3 is on and both HIGH/LOW LED−DS1 & HEAT LED−DS2 are off, the motor will operate in low speed (heating).

DS2 HEAT

If HEAT LED−DS2 is on, the blower is running in second− stage heat speed according to the HEAT" jumper setting. In heating mode only, there is a 45 second delay in energizing HEAT LED−DS2. Light will not go off until adjustable fan OFF" delay has expired.

DS1 HI/LOW

HIGH/LOW LED−DS1 indicates the blower is operating in

the cooling mode.

DS4 CFM

CFM LED−DS4 indicates the CFM the blower is providing,

according to the jumper settings.

VOLTAGES INTO VSP3−1

Voltage across J73 pins 13 to 1 and 6 to 1 is 24VAC as shown here.

34 volts

volts

−34 volts

Voltage across J73 pins 4 to 1 is approximately 15-20VDC (straight voltage) if CCB is used. If Harmony is used a voltage of 0−25VDC should be present.

If CCB or Harmony is not used, pin 4 to 1 voltage is 21VAC.

Refer to unit wiring diagram.

24VAC @ 60Hz.

VOLTAGES FROM VSP3−1 TO ELECTRONICALLY

CONTROLLED BLOWER MOTOR

Voltage across J46 pins 6 to 3 and 1 to 3 is half-rectified AC as shown here.

Approx. 34 volts

volts

Voltage across J46 pin 9 to 3 is approximately 15-20VDC if CCB is used. If CCB or

Harmony is not used, pin 9 to 3 voltage is approximately 21VAC. If Harmony is used

Refer to unit wiring diagram.

a voltage of 0−25VDC should be present.

24VAC Half-Rectified (DC

FIGURE 19

Pulse)

@ 60Hz.

Page 18

Page 19

Jumper Settings

SEE BLOWER PERFORMANCE TABLES AT FRONT

OF MANUAL FOR ANY REFERENCE TO CFM.

IMPORTANT

Before changing jumper setting, make sure the motor has completely stopped. Any jumper setting change will not take place while the motor is running.

After the CFM for each application has been determined, the jumper settings must be adjusted to reflect those given in the blower performance tables. Using the tables, determine which row of CFM volumes most closely matches the desired CFM. Once a specific row has been chosen (NORMAL or −), CFM volumes from other rows cannot be used. Below are the descriptions of each of the jumper selections.

Refer to table 7 for factory settings.

TABLE 7

VSP FACTORY SETTINGS FOR GHR32V−4 UNITS

MODEL DELAY COOL ADJUST HEAT

GHR32V3−75 4 4 NORM 3

GHR32V5−100 4 4 NORM 2

NOTE − In Harmony II zoning applications in the heating mode, the highest cooling speed selected is the highest blower speed obtainable. Also, the fan−only speed is used when the primary limit has been tripped. In non−zoning applications, refer to the section on the VSP3−1 control.

ADJUST

The ADJUST pins allow the motor to run at normal speed or approximately 15% lower than normal speed. The blower performance tables two rows (NORMAL and −) with their respective CFM volumes. The + adjustment setting is not operable. Notice that the normal adjustment setting for heat speed position #3 is 2150 CFM (1015 L/s) . After the adjustment setting has been determined, choose the remainder speed jumper settings from those in the table.

The TEST pin is available to bypass the VSP3−1 control and run the motor at approximately 70% to test that the motor is operational. This is beneficial primarily in troubleshooting. G must be energized for motor to run.

HTG. BLOWER

For GHR32V−4 units only, place the HTG. BLOWER jumper across the second and third pins (position #2).

NOTE − In Harmony II zoning applications, HTG. BLOWER jumper must be in position #2.

HEAT

The HEAT jumper is used to set the blower speed to obtain the required CFM as outlined in HEAT SPEED section of the blower performance tables. The HEAT jumper selec- tions are activated with a call for first−stage heating (W1) and second−stage heating (W2).

DELAY

The DELAY jumper is used to set the specific motor fan mode of operation during cooling. Depending on the application, one of four fan options may be chosen by moving the jumper to the appropriate set of pins.

Options 1, 2, 3, or 4 will have an increased dehumidification effect on the system. Option 1 will have the least effect and option 4 will have the greatest effect.

#1 PIN JUMPERED

A − Motor runs at 100% until demand is satisfied. B − Once demand is met, motor ramps down to off.

A B

100% CFM

COOLING DEMAND

OFFOFF

#2 PIN JUMPERED

A − Motor runs at 82% for approximately 7−1/2 minutes. B − If demand has not been satisfied after 7−1/2 minutes,

the motor runs at 100% until demand is satisfied.

C − Once demand is met, motor ramps down to off.

OFF

7 1/2 MIN

82%CFM

100% CFM

COOLING DEMAND

#3 PIN JUMPERED A − Motor runs at 50% for 1/2 minute. B − Motor then runs at 82% for approximately 7−1/2 min-

utes.

C − If demand has not been satisfied after 7−1/2 minutes,

motor runs at 100% until demand is satisfied.

D − Once demand is met, motor ramps down to off.

C D

100% CFM

OFF

1/2 MIN 50% CFM

7 1/2 MIN 82% CFM

COOLING DEMAND

Page 19

Page 20

#4 PIN JUMPERED A − Motor runs at 50% for 1/2 minute. B − Motor then runs at 82% for approximately 7−1/2 min-

utes.

C − If demand has not been satisfied after 7−1/2 minutes,

motor runs at 100% until demand is satisfied.

D − Once demand is met, motor runs at 50% for 1/2 min-

ute.

E − Motor ramps down to off.

C D

100% CFM

1/2 MIN 50% CFM

OFF

1/2 MIN 50% CFM

7 1/2 MIN 82% CFM

COOLING DEMAND

COOL

The cool jumper is used to set the blower speed to obtain the required CFM as outlined in the blower performance tables.

VSP Operation

Table 8 outlines the operation of the variable speed motor in relation to specific modes of operation. See table 9 for GHR32V with CCB1 and a two speed outdoor unit. Some information has been repeated from the previous section to provide an example. Refer to each diagnostic LED or jumper settings section for more information.

Heating Mode Cooling Mode

Units With

Single−Stage Heating

Non−Zoned Applications

Using a single−stage thermostat with "one−stage" heating, the HEAT LED−DS2 is lit when the thermostat calls for heat. The ON/OFF LED− DS3 is lit after 110 seconds (65 seconds prepurge and 45 seconds fan "ON" time) from the time a call for heat is made. This indicates the blower is operating in high speed heat.

Using a single−stage thermostat with "W2 TIMED" and W1 calling, the ON/OFF LED−DS3 is lit to indicate the blower is operating on low speed heat.

When HEAT LED−DS2 is lit, the blower is operating in high speed heat and second−stage (W2) is calling.

Harmony Zoned Applications

The blower speed is controlled by the PWM (pulse width modulation) signal sent from the control center of the zoning system to the terminal strip’s DS terminal. HI/LOW LED− DS1 and ON/OFF LED−DS3 are lit to indicate the blower is operating.

Note − In Harmony II zoning applications, HTG BLOWER jumper must be in position #2.

GHR32V−4 Units with VSP3−1

TABLE 8

Units With

Two−Stage Heating

Non−Zoned Applications

Using a two−stage thermostat with first−stage (W1) calling, the ON/ OFF LED−DS3 is lit to indicate the blower is operating in low speed heat.

When the ON/OFF LED−DS3 and HEAT LED−DS2 are lit, the blower is operating in high speed heat and second−stage (W2) is calling.

HEAT LED−DS2 is lit with a call for heat from the thermostat. ON/OFF LED−DS3 is after 110 seconds from the time a call for heat is made.

Harmony Zoned Application

The blower speed is controlled by the PWM (pulse width modulation) signal sent from the control center of the zoning system to the terminal strip’s DS terminal. HI/LOW LED− DS1 and ON/OFF LED−DS3 are lit to indicate the blower is operating.

Note − In Harmony II zoning applications, HTG BLOWER jumper must be in position #2.

Units With

Single−speed Compressor

Non−Zoned Applications

Y1−DS and Y1−Y2 must be jumpered together. With a call for cooling, G, Y1, Y2 and DS on the unit control board are energized from the thermostat. HI/LOW LED−DS1 and ON/OFF LED−DS3 are lit to indicate a call for cooling.

Note − Y1 to DS and Y1 to Y2 are factory jumpered for single−stage cooling, non−zoned applications.

Harmony Zoned Application

The blower speed is controlled by the PWM (pulse width modulation) signal sent from the control center of the zoning system to the terminal strip’s DS terminal. HI/LOW LED−DS1 and ON/OFF LED−DS3 are lit to indicate the blower is operating.

Units With

Two−speed Compressor

Non−Zoned Applications

Y1−DS must be jumpered together. With a call for single−stage cooling, G, Y1, and DS on the unit control board are energized from the Thermostat. With a call for second−stage cooling, G, Y1, Y2, and DS on the unit control board are energized from the thermostat. In both cases, HI/LOW LED−DS1 and ON/OFF LED−DS3 are lit to indicate a call for cooling.

Note − Jumper Y1−Y2 must be removed for units with two−speed compressor.

Harmony Zoned Application

The blower speed is controlled by the PWM (pulse width modulation) signal sent from the control center of the zoning system to the terminal strip’s DS terminal. HI/LOW LED− DS1 and ON/OFF LED−DS3 are lit to indicate the blower is operating.

NOTE − For zone applications with Harmony, remove the wire from pin #2 and pin #13 of the J49 terminal at the motor and the wire from pin #3 of the J73 terminal on the VSP control board, insulate the ends and secure to prevent shorting.

Page 20

Page 21

TABLE 9

Normal operation

blower speed follow thermostat

removal during 1st

ifi

ill i

When humidity demand is satisfied

satisfied during

gp p

Call f

idit

Call for 1st stage

Call for 2nd stage

Reduced blower speed (dehumidifi-

mostat demand), slide switch is

GHR32V−4 UNITS WITH CCB1 & TWO−SPEED OUTDOOR UNIT OPERATING SEQUENCE

Operating Sequence System Demand System Response

System

Condition

Step

Thermostat

Demand

*Relative Humidity

(EfficiencyPlus Lights)

***Compressor

Speed

Blower CFM

(COOL)

Comments

Normal operation

Call for humidity

removal during 1st

stage thermostat

demand

Significant increase

in humidity during

thermostat demand.

Humidity demand

satisfied during

thermostat demand.

or hum

removal during 2nd

stage thermostat

demand

*Call for 1st stage

cooling after call for

humidity removal.

Call for 2nd stage

cooling after call for

humidity removal

Call for cooling after

significant increase

in humidity

Humidity demand satisfied between

thermostat demands

(unit off cycle).

1 Y1 Acceptable (None) Low

2 Y2 Acceptable (None) High HIGH COOL

1 Y1 Acceptable (None) Low

2 Y1

Demand

satisfied

4 Y1 Slightly over setpoint (1) High

1 Y1 Acceptable (None) Low

2 Y1

1 Y1 Over Setpoint High

2 Y1

3 None Acceptable (None) Off Off

4 Y1 Acceptable (None) Low

1 Y2 Acceptable (None) High HIGH COOL

2 Y2

3 Y2 Acceptable (None) High HIGH COOL

1 None Slightly over setpoint (1) Off Off Dehumidification mode (high speed

2 Y1 Slightly over setpoint (1) Low

1 None Slightly over setpoint (1) Off Off

2 Y2 Slightly over setpoint (1) High

1 None

2 Y1 or Y2

1 None Over setpoint (1 or more) Off Off

2 Y1 or Y2

Change to slightly

over setpoint (1)

Slightly over setpoint (1) Off Off

Change to significantly

over setpoint (2 or more)

Change to Acceptable

(None)

Change to slightly

over setpoint (1)

Significantly over setpoint

(2 or more)

Significantly over

setpoint (2 or more

Change to

acceptable (None)

Low

High

High HIGH COOL

High

Off Off

High

High HIGH COOL

55% of

HIGH COOL

55% of

HIGH COOL

55% of

HIGH COOL

**77%/74% of

HIGH COOL

55% of

HIGH COOL

**77%/74% of

HIGH COOL

**77%/74% of

HIGH COOL

55% of

HIGH COOL

**77%/74% of

HIGH COOL

55% of

HIGH COOL

**77%/74% of

HIGH COOL

**77%/74% of

HIGH COOL

Compressor demand and indoor

blower s

Dehumidification mode begins with

next thermostat demand, after initial

thermostat demand is satisfied.

If humidity increases significantly

over setpoint, or if slide switch is

moved sign

ately go into dehumidification mode

(in presence of thermostat demand).

When humidity demand is satisfied

blower immediately shifts to the

HIGH COOL CFM in order to hasten

e end of the cycle. Unit can only

shift out of high speed compressor

operation at beginning of next cycle.

Blower immediately changes speed

in response to thermostat demand.

compressor) begins with next ther-

mostat demand after initial demand is

Reduced blower speed (dehumidifi-

cation speed) begins immediately

If humidity increases significantly

over setpoint, or if slide switch is

moved, unit immediately goes into

dehumidification mode (in presence

While unit is not operating (no ther-

mostat demand), slide switch is

moved down and back up. Blower

and compressor operate at high

speed until next thermostat demand.

eed follow thermostat

demand

cantly, u nit w

satisfied.

with thermostat demand

of thermostat demand).

mmedi-

Note − When changing unit mode of operation from cooling to heating, indicating lights that are on will stay on until the first thermostat heating demand.

*IMPORTANT - If power to unit is turned on with CCB1 calling for humidity removal, outdoor unit may be locked into high speed indefinitely. To reset, move humidity slide switch all the way down then back up to desired setpoint (with unit running) ** Reduced blower speed is 77% of COOL for the V3 units; 74% of COOL for V5. ***If the two−speed control on a two−speed outdoor unit is set for LATCH 2 (15 minutes) or LATCH 3 (30 minutes), the compressor will latch into high speed after a Y1 demand has occurred for that period of time.

Page 21

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8.Two Stage Integrated Control (A92) GHR32Q−5 Units

DANGER

Shock hazard.

Disconnect power before servicing. Control is not field repairable. If control is inoperable, simply replace entire control.

Can cause injury or death. Unsafe operation will result if repair is attempted.

All GHR32Q units are equipped with the Lennox two− stage integrated SureLight control board. The system consists of a ignition control board (figure 20 with control terminal designations in tables 12, 13 and 14) and ignitor (figure 8). The board and ignitor work in combination to ensure furnace ignition and ignitor durability. The board controls all major furnace operations. The board features two LED lights, DS1 and DS2 for troubleshooting. The board also has two accessory terminals rated at (1) one amp each. See table 15 for troubleshooting diagnostic codes.

Electronic Ignition

At the beginning of each heat cycle, SureLight control monitors the first stage and second stage combustion air inducer prove switch. The control will not begin the heating cycle if the first stage prove switch is closed (by−passed). Likewise the control will not begin the second stage heating cycle if the second stage prove switch is closed and will allow first stage heat only. However if the second stage prove switch closes during the first stage pre−purge, the control will still respond to second stage heat. Once the first stage prove switch is determined to be open, the combustion air inducer is energized on low (first stage) heat speed. When the differential in the prove switch is great enough, the prove switch closes and a 15−second pre−purge begins. If the switch is not proven within 2−1/2 minutes, the control goes into Watchguard−Pressure Switch mode for a 5−minute re−set period. After the 15−second pre−purge period, the SureLight ignitor warms up for 20 seconds after which the gas valve opens for a 4−second trial for ignition. The ignitor energizes during the trial until flame is sensed. If ignition is not proved during the 4−second period, the control will try four more times with an inter purge and warm−up time between trials of 35 seconds. After a total of five trials for ignition (including the initial trial), the control goes into Watchguard−Flame Failure mode. After a 60−minute reset period, the control will begin the ignition sequence again. The SureLight control board has an added feature that prolongs the life of the ignitor. After a successful ignition, the SureLight control utilizes less power to energize the ignitor on successive calls for heat. The control continues to ramp down the voltage to the ignitor until it finds the lowest amount of power that will provide a successful ignition. This amount of power is used for 255 cycles. On the 256th call for heat, the control will again ramp down until the lowest power is determined and the cycle begins again.

Two Stage Operation / Thermostat Selection Jumper

The control can be utilized in two modes: SINGLE−STAGE thermostat or TWO−STAGE thermostat. The thermostat selection jumper E20, located just below dip switches 1 through 4 (figure 20), must be positioned for the particular application. The jumper is factory set on TWO" for use with a two−stage thermostat with two stage heat. Re−position jumper to SINGLE" for use with a single stage thermostat with two stage heat. While in the single−stage thermostat mode (single jumper setting), the burners will always fire on first−stage heat. The combustion air inducer will operate on low speed and indoor blower will operate on low heat speed. After a field selectable 10 or 15 minute delay (dip switch 3), the unit will switch to second stage heat. While in the two−stage thermostat mode (two jumper setting) the burners will fire on first−stage heat. The combustion air inducer will operate on low speed and indoor blower will operate on low heat speed. The unit will switch to second−stage heat on call from the indoor thermostat. If there is a simultaneous call for W1 and W2 (first and second stage heat) the unit will fire on first stage heat and will switch to second stage heat after 30 seconds of operation. See Sequence of Operation flow charts in the back of this manual for more detail.

Dip Switch Settings

Dip Switches 1 and 2 − Heating Fan off Delay − The fan on

time of 45 seconds is not adjustable. Fan off time (time that the blower operates after the heat demand has been satisfied) can be adjusted by flipping the dip switches 1 and 2 located on the SureLight integrated control. The unit is shipped with a factory fan off setting of 90 seconds. Fan off time will affect comfort and is adjustable to satisfy individual applications. For customized comfort, monitor the supply air temperature once the heat demand is satisfied. Note the supply air temperature at the instant the blower is de−energized. Adjust the fan−off delay to achieve a supply air temperature between 90° − 110° at the instant the blower is de− energized. (Longer delay times allow for lower air temperature, shorter delay times allow for higher air temperature). See table 10 for dip switch settings.

TABLE 10

Heating Fan Off Delay

Delay (Seconds)

60 Off Off

90 Off On 120 On Off 180 On On

Switch 3 − Second Stage Delay (Used with Single−Stage Thermostat Only) −− This switch is used to determine the

Switch 1 Switch 2

Page 22

Page 23

it will provide a 15−minute delay before second−stage heat is initiated. This switch is only activated when the thermostat selector jumper is positioned for SINGLE−stage thermostat use.

Switch 4 − Cooling Fan off Delay − The fan on delay time of 2 seconds is not adjustable. Fan off time (time that the blower operates after the cool demand has been satisfied) can be adjusted by flipping dip switch 4. The unit is shipped with a factory fan off setting of 45 seconds. Fan off time will affect comfort and is adjustable to satisfy individual applications. See table 11 for cool fan off time settings.

TABLE 11

Cooling Fan Off Delay

Delay (Seconds) Switch 4

2 Off

45 On

Diagnostic LED’s (DS1 and DS2)

Two diagnostic LED’S are located on the two−stage integrated control board. See figure 20. These light flashes correspond with the codes detailed in table 15.

Factory Installed Jumper Y1 to Y2

A factory−installed jumper from Y1 to Y2 terminals on the integrated control board terminal strip must be removed for two−stage cooling.

TABLE 12

Integrated Control Board Terminals

120VAC Neutral

LINE Line

XFMR Transformer

EAC Electronic Air Cleaner

CIRC Indoor Blower

HUM Humidifier

120VAC Line

HUM Humidifier

XMFR Transformer

LINE Line

PARK For Unused Leads

COOL Cooling Speed

EAC Electronic Air Cleaner

HI HEAT High Heat Speed

LO HEAT Low Heat, Low Cool and Continuous Fan

Speed

TWO−STAGE INTEGRATED CONTROL BOARD

SWITCHES

SENSOR

FACTORY−

INSTALLED

JUMPER

THERMOSTAT CONNECTIONS (TB1)

DIP SWITCH(ES) FUNCTION

1 and 2 Blower Off Delay (Heating Mode)

3 Second Stage ON Delay (Single−stage t’stat) 4 Blower Off Delay (Cooling Mode)

FIGURE 20

LEDs

DIP

1 − 4

Page 23

Page 24

TABLE 13

ONONON

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

Integrated Control Board 5 Pin Terminal

PIN # Function

1 Ignitor

2 Combustion Air Inducer High Speed

3 Combustion Air Inducer Low Speed

4 Combustion Air Inducer Neutral

5 Ignitor Neutral

Integrated Control Board 12Pin Terminal

PIN # Function

1 Gas Valve 2nd Stage (High Fire)

2 Second Stage Prove Switch

3 Not Used

4 Ground

5 24V Hot

6 Primary Limit In

7 Gas Valve 1st stage (Low Fire)

8 Gas Valve Common

9 24V Neutral

10 Ground

11 Primary Limit Out

12 1st Stage Prove Switch

TABLE 14

TABLE 15

DIAGNOSTIC CODES

Diagnostic LEDs are labeled DS1 and DS2. See figure 20 for location of diagnostic LEDs.

DS1 DS2 DESCRIPTION

SIMULTANEOUS

SLOW FLASH

SIMULTANEOUS

FAST FLASH

SLOW FLASH ON

OFF SLOW FLASH

OFF FAST FLASH

ALTERNATING

SLOW FLASH

SLOW FLASH OFF Flame sensed without gas valve energized.

ON ON

OFF ON

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

SLOW FLASH FAST FLASH Low flame signal. Measures below 0.23 microAmps. Replace flame sense rod.

ALTERNATING

FAST FLASH

SIMULTANEOUS

SLOW FLASH

SIMULTANEOUS

FAST FLASH

ALTERNATING

SLOW FLASH

OFF

ALTERNATING

FAST FLASH

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

Normal operation − signaled when heating demand initiated at thermostat.

Primary, secondary or rollout limit switch open. Limits must close within 3 minutes or unit goes into 1 hour Watchguard. Pressure switch open; OR: Blocked inlet/exhaust vent; OR: Pressure switch closed prior to activation of combustion air inducer.

Pressure switch open; OR: Blocked inlet/exhaust vent; OR: Pressure switch closed prior to activation of combustion air inducer.

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

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

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

1) Improper main ground;

2) Broken ignitor; OR: Open ignitor circuit;

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

NOTE − Slow flash rate equals 1 Hz (one flash per second). Fast flash rate equals 3 Hz (three flashes per second). Minimum flame sense current = 0.17−0.22 microAmps.

Page 24

Page 25

9.Two Stage Variable Speed Integrated Control (A92) GHR32V−5 Units

All GHR32V−5 units are equipped with the Lennox two− stage, variable speed integrated SureLight control board. The system consists of a ignition / blower control board (figure 21 with control terminal designations in tables 16 through 19) and ignitor (figure 8). The board and ignitor work in combination to ensure furnace ignition and ignitor durability. The SureLight integrated board controls all major furnace operations. The board features two LED lights, DS1 and DS2 for troubleshooting and four LED lights (DS3, DS6, DS7 and DS8) to show furnace status. The board also has two accessory terminals rated at (1) one amp each. See table 20 for status code and table 21 for troubleshooting diagnostic codes.

Electronic Ignition

At the beginning of each heating cycle, the SureLight control monitors the first stage and second stage combustion air inducer prove switch. The control will not begin the heating cycle if the first stage prove switch is closed (by− passed). Likewise the control will not begin the second stage heating cycle if the second stage prove switch is closed, and will allow first stage heat only. However if the second stage prove switch closes during the first stage pre− purge, the control WILL respond to second stage heat call. Once the first stage prove switch is determined to be open, the combustion air inducer is energized on low (first stage) heat speed. When the differential in the prove switch is great enough, the prove switch closes and a 15−second pre−purge begins. If the switch is not proven within 2−1/2 minutes, the control goes into Watchguard−Pressure Switch mode for a 5−minute re−set period. After the 15−second pre−purge period, the SureLight ignitor warms up for 20 seconds after which the gas valve opens for a 4−second trial for ignition. The ignitor energizes during the trial until flame is sensed. If ignition is not proved during the 4−second period, the control will try four more times with an inter purge and warm−up time between trials of 35 seconds. After a total of five trials for ignition (including the initial trial), the control goes into Watchguard−Flame Failure mode. After a 60−minute reset period, the control will begin the ignition sequence again. The SureLight control board has an added feature that prolongs the life of the ignitor. After a successful ignition, the SureLight control utilizes less power to energize the ignitor on successive calls for heat. The control continues to ramp down the voltage to the ignitor until it finds the lowest amount of power that will provide a successful ignition. This amount of power is used for 255 cycles. On the 256th call for heat, the control will again ramp down until the lowest power is determined and the cycle begins again.

