GAS UNITS j _:_bic=lo.s
_ Techrlloal
KITS AND ACCESSORIES LithoU,S.A,
©1997 Lennox industries inc.
Datlas, Texas
503,770M
10/97
FURNACE TRANSITION KIT
INSTALLATION INSTRUCTIONS FOR FURNACE TRANSITION KIT CAT# 16L23
(LB-89657A), CAT# 16L24 (LB-89657B), AND CAT# 16L25 (LB-89658A),USED WHEN
CONVERTING FROM G14 UNITS TO G26 UNITS (UPFLOW)
Package 1of 1 contains:
1 - Supply airtransition
1 - External Filter rack (used with kit CAT# 16L23 and
16L24)
1 - Internal filter rack top piece (used with kit CAT#
16L25)
1 - Internal filter rack bottom piece (used with kit
CAT# 16L25)
1 - Filter rack door
1 - Roll of adhesive-backed foam tape (1/8" thick x
5/16" wide)
8- Insulation pins
8- Insulation washers
1 - 1/2" CPVC x 1/2"PVC bushing
2 - Wire ties (used with kit CAT# 16L25)
Check all components for shipping damage. Consult
last carrier immediately if damage is found.
Table 1 shows furnace transition kit usage. These kits
are used when replacing an existing G14 upflow
furnace with a G26 upflow furnace. It allows
installation of the G26 furnace without modification
of the existing supply and side return air plenums.
Bottom return air applications do not require the
provided filter rack,
TABLE 1
G14 installations with air conditionh_g - G14removal
may require raising of coil, or partially or fully
removing the coil. If coil needs to be removed, line
sets may need to be cut, which in turn requires system
pump-down or refrigerant recovery depending on
type of service valves provided on condensing unit or
ambient outdoor temperatures.
Refer to figure 1 for typical G14 installation.
A - G14 units without air conditioning
1 - Set the thermostat to the lowest setting,
2 - Disconnect electrical power to G14 unit,
3- Shut off gas to G14 unit.
4 - Disconnect supply air plenum at unit top.
5 - Remove control access panel,
6 - Cut combustion air intake pipe and exhaust pipe
in location(s) which will allow convenient
reconnection of pipes to G26 unit, and/or
removal of muffler(s) (if installed). Remove
muffler(s) (if installed), Support intake and
exhaust pipes to prevent damage to pipe joints,
7 - Cut condensate drain line in a location which will
allow convenient reconnection with G26 unit.
8 - Disconnect gas line at unit.
9 - Disconnect power wiring at unit.
10 -Disconnect low voltage wiring at unit.
11 -Remove blower access panel.
G14 CABINET WIDTH G26 CABINET WIDTH KIT CAT# (LB#)
inches (mm) inches (mm)
Q3-40 21-1/4 (540) Q2/Q3-50 16-1/4 (413) 16L23 (LB-89657A)
Q3-60 21-1/4 (540) Q3-50 or Q3-75 16-1/4 (413) 16L23 (LB-89657A)
Q4-60 21-1/4 (540) Q4/5-75 21-1/4 (540) 16L25 (LB-89658A)
Q3-80 21-1/4 (540) Q3-75 16-1/4 (413) 16L23 (LB-89657A)
Q4-80 21-1/4 (540) Q4/5-75 21-1/4 (540) 16L25 (LB-89658A
Q5-80 26-1/4 (667) Q4/5-75 21-1/4 (540) 16L24 (LB-89657B)
Q3-100 26-1/4 (667) Q3/4-100 21-1/4 (540) 16L24 (LB-89657B)
Q4/5-t00 26-1/4 (667) Q4/5-100 21-1/4 (540) 16L24 (LB-89657B)
Page 1
12- Removefilterfrominsideof unit(if present).
Units with side return air - Disconnect side
return air plenum at unit.
Units with bottom return air - Disconnect unit
base from return air plenum.
13 -Remove G14 unit,
B - 614 units with air conditioning
IMPORTANT
1 - Set the thermostat to the lowest setting.
2- Disconnect electrical power to G14 and
condensing unit.
3- Shut off gas to G14 unit.
4 - Remove control access panel.
5 - Cut and remove any section of intake pipe which
blocks access to air conditioning coil. Cut intake
and exhaust pipe at a location(s) which will
provide convenient reconnection of pipe(s) to
G26 unit and/or removal of muffler(s) (if
installed). Remove muffler(s) (if installed),
Support intake and exhaust pipe to prevent
damage to pipe joints.
