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Lennox G23(X) User Manual

Lennox G23(X)
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Page 1
ã 1998 Lennox Industries Inc.
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Corp. 9814-L8
G23(X)
Service Literature
Revised 08-2001
G23(X) SERIES UNITS
G23(X) series units are mid-efficiency upflow gas fur-
naces manufactured with Duralokt aluminized steel
clamshell type heat exchangers. G23(X) units are avail-
able in heating capacities of 50,000 to 150,000 Btuh and
cooling applications up to 6 tons. Refer to Engineering
Handbook for proper sizing.
Units are factory equipped for use with natural gas. A kit is
available for conversion to LPG operation. G23(X)-1, -2, -3
and-4modelunitsuseelectronic (intermittentpilot)ignition.
G23(X)-5 and -6 model units feature the Lennox Sur-
eLightT silicon nitride ignition system. All units meet the
California Nitrogen Oxides (NO
x
) Standards and California
Seasonal Efficiency requirements with the installation of
flame baffles. All units use a redundant gas valve to assure
safety shut-off as required by A.G.A. or C.G.A.
Information contained in this manual is intended for use by
qualified service technicians only. All specifications are
subject to change. Procedures outlined in this manual are
presented as a recommendation only and do not super-
sede or replace local or state codes. In the absence of lo-
cal or state codes, the guidelines and procedures outlined
in this manual (except where noted) are recommended
only.
SPECIFICATIONS
Model No. G23Q2(X)-50 G23Q3(X)-50 G23Q2/3(X)-75 G23Q4/5(X)-75 G23Q3(X)-100
Input Btuh (kW) 50,000 (14.7) 75,000 (22.0) 100,000 (29.3)
Output Btuh (kW) 40,000 (11.7) 61,000 (17.8) 80,000 (23.4)
lA.F.U.E. 80.7% 80.8% 80.4% 80.1%
California Seasonal Efficiency 75.5% 75.6% 76.9% 74.2% 76.6%
Flue size connection diameter in. (mm) round 3 (76) 4 (102)
Temperature rise range _F (_C) 30-60 (17-33) 35-65 (19-36) 20-50 (11-28) 45-75 (25-42)
High static certified by A.G.A. in wg. (Pa) .50 (125)
G
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in. 1/2
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Natural or LPG/propane
mm 12.7
B
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in. 10 x 7 10 x 8 11-1/2 x 9 10 x 8
B
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a
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diameter x width
mm 254 x 178 254 x 203 292 x 229 254 x 203
Blower motor output hp (W) 1/5 (149) 1/3 (249) 3/4 (560) 1/3 (249)
N
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Tons 1 to 2 1 to 3 3-1/2 to 5 1 to 3
N
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that can be added
kW 3.5 to 7.0 3.5 to 10.6 12.3 to 17.6 3.5 to 10.6
Shipping weight lbs. (kg) 1 package 135 (61) 140 (64) 146 (66) 186 (84) 159 (72)
Electrical characteristics 120 volts 60 hertz 1 phase (all models) (less than 12 amps)
lAnnual Fuel Utilization Efficiency based on U.S. DOE test procedures and FTC labeling regulations. Isolated combustion system rating for non-weatherized furnaces.
}Cleanable polyurethane frame type filter.

Table of Contents

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Lennox G23(X) Specifications

General IconGeneral
ModelG23(X)
Blower TypeMulti-Speed
WarrantyLimited Lifetime Heat Exchanger warranty, 5-Year Limited Parts Warranty
AFUE80%
Ignition SystemHot Surface Ignition
Vent TypeNatural Draft
Efficiency RatingUp to 80%
Fuel TypeNatural Gas/Propane
StagesSingle-stage
Blower Motor TypePSC
Ignition TypeHot Surface

Summary

G23(X) Series Unit Specifications

SPECIFICATIONS

Detailed technical specifications for G23(X) series furnaces, including input/output, efficiency, and dimensions.

Unit Features and Options

OPTIONAL ACCESSORIES

Lists optional accessories for G23(X) furnaces, such as filter kits and venting options.

HIGH ALTITUDE

Provides guidance on pressure regulator adjustments for high altitude installations of G23(X) furnaces.