Two Stage Operation / Thermostat Selection Jumper

The control can be utilized in two modes: SINGLE−STAGE thermostat or TWO−STAGE thermostat. The thermostat selection jumper E20, located just below dip switches 1 through 3 (figure 21), must be positioned for the particular application. The jumper is factory set on TWO" for use with a two−stage thermostat with two stage heat. Re−position jumper to SINGLE" for use with a single stage thermostat with two stage heat. While in the single−stage thermostat mode (single jumper setting), the burners will always fire on first−stage heat. The combustion air inducer will operate on low speed and indoor blower will operate on low heat speed. After a field selectable 10 or 15 minute delay (dip switch 3), the unit will switch to second stage heat. While in the two−stage thermostat mode (two jumper setting) the burners will fire on first−stage heat. The combustion air inducer will operate on low speed and indoor blower will operate on low heat speed. The unit will switch to second−stage heat on call from the indoor thermostat. If there is a simultaneous call for W1 and W2 (first and second stage heat) the unit will fire on first stage heat and switch to second stage heat after 30 seconds of operation. See Sequence of Operation flow charts in the back of this manual for more detail.

TABLE 16

Two Stage Ignition / Blower Control Terminals

120VAC Neutral

LINE Line 120VAC Neutral

XFMR Transformer 120VAC Neutral

EAC Electronic Air Cleaner 120VAC Neutral

CIRC Indoor Blower 120VAC Neutral

HUM Humidifier 120VAC Neutral

120VAC Line

HUM Humidifier 120VAC Hot

XMFR Transformer 120VAC Hot

LINE Line 120VAC Hot

CIRC Indoor Blower 120VAC Hot

EAC Electronic Air Cleaner 120VAC Hot

TABLE 17

SureLight Board 5 Pin Terminal Designation

PIN # Function

1 Ignitor

2 Combustion Air Inducer High Speed

3 Combustion Air Inducer Low Speed

4 Combustion Air Inducer Neutral

5 Ignitor Neutral

Page 25

Page 26

TW0−STAGE, VARIABLE SPEED INTEGRATED

CONTROL BOARD

DIAGNOSTIC

LEDs

DS8

DS7

ON−BOARD

JUMPER W914

(cut when CCB1 or

Harmony II are used)

FACTORY−

INSTALLED

DS3

JUMPER

16 PIN BLOWER

CONTROL TERMINALS

(cut when heat pump

THERMOSTAT CONNECTIONS (TB1)

DIP SWITCH FUNCTIONS

DIP SWITCH(ES) FUNCTION

1 and 2 Blower Off Delay

3 Second Stage ON Delay (Single−stage t’stat)

4 Not used 5 and 6 Cooling Mode Blower Speed 7 and 8 Blower Speed Adjustment

9 and 10 Cooling Mode Blower Ramping Profile

11 and 12 Heating Mode Blower Speed

SWITCHES

ON−BOARD

JUMPER W951

is used with FM21)

DIP

1 − 3

E20

JUMPER

DIP

5 − 12

LED DS6

TABLE 18

SureLight Board 12Pin Terminal Designation

PIN # Function

1 Gas Valve 2nd. Stage (High Fire)

2 Second Stage Pressure Switch

3 Not Used

4 Ground

5 24V Hot

6 Primary Limit In

7 Gas Valve 1st. Stage (Low Fire)

8 Gas Valve Common

9 24V Neutral

10 Ground

11 Primary Limit Out

12 1st Stage Pressure Switch

TABLE 19

SureLight Board 16 Pin Blower Control Terminals

PIN # Function

1 Ground

2 Low Heat Speed

3 Ground

4 DELAY" Dip Switch Selection

5 COOL" Dip Switch Selection

6 Y1" Signal

7 ADJUST" Dip Switch Selection

8 Ground

9 O" From Thermostat

10 DS" Output Signal

11 HEAT" Dip Switch Selection

12 24 VAC

13 HIGH HEAT Speed

14 Y2" Signal

15 G"

16 CFM LED

FIGURE 21

Page 26

Page 27

TABLE 20

ONONON

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

STATUS CODES

STATUS LED COLOR FUNCTION

DS3

ON / OFF ’

DS6

CFM"

DS7

HI / LO"

DS8

HEAT"

GREEN

YELLOW

YELLOW DS8−ON indicates the sytem is in HEAT mode.

DS3−ON indicates that the motor has a demand to operate. (This LED must be on in all modes).

DS6−blinking indicates the airflow (CFM) demand in the motor. The air flow is determined by counting blinks between two (2) second pauses. One blink equals roughly 100 CFM.

DS7−ON indicaties the DS to R" jumper has not been cut. When the jumper is cut the system will be operating with LENNOX HARMONY IIt (See Harmony Installation Instructions) or with the CCB1 Efficiency Plus control. CCB1: When ON, a 24 VAC is being applied and when OFF, it has been removed. This on/off operation varies the indoor blower’s performance so dehumidification can be enhanced.

TABLE 21

DIAGNOSTIC CODES

Diagnostic LEDs are labeled DS1 and DS2. See figure 21 for location of diagnostic LEDs.

DS1 DS2 DESCRIPTION

SIMULTANEOUS

SLOW FLASH

SIMULTANEOUS

FAST FLASH

SLOW FLASH ON

OFF SLOW FLASH

OFF FAST FLASH

ALTERNATING

SLOW FLASH

SLOW FLASH OFF Flame sensed without gas valve energized.

ON ON

OFF ON

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

SLOW FLASH FAST FLASH Low flame signal. Measures below 0.23 microAmps. Replace flame sense rod.

ALTERNATING

FAST FLASH

SIMULTANEOUS

SLOW FLASH

SIMULTANEOUS

FAST FLASH

ALTERNATING

SLOW FLASH

OFF

ALTERNATING

FAST FLASH

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

Normal operation − signaled when heating demand initiated at thermostat.

Pressure switch open; OR: Blocked inlet/exhaust vent; OR: Pressure switch closed prior to activation of combustion air inducer.

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

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

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

1) Improper main ground;

2) Broken ignitor; OR: Open ignitor circuit;

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

NOTE − Slow flash rate equals 1 Hz (one flash per second). Fast flash rate equals 3 Hz (three flashes per second). Minimum flame sense current = 0.17−0.22 microAmps.

Page 27

Page 28

Dip Switch Settings Switches 1 and 2 − Blower Off Delay The blower−on delay

of 45 seconds is not adjustable. The blower−off delay (time that the blower operates after the heating demand has been satisfied) can be adjusted by moving switches 1 and 2 on the integrated control board. The unit is shipped from the factory with a blower−off delay of 90 seconds. The blower off delay affects comfort and is adjustable to satisfy individual applications. Adjust the blower off delay to achieve a supply air temperature between 90° and 110°F at the exact moment that the blower is de−energized. Longer off delay settings provide lower supply air temperatures; shorter settings provide higher supply air temperatures.The table below provides the blower off timings that will result from different switch settings.

TABLE 22

Blower Off Delay Switch Settings

Blower Off Delay

(Seconds)

Switch 1 Switch 2

60 Off Off

90 Off On 120 On Off 180 On On

Switch 3 − Second Stage Delay (Used with Single−Stage Thermostat Only) This switch is used to determine the

second stage on delay when a single−stage thermostat is being used. The switch is factory−set in the ON position, which provides a 10−minute delay before second−stage heat is initiated. If the switch is toggled to the OFF position, it will provide a 15−minute delay before second−stage heat is initiated. This switch is only activated when the thermostat selector jumper is positioned for SINGLE−stage thermostat use.

Switch 4 − Not used

Switches 5 and 6 − Cooling Mode Blower Speed

Switches 5 and 6 are used to select cooling blower motor speed. The unit is shipped from the factory with the dip switches positioned for high speed (4) indoor blower motor operation during the cooling mode. The table below provides the cooling mode blower speeds that will result from different switch settings. Refer to blower data tables at the front of this manual for corresponding cfm values.

Cooling Mode Blower Speeds

TABLE 23

Speed Switch 5 Switch 6

1 − Low On On

2 − Medium Low Off On

3 − Medium High On Off

4 − High (Factory) Off Off

Switches 7 and 8 − Blower Speed Adjustment Switches 7 and 8 are used to select blower speed adjustment settings. The unit is shipped from the factory with the dip switches positioned for NORMAL (no) adjustment. The dip switches may be positioned to adjust the blower speed by +10% or −10% to better suit the application. The table below provides blower speed adjustments that will result from different switch settings. Refer to blower data tables at the front of this manual for corresponding cfm values.

TABLE 24

Blower Speed Adjustment

Adjustment Switch 7 Switch 8

+10% (approx.) On Off

NORMAL (Factory) Off Off

−10% (approx.) Off On

Switches 9 and 10 − Cooling Mode Blower Speed Ramping −− Switches 9 and 10 are used to select cooling

mode blower speed ramping options. Blower speed ramping may be used to enhance dehumidification performance. The switches are factory set at option A which has the greatest effect on blower motor performance. The table below provides the cooling mode blower speed ramping options that will result from different switch settings. The cooling mode blower speed ramping options are detailed on the next page. See unit nameplate for manufacturing date.

TABLE 25

Cooling Mode Blower Speed Ramping

Ramping Option Switch 9 Switch 10

A (Factory) Off Off

B On Off C Off On

D* On On

*Only option for CCB1

Page 28

Page 29

GHR32V units manufactured before April 2003

Ramping Option A (Factory Selection)

D Motor runs at 50% for 1/2 minute. D Motor then runs at 82% for approximately 7−1/2 min-

utes.

D If demand has not been satisfied after 7−1/2 minutes,

motor runs at 100% until demand is satisfied.

D Once demand is met, motor runs at 50% for 1/2 min-

ute.

D Motor ramps down to off.

GHR32V units manufactured April 2003 and later

Ramping Option A (Factory Selection)

S Motor runs at 50% for 30 seconds. S Motor then runs at 82% for approximately 7−1/2 min-

utes. If demand has not been satisfied after 7−1/2 minutes.

S Motor runs at 100% until demand is satisfied. S Once demand is met, motor runs at 50% for 30 sec-

onds then −

S ramps down to stop.

OFF

1/2 MIN 50% CFM

7−1/2 MIN 82% CFM

COOLING DEMAND

100% CFM

1/2 MIN 50% CFM

OFF

Ramping Option B

D Motor runs at 50% for 1/2 minute. D Motor then runs at 82% for approximately 7−1/2 min-

utes.

D If demand has not been satisfied after 7−1/2 minutes,

motor runs at 100% until demand is satisfied.

D Once demand is met, motor ramps down to off.

OFF

1/2 MIN 50% CFM

7−1/2 MIN 82% CFM

COOLING DEMAND

100% CFM

OFF

Ramping Option C

D Motor runs at 82% for approximately 7−1/2 minutes. D If demand has not been satisfied after 7−1/2 minutes,

the motor runs at 100% until demand is satisfied.

D Once demand is met, motor ramps down to off.

OFF

7−1/2 MIN

82%CFM

COOLING DEMAND

100% CFM

OFF

1/2 MIN 50% CFM

7 1/2 MIN 82% CFM

COOLING DEMAND

100% CFM

1/2 MIN 50% CFM

OFF

Ramping Option B

S Motor runs at 82% for approximately 7−1/2 minutes. If

demand has not been satisfied after 7−1/2 minutes −

S motor runs at 100% until demand is satisfied. S Once demand is met, motor ramps down to stop.

OFF

7 1/2 MIN 82%CFM

COOLING DEMAND

100% CFM

OFF

Ramping Option C

S Motor runs at 100% until demand is satisfied.

S Once demand is met, motor runs at 100% for 60 sec-

onds. Then,

S ramps down to stop.

OFF

100% CFM

COOLING DEMAND

100% CFM

OFF

Ramping Option D

D Motor runs at 100% until demand is satisfied. D Once demand is met, motor ramps down to off.

100% CFM

COOLING DEMAND

Ramping Option D

S− Motor runs at 100% until demand is satisfied.

S− Once demand is met, motor ramps down to stop.

OFFOFF

100% CFM

COOLING DEMAND

OFFOFF

Page 29

Page 30

Switches 11 and 12 − Heating Mode Blower Speed

idi

Dehumidification mode begins when rela

satisfied between

lid

Switches 11 and 12 are used to select heating mode blower motor speed. The unit is shipped from the factory with the dip switches positioned for medium low (2) speed indoor blower motor operation during the heating mode. The table below provides the heating mode blower speeds that will result from different switch settings. Refer to blower data tables at the front of this manual for corresponding cfm values.

TABLE 26

Heating Mode Blower Speeds

Speed Switch 11 Switch 12

1 − Low On On

2 − Medium Low

(Factory)

Off On

3 − Medium High On Off

4 − High Off Off

On−Board Jumper W914

On−board jumper W914, which connects terminals DS and R on the integrated control board, must be cut when the furnace is installed with either the Harmony II zone control board or the CCB1 EfficiencyPlus humidity control. Refer to table 27 for operation sequence in applications including a GHR32V, CCB1 and single−speed outdoor unit. Table 28 gives the operation sequence in applications with a two− speed outdoor unit.

On−Board Jumper W951

On−board jumper W951, which connects terminals R and O on the integrated control board, must be cut when the furnace is installed in applications which include a heat pump unit and the FM21 FuelMaster control board.

Factory−Installed Jumper Y1 to Y2

A factory−installed jumper from Y1 to Y2 terminals on the integrated control board terminal strip must be removed if two−stage cooling will be used.

Diagnostic LEDs (DS1 and DS2)

Two diagnostic LEDs are located on the two−stage, variable speed integrated control just to the left of the first bank of dip switches. These lights’ flashes correspond with diagnostic codes detailed on in table 15.

Status LEDs (HEAT, HI/LO, ON/OFF and CFM)

The integrated control includes four LEDs which indicate operating status. The green ON/OFF LED is lit any time the blower is operating. The green CFM LED indicates the blower motor speed. Count the number of blinks between the two−second pauses to determine the CFM. Each blink represents approximately 100 CFM. The yellow HI/LO LED is lit when the W914 (DS to R) jumper has not been clipped for CCB1 or Harmony operation. The yellow HEAT LED is lit when the indoor blower is operating at the HEATING speed.

Table 27

Operating Sequence

GHR32V−5, CCB1 and Single−Speed Outdoor Unit

OPERATING MODE SYSTEM DEMAND SYSTEM RESPONSE

System Condition

Normal operation Y1

*Call for humidity

removal during

cooling demand Dehumidification demand satisfied

during cooling demand.

Call for cooling after

call for hum

removal.

Humidity demand satisfied between

thermostat demands

(unit off cycle).

NOTE − When changing unit mode of operation from cooling to heating, indicating lights that are on will stay on until the first thermostat heating demand. * Reduced blower speed is 77% of COOL for V3 units and 74% of COOL for the V5 units.

Thermostat

Demand

None

None Over setpoint (1 or more) Off

Y1 Change to acceptable COOL

*Relative Humidity

(EfficiencyPlus Lights)

No demand. Humidity

level is acceptable

Humidity level rises

above setpoint. Demand

initiated.

Humidity level falls below

setpoint. No demand

Humidity level above set-

point. Demand initiated.

Humidity level above set-

point. Demand initiated.

Blower

CFM

(COOL)

COOL

77%/74% of COOL

COOL

Off

77%/74%

of COOL

Comments

Compressor demand and indoor blower speed controlled by thermostat demand.

Call for dehumidification initiated by CCB1 control. Indoor blower speed reduced by CCB1 control. When humidity demand is satisfied, blower speed immediately increases to the COOL CFM to hasten the end of the cycle.

Dehumidification mode begins when relative humidity is greater than setpoint.

While unit is not operating (no thermostat

emand), s

back up. Blower operates at COOL CFM.

e switch is moved down an

Page 30

Page 31

Table 28

Normal operation

blower speed controlled by

removal during

until after initial thermostat demand is

humidity duri

point, or if slide switch is moved signifi

When humidity demand is satisfied

satisfied during

speed compressor operation at begin

compressor) begins with next thermo

satisfied between

Operating Sequence

GHR32V−5, CCB1 and Two−Speed Outdoor Unit

OPERATING MODE SYSTEM DEMAND SYSTEM RESPONSE

System

Condition

Thermostat

Demand

*Relative Humidity

(EfficiencyPlus Lights)

****Compressor

Speed

Blower CFM

(COOL)

Comments

Normal operation

Call for humidity

1st−stage cooling

demand

Significant increase in

thermostat cooling

demand.

Humidity demand

satisfied durin

thermostat demand.

Call for humidity

removal during 2nd

stage thermostat

eman

*Call for 1st stage

cooling after call for

humidity removal.

Call for 2nd stage

cooling after call for

humidity removal

Call for cooling after

significant increase in

humidity

Humidity demand satisfied between

thermostat demands

(unit off cycle).

Y1 No demand. Acceptable Low

Y2 No demand. Acceptable High HIGH COOL

Y1 No demand. Acceptable Low

Demand satisfied

None

Y1 or Y2

None

Y1 or Y2

Humidity level rises slightly

(1) above setpoint. Demand

initiated.

Humidity level remains

slightly (1) above setpoint.

Demand continues.

Humidity level remains

slightly (1) above setpoint.

Demand continues.

No demand. Acceptable

Humidity level rises signifi-

cantly (2 or more) above

setpoint. Demand initiated.

Humidity level

above setpoint.

Humidity level falls below

setpoint. No demand.

No demand. Acceptable

Humidity level rises slightly

(1) above setpoint. Demand

initiated.

No demand. Acceptable

Humidity level is slightly (1)

above setpoint.

Humidity level is slightly (1)

above setpoint.

Humidity level is slightly (1)

above setpoint.

Humidity level is slightly (1)

above setpoint.

Humidity level is significantly

above setpoint (2 or more).

Humidity level is significantly

above setpoint (2 or more).

Humidity level is slightly (1)

above setpoint.

Humidity level falls below

setpoint. No demand.

Low

Off

High

Low

High

Off

Low

High

Off

Low

Off

High

Off

High

Off

High

55% of

HIGH COOL

55% of

HIGH COOL

55% of

HIGH COOL

**77%/74% of

HIGH COOL

55% of

HIGH COOL

**77%/74% of

HIGH COOL

**77%/74% of

HIGH COOL

55% of

HIGH COOL

**77%/74% of

HIGH COOL

55% of

HIGH COOL

**77%/74% of

HIGH COOL

**77%/74% of

HIGH COOL

Off

Compressor demand and indoor

blower speed controlled by

thermostat demand

Dehumidification mode does not begin

satisfied and new cooling demand is

initiated.

If humidity rises significantly above setpoint, or if slide switch is moved signifi-

cantly, unit will immediately go into de-

humidification mode (in presence of

thermostat demand).

When humidity demand is satisfied,

blower immediately shifts to the COOL

CFM in order to hasten the end of the

cycle. Unit can only shift out of high

speed compressor operation at begin-

ning of next cycle.

Blower immediately changes speed in

response to thermostat demand.

Dehumidification mode (high speed

compressor) begins with next thermo-

stat demand after initial demand is sat-

isfied.

Reduced blower speed (dehumidifica-

tion speed) begins immediately with

thermostat demand

If humidity increases significantly over

setpoint, or if slide switch is moved,

unit immediately goes into dehumidifi-

cation mode (in presence of thermostat

demand).

While unit is not operating (no thermo-

stat demand), slide switch is moved

down and back up. Blower and com-

pressor operate at high speed until

next thermostat demand.

Note − During mode of operation change from cooling to heating, indicating lights will not change until the first thermostat heating demand.

*IMPORTANT - If power to unit is turned on with CCB1 calling for humidity removal, outdoor unit may be locked into high speed indefinitely. To reset, move the humidity slide switch all the way down then back up to desired setpoint while the unit is running. ** Reduced blower speed is 77% of COOL for the V3 units; 74% of COOL for V5. ***If the two−speed control on a two−speed outdoor unit is set for LATCH 2 (15 minutes) or LATCH 3 (30 minutes), the compressor will latch into high speed after a Y1 demand has occurred for that period of time.

Page 31

Page 32

HEAT EXCHANGER

SUPPORT

HOT END HEADER

(COLLECTOR) BOX

GHR32 HEAT EXCHANGER

CONDENSER COIL

COMBUSTION

AIR BLOWER

COMBUSTION AIR

BLOWER MOTOR

COLD HEADER

(COLLECTOR)

BOX

PRIMARY LIMIT

CONTROL (S10)

LENNOX DURALOKPlust

HEAT EXCHANGER

(Assembly)

CLAMSHELL

(Each Segment)

CORBEL ORIFICE

CUPS

FLAME SENSOR

ASSEMBLY

GAS VALVE

MANIFOLD

BURNER

BOX

BURNERS

FIGURE 22

Page 32

BURNER ORIFICE

FLAME SIGHT

(VIEWING) GLASS

SURELIGHT

IGNITOR

Page 33

C−Heating Components (Figure 22)

Combustion air blower (B6), primary limit control (S10), SureLight ignitor, flame sensor, burners, flame rollout switch (S47), gas valve (GV1), combustion air blower switch (S18), and clamshell heat exchangers are located in the heating compartment. The heating compartment can be accessed by removing the burner access panel.

1.Combustion Air Inducer Blower (B6)

All GHR32 units use a two−stage combustion air inducer blower to move air through the burners and heat exchanger during heating operation. The blower uses a 120VAC motor. The motor operates during all heating operation and is controlled by the SureLight integrated board (A92) and two−stage control board (A86). The combustion air inducer blower operates on low speed during first stage heat (low fire), then switches to high speed for second stage heat (high fie).

2.Combustion Air Blower Capacitor (C3) PSC Motors only

GHR32 units with a PSC combustion air blower motor, will have a thermally protected 3 MFD 300VAC capacitor. The capacitor is mounted on the combustion air blower housing.

3.Primary Limit Control (S10)

Figure 23 shows the primary limit (S10) used on GHR32 units. S10 is located in the middle of the heating vestibule panel. When excess heat is sensed in the heat exchanger, the limit will open. If the limit is tripped, the furnace control energizes the supply air blower and closes the gas valve. The limit automatically resets when unit temperature returns to normal. The switch is factory set and cannot be adjusted. See table 29 for limit set points.

SPADE CONNECTORS

GHR32 UNIT SIZE LIMiT SET POINT

GHR32-50 300°

GHR32-75 300°

GHR32Q3/4-100 220°

GHR32-120 175°

LIMIT CONTROL (S10)

LIMIT

INSULATING COVER (s)

FIGURE 23

TABLE 29

DETAIL VIEW OF BURNER CLUSTER MOUNTING

Burner Box

Raised

Toggle Locks

Burner Cluster

Flange

Screw

FIGURE 24

4.Burners

Figure 22 shows the arrangement of the burner box. Table 30 shows how many burners are used per unit. See figure 24 for a more detailed view. Notice the position of the raised toggle lockets.

TABLE 30

NUMBER OF HEAT

GHR32 UNIT SIZE

GHR32-50 2 GHR32-75 3

GHR32Q3/4-100 4

GHR32-120 5

All units use inshot burners Burners are factory set and do not require adjustment. A sight glas s is fu rnis hed in the burn er box assembly for flame viewing. Always operate the unit wit h the burne r box cover in place. Burners can be removed as an assembly for service. Burner maintenance and service is detailed in the SERVICE CHECKS sections of this manual. Each burner uses an orifice which is precisely matched to the burner input. The orifice is threaded into the burner manifold. The burner is supported by the orifice and will easily slide off for service. Each orifice and burner are sized specifically to the unit. Refer to Lennox Repair Parts Listing for correct sizing information. A flame retention ring in the end of each burner maintains correct flame length and shape and keeps the flame from lifting off the burner head. In addition, the burner entrance to each clamshell (Figure 22) is fitted with a corbel cup (orifice) used to direct the flow of combustion products.

NOTE−Do not use thread-sealing compound on the orifices. Thread-sealing compound may plug the orifices.

EXCHANGER CLAMSHELLS /

BURNERS

Page 33

Page 34

5.Clamshell Heat Exchanger

GHR32 units use an aluminized steel primary and stainless steel secondary heat exchanger assembly. Table 30 shows how many heat exchanger clamshells are used per unit. Heat is transferred to the air stream from all surfaces of the heat exchanger. The shape of the heat exchanger ensures maximum efficiency.