6
Remove coil access panel.
7-
Disconnect coil cabinet/supply air plenum at G14
unit top. If coil/coil cabinet can be lifted enough
to provide vertical clearance for removal of G14
unit, support coil/coil cabinet at needed height
and go to step 11. Ifnot, prepare coil for removal.
8
If condensing unit has fully functional service
valves and outdoor ambient conditions permit
operating compressor, pump-down refrigerant
system; if not, recover refrigerant.
Cut line sets and coil drain line in a location which
will provide convenient reconnection. Move and
support to allow for coil removal,
10 -Slide coil from coil cabinet/supply air plenum.
11 - Cut G14 heat exchanger condensate drain line in
a location which wilt provide convenient
reconnection with G26 unit.
12 -Disconnect gas line at unit.
13 -Disconnect power wiring at unit.
14 -Disconnect low voltage wiring at unit.
15-Remove blower access panel.
16 -Remove filter from inside unit (if present)
Units with side return air - Disconnect side
return air plenum at unit.
Units with bottom return air - Disconnect unit
base from return air plenum,
Page 2
FLEXIBLE ISOLATION
HANGER
EXHAUST PIPE
TYPICAL G14 INSTALLATION
FLEXIBLE BOOT
/ SUPPLY AIR j ......
ii AIR
i
J ...... /_ _ RETURN
ii
f-f i i
ii j- ....
i" --- FLEXIBLE BOOT IN
RETURN AIR PLENUM
SUPPLY AIR PLENUM
INSULATED PAST FIRST ELBOW
FLEXIBLE BOOT IN PLENUM --
MUFFLER
CONDENSATE DRIP LEG
=
MANUAL
MAIN SHUT OFF
VALVE
GAS SUPPLY PIPING
CONTROL
ACCESS PANEL
............. 0
BLOWER RETURN AIR PLENUM
GP_ ELECTRICAL CONDUIT
RETURN AIR PLENUM
INSULATED PAST FIRST
ELBOW
FLEX BLE BOOT N
ISOLATION PADS (ISOMODE) (4) ._
Note - Installation must conform with these
instructions and the installation instructions
packaged with the G26 furnace.
Closet installations - G26 cabinet depth is 2-3/8"
(60.5ram) larger than G14. The G26 may be installed
one inch (25turn) closer to rear of closet (if space
permits) by rotating supply air transition 180 degrees
from that shown in figure 4 or5.
COMPARTMENT i
ACCESSFANEL !
FIGURE 1
A - Filter Rack Installation (Side Return Only)
Note - Filter rack is not used in bottom return air
applications.
I - External Filter Rack
(Used with kit CAT#16L23 and16L24)
1 - Lay G26 unit on its side and cut out return air
opening in cabinet. See figure 4.
2- Filter rack is shipped for right side installation
and for 16 inch (40.6 cm) filter size. If application
requires left side orientation, convert as shown in
figure 2. If application requires 20 inch (50.8 cm)
filter size convert as shown in figure 3.
Page 3
Note - It is recommended that rack be converted
to 20 inch filter size if filter is installed elsewhere
in return air duct.
3-In applications where rack uses a 16 inch
(50.8cm) filter, remove filler piece before cutting
rack opening. See figure 4.
4 - Cut four strips from rollofadhesive-backedfoam
tape (provided) to fit filter rack flanges, Apply to
flanges.
5 - Secure filter rack to cabinet as shown in figure 4.
6 - Cut opening in filter rack as shown in figure 4,
7 - In applications where rack uses a 16 inch (50,8cm)
filter, remove rack from cabinet, re-install filler
piece, then re-install rack to cabinet.
8-Install existing filter, unless filter is located
elsewhere in the return air duct,
9- Attach door to filter rack with thumb screws
provided.
II - Internal Filter Rack
(Used with kit CAT#16L25)
Note - If filter is not to be located inside of unit,
installation of this filter kit is not required.
1 - Lay G26 unit on its side and cut out return air
opening in cabinet at knockout guides, See G26
installation instructions.
2 - Install filter rack top and bottom inside unit as
shown in figure 5, tn right side installations
wiring must be carefully worked around.
3 - Install existing filter,
4 - Slide door into filter rack bottom seam and align
with filter rack top securing hole. Attach with
thumb screws provided.
