Corp.

0307−L5 G51MP
Revised 9−2007
Service Literature

G51MP SERIES UNITS

G51MP series units are high−efficiency multiple position
(upflow, downflow, horizontal left and horizontal right)
gas furnaces manufactured with Lennox DuralokPlust
aluminized and stainless steel clamshell-type heat ex-
changers. G51MP units are available in heating input ca-
pacities of 44,000 to 132,000 Btuh (13 to 38.6 kW) and cool-
ing applications from 2 through 5 tons (7.0 through 17.6 kW).
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. All G51MP units
are equipped with the Lennox SureLight® hot surface igni-
tion system. The gas valve is redundant to assure safety
shut−off as required by C.S.A.
The heat exchanger, burners and manifold assembly can be
removed for inspection and service. The maintenance section
gives a detailed description on how this is done.
Information contained in this manual is intended for use by
qualified service technicians only. All specifications are sub-
ject to change. Procedures outlined in this manual are pre-
sented as a recommendation only and do not supersede or
replace local or state codes.

Table of Contents
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 IMPORTANT
Blower Performance Data . . . . . . . . . . . . . . . . . . . . . . 4 Improper installation, adjustment, alteration, service
or maintenance can cause property damage, person-
I−Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 al injury or loss of life. Installation and service must
II Placement and Installation . . . . . . . . . . . . . . . . . . . . 19 be performed by a qualified installer, service agency
III−Start−Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 or the gas supplier.

IV−Heating System Service Checks . . . . . . . . . . . . . . 34

V−Typical Operating Conditions . . . . . . . . . . . . . . . . . 38 WARNING
VI−Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Electric shock hazard. Can cause injury
VII−Wiring and Sequence of Operation . . . . . . . . . . . 42 or death. Before attempting to perform
VIII−Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 any service or maintenance, turn the
electrical power to unit OFF at discon-
nect switch(es). Unit may have multiple
power supplies.

WARNING
Sharp edges.
Be careful when servicing unit to avoid sharp edges
which may result in personal injury.

© 2003 Lennox Industries Inc.

Page 1 Litho U.S.A.
 SPECIFICATIONS
Gas Model
No. G51MP G51MP G51MP G51MP G51MP
Heating
eat g −24B−045 −36B−045 −36B−070 −36C−090 −48C−090
P f
Performance Input
− Btuh (kW) 44,000 (12.9) 44,000 (12.9) 66,000 (19.3) 88,000 (25.8) 88,000 (25.8)
Output
− Btuh (kW) 41,000 (12.0) 41,000 (12.0) 62,000 (18.2) 82,000 (24.0) 82,000 (24.0)
1 AFUE 92.1% 92.1% 92.1% 92.1% 92.1%
California Seasonal Efficiency 82.7% 82.1% 85.1% 85.2% 85.5%
High
static
(CSA)
− in.
w.g. (Pa) .50 (124) .50 (124) .50 (124) .50 (124) .50 (124)
Temperature rise range − _F 30 − 60 25 − 55 40 − 70 40 − 70 40 − 70
(_C) (18 − 36) (14 − 31) (24 − 42) (24 − 42) (24 − 42)
Connections 2 Intake / Exhaust Pipe (PVC) 2/2 2/2 2/2 2/2 2/2
i
in. Condensate Drain Trap (PVC pipe) − i.d. 1/2 1/2 1/2 1/2 1/2
with field supplied (PVC coupling) − o.d. 3/4 3/4 3/4 3/4 3/4
hose with hose clamp − i.d. x o.d. 1−1/4 x 1 1−1/4 x 1 1−1/4 x 1 1−1/4 x 1 1−1/4 x 1
Gas
pipe
size
IPS
1/2 1/2 1/2 1/2 1/2
Indoor Wheel nominal diameter x width −
in. 10 x 7 10 x 8 10 x 8 10 x 8 10 x 10
Blower (mm) (254 x 178) (254 x 203) (254 x 203) (254 x 203) (254 x 254)
Motor
output − hp (W) 1/5 (149) 1/3 (249) 1/3 (249) 1/3 (249) 1/2 (373)
Tons
(kW) of
add-on
cooling 2 − 2.5 2−3 2−3 2−3 3−4
(7.0 − 8.8) (8.8 − 10.5) (8.8 − 10.5) (8.8 − 10.5) (10.5 − 14.0)
Air Volume Range − cfm (L/s) 465 − 1125 730 − 1555 710 − 1640 730 − 1630 950 − 2180
(220 − 530) (345 − 735) (335 − 775) (345 − 770) (450 − 1030)
Shipping
Data − lbs. (kg) − 1 package 132 (60) 136 (62) 146 (66) 164 (74) 168 (76)
Electrical
characteristics 120 volts − 60 hertz − 1 phase (less than 12 amps)

SPECIFICATIONS
Gas Model
No. G51MP−60C−090 G51MP−48C−110 G51MP−60C−110 G51MP−60D−135
H ti
Heating Input
− Btuh (kW) 88,000 (25.8) 110,000 (32.2) 110,000 (32.2) 132,000 (38.7)
Performance
Output
− Btuh (kW) 82,000 (24.0) 103,000 (30.2) 103,000 (30.2) 123,000 (36.0)
1 AFUE 92.1% 92.1% 92.1% 92.1%
California Seasonal Efficiency 83.9% 86.2% 85.6% 86.0%
High
static
(CSA)
− in.
w.g. (Pa) .50 (124) .50 (124) .50 (124) .50 (124)
Temperature rise range − _F (_C) 30 − 60 (18 − 36) 45 − 75 (27 − 45) 40 − 70 (22 − 39) 45 − 75 (25 − 42)
Connections 2 Intake / Exhaust Pipe (PVC) 2/2 2/2 2/2 3/3
i
in. Condensate Drain Trap (PVC pipe) − i.d. 1/2 1/2 1/2 1/2
with field supplied (PVC coupling) − o.d. 3/4 3/4 3/4 3/4
hose with hose clamp − i.d. x o.d. 1−1/4 x 1 1−1/4 x 1 1−1/4 x 1 1−1/4 x 1
Gas
pipe
size
IPS 1/2 1/2 1/2 1/2
Indoor Wheel
nominal
diameter
x
width −
in. 11−1/2 x 10 10 x 10 11−1/2 x 10 11−1/2 x 10
Blower (mm) (292 x 229) (254 x 254) (292 x 229) (292 x 229)
Motor
output − hp (W) 1 (746) 1/2 (373) 1 (746) 1 (746)
Tons
(kW) of
add-on
cooling 4 − 5 (14.0 − 17.5) 3 − 4 (10.5 − 14.0) 4 − 5 (14.0 − 17.5) 4 − 5 (14.0 − 17.5)
Air Volume Range − cfm (L/s) 1440 − 2840 885 − 2160 1470 − 2720 1440 − 2730
(680 − 1340) (420 − 1020) (695 − 1285) (680 − 1290)
Shipping
Data − lbs. (kg) − 1 package 176 (80) 178 (81) 186 (84) 206 (93)
Electrical
characteristics 120 volts − 60 hertz − 1 phase (less than 12 amps)
NOTE − Filters and provisions for mounting are not furnished and must be field provided.
1 Annual Fuel Utilization Efficiency based on DOE test procedures and according to FTC labeling regulations. Isolated combustion system rating for non-weatherized furnaces.
2 Determine from venting tables proper exhaust pipe size and termination kit required.