The combustion air blower pulls fresh air through the air intake box. This air is mixed with gas in the burner venturi and at the corbel orifices. The gas / air mixture is then burned at the entrance of each clamshell. Combustion gases are then pulled through the primary and secondary heat exchangers and exhausted out the exhaust vent pipe.

6.Flame Rollout Switch (S47)

Flame rollout switch S47 is a SPST N.C. high temperature limit located behind the burner air intake fitting on the burner box assembly (see figure 25). S47 is wir ed to the burne r ign itio n control A3. When S47 senses flame rollout (indicating a blockage in the combustion air passages), the flame rollout switch trips, and the ignition control immediately closes the gas valve.

Switch S47 in all GHR32 units is factory preset to open at 320_F + 12_F (160_C + 6.7_C) on a temperature rise. All flame rollout switches are manually reset.

7.Gas Valve

The GHR32 uses a gas valve manufactured by White Rodgers or Honeywell. The valve is two-stage internally redundant to assure safety shut−off. If the gas valve must be replaced, the same type valve must be used. The Honeywell valve can be field converted to LP and is adjustable on both low and high fire. WhiteRodgers supplies two seperate valves for natural and LP and is adjustable for high fire ONLY.

24VAC terminals and gas control knob are located on top of the valve. Terminals on the gas valve are connected to wires from the SureLight integrated control and the two−stage control. 24V applied to the terminals energizes the valve.

Inlet and outlet pressure taps are located on the valve. A regulator adjustment screw is located on the side of the valve. Refer to figures 26, 27 , and 28 for location of valve features.

NOTE−WhiteRodgers valve is not adjustable on low fire. Do not attempt to regulate low fire manifold pressure.

WHITE RODGERS 36E SERIES GAS VALVE

NATURAL GAS

(LOW HEAT MANIFOLD PRESSURE FACTORY SET.

DO NOT ADJUST.)

HIGH HEAT

MANIFOLD

PRESSURE

ADJUSTMENT

ON SIDE

(under cap)

FLAME ROLLOUT SWITCH (S47)

FLAME ROLLOUT

SWITCH (S47)

FIGURE 25

HONEYWELL VR8205 Series Gas Valve

HIGH FIRE ADJUSTMENT

SCREW (UNDER CAP)

LOW FIRE

ADJUSTMENT

SCREW

(UNDER CAP)

INLET PRESSURE TAP

VALVE SHOWN IN OFF POSITION

FIGURE 26

MANIFOLD

PRESSURE

TAP

MANIFOLD

PRESSURE

OUTLET ON

SIDE

FIGURE 27

WHITE RODGERS 36E SERIES GAS VALVE

PROPANE GAS

(LOW HEAT MANIFOLD PRESSURE FACTORY SET.

DO NOT ADJUST.)

HIGH HEAT MANIFOLD

PRESSURE

ADJUSTMENT

ON SIDE

(under cap)

MANIFOLD

PRESSURE

OUTLET ON

SIDE

FIGURE 28

100% Sealed Combustion

The burner box is completely sealed and operates under a negative pressure. A pressure hose is connected from the burner box to the gas valve regulator. The gas valve senses the pressure in the burner box and changes gas valve outlet (manifold) pressure based on changes in bu rner box pr essure. The intent is to compensate for different vent configurations which can greatly affect the firing rate of the unit.

Page 34

Page 35

NORMAL OPERATION (Natural Gas Units)

3.5

3.4

3.3

3.2

3.1

3.0

2.9

2.8

GAS VALVE OUTPUT

2.7

2.6

MANIFOLD PRESSURE (positive inches water gauge)

2.5

Gray area indicates normal operating range + 10% of manifold pressure The purpose of this chart is to explain unit operation . Each unit may vary depending on installation, altitude, intake/exhaust configuration and other factors.

OPERATION AT THIS EXTREME

MAY INDICATE A BLOCKED

INLET OR OTHER PROBLEM"

BURNER BOX PRESSURE

(Negative inches water gauge

measured on left side of burner box)

FIGURE 29

NORMAL OPERATION (L.P. Gas Units)

10.0

9.9

9.8

9.7

9.6

9.5

9.4

9.3

GAS VALVE OUTPUT

9.2

9.1

MANIFOLD PRESSURE (positive inches water gauge)

9.0

OPERATION AT THIS EXTREME

MAY INDICATE A BLOCKED

INLET OR OTHER PROBLEM"

BURNER BOX PRESSURE

(Negative inches water gauge

measured on left side of burner box)

Figures 29 and 30 show how gas valve manifold pressure changes as burner box pressure changes. The GHR32 is a self adjusting unit to maintain a constant output.

8.Combustion Air Prove Switch (S18) GHR32−1/−4 Units & (S102) GHR32−5 Units

GHR32 series units are equipped with a differential pressure switch S18 or S102 located on either side of the heating compartment cabinet (factory installed on left side ).The switch monitors the differential pressure between the downstream and upstream flue gas pressures. When the unit is installed for horizontal right-hand discharge, the air proving pressure switch must be moved to the opposite side of the unit. Any one of four different switches may be on the unit. One is manufactured by MPL. The other three switches are manufactured by TRIDELTA / HONEYWELL. Each switch operates the same and can be replaced

−1.0−0.20 −0.4 −0.6 −0.8

with one another. See figure 31 for combustion air prove switch replacment. Hoses must be connected to correct taps for switch to operate safely and properly. GHR32 model units have color coded tubing to designate positive and negative sides of the pressure switch. Red/Square tubing should always be connected to the positive side of the pressure switch. Gray or Black /Round tubing should always be connected to the negative side of the pressure switch. See figure 31.

The switch is a SPST N.O. pressure switch electrically connected to the integrated control. The purpose of the switch is to prevent burner operation if the combustion air blower is not moving enough air for proper combustion.

On start-up, the switch senses that the combustion air blower is operating. It closes a circuit to the ignition control when the difference in pressure across the pressure switch exceeds 0.90" W.C. (223.78Pa). If the switch doe s no t s uccessfully sense the required differential, the switch cannot close and the furnace cannot operate. The switch is factory set and is not adjustable. If the flue or air inlet become obstructed during operation, the switch senses a loss of pressure differential and opens the circuit to the ignition control. If the condensate line is blocked, water will back up into the header box and reduce the pressure differential across the switch. The pressure switch will open if the differential drops below 0.75" W.C. +

05" W.C. (186.48 Pa +

12.4 Pa).

FIGURE 30

Page 35

Page 36

NEGATIVE

PRESSURE

(Marked With "V")

TRIDELTA / HONEYWELL

(All Metal Construction)

NEGATIVE

PRESSURE (NO Markings) Hose Connec-

tion Side Only)

MPL

POSITIVE

PRESSURE

(Marked With "P")

POSITIVE PRESSURE (NO Markings Electrical Terminal

and Hose Connection Side)

NEGATIVE PRESSURE

(Marked With "−")

POSITIVE

PRESSURE

(Marked With "+")

TRIDELTA / HONEYWELL IS2

TRIDELTA / HONEYWELL

(Metal/Plastic Construction)

NEGATIVE PRESSURE

(gray side marked −")

HORIZONTAL LEFT HAND AIR DISCHARGE

Connect hose (red square) to POSITIVE side on pres-

sure switch and open tap on FRONT of collector box.

Pressure

Switch

AIR FLOW

Connect hose (gray or black

round) To "NEGATIVE"side on

pressure switch and open tap on

SIDE of collector box.

NEGATIVE PRESSURE CONNECTIONS

(Gray or Black round tubing beginning with −3 models)

SCALE1.000

POSITIVE PRESSURE

(black side marked +")

DOWN FLOW AIR DISCHARGE

Connect hose (gray or black round) To NEGATIVE side

on pressure switch and open tap on FRONT of collector

box.

AIR FLOW

Pressure

Switch

Connect hose

(red square) to

POSITIVE side

on pressure

switch and open

tap on FRONT

of collector box.

Collector Box

HORIZONTAL RIGHT HAND DISCHARGE

Connect the red square hose to the POSITIVE side on pressure

switch and the open tap on the FRONT of the collector box.

Pressure

Switch

must be

on top side

of unit.

Collector Box

BLANK STEMS EARLY MODEL

UNITS ONLY

POSITIVE PRESSURE CONNECTIONS

(Red tubing)

AIR FLOW

Connect the gray or black round hose to the NEGATIVE

side on the pressure switch and SIDE of the collector box.

FIGURE 31

Page 36

Page 37

To troubleshoot the pressure switch, temporarily jumper the

switch. The unit will not fire with pressure switch jumpered.

Therefore, the pressure switch must be bypassed after the

combustion air blower is activated. This will determine if the

pressure switch and furnace are operating properly. However,

this may not indicate if the sealed combustion system is oper-

ating properly. If the unit cannot attain 0.75" W.C. (186.48 Pa )

differential, the unit will not operate.

D−Blower Compartment (Figures 33 and 34)

Blower motor (B3), capacitor (C4), and secondary limit control (S21) are located in the blower compartment shown in figure 33. Blower motor (B3), Coil choke (L13) and secondary limit (S21) are shown in figure 34. The blower compartment can be accessed by removing the blower access panel.

IMPORTANT

Unit will not operate with pressure switch bypassed upon start-up. To troubleshoot pressure switch, jumper pressure switch following activation of combustion air blower!!

Checks of pressure differential can aid in troubleshooting.

When measuring the pressure differential, readings should be

taken at the pressure switch. Lack of differential usually indi-

cates problems in the intake or exhaust piping, but may ind i-

cate problems in the heat exchanger, condensing coil,

header boxes, combustion blower or other compo-

nents.

Measuring pressure differential

The differential pressure is the difference in pressure mea-

sured on either side of the pressure switch:

1 − Remove thermostat demand and allow unit to cycle

off.

2 − Disconnect hose from front of pressure switch and

install tee as shown in figure 32. Repeat sequence for hose connected to back of switch.

BLOWER COMPARTMENT

Q MODELS

SECONDARY LIMIT

CONTROL (S21)

BLOWER MOTOR

(B3)

BLOWER MOTOR

CAPACITOR (C4)

FIGURE 33

TEE AND 1/4"i.d. RUBBER HOSE FIELD PROVIDED

TO PRESSURE

SENSING HOSE

TO PRESSURE

SWITCH

TO DRAFT GAUGE

FIGURE 32

3 − Install manometer (draft gauge) to open ends of tee’s.

The hose from the back side of the switch goes to the zero side of the gauge.

4 − Operate unit and observe draft gauge reading. Read-

ings will change as heat exchanger warms.

a. Take one reading immediately after startup. b. Take a second reading after unit has reached steady state (approximately 5 minutes).

Pressure differential should be greater than .75"

W.C. (186.48 Pa).

5 − Remove thermostat demand and allow to cycle off.

6 − Remove draft gauge and Tee’s. Reinstall combustion air

sensing hoses to the pressure switch.

BLOWER COMPARTMENT

V MODELS

SECONDARY

LIMITS (S21)

COIL

CHOKE

(L13)

To Remove Blower From Unit: Remove Bolts and

Wiring Jackplugs. Then Slide Out Front of Unit.

BLOWER

WHEEL

BLOWER

MOTOR (B3)

FIGURE 34

Page 37

Page 38

1.Blower Motor (B3) and Capacitor (C4) GHR32Q Models

All GHR32Q model units use single phase direct drive blower motors. All motors are 120V permanent split capacitor motors to ensure maximum efficiency. See motor nameplate or SPECIFICATIONS section for motor ratings. Ratings for capacitor will be on side.

2.Secondary Limit Control (S21)

The secondary limit (S21) on GHR32 units is mounted on the back side of the blower housing. When excess heat is sensed in the blower compartment, the limit will open. If the limit is tripped, the furnace control energizes the supply air blower and closes the gas valve. The limit automatically resets when unit temperature returns to normal. The switch opens at 160_F + 5_F (71.1_C + 2.8_C) on a temperature rise and resets at 130_F + 8_F (54.4_C + 4.4_C) on a temperature fall. The switch is factory set and cannot be adjusted. The setpoint is printed on the face plate of the limit.

SECONDARY LIMIT CONTROL (S21)

SPADE CONNECTORS

LIMIT

INSULATING COVER (s)

GHR32V BLOWER MOTOR B3

J48

SHAFT

MOTOR

CONTROLLER

J49

FIGURE 36

GHR32V BLOWER MOTOR COMPONENTS

STATOR

(WINDINGS)

BEARING

OUTPUT

SHAFT

ROTOR

FIGURE 37

A solid-state controller is attached to the motor. The controller is primarily an A.C. to D.C. converter. Converted D.C. power is used to drive the motor. The controller contains a microprocessor which monitors varying conditions inside the motor (such as motor workload).

The controller uses sensing devices to sense what position the rotor is in at any given time. By sensing the position of the rotor and then switching the motor windings on and off in sequence, the rotor shaft turns the blower.

FIGURE 35

3. Blower Motor (B3) GHR32V MODELS

GHR32V model units use a single−phase, electronically controlled D.C. brushless motor (controller converts single phase A.C. to three phase D.C.), with a permanent-magnet-type rotor (figure 36). Because this motor has a permanent magnet rotor it does not need brushes like conventional D.C. motors. Internal components are shown in figure 37. The stator windings are split into three poles which are electrically connected to the controller. This arrangement allow s mot or windin gs to turn on and off in sequence by the controller.

DANGER

Disconnect power from unit and wait at least five minutes to allow capacitors to discharge before attempting to adjust motor speed tap settings. Failure to wait may cause personal injury or death.

GHR32V series blower motor ratings are listed in the SPECIFICATIONS section. All GHR32V blower motors use single phase power. An external run capacitor is not used. The motor uses permanently lubricated ball-type bearings. The VSM is a two part component; the motor and the control module. If motor fails, it is quite possible the control module only, will need to be replaced. Lennox provides a replacement kit for the control module.

Internal Operation

Each time the controller switches a stator winding (figure 37) on and off, it is called a pulse." The length of time each pulse stays on is called the pulse width." By varying the pulse width (figure 38), the controller varies motor speed (called pulsewidth modulation"). This allows for precise control of motor speed and allows the motor to compensate for varying load conditions as sensed by the controller. In this case, the controller monitors the static workload on the motor and varies motor rpm in order to maintain constant airflow (cfm).

The motor is equipped with 11 incremental taps which are driven by the integral controller. The controller is capable of controlling three of the 11 taps.

Page 38

Page 39

The motor controller is driven by the VSP2−1, VSP3−1 or two stage integrated SureLight control The VSP receives its demand (PWM signal or fixed 24 VAC or VDC signal) from optional controls such as the Harmony zone control system, Efficiency Plus Humidity Control (CCB1) or a conventional thermostat.

Motor rpm is continually adjusted internally to maintain constant static pressure against the blower wheel. The controller monitors the static work load on the motor and motor ampdraw to determine the amount of rpm adjustment. Blower rpm may be adjusted any amount in order to maintain a constant cfm as shown in Blower Ratings Tables. The amount of adjustment is determined by the incremental taps which are used and the amount of motor loading sensed internally. The cfm remains relatively stable over a broad range of static pressure. Since the blower constantly adjusts rpm to maintain a specified cfm, motor rpm is not rated. Hence, the terms blower speed" and speed tap" in this manual, on the unit wiring diagram and on blower B3 refer to blower cfm regardless of motor rpm.

When Harmony is used, speed taps are overridden and a PWM signal generated by the Harmony controller continuously varies motor speed based upon zone demands.

Initial Power Up

When line voltage is applied to B3, there will be a large inrush of power lasting less than 1/4 second. This in rush charges a bank of DC filter capacitors inside the controller. If the disconnect switch is bounced (rapid turning on and off) when the disconnect is closed, the disconnect contacts may become welded. Try not to bounce the disconnect switch when applying power to the unit.

Motor Start-Up

When B3 begins start-up, the motor gently vibrates back and forth for a moment. This is normal. During this time the electronic controller is determining the exact position of the rotor. Once the motor begins turning, the controller slowly eases the motor up to speed (this is called soft-start"). The motor may take as long as 10-15 seconds to reach full speed. If the motor does not reach 200rpm within 13 seconds, the motor shuts down. Then the motor will immediately attempt a restart. The shutdown feature provides protection in case of a frozen bearing or blocked blower wheel. The motor may attempt to start eight times. If the motor does not start after the eighth try, the controller locks out. Reset controller by momentarily turning off power to unit.

The DC filter capacitors inside the controller are connected electrically to the speed tap wires. The capacitors take

approximately 5 minutes to discharge when the disconnect is opened. For this reason it is necessary to wait at least 5 minutes after turning off power to the unit before attempting to change speed taps.

Page 39

Page 40

MOTOR SPEED CONTROL WITH D.C. PULSE-WIDTH MODULATION

Motor speed is determined by the size of the electrical pulse sent to the

motor windings. The longer the pulse, the faster the motor.

OUTPUT FROM CONTROLLER TO MOTOR WINDINGS

WINDINGS TURNED OFF

The frequency of the pulses to the windings is 20KHz.

DO NOT ATTEMPT TO MEASURE THESE VOLTAGES.

LOW SPEED HEAT/COOL (output from controller to motor windings)

One

Pulse

One revolution

325VDC

O volts

WINDING #1

325VDC

O volts

WINDING #2

325VDC

O volts

WINDING #3

HIGH SPEED HEAT (output from controller to motor windings)

One revolution

325VDC

O volts

WINDING #1

325VDC

O volts

WINDING #2

325VDC

O volts

WINDING #3

WINDINGS TURNED ON

ON PULSE

OFF PULSE

HIGH SPEED COOL (output from controller to motor windings)

One revolution

325VDC

O volts

WINDING #1

325VDC

O volts

WINDING #2

325VDC

O volts

WINDING #3

FIGURE 38

Page 40

Page 41

External Operation (Speed Tap Priority)

Figure 39 shows the two quick-connect jacks (J48 and J49) which connect the motor to the GHR32V. Jack J48 is the power plug and jack J49 connects the unit controls to the motor.

Line voltage must be applied to J48 pin 5 in order for the motor to operate. When using 120VAC pins 1 and 2 must be jumpered. When control voltage is applied to J49 pin 3 and 15 (single stage heating and cooling), the motor is energized on the low speed heat/cool tap.

4.Choke Coil (L13)

A choke coil is used on all GHR32V units. The choke is located on the blower housing and is used to block radio frequency interference.

Precautions

If the GHR32 V or its electronically controlled blower motor is improperly or inadequately grounded, it may cause television interference (commonly known as RFI or radio frequency interference).

When voltage is applied to J49 pin 2 in addition to pin 3 and 15 (second stage heating), the blower is energized on the high speed heating tap. When voltage is applied to J49 pin 10 in addition to pin 3 and 15 (second stage cooling), the blower is energized on the high speed cooling tap. The motor assigns priority to J49 pin 2 so that if a call for cooling and a call for heating are concurrent, heating call overrides and the blower operates on high speed heating tap.

ICM2 with VSP3 or Two stage Variable Speed Control

The ICM2 operates slightly different than stated above when matched with the VSP3 or Two stage variable speed control. When control voltage is applied to J49 pin 3 and 15, the motor is energized on continuous fan. When voltage is applied to J49 pin 2 in addition to pin 3 and 15 (first stage heating), the blower is energized on the low speed heating tap. When voltage is applied to J49 pin 13 in addition to pin 3 and 15 (second stage heating), the blower is energized on the high speed heating tap. The motor assigns priority to J49 pin 2 so that if a call for cooling and a call for heating are concurrent, heating call overrides and the blower operates on high speed heating tap.

BLOWER B3 HARNESS CONNECTORS

POWER

CONNECTOR J48

J48

PIN 1 - Jumper PIN 1 to PIN2 for 120VAC line input only. PIN 2 - Jumper PIN 1 to PIN2 for 120VAC line input only. PIN 3 - Ground PIN 4 - AC Line PIN 5 - AC Line

CONTROL

CONNECTOR J49

J49

PIN 1 - C1 PIN 2 - W / W1 PIN 3 - C2

PIN 4 − Delay PIN 5 - Cool PIN 6 - Y1 PIN 7 - Adjust PIN 8 - 0ut PIN 9 - 0 PIN 10 - BK / PWM PIN 11 - Heat PIN 12 - R PIN 13 - EM / W2 PIN 14 - Y / Y2 PIN 15 - G PIN 16 - Out +

FIGURE 39

This interference is caused by internal switching frequencies of the motor controller (see figure 40). TV interference may show up as small specks or lines which randomly appear on the TV screen accompanied by pops or clicks in the sound. Before attempting any service, make sure the indoor unit is causing the interference. To check, disconnect power to indoor unit then check TV for continued signs of interference.

TV interference may be stopped by making sure the motor is solidly grounded to the cabinet (metal to metal) and by making sure the cabinet is solidly grounded. If TV interference persists, make sure the television (and all affected RF appliances) are moved away from the GHR32V. Also make sure affected appliances are connected to a separate electrical circuit.

ECM SWITCHING FREQUENCY

The electrical pulses to the windings cycle on and off at a rate of

20,000 cycles per second (20Khz, this is called the switching

frequency). The effective D.C. voltage can be varied by chang-

ing the pulse width. The switching frequency is necessary in

order to vary the speed of the motor. If the motor is not securely

grounded to the cabinet and if the cabinet is not securely

grounded, the switching frequency may cause television inter-

OUTPUT FROM CONTROLLER TO MOTOR WINDINGS

One Pulse

325VDC

O volts

325VDC

O volts

325VDC

O volts

PULSE ON

PULSE OFF

WINDING OFF

WINDING #1

WINDING #2

WINDING #3

One cycle

ference.

ELECTRICAL

325VDC

PULSE

O volts

Switching Frequency

20Khz

ONE

FIGURE 40

Page 41

Page 42

II−PLACEMENT AND INSTALLATION

Make sure unit is installed in accordance with installation instructions and applicable codes.

A−PVC Joint Cementing Procedure

WARNING

DANGER OF EXPLOSION! Fumes from PVC glue may ignite during system check. Remove spark plug wire from ignition control before 120V power is applied. Reconnect wire after two minutes.

B−Venting Considerations

All GHR32 furnaces must be vented independently as shown in figure 42 and must not be connected to a common venting system. If a GHR32 furnace replaces a less efficient furnace which was vented with other gas appliances into a common vent, the size of the common vent pipe must be appropriate for gas appliances which remain connected. Without the heat of the original furnace flue products, the vent pipe is probably oversized for the single water heater or other appliance(s). The common vent should be checked for proper draw for all appliance(s) which remain connected.

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 liberal coat of PVC primer for PVC or

ABS cleaner for ABS to inside socket surface of fitting and male end of pipe to depth of fitting socket.

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 pipe 1/4 turn during assembly (but not after pipe is fully inserted) to distribute cement evenly. Once joint is made, PVC may swell. Hold joint together until bonded (approximately 20 seconds).

NOTE−Assembly should be completed within 20 seconds after last application of cement. Hammer blows should not be used when inserting pipe.

Checks of Common Venting System for Other Gas Appliances (Water Heater, etc...)

1 − Unused openings in the common venting system must be

sealed.

2 − The venting system should be visually checked for proper

size and horizontal pitch. You should also check and determine that there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition.

3 − Close all building doors and windows and all doors

between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliances not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

4 − Follow the lighting instructions. Place the appliance being

inspected in operation. Adjust thermostat so appliance will operate continuously.

5 − Test for spillage at the draft hood relief opening after 5

minutes of main burner operation. Use match or candle flame, or smoke from a cigarette or cigar.

6 − After it has been determined that each appliance re-

maining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-burning appliance to their previous condition of use.

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.

7 − If improper venting is observed during any of the tests, the

common venting system must be corrected. The common venting system should be resized to approach the minimum size as determined by using the appropriate tables in appendix G in the current standards of the National Fuel Gas Code in the U.S.A. or category 1 in the Natural Gas and Propane Installation Code in Canada.

Page 42

Page 43

GHR32 Intake and Exhaust Piping Considerations

If the GHR32 venting system must be altered or repaired, use the following as a guide. 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 42 through 45 show typical terminations.

1 − Use only recommended piping materials for both in-

take and exhaust piping.

2 − Secure permanent joints gas tight using approved ce-

ment.

3 − Piping diameters should be determined according to

length of pipe run. See table 31. Locate intake piping upwind (prevailing wind) from exhaust piping. To avoid recirculation of exhaust gas on roof terminations, end of exhaust pipe must be higher than intake pipe.

