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HomeMy WebLinkAboutPermit M97-0120 - PETERS MATT City of Tukwila (206) 431 -3670 Community Development / Public Works • 6300 Southcenter Boulevard, Suite 100 • Tukwila, Washington 98188 MECHANICAL PERMIT Permit No: M97 -0120 Type: B-MECH Category: NRES Address: 13552 MACADAM RD S Location: Parcel #: 261320 -0031 Contractor License No: GLENDHA053Q2 TENANT PETERS MATT 13552 MACADAM RD S, TUKWILA WA 98188 OWNER PETERS MATT OR JILL 13552 MACADAM RD S, TUKWILA WA 98168 CONTRACTOR GLENDALE HEATING & A/C Phone: 206 243 -7700 12462 DES MOINES WAY SOUTH, SEATTLE,, WA 981682266 CONTACT MATT PETERS., Phone: 206 242 -4252 13552 MACADAM RD S, TUKWILA WA 98168 *********************************************** **•k * *** ** * *** * *k* *•k * * * ** * * ** Permit Description: CHANGE OUT GAS. FURNACE FOR GAS FURNACE UMC Edition: 1994 Permit Cent Authorize 5ignature Date Valuation: Total Permit Fee: Status:. ISSUED. Issued: 08/27/1997 Expires: 02/23/1998 Phone: (206)242 -4252 900.00 44.06 *********************** * * * * * * *** * * * *k* * * * * * * * * * * * * * *** *'fir * * * ** *iii * * * ** * * *** Signature: /_ _ /. �� Date: Print Name•_ a 7-2 I hereby .certify that .I have read and examined this permit and'kn'ow, the same to be true and correct. All provisions of law and ordinances governing this work will be complied with,.. whether specified herein or not. The granting of this permit does not presume to give authority to violate or cancel,the provisions of any other'state or local laws regulating construction or the performance of work. I am authorized to sign for and obtain this building permit. This permit shall become..null and void if : the work is not commenced within 180 days from the date •of:'issuance, or if the work. is suspended or abandoned for a period of'180 days the., last inspection. Project Name/Tenant: �j /L / 7 ,be s Description of work to be done: Value of Construction , / % ®D ' Site Address: / 3 .5T Z ' —7/ C pA�i A City State/Zip: l� _ y gg/65 Tax Parcel Number: Phone: 2 y Z --( 1'›g - 2— Property Owner: //Ai 77 ��� r b-r�s Street Address: L s" - A4ca4 P4/ City State /Zip: Q ,g/ Fax #: Contact Person: (7 PEE - t& - /e s Phone: Z --- Z''-Z Street Address: 5R City State /Zip: Fax #: Contractor: .� 7/ C�..e = - C e A/c, Z/ 0 Standby Phone: if 3- 7 7 o n Fax #: Street Address: / 2-4-h Z - ,p Es /% /mil/ �S I* City State /Zip: s 6 9G/ 6 Architect: Phone: Street Address: City State /Zip: Fax #: Engineer: Phone: Street Address: City State /Zip: Fax #: MISCELLANEOUS PERMIT REVIEW AND APPROVAL REQUESTED: (TO BE FILLED OUT BY APPLICANT) Description of work to be done: Will there be storage of flammable /combustible hazardous material in the building? ❑ yes a no Attach list of materials and store • e location on se • arate 8 1/2 X 11 • a • er Indicating quantities & Material Safety Data Sheets ■ Above Ground Tanks I Antennas /Satellite Dishes ■CCCC Bulkhead /Docks ❑ Commercial Reroof 171 Demolition fl Fence R Mechanical ❑ Manufactured Housing - Replacement only CI Parking Lots CI Retaining Walls Temporary Pedestrian Protection /Exit Systems ❑ Temporary Facilities ❑ Tree Cutting MONTHLY SERVICE BILLINGS. TO: Name: Phone: Address: City /State /Zip: 0 Water 0 Sewer 0 Metro 0 Standby Name: Address: Date application accepted: 71 1 "7 MISCPMT.DOC 7/11/96 CITY OF TUKWILA Permit Center 6300 Southcenter Boulevard, Suite 100 Tukwila, WA 98188 (206) 431 -3670 OR STAFF USE ONLY Project Number: Permit Number: Miscellaneous Permit Application Application and plans must be complete in order to be accepted for plan review. Applications will not be accepted through the mall or facsimile. APPLICANT <REQUEST:FOR'MISCELL'ANEOUS PUBLIC WORKS PERMITS ❑ Channelization /Striping Cl Curb cut/Access /Sidewalk ❑ Fire Loop /Hydrant (main to vault) #: Size(s): ❑ Flood Control Zone ❑ Land Altering: 0 Cut cubic yards 0 Fill cubic yards 0 sq. ft.grading /clearing ❑ Landscape Irrigation ❑ Sanitary Side Sewer #: ❑ Sewer Main Extension 0 Private 0 Public ❑ Storm Drainage ❑ Street Use ❑ Water Main Extension 0 Private 0 Public ❑ Water Meter /Exempt # Size(s): 0 Deduct 0 Water Only ❑ Water Meter /Permanent # Size(s): ❑ Water Meter Temp # Size(s : Est. quantity: gal Schedule: ❑ Miscellaneous Moving Oversized Load /Hauling WATER METER DEPOSIT /REFUND BILLING: Date application expires: Phone: City /State /Zip: Value of Construction - In all cases, a value of construction amount should be entered by the applicant. This figure will be reviewed and is subject to possible revision by the Permit Center to comply with current fee schedules. Expiration of Plan Review - Applications for which no permit is issued within 180 days following the date of application shall expire by limitation. The building official may extend the time for action by the applicant for a period not exceeding 180 days upon written request by the applicant as defined in Section 107.4 of the Uniform Building Code (current edition). No application shall be extended more than once. Ap I attion, taken by: (initials) � � BUILDING 0 , , ER OR AUTHORI _ D • GEN . —A • SUBMIT APPLICATION AND REQUIRED CHECKLISTS FOR Above Ground Tanks/Water Tanks - Supported directly . upon grade exceeding 5 gallons and a ratio of height to diameter or width . which exceeds 2:1 PERMIT REVIEW Submit checklist No: M -9 Signature: iI � `.„ , cor , ;t .`/ Date* Submit checklist ' No M -1 7 `'/ Print name: 4wT4,E)� ` 4 , /© r C �` Pho ... ev Bulkhead/Dock Fax #: Address: City Submit checklist No M -6 0 0 SUBMIT APPLICATION AND REQUIRED CHECKLISTS FOR Above Ground Tanks/Water Tanks - Supported directly . upon grade exceeding 5 gallons and a ratio of height to diameter or width . which exceeds 2:1 PERMIT REVIEW Submit checklist No: M -9 E Antennas /Satellite Dishes Submit checklist ' No M -1 Ei Awnings /Canopies - No signage Commercial Tenant Improvement Permit " El Bulkhead/Dock Submit checklist No M -10 .. ; 0 Commercial Reroof ` Submit checklist No M -6 0 Demolition Submit checklist ; : No :. M -3, M -3a 0 Fences - Over 6 feet in Height Submit checklist No:: M -9 El Land Altering/Grading/Preloads Submit checklist No: M -2 El Loading Docks . Commercial Tenant Improvement Permit. Submit checklist No: H -17 El Mechanical (Residential & Commercial) Miscellaneous Public Works Permits Submit checklist No M -8, Residential only -. H -6, H -16 . Submit checklist No H -9 ci El Manufactured Housing (RED INSIGNIA ONLY) Submit checklist No: M -5. 0 Moving Oversized Load/Hauling Submit checklist No: M -5 in Parking Lots ' . Submit checklist No: M -4 El Residential Reroof - Exempt with following exception: If roof structure to be repaired or replaced Residential Building Permit Submit checklist . No:. M -6 El Retaining Walls - Over 4 feet in height Submit checklist No M -1 El Temporary Facilities Submit checklist No: M -7 El Temporary Pedestrian Protection/Exit Systems Submit checklist. No: M -4 0 Tree Cutting Submit checklist No: M -2 ALL MISCELLANEOUS PERT APPLICATIONS MUST BE SUBMI D WITH THE FOLLOWING: ➢ ALL DRAWINGS SHALL BE AT A LEGIBLE SCALE AND NEATLY DRAWN ➢ BUILDING SITE PLANS AND UTILITY PLANS ARE TO BE COMBINED ➢ ARCHITECTURAL DRAWINGS REQUIRE STAMP BY WASHINGTON LICENSED ARCHITECT ➢ STRUCTURAL CALCULATIONS AND DRAWINGS REQUIRE STAMP BY WASHINGTON LICENSED STRUCTURAL ENGINEER ➢ CIVIL/SITE PLAN DRAWINGS REQUIRE STAMP BY WASHINGTON LICENSED CIVIL ENGINEER (RE.) Copy of Washington State Department of Labor and Industries Valid Contractor's License. If not available at the time of application, a copy of this license will be required before the permit is issued, unless the homeowner will be the builder OR submit Form H -4, "Affidavit in Lieu of Contractor Registration ". Building Owner /Authorized Agent If the applicant is other than the owner, registered architect/engineer, , or contractor licensed by the State of Washington, a notarized letter from the property owner authorizing the agent to submit this permit application and obtain the permit will be required as part of this submittal. I HEREBY CERTIFY THAT I HAVE READ AND EXAMINED THIS APPLICATION AND KNOW THE SAME TO BE TRUE UNDER PENALTY OF PERJURY BY THE LAWS OF THE STATE OF WASHINGTON, AND I AM AUTHORIZED TO APPLY FOR THIS PERMIT. MISCPMT.DOC 7/11/96 Permit N Address :13552 MACADAM RD S Sui Tenant:" PETERS MATT Type s. B -MECH Parcel "4t::. 