Page 2
 OPTIONAL ACCESSORIES
B" Width Models C" Width Models D" Width Models
FILTER KITS
1Air Filter and Horizontal (end) Size of filter − in. 87L96 − 18 x 25 x 1 87L97 − 20 x 25 x 1 87L98 − 25 x 25 x 1
Rack Kit (mm) (457 x 635 x 25) (508 x 635 x 25) (635 x 635 x 25)
Side Return Single 44J22 44J22 44J22
Ten Pack 66K63 66K63 66K63
Size of filter − in. (mm) 16 x 25 x 1 16 x 25 x 1 16 x 25 x 1
(406 x 635 x 25) (406 x 635 x 25) (406 x 635 x 25)
EZ Filter Base Catalog No. − Ship. Wt. − lbs. (kg) 73P56 − 7 (3) 73P57 − 8 (4) 73P58 − 10 (5)
Size of field provided filter − in. 16 x 25 x 1 20 x 25 x 1 24 x 24 x 1
(mm) (406 x 635 x 25) (508 x 635 x 25) (610 x 610 x 25)
CABINET ACCESSORIES
Down−Flow Additive Base 11M60 11M61 11M62
Horizontal Support Frame Kit 56J18 56J18 56J18
Return Air Base 76M88 74M74 74M75
CONDENSATE DRAIN KITS
Condensate Drain Heat Cable 6 ft. (1.8 m) 26K68 26K68 26K68
24 ft. (7.3 m) 26K69 26K69 26K69
50 ft. (15.2 m) 26K70 26K70 26K70
Heat Cable Tape
p Fiberglass − 1/2 in. x 66 ft. 39G04 39G04 39G04
Aluminum foil − 2 in. x 60 ft. 39G03 39G03 39G03
Condensate Trap Alternate Location Kit − Up−Flow Only 76M20 76M20 76M20
CONTROLS
Twinning Kit 15L38 15L38 15L38
TERMINATION KITS − See Installation Instructions for specific venting information.
Termination Kits Concentric 1−1/2 in. (38 mm) 71M80 −−− −−−
Direct Vent
Applications 2 in. (51 mm) −−− 69M29 −−−
Only 3 in. (76 mm) −−− 60L46 60L46
Wall − Close 2 in. (51 mm) 22G44 −−− −−−
Co ple
Couple
3 in. (76 mm) 44J40 44J40 44J40
Close Couple WTK − 2 in. (51 mm) 30G28 −−− −−−
3 in. (76 mm) 81J20 81J20 81J20
2 Termination Roof 2 in. (51 mm) 15F75 15F75 15F75
Kits − Direct or
Wall − Wall Ring Kit 2 in (51 mm) 15F74 15F74 3 15F74
Non−Direct Vent
Roof Termination Flashing Kit − Direct or Non−Direct 44J41 44J41 44J41
Vent − Contains two flashings.
1 Cleanable polyurethane frame type filter.
2 Kits contain enough parts for two, non−direct vent installations.
3 Non−direct vent only.

Page 3
 BLOWER PERFORMANCE

G51MP−24B−045 PERFORMANCE (Less Filter)

External Static Air Volume / Watts at Different Blower Speeds
Pressure High Medium Low
in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts
0.00 0 1225 580 485 1000 470 365 820 385 290
0.10 25 1190 560 455 990 470 355 815 385 275
0.20 50 1160 545 435 970 460 340 805 380 265
0.30 75 1120 530 415 945 445 325 780 365 260
0.40 100 1070 505 395 910 430 305 755 355 245
0.50 125 1015 480 375 865 405 295 740 350 240
0.60 150 955 450 355 835 395 285 695 325 225
0.70 175 885 415 335 750 355 260 640 300 210
0.80 200 825 390 320 695 330 245 545 255 185
0.90 225 715 335 3000 600 285 220 435 205 170
NOTES − All air data is measured external to unit without filter (not furnished − field provided).
Air volume based on bottom air return air. Actual air volume may vary on side return air applications.

G51MP−36B−045 PERFORMANCE (Less Filter)

External Static Air Volume / Watts at Different Blower Speeds
Pressure High Medium−High Medium−Low Low
in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts
0.00 25 1555 735 630 1410 665 585 1190 560 520 1030 485 435
0.10 25 1515 715 605 1385 655 555 1190 560 485 1020 480 415
0.20 50 1470 695 580 1345 635 520 1170 550 455 1010 475 400
0.30 75 1410 665 555 1310 620 495 1155 545 440 1000 470 385
0.40 100 1350 640 535 1250 590 465 1120 530 410 980 465 360
0.50 125 1290 610 505 1205 570 450 1080 510 390 950 450 345
0.60 150 1220 575 485 1145 540 420 1020 480 365 905 430 320
0.70 175 1145 540 460 1080 510 400 975 460 345 860 405 300
0.80 200 1050 495 425 985 465 365 870 410 320 785 370 285
0.90 225 945 445 410 900 425 345 825 390 305 730 345 270
NOTES − All air data is measured external to unit without filter (not furnished − field provided).
Air volume based on bottom air return air. Actual air volume may vary on side return air applications.

G51MP−36B−070 PERFORMANCE (Less Filter)

External Static Air Volume / Watts at Different Blower Speeds
Pressure High Medium−High Medium−Low Low
in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts
0.00 0 1640 775 660 1415 665 575 1160 545 485 1005 475 410
0.10 25 1600 755 635 1395 660 550 1160 545 460 1000 470 385
0.20 50 1540 725 605 1370 650 525 1160 545 445 995 470 375
0.30 75 1495 705 580 1345 635 505 1145 540 425 990 465 365
0.40 100 1420 670 545 1275 605 480 1125 530 395 965 455 345
0.50 125 1360 640 525 1245 590 450 1080 510 375 945 445 325
0.60 150 1275 600 490 1165 550 410 1025 485 350 900 425 305
0.70 175 1170 555 465 1085 515 385 965 430 335 860 405 295
0.80 200 1080 510 440 1010 475 360 865 410 310 775 365 270
0.90 225 945 445 400 840 395 320 765 360 275 710 335 245
NOTES − All air data is measured external to unit without filter (not furnished − field provided).
Air volume based on bottom air return air. Actual air volume may vary on side return air applications.

Page 4
 BLOWER PERFORMANCE
G51MP−36C−090 PERFORMANCE (Less Filter)
External Static Air Volume / Watts at Different Blower Speeds
Pressure High Medium−High Medium−Low Low
in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts
0.00 0 1630 770 745 1360 640 635 1125 530 540 975 460 440
0.10 25 1620 765 715 1365 645 610 1160 545 515 1000 470 430
0.20 50 1590 750 680 1365 645 580 1160 545 495 990 465 405
0.30 75 1550 730 655 1355 640 565 1170 550 475 985 465 395
0.40 100 1520 715 630 1330 630 545 1160 545 460 980 460 380
0.50 125 1465 690 605 1300 615 515 1140 540 440 960 455 360
0.60 150 1415 670 570 1250 590 490 1095 515 420 940 445 350
0.70 175 1350 635 545 1215 575 470 1065 500 400 905 425 335
0.80 200 1260 595 510 1140 540 440 1005 475 375 850 400 310
0.90 225 1165 550 475 1035 485 395 900 425 335 730 345 285
NOTES − All air data is measured external to unit without filter (not furnished − field provided).
Air volume based on bottom air return air. Actual air volume may vary on side return air applications.

G51MP−48C−090 PERFORMANCE (Less Filter)

External Static Air Volume / Watts at Different Blower Speeds
Pressure High Medium−High Medium−Low Low
in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts
0.00 0 2180 1030 930 1835 865 790 1520 715 630 1280 605 510
0.10 25 2135 1005 885 1825 860 750 1510 710 610 1275 600 495
0.20 50 2085 985 840 1810 855 720 1505 710 580 1270 600 475
0.30 75 2030 955 800 1775 835 685 1500 705 565 1265 595 460
0.40 100 1940 915 760 1735 820 650 1480 700 535 1250 590 440
0.50 125 1865 880 725 1660 785 600 1430 675 505 1215 575 425
0.60 150 1740 820 670 1590 750 575 1380 650 475 1175 555 410
0.70 175 1645 775 640 1475 695 520 1290 610 450 1105 520 375
0.80 200 1540 725 600 1340 630 465 1175 555 405 1020 480 355
0.90 225 1335 630 540 1170 555 440 1070 505 375 950 450 330
NOTES − All air data is measured external to unit without filter (not furnished − field provided).
Air volume based on bottom air return air. Actual air volume may vary on side return air applications.

G51MP−48C−110 PERFORMANCE (Less Filter)

External Static Air Volume / Watts at Different Blower Speeds
Pressure High Medium−High Medium−Low Low
in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts
0.00 0 2160 1020 880 1880 890 755 1490 705 602 1235 580 485
0.10 25 2100 990 850 1855 875 730 1480 700 585 1230 580 475
0.20 50 2035 960 805 1815 860 690 1475 695 560 1225 580 460
0.30 75 1965 925 750 1755 830 650 1475 695 545 1220 575 445
0.40 100 1885 890 725 1715 810 625 1465 690 510 1215 575 430
0.50 125 1780 840 680 1630 770 580 1420 670 490 1150 540 400
0.60 150 1690 800 660 1550 735 550 1360 640 460 1110 525 380
0.70 175 1575 745 620 1410 665 505 1210 570 405 1035 490 350
0.80 200 1375 650 550 1230 580 450 1125 530 380 970 460 325
0.90 225 1225 580 520 1120 530 415 1050 495 365 885 420 310
NOTES − All air data is measured external to unit without filter (not furnished − field provided).
Air volume based on bottom air return air. Actual air volume may vary on side return air applications.

Page 5
 BLOWER PERFORMANCE

G51MP−60C−090 PERFORMANCE (Less Filter) − Single Side Return Air − Air volumes in bold require field fabricated transi-
tion to accommodate 20 x 25 x 1 in. (508 x 635 x 25 mm) air filter in order to maintain proper air velocity.