Unit Orientation and Components

G23(X) ORIENTATION

Illustrates the overall orientation of the G23(X) furnace and its main compartments.

G23(X) GENERAL PARTS ORIENTATION

Details the location and identification of major internal components within the G23(X) furnace.

Heat Exchanger and Control Boxes

G23(X) HEAT EXCHANGE ASSEMBLY

Exploded view and identification of parts for the G23(X) heat exchanger assembly.

CONTROL BOX

Illustrates the control boxes for different G23(X) models, showing internal components.

Unit Components, Control Boxes, and Installation

I-UNIT COMPONENTS

Describes the main unit components and how to access them for service or maintenance.

B-Control Box Components

Explains the function and purpose of components within the furnace control box.

MAKE-UP BOX INSTALLATION

Provides instructions and illustrations for installing the make-up box for the G23(X) furnace.

Blower Control, Ignition, and Safety

BCC Blower Control (A15)

Explains the BCC blower control, its settings, and fan timing adjustments.

ESD Precautions and Procedures

Outlines essential precautions for handling electronic components to prevent ESD damage.

Unit Operation and Ignition Control

Unit Operation

Details the operational sequence of the furnace during a heating call, from ignition to blower activation.

C-Ignition Control (-1 Through -4 Models)

Describes the intermittent pilot ignition control used in G23(X)-1 to -4 models.

SureLight Ignition and Combustion Air

Johnson G776 Ignition Control Operation

Explains the sequence of operations for the G776 ignition control, including LED diagnostics.

D-Combustion Air Blower (B6)

Describes the role and operation of the combustion air blower in the G23(X) furnace.

Furnace Components and Controls

E-Blower Motors and Capacitors

Lists the horsepower and capacitance ratings for G23(X) series blower motors.

F-Flame Rollout Switch (S47)

Explains the function and reset procedure for the flame rollout safety switch.

G-Primary Limit Control (S10)

Describes the primary limit control and its role in preventing furnace overheating.

Burner System and Flame Sensing

H-Pilot, Spark Electrode, Flame Sensor and Burners

Explains the arrangement and function of pilot, spark electrode, flame sensor, and burners.

SureLight Ignition System Details

I- SureLight Ignition System A3

Details the SureLight ignition system, its control board, and ignitor for specific models.

Flame Sensor

Explains the location, function, and mounting of the flame sensor.

SureLight Control Diagnostics and Terminals

SureLight Control Terminal Designations

Lists and describes the function of each terminal on the SureLight control board.

SureLight Control Diagnostic Codes

Provides a guide to interpreting diagnostic codes indicated by the LED lights on the control board.

SureLight Ignition and Fan Control Adjustments

a-Electronic Ignition

Describes the electronic ignition sequence, including pre-purge and flame sensing.

b-Fan Time Control

Explains how to adjust the fan-off time delay on the SureLight control for comfort.

Gas Valve and Pressure Switch Functions

J-Gas Valve

Describes the gas valve, its safety features, and replacement considerations.

K-Combustion Air Blower Prove (Pressure) Switch

Explains the role of the pressure switch in ensuring combustion air blower operation.

Installation Air and Venting Requirements

A-Fresh Air Requirements

Emphasizes the necessity of sufficient fresh air for proper and safe furnace operation.

Combustion Air Requirements

Outlines requirements for combustion air, including avoiding contaminants and space definitions.

Combustion Air Space and Venting

Unconfined Space

Explains the criteria for an unconfined space and its air supply requirements.

Confined Space

Defines a confined space and details the air supply and ventilation requirements for it.

Flue Venting and Chimney Requirements

B-Flue Venting Requirements

Covers compliance with codes, furnace classification, and vent sizing information.

Masonry Chimney Venting Procedures

Venting Using a Masonry Chimney

Details requirements for venting G23(X) furnaces into masonry chimneys, including lining and common venting.

General Venting Requirements and Capacity Tables

General Venting Requirements

Outlines requirements for vent diameter, runs, elbows, and connector types for G23(X) furnaces.

Type B Vent Capacity for Single Appliance

Provides capacity ratings for Type B double-wall vents serving a single appliance.

