Lennox International Inc Furnace G23 User Manual

PRODUCT LITERATURE  
W1996 Lennox Industries Inc.  
Dallas, Texas  
503,517M  
9/98  
G23  
SERIES  
Supersedes 8/96  
GAS FURNACE  
Litho U.S.A.  
WARNING  
If the information in this manual is not followed  
exactly, a fire or explosion may result causing  
property damage, personal injury or loss of  
life.  
WHAT TO DO IF YOU SMELL GAS:  
D Do not try to light any appliance.  
Do not store or use gasoline or other flamĆ  
mable vapors and liquids in the vicinity of  
this or any other appliance.  
D Extinguish any open flames.  
D Do not touch any electrical switch; do not use any  
phone in your building.  
Installation and service must be performed by  
a qualified installer, service agency or the gas  
supplier.  
D Immediately call your gas supplier from a neighbor's  
phone. Follow the gas supplier's instructions.  
D If you cannot reach your gas supplier, call the fire deĆ  
partment.  
 
CAUTION  
Before attempting to perform any service or mainteĆ  
nance, turn the electrical power to unit OFF at disĆ  
connect switch.  
WARNING  
Carbon monoxide gas is invisible, odorless, and  
toxic.  
Exposure to this gas can cause personal injury and even  
death to all occupants, including pets. Any item that is powĆ  
ered by or gives off heat from a combustion process (inĆ  
cluding lawn mowers, automobiles, and fireplaces) has the  
potential to produce carbon monoxide gas. Because of  
this, Lennox recommends the use of a carbon monoxĆ  
ide detector in your home, even if you do not own gas  
appliances. Reliable detectors are available at reasonĆ  
able retail prices. Contact your independent Lennox dealer  
for more details about this investment in your safety.  
WARNING  
Do not use this furnace if any part has been under  
water. Immediately call a qualified service techniĆ  
cian to inspect the furnace and to replace any part  
of the control system and any gas control which  
has been under water.  
Your furnace is designed to meet standards set by nationĆ  
al agencies, and to operate safely when properly installed  
and maintained. However, the unit's performance can be  
greatly impacted by the individual installation and the opĆ  
erating environment. It is your responsibility to ensure  
that this appliance is maintained. Proper maintenance is  
critical for your safety and the satisfactory operation of the  
product. Lennox strongly recommends annual inĆ  
spection and maintenance of this appliance. Contact  
your independent Lennox dealer for an inspection by a  
qualified service technician.  
IMPORTANT  
Any additions, changes, or conversions required in  
order for the appliance to satisfactorily meet the apĆ  
plication needs must be made by a Lennox service  
technician using factory specified and approved  
parts.  
Important Directions  
1- Keep the furnace area clear and free of combustible  
material, gasoline, and other flammable vapors and  
liquids. If installed in an insulated area, furnace must  
be kept free of insulating material. Insulating material  
may be combustible.  
Lighting Information & Operation  
2- DO NOT obstruct air flow to unit. Unit must receive an  
unobstructed flow of combustion and ventilating air.  
3- DO NOT store chlorine or fluorine products near unit  
or introduce these products into the combustion air.  
These products can cause furnace corrosion.  
WARNING  
If you do not follow these instructions exactly, a fire  
or explosion may result causing property damage,  
personal injury or loss of life.  
4- DO NOT draw return air from a room where this  
furnace, or any other gas appliance (ie., a water  
heater), is installed. When return air is drawn from a  
room, a negative pressure is created in the room. If a  
gas appliance is operating in a room with negative  
pressure, the flue products can be pulled back down  
the vent pipe and into the room. This reverse flow of  
the flue gas may result in incomplete combustion and  
the formation of carbon monoxide gas. This toxic gas  
might then be distributed throughout the house by  
the furnace duct system.  
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 try to repair it, call a qualified service  
technician. Force or attempted repair may result in a fire  
or explosion.  
Your furnace is a gas appliance. It is critical that the gas  
supplied to the unit be completely burned to avoid the proĆ  
duction of carbon monoxide gas. Complete combustion  
of the gas requires, but is not limited to, correct gas presĆ  
sure and gas flow rate, adequate combustion, air, and  
proper venting.  
To place G23 furnace into operation:  
G23(X) units are equipped with a SureLight ignition  
system. Do not attempt to manually light burners on  
these furnaces. Each time thermostat calls for heat,  
the burners will be automatically lit. The ignitor does  
not get hot when there is no call for heat on units with  
SureLight ignition system.  
Page 3  
 