Exhaust and intake exits must be in same pressure zone. Do not exit one through the roof and one through the side. Also, do not exit the intake on one side and the exhaust on another side of the house or structure.

4 − 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.

NOTE−If winter design temperature is below 32_ F (0_C), exhaust piping must 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 must be insulated with 1/2" (13mm) Armaflex or equivalent. In extreme cold climate areas, 3/4" (19mm) Armaflex or equivalent is recommended. Insulation on outside runs of exhaust pipe must be painted or wrapped to protect insulation from deterioration.

5 − Exhaust piping must terminate straight out or up as

shown. On roof terminations, the intake piping should terminate straight down using two 90_ elbows (See figure 42). In rooftop applications, a 2" X 1−1/2" (51mm X 38mm) reducer for 2" (51mm) venting, 3" x 2" (76mm X 51mm) reducer for 3" (76mm) venting must be used on exhaust piping at the point where it exits the structure to improve the velocity of exhaust and force flue products away from intake piping.

NOTE-Care must be taken to avoid recirculation of exhaust back into intake pipe.

6 − On side wall exits, exhaust piping should extend a

maximum of 12" (395mm) beyond the outside wall. Intake piping should be as short as possible. See figure 44.

7 − Minimum separation distance between the end of

the exhaust pipe and the end of the intake pipe is 8" (203mm).

8 − If intake and exhaust piping must be run up a side wall

to position above snow accumulation or other obstructions, refer to figure 45 for proper piping method. Piping must be supported every 3 ft. (.91m) as shown in figure 41 and must be insulated. When exhaust and intake piping must run up an outside wall, the exhaust piping is reduced accordingly after the final elbow.

9 − Position termination ends so they are free from any ob-

structions and above snow accumulation level (where applicable). Termination ends must be a minimum of 12" (305mm) above grade level. Do not point into window wells, stairwells, alcoves, courtyard areas or other recessed areas. Do not position termination ends directly below roof eaves.

10− 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, SDR−21 PVC, and SDR−26 PVC piping. A suitable hanger can be fabricated by using metal or plastic strapping or a large wire tie. See figure 41.

Page 43

Page 44

METAL OR PLASTIC

STRAPPING

FIGURE 41

60G77  For 2 inch (51 mm) Venting 33K97  For 3 inch (76 mm) Venting

2 x 1-1/2 in. (51 x 38 mm) 60G77

3 x 2 in. (76 x 51 mm) 33K97

REDUCER BUSHING (Furnished)

(940)

INTAKE AIR

11− 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 support straps.

12− Isolate piping at the point where it exits the outside wall

or roof.

13− Unit should not be installed in areas normally sub-

ject to freezing temperatures.

14− 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 exhaust tee, cold end header collector box, condensate collection trap and lines.

Intake Piping Requirements

Piping must be routed to outside of structure.

IMPORTANT

Combustion air intake inlet and exhaust outlet should not be located within 6 ft. (1.8m) of dryer vent or combustion air inlet or outlet of another appliance. Piping should not exit less than 3 ft. (.91m) from opening into another building.

3 (76)

ELBOW

(Furnished)

CLAMP

(Furnished)

INTAKE AIR

TERMINATION ASSEMBLY

EXHAUST

AIR

(Furnished)

60L46  For 3 inch (76 mm) Venting

46−3/4 (1187)

6−1/2 (165)

4−1/2 (114)

INTAKE AIR

ELBOW

(Field Supplied)

TERMINATION ASSEMBLY

(Furnished)

EXHAUST

AIR

CONCENTRIC WALL TERMINATION APPLICATIONS

Cat. No. A

60G77 10-1/2 (267) max. 33K97 10-1/2 (267) max. 60L46 7−1/2 (191) max.

EXHAUST

AIR

INTAKE

AIR

EXHAUS

AIR

INTAKE PIPE

Not Furnished)

12 (305)

Minimum

Above

Average

Snow

Accumulation

ROOF TERMINATION KITS 15F75  For 2 inch (51 mm) Venting 44J41  For 3 inch (76 mm) Venting

3 in. MAX.

(76 mm)

FLASHING

(2)

(Furnished)

INSULATION SLEEVES (2)

(Furnished)

8 (203)

Minimum

2 x 1-1/2 in.

(51 x 38 mm) 15J75

(76 x 51 mm) 44J41

REDUCER BUSHING

(Not Furnished)

EXHAUST PIPE (Not Furnished)

ARMAFLEX

INSULATION

(Not Furnished)

3 x 2 in.

FIGURE 42

INTAKE

AIR

OUTSIDE

WALL

INTAKE

AIR

GRADE

12 (305)

Minimum

Above Grade

CONCENTRIC ROOF TERMINATION APPLICATION

FLASHING

12 (305)

Minimum

Above Average

Snow

Accumulation

CLAMP

SHEET METAL STRAP

(Clamp and sheet metal strap must be field installed to support the weight of the termination kit.)

FIGURE 43

Page 44

Page 45

8 in. (203 mm)

minimum

(2 Furnished 1 for intake and 1 for exhaust)

NOTE  12 in. (305 mm) minimum height above

average snow accumulation.

12 in. (305 mm) maximum

6 in. (152 mm)

maximum

Typical Application

GALVANIZED STEEL INSIDE SEAL CAP

PVC COUPLING

(Not Furnished)

WALL TERMINATION KIT (RING KIT) 15F74  For 2 inch (51 mm) Venting

NOTE  Not for use with 3 inch (76 mm) Venting

NOTE  EXHAUST PIPE SHOWN

INSULATION SLEEVE

(2 Furnished 1 for intake and 1 for exhaust)

STAINLESS STEEL OUTSIDE SEAL CAP

(2 Furnished 1 for intake and 1 for exhaust)

2 in. (51 mm) PVC

(Not Furnished)

ARMAFLEX INSULATION

(Not Furnished)

INDOOR

EXHAUST ASSEMBLY

(Furnished)

INDOOR

INTAKE ASSEMBLY

(Furnished)

2 in. (51 mm) COUPLING

(Furnished)

*Bushing outside on plate for 44J40 kit.

SEAL RINGS (4 Furnished

2 for intake and 2 for exhaust)

2 x 1-1/2 in. (51 x 38 mm) 22G44

3 x 2 in. (76 x 51 mm) 44J40

*REDUCER BUSHING

FACE PLATE

(Furnished)

INTAKE

AIR

GASKET

(Furnished)

(305)

FIGURE 44

OUTDOOR

EXHAUST ASSEMBLY

(Furnished)

EXHAUST

AIR

2 x 1-1/2 in. (51 x 38 mm)

REDUCER BUSHING

(Not Furnished)

WALL TERMINATION KITS (CLOSE-COUPLE)

22G44  For 2 inch (51 mm) Venting

44J40  For 3 inch (76 mm) Venting

If Intake and Exhaust Pipe is less than 12 in. (305 mm) above snow accumulation or other obstructions, field fabricated piping must be installed.

EXHAUST

AIR

INTAKE

AIR

5 (127)

5-1/2 (140)

EXHAUST

AIR

INSULATION

(Not Furnished)

FIGURE 45

Page 45

(305)

(51)

INTAKE

AIR

(305)

GRADE

12 (30

Minim

ABOVE G

Page 46

TABLE 31

3 in. (76 mm)

2 in. (51 mm) 2 i

(51

)

3 in. (76 mm)

Maxi

aust

run, either intake or exhaust

3 i

(76

)

Not Available

3 in. (76 mm)

Acceptable

()

NOTE Exhaust pipe

Termination Kits

NOTE Intake

12 in. (305 mm) in length

Kits f

(76

)

Venting

must be terminated with

)pp,

VENTING REQUIREMENTS

Model No. GHR32−50 GHR32−75 GHR32−100 GHR32−120

Vent Pipe Minimum Equivalent Length with Accelerator − Exhaust pipe should terminate with an accelerator. See Termination Kits, below.

feet (m) Minimum Vent Pipe Diameter Required

15 (4.6) Not Recommended 2 in. (51 mm) 20 (6.1) 25 (7.6) 30 (9.1)

Maximum Equivalent Vent Length

mum length is for one individua

run, either intake or exh

35 (10.7) 40 (12.2) 45 (13.7) 50 (15.2) 55 (16.8) 60 (18.3) 70 (21.3) 80 (24.4) 90 (27.4) 100 (30.5)

VENT/INTAKE AIR TERMINATION KIT USAGE

Cat. No.

Kits for 2 in. (51 mm)

Venting

NOTE − Exhaust pipe

must be terminated with

an accelerator; 1−1/2 in.

(38.1 mm) diameter pipe,

NOTE − Intake

and Exhaust

pipes must be the

same

diameter.

2 in. (51 mm) pipe may be used to adapt terminations and intake/exhaust furnace connections. The TOTAL of 2 in. (51 mm) pipe that can be used CANNOT exceed 3 feet (1 m).

Equivalent Vent Lengths:

10 ft. (3 m) and two 90° elbows of 2 in. (51 mm) pipe equals 20 ft. (6.1 m). 5 ft. (1.5 m) and two 90° elbows of 2 in. (51 mm) pipe equals 15 ft. (4.6 m). 5 ft. (1.5 m) and two 90° elbows of 3 in. (76 mm) pipe equals 15 ft. (4.6 m).One 90_elbow equals 5 feet (1.5 m) of straight vent pipe. One 45_ elbow equals 2.5 feet (.75 m) of straight vent pipe. When additional/field supplied venting is used to clear average snow accumulation, the additional length of pipe and elbows must be figured into

the Maximum Equivalent Vent Length/Minimum Vent Pipe Diameter Requirements.

90° intake elbow CANNOT be used in this application. 12 feet (3.6 m) of additional vent must be figured into the Maximum Equivalent Vent Length/Minimum Vent Pipe Diameter Requirements if this kit is

used. Only used with minimum vent length.

12 in. (305 mm) in length.

or 3 in.

Venting

NOTE − Exhaust pipe

an accelerator; 2 in. (51

mm) diameter pipe, 12 in.

(305 mm) in length.

Roof Kit (15F75) Wall Ring Kit (15F74) Closed Couple Wall Kit

(22G44) Concentric Roof/Wall Kit (60G77) Not Available Closed Couple Wall Kit

(30G28)

Closed Couple Wall Kit with extension riser (30G79)

Cat. No.

Concentric Roof/Wall Kit (60L46) Not Available Acceptable Vent/Intake Air Roof Kit

(44J41)

Closed Couple Wall Kit (44J40)

Concentric Roof/Wall Kit (33K97) Acceptable

20 ft. (6.1 m) 20 ft. (6.1 m) 15 ft. (4.6 m) 15 ft. (4.6 m)

3 in. (76 mm)

2 in. (51 mm)

3 in. (76 mm)

cceptable

Acceptable Acceptable Acceptable

cceptable

3 in. (76 mm)

ot Available

Acceptable

Acceptable

ot Available

Not Available

ot Available

cceptable

Exhaust Piping Requirements

This unit is designed for left or right air exhaust piping for the down-flow configuration. In horizontal applications, flue piping must exit the top side of the unit.

All horizontal runs of exhaust pipe must slope toward unit. A minimum of 1/4" (6mm) drop for every 12" (305mm) of horizontal run is mandatory for drainage. Horizontal runs of exhaust piping must be supported every 5 ft. (1.5m) [3 ft. (0.9m) for ABS and SDR] using hangers.

NOTE−Exhaust piping must be installed on the same side as the condensate trap.

NOTE−Exhaust piping should be checked carefully to make sure there are no sags or low spots.

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 above 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.

Page 46

Page 47

Condensate Piping Requirements

The GHR32 unit is designed for either left or right condensate plumbing in the down-flow configuration. In the horizontal position, trap should extend below unit; provide for a 3-3/4" (92mm) service clearance. Condensate drain line should be routed only within the conditioned space to avoid freezing of condensate and blockage of drain line. An electric heat cable should be used where condensate piping is exposed to unconditioned areas. If condensate piping needs to be relocated to another position or removed for service, use the following procedure to reinstall.

CAUTION

Do not use copper tubing or existing copper condensate lines for drain line.

1 − Determine the side the condensate trap is to be installed.

Remove temporary plugs from condensate collar on which the condensate trap is to be installed.

CONDENSATE ASSEMBLY

(Right Side Installation Shown)

CONDENSATE

STEMS

DRAIN

PLUG CAP

FIGURE 46

COLLAR

DRAIN PLUG

CONDENSATE

DRAIN LINE

CONNECTION

(route line to one side

glue cap to unused side)

CONDENSATE

TRAP

CAUTION

5 − Install a tee and vent pipe in the drain line near the trap.

Top of vent pipe should be 7" (178mm) above drain level on trap.

6 − Condensate line must be sloped downward away from

trap (a minimum of 1/4" [6mm] drop for each 12" [305mm] of horizontal line) to drain. If drain level is above condensate trap, condensate pump must be used in condensate line.

III−START-UP A−Preliminary and Seasonal Checks

1 − Inspect electrical wiring, both field and factory installed

for loose connections. Tighten as required.

2 − Check voltage at disconnect switch. Voltage must be with-

in range listed on the nameplate. If not, consult th e pow er company and have voltage condition corrected before starting unit.

3 − Inspect condition of condensate traps and drain as-

sembly. Disassemble and clean seasonally.

B−Heating Start-Up

FOR YOUR SAFETY READ BEFORE LIGHTING

WARNING

Do not use this furnace if any part has been underwater. Inspect the furnace and replace any part of the control system and any gas control which has been under water.

WARNING

If overheating occurs or if gas supply fails to shut off, shut off the manual gas valve to the appliance before shutting off electrical supply.

Condensate trap must be installed on the same side as exhaust piping in downflow applications and on bottom of unit in horizontal applications.

2 − Apply glue to condensate trap stems and insert trap

into holes provided in condensate collar. Make sure condensate trap is completely sealed to avoid any leaks. Use the provided 1/2" screw to secure the top of the condensate trap to the side of the unit. See figure 46.

3 − For downflow applications only, remove plugs from the

unused condensate collar on the opposite side of the unit. Apply glue to the plugs and place them back into the condensate collar.

4 − Glue the drain line (field provided) to the trap. Route

drain line to an open drain. Glue 1" (25mm) cap (provided on trap) on unused condensate drain line connection.

CAUTION

Before attempting to perform any service or maintenance, turn the electrical power to unit OFF at disconnect switch.

BEFORE LIGHTING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not push in or turn by hand, do not force. Force or attempted repair may result in a fire or explosion.

GHR32 units are equipped with a hot surface ignition system. Do not attempt to manually light burners on these furnaces. Each time thermostat calls for heat, the burners will be automatically lit.

Page 47

Page 48

How To Operate Gas Valve

WARNING

If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

1 − STOP! Read the safety information at the beginning of

this section.

2 − Set thermostat to lowest setting.

3 − Turn off all electrical power to furnace.

4 − This appliance is equipped with an ignition device

which automatically lights the burner. Do not try to light the burner by hand.

5 − Remove unit access panel.

6 − Natural valve, move lever to OFF. Propane valve,

turn knob to OFF. Do not force.

7 − Wait five (5) 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.

8 − Natural valve, move lever to ON. Propane valve, turn

knob to ON. Do not force.

9 − Replace access panel.

10− Turn on all electrical power to unit.

11− Set thermostat to desired setting.

12− If the appliance will not operate, follow the instructions

To Turn Off Gas To Unit" and call your service technician or gas supplier.

Turning Off Gas To Unit

1 − Set thermostat to lowest setting.

2 − Turn off all electrical power to unit if service is to be per-

formed.

3 − Remove access panel. 4 − Natural valve, move lever to OFF. Propane valve, turn

knob to OFF. Do not force.

5 − Replace access panel.

NOTE−On initial start−ups and when condensate trap is dry, unit may turn itself off and on to allow condensate trap to fill. This is normal operation.

C−Safety or Emergency Shutdown

Turn off unit power. Close manual and main gas valves.

D−Extended Period Shutdown

Turn off thermostat or set to UNOCCUPIED" mode. Close all gas valves (both internal and external to unit) to guarantee no gas leak into combustion chamber. Turn off power to unit. All access panels, covers and vent caps must be in place and secured.

Refer to Maintenance" section of this manual for instructions on how to prepare condensate assembly for extended period shutdown.

IV−HEATING SYSTEM SERVICE CHECKS

A−A.G.A./C.G.A. Certification

All units are A.G.A. and C.G.A. design certified without modifications. Refer to the GHR32 Operation and Installation Instruction Manual Information.

B−Gas Piping

Gas supply piping should not allow more than 0.5"W.C. drop in pressure between gas meter and unit. Supply gas pipe must not be smaller than unit gas connection.

Compounds used on gas piping threaded joints should be resistant to action of liquefied petroleum gases.

C−Testing Gas Piping

When pressure testing gas lines, the gas valve must be disconnected and isolated. Gas valves can be damaged if subjected to more than 0.5psig (14" W.C.). See figure 47. If the pressure is equal to or less than 0.5psig (14"W.C.), use the manual shut−off valve before pressure testing to isolate furnace from gas supply.

GAS PIPING TEST PROCEDURE (Typical)

MANUAL MAIN SHUT−OFF

VALVE WILL NOT HOLD

NORMAL TEST PRESSURE

1/8" N.P.T.

PLUGGED TAP

CAP

FIGURE 47

FURNACE

ISOLATE

GAS VALVE

IMPORTANT

In case emergency shutdown is required, turn off the main shut-off valve and disconnect the main power to unit. These controls should be properly labeled by the installer.

When checking piping connections for gas leaks, use preferred means. Kitchen detergents can cause harmful corrosion on various metals used in gas piping. Use of a specialty Gas Leak Detector is strongly recommended. It is available through Lennox under part number 31B2001.

Do not use matches, candles, flame or any other source of ignition to check for gas leaks.

Page 48

Page 49

TOP

SIDE

PIPING

1/8" NPT

PLUGGED

TAP

MANUAL MAIN

SHUT−OFF

GAS VALVE

BOTTOM

SIDE

PIPING

MANUAL

MAIN

SHUT−OFF

VALV E

1/8" NPT PLUGGE

TAP

LEFT SIDE

PIPING

GAS VALVE

RIGHT

SIDE

PIPING

FIGURE 48

D−Testing Gas Supply Pressure

When testing supply gas pressure, connect test gauge to inlet pressure tap (field provided). See figure 48. Check gas line pressure with unit firing at maximum rate. Low pressure may result in erratic operation or underfire. High pressure can result in permanent damage to gas valve or overfire. For natural gas units, operating pressure at unit gas connection must be a minimum of 4.5" W.C. (1.12kPa). For L.P. gas units, operating pressure at unit gas connection must be a minimum of 11.0" W.C. (2.74kPa). For both natural and L.P. gas units, operating pressure must not exceed 13" W.C. (3.23 kPa).

On multiple unit installations, each unit should be checked separately, with and without the other units operating. Supply pressure minimum and maximum must be the same as listed in previous paragraph.

E−Check Manifold Pressure

Manifold Operating Pressure is the manifold pressure measured during normal operation (sensing burner box pressure). Manifold Absolute Pressure is manifold pressure measured when the gas valve regulator is operating at factory preset level (sensing atmospheric pressure).

After line pressure has been checked and adjusted, check manifold absolute pressure. Move pressure gauge to outlet pressure tap located on unit gas valve (GV1). Checks of manifold absolute pressure are made as verification of proper regulator adjustment. Manifold operating pressure for the GHR32 can be measured at any time the gas valve is open and is supplying

VALV E

MANUAL MAIN

SHUT−OFF

VALV E

1/8" NPT

PLUGGED

TAP

SHUT−OFF

PLUGGE

MANUAL

MAIN

VALV E

1/8" NPT

TAP

Page 49

gas to the unit. Normal manifold operating pressure for natural gas units is 2.5 to 3.5" W.C. (621 to 870 Pa). See figure 29. For LP/propane gas the correct manifold operating pressure is 9.0 to 10.0" W.C. (2.24 to 2.49 Pa). See figure 30.

IMPORTANT

For safety, connect a shut-off valve between the manometer and the gas tap to permit shut off of gas pressure to the manometer.

TABLE 32

GAS VALVE REGULATION*

Unit (Fuel)

Natural L.P.

Absolute Pressure (outlet) in. W.C.

3.5

10.0

The gas valve is factory set and should not require adjustment. See table 32. Also, gas valve regulation varies with burner box pressure (figures 29 and 30).

*Manifold Absolute Pressure Measurement and Adjustment

1 − Connect test gauge to outlet tap on gas valve. 2 − Disconnect pressure sensing hose from gas valve

and plug hose by covering opening with tape or equivalent. Leave hose barb on valve open to atmosphere.

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. L.P. gas should burn mostly blue with some orange streaks.

5 − After allowing unit to stabilize for 5 minutes, record

manifold pressure and compare to values given in table 32. If values are different, adjust to table 32.

IMPORTANT

For safety, shut unit off and remove manometer as soon as an accurate reading has been obtained. Take care to replace pressure tap plug.

NOTE−During this test procedure, the unit will be overfiring:

D Operate unit only long enough to obtain accurate read-

ing to prevent overheating heat exchanger.

D Attempts to clock gas valve during this procedure will

be inaccurate. Measure gas flow rate only during normal unit operation.

6 − When test is complete remove obstruction from hose

and return hose to gas valve barb.

F− Proper Gas Flow

Furnace should operate at least 5 minutes before checking gas flow. Determine time in seconds for two revolutions of gas through the meter. (Two revolutions assures a more accurate time.) Divide by two and compare to time in table 33 below. Adjust manifold on gas valve to match time needed.

NOTE−To obtain accurate reading, shutoff all other gas appliances connected to meter.

Page 50

TABLE 33

GHR32

18M34

63K89

GAS METER CLOCKING CHART

Seconds for One Revolution

GHR32

Unit

−50 72 144 180 360

−75 48 96 120 240

−100 36 72 90 180

−120 30 60 75 150

Natural−1000 btu/cu ft LP−2500 btu/cu ft

Natural LP

1 cu ft

Dial

2 cu ft

Dial

1 cu ft

Dial

2 cu ft

DIAL

G−Flame Signal

A microamp DC meter is needed to check the flame signal on the SureLight control. Use a flame signal transducer (part number 78H5401) available from Lennox to measure the flame signal, if meter used will not read microamp signal. Flame (microamp) signal is an electrical current which

passes from the ignition control through the sensor electrode during unit operation. Current passes from the sensor through the flame to ground to complete a safety circuit.

To Measure Flame Signal:

1 − Set the volt meter to the DC voltage scale. Insert trans-

ducer into the VDC and common inputs. Observe correct polarities. Failure to do so results in negative (−)

values. 2 − Turn off supply voltage to control. 3 − Disconnect flame sensor lead from terminal of ignition

control. 4 − Connect (+) lead of transducer to ignition control sen-

sor connection. 5 − Connect (−) lead of the transducer to sensor wire. 6 − Turn supply voltage on and close thermostat contacts

to cycle system. 7 − When unit lights, read voltage on meter display. Re-

member 1 DC volt = 1 DC microamp.

TABLE 34

FLAME SIGNAL MICROAMPS

Boards

Normal u0.23

V−TYPICAL OPERATING CHARACTERISTICS A−Blower Operation and Adjustment

NOTE− The following is a generalized procedure and does not apply to all thermostat controls.

1 − Blower operation is dependent on thermostat con-

trol system.

2 − Generally, blower operation is set at thermostat sub-

base fan switch. With fan switch in ON position, blower operates continuously. With fan switch in AUTO position, blower cycles with demand.

3 − In all cases, blower and entire unit will be off when the

system switch is in OFF position.

B−Temperature Rise

Temperature rise for GHR32 units depends on unit input, blower speed, blower horsepower and static pressure as marked on the unit rating plate. The blower speed must be set for unit operation within the range of AIR TEMP. RISE °F" listed on the unit rating plate.

To Measure Temperature Rise:

1 − Place plenum thermometers in the supply and return air

plenums. Locate supply air thermometer in the first horizontal run of the plenum where it will not pick up radiant heat from the heat exchanger.

2 − Set thermostat to highest setting. 3 − After plenum thermometers have reached their high-

est and steadiest readings, subtract the two readings. The difference should be in the range listed on the unit rating plate. If the temperature is too low, decrease blower speed. If temperature is too high, first check the firing rate. Provided the firing rate is acceptable, increase blower speed to reduce temperature. To change blower speed taps see the Blower Speed Taps section in this manual.

