Lennox International Inc Furnace G21 V SERIES User Manual

PRODUCT LITERATURE  
1996 Lennox Industries Inc.  
Dallas, Texas  
503,072M  
8/99  
Supersedes 6/96  
G21Q & V  
SERIES  
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  
flammable 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.  
D Immediately call your gas supplier from a  
neighbor's phone. Follow the gas suppliĆ  
er's instructions.  
Installation and service must be perĆ  
formed by a qualified installer, serĆ  
vice agency or the gas supplier.  
D If you cannot reach your gas supplier, call  
the fire department.  
E1994 Lennox Industries Inc.  
 
Use only your hand to push in or move the gas control  
lever or switch. Never use tools. If the lever or switch  
will not push in or move by hand, do not try to repair it,  
call a qualified service technician. Force or attempted  
repair may result in a fire or explosion.  
gas appliances. Reliable detectors are available at reaĆ  
sonable retail prices.  
Contact your independent Lennox dealer for more details  
about this investment in your safety.  
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 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.  
2. DO NOT obstruct air flow to unit. Unit must receive  
an unobstructed flow of combustion and ventilatĆ  
ing 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.  
Unit Operation  
4 - DO NOT draw the return air from a room where  
another gas appliance (ie., a water heater) is  
installed. Even though this furnace draws its comĆ  
bustion air from outside of the structure, other gas  
appliances that share a utility room may not. 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 distribĆ  
uted through the house by the furnace duct system.  
This appliance does not have a pilot. It is equipped  
with an ignition system which automatically lights  
the burner. Do not try to light by hand.  
A-Gas Valve Operation  
WARNING  
If you do not follow these instructions exactly, a fire  
or explosion may result causing property damage,  
personal injury or death.  
Gas Valve Operation for Robertshaw and White  
Rodgers Valves (Figures 2 and 4)  
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.  
ROBERTSHAW 7200 GAS VALVE  
GAS VALVE  
SELECTOR ARM  
IN OFF  
POSITION  
WARNING  
Carbon monoxide gas is invisible, odorless, and  
toxic  
WHITE RODGERS  
36E GAS VALVE  
Exposure to this gas can cause personal injury and even  
death to all occupants, including pets. Any item that is  
powered by or gives off heat from a combustion process  
(including lawn mowers, automobiles, and fireplaces) has  
the potential to produce carbon monoxide gas. Because  
of this, Lennox recommends the use of a carbon monĆ  
oxide detector in your home, even if you do not own  
GAS VALVE  
SHOWN  
IN OFF  
POSITION  
FIGURE 2  
Page 2  
 
6- Wait five (5) minutes to clear out any gas. Smell for  
gas, including near the floor. If you then smell gas,  
STOP! Immediately call your gas supplier from a  
neighbor's phone. Follow the gas supplier's instrucĆ  
tions. If you do not smell gas go to next step.  
THERMOSTATS  
7- On Robertshaw 7200 gas valve, depress lever on  
gas control and move to ON and release. For White  
Rodgers 36E gas valves, move switch to ON.  
8- Replace unit access panel.  
9- Turn on all electrical power to unit.  
10- Set thermostat to desired setting. See figure 3.  
FIGURE 3  
11- If the furnace will not operate, follow the instructions  
To Turn Off Gas To Unit" and call your service techniĆ  
cian or gas supplier.  
1- Set thermostat to lowest setting. See figure 3.  
2- Turn off all electrical power to furnace. See figure 5.  
3- This appliance Is equipped with an ignition device  
which automatically lights the burner. Do not try to  
light the burner by hand.  
B-To Turn Off Gas To Unit  
1- Set thermostat to lowest setting.  
2- Turn off all electrical power to unit if service is to be  
performed.  
4- Remove unit access panel.  
3- Remove heat section access panel.  
5- On Robertshaw 7200 gas valve, depress lever on  
gas control and move to OFF and release. For  
White Rodgers 36E gas valves, move switch to OFF.  
Do not force.  
4- On Robertshaw 7200 gas valve, depress lever on  
gas control and move to OFF and release. For White  
Rodgers 36E gas valves, move switch to OFF.  
5- Replace unit access panel.  
Page 3  
 