261320- 0031 ****A** A***************' A** k ****** **,* ' k• k************ * * * **A•k * **•k *•k *•k * *•k'k *•k ** Permit Conditions: No changes, wi.11 be made to the plans unless approved 'by, Architect or- :Engineer and the Tukwi.la Building Division. All permits, inspection. recur ds;, an'd approved plans sha l 1 b available labia at the j ;•i•te- - prior to `the rt sta of any con - str:uction. These; dic'uments are to be maintained and avai 1 able until final, Inspection a� pro,v,a:,l is granted...:• All constru o ` n tbedohe , ,in - 'conformance with approved plans and,,,;; re;q'uireme,nts: of the ,Uniform Building Code (`1994 Edition) =t sr' amended'; Uniform M' Mechanical Code '(•1>994.. Ed'i'tion) and Wash in"gto:p State En`e Code (1994 Edi. :_M97 -0120 Status: ISSUED Applied :. 08/27/1997 Issued: 08/27/1997. Vali of Permit. The .;iss a permit or approval; of plan:', specificati "ons, and: oomputat,i ons sha11 - not be con= str ued; to- be a permit ''for, or an approval of, any violation of any of the provisions of ,the building code or of :any other: ordinance of the jurisdiction No permit presuming give` authority to violate «or�i.cance'I the provisions.,of,:this co shall ba valid M NUFACTURER'S INSTALLATION < <INSTRUCTIONS,. REQUIRED ON. SIT FOR! THE BUILDING INSPECTORS? REVIEW. .;;'' ProjT( (� y,) a ti . 1U t l t ction: � D ca g ° 97 [ ) ---� Address: 355A r1 � ada u Special instructions: d S Date wants Requester;n . 0 il S Phone No.:c9 qr Liz QFiPtMVgmn.uu.•... I INSPEC1TON NO. Approved per applicable codes, COMMENTS: Inspecto Y...s■••••ww. .,Mp INSPECTION RECORD Retain a copy with permit CITY OF TUKWILA BUILDING DIVISION 6300 Southcenter Blvd., #100, Tukwila, WA 9818 Date: 101-01 PERMIT NO. (206) 431 -3670 Corrections required prior to approval. I $42.' • REINSPECTION f EE RE • UIRED. Prior to inspection, fee must be paid at 6300 Southcenter Blvd., Suite 100, Call to schedule reinspection. I Receipt No.: Date: FJ, 1/4.* h* * *k* * * * * * * * * * * *A*• ** * * *k * * *1* * * •k* * * ** ** / *A * * * * *A*k * * * * * ** ;ITV OF TUKWILA, WA R{'i 'TRANSMIT 4 * ** **.tit * *sk * * *fir **** *R**' ** k * !h ** A * ** * ** * * **** ** *** *** *** TRANSMIT NumbOr: 89700635 Amount. 44.06 08/27/97 13:57 Payment Method . CHECK Notation: ULE:NDALE HEATING In i t x Kan Permit No: ..M97-0120 Typed B-MECH MECHANICAL PERMIT' Parcel No: .261320 -0031 Site Address: s: 13552, MACADAM RD S Total Fees: 44.06 lhis Payment 44« Total ALL Pmts: 44.06 Balance: .00 kki** * * *kA * * * * * *A * *•AA * * * * * * * * * * ** **• kA4*A * * *•A * * * * **• * * * * * ** * * * ** Account,'Code 000/345.530 000/322 Deription • PLAN CHECK '- MECHANICAL 7 NONRES Amount G1YS1 35.25 . _.. � tf .. •n; •• ,,,, :�: ` ,r . , ` ., . v: •.t! 1it ! 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Yq J•, • 4....,4,....,„40., ` 1 ' <�{ty�. �ylj { .J r� x A ' '; O. ±,i,`� ?;tSyil''e• v s , 'k;•. ., •i, ,, •.Y, 11 :,:: • : r. jl^ . i t , ,,� 1 • t r:• ,J• ,,�c•:r1.'' � ( h . r. k : i.•i� i' . J f�. .'.Z. �, +L,,i ; , `, '_ . rn -REGISTERED.. AS.PROVIDED .-BY,I_AW AS•, SIGNATURE, . ..... ..._ _....... _._._,,........ _.,� _.. ISSUED BY DEPARTMENT OF LABOR AND INDUSTRIES 13k wen ze s,v4gaiairsit oviktut owitotklattoorktcandotaxeutisoikt otottream o re& -7 t114241'4'4440(sWw INi 4 A Ao --- ------- T . I14 IHEE3., t i 13k wen ze s,v4gaiairsit oviktut owitotklattoorktcandotaxeutisoikt otottream o re& -7 LII1WDX 0 PRODUCT LITERATURE ©1995 Lennox Industries Inc. Dallas, Texas Page 1 INSTALLATION INSTRUCTIONS G20 SERIES UNITS GAS UNITS 503,222M 5/95 Supersedes 502,836M RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE Technical Publications Litho U.S.A. / TABLE OF CONTENTS UNIT DIMENSIONS 2 PARTS ARRANGEMENT 3 REQUIREMENTS 4 GENERAL 5 COMBUSTION, DILUTION AND VENTILATION AIR 5 INSTALLATION - Setting Equipment 7 RETURN AIR OPENING GUIDELINES 7 FILTER ASSEMBLY AND FILTERS 8 DUCT SYSTEM 8 VENTING 8 GAS PIPING 10 ELECTRICAL 11 UNIT START -UP 14 HIGH ALTITUDE INFORMATION 15 GAS PRESSURE ADJUSTMENT 15 OTHER UNIT ADJUSTMENTS 16 SERVICE 17 REPAIR PARTS 19 START -UP AND PERFORMANCE CHECK LIST 19 BCC2 TROUBLESHOOTING 20 Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. Installation and service must be performed by a qualified installer, service agency or the gas supplier. �Mk WARNING If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or Toss of life. \ ...........) WHAT TO DO IF YOU SMELL GAS: • Do not try to light any appliance. • Extinguish any open flames. • Do not touch any electrical switch; do not use any phone in your building. • Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions. • If you cannot reach your gas supplier, call the fire department. Model No. A B C D E F G H G20Q2E(X) -50 G2003E(X) -50 49 16 -1/4 14-1/8 14 11 2 -5/8 8 -1/8 3 -1/8 G20Q2E(X) -75 (1245) (413) (359) (356) (279) (67) (206) (79) G20Q3E(X) -75 G2004E(X) -75 49 21 -1/4 19-1/8 14 14 3 -5/8 10 -5/8 3 -1/8 G2003 /4E(X) -100 (1245) (540) (486) (356) (356) (92) (270) (79) G20(25/6E(X)-100 53 26-1/4 24-1/8 18 21 2-5/8 13 -1/8 3 -3/8 G20Q3 /4E(X) 125 G2005 /6E(X) -125 (1346) (667) (613) (457) (533) (67) (333) (86) G20Q5 /6EIX) -150 53 (1346) 31 -1/4 (794) 29 -1/8 (740) 18 (457) 26 (660) 2 -5/8 (67) 15 -5/8 (397) 3 -3/8 (86) fG20'UNIT:DIMENSIDNS -- INCHES (MMI 1 -1/16 (27) 44 17 -3/4 —O► (451) C SUPPLY I l r AIR OPENING L 1 -1/16 (27) .." 28-3/8 (721) _ 26-1/8 (664) 111111 III GAS INLET (Both Sides) iI 4 1 -1/2 (38) 22(559) 1-11/16 Return Air (43) FLUE OUTLET (center side to side) o- 2 -1/4 (57) T 17-1/2 (445) (Left) 20-1/2 (521) (Right) 2-5/8 (67) (Right) 2 -3/8 (60) (Left) UU ELECTRICAL INLETS (Both Sides) � -� 22 (559) 411111r- 2 -1/16 RETURN AIR I (52) D OPENING Eithr Side L �_ Bo Page 2 HMknW il, eMMttp at" � M • = Mm! AIR FLOW RETURN AIR FILTER (Either Side or *Bottom) n17.4 r r A *OPTIONAL BOTTOM RETURN AIR FILTER KIT REQUIRED Return E Air 1.1111E. F mvn' N. YArPN .W- NrY'WJSx�iMe4YY >2h"I.kfS t` ri:w+m- F'q�:•.Ka;A,f!f,: REMOVABLE BURNER BOX TOP S DAMPER SWITCH COVER ROLL-OUT SWITCH DAMPER SWITCH Ik SPRING PATCH PLATE 4 CABINET CAP UPPER ACCESS PANEL GAS MANIFOLD GAS VALVE PARTS IDENTIFICATION TOP STRIP (G20 Units Shown) DRAFT HOOD 611 74 14 °I. P I L O s E E L ODE vt, BURNER BOX 3)64,i5 DAMPER ASSEMBLY BURNERS BLOCKED VENT SHUT-OFF SWITCH REMOVABLE BURNER BOX TOP REAR BAFFLE BURNER BOX BLOWER CONTROL BOX FIGURE 1 DAMPER BOX PARTS ARRANGEMENT FIGURE 2 Page 3 te 14C. DAMPER MOTOR/GEAR V6ety* Clearances Location Inches (mm) S ervice access Front 36 (914)* To combustible materials L Top, side and rear 1 (25) Flue 6 (152)** Floor 0 (0) From Draft Hood Relief Opening Front 6 (152) All G20 units are A.G.A. (American Gas Association) and C.G.A (Canadian Gas Association) certified. In the US, installation of Lennox gas central furnaces must conform with local building codes or, in the ab- sence of local codes, with the current National Fuel Gas Code (ANSI- Z223.1). The National Fuel Gas Code is available from: American National Standards Institute, Inc. 1430 Broadway New York, NY 10018 NOTE -G2OX series units (units equipped with flame rods) are certified for use with natural gas only. Air supply for combustion and ventilation must con- form to the methods outlined in the current National Fuel Gas Code. 