46M99 18M99 49M59

Boards

24L85 56L83 97L48

Low 0.17 to 0.22

Drop Out 0.16

Normal u0.61

Low 0.21 to 0.60

Drop Out 0.20

H− Variable Speed Motor

To check out the VSM blower and blower control board, begin with the ICM2 motor and follow the procedures outlined in section IX−TROUBLESHOOTING. The ICM2 consists of a control module and motor. The control module can be replaced separately form the the motor if necessary. However, if the motor fails the motor/control module assembly will have to be replaced.

Page 50

Page 51

C−External Static Pressure

1 − Measure tap locations as shown in figure 49. 2 − Punch a 1/4" diameter hole in

supply and return air plenums. Insert manometer hose flush with inside edge of hole or insulation. Seal around the hose with permagum. Connect the zero end of the manometer to the discharge (supply) side of the system. On ducted systems, connect the other end of manometer to the return duct as above. For systems with non−ducted returns, leave the other end of the manometer open to the atmosphere.

3 − With only the blower motor running and the evapo-

rator coil dry, observe the manometer reading. Adjust blower motor speed to deliver the air desired according to the job requirements.

4 − Pressure drop must not exceed 0.5" W.C.

5 − Seal around the hole when the check is complete.

GHR32 BLOWER REMOVAL

STATIC PRESSURE

TEST

MANOMETER

FIGURE 49

D−Blower Speed Taps GHR32Q Motors

Blower speed tap changes are made on the SureLight control board. See figure 9. Unused taps must be secured on dummy terminals "PARK M1" and or "PARK M2" on the SureLight board. The heating tap is connected to the "ACB HEAT " terminal and the cooling tap is connected to the "ACB COOL" terminal. The continuous blower tap is connected to the "ACB LOW" terminal. To change existing heat tap, turn off power then switch out speed tap on "ACB HEAT" with tap connected to "PARK M1" or "PARK M2". See wiring diasgrams for blower motor tap colors for each speed.

To Remove Blower:

1. Turn off line voltage power. Unplug the following jack/plugs: J96/P96 power interface, J135/P135 secondary limit, J58/P58 control, J98/P98 CAB.

2. Remove screws (2) and remove control box cover. Disconnect thermostat wiring connections by removing low voltage terminal strip. Disconnect spark wire and grommet.

3. Loosen screws (2) and remove control box from unit. Holes are slotted so screws do not need to be removed.

4. Remove bolts (2) and remove blower from unit.

J69/P69

J98/P98

FIGURE 50

J96/P96

J135/P135

Page 51

Page 52

VI−MAINTENANCE

Retainers for factory supplied return air filter are shown in figure 51.

CABINET

WRAPPER

FILTER

SIDE FILTER CLIP DETAIL

Press up on side filter clip to release filter

(One on each side of cabinet)

BACK FILTER CLIP

FILTER CLIP

Press up on side filter clip to release filter

(One on each side of cabinet)

FILTER

CLIP

FIGURE 51

A−Filters

At the beginning of each heating season, the system should be checked as follows:

1 − Filters should be inspected monthly and must be

cleaned or replaced when dirty to ensure proper furnace operation.

2 − Reusable foam filters used with the GHR32 can be

washed with water and mild detergent. When dry, they should be sprayed with filter handicoater prior to reinstallation. Filter handicoater is RP Products coating no. 418 and is available as Lennox part no. P-8-5069.

3 − If replacement is necessary, order Lennox part no. 31J81

for 14 X 25 inch (356 X 635mm) filter for GHR32-50 and

-75 units and P-8-7831 for 20 X 25 inch (508 X 635mm) filter for GHR32-100 and -120 units.

B−Cleaning Heat Exchanger and Burners

NOTE−Use papers or protective covering in front of furnace while cleaning furnace.

Cleaning the heat exchanger is not recommended; but, if it becomes necessary, follow the procedures outlined below and refer to figure 1 for parts arrangement. Pay close attention to wire routing and plumbing connections. If at all possible, the unit should be removed and placed on its back. Tools needed are: slotted screwdriver, extra long 1/4" nut driver, extra long 5/16" nut driver, and duckbill pliers.

CABINET

WRAPPER

Heat Exchanger

1 − Turn off electrical and gas power supplies to furnace. 2 − Remove upper and lower furnace access panels. 3 − Remove 3/8" rubber cap from condensate drain plug

and drain. Replace cap after draining.

4 − Disconnect and remove intake pipe from air intake fit-

ting.

5 − Mark all gas valve wires and disconnect them from

valve.

6 − Remove gas supply line connected to gas valve.

Disconnect gas valve sensing hose from side of burner box. Remove burner box cover by removing six (four on some units) securing screws. Remove gas valve/ manifold assembly.

7 − Detach burner box from vestibule panel by removing four

securing screws. Take care to avoid damaging the glass fiber gasket.

8 − Mark and disconnect spark and sensor electric wires

from the ignitor and flame sensor.

9 − Disconnect wires from flame roll−out switch. Remove

wires from patch plates. Remove side plates on burner box holding sensor and spark electrode. Set burner burner box assembly aside.

NOTE− If burner cleaning is needed, do so at this time. Refer to burner cleaning procedure.

10− Remove flexible exhaust tee by loosening three

clamps.

11− Disconnect drain line attached to condensate trap. Re-

move screws that secure both condensate collars to either side of the unit and remove collars. It may be necessary to cut the pipe to allow for removal of the condensate trap. Remove drain tubes from cold end header collector box.

12− Disconnect condensate drain tubing from exhaust

pipe. Remove screws that secure both flue collars into place. Remove flue collars. It may be necessary to cut the exiting exhaust pipe to allow for removal of the fittings.

13− Disconnect 2−pin plug from combustion air blower.

Remove combustion air blower from bracket by removing four securing screws. Remove ground wire from bundle.

14− Remove combustion air blower bracket by removing two

screws from collector box and two screws from vestibule panel.

15− Disconnect combustion air pressure and condensate

sensing hoses from cold end header collector box. Remove pressure hose from two blank stems on cold end header collector box.

16− Mark and remove wires from pressure switch. Re-

move pressure switch/bracket assembly. Keep hoses attached to pressure switch. Remove pressure switch installation screws from both sides of the unit.

17− Disconnect 9−pin and 3− pin plugs at blower deck. Re-

move both plugs from the heat exchanger side of the blower deck.

18− Remove the primary limit from vestibule panel.

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Page 53

19− Remove two (2) screws from the front cabinet flange at

the blower deck. Remove front screws from cabinet at blower deck on left and right sides. Cabinet sides must be slightly spread apart to clear heat exchanger passage.

NOTE−To protect insulation in horizontal applications, slide a piece of sheet metal between the coil sec tion of the heat exchanger and the cabinet when removing and replacing heat exchanger. Remove indoor blower for horizontal installations. Remove sheet metal when complete.

20− Remove screws along vestibule sides and bottom

which secure vestibule panel and heat exchanger assembly to cabinet.

21− With a pair of duck bills, carefully bend bottom flange

straight. Use caution not to damage the cabinet. Remove heat exchanger.

22− Back wash heat exchanger with soapy water solu-

tion or steam. If steam is used it must be below

275_F (135_C).

23− Thoroughly rinse and drain the heat exchanger. Soap

solution can be corrosive so take care that entire assembly is completely rinsed.

24− Re−install heat exchanger into cabinet (blower deck end

first) making sure that the clamshells of the heat exchanger assembly are resting on the supports at the rear of the cabinet. This can be viewed by removing the indoor blower and examining through the blower opening.

25− Re−secure the supporting screws along the vestibule

sides and bottom to the cabinet. Carefully bend bottom flange back to a 90 degree angle with a pair of duck bills. Once again, use caution not to damage the cabinet.

26− Re−install cabinet screws on sides and front flange at

blower deck.

27− Re−install primary limit to vestibule panel.

28− Re−install 9−pin plug to blower deck and connect it to the

9−pin plug from below the blower deck. Re−install 3−pin plug to blower deck and connect it to the 3−pin plug from below the blower deck.

29− Re−install pressure switch/bracket assembly and re-

place pressure switch screws on both sides of unit from installed pressure switch. Reconnect wires to pressure switch.

30− Connect combustion air pressure and condensate

sensing hoses from pressure switch to cold end header collector box. See figure 31to confirm hose location.

31− Re−install the combustion air bracket.

32− Re−install the combustion air blower to bracket. Re-

connect the 2−pin plug to the wire harness.

33− Replace flue collars with securing screws to either side of

the unit. Reconnect exhaust piping and exhaust drain tubing.

34− Replace condensate collars with securing screws to

either side of the unit. Reconnect drain line to condensate trap. Reconnect drain tubing from cold end header collector box. Reconnect condensate drain tubing from exhaust pipe.

35− Replace flexible exhaust tee to combustion air

blower and exhaust pipes and secure with three clamps.

36− Align burner box gasket to securing holes closest to

the end of the unit. Use a small piece of tape to secure gasket to vest panel. Make sure glass fiber gasket has not been damaged so it will provide a continuous seal between the burner box and the vestibule panel.

37− Move burner box assembly to vestibule area.

38− Reconnect flame roll−out switch wires. Re−install

patch plates to side of burner box. Connect wires to patch plates.

39− Reconnect sensor and spark electrode or SureLight

ignitor wires through provided openings in the burner plate.

40− Replace four screws to secure reassembled burner

box assembly to vestibule panel. Make sure burn-

ers line up in center of burner ports.

41− Re−install gas valve manifold assembly. Replace

burner box cover. Re−install gas supply line to gas valve. Attach gas valve pressure sensing hose to burner box.

42− Reconnect gas valve wires to gas valve.

43− Re−install intake vent pipe to rubber connector on in-

take fitting with hose clamp.

44− Replace both upper and lower access panels.

45− Refer to instruction on verifying gas and electrical con-

nections when re−establishing supply.

46− Following lighting instructions, light and run unit for 5

minutes to ensure heat exchanger is clean, dry and operating safely.

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Page 54

Cleaning the Burner Assembly

1 − Turn off electrical and gas power supplies to furnace.

2 − Remove upper and lower furnace access panels.

3 − Disconnect and remove intake pipe from air intake fit-

ting.

4 − Mark all gas valve wires and disconnect them from

valve.

5 − Remove gas supply line connected to gas valve.

Disconnect gas valve sensing hose from valve. Remove burner box cover (4 to 6 screws). Remove gas valve/manifold assembly.

18− Re−install gas valve/manifold assembly. Re−install

burner box cover. Reconnect gas valve sensing hose to side of burner box. Re−install gas supply line to gas valve.

19− Reconnect gas valve wires to gas valve.

20− Replace both upper and lower access panels.

21− Refer to instruction on verifying gas and electrical con-

nections when re−establishing supply.

22− Following lighting instructions, light and run unit for 5

minutes to ensure heat exchanger is clean, dry and operating safely.

6 − Loosen hose clamp holding the air intake pipe to the

no−hub connector on the top of the burner box. Remove pipe from no−hub connector and set aside.

7 − Mark and disconnect spark or SureLight ignitor and

sensor electrical wires from the ignitor and flame sensor.

8 − Detach burner box from vestibule panel by remov-

ing four securing screws. Take care to avoid damaging the glass fiber gasket.

9 − On GHR32−50 and −75 units, remove air intake fitting from

burner box top.

10 − Remove burner box top from burner box assembly.

11− Using 1/4" nut driver, remove two screws holding

burners in place. Slide burner assembly out of burner box.

12− Clean burner by running a vacuum with a soft brush at-

tachment over face of burners. Visually inspect inside of burners and crossovers for any blockage caused by foreign matter. Remove any blockage.

13− Re−install burner assembly so that protruding side (not

cavity side) of metal buttons are toward the burner box top (intake side).

14− Replace top and air intake piece to burner box.

C−Supply Air Blower

1 − Check and clean blower wheel.

2 − Motors are prelubricated for extended life; no further lu-

brication is required.

D−Electrical

1 − Check all wiring for loose connections.

2 − Check circuit breaker located in unit control box.

3 − Check for correct voltage at unit (unit operating).

4 − Check amp-draw on blower motor.

Motor Nameplate_________Actual_________

5 − Check to see that heat (if applicable) is operating.

E−Intake and Exhaust Lines

Check intake and exhaust lines and all connections for tightness and make sure there is no blockage. Also check condensate line for free flow during operation.

F−Insulation

Outdoor piping insulation should be inspected yearly for deterioration. If necessary, replace with same materials.

15− Reconnect sensor and spark electrode or SureLight

ignitor wires.

16− Align burner box gasket to securing holes closest to

17− Replace four screws to secure reassembled burner

box assembly to vestibule panel. Make sure burn-

ers line up in center of burner ports.

G−Winterizing and Condensate Trap Care

If the unit is to be shut down for an extended period of time and will be exposed to sub-freezing temperatures, the unit should be winterized by draining water from the condensate trap.

To drain condensate trap remove the 3/8" cap located on the bottom corner of the condensate trap (see figure 46). Periodically drain condensate trap to insure proper drainage and check for blockage.

Page 54

Page 55

VII−WIRING DIAGRAM AND SEQUENCE OF OPERATION

GHR32Q −1 UNIT DIAGRAM

Page 55

Page 56

GHR32Q −3 UNIT DIAGRAM

Page 56

Page 57

Sequence of Operation GHR32Q −1, −3 Units

Ignitor operation will vary between SureLight boards. Board 56L83 will energize ignitor for the first second of the 4 second ignition trial. Board 97L48 will energize ignitor during the entire ignition trial until flame is sensed.

1 − When there is a call for heat, W1 of the thermostat en-

ergizes W of the furnace control with 24VAC.

2 − SureLight control runs self−check for S10 primary limit

switch normally closed contacts and S18 combustion air prove switch normally open contacts. Follow steps 4 through 8 per respective thermostat.

Single−stage Mode, Single−stage Thermostat

3 − SureLight control energizes combustion air inducer

B6 on high speed. Combustion air inducer runs until S18 prove switch closes (switch will close within 2−1/2 minutes or control goes into Watchguard−Prove Switch mode). A 15−second pre−purge follows after S18 closes.

4 − SureLight control energizes ignitor. A 20−second

warm−up period begins.

5 − Gas valve is energized on first stage heat (low). Gas

valve opens for a 4−second trial for ignition.

6 − Flame is sensed, After 8 seconds from when gas valve

opens, valve energizes on second stage (high heat).

7 − After 45−second delay, indoor blower B3 is energized

on heating speed.

Two−stage Mode, Single−stage Thermostat

1 − SureLight control energizes combustion air inducer

B6 on low speed. Combustion air inducer runs until combustion air proving switch S18 closes (switch will close within 2−1/2 minutes or control goes into Watchguard−Prove Switch mode). A 15−second pre−purge follows once S18 closes.

2 − SureLight control energizes ignitor. A 20−second

warm−up period begins.

3 − Gas valve is energized on first stage. Gas valve opens

for a 4−second trial for ignition. Signal is sent from control module to two−stage control board to begin W2 (second−stage) ON delay.

4 − Flame is sensed, gas valve remains open for the heat

call.

5 − After 45−second delay, indoor blower B3 is energized

on low speed.

6 − Second stage time on delay complete (8, 12, or 15

minutes). Combustion air inducer B6 switches to high speed, indoor blower B3 switches to heating speed and gas valve opens on high heat (second stage.)

Two−stage Mode, Two−stage Thermostat

1 − SureLight control energizes combustion air inducer

B6 on low speed. Combustion air inducer runs until combustion air inducer switch S18 closes. Switch will close within 2−1/2 minutes or control goes into Watchguard−Proving Switch mode). A 15−second pre−purge follows once S18 closes.

2 − SureLight control energizes ignitor. A 20−second

warm−up period begins.

3 − Gas valve is energized on first stage only. Gas valve

opens for a 4−second trial for ignition.

4 − Flame is sensed, gas valve remains open for the heat

call.

5 − After 45−second delay, indoor blower B3 is energized

on low speed.

6 − Call for second stage heat comes from indoor thermo-

stat (W2).

Page 57

Page 58

GHR32Q −5 & −6 UNIT DIAGRAM

Page 58

Page 59

Sequence of Operation. GHR32Q with SureLight Two Stage Control

Sequence depends on type thermostat used. Units are applicable for single stage or two stage thermostats. Both type thermostats are described below. Thermostat jumper E20 dictates which mode unit will operate in. See flow chart for more sequence detail.

SureLight Control Self Check

When there is a call for heat, the SureLight integrated control runs a self check. The control checks for S10 primary limit, S21 secondary limit (s) and S47 rollout switch normally closed contacts. The control also checks for S102 prove switch normally open contacts. Once self check is complete and all safety switches are operational, heat call can continue.

Two−Stage Thermostat, Two Stage Heat. Jumper E20

set at TWO".

1− SureLight control energizes combustion air inducer B6

on low heat speed. Combustion air inducer runs until S102 closes (switch must close within 2 1/2 minutes or control goes into Watchguard Pressure Switch mode. A 15 second pre−purge follows once S102 closes.

2− SureLight control begins 20 second ignitor warm up

period.

3− Gas valve opens on first stage for a 4 second trial for

ignition. Ignitor stays energized during the trial or until flame sensed.

4− Flame is sensed, gas valve remains on first stage heat,

ignitor de−energizes.

5− After 45 second delay, indoor blower B3 is energized

on low heat speed.

The furnace will stay in this mode until first stage demand is satisfied OR a second stage heat demand is initiated.

6− Second stage heat demand initiated. A 30 second sec-

ond stage recognition period begins.

7− The combustion air inducer ramps up to high heat

speed.

8− B3 indoor blower ramps up to high heat speed.

Single−Stage Thermostat, Two Stage Heat. Jumper

E20 set at SINGLE"

1− SureLight control energizes combustion air inducer B6

on low heat speed. Combustion air inducer runs until S102 prove switch contacts close (switch must close within 2 1/2 minutes or control goes into Watchguard Pressure Switch mode. A 15 second pre−purge follows once S102 closes.

2− SureLight control begins 20 second ignitor warm up

period.

3− Gas valve opens on first stage for a 4 second trial for

ignition. Ignitor stays energized during the trial or until flame sensed.

4− Flame is sensed, gas valve remains on first stage heat,

ignitor de−energizes.

5− After 45 second delay, indoor blower B3 is energized

on low heat speed.

6− A 10 minute (factory set) or 15 minute (field set) second

stage heat delay period begins.

7− The combustion air inducer ramps up to high heat

speed.

8− B3 indoor blower ramps up to high heat speed.

Page 59

Page 60

GHR32V −1 UNIT DIAGRAM

Page 60

Page 61

GHR32V −3 UNIT DIAGRAM

Page 61

Page 62

GHR32V −4 UNIT DIAGRAM

Page 62

Page 63

Sequence of Operation GHR32V −1 / −4 Units

1 − When there is a call for heat, W1 of the thermostat en-

ergizes W of the furnace control with 24VAC.

2 − SureLight control runs self−check for S10 primary limit

switch normally closed contacts and S18 combustion air prove switch normally open contacts. Follow steps 4 through 8 per respective thermostat.

Single−stage Mode, Single−stage Thermostat

3 − SureLight control energizes combustion air inducer

4 − SureLight control energizes ignitor. A 20−second

warm−up period begins.

5 − Gas valve is energized on first stage heat (low). Gas

valve opens for a 4−second trial for ignition.

6 − Flame is sensed, After 8 seconds from when gas valve

opens, valve energizes on second stage (high heat).

7 − After 45−second delay, indoor blower B3 is energized

on heating speed.

Two−stage Mode, Single−stage Thermostat

1 − SureLight control energizes combustion air inducer

2 − SureLight control energizes ignitor. A 20−second

warm−up period begins.

3 − Gas valve is energized on first stage. Gas valve opens

for a 4−second trial for ignition. Signal is sent from control module to two−stage control board to begin W2 (second−stage) ON delay.

4 − Flame is sensed, gas valve remains open for the heat

call.

5 − After 45−second delay, indoor blower B3 is energized

on low speed.

6 − Second stage time on delay complete (8, 12, or 15

minutes). Combustion air inducer B6 switches to high speed, indoor blower B3 switches to heating speed and gas valve opens on high heat (second stage.)

Two−stage Mode, Two−stage Thermostat

1 − SureLight control energizes combustion air inducer

2 − SureLight control energizes ignitor. A 20−second

warm−up period begins.

3 − Gas valve is energized on first stage only. Gas valve

opens for a 4−second trial for ignition.

4 − Flame is sensed, gas valve remains open for the heat

call.

5 − After 45−second delay, indoor blower B3 is energized

on low speed.

6 − Call for second stage heat comes from indoor thermo-

stat (W2).

Page 63

Page 64

GHR32V −5 & −6 UNIT DIAGRAM

Page 64

Page 65

Sequence of Operation GHR32V with SureLight Two Stage Variable Speed Control

SureLight Control Self Check

Two−Stage Thermostat, Two Stage Heat. Jumper E20

set at TWO".

1− SureLight control energizes combustion air inducer B6

2− SureLight control begins 20 second ignitor warm up

period.

3− Gas valve opens on first stage for a 4 second trial for

ignition. Ignitor stays energized during the trial or until flame sensed.

4− Flame is sensed, gas valve remains on first stage heat,

ignitor de−energizes.

5− After 45 second delay, indoor blower B3 is energized

on low heat speed.

The furnace will stay in this mode until first stage demand is satified OR a second stage heat demand is initiated.

6− Second stage heat demand initiated. A 30 second sec-

ond stage recognition period begins.

7− The combustion air inducer ramps up to high heat

speed.

8− B3 indoor blower ramps up to high heat speed.

Single−Stage Thermostat, Two Stage Heat. Jumper

E20 set at SINGLE"

1− SureLight control energizes combustion air inducer B6

2− SureLight control begins 20 second ignitor warm up

period.

3− Gas valve opens on first stage for a 4 second trial for

ignition. Ignitor stays energized during the trial or until flame sensed.

4− Flame is sensed, gas valve remains on first stage heat,

ignitor de−energizes.

5− After 45 second delay, indoor blower B3 is energized

on low heat speed.

6− A 10 minute (factory set) or 15 minute (field set) second

stage heat delay period begins.

7− The combustion air inducer ramps up to high heat

speed.

8− B3 indoor blower ramps up to high heat speed.

Page 65

Page 66

VIII−Sequence of Operation Flow Charts GHR32Q −1 & −3 GHR32V−1 / −4

HEATING SEQUENCE OF OPERATION

NOTE: LED REFERS TO SURELIGHT CONTROL . LED−DS REFERS TO VSP CONTROL.

NORMAL HEATING MODE ABNORMAL HEATING MODE

POWER ON

CONTROL SELF−CHECK OKAY?

COMBUSTION AIR BLOWER ON FOR 1 SECOND.

POLARITY OKAY?

LED#1 AND #2

ALTERNATING FAST

FLASH. SIGNAL

HOLDS UNTIL UNIT IS

PROPERLY GROUND.

NO YES

YES

IS THERE A

PROPER GROUND?

IS VOLTAGE

ABOVE 75 VOLTS?

YES

GAS VALVE OFF. COMBUSTION AIR INDUCER ON. INDOOR BLOWER ON. LED #1 AND #2 ALTERNATING FAST FLASH. CHECK FOR BROKEN IGNITOR OR OPEN IGNITOR CIRCUIT.

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

(RESET CONTROL BY TURNING MAIN POWER OFF.)

INDOOR BLOWER DELAY OFF.

LED #1 AND #2 ALTERNATING FAST FLASH.

SIGNAL HOLDS UNTIL VOLTAGE RISES

LED #1 ON LED #2 ON

POLARITY REVERSED.

LED #1 −− FAST FLASH

LED #2 −− SLOW FLASH

ABOVE 75 VOLTS.

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

PRESSURE SWITCH CONTACTS OPEN?

ENERGIZE COMBUSTION AIR BLOWER.

IS LINE VOLTAGE ABOVE 75 VOLTS?

TWO−STAGE MODE

CALL FOR 1ST STAGE HEAT

ROLLOUT SWITCH CLOSED?

YES

(CONTINUOUS FLAME CHECK)

THERMOSTAT CALLS FOR HEAT:

PRIMARY LIMIT SWITCH CLOSED?

IS UNIT PROPERLY GROUNDED?

BURNER OFF?

YES

NORMAL OPERATION:

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

YES

(HIGH AND LOW HEAT)

YES

ENERGIZE HTG ACC. TERM.

YES

W2 TIMED MODE

SINGLE STAGE T’STAT

SINGLE−STAGE MODE

HIGH HEAT ONLY

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF DELAY.

LED #1 −− ON

LED #2 −− SLOW FLASH

GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

INDOOR BLOWER ON.

