Lennox G24M2-45 Installation Instructions Manual Download Page 28

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Page 28

Repair Parts List

The following repair parts are available through independent Lennox dealers. When ordering parts, include the complete furnace model number listed on the

A.G.A. or C.G.A. rating plate Example: G24M3-75. Refer to page 3 for parts identification.

CABINET PARTS

BLOWER PARTS

NOx turbulator (60 Hz. X units only)

Front access panel

Blower wheel

Hot Surface Ignitor

Blower access panel

Motor

Flame rollout switch (two)

Cabinet cap

Blower housing cut-off plate

Flame sensor

Cabinet bottom

Motor capacitor

Primary limit

Vent adapter

HEATING PARTS

Secondary limit (two)

ELECTRICAL PARTS

Heat exchanger

Pressure switch

Transformer

Main burners

Wire harness plug / cap

Control board (Hot Surface Ignition)

Main burner orifices

Flue box

Door interlock switch

Gas manifold/Burner box assembly

Combustion air blower

Gas valve

Gaskets

Low gas pressure switch (propane only)

Ignition Control Board Diagnostic Codes

DIAGNOSTIC CODES

LED #1

LED #2

DESCRIPTION

SLOW FLASH

SIMULTANEOUS

SLOW FLASH

FAST FLASH

ON
ON

OFF

SLOW FLASH

FAST FLASH

Primary or secondary limit switch open.

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

Flame sensed without gas valve energized.

Pressure switch open or has opened 5 times during a single call for heat;

OR: Blocked inlet/exhaust vent; OR: Condensate line blocked;

OR: Pressure switch closed prior to activation of combustion air blower.

Power on -- Normal operation.

Also signaled during cooling and continuous fan.

Main power polarity reversed. Switch line and neutral.
Low flame signal. Measures below .7 microAmps. Replace flame sense rod.

Circuit board failure or control wired incorrectly.

Watchguard -- burners failed to ignite.

SIMULTANEOUS

SLOW FLASH

SIMULTANEOUS

FAST FLASH

SIMULTANEOUS

FAST FLASH

Normal operation - signaled when heating demand initiated at

thermostat.

ALTERNATING

SLOW FLASH

ALTERNATING

SLOW FLASH

OFF

ALTERNATING

FAST FLASH

ALTERNATING

FAST FLASH

Improper main ground or line voltage below 75 volts;

OR: Broken ignitor; OR: Open ignitor circuit.

NOTE - Slow flash equals 1 Hz (one flash per second). Fast flash equals 3 Hz (three flashes per second).

Minimum flame sense current = 0.15 microAmps.

Summary of Contents for G24M2-45

Page 1: ...ion Control Board Diagnostic Codes 28 Troubleshooting 29 G24M Start up Performance Check List 32 WHAT TO DO IF YOU SMELL GAS If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or death WARNING Do not store or use gasoline or oth er flammable vapors and liquids in the vicinity of this or any other ap pliance Installation ...

Page 2: ...95 19 1 2 495 15 381 1 25 1 25 1 25 1 25 3 4 19 NOTE The return air opening is equipped with a 3 4 inch 19 mm scored flange that may be bent 90 for plenum connection The dimensions shown were taken after the flange was bent The double scored flange at the front of the supply air open ing may be bent for a total opening dimension front to rear of either 19 1 2 inches 495 mm or 19 inches 483 mm Mode...

Page 3: ...nal items may be ordered separately if required 1 Thermostat 1 External filter rack kit 1 Hanging bracket kit 1 Propane LP changeover kit Check equipment for shipping damage If you find any damage immediately contact the last carrier Requirements Lennox G24M units are American Gas Association AGA and Canadian Gas Association CGA certified In the USA installation of Lennox gas central furnaces must...

Page 4: ...onal Electric Code ANSI NFPA No 70 The National Electric Code ANSI NFPA No 70 is available from the following ad dress National Fire Protection Association 1 Battery March Park Quincy MA 02269 In Canada all electrical wiring and grounding for the unit must be installed according to the current regulations of the Canadian Electrical Code Part I CSA Standard C22 1 and or local codes Field wiring con...