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 exposure to this substance or for further information, consult material safety data sheets available from address shown below, or contact your supervisor. Lennox Industries Inc. P.O. Box 799900 Dallas, TX 75379 -9900 The furnace is certified for installation clearances to com- bustible material as listed on the appliance rating plate and in table 1 for installations in an alcove or closet. TABLE 1 NOTE - Service access clearance must be maintained. * If tight installation, front service clearance may be 24" (610mm). "1" (25mm) for type "B1" Vent Pipe. Accessibility and service clearances must take prece- dence over fire protection clearances. Vent installations shall be in accordance with the GAMA venting tables booklet supplied with this unit and applicable provisions of local building codes . Page 4 NOTE -For installation on combustible floors, appliance shall not be installed directly on carpeting, tile, or other combustible material other than wood flooring. For installation in a residential garage, unit must be installed so that burner(s) and ignition source are lo- cated no less than 18" (457 mm) above floor. Furnace must be located or protected to avoid physical damage by vehicles. Unit must be adjusted to obtain a temperature rise within the range specified on appliance rating plate. The draft hood shall be installed in the same atmospheric pressure zone as the combustion air inlet to the furnace. G20 units must be installed so that electrical compo- nents are protected from water. When furnace is used in conjunction with cooling units, it shall be installed in parallel with, or on the up- stream side of, cooling units to avoid condensation in the heating element. With a parallel flow arrangement, damper (or other means to control the flow of air) shall be adequate to prevent chilled air from entering the furnace and, if manually operated, must be equipped with means to prevent operation of either unit, unless damper is in the full "heat" or "cool" position. When installed, furnace must be electrically grounded in accordance with local codes or, in the absence of lo- cal codes, with the current National Electric Code, ANSI /NFPA No. 70. The National Electric Code (ANSI/ NFPA No. 70) is available from: National Fire Protection Association 470 Atlantic Avenue Boston, MA 02210 Field wiring connection with unit must meet or exceed specifications of type T wire and withstand a 63 °F (17 °C) temperature rise. When furnace is installed so that supply ducts carry air circulated by furnace to areas outside space containing furnace, return air shall be handled by a duct(s) sealed to the furnace casing and terminating outside space containing furnace. This furnace is certified for installation clearances to combustible material as listed on appliance rating plate and in table 1. Accessibility and service clearances must take precedence over fire protection clearances. In Canada, installation of C.G.A. certified units must conform with current Standard CAN/CGA-B149.1 "Installation Code for Natural Gas Burning Appliances and Equipment" and CAN/CGA-B149.2 "Installation Code for Propane Gas Burning Appliances and Equip- ment," local plumbing or waste water codes and other applicable local codes. Authorities having jurisdiction should be consulted before installation. Adequate clear- ance shall be made around air openings into the vesti- bule area. Provisions shall be made for proper opera- tion and for combustion air and ventilation air supply according to the current CAN /CGA -B149 standards. All electrical wiring and grounding for the unit must be in accordance with the current regulations of the Cana- dian Electrical Code Part I (C.S.A. Standard C22.1) and/ or local codes. NOTE -G20 series units must not be used as a "construction heater" at any time during any phase of construction. Very low return air temperature, harm- ful vapors and misplacement of the filters will damage the unit and its efficiency. GENERAL / These instructions are intended as a general guide and do not supersede local codes in any way. Authori- ties having jurisdiction should be consulted before installation. A- Shipping and Packing List 1- Leveling bolt package (if ordered) 1- Thermostat (if ordered) 1- Rubber grommet (for electrical make-up) B- Shipping Damage Check unit for shipping damage. Receiving party should contact last carrier immediately if any shipping damage is found. © WARNING Improper installation, adjustment, alteration, ser- vice or maintenance can cause property damage, personal injury or loss of life. Installation and ser- vice must be performed by a qualified installer, service agency or the gas supplier. / COMBUSTION, DILUTION & VENTILATION AIR / Until recently, there was no problem in bringing in suf- ficient amounts of outdoor air for combustion — in- filtration provided all the air that was needed and then some. In today's homes built with energy conservation in mind, tight construction practices make it necessary to bring in air from outside for combustion. Consider- ation must also be given to the use of exhaust fans, ap- pliance vents, chimneys and fireplaces because they force additional air that could be used for combustion out of the house. Unless outside air is brought into the home for combustion, negative pressure (pressure outside is greater than inside pressure) will build to the point that a down draft can occur in the furnace vent pipe or chimney. Combustion gases enter the living space creating a potentially dangerous situation. Page 5 In the absence of local codes concerning air for com- bustion and ventilation, this section outlines guide- lines and recommends procedures for installing G20 furnaces in a manner that ensures efficient and safe op- eration. Special consideration must be given to com- bustion air needs as well as requirements for exhaust vents and gas piping. A portion of this information has been reprinted with permission from the National Fuel Gas Code (ANSI- Z223.1). This reprinted material is not the complete and official position of the ANSI on the referenced subject, which is represented only by the standard in its entirety. In Canada, refer to the standard CAN /CGA- B149.1 and - B149.2 installation codes. Combustion Air Requirements © CAUTION Insufficient combustion air can cause headaches, nausea, dizziness or asphyxiation. Excessive ex- posure to contaminated combustion air will result in safety and performance related problems. Avoid exposure to the following substances in the com- bustion air supply: Permanent wave solutions; Chlorinated waxes and cleaners; Chlorine base swimming pool chemicals; Water softening chemicals; De -icing salts or chemicals; Carbon tetrachloride; Halogen type refrigerants; Cleaning solvents (such as perchloroethylene); Printing inks, paint removers, varnishes, etc.; Hydrochloric acid; Cements and glues; Antistatic fabric softeners for clothes dryers; and Masonry acid washing materials. All gas -fired appliances require air to be used for the combustion process. If sufficient amounts of combus- tion air are not available, the furnace or other appliance will operate in an inefficient and unsafe manner. Enough air must be provided to meet the needs of all fuel- burning appliances, as well as appliances such as exhaust fans which force air out of the home. When fire- places, exhaust fans, or clothes dryers are used at the same time as the furnace, much more air is required to ensure proper combustion and to prevent a down -draft situation. Insufficient amounts of air also cause incom- plete combustion which can result in carbon monoxide. The requirements for providing air for combustion and ventilation depend largely on whether the furnace is installed in an unconfined or confined space. Unconfined Space An unconfined space is an area such as a basement or large equipment room with a volume greater than 50 cubic feet per 1,000 Btu (1.42 m per .29kW) per hour of the combined input rating of all appliances installed in that space. This space also includes adjacent rooms which are not separated by a door. Though an area may appear to be unconfined, it might be necessary to bring in outdoor air for combustion if the structure does not provide enough air by infiltration. If the furnace is lo- cated in a building of tight construction with weather stripping and caulking around the windows and doors, follow the procedures outlined for using air from the outside for combustion and ventilation. Confined Space A confined space is an area with volume less than 50 cu- bic feet per 1,000 Btu (1.42 m per .29kW) per hour of the combined input rating of all appliances installed in that space. This definition includes furnace closets or small equipment rooms. When the furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air must be handled by ducts which are sealed to the furnace casing and which terminate outside the space containing the