External Static Air Volume / Watts at Different Blower Speeds

Pressure High Medium−High Medium−Low Low
in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts
0.00 0 2835 1335 1495 2340 1105 1155 1800 850 895 1440 680 695
0.10 25 2785 1315 1475 2345 1105 1135 1805 855 865 1515 715 690
0.20 50 2715 1280 1435 2275 1075 1080 1825 860 845 1560 735 685
0.30 75 2620 1235 1380 2260 1065 1035 1840 870 825 1600 755 680
0.40 100 2550 1205 1350 2230 1055 1015 1845 870 815 1620 765 670
0.50 125 2450 1155 1305 2175 1025 990 1850 870 790 1615 765 655
0.60 150 2365 1115 1270 2130 1005 940 1830 865 775 1615 760 640
0.70 175 2240 1060 1205 2070 975 915 1815 855 760 1595 755 620
0.80 200 2185 1030 1190 1965 925 865 1775 840 745 1555 735 605
0.90 225 2015 950 1150 1820 860 820 1690 800 715 1440 680 580
NOTES − All air data is measured external to unit without filter (not furnished − field provided).

G51MP−60C−090 PERFORMANCE (Less Filter) − Bottom Return Air, Side Return Air with Optional RAB Return Air Base, Re-
turn Air from Both Sides or Return Air from Bottom and One Side.

External Static Air Volume / Watts at Different Blower Speeds

Pressure High Medium−High Medium−Low Low
in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts
0.00 0 2840 1340 1450 2345 1105 1105 1895 895 900 1515 715 700
0.10 25 2765 1305 1415 2365 1115 1080 1950 920 885 1580 745 700
0.20 50 2695 1270 1385 2345 1105 1050 1985 935 870 1620 765 695
0.30 75 2605 1230 1335 2315 1090 1030 1990 940 850 1645 775 690
0.40 100 2530 1195 1300 2265 1070 990 1990 940 825 1665 785 675
0.50 125 2420 1140 1260 2210 1045 955 1970 930 800 1675 790 665
0.60 150 2330 1100 1220 2145 1010 925 1930 910 775 1665 785 650
0.70 175 2250 1060 1190 2050 965 885 1875 885 745 1645 775 630
0.80 200 2135 1010 1140 2000 945 865 1810 855 715 1620 765 615
0.90 225 2030 960 1090 1885 890 830 1720 810 685 1560 735 590
NOTES − All air data is measured external to unit without filter (not furnished − field provided).

G51MP−60C−110 PERFORMANCE (Less Filter) − Single Side Return Air − Air volumes in bold require field fabricated transi-
tion to accommodate 20 x 25 x 1 in. (508 x 635 x 25 mm) air filter in order to maintain proper air velocity.
External Static Air Volume / Watts at Different Blower Speeds
Pressure
High Medium−High Medium−Low Low
in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts
0.00 0 2625 1240 1350 2310 1090 1080 1885 890 885 1515 715 700
0.10 25 2570 1215 1330 2325 1095 1060 1910 900 865 1575 745 700
0.20 50 2410 1135 1305 2285 1080 1035 1930 910 845 1620 765 690
0.30 75 2425 1145 1265 2230 1055 990 1925 905 825 1635 770 675
0.40 100 2335 1100 1220 2175 1025 950 1910 900 810 1640 775 660
0.50 125 2270 1070 1195 2120 1000 935 1895 895 785 1640 775 640
0.60 150 2170 1025 1155 2045 965 885 1860 875 765 1630 770 630
0.70 175 2110 995 1130 1950 920 855 1795 845 730 1590 750 610
0.80 200 2035 960 1090 1885 890 820 1745 825 705 1540 725 580
0.90 225 1900 895 1055 1760 830 780 1665 785 680 1470 695 565
NOTES − All air data is measured external to unit without filter (not furnished − field provided).

Page 6
 BLOWER PERFORMANCE

G51MP−60C−110 PERFORMANCE (Less Filter) − Bottom Return Air, Side Return Air with Optional RAB Return Air Base, Re-
turn Air from Both Sides or Return Air from Bottom and One Side.
External Static Air Volume / Watts at Different Blower Speeds
Pressure
High Medium−High Medium−Low Low
in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts
0.00 0 2720 1285 1385 2410 1135 1090 2055 970 935 1620 765 710
0.10 25 2665 1255 1355 2385 1125 1075 2025 955 885 1730 815 735
0.20 50 2585 1220 1315 2350 1110 1015 2030 955 865 1680 795 690
0.30 75 2505 1180 1275 2290 1080 990 2025 955 840 1695 800 675
0.40 100 2435 1150 1250 2235 1055 940 2030 960 830 1695 800 660
0.50 125 2350 1110 1205 2170 1025 930 1975 930 790 1735 820 665
0.60 150 2255 1065 1185 2100 990 895 1915 905 765 1720 810 650
0.70 175 2160 1020 1150 2005 945 840 1865 880 730 1680 795 635
0.80 200 2020 955 1090 1905 900 825 1810 855 710 1625 765 610
0.90 225 1910 900 1050 1820 860 795 1705 805 675 1540 725 590
NOTES − All air data is measured external to unit without filter (not furnished − field provided).

G51MP−60D−135 PERFORMANCE (Less Filter) − Single Side Return Air − Air volumes in bold require field fabricated transi-
tion to accommodate 20 x 25 x 1 in. (508 x 635 x 25 mm) air filter in order to maintain proper air velocity.
External Static Air Volume / Watts at Different Blower Speeds
Pressure
High Medium−High Medium−Low Low
in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts
0.00 0 2665 1260 1440 2325 1095 1100 1865 880 890 1410 665 690
0.10 25 2615 1235 1405 2310 1090 1065 1915 905 865 1465 690 685
0.20 50 2530 1195 1370 2280 1075 1055 1925 910 850 1570 740 675
0.30 75 2470 1165 1330 2235 1055 1015 1920 905 825 1590 750 670
0.40 100 2380 1125 1290 2175 1025 985 1910 900 805 1590 750 655
0.50 125 2310 1090 1265 2120 1000 965 1890 890 790 1595 755 645
0.60 150 2200 1035 1230 2055 970 935 1835 865 765 1580 745 630
0.70 175 2120 1000 1190 1970 930 900 1790 845 740 1545 730 605
0.80 200 2025 955 1160 1890 890 875 1720 810 710 1515 715 590
0.90 225 1930 910 1110 1800 850 835 1655 780 685 1440 680 570
NOTES − All air data is measured external to unit without filter (not furnished − field provided).

G51MP−60D−135 PERFORMANCE (Less Filter) − Bottom Return Air, Side Return Air with Optional RAB Return Air Base, Re-
turn Air from Both Sides or Return Air from Bottom and One Side.
External Static Air Volume / Watts at Different Blower Speeds
Pressure
High Medium−High Medium−Low Low
in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts
0.00 0 2730 1290 1465 2425 1145 1125 2055 970 915 1560 735 680
0.10 25 2670 1260 1440 2400 1135 1100 2065 975 890 1590 750 675
0.20 50 2600 1225 1400 2365 1115 1070 2045 965 865 1620 765 665
0.30 75 2525 1190 1360 2315 1095 1045 2035 960 845 1615 760 655
0.40 100 2445 1155 1325 2260 1065 1015 2020 955 820 1615 760 645
0.50 125 2360 1115 1280 2195 1035 985 1960 925 790 1610 760 635
0.60 150 2290 1080 1255 2130 1005 965 1900 895 755 1600 755 615
0.70 175 2205 1040 1220 2035 960 910 1825 860 730 1570 740 600
0.80 200 2110 995 1195 1945 915 880 1765 830 710 1540 725 580
0.90 225 1970 930 1120 1835 865 830 1680 795 690 1540 725 545
NOTES − All air data is measured external to unit without filter (not furnished − field provided).

Page 7
 G51MP PARTS IDENTIFICATION

TOP CAP

DuralokPlusTM
HEAT EXCHANGER
ASSEMBLY

CABINET

BURNER BOX
ASSEMBLY

GAS VALVE
AND MANIFOLD

BURNER BOX
COVER

FLUE
COLLAR

WARM HEADER
COMBUSTION (COLLECTOR)
AIR PROVE BOX
SWITCHES

COMBUSTION AIR
INDUCER CONDENSER COIL

BURNER
ACCESS PRIMARY LIMIT
PANEL
COLD HEADER
(COLLECTOR)
BOX

BLOWER
ACCESS DOOR
DOOR INTERLOCK
SWITCH

SECONDARY LIMITS

SIGHT
GLASS

CONTROL BOX

FIGURE 1

Page 8
I−UNIT COMPONENTS B−Control Box Components (Figure 3)
G51MP unit components are shown in figure 1. The com- Unit transformer (T1), igntion control (A92) and circuit
bustion air inducer, gas valve and burners can be accessed breaker (CB8) are located in the control box. In addition, a
by removing the burner access panel. The blower and con- door interlock switch (S51) is located in the control box.
trol box can be accessed by removing the blower access
door. G51MP units are designed for bottom and side re-
turn air.