Gas Valve Operation (Figure 3)  
NOTE-When unit is first started, steps 1 through 11 may  
need to be repeated to purge air from line.  
1- STOP! Read the safety information at the beginning  
of this section.  
12- If the appliance still will not operate, follow the inĆ  
structions To Turn Off Gas To Unit" and call your serĆ  
vice technician or gas supplier.  
2- Set thermostat to lowest setting. See figure 2.  
THERMOSTATS  
Turning Off The Gas To The Unit  
1- Set thermostat to lowest setting.  
2- Turn off all electrical power to unit if service is to be  
performed.  
3- Remove upper access panel.  
4- On Honeywell VR8204 gas valves, turn knob on gas  
valve clockwise to OFF. For White Rodgers 36E  
gas valves, move switch to OFF. Do not force.  
FIGURE 2  
5- Replace upper access panel.  
3- Turn off all electrical power to appliance.  
4- This appliance is equipped with an ignition device  
which automatically lights the burners. Do not try to  
light the burners by hand.  
Filters  
A filter must be in place anytime the unit is in operation. The  
filter may be located in the unit (optional kit) or installed in a  
return air grille. Ask your dealer to show you the filter location.  
The filter should be inspected monthly and cleaned when  
necessary to assure proper furnace operation.  
5- Remove upper access panel.  
6- On Honeywell VR8204 gas valves, turn knob on gas  
valve clockwise  
to OFF. For White Rodgers 36E  
gas valves, move switch to OFF. Do not force the  
Filters used inside the G23 series unit are available from LenĆ  
nox and must be ordered separately. These foam filters may  
be cleaned for reuse. If replacement is necessary, order LenĆ  
nox part no. 31J81 for 14 X 25 inch filter for G23Q2-50,  
Q3-50 and Q2/3-75 units, P-8-7822 for 16 X 25 inch filter for  
G23Q3-100 units, and P-8-7831 for 20 X 25 inch filter for  
G23Q3/4-100, Q3/4-125, Q4/5-75, Q4/5-100, Q5/6-125 and  
Q5/6-150 units. Use the following procedure to clean filter.  
Refer to figure 1.  
switch. See figure 3.  
HONEYWELL VR8204 SERIES GAS VALVE  
ON  
In-Unit Filter with Bottom Return Air  
1- Turn off electric power to furnace.  
OFF  
GAS VALVE SHOWN IN OFF POSITION  
2- Remove blower access panel.  
3- Remove filter by pressing side filter clips and pulling filter  
up and out. See figure 4.  
WHITE RODGERS  
36E GAS VALVE  
BOTTOM RETURN FILTER INSTALLATION  
REAR FILTER CLIP  
GAS VALVE  
SHOWN  
IN OFF  
FURNACE  
BACK  
SIDE FILTER CLIPS (2)  
POSITION  
FIGURE 3  
RETURN AIR OPENING  
7- Wait fifteen (15) 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.  
FURNACE  
FURNACE  
FRONT  
BASE BOTĆ  
TOM  
FIGURE 4  
8- For Honeywell VR8204 gas valves, turn knob on gas  
4- Clean filter with cold water and a mild soap. Direct  
water through filter in the opposite direction of air  
flow. Remove all soap residue.  
valve counterclockwise  
to ON. For White RodgĆ  
ers 36E gas valves, move switch to ON. Do not force.  
9- Replace upper access panel.  
5- Allow filter to dry then spray with filter handicoater  
(P-8-5069), available from your Lennox dealer, prior  
to reinstallation.  
10- Turn on all electrical power to unit.  
11- Set thermostat to desired setting.  
Page 4  
 