Page 5: ...ilation air requirements as well as all local codes WARNING Product contains fiberglass wool Disturbing the insulation in this product during installation maintenance or repair will expose you to fiberglass wool Breathing this may cause lung cancer Fiberglass wool is known to the State of California to cause cancer Fiberglass wool may also cause respiratory skin and eye irritation To reduce exposu...

Page 6: ...ut rat ing of all gas fired equipment in the confined space Each opening must be at least 100 square inches 64516 mm2 One opening shall be within 12 inches 305 mm of the top of the enclosure and one opening within 12 inches 305 mm of the bottom See figure 1 Air from Outside If air from outside is brought in for combustion and ventilation the confined space must have two permanent openings One open...

Page 7: ...e square inch 645 mm2 per 4 000 Btu 1 17 kW per hour of the total input rating of all equip ment in the enclosure CHIMNEY OR GAS VENT WATER HEATER OUTLET AIR VENTILATION LOUVERS Each end of attic INLET AIR Ends 12 above bottom G24M FURNACE FIGURE 3 EQUIPMENT IN CONFINED SPACE ALL AIR FROM OUTSIDE OUTLET AIR INLET AIR WATER HEATER CHIMNEY OR GAS VENT NOTE Each air duct opening shall have a free are...

Page 8: ...or either side of the furnace If a furnace with bottom return air is installed on a platform make an airtight seal between the bottom of the furnace and the platform to ensure proper and safe operation Knockouts are provided on both sides of the furnace cabi net for installations with side return air When side return air is used seal the bottom of the furnace using the panel pro vided An upflow fi...

Page 9: ... 25mm FRONT 2 51mm 2 51mm BACK 0 0 SIDES 0 0 VENT 6 152mm 1 25mm TOP BOTTOM RIGHT SIDE LEFT SIDE NC Non combustible floor Front clearance in alcove installation must be a min of 24 610mm for front service access With additive base on combustible floor FLOOR NC NC 60 Hz only FIGURE 7 A separate downflow filter kit is available for use in down flow applications A Installation on Non Combustible Floo...

Page 10: ... minimum of 24 in 610 mm for front service access For installations on a combustible floor do not install the furnace directly on carpeting tile or other combus tible materials other than wood flooring FIGURE 9 Allow for clearances to combustible materials as indicated on the unit rating plate Minimum clearances for closet or alcove installations are shown in figure 9 Furnaces may be installed in ...

Page 11: ...t System Use industry approved standards to size and install the supply and return air duct system This will result in a quiet and low static system that has uniform air distribution Supply Air Plenum Furnaces installed without a cooling coil require the installa tion of a removable access panel in the supply air duct The access panel should be large enough to permit inspection ei ther by smoke or...

Page 12: ...ur naces must be either tile lined or lined with a listed metal lining system or dedicated gas vent Unlined masonry chimneys are prohibited See figures 15 and 16 for com mon venting A Category I appliance must never be connected to a chim ney that is servicing a solid fuel appliance If a fireplace chimney flue is used to vent this appliance the fireplace opening must be permanently sealed A fan as...

Page 13: ...ided venting tables or lined with listed metal lining system PERMANENTLY SEALED FIREPLACE OPENING VENT CONNECTOR SEE NOTE 1 BELOW Note 1 Either single walled or double walled vent connector may be used Refer to the capacity requirements as shown in the pro vided venting tables for installations in USA and the venting tables in current CAN CGA B149 1 for installations in Canada NOTE Refer to provid...

Page 14: ...d the appliance See local and national installation codes for support intervals and methods National installation code in the USA is current edition of Na tional fuel Gas Code ANSI Z223 1 National installa tion codes in Canada are current editions of CAN CGA B149 codes 11 Vent connectors shall be firmly attached to furnace flue collars by screws or other approved means ex cept vent connectors of l...

Page 15: ... 226 22 339 15 5 22 65 30 130 39 219 49 330 5 10 29 59 40 121 51 206 64 315 15 35 53 48 112 61 195 76 301 0 0 97 0 202 0 349 0 540 2 10 75 14 149 18 250 20 377 20 5 21 71 29 143 38 242 47 367 20 10 28 64 38 133 50 229 62 351 15 34 58 46 124 59 217 73 337 20 48 52 55 116 69 206 84 322 0 0 100 0 213 0 374 0 587 2 9 81 13 166 14 283 18 432 5 21 77 28 160 36 275 45 421 30 10 27 70 37 150 48 262 59 405...

