Lennox G40DF?24A?045 Unit Information Download Page 8 | Manualshive

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Page 8

G40DF(X) PARTS ARRANGEMENT

FIGURE 1

Blower Assembly

Blower Motor

Capacitor

Internal Flue Pipe

Assembly

Flue Box Gasket

Flue Collector Box

Gasket

Combustion Air Inducer

Gasket

Manifold

Burner

Gas Valve

Flame Rollout

Switches

Flame

Sensor

Primary

Limit

Ignitor

Heat Exchanger

Ignitor

Bracket

Combustion Air

Pressure Switch

Combustion

Air Orifice

Gas

Orifices

Flue

Chase

Gasket

Limit Sheild with

−3 Units only

Ignition
Control

Transformer

DoorInterlock Switch

Pressure Port

Pressure Port

Location for

−1 to −14 units

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Summary of Contents for G40DF?24A?045

Page 1: ...dation only and do not supersede or replace local or state codes In the absence of local or state codes the guidelines and procedures outlined in this manual except where noted are recommended only an...

Page 2: ...eating P f Model No G40DF 48C 090 G40DF 48C 110 G40DF 60C 110 G40DF 60D 135 eat g Performance Low NOx Model No 48C 090X 60C 110X Input Btuh 88 000 110 000 110 000 132 000 Output Btuh 71 000 89 000 90...

Page 3: ...5M22 56L32 25W20 25W21 135 59M17 49L90 15M22 25W20 25W21 1 Required for proper operation at altitudes from 7501 to 10 000 ft NOTE G40DF X units do NOT require a manifold change due to elevation Manifo...

Page 4: ...to unit with 1 in 25 mm cleanable filter not furnished field provided in place Also see Filter Air Resistance table G40DF 36B 090 PERFORMANCE External Static Air Volume Watts at Different Blower Speed...

Page 5: ...79 1739 820 585 1526 720 503 1329 625 428 0 25 62 1844 870 662 1701 805 568 1502 710 488 1301 615 414 0 30 75 1802 850 645 1663 785 551 1477 695 473 1272 600 399 0 40 100 1693 800 606 1583 745 517 141...

Page 6: ...1515 715 640 1435 675 555 G40DF 60D 135 PERFORMANCE External Static Air Volume Watts at Different Blower Speeds External Static Pressure High Medium High Medium Low Low in w g Pa cfm L s Watts cfm L...

Page 7: ...dium Low Low in w g Pa cfm L s Watts cfm L s Watts cfm L s Watts cfm L s Watts 00 0 2660 1255 1379 2325 1095 1059 1960 925 864 1655 780 684 10 25 2560 1210 1353 2310 1090 1030 1945 915 840 1640 775 66...

Page 8: ...ion Air Inducer Gasket Manifold Burner Gas Valve Flame Rollout Switches Flame Sensor Primary Limit Ignitor Heat Exchanger Ignitor Bracket Combustion Air Pressure Switch Combustion Air Orifice Gas Orif...

Page 9: ...d repairable If control is inoperable sim ply replace entire control Can cause injury or death Unsafe operation will result if repair is attempted 3 SureLight Ignition Control A92 Figure 3 Control 56L...

Page 10: ...mes with an inter purge and warm up time between trials of 35 seconds Af ter a total of five trials for ignition including the initial trial the control goes into Watchguard Flame Failure mode Af ter...

Page 11: ...oard can be used with either electronic or electro mechanical thermostats with out modification The SureLight ignitor is made of durable silicon nitride Ignitor longevity is also enhanced by volt age...

Page 12: ...e SureLight integrated con trol 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 co...

Page 13: ...n 2 1 2 minutes the control board goes into Watchguard Pressure Switch mode for a 5 min ute re set period After the 15 second pre purge period the ignitor warms up for 20 seconds during which the gas...

Page 14: ...on air inducer ALTERNATING SLOW FLASH ALTERNATING SLOW FLASH Watchguard burners failed to ignite SLOW FLASH OFF Flame sensed without gas valve energized ON SLOW FLASH Rollout switch open OR 24V pin co...

Page 15: ...and are matched with blower wheels with 2 set screws FIGURE 10 B Ignitor Location BURNERS FRONT VIEW MEASUREMENT IS TO I D OF RETENTION RING BRACKET Silicon nitride Mini Nitride A B 625 406 685 306 A...

Page 16: ...well or White Rodgers The valve is internally redundant to assure safety shut off If the gas valve must be replaced the same type valve must be used 24VAC terminals and gas control knob or switch are...

Page 17: ...sing by means of a flexible silicone hose It moni tors negative air pressure in the combustion air inducer housing The switch is a single pole single throw proving switch elec trically connected to th...

Page 18: ...tructions To Turn Off Gas To Unit 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 per formed 3 Remove access panel 4 Switch lever...

Page 19: ...to the manometer The gas valve is factory set and should not require adjust ment All gas valves are factory regulated See specifica tions section of this manual for High Altitude manifold pres sure s...