fur- nace. This is especially important when the furnace is mounted on a platform in a confined space such as a closet or small equipment room. Even a small leak around the base of the unit at the platform or at the re- turn air duct connection can cause a potentially dan- gerous negative pressure condition. Air for combus- tion and ventilation can be brought into the confined space either from inside the building or from outside. Air from Inside If the confined space housing the furnace adjoins space categorized as unconfined, air can be brought in by pro- viding two permanent openings between the two spaces. Each opening must have a minimum free area of 1 square inch per 1,000 Btu (645mm per .29kW) per hour of the total input rating of all gas -fired equipment in the confined space. Each opening must be at least 100 square inches (645cm 2) . One opening shall be within 12" (305mm) of the top of the enclosure and one open- ing within 12" (305mm) of the bottom (See figure 3). Air from Outside If air from outside is brought in for combustion and ventilation, the confined space shall be provided with two permanent openings. One opening shall be within Page 6 12" (305mm) of the top of the enclosure and one within 12" (305mm) of the bottom. These openings must communicate directly or by ducts with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors or indirectly through vertical ducts. Each opening shall have a minimum free area of 1 square inch per 4,000 Btu (645mm per 1.17kW) per hour of to- tal input rating of all equipment in the enclosure (See figures 4 and 5). When communicating with the out- doors through horizontal ducts, each opening shall have a minimum free area of 1 square inch per 2,000 Btu (645mm per .59kW) per total input rating of all equipment in the enclosure (See figure 6). CHIMNEY OR GAS VENT 020 FURNACE CHIMNEY OR GAS G20 FURNACE VENTILATION LOUVERS (For unheated crawl space) EQUIPMENT IN CONFINED SPACE ALL AIR ROM INSIDE 1•111MNI•im 1•1111111•11181•11111111111•1•1••••••••1 OPENINGS (To Adjacent oom) NOTE —Each opening shall have a free area of at least 1 square Inch per 1,000 Btu (645mm 2 per .29kW) per hour of the total input rating of all equipment in the enclosure, but not less than 100 square inches. VENTILATION LOUVERS (Each end of attic) FIGURE 3 EQUIPMENT IN CONFINED SPACE ALL AIR FROM OUTSIDE (Inlet Air from Crawl Space and Outlet Alr to Ventilated Attic) FIGURE 4 WATER HEATER INLET AIR ) I;EOM r ^ (MD NOTE —The Inlet and outlet air openings shall each have a free area of at least 1 square inch per 4,000 Btu (645mm 1.17kW) per hour of the total input ratin of all equ ipment in the enclosure. 020 FURNACE OR CHIMNEY VENT O 1111 CHIMNEY OR GAS VENT EQUIPMENT IN CONFINED SPACE ALL AIR FROM OUTSIDE (Ail Air Through Ventilated Attic) VENTILATION LOUVERS (Each end of attic) G20 FURNACE 1i INLET AIR (Endss WATER HEATER •/11•1•SI f 1 1 1 1 11_ 1 1 1 1 1 1 1 1 1 11 1 1 1 1 1 1 NOTE –The Into and outlet air openings shall each have a free area of at least one square Inch per 4,000 Btu (645mm per 1.17kW) per hour of the total lnpu rating of all equipment In the enclosure. FIGURE 5 EQUIPMENT IN CONFINED SPACE ALL AIR FROM OUTSIDE 0 WATER HEATER FIGURE 6 UTLEF A13 NLET Al 1 1 L 1 1 1 1 1 1 L 1 1 L 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 I NOTE –Each alr duct opening shall have a free area of at least one square Inch per 2,000 Btu (645mm per .59kW) per hour of the total input rating of all equipment in the enclosure. If the equipment room Is located against an outside wall and the air openings communicate di- rectly with the outdoors, each opening shall have a free area of at least 1 square inch per4,000 Btu (645mm per 1.17kW) per hour of the total Input rating of all other equipment in the enclosure. When ducts are used, they shall be of the same cross — sectional area as the free area of the openings to which they connect. The minimum dimension of rectangular air ducts shall be no Tess than 3" (76mm). In calculating free area, the blocking effect of louvers, grilles, or screens must be considered. If the design and free area of protective covering is not known for calculating the size opening required, it may be assumed that wood louvers will have 20 to 25 percent free area and metal louvers and grilles will have 60 to 75 percent free area. Louvers and grilles must be fixed in the open position or interlocked with the equipment so that they are opened automatically during equipment operation. Page 7 I INSTALLATION - Setting Equipment 1— Holes are provided in the corners of unit base for leveling unit. Install leveling bolts (if desired) or shim under unit. See figure 7. NOTE —If leveling bolts are used, be sure to install the plastic nuts and tighten snugly before setting the unit. CABINET SIDE LEVELING BOLT INSTALLATION AFTER UNIT IS LEVEL, TIGHTEN THIS NUT INSTALL PLASTIC NUTS WITH FLAT SIDE TOWARD BASE. /S■ UNfT SE LEVEL UNIT WITH THIS NUT LEVEUNO BOLT FIGURE 7 2— Set unit in desired location allowing for clearances listed on appliance rating plate. Also allow for gas supply connection, electrical supply, vent connec- tions and installation and service clearances. I RETURN AIR OPENING GUIDELINES WARNING Improper installation of unit can result in personal injury or death. Combustion and flue products must never be allowed to enter the return air system or air in the living space. Use sheet metal screws and joint tape to seal return air system to furnace. In platform installations with furnace return, the furnace should be sealed airtight to the return air plenum. A door must never be used as a portion of the return air duct system. The base must provide a stable support and an airtight seal to the furnace. Allow absolutely no sagging, cracks, gaps, etc. For no reason should return and supply, air duct systems ever be connected to or from other heat- ing devices such as a fireplace or stove, etc. Fire, explosion, carbon monoxide poisoning, personal injury and /or property damage could result. WARNING Blower door must be securely in place when blow- er and burners are operating. Gas fumes, which could contain carbon monoxide, can be drawn into living space resulting in personal injury or death. If cold air return is to terminate through the floor under the furnace, a direct, airtight and sealed connection must be made to the bottom of the furnace. For instal- lations where the return air is taken from a return air drop, unit may be installed using either the left or right side of furnace. For side return air applications, cut furnace cabinet at sized knockout squares for maximum return air. Return air can be brought in either side or at the bottom of the unit. Scribe lines show the outline of each side return air opening. FILTER ASSEMBLY AND FILTERS G20 series units are equipped with a reusable foam filter, The filter must be in place anytime the unit is in operation. A bottom return air kit is available for bottom return air opening applications. For side return air openings, use supplied filter racks to hold filter. To install lower filter rack, remove two screws from lower side of cabinet. Place flange of filter rack inside bottom panel and side panel. Secure with previously removed cabinet /base bottom screws. To install upper filter rack, loosen screws from side of cab- inet at blower deck level. Insert three tabs in slots that are on the inside of the cabinet. Tabs must be between side panel and blower deck flange. Retighten screws to secure. See figure 8. FILTER RACK FOR G20 (Used on side return only) UPPER FILTER RACK TABS PLACE UPPE FILTER RACK TAB INTO SLOT LOWER FILTER RACK BLOWER DEC LOWER FILTER RACK BOTTOM BASE FILTER SIDE P NEL [DUCT SYSTEM FIGURE 8 Size and install supply and return air duct system us- ing industry- approved standards that result in a quiet and low- static system with uniform air distribution. Supply Air Duct System Installation of units not equipped with a cooling coil re- quire a removable access panel in the supply air duct. The access panel should be large enough to permit in- spection of heat exchanger for leaks after installation. Lennox recommends using the SENSITTM HT kit for heat exchanger inspections. The