TABLE 1  
GAS PIPING  
MANUAL MAIN  
SHUT-OFF VALVE  
Filter Part  
No.  
G21 Model No.  
Filter Size  
AUTOMATIC  
GAS VALVE  
All Q-40,-60,  
Q3-80, Q4-80 and  
V3-60, -80 units  
16" x 25"  
(406 x 635mm)  
P-8-7822  
P-8-7831  
GROUND  
JOINT  
UNION  
Q5-80 and all  
Q-100 units: and  
V5-80,-100 units  
20" x 25"  
(508 x 635mm)  
5- Reinstall filter. Slide filter into top channel and drop  
into lower channel.  
DRIP LEG  
RIGHT SIDE PIPING  
IMPORTANT-Do not replace foam reusable filters  
with throw-away type filters.  
GAS CONNECTOR  
6- Replace blower access panel.  
FIGURE 4  
Lubrication  
Motors are prelubricated for extended bearing life; no  
further lubrication is required.  
Service  
At the beginning of each heating season, the system  
should be checked as follows:  
FOR UNIT TO  
OPERATE DISCONNECT  
SWITCH MUST  
BE IN ON" POSITION  
1- Examine the termination ends of the intake and exĆ  
haust lines for obstructions or blockages.  
2- Check the intake and exhaust lines for holes, sagĆ  
ging or broken isolation hangers. If a sag is found in  
either line, raise the line and support it with an isolaĆ  
tion hanger. Replace any damaged isolation hangĆ  
ers.  
TYPICAL  
FUSE/DISCONNECT  
SWITCH BOX MOUNTED  
ON FURNACE  
FIGURE 5  
3- The return air duct connection should be sealed to  
the furnace casing and terminate outside the space  
containing the furnace.  
Servicing the Filter  
Inspect and clean air filters each month. Filters must  
be cleaned when dirty to assure proper furnace opĆ  
eration and maintain efficiency.  
4- Check the physical support of the furnace. It should  
be sound without sagging, cracks, gaps, etc., around  
the base so as to provide a seal between the support  
and the base.  
A-Cleaning Reusable Foam Filter  
1- Turn off electrical power to furnace.  
5- Check that there is no obvious signs of deterioration  
of the furnace.  
2- Remove blower access panel. Wait for blower to stop.  
3- Remove filter by sliding up and out of channel.  
6- Inspect and clean condensate drain system for free  
flow of condensate.  
4- Wash filter with water and a mild detergent. For inĆ  
creased efficiency, filter media should be sprayed with  
Filter Handicoater when dry. Filter Handicoater is RP  
products No. 418 and is available as Lennox part No.  
P-8-5069. See table 1 for replacement filters.  
IMPORTANT-If a change in the sound level of the unit  
is detected or there is evidence of condensate leakĆ  
age around the unit, contact your Lennox service  
technician.  
Page 4  
 
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 the unit is inopĆ  
erative. Before calling, always check the following to  
be sure service is required:  
Planned Service  
1- Be sure electrical switches are ON.  
2- Check the room thermostat for proper setting.  
3- Replace any blown fuses or reset circuit breakers.  
4- Make sure gas valve is on.  
You should expect a service technician to check the following  
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- Blower access panel is in place.  
6- Air filter must be clean.  
Burners- Must be inspected for rust, dirt, or signs of water.  
Vent pipe - Must be inspected for dirt, signs of water, damĆ  
aged or sagging unsupported pipe, or disconnected joints.  
Unit appearance - Must be inspected for rust, dirt, signs of  
water, burnt or damaged wires, or components.  
Blower access door - Must be properly in place and provide  
a seal between the return air and the room where the furnace  
is installed.  
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  
airtight seal to the 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 opĆ  
eration to monitor proper performance of the unit and the  
vent system.  
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.  
Combustion gases - Flue products must be analyzed and  
compared to the unit specifications.  
Problems detected during the inspection may make it necesĆ  
sary 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 unsafe  
operation. For instance, items innocently stored next to the  
furnace may obstruct the combustion air supply. This could  
cause incomplete combustion and the production of carbon  
monoxide gas.  
Your vigilance may pay off in early detection of a problem  
Page 5  
 

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