LED #1 −− SLOW FLASH

LED #2 −− OFF

COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER ON.

LED #1 −− SLOW FLASH

LED #2 −− ON

GAS VALVE OFF.

COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF DELAY.

LED #1 OFF

LED #2 SLOW FLASH

(Sequence holds until pressure switch

closes or thermostat resets control.)

COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF. LED #1 −− ALTERNATING FAST FLASHES LED #2 −− ALTERNATING FAST FLASHES

COMBUSTION AIR BLOWER

ON LOW SPEED (t 2.5 MINUTES)

LOW−HEAT PRESSURE

SWITCH CLOSED?

YES YES

PREPURGE

15 SECONDS

CONTINUED ON NEXT PAGE

COMBUSTION AIR BLOWER

ON HIGH SPEED (t 2.5 MINUTES)

HIGH−HEAT PRESSURE

SWITCH CLOSED?

Page 66

PRESSURE SWITCH WATCHGUARD

(5 MINUTES)

COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF.

LED #1 OFF

LED #2 SLOW FLASH

WATCHGUARD 60-MINUTE DELAY

(SIGNAL LIMIT OR IGNITION FAILURE)

GAS VALVE OFF. COMBUSTION AIR

AND INDOOR BLOWER OFF.

LED #1 AND LED #2

ALTERNATING SLOW FLASHES

Page 67

HEATING SEQUENCE CONTINUED

NORMAL HEATING MODE ABNORMAL HEATING MODE

PREPURGE

15 SECONDS

IGNITION SEQUENCE BEGINS

(Ignition trial counter initiated.)

IGNITOR WARM−UP

(20 SECONDS)

WATCHGUARD 60-MINUTE DELAY

(SIGNAL LIMIT OR IGNITION FAILURE)

GAS VALVE OFF. COMBUSTION AIR

AND INDOOR BLOWER OFF.

LED #1 AND LED #2

ALTERNATING SLOW FLASHES

WATCHGUARD −− FLAME FAILURE.

GAS VALVE OFF.

COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF.

LED #1 & LED #2 ALTERNATE FLASH.

TWO−STAGE MODE

CALL FOR 1st STAGE HEAT

MAIN GAS VALVE OPEN

LOW HEAT ONLY

W2 TIMED MODE

SINGLE STAGE T’STAT

MAIN GAS VALVE OPEN

LOW HEAT ONLY

SECOND STAGE

TIME ON BEGINS

4 SECONDS

SINGLE−STAGE MODE

HIGH HEAT ONLY

GAS VALVE OPEN ON LOW HEAT.

WITHIN 8 SEC. VALVE OPENS HIGH HEAT.

8 SECONDS

FLAME RECTIFICATION CURRENT CHECK

(u0.20 microamps)

FLAME PRESENT?

(Response time −− 2 seconds maximum.)

45 SECOND INDOOR BLOWER DELAY BEGINS. AFTER DELAY ACC. TERMINAL IS

ENERGIZE. Q" MODELS: ACB HEAT SPEEDIS ENERGIZED. V" MODELS: HEAT"

LED−DS2 LIT. BLOWER ON HEAT SPEED.

TWO−STAGE MODE

CALL FOR 1st STAGE HEAT

W2 TIMED MODE

SINGLE STAGE T’STAT

Q" MODELS: INDOOR BLOWER ON LOW

SPEED. V" MODELS: CFM" LED−DS4

BLINKS ONCE FOR EVERY 100CFM.

Q" MODELS: INDOOR BLOWER ON

SINGLE−STAGE MODE

HIGH HEAT ONLY

HIGH HEATING SPEED. V"

MODELS: CFM" LED−DS4 BLINKS

ONCE FOR EVERY 100CFM.

FLAME PRESENT?

(Continuous flame check)

FLAME SIGNAL

(u0.61 microamps)

COMBUSTION AIR INDUCER DE−ENERGIZED.

PRIMARY LIMIT SWITCH CLOSED?

CONTROL CHECKS RETRY

FOR IGNITION COUNT. HAVE FOUR RE-TRIES

BEEN COMPLETED?

GAS VALVE

DE−ENERGIZED

YES

LIMIT SWITCH WATCHGUARD MODE. GAS VALVE OFF. COMB. AIR INDUCER OFF. INDOOR BLOWER OFF AFTER DELAY. LED#1−SLOW FLASH LED#2−ON. IS 60 MINUTE

RESET PERIOD COMPLETE?

LOW FLAME SIGNAL

LED #1 −− SLOW FLASH

LED #2 −− FAST FLASH

GAS VALVE DE−ENERGIZED.

INDOOR BLOWER ON.

LED #1 − SLOW FLASH; LED #2 − ON.

YES

ROLLOUT SWITCH CLOSED?

PRESSURE SWITCH CLOSED?

(CONTINUED ON NEXT PAGE)

CONTINUED ON NEXT PAGE

Page 67

HAS PRIMARY/SECODARY LIMIT

CLOSED (RESET) WITHIN 3 MINUTES?

GAS VALVE DE−ENERGIZED.

COMBUSTION AIR INDUCER DE−ENERGIZED.

INDOOR BLOWER OFF DELAY (Selected time)

LED #1 −− ON

LED #2 −− SLOW FLASH

YES

Page 68

HEATING SEQUENCE CONTINUED

NORMAL HEATING MODE ABNORMAL HEATING MODE

PREPURGE

PRESSURE SWITCH CLOSED?

(See top of previous page.)

YES YES

TWO−STAGE MODE

CALL FOR 1st STAGE HEAT

CALL FOR 2nd STAGE

HEAT (HIGH HEAT)

FROM THERMOSTAT

W2 TIMED MODE

SINGLE STAGE T’STAT

2nd STAGE ON DELAY ON CONTROL BOARD

COMPLETE

(8, 12 OR 15 MIN.)

Q" MODELS: INDOOR BLOWER SWITCHES TO HEATING SPEED. V" MODELS: CFM" LED−DS4 BLINKS ONCE FOR

EVERY 100 CFM.

COMBUSTION AIR INDUCER SWITCHES TO

HIGH SPEED?

HIGH HEAT PRESSURE SWITCH CLOSED?

YES

HIGH HEAT GAS VALVE OPEN? (8 SEC. DELAY)

YES

TWO−STAGE MODE

CALL FOR 1st STAGE HEAT

W2 TIMED MODE

SINGLE STAGE T’STAT

CONTROL CHECKS: FLAME PRESENCE, CLOSED PRIMARY

LIMIT, CLOSED PRESSURE SWITCHES, CONTINUOUSLY

CLOSED ROLLOUT SWITCH (during heating cycle).

SEE PREVIOUS SEQUENCES FOR FAILURE MODES.

DEMAND FOR HEAT SATISFIED.

THERMOSTAT OPENS.

GAS VALVE DE−ENERGIZED.

COMBUSTION AIR INDUCER POST−PURGE 5

SECONDS. HTG ACC. TERM. DE−ENERGIZED

COMBUSTION AIR INDUCER ON FOR 2.5 MINUTES.

¦ 2.5

MINUTES

SINGLE−STAGE MODE

HIGH HEAT ONLY

SLOW FLASH

FAST FLASH

SLOW FLASH

ALTERNATING SLOW FLASH

ALTERNATING FAST FLASH

GAS VALVE DE−ENERGIZED.

INDOOR BLOWER DE−ENERGIZED.

PRESSURE SWITCH

CLOSED?

PRESSURE SWITCH WATCHGUARD

COMBUSTION AIR INDUCER

DE−ENERGIZED.

5−MINUTE DELAY

COMBUSTION AIR

BLOWER ON.

DIAGNOSTIC CODES

LED #1 LED #2 DESCRIPTION

Primary or secondary limit open

OFF

SLOW FLASH

OFF

SLOW FLASH

FAST FLASH

SLOW FLASH

FAST FLASH

Rollout switch open

Flame sensed without gas valve energized

Pressure switch open

Power on

Heating demand

Polarity reversed

Low flame signal

Circuit board failure

Watchguard −− burners failed to ignite

Watchguard −− low voltage, below 75V or improper main ground.

INDOOR BLOWER AND ACC TERMINAL OFF AFTER SELECTED

TIME OFF DELAY.

Page 68

Page 69

COOLING SEQUENCE OF OPERATION

NORMAL COOLING MODE ABNORMAL COOLING MODE

POWER ON

IGNITION CONTROL MAIN POWER ON.

SIGNAL IMPROPER

GROUND AT LED.

SIGNAL HOLDS

UNTIL UNIT IS

PROPERLY

GROUNDED.

ROLLOUT SWITCH MONITORED CONTINUOUSLY.

CHECK FOR MAIN BURNER FLAME SENSE.

LED: SLOW FLASH RATE REMAINS UNCHANGED

CONTROL SELF DIAGNOSTIC CHECK.

IS CONTROL OPERATING NORMALLY?

YES

TURN INDUCER ON FOR 1 SECOND.

IS POLARITY REVERSED?

IS ROLLOUT SWITCH CLOSED?

IS MAIN BURNER FLAME OFF?

THROUGHOUT COOLING CYCLE.

THERMOSTAT CALLS FOR COOLING.

IS THERE

PROPER GROUND?

YES

IS VOLTAGE

ABOVE 75 VOLTS?

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF WITH NORMAL DELAY.

SIGNAL CIRCUIT BOARD FAILURE AT LED.

INTERRUPT MAIN POWER TO RESET CONTROL.

SIGNAL POLARITY REVERSED AT LED.

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF WITH NORMAL DELAY.

SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES.

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF WITH NORMAL DELAY.

SEQUENCE HOLDS UNTIL FLAME IS NOT SENSED.

LOW VOLTAGE SIGNAL AT LED HOLDS

UNTIL VOLTAGE RISES ABOVE 75 VOLTS.

SIGNAL CIRCUIT BOARD FAILURE AT LED.

COMPRESSOR CONTACTOR AND INDOOR

BLOWER ENERGIZED WITH 0-SECOND DELAY

Q" MODELS: ACB COOL AND ACC TERMINAL ENERGIZED. V" MODELS: HI/LO" LED−DS1 IS

LIT. CFM" LED−DS4 BLINKS ONCE FOR EVERY

INDOOR BLOWER AND ACC TERMINAL OFF

WITH 0−SECOND DELAY.

100CFM.

THERMOSTAT OPENS.

COMPRESSOR OFF.

Page 69

Page 70

CONTINUOUS LOW SPEED FAN SEQUENCE OF OPERATION

LED: SLOW FLASH RATE REMAINS

UNCHANGED THROUGHOUT SEQUENCE.

MANUAL FAN SELECTION MADE AT THERMOSTAT. CONTROL

(G)ENERGIZING ACC TERMINAL. Q" MODELS: ACB LOW

SPEED ENERGIZED. V" MODELS: ON/OFF" LED−DS3 LIT.

INDOOR BLOWER ENERGIZED ON LOW SPEED.

THERMOSTAT CALLS FOR HEAT (W).

NO YES

THERMOSTAT CALLS FOR COOLING.

YES

Q" MODELS: INDOOR BLOWER SWITCHED TO ACB

COOL SPEED. V" MODELS: HI/LO LED−DS1 LIT.

THERMOSTAT OPENS.

Q" MODELS − INDOOR BLOWER SWITCHES TO ACB

LOW SPEED. V" MODELS − ON/OFF" LED−DS3 LIT.

INDOOR BLOWER ON LOW SPEED.

HTG ACC TERMINAL ENERGIZES

WITH COMB. AIR INDUCER.

45 SECOND INDOOR BLOWER DELAY BEGINS. AFTER DELAY − Q"

MODELS: ACB HEAT SPEED ENERGIZED. V" MODELS: HEAT"

LED−DS2 LIT. BLOWER ON HEAT SPEED.

THERMOSTAT OPENS.

INDOOR BLOWER TIME OFF DELAY BEGINS. HTG ACC TERMINAL

DE−ENERGIZED WITH COMBUSTION AIR INDUCER. ACC TERMINAL

REMAINS ENERGIZED. AFTER DELAY − "Q" MODELS: ACB HEAT

SPEED DE−ENERGIZED. V" MODELS: INDOOR BLOWER HEAT

SPEED DE−ENERGIZED.

(blower remains energized during continuous fan mode)

Page 70

Page 71

GHR32Q with Two Stage Control and GHR32V with Two Stage Variable Speed Control

HEATING SEQUENCE OF OPERATION

NORMAL AND ABNORMAL HEATING MODE

POWER ON

CONTROL SELF−CHECK OKAY?

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF. INDOOR BLOWER OFF. CHECK FOR BROKEN IGNITOR OR OPEN IGNITER CIRCUIT. DS 1 AND DS 2 ALTERNATING FAST FLASH.

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF. (RESET CONTROL BY

TURNING MAIN POWER OFF.) DS1 ON, DS2 ON

POLARITY OKAY?

YES

IS THERE A

PROPER GROUND?

YES

IS VOLTAGE

ABOVE 75 VOLTS?

YES

BURNER OFF?

(CONTINUOUS FLAME CHECK)

YES

NORMAL OPERATION:

DS 1 −− SIMULTANEOUS SLOW FLASH DS 2 −− SIMULTANEOUS SLOW FLASH

THERMOSTAT CALLS FOR HEAT:

DS 1 −− SIMULTANEOUS FAST FLASH DS 2 −− SIMULTANEOUS FAST FLASH

YES

PRIMARY LIMIT

SWITCH CLOSED?

YES

ROLLOUT SWITCH CLOSED?

YES

PRESSURE SWITCH CONTACTS OPEN?

SIGNAL HOLDS UNTIL UNIT IS PROPERLY GROUNDED.

DS1 AND DS2 ALTERNATING FAST FLASH.

SIGNAL HOLDS UNTIL VOLTAGE RISES ABOVE 75 VOLTS.

DS1 AND DS2 ALTERNATING FAST FLASH.

GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

INDOOR BLOWER ON HEATING SPEED.

INDOOR BLOWER ON. HAS PRIMARY LIMIT

60−MINUTE LIMIT WATCHGUARD MODE.

GAS VALVE OFF, COMBUSTION AIR INDUCER

OFF, INDOOR BLOWER OFF WITH DELAY.

DS1 AND DS2 ALTERNATING SLOW FLASH,

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

HAS MANUAL ROLLOUT SWITCH(ES) BEEN

RESET (CLOSED) WITHIN 3 MINUTES?

POLARITY REVERSED.

DS 1 −− FAST FLASH

DS 2 −− SLOW FLASH

DS1 SLOW FLASH, DS2 OFF,

ON/OFF LED OFF

COMBUSTION AIR INDUCER OFF.

RESET WITHIN 3 MINUTES?

DS1 SLOW FLASH, DS2 ON,

ON/OFF LED ON, HEAT LED ON.

ON/OFF LED OFF, HEAT LED ON.

DS1 SLOW FLASH, DS2 ON,

ON/OFF LED ON, HEAT LED ON.

YES

TWO−STAGE OR SINGLE−STAGE THERMOSTAT

CALL FOR HEAT

COMBUSTION AIR INDUCER ON LOW SPEED.

DS1 AND DS2 SIMULTANEOUS FAST FLASH

CONTINUED ON NEXT PAGE

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF. INDOOR BLOWER OFF. CONTROL REMAINS UNTIL

PRESSURE SWITCH IS DETECTED OPEN.

DS1 OFF, DS2 SLOW FLASH,

ON/OFF LED OFF, HEAT LED OFF.

Page 71

Page 72

HEATING SEQUENCE OF OPERATION

CONTINUED

PRESSURE SWITCH CLOSED WITHIN

2.5 MINUTES?

YES

15−SECOND COMBUSTION AIR INDUCER

PRE−PURGE INITIATED BY CLOSED PRESSURE

SWITCH (or 15 SECOND INTER−PURGE PERIOD.)

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

IGNITOR WARM−UP (20 SECONDS)

DS1 AND DS2 SIMULTANEOUS FAST FLASH

IS VOLTAGE ABOVE 75 VOLTS?

YES

IS THERE A PROPER GROUND?

IS IGNITOR INTACT AND CONNECTED?

YES

THERMOSTAT CALLS FOR HEAT

DS1 AND DS2 SIMULTANEOUS FAST FLASH

(Refer to box A on previous page)

GAS VALVE OFF. COMBUSTION AIR INDUCER

OFF. INDOOR BLOWER OFF. UNIT WILL RETRY

AFTER 5−MINUTE WAIT PERIOD.

DS1 OFF, DS2 SLOW FLASH,

ON/OFF LED OFF, HEAT LED OFF.

COMBUSTION AIR INDUCER OFF, IGNITER OFF.

SIGNAL HOLDS UNTIL VOLTAGE RISES ABOVE 75 VOLTS.

DS1 AND DS2 ALTERNATING FAST FLASH.

COMBUSTION AIR INDUCER OFF, IGNITER OFF.

SIGNAL HOLDS UNTIL UNIT IS PROPERLY GROUNDED.

DS1 AND DS2 ALTERNATING FAST FLASH.

COMBUSTION AIR INDUCER OFF, IGNITOR OFF.

SIGNAL HOLDS UNTIL IGNITOR IS REPLACED

OR RECONNECTED.

DS1 AND DS2 ALTERNATING FAST FLASH.

AT END OF IGNITOR 20 SECOND WARM UP

PERIOD, 4−SECOND TRIAL FOR IGNITION.

GAS VALVE OPENS, IGNITOR ENERGIZED DURING

4−SECOND TRIAL UNTIL FLAME SENSED.

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

YES

4−SECOND FLAME STABILIZATION PERIOD.

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

FLAME RECTIFICATION CURRENT CHECK

CAN FLAME BE PROVEN WITHIN 4

SECONDS AFTER GAS VALVE OPENS?

(u0.16 microamps)

FLAME PRESENT?

YES

CONTINUED ON NEXT PAGE

GAS VALVE OFF. COMBUSTION AIR

INDUCER ON. INDOOR BLOWER OFF.

DS1 SLOW FLASH, DS2 FAST FLASH,

ON/OFF LED OFF, HEAT LED 0N.

HAS CONTROL FAILED TO SENSE

FLAME FOR FIVE CONSECUTIVE TRIES

DURING A SINGLE HEAT DEMAND?

YES

WATCHGUARD MODE. GAS VALVE OFF,

COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF.

DS1 AND DS2 ALTERNATING SLOW FLASH.

ON/OFF LED 0FF, HEAT LED OFF.

IS 60−MINUTE RESET PERIOD COMPLETE?

YES

HAS CONTROL RESET IGNITION SEQUENCE

FOUR (4) TIMES?

DS1 SLOW FLASH, DS2 FAST FLASH,

ON/OFF LED OFF, HEAT LED ON .

YES

Page 72

Page 73

CONTINUED

FLAME SIGNAL ABOVE

0.23 microamps)

YES

HEATING SEQUENCE OF OPERATION

THERMOSTAT CALLS FOR HEAT.

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

YES

DS1 SLOW FLASH, DS2 FAST FLASH.

LOW FLAME SIGNAL

(Does not affect control operation)

SEE BOX A.

SINGLE−STAGE THERMOSTAT MODE

(E20 SET AT SINGLE")

YES

START SECOND−STAGE RECOGNITION

ON DELAY (10 OR 15 MINUTES).

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

PRESSURE SWITCH CLOSED?

YES

FIRST−STAGE HEAT DEMAND SATISFIED?

DS1 AND DS2 SIMULTANEOUS SLOW FLASH.

GAS VALVE OFF, COMBUSTION AIR INDUCER

OFF FOLLOWING POST PURGE.

INDOOR BLOWER OFF WITH DELAY

DS1 AND DS2 SIMULTANEOUS SLOW FLASH

SECOND−STAGE HEAT DEMAND.

SECOND−STAGE HEAT DEMAND REQUIRED?

DS1 AND DS2 SIMUTANEOUS SLOW FLASH.

SECOND−STAGE 30−SECOND DELAY ON BEGINS.

DS1 AND DS2 SIMULTANEOUS FAST FLASH

SECOND−STAGE COMBUSTION AIR INDUCER

ON. SECOND−STAGE GAS VALVE ON. HIGH

HEAT INDOOR BLOWER SPEED ON.

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

PRESSURE SWITCH CLOSED

IN LESS THAN TEN (10) SECONDS?

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

YES

ON/OFF LED ON.

YES

CONTINUED ON NEXT PAGE

TWO STAGE THERMOSTAT MODE

(E20 SET AT TWO")

YES

45−SECOND INDOOR BLOWER ON DELAY BEGINS.

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

YES

GAS VALVE OFF, COMBUSTION AIR INDUCER OFF, INDOOR BLOWER ON. DS1 SLOW FLASH, DS2 ON,

SWITCH CLOSED WITHIN 3 MINUTES?

(Indoor blower on low speed during 3−minute period)

GAS VALVE OFF, COMBUSTION AIR INDUCER OFF,

DS1 AND DS2 ALTERNATING SLOW FLASH,

IS 60−MINUTE RESET PERIOD COMPLETE?

GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

INDOOR BLOWER OFF AFTER DELAY.

GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

INDOOR BLOWER OFF AFTER DELAY.

YES

PRIMARY LIMIT AND

ROLLOUT SWITCH CLOSED?

ON/OFF LED ON, HEAT LED ON.

HAS PRIMARY LIMIT OR ROLLOUT

LIMIT SWITCH WATCHGUARD MODE.

INDOOR BLOWER OFF WITH DELAY.

ON/OFF LED OFF, HEAT LED OFF.

DS1 OFF, DS 2 SLOW FLASH,

ON/OFF LED OFF, HEAT LED ON.

DS1 OFF, DS 2 SLOW FLASH,

ON/OFF LED OFF, HEAT LED ON.

YES

Page 73

Page 74

CONTINUED

HEATING SEQUENCE OF OPERATION

SEE BOX A

NORMAL OPERATION

DS1 AND DS2 SIMULTANEOUS SLOW FLASH.

ARE PRIMARY LIMIT AND ROLLOUT

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

SINGLE−STAGE THERMOSTAT MODE

SWITCH CLOSED?

YES

PRESSURE SWITCH CLOSED?

YES

HEAT DEMAND SATISFIED?

YES

(E20 SET AT SINGLE")

YES

THERMOSTAT CALLS FOR HEAT

DS 1 AND DS 2 SIMULTANEOUS FAST

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

HAS PRIMARY LIMIT OR ROLLOUT SWITCH

LIMIT SWITCH WATCHGUARD MODE. GAS VALVE

OFF. COMBUSTION AIR INDUCER OFF. INDOOR

BLOWER OFF WITH DELAY. IS 60−MINUTE RESET

PERIOD COMPLETE? DS SLOW FLASH, DS2 ON,

GAS VALVE OFF, COMBUSTION AIR INDUCER

OFF AFTER 15 SECOND POST PURGE, INDOOR

TWO STAGE THERMOSTAT MODE?

(E20 SET AT TWO")

INDOOR BLOWER ON.

DS1 SLOW FLASH, DS2 ON,

ON/OFF LED ON, HEAT LED 0N.

CLOSED WITHIN 3 MINUTES?

ON/OFF LED OFF, HEAT LED OFF.

BLOWER OFF AFTER DELAY.

DS1 OFF, DS2 FAST FLASH,

ON/OFF LED ON, HEAT LED ON.

RETURN TO HEAT DEMAND?

SEE BOX B

FLASH.

YES

HEAT DEMAND SATISFIED?

DS1 AND DS2

SIMULTANEOUS FAST FLASH.

YES

GAS VALVE OFF, COMBUSTION AIR

INDUCER OFF AFTER 5−SECOND

LOW SPEED POST PURGE PERIOD,

INDOOR BLOWER OFF DELAY

INITIATED ON LOW HEAT SPEED.

DS1 AND DS2

SIMULTANEOUS FAST FLASH

DEMAND FOR HEAT SATISFIED.

POWER ON STAND BY.

DS1 AND DS2

SIMULTANEOUS SLOW FLASH

YES

FIRST AND SECOND STAGE HEAT

DEMAND SATISFIED SIMULTANEOUSLY.

DS1 & DS2 SIMULTANEOUS FAST FLASH.

YES

GAS VALVE, COMBUSTION AIR INDUCER

AND INDOOR BLOWER RETURN TO FIRST−

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

FIRST STAGE HEAT DEMAND SATISFIED?

GAS VALVE OFF. COMBUSTION AIR INDUCER

OFF AFTER 5−SECOND LOW SPEED POST−

PURGE PERIOD. INDOOR BLOWER OFF. DELAY INITIATED ON LOW HEAT SPEED. DS1 & DS2 SIMULTANEOUS FAST FLASH.