access panel must not allow Teaks in the supply air duct system. Return Air Duct System NOTE All G20 series units with bottom return air require a bottom return kit which is available as an accessory. NOTE - Return air duct should be secured to the unit us- ing rivets or S- locks. Using screws to secure the return air duct to the unit will interfere with the filter and cause improper filtration. Page 8 :VENTING G20 series furnaces must be vented in compliance with all local codes, the GAMA venting tables booklet in- cluded with this unit in the U.S.A. and the current stan- dards of CAN /CGA- B149.1 and - B149.2 in Canada and these instructions. G20 series units have been classified as Category 1 type furnaces when vertically vented in accordance with the latest edition of ANSI Z2.1.47 Central Furnace Standard in the U.S.A. and the current standard of CAN /CGA- B149.1 and B149.2 of the National Gas and Propane Installation Code in Canada. Round vent connectors should be used in the following sizes: -50 and -75 units, 4" (102mm); -100 units, 5" (127mm); and -125 and -150 units, 6" (152mm). A 9" (229mm) minimum length vertical vent connector must be run from the furnace flue outlet to the first el- bow. See figure 9. Venting Using a Masonry Chimney Any masonry chimney used for venting a G20 se- ries gas furnace must be lined, and must be sized and installed per all applicable local building codes or, in the absence of local codes, the current National Fuel Gas Code (ANSI- Z223.1) in the U.S.A. and the current standards of CAN /CGA- B149.1 and -B149.2 in Canada. Venting in an un- lined masonry chimney is prohibited. The effec- tive area of the chimney serving a single appliance must be no less than the effective area of the draft hood outlet. The chimney must extend vertically at least 5 ft. (1.5m) above the flue collar. The G20 series gas furnace must not be connected to a chimney serving a separate appliance de- signed to burn solid fuel. Masonry chimneys serving fireplaces cannot be used for venting purposes unless the fireplace opening is permanently sealed. See figure 9. i 9' (229mm m4. VERTICAL VENT USING LINED MASONRY CHIMNEY ) G20 FURNACE PERMANENTLY SEALED FIREPLACE OPENING FIGURE 9 • When inspection reveals that'an existing chimney is not safe for the intended purpose, it shall be re- built to conform to nationally recognized stan- dards, lined or relined with suitable materials or replaced with a gas vent or chimney suitable for venting G20 series units. The chimney passage- way must be checked periodically to ensure that it is clear and free of obstructions. Removal of Unit from Common Venting System In the event that an existing furnace is removed from a venting system commonly run with separate gas ap- pliances, the venting system is likely to be too large to properly vent the remaining attached appliances. The following test should be conducted while each ap- pliance in operation and the other appliances not in op- eration remain connected to the common venting sys- tem. If the venting system has been installed improperly, the system must be corrected as outlined in the previous section. 1- Seal any unused openings in the common venting system. 2- Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition. 3- Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the com- mon venting system are located and other spaces of the building. Turn on clothes dryers and any ap- pliances not connected too the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will oper- ate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers. 4- Follow the lighting instruction. Place the appliance being inspected in operation. Adjust thermostat so appliance will operate continuously. 5- Test for spillage at the draft hood relief opening af- ter 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a ciga- rette, cigar or pipe. 6- After it has been determined that each appliance remaining connected to the common venting sys- tem properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas- burning appliance to their previous condition of use. .,.. �' >irt?:•9Y'oUT:Peti::` s ite:; tf :,`i {.°Y4`;`; �h ., ..., "."•Yf�ii: a: Page 9 7- If improper venting is observed during any of the above tests, the common venting system must be corrected. The common venting system should be re -sized to approach the minimum size as deter- mined by using the appropriate tables in appendix G in the current standards of the National Fuel Gas Code ANSI Z223 -1 in the U.S.A., and the appropri- ate Category 1 Natural Gas and Propane ap- pliances venting sizing tables in the current stan- dards of the CAN /CGA- 8149.1 and .2 in the Natural Gas and Propane Installation Code in Canada. Horizontal Venting SIDE WALL VENTING KIT WIRING CK -40 CONTROL BOX PPC -5 (OPTIONAL) SwG POWER VENTER MOTOR THERMOSTAT CONNECTIONS TERMINAL IN FURNACE JUNCTION BOX 24 VAC THERMOSTAT — — -- FACTORY INSTALLED WIRING FIELD INSTALLED WIRING FIGURE 10 This furnace is design certified by the American Gas Association for horizontal venting through an outside wall only with the use of a Field Controls Company Model #SWG -5L side wall venting kit available from Lennox Dealer Service Center. No other Field brand venting kit or any other manufacturer's venting kit is acceptable. Horizontal venting of this furnace without the use of the above stated kit is prohibited. See figure 10 for field wiring of side wall horizontal venting kit. When horizontally vented, minimum clearance for ter- mination from electric meters, gas meters, regulators and relief equipment is 4 ft. (1.2m). At vent termination, care must be taken to maintain protective coatings over building materials (prolonged exposure to exhaust condensate can destroy protec- tive coatings). It is recommended that the exhaust out- let not be located within 6 ft. (1.8m) of a condensing unit because the condensate can damage the painted coating. Nominal Iron Pipe Size - Incheslmm) Internal ( Diameter -Inches(mm) I Length of Pipe - Feet(m) , (3.048) t 50 ®�® (15.240) i 90 (27.432) 100 (30.480) 1/4 .364 43 29 24 20 18 16 15 14 13 12 (6.35) (9.246) t 3/8 .493 95 65 52 45 40 36 33 31 29 27 (9.53) (12.522) 1/2 .622 175 120 97 82 73 66 61 57 53 50 (12.7) (17.799) 3/4 .824 360 250 200 170 151 138 125 118 110 103 (19.05) (20.930) I (7.08) (4.81) (4.28) (2.92) 1 (25.4) 1.049 (26.645) :P LII 1 -1/4 1.380 950 770 660 580 530 490 460 430 400 (31.75) (35.052) 1 -1/2 1.610 2100 460 1180 990 900 810 750 690 650 620 (38.1) 140.894) (59.46) (41.34) (33.41) (25.48) (22.94) (21.24) (19.54) (18.41) (17.56) 2 2.067 3950 2750 2200 1900 1680 1520 1400 1300 1220 1150 2-1/2 2.469 6300 4350 3520 3000 2650 2400 2250 2050 1950 1850 0• 3 3.068 11000 7700 6250 5300 4750 4300 3900 3700 3450 3250 176.2) (77.927) (311.48) (218.03) (176.98) (150.07) (134.50) (121.76) (110.43) (104.77) (97.69) (92.03) 4 4.026 23000 15800 12800 10900 9700 8800 8100 7500 7200 6700 (101.6) (102.260) (651.27) (447.39) (362.44) (308.64) (274.67) (249.18) (229.36) (212.37) (203.88) (189.72) GAS PIPING Gas Supply 1- This unit is shipped standard for left side installa- tion of gas piping. Simply connect gas supply to piping assembly. 2- A piping hole is also fabricated in the right side of the unit for alternate piping arrangements. 3- When connecting gas supply, factors such as length of run, number of fittings and furnace rating must be considered to avoid excessive pressure drop. Table 2 lists recommended pipe sizes for typ- ical applications. 4- Gas piping must not run in or through air ducts, clothes chutes, chimneys or gas vents, dumb wait- ers or elevator shafts. 