ELECTROSTATIC DISCHARGE (ESD)

Precautions and Procedures

CAUTION
Electrostatic discharge can affect electronic
CIRCUIT BREAKER
components. Take precautions during furnace (CB8)
installation and service to protect the furnace’s
electronic controls. Precautions will help to avoid
control exposure to electrostatic discharge by
putting the furnace, the control and the techni- DOOR INTERLOCK
cian at the same electrostatic potential. Neutral- SWITCH (S51) IGNITION
ize electrostatic charge by touching hand and all CONTROL TRANSFORMER
(A92) (T1)
tools on an unpainted unit surface, such as the
gas valve or blower deck, before performing any
service procedure. FIGURE 3

1. Transformer (T1)
A−Make-Up Box (Figure 2) A transformer located in the control box provides power to
A field make-up box is provided for line voltage wiring. Line the low voltage section of the unit. The transformers on all
voltage wiring to unit is routed from the make up box. The hot" models are rated at 40VA with a 120V primary and 24V
wire is connected to the door switch and then from the switch secondary.
to the ignition control. The make−up box may be installed inside
or outside the unit and on the unit left or right side (right side
2. Circuit Breaker (CB8)
shown figure 2). A 24V circuit breaker is also located in the control box. The
switch provides overcurrent protection to the transformer
(T1). The breaker is rated at 3A at 32V. If the current ex-
INTERIOR MAKE−UP BOX INSTALLATION
ceeds this limit the breaker will trip and all unit operation
MAKE−UP will shutdown. The breaker can be manually reset by
BOX
pressing the button on the face. See figure 4.
CIRCUIT BREAKER CB8

PRESS TO RESET
Right Side

FIGURE 4
3. Door Interlock Switch (S51)
CLAMP LOCATION
A door interlock switch rated 14A at 120VAC is located on
the control box. The switch is wired in series with line volt-
FIGURE 2 age. When the blower door is removed the unit will shut
down.

Page 9
 TABLE 1
WARNING IGNITION CONTROL 97L48 J156 TERMINAL
DESIGNATIONS
Shock hazard.
Disconnect power before servicing. Control is PIN # FUNCTION
not field repairable. If control is inoperable, sim- 1 Ignitor
ply replace entire control.
Can cause injury or death. Unsafe operation will 2 Not Used
result if repair is attempted. 3 Ignitor Neutral

4. SureLight® Integrated Ignition Control 4 Combustion Air Inducer Line Voltage

97L48 (A92) ALL −1 units and 090−2 units 5 Not Used
The SureLight hot surface ignition system consists of inte- 6 Combustion Air Inducer Neutral
grated ignition control (figure 6 with control terminal desig-
TABLE 2
nations in table 3), hot surface ignitor (figure 9) and sensor
IGNITION CONTROL 97L48 J58 TERMINAL
(figure 10). The ignition control and ignitor work in com- DESIGNATIONS
bination to ensure furnace ignition and ignitor durability.
PIN # FUNCTION
The ignition control, controls all major furnace operations.
1 Primary Limit In
The ignition control also features two green LED lights
2 Gas Valve Common
(DIAG 1 and DIAG 2) for troubleshooting and two accesso-
ry terminals each rated at (1) one amp. Tables 1 and 2 show 3 Roll Out Switch Out
jack plug terminal designations. See table 8 for trouble- 4 Gas Valve 24V
shooting diagnostic codes. Units equipped with the Sur- 5 Pressure Switch In
eLight hot surface ignition system can be used with either 6 Pressure Switch and Primary Limit Out
electronic or electro−mechanical thermostats without mod- 7 Not Used
ification. The ignitor is made of durable silicon−nitride. Igni- 8 Roll Out Switch In
tor longevity is also enhanced by voltage ramping by the
9 Ground
ignition control. The ignition control finds the lowest ignitor
temperature which will successfully light the burner, thus The ignition control has an added feature that prolongs the
increasing the life of the ignitor. Each time power is applied life of the ignitor. After a successful ignition, the ignition con-
to the furnace, the ignition control performs a self check in- trol utilizes less power to energize the ignitor on successive
cluding energizing the combustion air inducer for a period calls for heat. The ignition control continues to ramp down
of 1 second. the voltage to the ignitor until it finds the lowest amount of
a−Electronic Ignition (See Figure 7) power that will provide a successful ignition. This amount of
On a call for heat the ignition control monitors the combus- power is used for 255 cycles. On the 256th call for heat, the
tion air inducer prove switches. The ignition control will not ignition control will again ramp down until the lowest power
begin the heating cycle if the prove switch is closed (by− is determined and the cycle begins again.
passed). Once the proving switch is determined to be open, b−Fan Time Control
the combustion air inducer is energized. When the differen- The fan on time of 45 seconds is not adjustable. Fan off time
tial in the prove switch is great enough, the prove switch (time that the blower operates after the heat demand has
closes and a 15−second pre−purge begins. If the prove been satisfied) can be adjusted by setting the dip switches
switch is not proven within 2−1/2 minutes, the control goes located on the ignition control board. The unit is shipped
into Watchguard−Pressure Switch mode for a 5−minute re− with a factory fan off setting of 90 seconds. Fan off time will
set period. affect comfort and is adjustable to satisfy individual applica-
After the 15−second pre−purge period, the ignitor warms up tions. For customized comfort, monitor the supply air tem-
for 20 seconds then the gas valve opens for a 4−second trial perature once the heat demand is satisfied. Note the supply
for ignition. The ignitor is energized during the 4−second air temperature at the instant the blower is de−energized.
ignition trial until flame is sensed. If ignition is not proven Adjust the fan−off delay to achieve a supply air temperature
during the 4−second period, the ignition control will try four between 90°F − 110°F at the instant the blower is de−ener-
more times with an inter purge and warm−up time between gized. (Longer delay times allow for lower air temperature,
trials of 35 seconds. After a total of five trials for ignition (in- shorter delay times allow for higher air temperature). See
cluding the initial trial), the ignition control goes into Watch- figure 5.
guard−Flame Failure mode. After a 60−minute reset period,
the ignition control will begin the ignition sequence again.

Page 10
 FAN-OFF TIME ADJUSTMENT TABLE 3
60sec. 90sec. 120sec. 180sec. IGNITION CONTROL 97L48 TERMINAL DESIGNATIONS
OFF ON OFF ON OFF ON OFF ON ACB COOL blower − cooling speed (line voltage)
ACB HEAT blower − heating speed (line voltage)

1
1

1
1

OFF
OFF

OFF
OFF

2
2

2
PARK alternate blower speeds
(Black square indicates switch position)
To adjust fan−off timing, set dip switch to desired setting. ACB LOW continuous low speed
FIGURE 5 ACC accessory terminal (line voltage)
TX 120vac hot to transformer
INTEGRATED IGNITION CONTROL 97L48
HOT 120vac hot input
HTG ACC heat only accessory (line voltage)
NEUTRALS 120vac neutral
24VAC HOT 24vac hot from transformer
J156 24VAC RTN 24vac return from transformer
FLAME SENSE flame sense terminal

J58

LED’s

FIGURE 6

SureLight Control Ignition Sequence

ÉÉ 15 Sec. 20 sec. 4 Sec.Trial Blower On" End of 5 SEC

ÉÉ
Pre −Purge Ignitor Warmup for Ignition Delay Heat Demand Blower
ON Post Off

ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
OFF Purge Time

ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉÉÉÉ
DEMAND
CAI

ÉÉÉÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉ
IGNITOR

ÉÉÉÉÉÉÉÉÉÉ
GAS VALVE
INDOOR BLOWER
*Blower on time will be 45 seconds after gas valve is energized. Blower off time will depend on OFF TIME" Setting.