SECOND STAGE HEAT

DEMAND SASTISFIED?

DS1 AND DS2

SIMULTANEOUS FAST FLASH.

YES

STAGE OPERATION.

YES

Page 74

Page 75

COOLING SEQUENCE OF OPERATION

POWER ON

SIGNAL IMPROPER

GROUND AT DS.

SIGNAL HOLDS

UNTIL UNIT IS

PROPERLY

GROUNDED.

(V MODELS ONLY)

THERMOSTAT CALLS FOR FIRST−STAGE COOL.

INDOOR BLOWER ENERGIZED ON FIRST STAGE

FIRST−STAGE DEMAND FOR COOL SATISFIED?

THERMOSTAT CALLS FOR SECOND−STAGE COOL.

IS POLARITY REVERSED?

COMPRESSOR AND CONDENSER FAN

COOL SPEED AFTER 2 SECOND DELAY.

IS THERE

PROPER GROUND?

ENERGIZED.

YES

IS VOLTAGE

ABOVE 75 VOLTS?

YES

SIGNAL POLARITY REVERSED.

DS1 FAST FLASH, DS2 SLOW FLASH.

COMPRESSOR AND CONDENSER FAN DE−ENERGIZED.

LOW VOLTAGE SIGNAL AT DS HOLDS

UNTIL VOLTAGE RISES ABOVE 75 VOLTS.

INDOOR BLOWER DE−ENEGIZED.

INDOOR BLOWER RAMPS UP TO SECOND−STAGE COOL SPEED.

SECOND−STAGE DEMAND FOR COOL SATISFIED?

YES

UNIT RETURNS TO FIRST STAGE COOL

Page 75

Page 76

CONTINUOUS LOW SPEED FAN SEQUENCE OF OPERATION

GHR32V−5 UNITS

MANUAL FAN SELECTION MADE AT THERMOSTAT.

AFTER 2 SECOND DELAY, INDOOR BLOWER IS

ENERGIZED ON CONTINUOUS FAN SPEED.

YES YES

YES

INDOOR BLOWER RAMPS TO FIRST STAGE

COOLING SPEED AFTER A 2−SECOND DELAY.

THERMOSTAT CALLS FOR FIRST−STAGE HEAT.THERMOSTAT CALLS FOR FIRST STAGE COOL.

YES

AFTER 45−SECOND DELAY, INDOOR BLOWER

SWITCHES TO LOW HEAT SPEED.

YES

FIRST−STAGE COOL DEMAND SATISFIED?

SECOND STAGE COOL DEMAND

INDOOR BLOWER RAMPS TO SECOND

STAGE COOL SPEED

SECOND STAGE COOL DEMAND SATISFIED?

YES

INDOOR BLOWER RAMPS DOWN TO FIRST STAGE

COOL SPEED.

NOTE − Continuous low speed fan and cooling low speed are equal to the low heat fan speed.

MANUAL FAN SELECTION MADE AT THERMOSTAT.

AFTER 2 SECOND DELAY, INDOOR BLOWER IS

ENERGIZED ON CONTINUOUS FAN SPEED

FIRST−STAGE HEAT DEMAND SATISFIED.

THERMOSTAT CALLS FOR SECOND−STAGE HEAT.

INDOOR BLOWER SWITCHES TO HIGH HEAT SPEED

AFTER 30−SECOND RECOGNITION PERIOD.

SECOND−STAGE HEAT DEMAND SATISFIED.

INDOOR BLOWER RAMPS DOWN TO LOW

GHR32Q−5 UNITS

(LOW HEAT / LOW COOL).

YES YES

YES

HEAT SPEED.

YES

COMPRESSOR IS ENERGIZED AND INDOOR

BLOWER CONTINUES TO OPERATE IN LOW

YES

FIRST−STAGE COOL DEMAND SATISFIED?

SECOND−STAGE COOL DEMAND

INDOOR BLOWER SWITCHES TO

SECOND−STAGE COOL SPEED

SECOND−STAGE COOL DEMAND SATISFIED?

INDOOR BLOWER SWITCHES TO FIRST−STAGE

COOL SPEED.

YES

COOL SPEED.

Page 76

THERMOSTAT CALLS FOR FIRST−STAGE HEAT.THERMOSTAT CALLS FOR FIRST−STAGE COOL.

YES

BURNERS IGNITE AND INDOOR BLOWER

CONTINUES TO OPERATE IN CONTINUOUS

LOW (LOW HEAT / LOW COOL) MODE.

FIRST−STAGE HEAT DEMAND SATISFIED.

THERMOSTAT CALLS FOR SECOND−STAGE HEAT.

YES

INDOOR BLOWER SWITCHES TO HIGH HEAT SPEED

AFTER 30−SECOND RECOGNITION PERIOD.

YES

SECOND−STAGE HEAT DEMAND SATISFIED.

YES

INDOOR BLOWER SWITCHES TO LOW HEAT

SPEED.

YES

Page 77

IX− Troubleshooting

Diagnostic lights flash the roll out

LED#1−On

ACTION 1

blower does not energize

120V field connection

SureLight Control UPON INITIAL POWER UP, REMOVE ALL THERMOSTAT DEMANDS TO THE UNIT Unless otherwise noted, condition applies to all GHR32Q/V units.

PROBLEM: 1 UNIT FAILS TO OPERATE IN THE COOLING, HEATING, OR CONTINUOUS FAN MODE

Condition Possible Cause Corrective Action / Comments

1.1

− Both diagnostic lights fail to light up.

Main voltage 120V not supplied to unit.

1.1.1

ACTION 1 − Check 120V main voltage.

Determine cause of main power failure.

LED#1−Off LED#2−Off

1.2

GHR32Q/V−1 through −4 Units Only

− Diagnostic lights flash the roll−out

−

code.

−

LED#2−Slow Flash

1.3

− On initial power−up the comb. air .

− Diagnostic lights flash the reverse

polarity code.

1.1.2

Miswiring of furnace or improper connections.

1.1.3

Circuit breaker tripped or fails to close.

1.1.4

Door interlock switch failure.

1.1.5

Transformer Failure.

1.1.6

Failed control board.

1.2.1

Roll−out switch open.

1.2.2

Roll−out switch failure.

1.2.3

Miswiring or improper connections at roll−out switch.

1.2.4

Nine pin connector failure

1.3.1

120V main power polarity reversed.

ACTION 1 − Check for correct wiring of 120V to power make up box and transformer.

ACTION 2 − Check 24V wiring to control board.

ACTION 1 − Replace circuit breaker if it is reset

but does not have continuity. ACTION 2 − If circuit breaker still trips, check for short.

ACTION 1 − Check that door switch is activated when door is closed. ACTION 2 − Check wire connections to switch, replace loose connectors. ACTION 3 − Check continuity of switch in closed position. Replace if malfunctioning

ACTION 1 − Check that transformer output is 24V. Replace if malfunctioning

ACTION 1 − If all the above items have been checked, replace board.

ACTION 1 − Manually reset the roll−out switch by pushing the top button. ACTION 2 − Determine the cause of the roll−out switch activation before leaving furnace.

ACTION 1 − Check continuity across roll−out switch. Replace roll−out switch if switch is reset but does not have continuity.

− Check wiring connections to switch.

ACTION 1 − Check 9−pin connector for proper

connection to control board. ACTION 2 − Check continuity of the multi plug pin.

ACTION 1 − Check the 120V has line and neutral correctly input into control. ACTION 2 − Reverse the line and neutral at the 120V field connection.

LED#1−Fast Flash, LED#2−Slow Flash.

1.4

GHR32Q/V−1 through −4 Units Only

− On initial power up the combustion

air blower does not energize.

− Diagnostic lights flash normal power

on operation.

LED#1−Slow Flash LED#2−Slow Flash

1.4.1

Open combustion air blower motor circuit.

1.4.2

Failed combustion air blower motor.

Page 77

ACTION 1 − Check for 120V to combustion air blower. If no power, check wire and connections.

ACTION 1 − If power is present at blower, replace blower.

Page 78

PROBLEM 1: UNIT FAILS TO OPERATE IN THE COOLING, HEATING, OR CONTINUOUS FAN MODE

Diagnostic lights flash the pressure

Condition Possible Cause Corrective Action / Comments

1.5

− On initial power−up the combustion

air blower remains energized.

− Diagnostic lights flash the improper main ground.

LED#1−Alternating Fast Flash LED#2−Alternating Fast Flash

1.5.1

Improper ground to the unit.

1.5.2

6−Pin connector is improperly at-

tached to the circuit board.

1.5.3

Line voltage is below 75V.

ACTION 1 − Check that the unit is properly grounded. ACTION 2 − Install a proper main ground to the unit

ACTION 1 − Check 6−pin connector for proper installation. Correctly insert connector into control.

ACTION 1 − Check that the line voltage is above 75V. Determine cause of voltage drop and supply correct voltage to the control.

PROBLEM 2: UNIT FAILS TO OPERATE IN THE COOLING OR HEATING MODE, BUT COMBUSTION

AIR BLOWER OPERATES CONTINUOUS. GHR32Q/V−1 through −4 UNITS WITH CONTROL BOARDS DATE CODED AFTER NOV.1 1997, WILL OPERATE IN COOLING WITH COMBUSTION AIR BLOWER

CYCLING 5 SECONDS ON 55 SECONDS OFF, BUT NOT IN THE HEATING MODE.

Condition Possible Cause Corrective Action / Comments

2.1

− On initial power−up the combustion

air blower remains energized.

− Diagnostic lights flash the improper main ground.

− G32V−1 to −4 Units with control boards date coded after Nov.1 1997; combustion air blower will cycle 5 seconds on 55 seconds off.

LED#1−Alternating Fast Flash LED#2−Alternating Fast Flash

2.1.1

Open ignitor circuit.

2.1.2

Broken or failed ignitor.

ACTION 1 − Check for correct wiring and loose connections in the ignitor circuit. Check multi − plug connections for correct installation.

ACTION 1 − Unplug ignitor and read resistance across ignitor. If resistance does not read between 10.9 and 19.7 ohms, replace the ignitor.

PROBLEM 3: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR BLOWER DOES NOT

ENERGIZE

Condition Possible Cause Corrective Action / Comments

3.1

− Unit operates with a cooling or contin-

uous fan demand.

− Combustion air blower will not start with a Heating demand.

− Diagnostic lights flash the limit failure mode.

LED#1−Slow Flash, LED#2−On

3.2

− Unit operates with a cooling and continuous fan demand.

− Combustion air blower will not start with a Heating demand.

− Diagnostic lights flash the pressure

−

switch failure code.

LED#1−Off, LED#2−Slow Flash

3.1.1

Primary or secondary (if equipped) or

rollout limit switch open.

3.1.2

Miswiring of furnace or improper con-

nections at limit switch(es).

3.2.1

Miswiring of furnace or improper con-

nections to combustion air blower.

3.2.2

Pressure switch stuck closed.

ACTION 1 − Check continuity across switch(es). Switches reset automatically upon cool down.

Rollout switch must be reset manually. ACTION 2 − Check for restrictions on blower inlet

air (including filter) and outlet air. Determine cause for limit activation before placing unit back in operation.

ACTION 1 − Check for correct wiring and loose connections. Correct wiring and/or replace any loose connections.

ACTION 1 − Check that the pressure switch is open without the combustion air blower operating. Replace if malfunctioning

Page 78

Page 79

PROBLEM 3: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR BLOWER DOES NOT

LED#1 Off

ENERGIZE (CONT.).

Condition Possible Cause Corrective Action/Comments

3.3

− Unit operates with a cooling and con-

tinuous fan demand.

− Combustion air blower will not start

with a Heating demand.

Miswiring of furnace or improper con-

nections to combustion air blower.

3.3.1

ACTION 1 − Check for correct wiring and loose

connections. Correct wiring and/or replace any loose connections.

− Diagnostic lights flash the pressure

switch failure code 2.5 minutes after heating demand.

ACTION 1 − If there is 120V to combustion air blower and it does not operate, replace combustion air blower.

LED#1−Off,

3.3.2

Combustion air blower failure.

LED#2−Slow Flash

PROBLEM 4: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR BLOWER

ENERGIZES, IGNITOR IS NOT ENERGIZED.

Condition Possible Cause Corrective Action/Comments

4.1

− Unit operates with a cooling and

continuous fan demand.

− Combustion air blower energizes

with a heating demand.

− Diagnostic lights flash the pressure

switch failure code 2.5 minutes after heating demand.

LED#1−Off LED#2−Slow Flash

Pressure switch does not close due

to incorrect routing of the pressure

Pressure switch does not close due

to obstructions in the pressure tubing.

Pressure switch tubing damaged

Condensate in pressure switch tub-

Pressure switch does not close due to a low differential pressure across

the pressure switch.

Wrong pressure switch installed in the

unit, or pressure switch is out of cal-

Miswiring of furnace or improper con-

nections at pressure switch.

Pressure switch failure.

4.1.1

switch tubing.

4.1.2

4.1.3

4.1.4

ing.

4.1.5

4.1.6

ibration.

4.1.7

4.1.8

ACTION 1 − Check that the pressure switch tub-

ing is correctly routed. Correctly route pressure switch tubing.

ACTION 1 − Remove any obstructions from the pressure tubing and/or taps.

ACTION 1 − Check pressure switch tubing for leaks. Replace any broken tubing.

ACTION 1 − Check pressure switch tubing for condensate. Remove condensate from tubing. Check that the condensate tubing is located correctly.

ACTION 1 − Check the differential pressure across the pressure switch. This pressure should exceed the set point listed on the switch. ACTION 2 − Check for restricted inlet and exhaust vent. Remove all blockage. ACTION 3 − Check for proper vent sizing and run length. See installation instructions.

ACTION 1 − Check that the proper pressure switch is installed in the unit. Replace pressure switch if necessary.

ACTION 1 − Check for correct wiring and loose connections. Correct wiring and/or replace any loose connections.

ACTION 1 − If all the above modes of failure have been checked, the pressure switch may have failed. Replace pressure switch and determine if unit will operate.

Page 79

Page 80

PROBLEM 5: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR BLOWER

rners light but unit shuts off prior

ignite code

ENERGIZES, IGNITOR IS ENERGIZED. (CONT.)

Condition Possible Cause Corrective Action/Comments

5.1

− Unit operates with a cooling and continuous fan demand.

− Combustion air blower energizes with Heating demand.

− Ignitor is energized but unit fails to light.

LED#1−Alternating Slow Flash LED#2−Alternating Slow Flash

5.1.1

Check that gas is being supplied to

the unit.

5.1.2

Miswiring of gas valve or loose con-

nections at multi−pin control amp

plugs or valve.

5.1.3

Malfunctioning gas valve or ignition

control.

ACTION 1 − Check line pressure at the gas valve. Pressure should not exceed 13" WC for both natural and propane. Line pressure should read a minimum 4.5" WC for natural and 8.0"WC for propane.

ACTION 1 − Check for correct wiring and loose connections. Correct wiring and/or replace any loose connections.

ACTION 1 − Check that 24V is supplied to the gas valve approximately 35 seconds after heat demand is initiated. ACTION 2 − Replace the valve if 24V is supplied but valve does not open (check for excessive gas line pressure before replacing gas valve). ACTION 3 − Replace the control board if 24V is not supplied to valve.

PROBLEM 6: BURNERS LIGHT WITH A HEATING DEMAND BUT UNIT SHUTS DOWN

PREMATURELY

Condition Possible Cause Corrective Action/Comments

6.1

− Burners fire with a heating demand.

−

− Bu to satisfying T−stat demand.

− Diagnostic lights flash the pressure switch code.

LED#1−Off LED#2−Slow Flash

6.2

− Combustion air blower energizes with a heating demand.

− Burners light but fail to stay lit.

− After 5 tries the control diagnostics flash the watchguard burners failed to ignite code.

LED#1−Alternating Slow Flash LED#2−Alternating Slow Flash

6.1.1

Wrong concentric vent kit used for

terminating the unit.

6.1.2

Condensate drain line is not draining

properly.

6.1.3

Low pressure differential at the pres-

sure switch.

6.2.1

Sensor or sense wire is improperly

installed.

6.2.2

Sensor or sense wire is broken.

6.2.3

Sensor or sensor wire is grounded to

the unit.

6.2.4

Control does not sense flame.

ACTION 1 − Check vent termination kit installed. 1−1/2" dia. concentric vent (kit60G77) for 50 and 75 inputs and 2" dia. concentric vent (kit 33K97) for 100 &125 inputs.

ACTION 1 − Check condensate line for proper vent slope, and any blockage. Condensate should flow freely during operation of furnace. Repair or replace any improperly installed condensate lines.

ACTION 1 − Check for restricted vent inlet or exhaust. Remove all blockage. ACTION 2: Check for proper vent sizing. See installation instructions.

ACTION 1 − Check that sensor is properly located (page 10) and that the sense wire is properly attached to both the sensor and the control.

ACTION 1 − Check for a broken sensor. ACTION 2 − Test continuity across the sense

wire. If wire or sensor are damaged replace the component.

ACTION 1 − Check for resistance between the sensor rod and the unit ground. ACTION 2 − Check for resistance between the sensor wire and the unit ground.

ACTION 3 − Correct any shorts found in circuit.

ACTION 1 − Check the microamp signal from

the burner flame. If the microamp signal is below normal, check the sense rod for proper location or contamination. ACTION 2 − Replace, clean, or relocate flame sense rod. If rod is to be cleaned, use steel wool or replace sensor. DO NOT CLEAN ROD WITH SAND PAPER. SAND PAPER WILL CONTRIBUTE TO THE CONTAMINATION PROBLEM. NOTE: Do not attempt to bend sense rod.

Page 80

Page 81

PROBLEM 6: BURNERS LIGHT WITH HEATING DEMAND BUT UNIT SHUTS DOWN

ure.

LED#2−Sl

flame failure.

Condition Possible Cause Corrective Action/Comments

6.3

− Combustion air blower energizes

with a heating demand.

− Burners light.

− Roll−out switch trips during the

heating demand.

− Diagnostic lights flash roll−out fail-

ure.

GHR32Q/V−1 through −4 Units Only

LED#1−On

ow Flas

GHR32Q/V−5 Units

LED#1−Slow Flash LED#2−On

6.4

− Combustion air blower energizes

with a heating demand.

− Burners light roughly and the unit

fails to stay lit.

− Diagnostic lights flash watchguard

flame failure.

PREMATURELY (CONT.)

6.3.1

Unit is firing above 100% of the

nameplate input.

6.3.2

Gas orifices leak at the manifold con-

nection.

6.3.3

Air leakage at the connections be-

tween the primary heat exchanger,

secondary heat exchanger, and com-

bustion air blower.

6.3.4

Insufficient flow through the heat ex-

changer caused by a sooted or re-

stricted heat exchanger.

6.3.5

Burners are not properly located in

the burner box.

6.4.1

Recirculation of flue gases. This con-

dition causes rough ignitions and op-

eration. Problem is characterized by

nuisance flame failures.

ACTION 1 − Check that the manifold pressure matches value listed on nameplate. See installation instructions for proper procedure. ACTION 2 − Verify that the installed orifice size match the size listed on the nameplate or installation instructions. ACTION 3 − Check gas valve sensing hose to insure no leaks are present. ACTION 4 − Check the input rate to verify rate matches value listed on nameplate.

ACTION 1 − Tighten orifice until leak is sealed. NOTE: Be careful not to strip orifice threads. ACTION 2 − Check for gas leakage at the

threaded orifice connection. Use approved method for leak detection (see unit instructions).

ACTION 1 − Check for air leakage at all joints in the heat exchanger assembly. Condition may cause high CO2 with high CO. ACTION 2 − Seal leakage if possible (high temperature silicon is recommended), replace heat exchanger if necessary, tag and return heat exchanger to proper Lennox personnel.

ACTION 1 − Check for sooting deposits or other restrictions in the heat exchanger assembly. Clean assembly as outlined in instruction manual. ACTION 2 − For GHR32 gas furnaces, check for proper combustion and flow. CO2 should measure between 6.0% and 8.0% for NAT and 7.0% and 9.0% for LP. CO should measure below .04% (400PPM) in an air−free sample of flue gases.

ACTION 1 − Check that the burners are firing into the center of the heat exchanger openings. Correct the location of the burners if necessary.

ACTION 1 − Check for proper flow of exhaust gases away from intake vent. Remove any obstacles in front of the intake and exhaust vent which would cause recirculation. ACTION 2 − Check for correct intake and exhaust vent installation.

LED#1−Alternating Slow Flash LED#2−Alternating Slow Flash

6.4.2

Improper burner cross−overs

Page 81

ACTION 1 − Remove burner and inspect the cross−overs for burrs, or any restriction or if crossover is warped. Remove restriction or replace burners.

Page 82

PROBLEM 6: BURNERS LIGHT WITH HEATING DEMAND BUT UNIT SHUTS DOWN

6.5

− Combustion air blower energizes with a heating demand.

− Burners light.

− Diagnostic lights flash watch guard flame failure.

− NOTE" Unit might go into 60 minute Watchguard mode depending on intermittent nature of sensor signal.

LED#1−Alternating Slow Flash LED#2−Alternating Slow Flash

PROBLEM 7: CONTROL SIGNALS LOW FLAME SENSE DURING HEATING MODE

Condition Possible Cause Corrective Action/Comments

7.0

− Unit operates correctly but the diagnostic lights flash low flame sense code.

LED#1−Slow Flash LED#2−Fast Flash

PREMATURELY (CONT.)

6.5.1

Loose sensor wire connection causes

intermittent loss of flame signal.

7.1.1

Sense rod is improperly located on

the burner.

7.1.2

Sense rod is contaminated.

ACTION 1 − Check that the sensor is properly located. ACTION 2 − Check that the sense wire is properly attached to both the sensor and the control. Pay extra attention to the pin connectors.

ACTION 1 − Check the sense rod for proper location on the burner. Properly locate the sense rod or replace if rod cannot be located correctly.

ACTION 1 − Check sense rod for contamination or coated surface. Clean the sense rod with steel wool or replace sensor. DO NOT USE SAND PAPER TO CLEAN ROD. SAND PAPER WILL CONTRIBUTE TO THE CONTAMINATION PROBLEM.

PROBLEM 8: RF STATIC DURING TIME FOR IGNITION

Condition Possible Cause Corrective Action/Comments

8.0

− AM radio interference

8.1.1

Ignitor operation

ACTION 1− Call Technical Support, Dallas

Page 82

Page 83

VSP2−1 Blower Control Board GHR32V−1 / −3 Units

DOES UNIT OPERATE?

YES

IS 24VAC ACROSS

COOLING MODE

PLACE JUMPER ACROSS R AND G.

IS BLOWER ON LOW SPEED AND IS

ON/OFF" LED−DS3 LIT? CFM" LED−DS4

LIGHT SHOULD BLINK ONCE FOR EV-

ERY 100 CFM SELECTED IN THE

TABLES ON PAGE 2.

IS 24 VOLTS PRESENT AT J73

PIN 12 ON VSP2 BOARD?

IN ADDITION TO R AND G,

JUMPER R AND DS.

R AND C?

YES

CHECK: 1−UNIT POWER 2−INTERLOCK SWITCH 3−TRANSFORMER 4−LIMIT SWITCH

CHECK UNIT WIRING

AND IF CORRECT,

REPLACE VSP2−1.

END OF COOLING TEST

HEATING MODE

YES

IS BLOWER ON HIGH SPEED AND ARE DS1 AND

DS3 LIT? DOES THE CFM" LED−DS4 LIGHT BLINK

ONCE FOR EVERY 100 CFM SELECTED IN THE

TABLES ON PAGE 2?

DOES UNIT OPERATE?

YES

IS 24VAC ACROSS

R AND C?

YES

PLACE HTG. BLOWER" JUMPER IN POSITION #2.

PLACE JUMPER ACROSS R AND W1. WAIT 75

SECOND FOR PREPURGE AND FANON" DELAY.

IS BLOWER ON LOW SPEED AND IS ON/OFF" LED−

DS3 LIT? CFM" LED−DS4 LIGHT SHOULD BLINK

ONCE FOR EVERY 100 CFM SELECTED IN THE

TABLES ON PAGE 2.

YES

IS 24 VOLTS PRESENT AT J73

PIN 12 ON VSP2 BOARD?

YES

PLACE HTG. BLOWER"

JUMPER IN POSITION #1.