5- Piping should be sloped 1/4 inch per 15 feet (6mm per 4.57m) upward toward the meter from the fur- nace. The piping must be supported at proper inter- vals, every 8 to 10 feet (2.44m to 3.05m), using suit- able hangers or straps. A drip leg should be installed in vertical pipe runs to the unit. 6- In some localities, codes may require installation of a manual main shut -off valve and union (fur- nished by installer) external to the unit. Union must be of the ground joint type. A IMPORTANT Compounds used on threaded joints of gas piping must be resistant to the actions of liquified petro- leum gases. Page 10 NOTE -In the case e ergency -off is required, shut off main manual gas valve and disconnect main power to unit. These devices should be properly labeled by the installer. NOTE - Installer must provide a 1/8" (3.2mm) N.P.T. plugged tap in the field piping upstream of the gas sup- ply connection to the unit. Tap must be accessible for test gauge connection. See figure 11. MANUAL MAIN SHUT -OFF VALVE (With 1 /a' (3.2mm) NPT Plugged Tap Shown). GROUND JOINT UNION FIELD PROVIDED AND INSTALLED TABLE 2 GAS PIPE CAPACITY - FT /HR (kL /HR) DRIP LEG LEFT SIDE PIPING (STANDARD) AUTOMATIC GAS VALVE (with manual shut -off valve) AUTOMATIC RIGHT SIDE PIPING GAS VALVE (ALTERNATE) (with manual shut-off valve) FIGURE 11 NOTE - Capacity given in cubic feet of gas per hour (kilo liters of gas per hour) and based on 0.60 specific gravity gas. MANUAL MAIN SHUT -OFF VALVE (With 1/8 (3.2mm) NPT 0/ Plugged Tap Shown) GROUND JOINT UNION DRIP LEG Leak Check After gas piping is completed, carefully check all piping connections (factory and field) for gas leaks. Use a leak detecting solution or other preferred means. © CAUTION Some soaps used for leak detection are corrosive to certain metals. Carefully rinse piping thoroughly after leak test has been completed. Do not use matches, candles, flame or other sources of igni- tion to check for gas leaks. NOTE -In case emergency shutdown is required, shut down main manual gas valve and disconnect main power to unit. These devices should be properly la- beled by the installer. A IMPORTANT When testing pressure of gas lines, gas valve must be disconnected and isolated. See figure 12. Gas valves can be damaged if subjected to more than 1/2 psig (3.48 kPa). MANUAL MAIN SHUT -OFF VALVE WILL NOT HOLD NORMAL TEST PRESSURE FURNACE - ISOLATE GAS VALVE FIGURE 12 The furnace must be isolated from the gas supply sys- tem by closing its individual manual shut -off valve during any pressure testing of the gas supply system at pressures equal to or less than 1/2 psig (3.48 kPa). © IMPORTANT G2OX series units (units equipped with flame rods) are approved for use with natural gas only. Page 11 it / ELECTRICAL Refer to figure 13 for blower control board, figure 14 for point to point field wiring and figure 15 for schematic wiring diagrams and troubleshooting. 1- Select fuse and wire size according to the blower motor amps. 2- Snaphole plugs are provided on both sides of cabi- net to facilitate wiring. 3- Install room thermostat according to instructions provided with thermostat. 4- Install a separate fused disconnect switch near the unit so power can be turned off for servicing. 5- Before connecting thermostat wiring to unit, re- move screws holding the hinged section of the control box. Swing the hinged section downward to to ensure wires are proper length. 6- Complete wiring connections to equipment using wiring diagrams provided with unit and in figures 14, 15 and NO TAG. Use 18 gauge wire or larger for thermostat connections. 7- Electrically ground unit in accordance with local codes or, in the absence of local codes, in accor- dance with the current National Electric Code (ANSI/ NFPA No. 70) and in Canada with the current Cana- dian Electric Code part 1 (CSA standard C22.1). NOTE — Non - insulated ground wires must be wrapped in electrical tape to avoid damaging the BCC2 blower control center. 8-- A 120 volt accessory terminal (ACC) is provided on the BCC2 blower control center. Any accessory rated up to 1 amp can be connected to this terminal and the neutral leg of the accessory can be at- tached to any free 120 volt neutral terminal on the BCC2 blower control center. The accessory termi- nal is energized whenever the blower is in opera- tion. See figure 13. A troubleshooting flowchart for the BCC2 blower control is located in figure 31. 9- The continuous fan (CF) 120 volt terminal is used with an optional continuous low fan kit that is available from Lennox. The kit allows the furnace blower to run continuously on low speed. r.r • • . ••••• • w Ye t..Ai. to rL r aww, ..i....�.�...�..+�...,..�.�.+rn �rrx..w+�r.te<a m.�+✓n. r�nrrvms�4rA,a.r1 nrtrvau • NEUTRAL TERMINALS BCC2 BLOWER CONTROL BOARD COOLING CONTINUOUS FAN SPEED TAP DUMMY TER INAL HEATING TERMINAL TERMINALS SPEED TAP VALVE SENSE r!� LIMIT IT W I K40 CAB L1 \A XFMR D 0 0 GOpOGC OG — a0 O W R Y C G 0000 K3 K2 K1 270 150 + 210 W R Y C O \ 90 BLOWER TIME ADJUSTMENT JUMPER 0 0 [1 24V C COM THERMOSTAT TERMINAL STRIP (DETACHABLE) FIGURE 13 r TO COMPRESSOR CONTACTOR TYPICAL G20 FIELD WIRING DIAGRAM DAMPER DOOR SWITCH FLAME ROLLOUT SWITCH GAS VALVE CONTROL BOX BCC2 CONTROL e BLOCKED VENT SHUTOFF SWITCH IGNITION CONTROL TRANSFORMER BLACK WHITE /' DOOR INTERLOCK SWITCH - - - FIELD INSTALLED LOW VOLTAGE FIELD INSTALLED LINE VOLTAGE n Lt 106 z g GROUND N FIGURE 14 Page 12 7N7 L ACCESSORY TERMINAL To Remove Terminal Strip, Grasp Ends of Block Between Thumb and Forefinger. Push Block Down and Out. BLOWER SPEED CHART UNIT FACTORY CONNECTED SPEED TAPS MOTOR SPEEDS AVAILABLE COOL HEAT 02 -50 2 3 4 02 -75 2z 3 62004E -75- 3,4,5,6 55 3 Fore f]o. 4 0-60,/5, 04 -75 4 4 04/5.05/6 2 4 5 02003/4 4 5 05/6 -100 J__ 5 BLOWER SPEED SELECTION LO HI 2 3 4 3 SPEED TAPS 3 4 2 3 4 5 6 5 LENNOXi°r,r,ro/ns. WIRING DIAGRAM 5/95 HEATING UNITS -GAS 02002E,X -50- 3,4,5,6 62004K-75-2,3,4,5 G2003E,X •50- 3,4,5,6 62003/4E,X -I00- 2,3,4,5 02002E,X,75- 1,2,3,4 G2005/6E,X -100•2,3,4,5 02003E -75- 3,4,5,6 G2003 /4E,X -125- 3,4,5,6 G2003X •75- 2,3,4,5 G2005 /6E,X -125- 3,4,5,6 62004E -75- 3,4,5,6 02005/6E -150 -2 3,4.5 SFr A Supor.odo. room No. Fore f]o. 529,559W 6 529,751W .Now 3) , 611W e(..'. ,rt; :AuMFi.+! w' raltM4i;; 1 i S9`'kT rY is fWi. crxe :a..enw�r,.vaSUYnv2+Kea rews.. Mme. �xa. r+ rnw.r n<. ave» mvr. r> rv.... nuxaewr e.. ww..., r-...«. awmw. sw ,.+ab.leelm FIGURE 15 Page 13 et. 1flaI:IL 1 :A(H:IYY(,1;r CI .,. I: '1V1 � 1T:�7i�iT w • � � r : � � . 1Y b9COli!1:1.9Yr ELAY.ECONOMIZER RELAY ACCESSORY PLUG. GAS P f r WER MOTOR OFSCRIPTION � NTINUOUS RI01/FR TRANSFORMER CONTROL N _I )(FAIR SENCEE K109 -I O S6B -2 ACC SPARK ELECTRODE LIMIT LI •0 N -i 1-. 551 WHITE I Ili in EQUIPMENT � GROUND P20 ^/I\ J20 IMPORTANT -TO PREVENT MOTOR 7 BURNOUT,NEVER CONNECT MORE 017 q THAN ONE MOTOR LEAD TO ANY w ONE CONNECTION. TO CHANGE MOTOR SPEED TAP AND 0 FOR BLOWER SPEED SELECTION PROCEOURE,REFER TO INSTALLATION INSTRUCTION IF HEATING AND LOW SPEED f ARE TO BE THE SAME,CONNECT JUMPER BETWEEN 560 -I AND A15 -H(AS SHOWN).REMOVE UNUSED MOTOR SPEED WIRE. TYPICAL G20E WIRING DIAGRAM SEE BLOWER SPEED CHART LINE VOLTAGE FIELD INSTALLED — — CLASS II VOLTAGE FIELD WIRING DENOTES OPTIONAL COMPONENT5 L 24V COMMON (C) J w a \ z ^ .143 NOTE- ( A151 IF ANY WIRE IN THIS APPLIANCE IS REPLACED,IT MUST BE REPLACED WITH WIRE OF LIKE SIZE, RATING AND INSULATION THICKNESS. WARNING - ELECTRIC SHOCK HAZARD,CAN CAUSE INJURY OR DEATH.UNIT MUST BE GROUNDED IN ACCORDANCE WITH NATIONAL AND LOCAL CODES. P43 SET HEAT ANTICIPATION AT 0.1 AMPS Inh.irIs. Inr. r 24V POWER (R) K43 - 1A15 ECON - BLOWER (GL - HEAT I (WIL < Y Y K36- DELAY ON DELAY OFF I J94 P94 J COOL I (VI) Litho U.S.A. UNIT START -UP FOR YOUR SAFETY READ BEFORE LIGHTING A WARNING Do not use this furnace if any part has been under- water. Immediately call a qualified service techni- cian to inspect the furnace and to replace any part of the control system and any gas control which has been under water. A WARNING If overheating occurs or if gas supply fails to shut off, shut off the manual gas valve to the appliance before shutting off electrical supply. A CAUTION Befpre attempting to perform any service or main- tenance, turn the electrical power to unit OFF at disconnect switch. 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 or lever. Never use tools. If the knob or lever 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. To place G20 furnace into operation: All G20 units are equipped with an intermittent pilot igni- tion system. Do not attempt to manually light pilots on these furnaces. Each time thermostat calls for heat, the pi- lot will automatically light. The pilot does not burn when there is no call for heat on units with electronic ignitions. A WARNING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. Gas Valve Operation (Figures 17 & 18) 1- STOP! Read the safety information at the begin- ning of this section. 