FIGURE 7

Page 11
5. SureLight® Integrated Ignition Control
INTEGRATED IGNITION CONTROL 69M15
69M15 (A92) Figure 8
G51MP045−2, 070−2, 110−2, 135−2, 090−3 and later dash
number units are also equipped with the Lennox SureLight
hot surface ignition system. Like earlier dash number
units, the system consists of ignition control board, ignitor
and sensor. The ignition control and ignitor work in com-
bination to ensure furnace ignition and ignitor durability.
The ignition control controls all major furnace operations.
The ignition control also features two LED lights (DS1 red
and DS2 green) for troubleshooting and two 120 volt ac- FLAME

cessory terminals each rated at (1) one amp. A 24 volt ac-

cessory terminal rated at 0.5 amps is also provided. Table 4
shows 24 volt and 120 volt control terminal designations.
Tables 5 and 6 show jack plug terminal designations. See
table 8 for troubleshooting diagnostic codes. Units
equipped with the SureLight hot surface ignition system
can be used with either electronic or electro−mechanical
thermostats without modification. The ignitor is made of
LED’s
durable silicon−nitride. Ignitor longevity is also enhanced
by voltage ramping by the ignition control. The ignition con-
trol finds the lowest ignitor temperature which will success-
fully light the burner, thus increasing the life of the ignitor.
Each time power is applied to the furnace, the ignition con-
trol performs a self check.
FIGURE 8
TABLE 4 TABLE 6
IGNITION CONTROL 69M15 TERMINAL IGNITION CONTROL 69M15 (E1) TERMINAL
DESIGNATIONS DESIGNATIONS
COOL Blower − Cooling Speed (120V) PIN # FUNCTION
HEAT Blower − Heating (120V) 1 Prove Switch and Limit Out
PARK Unused blower lead not energized 2 Not Used
FAN Continuous Low Blower Speed 3 24V Hot
EAC Accessory Terminal (120V) 4 Not Used
XFMR Transformer (120V) 5 Roll Out Switch Out
LINE Input (120V) 6 24V Common
HUM Heat Only Accessory (120V) 7 Limit In
5 Terminals 120 Volt Neutral 8 Ground
FS Flame Sensor 9 Gas Valve Common
24V HUM Heat Only Accessory (24V) 10 Prove Switch In
11 Roll Out Switch In
TABLE 5
12 Gas Valve 24V Hot
IGNITION CONTROL 69M15 (E4) TERMINAL
DESIGNATIONS
PIN # FUNCTION
1 Combustion Air Inducer Line Voltage
2 Ignitor Voltage
3 Combustion Air Inducer Neutral
4 Ignitor Neutral

Page 12
a−Electronic Ignition (See Figure 7) b−Fan Time Control Heating
On a call for heat the ignition control board monitors the The heating fan on time of 45 seconds is not adjustable. Fan
combustion air inducer prove switch. The ignition control off time (time that the blower operates after the heat de-
will not begin the heating cycle if the prove switch is closed mand has been satisfied) can be adjusted by setting the S1
(by−passed). Once the proving switch is determined to be dip switches (switches 1 and 2) located on the ignition con-
open, the combustion air inducer is energized. When the trol. The unit is shipped with a factory fan off setting of 90
differential in the prove switch is great enough, the prove seconds. Fan off time will affect comfort and is adjustable to
switch closes and a 15−second pre−purge begins. If the satisfy individual applications. For customized comfort,
prove switch is not proven within 2−1/2 minutes, the control monitor the supply air temperature once the heat demand is
goes into a 5 minute prove switch reset period. satisfied. Note the supply air temperature at the instant the
After the 15−second pre−purge period, the ignitor warms up blower is de−energized. Adjust the fan−off delay to achieve a
for 20 seconds then the gas valve opens for a 4−second trial supply air temperature between 90° − 110° at the instant the
for ignition. The ignitor stays energized during the trial until blower is de−energized. (Longer delay times allow for lower
flame is sened. If ignition is not proved during the 4−second air temperature, shorter delay times allow for higher air tem-
period, the ignition control will try four more times with an in- perature). See table 7 for switch settings and fan delay
ter purge and warm−up time between trials of 35 seconds. times..
After a total of five trials for ignition (including the initial trial), c−Fan Time Control Cooling
the ignition control goes into Watchguard−Flame Failure The cooling fan on time is fixed at 2 seconds and cannot be
mode. After a 60−minute reset period, the ignition control will adjusted. Fan off time (time that the blower operates after
begin the ignition sequence again. the cool demand has been satisfied) is factory set at 2 sec-
The ignition control has an added feature that prolongs the onds but can be adjusted by setting the S1 dip switches
life of the ignitor. After a successful ignition, the ignition con- (switch 3) located on the SureLight integrated control. See
trol utilizes less power to energize the ignitor on successive table 7 for switch settings and fan delay times.
calls for heat. The ignition control continues to ramp down TABLE 7
the voltage to the ignitor until it finds the lowest amount of
power that will provide a successful ignition. This amount of S1 DIP SWITCH SETTINGS
power is used for 255 cycles. On the 256th call for heat, the Heat Off Delay
ignition control will again ramp down until the lowest power Switch 1 Switch 2 SECONDS
is determined and the cycle begins again. OFF OFF 60
OFF ON 90
ON OFF 120
ON ON 180

Cool Off Delay

Switch 3 SECONDS
OFF 2
(factory setting)
ON 45

Page 13
The SureLight® integrated ignition control is equipped with
two LED lights for troubleshooting. The diagnostic codes
are listed below in table 8.
TABLE 8
DIAGNOSTIC CODES
Make sure to Identify LED’S Correctly. Refer to figure 6 or 8.
LED #1 LED #2
97L48 − DIAG1 Green 97L48 − DIAG2 Green DESCRIPTION
69M15 − DS1 Red 69M15 − DS2 Green
SIMULTANEOUS SIMULTANEOUS Power on − Normal operation.
SLOW FLASH SLOW FLASH Also signaled during cooling and continuous fan.
SIMULTANEOUS SIMULTANEOUS
Normal operation − signaled when heating demand initiated at thermostat.
FAST FLASH FAST FLASH
Primary or secondary limit switch open. Limit must close within 3 minutes or unit goes into 1
SLOW FLASH ON
hour Watchgurad.
Prove Switch open
OR: Blocked inlet/exhaust vent;
OFF SLOW FLASH
OR: Prove switch closed prior to activation of combustion air blower.
OR: Blocked condensate line
ALTERNATING ALTERNATING Watchguard −− burners failed to ignite.
SLOW FLASH SLOW FLASH Limit open more than 3 minutes OR: Lost flame sense 5 times in one heating cycle.
SLOW FLASH OFF Flame sensed without gas valve energized.
ON SLOW FLASH Rollout switch open. OR: Low voltage pin connector improperly attached.
ON ON
ON OFF Circuit board failure or control wired incorrectly.
y Check 120 and 24 voltage
g to board.
OFF ON
FAST FLASH SLOW FLASH Main power polarity reversed. Switch line and neutral. Improper main ground.
Low flame signal. Measures below:
Control 97L48 0.61 microAmps
SLOW FLASH FAST FLASH
Control 69M15 0.31 microAmps.
Replace flame sense rod.
The following conditions are sensed during the ignitor warm−up period only:
1) Improper main ground;
ALTERNATING ALTERNATING 2) Broken ignitor; OR: Open ignitor circuit;
FAST FLASH FAST FLASH 3) Line voltage below 75 volts.
(If voltage lower than 75 volts prior to ignitor warm-up, control will signal waiting on call from
thermostat, and will not respond.

NOTE − Slow flash rate equals 1 Hz (one flash per second). Fast flash rate equals 3 Hz (three flashes per second).
Low flame sense current − 97L48 control = 0.21−0.60 microAmps. 69M15 control = 0.25 − 0.30 microAmps.
C−Heating Components Ignitor Location
Combustion air inducer (B6), primary limit control (S10), ig- (up flow position)
nitor, burners, flame rollout switch (S47), gas valve (GV1), 5/8" MEASUREMENT IS TO I.D.
OF RETENTION RING
combustion air prove switch (S18), and clamshell heat ex-
changers are located in the heating compartment. The heat-
ing compartment can be accessed by removing the burner
13/32’
access panel.
1. Ignitor (Figure 9)
BRACKET
The ignitor is made of durable silicon nitride. Ignitor longev-
ity is enhanced by controlling voltage to the ignitor. The igni-
tion control finds the lowest ignitor temperature which will
successfully light the burner, thus increasing the life of the IGNITOR
ignitor. Due to this feature of the board, voltage cannot be
BURNERS FRONT VIEW
measured so ignitor must be ohmed. Ohm value should be
FIGURE 9
10.9 to 19.7

Page 14
2. Flame Sensor PRIMARY LIMIT LOCATION
(Figure 10 up flow position)
A flame sensor is located on the left side of the burner sup-
port. The sensor is mounted on the bottom burner box plate
and the tip protrudes into the flame envelope of the left−most
burner. The sensor can be removed for service without re-
moving any part of the burners. During operation, flame is
sensed by current passed through the flame and sensing
electrode. The ignition control allows the gas valve to re-
main open as long as flame signal is sensed. See table 20
for flame signal.
NOTE − The G51MP furnace contains electronic com-
limit shield
ponents that are polarity sensitive. Make sure that the
090, −110 and
furnace is wired correctly and is properly grounded. −135 only

limit faces shield

FIGURE 11
4. Burners (Figure 12)
All units use inshot burners. Burners are factory set and do not
5/16"
require adjustment. Burners can be removed as an assembly
for service. Burner maintenance and service is detailed in the
MAINTENANCE section of this manual. Each burner uses
an orifice which is precisely matched to the burner input. All
G51MP natural gas units are fitted with .089" sized orifices.
See table 22 or SPECIFICATIONS" tables for LP kits and
high altitude. The orifice is threaded into the burner manifold.
FIGURE The burner is supported by the orifice and will easily slide off
10 for service. A flame retention ring in the end of each burner
3. Primary Limit Control (S10) maintains correct flame length and shape and keeps the flame
from lifting off the burner head. In addition, the burner entrance
Figure 11 shows the primary limit (S10) used on G51MP units
to each clamshell is fitted with a corbel cup (orifice) used to di-
located in the heating vestibule panel. S10 is provided with a
rect the flow of combustion products.
shield on some models (figure 11) and must not be removed.
Note orientation of shield and limit if limit is replaced. When ex- NOTE − Do not use thread-sealing compound on the ori-
cess heat is sensed in the heat exchanger, the limit will open. fices. Thread-sealing compound may plug the orifices.
Once the limit opens, the ignition control energizes the sup- BURNER DETAIL TOP VIEW
ply air blower and de−energizes the gas valve. The limit au-
tomatically resets when unit temperature returns to normal.
The switch is factory set and cannot be adjusted.