R AND W1 REMAIN JUMPERED.

CHECK UNIT WIRING

AND IF CORRECT

REPLACE THE

VSP2−1.

CHECK: 1−UNIT POWER 2−INTERLOCK SWITCH 3−TRANSFORMER 4−LIMIT SWITCH

1−CHECK UNIT WIRING AND IF

CORRECT, REPLACE

2−BREAK AND REMAKE JUMPER

VSP2−1. (R TO W1).

3−AFTER 30−35 SECOND

PURGE, IS 24VAC PRESENT AT GAS VALVE?

REPLACE VSP2−1.

END OF TEST

DOES BLOWER SHIFT TO HEAT SPEED

AND IS HEAT" LED−DS2 ON? DOES THE

CFM" LED−DS4 LIGHT BLINK ONCE

FOR EVERY 100 CFM SELECTED IN

THE TABLES ON PAGE 2?

YES

REMOVE JUMPERS

YES

AFTER THE SELECTED

TIME, DOES BLOWER

TURN OFF?

Page 83

CHECK UNIT WIRING

AND IF CORRECT, REPLACE VSP2−1.

REPLACE THE VSP2−1.

Page 84

VSP3−1 Blower Control Board GHR32V−4 Units

DOES UNIT OPERATE?

YES

IS 24VAC ACROSS

COOLING MODE

PLACE JUMPER ACROSS R, G, AND Y1.

IS BLOWER ON LOW SPEED AND IS ON/

OFF LED−DS3 AND HI/LOW LED−DS1 LIT?

CFM LED−DS4 LIGHT SHOULD BLINK ONCE

FOR EVERY 100 CFM SELECTED IN THE

TABLES ON PAGE 2.

R AND C?

YES

CHECK: 1−UNIT POWER 2−INTERLOCK SWITCH 3−TRANSFORMER 4−LIMIT SWITCH

CHECK UNIT WIRING AND IF

CORRECT, REPLACE VSP3−1.

END OF COOLING TEST

HEATING MODE

YES

IS 24 VOLTS PRESENT AT J73

PIN 12 ON VSP3 BOARD?

YES

IN ADDITION TO R G, AND Y1

JUMPER R AND Y2.

IS BLOWER ON HIGH SPEED AND ARE DS1 AND DS3 LIT? DOES THE CFM LED−DS4 LIGHT BLINK

ONCE FOR EVERY 100 CFM SELECTED IN THE

YES

PLACE HTG. BLOWER JUMPER IN POSITION #2.

PLACE JUMPER ACROSS R AND W1. WAIT 75 SEC-

OND FOR PREPURGE AND FAN ON DELAY.

IS BLOWER ON LOW SPEED AND IS ON/OFF"

LED−DS3 LIT? CFM" LED−DS4 LIGHT SHOULD

BLINK ONCE FOR EVERY 100 CFM SELECTED IN

TABLES ON PAGE 2?

DOES UNIT OPERATE?

IS 24VAC ACROSS

R AND C?

YES

THE TABLES ON PAGE 2.

YES

IS 24 VOLTS PRESENT AT J73

PIN 12 ON VSP3 BOARD?

REPLACE VSP3−1.

CHECK UNIT WIRING

AND IF CORRECT

REPLACE THE

VSP3−1.

CHECK: 1−UNIT POWER 2−INTERLOCK SWITCH 3−TRANSFORMER 4−LIMIT SWITCH

1−CHECK UNIT WIRING AND IF

CORRECT, REPLACE VSP3−1.

2−BREAK AND REMAKE JUMPER

(R TO W1).

3−AFTER 30−35 SECOND PURGE,

IS 24VAC PRESENT AT GAS VALVE?

REPLACE VSP3−1.

CFM" LED−DS4 LIGHT BLINK ONCE FOR

END OF TEST

YES

PLACE HTG. BLOWER

JUMPER IN POSITION #1.

R AND W1 REMAIN JUMPERED.

DOES BLOWER SHIFT TO HIGH SPEED

AND IS HEAT" LED−DS2 ON? DOES THE

EVERY 100 CFM SELECTED IN THE

TABLES ON PAGE 2?

YES

REMOVE JUMPERS

AFTER THE SELECTED

TIME, DOES BLOWER

TURN OFF?

Page 84

CHECK UNIT WIRING

AND IF CORRECT, REPLACE VSP3−1.

REPLACE THE VSP3−1.

Page 85

ICM−2 WITH VSP2

120V to the motor must not be interupted. All connections for check out will be from the voltage source below (battery or 24V) to plug J46, after disconnectiong from blower control board VSP2.

J46

CHECK−OUT PROCEDURE USING BATTERY

An ordinary 9 volt battery with maximum DC 20volts is recommended. A 9 volt battery will last for about one day of normal operation.

LOW SPEED CHECK−OUT

12345678 910111213

J46

1− Disconnect power to unit. 2− Disconnect plug J46 from P46 located on the

blower control board. 3− Connect voltage source as shown above. 4− Turn on power to unit. Blower should operate

at low speed.

HIGH SPEED CHECK−OUT

12345678 910111213

J46

CHECK−OUT PROCEDURE USING 24V SOURCE

Unit transformer T1 with a maximum AC 30 volts may be used in lieu of a battery. If transformer T1 is used, double check all wiring connections before placing unit back in operation.

LOW SPEED CHECK−OUT

12345678 910111213

J46

1− Disconnect power to unit. 2− Disconnect plug J46 from P46 located on the

blower control board. 3− Disconnect C and R from control board. 4− Connect voltage source as shown above. 5− Turn on power to unit. Blower should operate

at low speed.

HIGH SPEED CHECK−OUT

12345678 910111213

J46

5− Disconnect power to unit. 6− Connect voltage source as shown above. 7− Turn on power to unit. Blower should operate

at high speed.

HEATING SPEED CHECK−OUT

12345678 910111213

J46

8− Disconnect power to unit. 9− Connect voltage source as shown above.

10−Turn on power to unit. Blower should operate

at heating speed.

6− Disconnect power to unit. 7− Connect voltage source as shown above. 8− Turn on power to unit. Blower should operate

at high speed.

HEATING SPEED CHECK−OUT

12345678 910111213

J46

9− Disconnect power to unit. 10− Connect voltage source as shown above. 11− Turn on power to unit. Blower should operate

at heating speed.

A kit is available from the Lennox parts center to use in testing the variable speed motor. The kit 70J11 includes a test plug harness to facilitate ICM−2 check−out. Follow testing procedures outlined in the instructions provided with the kit.

The testing procedures are different than those listed above.

Page 85

Page 86

ICM−2 WITH VSP3

120V to the motor must not be interupted. All connections for check out will be from the voltage source below (battery or 24V) to plug J46, after disconnectiong from blower control board.

CHECK−OUT PROCEDURE USING BATTERY

An ordinary 9 volt battery with maximum DC 20volts is recommended. A 9 volt battery will last for about one day of normal operation.

LOW COOL SPEED

1 2 3 4 5 6 7 8 9 10111213

J46

1− Disconnect power to unit. 2− Disconnect plug J46 from P46 located on the

blower control board. 3− Connect voltage source as shown above. 4− Turn on power to unit. Blower should operate

at low cool speed.

HIGH COOL SPEED

12345678 910111213

5− Disconnect power to unit. 6− Connect voltage source as shown above.

7− Disconnect Y" on ignition control AND re-

move connection from Y2" on TB1 in control box. Connect a seperate wire between the − side of the battery and BOTH Y" on the ignition control and Y2" on TB1.

8− Turn on power to unit. Blower should operate

at high cool speed.

LOW HEAT SPEED

12345678 910111213

J46

To W" on ignition control board. !

9− Disconnect power to unit. 10− Connect voltage source as shown above. 11− Disconnect W" terminal on ignition control

board and connect a seperate wire between

W" and + side of battery. 12− Turn on power to unit. Blower should oper-

ate at low heat speed.

To Y2" on TB1.!

To Y" on ignition control. !

CHECK−OUT PROCEDURE USING 24V SOURCE

Unit transformer T1 with a maximum AC 30 volts may be used in lieu of a battery. If transformer T1 is used, double check all wiring connections before placing unit back in operation.

LOW COOL SPEED

12345678 910111213

J46

1− Disconnect power to unit.

2− Disconnect plug J46 from P46 located on the

blower control board.

3− Disconnect C and R from ignition control

board.

4− Disconnect Y" from ignition control and con-

nect a seperate wire between R" on the

transfomer and Y" on the ignition control. 5− Connect voltage source as shown above. 6− Turn on power to unit. Blower should operate

at low cool speed.

To Y" on ignition control. !

HIGH COOL SPEED

1 2 3 4 5 6 7 8 9 1011 1213

J46

7− Disconnect power to unit. 8− Connect voltage source as shown above. 9− Disconnect Y2" on TB1 in control box and

connect a seperate wire between R" on transformer and Y2" on TB1.

10− Turn on power to unit. Blower should oper-

ate at high cool speed.

LOW HEAT SPEED

12345678910111213

J46

11− Disconnect power to unit. 11− Connect voltage source as shown above. 12− Disconnect W" from ignition control and

connect a seperate wire between R" on transformer and W" on the ignition control.

13− Turn on power to unit. Blower should operate

at low heat speed.

To W" on on ignition control. !

To Y2" on TB1.!

HIGH HEAT SPEED

12345678 910111213

J46

To W2" on TB1 !

13− Disconnect power to unit. 14− Connect voltage source as shown above.

15−Disconnect W2" on TB1 in control box and

connect a seperate wire between W2" and + side of battery.

16−Turn on power to unit. Blower should operate

at high heat speed.

Page 86

HIGH HEAT SPEED

12345678 910111213

J46

14− Disconnect power to unit. 15− Connect voltage source as shown above. 16− Disconnect W2" from TB1and connect a

seperate wire between R" on transformer and W2" on TB1.

17− Turn on power to unit. Blower should operate

at low heat speed.

To W2" on TB1 !

Page 87

ICM−2 WITH TWO STAGE VARIABLE SPEED CONTROL BOARD

120V to the motor must not be interrupted. All connections for check out will be from the voltage source below (battery or 24V) to plug J46, after disconnecting from blower control board.

REMOVE PLUG FROM BOARD

CHECK−OUT PROCEDURE USING BATTERY

An ordinary 9 volt battery with maximum DC 20volts is recommended. A 9 volt battery will last for about one day of normal operation.

LOW

COOL

J46

SPEED

1− Disconnect power to unit. 2− Disconnect plug J46 from P46 located on the blower control board. 3− Connect voltage source as shown above. 4− Turn on power to unit. Blower should operate at low cool speed.

HIGH

COOL

SPEED

J46

CHECK−OUT PROCEDURE USING 24V SOURCE

Unit transformer T1 with a maximum AC 30 volts may be used in lieu of a battery. If transformer T1 is used, double check all wiring connections before placing unit back in operation.

LOW

COOL

J46

SPEED

HIGH

COOL

SPEED

J46

5− Disconnect power to unit. 6− Connect voltage source as shown above.

7− Turn on power to unit. Blower should operate at high cool speed.

LOW

HEAT

J46

SPEED

8− Disconnect power to unit. 9− Connect voltage source as shown above.

10− Turn on power to unit. Blower should operate at low heat speed.

HIGH

HEAT

SPEED

11− Disconnect power to unit. 12− Connect voltage source as shown above.

13− Turn on power to unit. Blower should operate at high heat speed.

5− Disconnect power to unit. 6− Connect voltage source as shown above.

7− Turn on power to unit. Blower should operate at high cool speed.

LOW

HEAT

J46

SPEED

8− Disconnect power to unit. 9− Connect voltage source as shown above.

10− Turn on power to unit. Blower should operate at low heat speed.

HIGH

HEAT

SPEED

11− Disconnect power to unit. 12− Connect voltage source as shown above.

13− Turn on power to unit. Blower should operate at high heat speed.

J46J46

Page 87

Page 88

GHR32V−1 / −3 UNITS OPERATION SEQUENCE AND JUMPERS SUMMARY WITH VSP2−1 (HEATING)

MATCH UP COMMENTS OR SEQUENCE

Single-Stage Heating

with Single−Stage

Thermostat

Blower operates on the high

speed heat tap during the

heating mode.

Two-Stage Heating

With Single−Stage

Thermostat

Jumpers

Blower operates on the low

speed heat/cool tap during the

first stage of heating. Blower

operates on the high speed

heat tap during second stage

heating.

Harmony Heating No

Jumpers

Blower operates on PWM

signal generated by Har-

mony. Harmony overrides blower speed taps. Blower

speed varies according to

zone demand.

TABLE 35

FOR COOLING JUMPERS

SEE COOLING SECTION

BELOW

T−Strip Jumper

Mode of

Operation

Jumpers

One−Stage

W2 Timed

Two−Stage

Remove pin #3 of the J73

plug on the VSP control.

See fig. 16. Insulate end to

prevent it from shorting.

Low and high fire controlled by temperature modulating switch.

(continued on following page)

Jumper

Page 89

MATCH UP COMMENTS OR SEQUENCE

GHR32V−1 / −3 UNITS OPERATION SEQUENCE AND JUMPERS SUMMARY WITH VSP2−1 (COOLING)

Two-Speed Compressor,

no CCB1, no Harmony

Blower operates on low

speed heat/cool tap when

compressor is in first stage cooling. Blower operates on high speed cool

tap when compressor is in

second stage cooling.

DS" to Y2"

Single-Speed Com-

pressor, no CCB1,

no Harmony

Blower operates on high speed

cool tap during cooling.

(continued on following page)

FOR HEATING JUMPERS

SEE HEATING SECTION

ABOVE

GHR32V−1 / −3 UNITS OPERATION SEQUENCE AND JUMPERS SUMMARY WITH VSP2−1 (HEATING CONTINUED)

Two−Stage Heating

With Two−Stage

Thermostat

Jumpers

Two−Stage Blower operates on the low

speed heat/cool tap during first

stage heating. Blower operates

on high speed heat tap during

second stage heating.

MATCH UP

COMMENTS OR SEQUENCE

T−STRIP JUMPER

T−Strip Jumper

Mode of Operation

DS to Y1"

Move factory

wired jumper from

Y1 to Y2".

(continued from previous page)

(factory wired)

Jumper

Remove Jumper

DS to Y1"

Blower operates on low speed

heat/cool during cooling

Page 90

MATCH UP COMMENTS OR SEQUENCE

GHR32V−1 / −3UNITS OPERATION SEQUENCE AND JUMPERS SUMMARY WITH VSP2−1 (COOLING CONTINUED)

CCB1 with Two-Speed

Compressor, no Harmony

Blower speed is controlled by

the DC signal from CCB1. Blower operates on low speed heat/cool tap during dehumidi-

fication. Otherwise, blower op-

erates on high speed cool tap during high speed compressor operation and low speed heat/

cool tap during low speed

compressor operation.

FOR HEATING JUMPERS

SEE HEATING SECTION

ABOVE

CCB1 with Single-Speed

Compressor, no Harmony

Blower speed is controlled by

the DC signal from CCB1.

Blower operates on low speed heat/cool tap during dehumidification. Otherwise, blower oper-

ates on high speed cool tap

during cooling cycle.

No Jumpers

(Remove jumper

from Y1 to DS")

T−STRIP JUMPER

No Jumpers

(Remove jumper

from Y1 to DS")

(continued from previous page)

(continued on following page)

Page 91

MATCH UP COMMENTS OR SEQUENCE WIRING CONNECTIONS

GHR32V−1 / −3 UNITS OPERATION SEQUENCE AND JUMPERS SUMMARY WITH VSP2−1 (COOLING CONTINUED)

Harmony and Two-

Speed Compressor

Harmony and Single-

Speed Compressor

No Jumpers

(Remove

jumper from

Y1 to DS").

Remove pin #3 of the J73

terminal on the VSP con-

trol. Insulate end to pre-

vent shorting. Blower oper-

ates on PWM signal gener-

ated by Harmony. Harmony

overrides blower speed

taps. Blower speed varies

according to zone demand.

(continued from previous page)

FOR HEATING JUMPERS

SEE SEE HEATING SECTION

ABOVE

T−STRIP JUMPER

No Jumpers

(Remove

jumper from

Y1 to DS").

Remove pin #3 of the J73

terminal on the VSP con-

trol. Insulate end to pre-

vent shorting. Blower oper-

ates on PWM signal gener-

ated by Harmony. Harmony

overrides blower speed

taps. Blower speed varies

according to zone demand.

Page 92

GHR32V−4 OPERATION SEQUENCE AND JUMPERS SUMMARY WITH VSP3−1 (HEATING)

MATCH UP

COMMENTS OR SEQUENCE

Single-Stage Heating

with Single−Stage

Thermostat

Blower operates on

high speed during the

heating mode.

Two-Stage Heating

With Single−Stage

Thermostat

Jumpers

Blower operates on low

speed during the first stage

of heating. Blower operates

on high speed during

second−stage heating.

Harmony Heating No

Jumpers

Blower operates on PWM signal

generated by Harmony. Harmo-

ny overrides blower speed taps.

Blower speed varies according

to zone demand.

TABLE 36

WIRING CONNECTIONS

FOR COOLING JUMPERS

SEE COOLING SECTION

BELOW

T−Strip Jumper

Mode of

Operation

Jumpers

One−Stage

W2 Timed

Two−Stage

Remove pin #3 of the J73 plug on

the VSP control, and pins #2 and 13 of the J49 plug at the

motor. See fig 19 and 39. Insulate

ends to prevent them from shorting.

Low and high fire controlled by

temperature modulating switch.

(continued on following page)

Jumper

TEMPERATURE

SWITCH

MODULATING

Page 93

MATCH UP

COMMENTS OR SEQUENCE

WIRING CONNECTIONS

GHR32V−4 OPERATION SEQUENCE AND JUMPERS SUMMARY WITH VSP3−1 (COOLING)

Two-Speed Compressor,

no CCB1, no Harmony

Blower operates on low speed

cool when compressor is in

first stage cooling.

Blower operates on high

speed cool when compressor

is in second stage cooling.

DS to Y1

and

O to R

Remove factory−wired

jumper Y1 to Y2.

Single-Speed Com-

pressor, no CCB1,

no Harmony

Blower operates on high speed

during cooling.

(continued on following page)

FOR HEATING JUMPERS

SEE HEATING SECTION

ABOVE

GHR32V−4 OPERATION SEQUENCE AND JUMPERS SUMMARY WITH VSP3−1 (HEATING CONTINUED)

MATCH UP

COMMENTS OR SEQUENCE

WIRING CONNECTIONS

T−STRIP JUMPER

T−Strip Jumper

Mode of Operation

DS to Y1

and Y1 to Y2

and O to R

(continued from previous page)

(factory wired)

Jumper

Two−Stage Heating

With Two−Stage

Thermostat

Jumpers

Two−Stage

Blower operates on low speed during first stage

heating. Blower operates on

high speed during second

stage heating.

Blower operates on low speed

during cooling.

Remove jumper

DS to Y1

Page 94

MATCH UP COMMENTS OR SEQUENCE

WIRING CONNECTIONS

GHR32V−4 OPERATION SEQUENCE AND JUMPERS SUMMARY WITH VSP3−1 (COOLING CONTINUED)

CCB1 with Two-Speed

Compressor, no Harmony

See table 9.

FOR HEATING JUMPERS

SEE HEATING SECTION

ABOVE

CCB1 with Single-Speed

Compressor, no Harmony

Blower speed is controlled

by the DC signal from

CCB1. Blower operates on

low speed during

dehumidification.

Otherwise, blower operates

on high speed during

cooling cycle.

Y1 to Y2

and

O to R

Remove the

factory−wired

jumper

Y1 to DS.

T−STRIP JUMPER

O to R

Remove jumper

from Y1 to DS

and

Y1 to Y2.

(continued from previous page)

(continued on following page)

Y 1

Page 95

MATCH UP COMMENTS OR SEQUENCE

WIRING

GHR32V−4 OPERATION SEQUENCE AND JUMPERS SUMMARY WITH VSP3−1 (COOLING CONTINUED)

Harmony and

Two-Speed Compressor

Y1 to Y2

and

O to R

(Remove

jumper from

Y1 to DS.)

Remove the wire from Pin #2 and

Pin #13 of the J49 harness connec-

tor at the motor and the wire from

Pin #3 of the J73 harness connec-

tor on the VSP control board.

Insulate the wire ends and secure

them to prevent shorting. Blower operates on PWM signal generated by the Harmony control board con-

trol board. The Harmony control

board overrides blower speed taps.

Blower speed varies according to

the zone’s demand.

(continued from previous page)

FOR HEATING JUMPERS

SEE SEE HEATING SECTION

ABOVE

T−STRIP JUMPER

O to R

(Remove jumper

from Y1 to DS

and Y1 to Y2.)

Remove the wire from Pin #2 and Pin

#13 of the J49 harness connector at

the motor and the wire from Pin #3 of

the J73 harness connector on the

VSP control board.

Insulate the wire ends and secure

them to prevent shorting. Blower op-

erates on PWM signal generated by

the Harmony control board.

The Harmony control board overrides

blower speed taps. Blower speed

varies according to zone’s demand.

CONNECTIONS

Harmony and

Single-Speed

Compressor

Page 96

Thermostat

1 Heat / 1 Cool

NOTE − Use dip switch 3 to set second−stage heat ON delay. ON−10 minutes. OFF−15 minutes.

Table 37

GHR32V−5 Units Field Wiring Applications

Jumper Settings (See figure 21)

E20

Term. Strip

Y1 to Y2

W914 W951

SINGLE Ye s Intact Intact

Wiring Connections

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

1 Heat / 1 Cool with CCB1

NOTE − Use dip switch 3 to set second−stage heat ON delay. ON−10 minutes. OFF−15 minutes.

SINGLE Ye s Cut Intact

T’STAT

CCB1

CONTROL

TERM. STRIP

OUTDOOR

UNIT

Page 96

Page 97

Thermostat

1 Heat / 2 Cool

NOTE − Use dip switch 3 to set second−stage heat ON delay. ON−10 minutes. OFF−15 minutes.

Table 37

GHR32V−5 Units Field Wiring Applications (Continued)

Jumper Settings (See figure 21)

E20

Term. Strip

Y1 to Y2

W914 W951

SINGLE No Intact Intact

Wiring Connections

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

1 Heat / 2 Cool

SINGLE No Cut Intact

with CCB1

NOTE − Use dip switch 3 to set second−stage heat ON delay. ON−10 minutes. OFF−15 minutes.

2 Heat / 2 Cool TWO No Intact Intact

T’STAT

CCB1

CONTROL

TERM. STRIP

CONTROL

TERM. STRIP

OUTDOOR

UNIT

OUTDOOR

UNIT

2 Heat / 2 Cool

TWO No Cut Intact

with CCB1

Page 97

T’STAT

CCB1

CONTROL

TERM. STRIP

OUTDOOR

UNIT

Page 98

Table 37

GHR32V−5 Units Field Wiring Applications (Continued)

Jumper Settings (See figure 21)

Thermostat

E20

Term. Strip

Y1 to Y2

W914 W951

2 Heat / 1 Cool TWO Yes Intact Intact

Wiring Connections

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

FM21 Heat Pump / 1 Cool

Harmony Application* 2 Heat / 1 Cool

SINGLE Ye s Intact Cut

TWO Yes Cut Intact

*Disconnect existing furnace transformer and replace with 75VA, 24V transformer if defrost option to be used.

75VA, 24V

TRANSFORMER*

NOTE − Wiring connections to outdoor unit and thermostat made at FM21 control board per FM21 instructions.

TEMP.

MOD.

SWITCH

FAN LO

FAN LINE

HARMONY

CONTROL

TERM. STRIP

CONTROL

TERM. STRIP

FM21

NOTE − Remove Y1/Y2 jumper for two−stage cooling.

OUT-

DOOR

UNIT

Harmony

TWO No Cut Intact Application* 2 Heat / 2 Cool

*Cut wires at pin positions 2 and 13 of J/P46. Insulate ends to prevent a short. Blower operates on PWM signal generated by Harmony. Harmony overrides blower speed taps. Blower speed varies according to zone demand. Low and high−fire controlled by temperature modulating switch.

Page 98

TEMP.

MOD.

SWITCH

FAN LO

FAN LINE

HARMONY

CONTROL

TERM. STRIP

OUT-

DOOR

UNIT

Page 99

SERVICE NOTES

Page 99

Lennox GHR32Q, GHR32V Unit Information

Specifications and Main Features

Frequently Asked Questions

User Manual