2- Set thermostat to lowest setting. See figure 16. 3- Turn off all electrical power to appliance. 4- This appliance is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand. Page 14 THERMOSTATS FIGURE 16 5- Remove control access panel. 6- On Honeywell VR8204 gas valves, turn knob on gas valve clockwise/0 to OFF. Units with Robert- shaw 7200 gas valve, depress lever and move to OFF position. Do not force. See figure 18. HONEYWELL VR8204 SERIES GAS VALVE GAS VALVE SHOWN IN OFF POSITION FIGURE 17 GAS VALVE SELECTOR ARM IN OFF POSITION FIGURE 18 7- Wait five (5) 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. 8- On Honeywell VR8204 gas valves, turn knob on gas valve counterclockwise to ON. Units with Robertshaw 7200 gas valve, depress lever and move to ON position. Do not force. 9- Replace control access panel. 10- Turn on all electrical power to unit. . •.+ 11- Set thermostat to desired setting. NOTE -When unit is initially started, steps 1 through 11 may need to be repeated to purge air from pilot line. 12- If the appliance still will not operate, follow the instructions "To Turn Off Gas To Unit" and call your service technician or gas supplier. To Turn ON Gas To Unit 1- Set thermostat to lowest setting. 2- Turn off all electrical power to unit if service is to be performed. 3- Remove control access panel. 4- On Honeywell VR8204 gas valves, turn knob on gas valve clockwise0 to OFF Units with Robertshaw 7200 gas valve, depress lever and move to OFF posi- tion. Do not force. 5- Replace control access panel. HIGH ALTITUDE INFORMATION US Installations G20 series units are certified for US installations from 0 to 4000 feet (0 to 1219m) above sea level without modi- fication. For installations from 4000 feet to 7500 feet (1219m to 2286m) above sea level, a high altitude kit (44H56) must be installed. The kit contains special baffles used to replace factory - installed baffles and is applicable to US units only. No derate is required. Canadian Installations G20 units are certified for Canadian installations from 0 to 2000 feet (0 to 610m) above sea level without modifi- cation. For installations from 2000 feet to 4500 feet (610 to 1372m), a dedicated G20(H) series unit is required. G20(H) series units have been factory adjusted for high altitude applications and require no field modifications. GAS PRESSURE ADJUSTMENT Gas Flow To check for proper gas flow to combustion chamber, de- termine Btu input from appliance rating plate. Divide this input rating by the Btu per cubic foot of available gas. Re- sult is the required number of cubic ft. (cubic meter) per hour. Determine the flow of gas through gas meter for two minutes and multiply by 30 to get the hourly flow of gas to burner. Page 15 Gas Pressure 1- Check gas line pressure with unit firing at maxi- mum rate. A minimum of 4.5" w.c. (1.12kPa) for natural gas or 10.5" w.c. (2.61 kPa) for LP /propane gas should be maintained. 2- After line pressure has been checked and adjusted, check manifold pressure. Correct manifold pres- sure for LP /propane gas is 9.5" w.c. (2.36kPa) No adjustment is needed in high altitude applications. A natural gas to LP /propane gas changeover kit is required to convert unit. Refer to the installation instructions supplied with changeover kit for con- version procedure. Correct manifold pressure for natural gas is 3.5" w.c. (.87kPa). No adjustment is needed in high alti- tude applications. See figures 19 and 20 for man- ifold pressure adjustment screw location. ROBERTSHAW 7200 GAS VALVE REGULATOR ADJUSTMENT SCREW LOCATION REGULATOR COVER SCREW INLET PRESSURE TAP IN ADJUSTING SCREW FIGURE 19 HONEYWELL GAS VALVE REGULATOR ADJUSTMENT SCREW LOCATION CAP SCREW PRESSURE REGULATOR r� (Black) ADJUSTING SCREW (White) INLET PRESSURE TAP I 1*- OW 4. GAS INLET FIGURE 20 150 150 a CI 210 NMI 90 JUMPER 90 SECOND FAN OFF TIME 27 JUMPER 210 90 210 SECOND FAN OFF TIME NO JUMPER 270 •• 150 • • 90 FIGURE 21 / OTHER.UNITADJUSTMENTS.• Limit Control Limit Control- Factory set: No adjustment necessary. Fan Control The fan on time of 45 seconds is not adjustable. Fan off time (time that the blower operates after the heat de- mand has been satisfied) can be adjusted by moving the jumper on the BCC2 blower control center. The unit is shipped with a factory fan off setting of 90 seconds. Fan off time will affect comfort and is adjustable to sat- isfy individual applications. See figure 21. FAN OFF TIME ADJUSTMENT 270 JUMPER 270 150 210 90 150 SECOND FAN • • 270 JUMPER 150 • • 210 90 270 SECOND FAN 330 SECOND FAN 210 OFF TIME Temperature Rise Check temperature rise and, if necessary, adjust blow- er speed to maintain temperature rise within range shown on unit rating plate. Thermostat Adjustment Set thermostat heat anticipation setting for G20 units at .10 amps or at the lowest setting available but not be- low .10 amps. An isolation relay is built into the BCC2 blower control board to enhance the compatibility of the thermostat to the gas control. Electrical 1- Check all wiring for loose connections. 2- Check for correct voltage at unit (unit operating). 3- Check amp -draw on blower motor. Motor Nameplate Actual Blower Speeds Blower speed selection is accomplished by changing the taps at the harness connector at the blower motor. See figure 22. Refer to speed selection chart on unit wiring diagram. NOTE -CFM readings are taken external to unit with a dry evaporator coil and without accessories. Page 16 BLOWER SPEED TAP SELECTION DEPRESS TAB TO RELEASE WIRE CONNECTOR. SELECT CONNECTOR LOCATION FOR NEW SPEED. INSERT WIRE UN- TIL IT CLICKS. FIGURE 22 HARNESS CONNECTOR Flue and Chimney 1- Check flue pipe, chimney and all connections for tightness and to make sure there is no blockage. 2- Check unit for proper draft. Failure to Operate If unit fails to operate check the following: 1- Is thermostat calling for heat? 2- Is main disconnect switch closed? 3- Is there a blown fuse? 4- Is filter dirty or plugged? Dirty or plugged filters will cause unit to go off on limit control. 5- Is gas turned on at meter? 6- Is manual main shut -off valve open? 7 -• Is internal manual shut -off valve open? After items 1 through 7 have been checked and unit still will not start, manually reset vent safety shut -off switch located at the right side of draft hood. If unit operation re- sumes and then cuts out again, inspect furnace vent sys- tem for proper sizing and installation. Also, check for vent blockage and for proper draft. If unit still does not start, reset roll -out switch on burner box. See figure 2. If unit starts and cuts out, check heat section for blockage. Pilot and Burner Flame After the G20 unit has been installed and wired, the pi- lot flame should be periodically checked and adjusted, if necessary, to insure proper unit operation. Use the following procedure to adjust the pilot flame. Pilot Flame Adjustment 1- Turn off power to the unit. 2- Disconnect wire from MV terminal on the gas valve. 'x:31:.. ....... vtA;•r- ::;�c;:,e �`'fP ,. . �er.ao... 3- On Honeywell VR8204 gas valves, turn knob on gas valve counterclockwise to ON. Units with Rob - ertshaw 7200 gas valve, depress lever and move to ON position. Do not force. 4- Restore power to unit. 5- Set thermostat to call for heat. At this point the pilot valve portion of the gas valve will be energized after a call for heat is initiated. Pilot will then light. Examine the pilot flame to determine if it is a soft, stable flame that surrounds the flame sensor. See figure 23. If this is not the case, the pilot needs adjustment. 1 I h� IIl o o c o c c c • r.iI, ��1 ii gi III .' T FLAME SENSOR P LOT FLAME (Side View) FIGURE 23 6- Identify the gas valve being used and locate the pi- lot adjustment screw. On some gas valves the ac- tual adjustment screw is under a cap. See figures 24, and 25 for pilot adjustment screw locations. HONEYWELL VR8204 SERIES GAS VALVE PILOT ADJUSTMENT SCREW (UNDER CAP) FIGURE 24 ANIIMM FIGURE 25 Page 17 �..r 7- Turn the pilot adjustment screw until the pilot flame is soft and stably surrounds the flame sensor, 8- Take a microamp reading of the flame signal com- ing from the flame sensor. The normal range is 0.80 to 1.20 microamps with a minimum of 0.70 microamps. 