5/16"

ignitor
FIGURE 12

Page 15
5. Clamshell Heat Exchanger 24VAC terminals and gas control knob are located on top
of the valve. All terminals on the gas valve are connected
G51MP units use an aluminized steel primary and stain-
to wires from the ignition control. 24V applied to the terminals
less steel secondary heat exchanger assembly. Heat is
opens the valve.
transferred to the air stream from all surfaces of the heat
Inlet and outlet pressure taps are located on the valve. A
exchanger. The shape of the heat exchanger ensures
manifold adjustment screw is also located on the valve.
maximum efficiency.
An LPG changeover kit is available. See table 22. For
The combustion air inducer pulls fresh air through the air in- units equipped with the Honeywell VR205 valve, the kit
take box. This air is mixed with gas in the burner venturi and includes a low pressure switch that must be installed in
at the corbel orifices. The gas / air mixture is then burned the valve as shown in figure 14.
at the entrance of each clamshell. Combustion gases are The burner box is sealed and operates under a negative
then pulled through the primary and secondary heat exchang- pressure. A pressure hose is connected from the burner box
ers and exhausted out the exhaust vent pipe. to the gas valve. The gas valve senses the pressure in the
burner box and changes gas valve outlet (manifold) pres-
6. Backup Secondary Limit Control (S113)
sure based on changes in the burner box pressure. The in-
(G51MP−090, 110, 135 only) tent is to compensate for different vent configurations which
Backup secondary limit control S113 is a N.C. auto−reset can greatly affect the rate of the unit.
switch located on the combustion air inducer. S113 acts as a
backup to primary limit S10 in the event of an indoor blower
failure. S113 contacts open when temperature on the CAI
IMPORTANT
The White Rodgers 36G gas valve (figures 14 and 42)
reaches 142°. is equipped with pressure posts for measuring sup-
ply and manifold pressures. The posts provide built−
in hose connections and have an integral 3/32" Allen−
7. Flame Rollout Switches (S47) head screw. Rotate the screw counterclockwise one
full turn to permit pressure measurement. Reseat the
Flame rollout switches S47 are SPST N.C. high temperature screw (rotate one full turn clockwise) after measure-
limits located on each side of the burner box assembly (see fig- ments have been taken to prevent gas leakage.
ure 13). S47 is wired to the ignition control A92. When ei-
ther of the switches sense flame rollout (indicating a HONEYWELL VR8205 SERIES GAS VALVE
blockage in the combustion passages), the flame rollout
switch trips, and the ignition control immediately closes PRESSURE BARBED
the gas valve. Switch S47 in all G51MP units is factory pre- SWITCH FITTING
(LP ONLY) MANIFOLD
set to open at 250_F + 12_F (121_C + 6.7_C) on a tempera- PRESSURE
ture rise. All flame rollout switches are manual reset. OUTLET

ROLLOUT SWITCH
ON
(each side)
INLET
PRESSURE
OFF
PORT WITH
INLET TAP
FITTING
WHITE RODGERS 36G SERIES GAS VALVE
MANIFOLD
PRESSURE
OUTLET POST

REFERENCE
TO BURNER
FIGURE 13 BOX

MANIFOLD
PRESSURE
8. Gas Valve (GV1) ADJUSTMENT
LINE PRESSURE SCREW
The G51MP uses a gas valve manufactured by Honeywell or INLET POST
White Rodgers (see figure 14 ). The valves are internally redun- GAS VALVE SHOWN IN OFF POSITION
dant to assure safety shut-off. If the gas valve must be re-
placed, the same type valve must be used. FIGURE 14

Page 16
9. Combustion Air Inducer (B6) PROVE SWITCH (S18)
All G51MP units use a combustion air inducer to move air side view negative (−) barb
through the burners and heat exchanger during heating gray
operation. The blower uses a shaded pole 120VAC motor. bracket
The motor operates during all heating operation and is con-
trolled by burner ignition control A3. Blower operates contin-
uously while there is a call for heat. The burner ignition con- positive (+) barb
terminals black
trol will not proceed with the ignition sequence until
FIGURE 15
combustion air inducer operation is sensed by the proving
switches. On start-up, the switches sense that the combustion air induc-
er is operating. They close a circuit to the ignition control
The CAI is installed on the cold end header box. The cold
when the difference in pressure across the CAI orifice ex-
end header box is a single piece made of hard plastic. The
ceeds a non−adjustable factory setting. If the switches do not
box has an internal channel where the combustion air in-
successfully sense the required differential, the
ducer creates negative pressure at unit start up. The
switches cannot close and the furnace cannot operate. If
channel contains an orifice used to regulate flow created
the flue or air inlet become obstructed during operation,
by the CAI. The box has pressure taps for the CAI prove
the switches sense a loss of pressure differential and opens
switch hoses. The prove switches measure the pressures
the circuit to the ignition control. If the condensate line is
across the CAI orifice or difference in the channel and the
blocked, water will back up into the header box and reduce
box. A window is provided on the bottom right hand side of
the pressure differential across the switch. The prove
the box to indicate orifice size. See figure 16. See table 9
switches open if the differential drops below the set point.
for orifice size per unit. If replacement is necessary the
Table 10 shows the set point for units installed from 0’ to
gaskets used to seal the box to the vestbule panel and
10000’. If the unit is installed above 4500’ a high altitude
the CAI to the box, must also be replaced.
kit must be installed. See section IV− sub section J− for
TABLE 9 High Altitude information.
G51MP Unit C.A.I. Orifice Size To troubleshoot the prove switches, temporarily jumper them.
−045 .703" The unit will not fire with the switches jumpered. Therefore, the
−045 −1 to −6 .750" prove switches must be bypassed after the combustion air in-
−070 .922" ducer is activated. This will determine if the prove switches
−070−1 to −6 .969" and furnace are operating properly. However, this may not indi-
−090 1.063" cate if the sealed combustion system is operating properly.
−110 1.344" Checks of pressure differential can aid in troubleshooting.
−135 1.625" When measuring the pressure differential, readings should be
taken at the prove switch. Lack of differential usually indicates
10. Combustion Air Prove Switch (S18) problems in the intake or exhaust piping, but may indicate
problems in the heat exchanger, condensing coil, head-
G51MP series units are equipped with two differential
er boxes, combustion inducer or other components.
prove switches located on the combustion air inducer
housing. The switches are factory set and require no ad- Measuring pressure differential
justment. See figures 15 and 16. All G51MP units installed The differential pressure is the difference in pressure mea-
from One side of the switch is gray (negative hose barb) and sured across the cold end header box orifice.
the other side is black (positive hose barb). The switches moni- 1 − Remove thermostat demand and allow unit to cycle
tor across the CAI orifice to insure proper flow through the heat off.
exchanger. The switches DO NOT have to be removed and
2 − Install a tee in the negative (−) line and a tee in the positive
re−installed per unit application (up−flow, down flow, hori-
(+) line running from one of the prove switches to the cold
zontal left, right).
end header box.
The switches are SPST N.O. prove switches electrically con- 3 − Install a manometer with hose from the negative (−) side
nected to the integrated control. The purpose of the switches of the manometer to the tee installed in the negative (−)
is to prevent burner operation if the combustion air inducer is line and with hose from the positive (+) side of the ma-
not moving enough air for proper combustion. nometer to the tee in the positive (+) line.
NOT − The two prove switches in the G51MP are identical NOTE − Both sides of the cold end header box are negative.
and work together for safe operation. Never operate the However the (+) port reads less negative pressure than the
G51MP with either switch by−passed. (−) port.