6- Place filter in bottom of blower compartment beneath  
rear filter clip. Press down on filter sides. Filter clips  
flex allowing filter to snap into place.  
Seasonal Inspections  
A qualified service technician should inspect the comĆ  
plete system each season (heating and cooling). The folĆ  
lowing maintenance procedures should be conducted by  
a qualified service technician. Do not attempt to service  
the unit in any way.  
7- Replace blower access panel.  
WARNING  
Venting System  
Blower door must be securely in place when blower  
and burners are operating. Gas fumes, which could  
contain carbon monoxide, can be drawn into living  
space which could cause personal injury or death.  
Annually (before heating season) inspect furnace venting  
system, draft hood, vent cap, heat exchanger, and burners  
for corrosion, deterioration, or deposits of debris. Remove  
any obstructions.  
In-Unit Filter with Side Return Air (See Figure 5)  
1- Turn off electric power to furnace.  
Inspect furnace venting system to make sure it is in  
place, physically sound, and without holes, corrosion, or  
blockage. Vent connector must be in correct position,  
sloped upward and be physically sound without holes or  
excessive corrosion.  
2- Locate the filter door of the filter rack assembly.  
3- Using the filter door pins, pull filter door, with filter atĆ  
tached, out of filter rack assembly. Remove filter door  
from filter by pulling up on securing tabs.  
4- Clean filter with cold water and a mild soap. Direct waĆ  
ter through filter in the opposite direction of air flow. AlĆ  
low filter to dry then spray with filter handicoater, availĆ  
able from your Lennox dealer, prior to reinstallation.  
Inspect furnace return air duct connection to ensure duct is  
sealed to the furnace and terminates outside the space conĆ  
taining the furnace.  
Inspect the physical support of the furnace to guarantee that  
it is sound without sagging, cracks or gaps around base and  
it maintains seal between base and support.  
5- Position filter door on end of filter so that the thumb  
tab side of the filter door is away from the furnace.  
Check for correct air flow position. Squeeze thumb  
tabs to secure filter to door.  
During a seasonal check the service technician will inspect  
the indoor blower and the burner flames along with the ventĆ  
ing system.  
6- Guide filter and filter door into the filter rack  
installed on side of furnace. Push door into filter  
rack until secure.  
Blower  
REMOVING / REPLACING FILTER DOOR  
Check and clean blower wheel for any debris. Blower motor  
is pre-lubricated for extended bearing life. No further lubricaĆ  
tion is needed.  
FILTER DOOR  
PIN  
TAB  
Burner Flame  
Burner Flame  
Start burner and allow to operate for a few minutes to esĆ  
tablish normal burning conditions. Check burner flame by  
observation. Flame should be predominantly blue and  
strong in appearance.  
FILTER  
FILTER DOOR  
FILTER DOOR  
PIN  
CAUTION  
To ensure proper operation, a qualified technician  
should periodically check the burner flame.  
TAB  
FIGURE 5  
Page 5  
 
Your vigilance may pay off in early detection of a problem  
before either personal injury or property damage occurs.  
Do not hesitate to contact a qualified service technician as  
an investment in your well being.  
Service Reminder  
Call your Lennox service technician if unit is inoperative.  
Before calling, always check the following to be sure serĆ  
vice is required.  
Planned Service  
1- Check that electrical disconnect switches are ON.  
2- Check room thermostat for proper setting.  
3- Replace any blown fuses or reset circuit breakers.  
4- Gas valve should be ON.  
You should expect a service technician to check the folĆ  
lowing items during an annual inspection. Power to the  
unit must be shut off for the service technician's safety.  
Fresh air grilles and louvers (on the unit and in the room  
where the furnace is installed) - Must be open and unobĆ  
structed to provide combustion air.  
5- Air filter should not be plugged limiting air flow.  
6- Is gas turned on at meter?  
7- Is manual main shut-off valve open?  
Burners- Must be inspected for rust, dirt, or signs of water.  
Vent pipe - Must be inspected for signs of water, damĆ  
aged or sagging pipe, or disconnected joints.  
Unit appearance - Must be inspected for rust, dirt, signs  
of water, burnt or damaged wires, or components.  
Blower access door - Must be properly in place and proĆ  
vide a seal between the return air and the room where the  
furnace is installed.  
Safety Precautions  
If you discover any of the following, shut down your  
unit, and contact an independent Lennox dealer for  
an inspection by a qualified technician.  
D If you repeatedly hear any new or unfamiliar sounds  
while your unit is operating, there may be a problem.  
For example, poorly performing burners can produce  
unfamiliar noises.  
Return air duct - Must be properly attached and provide  
an air seal to unit.  
D If you smell any unusual odors, your unit may be operĆ  
ating improperly. For example, units can give off unfaĆ  
miliar odors if components are required to operate in  
abnormal conditions.  
Operating performance - Unit must be observed during  
operation to monitor proper performance of the unit and  
the vent system.  
Combustion gases - Flue products must be analyzed  
and compared to the unit specifications.  
D Look for visible signs of a malfunctioning unit. ExamĆ  
ples include unusual amounts of condensate on winĆ  
dows inside your house, visibly burnt components or  
unusual dirt or rust accumulations on the vent pipe or  
in the unit.  
Problems detected during the inspection may make it  
necessary to temporarily shut down the furnace until the  
items can be repaired or replaced.  
D If you experience headache, nausea, fatigue, or dizziĆ  
ness, the cause could be exposure to carbon monoxĆ  
ide gas. This is often misdiagnosed as the flu because  
symptoms are similar. If you suffer from flu-like sympĆ  
toms that are exaggerated at home, but seem to subĆ  
side while you are away from the house, exposure to  
carbon monoxide could be the cause.  
Pay attention to your furnace. Situations can arise beĆ  
tween annual furnace inspections that may result in unĆ  
safe operation. For instance, items innocently stored next  
to the furnace may obstruct the combustion air supply.  
This could cause incomplete combustion and the producĆ  
tion of carbon monoxide gas.  
Page 6  
 

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