9- After correct pilot flame has been obtained, adjust thermostat to stop a call for heat. 10- Turn off power to unit. 11- Reconnect MV wire to MV terminal on gas valve. 12- Restore power to unit and assure normal operation. Burner Flame Start burner and allow to operate for a few minutes to establish normal burning conditions. Check burner flame by observation. Flame should be predominantly blue in color, strong in appearance and should rise di- rectly from the burner ports in the heat exchanger. Check to see that flame is burning from all continuous ribbon ports and that flame does not impinge on the sides of the heat exchanger. BURNER FLAME NOTE -VIEW BURNER FLAME THROUGH DAMPER OPENING (Not Shown) ..-m.. w.,..rw�,tk.•�m:e' :clyt4tl. :a1: .3R»::Y7Attt4tt�:�'.•rxtar ;•,°dt;"E' FIGURE 26 SERVICE A WARNING Disconnect power before servicing unit. A CAUTION Label all wires prior to disconnection when servic- ing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. At the beginning of each heating season, the system should be checked as follows: Blower Check and clean blower wheel for any debris. Blower motor is prelubricated for extended bearing life. No further lubrication is needed. MODEL NUMBER SIDE RETURN Inches (mm) BOTTOM RETURN Inches (mm) Q2- 50,Q3 -50, 16X25X1 16X25X1 02 -75, Q3 -75, (406 X 635 X 25) P -8 -7822 (406 X 635 X 25) P -8 -7822 16X25X1 18X25X1 04 -75, 03/4 -100 (406 X 635 X 25) (457 X 635 X 25) P -8 -7822 97H06 05/6 -100, 20X 25 X 1 25 X 25 X 1 03/4 -125, 05/6 -125 (508 X 635 X 25) P -8 -7831 (635 X 635 X 25) 97H07 20X25X1 24X30X1 05/6 -150 (508 X 635 X 25) (610 X 7692 X 25) P -8 -7831 97H08 TABLE 3 FILTER SIZE AND PART NUMBER Filters 1- Filters should be inspected monthly and must be cleaned or replaced when dirty to assure proper furnace operation. 2- Reusable foam filters supplied with G20 can be washed with water and mild detergent. When dry, they should be sprayed with filter handicoater prior to reinstallation. Filter handicoater is RP Products coating no. 481 and is available as Lennox part no. P- 8-5069. If replacement is necessary, refer to table 3. Flue and Chimney Check flue pipe, chimney and all connections for tight- ness and to make sure there is no blockage. Electrical Check 1- Check all wiring for loose connections. 2- Check for correct voltage at unit (unit operating). 3- Check amp -draw on blower motor. Motor Nameplate Actual Cleaning Heat Exchanger and Burners NOTE -Use papers or protective covering in front of fur- nace while cleaning furnace. To clean heat exchanger: 1- Turn off both electrical and gas power supplies to furnace. Refer to figures 1 and 2 during disassem- bly and reassembly procedures. 2- Remove burner and upper access panel, flue pipe and draft hood. 3- Disconnect supply gas piping. 4- Remove burner box top by removing four holding screws. 5- Remove two screws each from the left and right patch plates. Remove patch plates, damper prove switch cover and damper. 6- Remove screws holding gas manifold in place and pull burners from heat exchanger. 7- Remove baffles inside top opening of heat exchang- er by twisting tabs to align with slots in baffles. Page 18 8- Insert a 24" (600 mm) steel rod that has a 20" (508mm) length of chain attached to one end into top opening of heat exchanger. See figure 27. CLEANING HEAT EXCHANGER Connect chain to rod and drop chain down through top of heat ex- changer. Connect at bottom to another rod. Move rods up and down, back and forth to clean heat exchanger. FIGURE 27 9- Shake rod to drop chain through the clamshell into burner cavity in bottom of heat exchanger. 10- Attach bottom of chain to another 24" (600 mm) rod. 11- Push and pull the rods back and forth and up and down with a vigorous motion. The chain will dis- lodge the soot and scale deposits inside the heat exchanger. Repeat for each clamshell. 12- With a shop vacuum or rags, clean out soot and scale deposits from bottom of heat exchanger. To clean burners: NOTE -FOR UNITS WITH FLAME RODS, remove two springs and withdraw rods from back of burner. Clean flame rods with wire brush. Continue with items 13 through 15 below and reinstall flame rods and springs. 13- Clean top of burner ports with a wire brush. 14- Clean burner ports by inserting a cleaning tool (made from a piece of sheet metal cut to fit the burner ports) and work in and out of each port. See figure 29. FIGURE 28 FIGURE 30 15- Clean inside of each burner with a bottle cleaning brush. See figure 30. 16- Replace burners making sure to fully engage in rear receiving slot in heat exchanger. Resecure gas manifold and supply piping. 17- Reinstall baffles inside top opening of heat ex- changer twisting tabs to secure baffles. 18- Resecure damper assembly, damper prove switch cover and burner box top. Carefully open damper by hand to ensure that the damper spring closes damper correctly and that the damper prove switch is engaged when damper is open. A CAUTION Use extreme care when opening damper door to prevent permanent damage to the damper motor. 19- Before replacing draft hood, flue pipe and access panels, inspect draft hood gasket. Replace gasket if necessary. 20 -- Carefully check all piping connections (factory and field) for gas leaks. Use a leak detecting solution or other preferred means. A CAUTION Some soaps used for leak detection are corrosive to certain metals. Carefully rinse piping thoroughly after leak test has been completed. Do not use matches, candles, flame or other sources of igni- tion to check for gas leaks. 21- Turn on gas and electrical supply. LG20 START AND PERFORMANCE CHECK LIST Page 19 REPAIR PARTS LIST The following repair parts are available through inde- pendent Lennox dealers. When ordering parts, include the complete furnace model number listed on the A.G.A. orC.G.A. rating plate — Example: G20Q5/6 -150. CABINET PARTS Upper access panel Blower panel Top strip Cabinet cap CONTROL PANEL PARTS Transformer Blower Control Center (BCC2) BLOWER PARTS Blower wheel Motor Motor mounting frame Blower housing cut -off plate HEATING PARTS Heat exchanger Gas manifold Draft hood Gas valve Main burners Ignition control Main burner orifices Ignition cable Pilot burner Igniter Pilot/electrode assembly Damper switch Limit control Couplings Flame roll -out switch Damper spring Blocked vent shut -off switch 9 pin plug Damper motor Grommets START-UP AND PERFORMANCE CHECK LIST Job Name Job No. Job Location City Installer City Unit Model No. Serial No. HEATING SECTION O Fan Control Off Setting Filter Clean & Secure? 0 Date State State Service Technician Electrical Connections Tight? 0 Air Shutters Properly Adjusted (If Installed)? Supply Voltage Blower Motor Amps Flue Connections Tight? 0 Blower Motor H P Fan Control Setting (45 Seconds Fixed On) Blower Motor Lubrication O.K.? 0 Gas Piping Connections Tight & Leak — Tested? Fuel Type: Natural Gas? 0 LP /Propane Gas? 0 Furnace Btu Input Line Pressure Regulator Pressure w.c. -- Nat.: w.c. — LP /Propane Temperature Rise Vent Clear? 0 0 Proper Draft? 0 THERMOSTAT Calibrated? 0 Heat Anticipator Properly Set? 0 Level? 0 JUMPER ACROSS R&W (REMOVE R & G JUMPER) DAMPER MOTOR ON? IS 120VAC ACROSS N & CAB? DOES UNIT OPERATE? IS 24VAC ACROSS.. R & C? REPLACE BCC2 IS 120VAC ACROSS N & ACC? IS BLOWER RUNNING ON HIGH SPEED? REPLACE BCC2 IS 120VAC ACROSS N & ACC? IS 120VAC ACROSS N & H? IS 24VAC ACROSS C&V? IS BLOWER RUNNING ON LOW SPEED, 45 SEC. AFTER FURNACE LIGHTS IS 120VAC ACROSS N & A? NO REPLACE BCC2 NO CHECK BLOWER WIRING AND BLOWER BCC2 TROUBLESHOOTING FLOWCHART NO I REPLACE BCC2 END OF TEST YES NO YES YES REMOVE H&W JUMPER YES YES CHECK DAMPER MOTOR WIRING AND DAMPER MOTOR YES AFTER THE SELECTED TIME, DOES THE BLOWER TURN OFF? C sT NO REPLACE IF NEEDED.' CHECK FUSE. YES JUMPER ACROSS SCREWS R&G YES NO REPLACE BCC2 YES . NO NO NO CHECK 1 -UNIT POWER 2- INTERLOCK SWITCH 3- 1AANSFORMER 4 -OMIT SWITCH NO I CHECK WIRING YES CHECK BLOWER WIRING AND BLOWER CHECK: 1- DAMPER MOTOR 2- IGNITION CONTROL 3 -GAS VALVE 4- IGNITOR 6 -LIMIT SWITCHES 8 -PROVE SWITCH YES REPLACE BCC2 FIGURE 31 Page 20