Page 16: ...6 80 225 115 337 15 5 51 63 75 128 102 216 144 326 5 10 NR NR 95 116 128 201 182 308 15 NR NR NR NR 158 186 220 290 0 35 96 54 200 78 346 114 537 2 37 74 56 148 78 248 113 375 20 5 50 68 73 140 100 239 141 363 20 10 NR NR 93 129 125 223 177 344 15 NR NR NR NR 155 208 216 325 20 NR NR NR NR 186 192 254 306 0 34 99 53 211 76 372 110 584 2 37 80 55 164 76 281 109 429 5 49 74 72 157 98 271 136 417 30 ...

Page 17: ...6 69 220 1 21 50 33 89 47 142 64 220 15 2 22 53 35 96 49 153 66 235 5 3 24 55 36 102 51 163 68 248 1 21 54 33 99 46 157 62 246 20 2 22 57 34 105 48 167 64 259 0 3 23 60 35 110 50 176 66 271 1 20 62 31 113 45 181 60 288 30 2 21 64 33 118 47 190 62 299 30 3 22 66 34 123 48 198 64 309 TABLE 7 COMMON VENT CAPACITY TYPE B DOUBLE WALL VENTS WITH TYPE B DOUBLE WALL CONNECTORS SERVING TWO OR MORE CATEGORY...

Page 18: ...tem commonly run with separate gas ap pliances the venting system is likely to be too large to properly vent the remaining attached appliances The fol lowing test should be conducted while each appliance in operation and the other appliances not in operation re main connected to the common venting system If the venting system has been installed improperly the system must be corrected as indicated ...

Page 19: ...s 4 feet 1 2 m for US installations Refer to the current CAN CGA B149 1 and B149 2 for installations in Canada or with authorities having local ju risdiction At vent termination care must be taken to maintain pro tective coatings over building materials prolonged expo sure to exhaust condensate can destroy protective coat ings It is recommended that the exhaust outlet not be located within 6 feet ...

Page 20: ... 15800 447 39 12800 362 44 10900 308 64 9700 274 67 8800 249 18 8100 229 36 7500 212 37 7200 203 88 6700 189 72 NOTE Capacity given in cubic feet m3 of gas per hour and based on 0 60 specific gravity gas GROUND JOINT UNION AUTOMATIC GAS VALVE with manual shut off valve FIELD PROVIDED AND INSTALLED GROUND JOINT UNION Left Side Piping Standard Right Side Piping Alternate AUTOMATIC GAS VALVE with man...

Page 21: ...8 gauge wire or larg er for thermostat connections 7 Electrically ground the unit according to local codes or in the absence of local codes according to the current National Electric Code ANSI NFPA No 70 for the USA and current Canadian Electric Code part 1 CSA standard C22 1 for Canada NOTE The G24M furnace contains electronic com ponents that are polarity sensitive Make sure that the furnace is ...

Page 22: ...SED OR CIRCUIT BREAKER DISCONNECT 120V 1PH 60 HZ FIGURE 20 50A62 SureLight INTEGRATED CONTROL BOARD Silicon Nitride Ignition System TERMINAL DESIGNATIONS ACB COOL ACB HEAT PARK ACB LOW ACC TX HOT HTG ACC NEUTRALS 24VAC HOT 24VAC RTN FLAME SENSE Blower Cooling Speed Line Volt Blower Heating Speed Line Volt Alternate Blower Speeds Dead Continuous Low Speed Blower Accessory Terminal Line Volt 120VAC ...

Page 23: ...Page 23 G24M Schematic Wiring Diagram 120V 1PH 60HZ FIGURE 22 ...

Page 24: ...electrical power to the unit 4 This furnace is equipped with an ignition device which automatically lights the burners Do not try to light the burners by hand 5 Remove the access panel 6 White Rodgers 36E Gas Valve Switch gas valve le ver to OFF See figure 23 Honeywell VR8205 Gas Valve Turn knob on gas valve clockwise to OFF Do not force See figure 24 7 Wait five minutes to clear out any gas If yo...