Page 20: ...sconnect ignition control flame sensor wire from the flame sensor 4 Connect lead of the transducer to flame sensor 5 Connect lead of transducer to the ignition control sen sor wire 6 Turn supply volta...

Page 21: ...Seal around the hole when the check is complete D Blower Speed Taps Blower speed tap changes are made on the SureLight con trol board See figures 3 5 and 6 For controls 56L84 10M93 and 32M88 the heat...

Page 22: ...at exchanger leaks Replace all screws to the collector box and com bustion air inducer Leaving off screws may cause leaks 13 Clean burner by running a vacuum with a soft brush at tachment over face of...

Page 23: ...or control goes into 5 minute Watchguard Pressure Switch delay Once S18 closes a 15 second pre purge follows 4 SureLight control A92 energizes ignitor A 20 second warm up period begins 5 Gas valve ope...

Page 24: ...DS UNTIL ROLLOUT SWITCH CLOSES GAS VALVE OFF COMBUSTION AIR INDUCER ON INDOOR BLOWER ON HEATING SPEED LED 1 SLOW FLASH LED 2 OFF GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF WITH DELAY L...

Page 25: ...HAS CONTROL FAILED TO SENSE FLAME FOR FIVE CONSECUTIVE TRIES DURING A SINGLE HEAT DEMAND WATCHGUARD MODE GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF WITH DELAY LEDs SIGNAL WATCHGUARD FA...

Page 26: ...EMAINS UNCHANGED THROUGHOUT COOLING CYCLE THERMOSTAT CALLS FOR COOLING COMPRESSOR CONTACTOR ENERGIZED AND SYSTEM FAN ENERGIZED Control 69M08 ONLY will have a 2 second delay COOLING SPEED and EAC TERM...

Page 27: ...W THERMOSTAT CALLS FOR COOLING THERMOSTAT OPENS SYSTEM FAN SWITCHED TO COOLING SPEED EAC TERMINAL REMAINS ENERGIZED THERMOSTAT OPENS CONTROL G ENERGIZES SYSTEM FAN AT HEATING SPEED EAC TERMINAL ENERG...

Page 28: ...to 5 minute Watchguard Pressure Switch delay Once S18 closes a 15 second pre purge follows 4 Ignition control A92 energizes ignitor A 20 second warm up period begins 5 Gas valve opens for a 4 second t...

Page 29: ...M OF 1 SECOND GAS VALVE OFF COMBUSTION AIR INDUCER ON INDOOR BLOWER ON HEATING SPEED LED 1 SLOW FLASH LED 2 OFF GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF WITH DELAY LED 1 OFF LED 2 SL...

Page 30: ...DE GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF WITH DELAY LEDs SIGNAL WATCHGUARD FAILURE CODE IS 60 MINUTE RESET PERIOD COMPLETE YES 4 SECONDS YES HAS CONTROL RESET IGNITION SEQUENCE FO...

Page 31: ...OUGHOUT COOLING CYCLE THERMOSTAT CALLS FOR COOLING COMPRESSOR CONTACTOR AND SYSTEM FAN ENERGIZED WITH 2 SECOND DELAY COOLING SPEED EAC TERM ENERGIZED COMPRESSOR OFF THERMOSTAT OPENS SYSTEM FAN AND EAC...

Page 32: ...ED THERMOSTAT CALLS FOR HEAT W THERMOSTAT CALLS FOR COOLING THERMOSTAT OPENS SYSTEM FAN SWITCHED TO COOL SPEED EAC TERM REMAINS ON THERMOSTAT OPENS MANUAL FAN SELECTION MADE AT THERMOSTAT CONTROL G EN...

Page 33: ...the top button ACTION 2 Determine the cause of the roll out switch activation before leaving furnace code LED 1 O 1 2 2 Roll out switch failure ACTION 1 Check continuity across roll out switch Replace...

Page 34: ...BLEM 2 UNIT FAILS TO FIRE IN THE HEATING MODE COMBUSTION AIR BLOWER DOES NOT ENERGIZE Condition Possible Cause Corrective Action Comments 2 1 Unit operates with a cooling or contin uous fan demand Com...

Page 35: ...h a heating demand Diagnostic lights flash the pressure switch failure code 2 5 minutes after heating demand 3 1 2 Prove switch does not close due to obstructions in the pressure lines ACTION 1 Remove...

Page 36: ...switch code LED 1 Off LED 2 Slow Flash 5 1 1 Low pressure differential at the prove switch ACTION 1 Check for restricted exhaust vent Remove all blockage ACTION 2 Check for proper vent sizing See ins...

Page 37: ...the center of the heat exchanger openings Cor rect the location of the burners if necessary 5 4 Combustion air inducer energizes with a heating demand B li ht hl d th it 5 4 1 Poor Venting ACTION 1 Ch...

Page 38: ...Action Comments 7 0 Indoor blower fails to operate in continuous fan cooling or heating mode 7 1 1 Miswiring of furnace or improper connections at control or indoor blower motor ACTION 1 Correct wirin...

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