5- Securewiring awayfrom filter access areawith two
provided wire ties. Use existing screws in existing
screw locations to prevent accidental damage to
control board(s)/wiring by drilling of new holes.
B - Supply Air Transition Installation
1 - Cut four strips from roll ofadhesive-backedfoam
tape (provided) to fit supply air transition flanges
at G26 unit connection. Apply to flanges. See
figure 4 or 5,
2- Position supply air transition on unit top as
shown in figure 4 or 5.
3- If required, internally insulate transition with
foil-faced insulation (field provided) and fasten
with kit provided insulation pins and washers,
4- Use four screws and/or bend cabinet flanges
over transition tips to secure transition.
C - Unit Installation
1 - Align unit with existing supply air plenum (coil
cabinet in air conditioning applications) and
return air plenum.
Note - If required, use existing G14 isomode pads
to achieve this alignment.
2 - Make connections to unit, In bottom return air
applications, follow the instructions provided
with the G26 unit, note especiallythe warnings in
the "Return Air Opening Guidelines" section.
3 - ff air conditioning coil was removed, re-install
coil, reconnect line set and coil drain. See
condensing unit installation instructions for
re-processing of refrigerant system.
Note - Coil drain line must not be connected to
heat exchanger condensate drain line. If lines
were connected, debris from evaporator could
affect heat exchanger operation.
4- Make tow voltage wiring entrance to unit on
opposite side from return air connection to
prevent blocking filter access. Connect as
illustrated in G26 installation instructions.
5 - Connect high voltage wiring as outlined in G26
installation instructions,
6- Connect gas piping as outlined in G26
installation instructions.
Consult local codes for flexible connector
installation restrictions on G26 furnace.
7 - Connect venting as outlined in G26 installation
instructions.
Note - Mufflers can not be used in G26
installation. Check existing venting for size
(diameter and length). It should meet the
specifications as outlined in G26 installation
instructions.
8 - Connect heat exchanger condensate drain line as
shown in figure 6 and as outlined in G26 unit
installation instructions, (A 1/2" PVCto 1/2" CPVC
bushing is provided for connecting PVC to
existing CPVC condensate line,)
9 - Continue with Unit Start-up Section as outlined
in G26 installation instructions.
Note - See G26 installation instructions for heat
anticipation settings.
Page 4
EXTERNAL FILTER RACK CONVERSION KIT CAT# 16L23 AND 16L24)
FILLER PIECE_ ... --_
FRAME
HOLDING ANGLE _ -_.
SECURING SCREW
16 INCH (40.6 CM)_ I
BOTTOM HOLDING ANGLE _
From Right S de to Left S de Conf gurat on
A= C
........
I
f
Right side configuration I_ Intermediate step
To convert to left side configuration:
1 - Remove screws securing filler piece to frame. See detail A.
2 - Flip filler piece 180 degrees and secure to bottom of frame. See detail B.
3 - Remove bottom holding angle, flip 180 degrees and secure to top of frame. See detail B.
4 - Flip frame 180 degrees to give orientation as in detail C.
EXTERNAL FILTER RACK CONVERSION (KIT CAT# 16L23 AND 16L24)
SECURING
SCREW _--_-_____ =
FRAME
FILLER PIECE --
HOLDING
ANGLE
From 16 inch (40.6 cm) Filter Size to 20 inch (50.8 cm)
E_> Left side configuration
FIGURE 2
LeftSide Orientation Shown
NOTE - THIS CONVERSIONISALSO RECOMMENDED IF
__ FILTERIS NOT INSTALLED IN RACK, BUT IS LOCATED
ELSEWHEREIN RETURNAIR DUCT.
TO convert from 16 inch (40.6 cm)
to 20 inch (50.8 cm) filter size:
1 - Remove screws securing filler piece to frame.
2 - Remove holding angle from filler piece. Discard filler piece.
16 INCH
(40.6 CM)
FILTER
_. 3- Re-secure ho d ng ang e to top of frame.
20 INCH (50.8 CM)
FILTER
FIGURE 3
Page 5
ADHESIVE-BACKED
FOAMTAPE
INSTALLATION OF SUPPLY AIR TRANSITION
AND EXTERNAL FILTER RACK (KIT CAT# 161.23 AND 16L24)
_ SUPPLY AIR TRANSITION
SECURING SCREWS
(2 each side)
SUPPLY AIR TRANSITION
SMALL END OF TRANSITION
INSTALL LARGE END OF TRANSITION
TO FRONT OF UNIT.