Page 17
 TABLE 10 D−Blower Compartment (Figure 17)
Prove Switch Set Points* Blower motor (B3) and capacitor (C4), are located in the
Altitude ft blower compartment. The blower compartment can be ac-
0 − 4500 4501 − 7500 7501 − 10000 cessed by removing the blower access panel.
G51MP
Set Point SetPoint Set Point 1.Blower Motor (B3) and Capacitor (C4)
(Pa) (Pa) (Pa) All G51MP units use single−phase direct−drive blower mo-
−045−7 tors. All motors are 120V permanent split capacitor motors to
and later 1.10"(274) 1.10" (274) 1.00" (249)
ensure maximum efficiency. See SPECIFICATIONS table at
−045−1 to the front of this manual for more detail. See motor nameplate
−6 units .95" (236) .95" (236) .85" (211)
for capacitor ratings.
−070−7 2. Secondary Limit Controls (S21)
and later 1.00"(249) .95" (236) .85" (211)
The secondary limits (S21) on G51MP units are located in the
−070−1 to
−6 units .95" (236) .95" (236) .85" (211) blower compartment in the back side of the blower housing.
See figure 17. When excess heat is sensed in the blower
all −090
.85"
85" (211) .75"
75" (186) .65"
65" (162) compartment, the limit will open. If the limit is open, the ignition
all −110
control energizes the supply air blower and de−energizes the
all −135 .65 (162) .55" (137) .45" (112) gas valve. The limit automatically resets when unit temperature
NOTE − See table 22 for high altitude kits. returns to normal. The switch is factory set to open at 125°F
*Set point is factory set and non−adjustable. and cannot be adjusted.
SUPPLY AIR BLOWER
CAI & COLD END HEADER BOX ASSEMBLY AND SECONDARY LIMITS
Left Side
Right Side

Install tee’s in the

negative line and
positive line then
connect hoses to
manometer.

SECONDARY
LIMIT (S)

MOTOR/BLOWER
CAPACITOR ASSEMBLY
− + + − To Remove Blower From Unit: Disconnect Power, Remove Control
Box, Unplug Secondary Limit Wires From Unit Harness. Remove
Bolts and Unplug Motor Wires From Control Board. Then Slide Out
Front of Unit.

FIGURE 17
cold end header box prove switches orifice size
FIGURE 16
4 − Operate unit and observe draft gauge reading. Read-
ings will change as heat exchanger warms.
a. Take one reading immediately after start-up.
b. Take a second reading after unit has reached steady
state (approximately 5 minutes). This will be the pres-
sure differential.
The pressure differential should be greater
than those listed in table 10.
5 − Remove thermostat demand and allow to cycle off.
6 − Remove manometer and tee’s. Reinstall combustion air
sensing hoses to the prove switch.
7 − Repeat steps 1 through 6 for the other prove switch.

Page 18
II−PLACEMENT AND INSTALLATION
Make sure unit is installed in accordance with installation in-
structions and applicable codes.
TABLE 11
OUTDOOR TERMINATION KITS AND CORRESPONDING EQUIVALENCIES
Vent Pipe Length Equivalency (feet)
Outdoor Outdoor
2" Wall
VENT Exhaust Exhaust 1−1/2" 2" Con- 3" Con-
2" Wall 3" Wall Kit with 2" Wall
UNIT PIPE Accelerator Accelerator Concen- centric centric
Plate Kit Plate Kit Vent Ex- Ring Kit
MODEL DIA. (Dia. X (Dia. X tric Kit Kit Kit
tension
(in.) Length) Length)
44J40
1−1/2" X 12" 2" X 12" 71M80 60M29 60L46 22G44 30G28 15F74
81J20

2 4 Not 12 Not Not 4 4* 4 4

Allowed Allowed Allowed
2−1/2 5 Not 15 Not Not 5 5* 5 5
24B 045
24B−045 Allowed Allowed Allowed
36B−045 Not Not Not
3 7 21 7 7* 7 7
Allowed Allowed Allowed
4 14 Not 42 Not Not 14 14* 14 14
Allowed Allowed Allowed
2 4 Not 12 Not Not 4 4* 4 4
Allowed Allowed Allowed
2−1/2 5 Not 15 Not Not 5 5* 5 5
Allowed Allowed Allowed
36B−070
3 8 Not 24 Not Not 8 8* 8 8
Allowed Allowed Allowed
4 14 Not 42 Not Not 14 14* 14 14
Allowed Allowed Allowed
2 Not 1 Not 3 3 Not 1 Not 1**
Allowed Allowed Allowed Allowed
2−1/2 Not 2 Not 6 6 Not 2 Not 2**
48C 090
48C−090 Allowed Allowed Allowed Allowed
60C−090 Not Not Not Not
3 2 6 6 2 2**
Allowed Allowed Allowed Allowed
4 Not 4 Not 12 12 Not 4 Not 4**
Allowed Allowed Allowed Allowed
2 Not 1 Not 3 3 Not 1 Not 1**
Allowed Allowed Allowed Allowed
2−1/2 Not 2 Not 6 6 Not 2 Not 2***
48C 110
48C−110 Allowed Allowed Allowed Allowed
60C−110 Not Not Not Not
3 2 6 6 2 2***
Allowed Allowed Allowed Allowed
4 Not 4 Not 12 12 Not 4 Not 4***
Allowed Allowed Allowed Allowed
3 Not 6 Not Not 15 Not 6 Not 6***
Allowed Allowed Allowed Allowed Allowed
60D−135
4 Not 10 Not Not 25 Not 10 Not 10***
Allowed Allowed Allowed Allowed Allowed
*Requires field−provided and installed 1−1/2" exhaust accelerator. not required. Requires field−provided and installed 2" exhaust ac-
**Requires field−provided and installed 2" exhaust accelerator. celerator.
***For use only in non−direct vent applications, when snow riser is

Page 19
A−Vent Piping Guidelines Use the following steps to correctly size vent pipe diameter.
The G51MP can be installed as either a Non−Direct Vent 1 − Determine the vent termination and its corresponding
or a Direct Vent gas central furnace. equivalent feet value according to table 11.
NOTE − In Non-Direct Vent installations, combustion air is 2 − Determine the number of 90° elbows required for both
taken from indoors and flue gases are discharged outdoors. indoor and outdoor (e.g. snow riser) use. Calculate the
In Direct Vent installations, combustion air is taken from out- corresponding equivalent feet of vent pipe.
doors and flue gases are discharged outdoors. 3 − Determine the number of 45° elbows required for both
Intake and exhaust pipe sizing in Direct Vent applications indoor and outdoor use. Calculate the corresponding
and exhaust pipe sizing in Non-Direct Vent applications −− equivalent feet of vent pipe.
Size pipe according to tables 12, 13 (direct vent) and 14 4 − Determine the length of straight pipe required.
(non−direct vent). Table 12 lists the minimum equivalent
5 − Add the total equivalent feet calculated in steps 1
vent pipe lengths permitted. Tables 13 and 14 list the maxi-
through 4 and compare that length to the maximum val-
mum equivalent pipe lengths permitted.
ues given in table 13 or 14 for the proposed vent pipe
Maximum vent length is defined as:
diameter. If the total equivalent length required ex-
Total length (linear feet) of pipe,
ceeds the maximum equivalent length listed in the ap-
Plus Equivalent length (feet) of fittings,
propriate table, evaluate the next larger size pipe.
Plus Equivalent length (feet) of termination.
NOTE − Include ALL pipe and ALL fittings, both in
doors and outdoors. IMPORTANT
Regardless of the diameter of pipe used, the standard roof Do not use screens or perforated metal in exhaust ter-
and wall terminations described in section Exhaust Piping minations. Doing so will cause freeze−ups and may
Terminations should be used. Exhaust vent termination block the terminations.
pipe is sized to optimize the velocity of the exhaust gas as it TABLE 12
exits the termination. Refer to table 15. MINIMUM VENT PIPE LENGTHS
*NOTE − The exhaust pipe should be offset a minimum of 12 G51MP MIN. EQUIV.
MODEL VENT LENGTH EXAMPLE
inches to avoid the possibility of water droplets being re-
045, 070, 5 ft. plus 2 elbows of 2", 2−1/2", 3" or
leased from the exhaust termination. The minimum exhaust 090 4" diameter pipe
vent length is 15 ft. Shorter exhaust vent lengths may result 5 ft. plus 2 elbows of 2−1/2" 3" or 4"
110** 15 ft.*
in the discharge of water droplets from the exhaust termina- diameter pipe
tion, in spite of the 12−inch vertical offset. 5 ft. plus 2 elbows of 3" or 4"
135*** diameter pipe
Each 90° elbow (including those provided with the furnace)
*Any approved termination may be added to the minimum equivalent length
of any diameter is equivalent to 5 feet (1.52m) of vent pipe of
listed.
the same diameter. Two 45° elbows are equivalent to one
**G51MP−48C−110 and G51MP−60C−110 must have 90° street ell (supplied)
90° elbow of the same diameter. One 45° elbow is equal to
installed directly into unit flue collar.
2.5 feet (.76m) of vent pipe of the same diameter.
***G51MP−60D−135 must have 3" to 2" reducing ell (supplied) installed directly
In some applications which permit the use of several differ-
into unit flue collar.
ent sizes of vent pipe, a combination vent pipe may be used.
Contact the Application Department for assistance in sizing
vent pipe in these applications.
NOTE − The flue collar on all models is sized to accommo-
date 2" Schedule 40 flue pipe. When vent pipe which is
larger than 2" must be used in an upflow application, a 2"
elbow must be applied at the flue collar in order to properly
transition to the larger diameter flue pipe. This elbow must
be added to the elbow count used to determine accept-
able vent lengths. Assign an equivalent feet value to this
elbow according to the larger size pipe being used. Con-
tact the Application Department for more information con-
cerning sizing of vent systems which include multiple pipe
sizes.