Vent Capacity Tables for Single Appliances

Type B Vent Capacity with Type B Connectors

Lists capacity ratings for Type B double-wall vents with Type B connectors serving single appliances.

Type B Vent Capacity with Single-Wall Connectors

Provides capacity ratings for Type B double-wall vents with single-wall connectors serving single appliances.

Venting Tables for Multiple Appliances

Type B Vent Capacity with Type B Connectors (Multiple Appliances)

Shows vent connector capacity ratings for Type B double-wall vents serving multiple appliances.

Common Vent Capacity with Type B Connectors (Multiple Appliances)

Lists common vent capacity ratings for Type B double-wall vents serving multiple appliances.

Additional Venting Capacity Tables

Type B Vent Capacity with Single-Wall Connectors (Multiple Appliances)

Lists vent connector capacity ratings for Type B double-wall vents with single-wall connectors.

Common Vent Capacity with Single-Wall Connectors (Multiple Appliances)

Provides common vent capacity ratings for Type B double-wall vents with single-wall connectors.

Common Venting System Removal

Removal of Unit from Common Venting System

Details the procedures for testing and removing a unit from a common venting system.

Horizontal Venting and Start-Up Procedures

Horizontal Venting

Covers the requirements and wiring for horizontal side wall venting kits.

START-UP Procedures

Outlines the critical checks and procedures before and during the initial heating start-up.

Shutdown Procedures and Heating Service Checks

Safety or Emergency Shutdown

Describes procedures for safe and emergency shutdown of the furnace.

Extended Period Shutdown

Provides instructions for safely shutting down the unit for extended periods.

HEATING SYSTEM SERVICE CHECKS

Lists essential checks for the heating system, including AGA certification and gas piping.

Gas Pressure Checks and Adjustments

Check Manifold Pressure

Details how to check and verify manifold pressure for correct unit operation.

Testing Gas Supply Pressure

Explains how to test the gas supply pressure to ensure it's within operational limits.

Gas Flow, Altitude, and Flame Signal

Proper Gas Flow (Approximate)

Describes how to measure gas flow using the meter clocking method.

High Altitude Derate

Provides guidance on adjusting the pressure regulator based on installation altitude.

Flame Signal

Explains how to check the flame signal using a DC microammeter for ignition troubleshooting.

Operating Characteristics and Measurements

Measure Flame Signal G776 Ignition Control

Provides a step-by-step guide for measuring the flame signal with a transducer.

TYPICAL OPERATING CHARACTERISTICS

Outlines typical operating characteristics and adjustment procedures for the furnace.

Blower Operation and Adjustment

Explains how blower operation is controlled by the thermostat and how to adjust fan speeds.

Temperature Rise

Details the procedure for measuring temperature rise and adjusting blower speed accordingly.

External Static Pressure

Describes how to measure external static pressure in the furnace's air system.

Blower Service and Speed Adjustment

G23(X) BLOWER REMOVAL

Provides step-by-step instructions for safely removing the blower motor from the furnace.

Blower Speed Taps Leadless Motors

Explains how to change blower speed settings for leadless motor configurations.

Blower Speed Taps Leaded Motors

Details how to adjust blower speed taps for leaded motor configurations using the SureLight control.

Furnace Maintenance Procedures

MAINTENANCE

Outlines the recommended maintenance schedule and procedures for the G23(X) furnace.

Filters

Provides guidance on inspecting, cleaning, or replacing the return air filters.

Cleaning Heat Exchanger and Burners

Details the process for cleaning the heat exchanger and burners for optimal performance.

Component Checks and Cleaning

Supply Air Blower

Instructs on cleaning the supply air blower wheel and mentions motor lubrication.

Flue and Chimney

Describes checks for flue pipe, chimney, and connections to ensure safety and proper function.

Electrical

Outlines checks for wiring connections, voltage, and blower motor amp-draw.

Wiring Diagrams and Thermostat Settings

TYPICAL G23(X) FIELD WIRING DIAGRAM

Illustrates the field wiring connections for the G23(X) furnace, including thermostat and accessories.

G23(X) and CONDENSING UNIT THERMOSTAT DESIGNATIONS

Shows the wiring designations for G23(X) furnaces and their corresponding condensing units.