(If unit in installed one inch further
to the rear rotate transition 180 degrees.)
CUT OPENING IN CABINET USING
CABINET KNOCKOUT GUIDES
KED
FOAM TAPE
EXISTING BLOWER
DECK SCREWS (3)
ii
FILTER RACK
FILTER RACK DOOR
THUMB SCREW -_. _;_
CUT OPENING IN FILTER RACK AS FOLLOWS:
Note - In 16 inch (40.6 cm) filter applications, remove filler piece before cutting opening.
1 - Measure horizontally from rear of G14 to existing return air opening to give dimension "A'.
Mark vertical bend line. (If supply air transition was rotated 180 degrees add one inch.)
2 - Measure vertically from floor to existing G14 return air opening to give dimension "B"
Mark horizontal bend line.
3 - Transfer remaining two sides from G14 to G26 and mark.
4- Add 1/2" to these lines and mark cut lines.
5 - Cut out opening and bend flanges out toward return air plenum.
B
EXISTING BASE
SCREWS (3)
FIGURE 4
Page 6
INSTALLATION OF SUPPLY AIR TRANSITION AND INTERNAL FILTER RACK
SUPPLY AIR TRANSITION (KIT CAT# 16L25)
SECURING SCREWS NOTE - FILTERRACK INSTALLATION REQUIRED
(2 each side) ,_
ADHESIVE-BACKED
FOAM TAPE
T
SUPPLY AIR TRANSITION
ONLYIF FILTERWILL BE INSTALLED INSIDE OF UNIT
CABINET SIDE
;MALL END OF TRANSITION
BLOWER DECK
\
"D" HOLES (Left side
installation holes)
"C" HOLES (Right side
installation holes
FILTER RACK TOP
;TALL LARGE END
OF TRANSITION TO
FRONT OF UNIT.
(If unit in installed one inch
further to the rear, rotate
transition 180 degrees.)
INSTALL FILTER RACK TOP AS FOLLOWS:
(Right side installation shown)
1 - Loosen blower deck screws. Remove center two.
2 - Cut away any interfering insulation at A.
3 - Slide filter rack top between blower deck and cabinet and
push back to align "C" holes (right side installation holes).
(For left side installation flip bracket and use "D'holes.)
4 -Secure with existing screws.
5 - Fasten filter rack top with two additional self-drilling self
tapping screws at B approximately one inch from edge. See
view A.
6 - Re-tighten remaining blower deck screws.
EXISTING BLOWER
DECK SCREWS
EXISTING BASE SCREWS
FILTER RACK TOP
,I,I,IB }3
1 inch
(25 mm)
VIEW A
// CABINET SIDE
A
J
"_ FILTER RACK BOTTOM
"FILTER RACK DOOR
THUMB SCREW
"FILTER RACK BOTTOM
1
VIEW A CABINETBASE
INSTALL FILTER RACK BOTTOM AS FOLLOWS:
(Right side installation shown)
(Flip bracket for left side installation)
1 - Loosen base screws. Remove center two.
2 - Cut away any interfering insulation at A.
3 - Slide filter rack bottom between base and cabinet,
4 - Align center two holes and secure with existing screws.
5 - Re-tighten remaining base screws.
FIGURE 5
Page 7
1/2 INCH CPVC
G26 CONDENSATE ASSEMBLY
(Forleft or right installation - left shown)
HEAT EXCHANGER COIL
COMBUSTION AIR
BLOWER BRACKET _ //
COLD
HEADER
BOX
VENT TERMINATION
MUST BE
HIGHER THAN COIL
i i
Y
LEFT SIDE OF CABINET
PLUG PROVIDED WITH G26
CONDENSATE TRAP
1/2"PVC X 1/2"MPT ADAPTER PROVIDED WITH G26
1/2" PVC X 1/2" CPVC BUSHING (KIT PROVIDED)
(Bushing fits in one direction only. One end fits inside of 1/2 PVC
adapter or coupling while 1/2 CPVC fits inside the other.)
Note - Bushing may be installed further downstream with a
1/2 inch coupling instead of with 1/2 inch adapter (shown).
NOTE - USE ADHESIVE SUITABLE FOR CPVC AND
PVC WHEN JOINING THESE TWO MATERIALS
FIGURE 6
Page 8
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