Page 25: ...nd for different fuels TABLE 11 MANIFOLD ABSOLUTE PRESSURE OUTLET IN W C KPA Altitude feet m above sea level FUEL 0 2000 0 610 2000 4500 610 1372 4500 5500 1372 1676 5500 6500 1676 1981 6500 7500 1981 2286 3 5 NAT 3 5 0 87 3 5 0 87 3 4 0 85 3 3 0 82 3 2 0 80 NAT 3 5 0 87 3 5 0 87 3 4 0 85 3 3 0 82 3 2 0 80 LP 9 5 9 5 2 36 9 2 2 29 8 9 2 21 8 6 2 14 LP 9 5 2 36 9 5 2 36 9 2 2 29 8 9 2 21 8 6 2 14 N...

Page 26: ...rd will break and remake thermostat demand to the furnace and automatically reset the control to relight the furnace Flue And Chimney 1 Check flue pipe chimney and all connections for tight ness and to make sure there is no blockage 2 Check unit for proper draft 3 Is pressure switch closed Obstructed flue will cause unit to shut off at pressure switch Check flue and out let for blockages 4 Reset m...

Page 27: ...f each burner with a bottle brush as shown in figure 27 Cleaning Burners BOTTLE BRUSH BURNER FIGURE 27 6 Replace the burners and the burner retaining bracket Make sure the burners are properly seated in the slots on the tray The burner orifice must be aligned with the manifold 7 Reinstall the burner box top 8 Restore electrical power and gas supply to the furnace Follow lighting instructions on th...

Page 28: ...SH SLOW FLASH FAST FLASH ON ON OFF ON OFF ON SLOW FLASH SLOW FLASH SLOW FLASH FAST FLASH Primary or secondary limit switch open Rollout switch open OR 9 pin connector improperly attached Flame sensed without gas valve energized Pressure switch open or has opened 5 times during a single call for heat OR Blocked inlet exhaust vent OR Condensate line blocked OR Pressure switch closed prior to activat...

Page 29: ...BLOWER OFF INDOOR BLOWER OFF WITH DELAY LED 1 ON LED 2 SLOW FLASH SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES GAS VALVE OFF COMBUSTION AIR BLOWER ON INDOOR BLOWER ON HEATING SPEED LED 1 SLOW FLASH LED 2 OFF GAS VALVE OFF COMBUSTION AIR BLOWER OFF INDOOR BLOWER OFF WITH DELAY LED 1 OFF LED 2 SLOW FLASH Sequence holds until pressure switch closes or thermostat resets control YES NO IS THERE PROPER GR...

Page 30: ... IGNITION GAS VALVE OPENS IGNITOR ENERGIZED FOR 1 SECOND AFTER VALVE OPENS NO FLAME SENSED DURING THIS PERIOD GAS VALVE OFF COMBUSTION AIR BLOWER ON INDOOR BLOWER OFF HAS CONTROL FAILED TO SENSE FLAME FOR FIVE CONSECUTIVE TRIES DURING A SINGLE HEAT DEMAND NO YES YES NO 4 SECONDS YES NO FLAME SIGNAL ABOVE 0 7 MICROAMPS NO NO YES NO ROLLOUT SWITCH CLOSED GAS VALVE OFF COMBUSTION AIR BLOWER OFF INDOO...

Page 31: ...LOUT SWITCH CLOSED CHECK FOR MAIN BURNER FLAME SENSE IS MAIN BURNER FLAME OFF LED SLOW FLASH RATE REMAINS UNCHANGED THROUGHOUT COOLING CYCLE THERMOSTAT CALLS FOR COOLING COMPRESSOR CONTACTOR AND SYSTEM FAN ENERGIZED WITH 0 SECOND DELAY ACB COOL SPEED ENERGIZED ACC TERM ENERGIZED COMPRESSOR OFF THERMOSTAT OPENS SYSTEM FAN AND ACC TERM OFF WITH 0 SECOND DELAY NO YES NO GAS VALVE OFF COMBUSTION AIR B...

Page 32: ... OFF ACC TERM OFF AFTER OFF DELAY COMPLETED NO YES YES NO HTGACC TERM ENERGIZES WITH COMB AIR BLOWER G24M Start up and Performance Check List START UP AND PERFORMANCE CHECK LIST Job Name Job Number Date Job Location City State Province Installer City State Province Unit Model Number Serial Number Service Technician HEATING SECTION Electrical Connections Tight Supply Voltage Blower Motor Amps Blowe...

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