Furnace Operation Sequences

OPERATION SEQUENCE-G23(X) -1, -2, -3 and -4 MODELS

Explains the operational sequence for G23(X) models -1 through -4 during heating.

BCC Blower Control Troubleshooting

BCC TROUBLESHOOTING FLOWCHART

Provides a flowchart for diagnosing and resolving issues related to the BCC blower control.

G776 Ignition Control Troubleshooting

G776 IGNITION CONTROL TROUBLESHOOTING

Offers a troubleshooting flowchart for situations where the pilot fails to light despite spark.

G776 Ignition Control: No Spark or System Failure

G776 IGNITION CONTROL TROUBLESHOOTING

Provides a troubleshooting flowchart for issues where no spark is produced or the system won't operate.

G776 Ignition Control: Pilot Issues

G776 IGNITION CONTROL TROUBLESHOOTING

Offers a flowchart for troubleshooting when the pilot lights but the main valve does not open.

SureLight Control Heating Sequence (-5/-6 Models)

OPERATION SEQUENCE-G23(X) -5 and -6 MODELS WITH SURELIGHT CONTROL

Details the heating sequence of operation for G23(X) models equipped with the SureLight control.

SureLight Heating Sequence Flowchart

SURELIGHT CONTROL HEATING SEQUENCE OF OPERATION

Illustrates the heating sequence of operation for the SureLight control, including normal and abnormal modes.

SureLight Heating Sequence Continued

HEATING SEQUENCE CONTINUED

Continues the heating sequence flowchart, detailing ignition trials and limit checks.

SureLight Cooling Sequence Flowchart

SURELIGHT CONTROL COOLING SEQUENCE OF OPERATION

Illustrates the cooling sequence of operation for the SureLight control, including normal and abnormal modes.

Continuous Low Speed Fan Operation

CONTINUOUS LOW SPEED FAN SEQUENCE OF OPERATION

Details the sequence of operation for the continuous low speed fan mode.

SureLight Troubleshooting Guide

SURELIGHT - TROUBLE SHOOTING GUIDE

Provides a troubleshooting guide for common initial power-up issues with the SureLight control.

Troubleshooting Unit Operation Issues

UNIT FAILS TO OPERATE IN COOLING, HEATING, OR CONTINUOUS FAN MODE

Addresses issues where the unit fails to operate in cooling, heating, or fan modes.

UNIT FAILS TO OPERATE IN COOLING OR HEATING MODE, BUT COMBUSTION AIR BLOWER OPERATES CONTINUOUS

Covers failures related to combustion air blower operation in cooling/heating modes.

UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR BLOWER DOES NOT ENERGIZE

Diagnoses issues where the combustion air blower does not energize during heating.

Troubleshooting Combustion Air and Ignition Failures

UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR BLOWER DOES NOT ENERGIZE (CONT.)

Addresses combustion air blower issues, specifically pressure switch failures.

UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR BLOWER ENERGIZES, IGNITOR IS NOT ENERGIZED

Diagnoses issues where the unit fails to fire, but the combustion air blower energizes.

Troubleshooting Burner Ignition and Shutdowns

UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR BLOWER ENERGIZES, IGNITOR IS ENERGIZED

Covers scenarios where the ignitor energizes, but the unit fails to light.

BURNERS LIGHT WITH HEATING DEMAND BUT UNIT SHUTS DOWN PREMATURELY

Addresses problems where burners light but the unit shuts down prematurely.

Burner Performance and Recirculation Issues

BURNERS LIGHT WITH HEATING DEMAND BUT UNIT SHUTS DOWN PREMATURELY (CONT.)

Details issues related to roll-out switch trips, gas leaks, and air leakage.

Control Signal and Interference Troubleshooting

CONTROL SIGNALS LOW FLAME SENSE DURING HEATING MODE

Addresses issues where the control board signals a low flame sense during heating.

INDOOR BLOWER FAILS TO OPERATE IN COOLING, HEATING, OR CONTINUOUS FAN MODE

Covers failures related to the indoor blower not operating in various modes.

RF STATIC DURING TIME FOR IGNITION

Addresses potential RF static interference during the ignition sequence.

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