Page 20
 TABLE 13 TABLE 14
MAXIMUM VENT PIPE LENGTHS DIRECT VENT (2 PIPE) MAXIMUM VENT PIPE LENGTHS NON−DIRECT (1 PIPE)
MAXIMUM EQUIVALENT VENT MAXIMUM EQUIVALENT VENT
LENGTH FEET LENGTH FEET
G51MP G51MP
ALTITUDE ALTITUDE
MODEL 2" 2−1/2" MODEL 2−1/2" 4"
3" dia. 4" dia. 2" dia. 3" dia.
dia. dia. dia. dia.
045 110 135 160 250 045 110 135 160 250
045 −1 to −6 59 80 107 234 045 −1 to −6 104 120 137 234
070 70 135 160 250 070 70 135 160 250
070 −1 to −6 59 80 108 214 070 −1 to −6 84 110 138 214

0 − 2000 090 50 100 125 225 0 − 2000 090 50 100 125 225
(0 − 609 m) 090−1 26 42 72 204 (0 − 609 m) 090−1 26 42 72 204
110* 30 70 125 200 110* 30 70 125 200
110* −1, −2 n/a 32 72 179 110* −1, −2 n/a 32 72 179
135** n/a n/a ***125 180 135** n/a n/a ***125 180
135** −1, −2 n/a n/a 61 160 135** −1, −2 n/a n/a 61 160
045 110 135 160 250 045 110 135 160 250
045 −1 to −6 59 80 107 234 045 −1 to −6 104 120 137 234
070 70 135 160 250 070 70 135 160 250
070 −1 to −6 59 80 108 214 070 −1 to−6 84 110 138 214
2001 − 4500 090 50 100 125 225 090 50 100 125 225
2001 − 4500
(610 − 1371
09−1 26 42 72 204 (610 − 1371 m) 090−1 26 42 72 204
m)
110* 20 70 125 200 110* 20 70 125 200
110 −1, −2 n/a 32 72 179 110* −1, −2 n/a 32 72 179
135** n/a n/a ***90 180 135** n/a n/a ***90 180
135** −1, −2 n/a n/a 61 160 135** −1, −2 n/a n/a 61 160
045 110 135 160 250 045 110 135 160 250
045 −1 to −6 59 65 77 234 045 −1 to −6 59 65 77 234
070 70 135 160 250 070 70 135 160 250
070 −1 to −6 59 65 78 214 070 −1 to −6 59 65 78 214

4501−7500 090−1 26 42 72 204 4501−7500 090 30 100 125 225

(1372−2286 m) 090 30 100 125 225 (1372−2286 m) 090−1 26 42 72 204
110* n/a 70 125 200 110* 20 70 125 200
110* −1, −2 n/a 32 72 179 110* −1, −2 n/a 32 72 179
135** n/a n/a ***90 180 135** n/a n/a ***90 180
135** −1, −2 n/a n/a 61 160 135** −1, −2, n/a n/a 61 160
045 110 135 160 250 045 110 135 160 250
045 −1 to −6 59 65 77 234 045 −1 to −6 59 65 77 234
070 70 135 160 250 070 70 135 160 250
070 −1 to −6 59 65 78 214 070 −1 to −6 59 65 78 214
7501 − 10000 090 n/a 100 125 225 090 n/a 100 125 225
7501 − 10000
(2287 − 3048
090−1 26 42 72 204 (2287 − 3048 m) 090−1 26 42 72 204
m)
110* n/a 70 125 200 110* n/a 70 125 200
110* −1, −2 n/a 32 72 179 110* −1, −2 n/a 32 72 179
135** n/a n/a ***90 180 135** n/a n/a ***90 180
135** −1, −2 n/a n/a 61 160 135** −1, −2 n/a n/a 61 160
*G51MP−48C−110 and G51MP−60C−110 must have 90° street ell (supplied) *G51MP−48C−110 and G51MP−60C−110 must have 90° street ell (supplied)
installed directly into unit flue collar. installed directly into unit flue collar.
**G51MP−60D−135 must have 3" to 2" reducing ell (supplied) installed directly **G51MP−60D−135 must have 3" to 2" reducing ell (supplied) installed directly
into unit flue collar. into unit flue collar.
***90° elbows used in configuration of G51MP−60D−135 vent, must be limit- ***90° elbows used in configuration of G51MP−60D−135 vent, must be limit-
ed to 3" sweep elbows. ed to 3" sweep elbows.

Page 21
B−PVC Joint Cementing Procedure 6 − Promptly apply solvent cement to end of pipe and in-
All cementing of joints should be done according to the side socket surface of fitting. Cement should be ap-
specifications outlined in ASTM D 2855. plied lightly but uniformly to inside of socket. Take care
to keep excess cement out of socket. Apply second
coat to end of pipe.
WARNING NOTE − Time is critical at this stage. Do not allow prim-
DANGER OF EXPLOSION! er to dry before applying cement.
Fumes from PVC glue may ignite during system 7 − Immediately after applying last coat of cement to pipe,
check. Allow fumes to dissipate for at least 5 minutes and while both inside socket surface and end of pipe
before placing unit into operation.
are wet with cement, forcefully insert end of pipe into
1 − Measure and cut vent pipe to desired length. socket until it bottoms out. Turn pipe 1/4 turn during as-
sembly (but not after pipe is fully inserted) to distribute
2 − Debur and chamfer end of pipe, removing any ridges or
cement evenly.
rough edges. If end is not chamfered, edge of pipe may
NOTE − Assembly should be completed within 20 sec-
remove cement from fitting socket and result in a leak-
onds after last application of cement. Hammer blows
ing joint.
should not be used when inserting pipe.
3 − Clean and dry surfaces to be joined.
8 − After assembly, wipe excess cement from pipe at end
4 − Test fit joint and mark depth of fitting on outside of pipe. of fitting socket. A properly made joint will show a bead
5 − Uniformly apply liberal coat of PVC primer for PVC or around its entire perimeter. Any gaps may indicate a
ABS cleaner for ABS to inside socket surface of fitting defective assembly due to insufficient solvent.
and male end of pipe to depth of fitting socket. 9 − Handle joints carefully until completely set.

Page 22
C− Venting Practices 3. In areas where piping penetrates joists or interior walls,
The thickness of construction through which vent pipes may hole must be large enough to allow clearance on all
be installed is 24" (610mm) maximum and 3/4" (19mm) sides of pipe through center of hole using a hanger.
minimum. If a G51MP furnace replaces a furnace which 4. Secure piping at the point where it exits the outside wall
was commonly vented with another gas appliance, the size or roof in order to prevent transmission of vibration to
of the existing vent pipe for that gas appliance must be the structure.
checked. Without the heat of the original furnace flue prod- 5. When furnace is installed in a residence where unit is
ucts, the existing vent pipe is probably oversized for the shut down for an extended period of time, such as a
single water heater or other appliance. The vent should be vacation home, make provisions for draining condensate
checked for proper draw with the remaining appliance. collection trap and lines.
1. Use recommended piping materials for exhaust piping. Exhaust Piping
2. Secure all joints, including drip leg, gas-tight using ap- NOTE − A 2" diameter street ell is strapped to the blower
proved cement. deck of 48C−110 and 60C−110 units. Street ell must be
Suspend piping using hangers at a minimum of every 5 glued directly into the unit flue collar. See figure 20. A 3" to 2"
feet (1.52m) for schedule 40 reducing ell is strapped to the blower deck of the 60D−135
PVC and every 3 feet STRAPPING
units. In upflow or downflow applications, the reducing
(.91m) for ABS−DWV, PVC− (metal, plastic ell must be glued directly into the unit flue collar.
or large wire
DWV, SPR−21 PVC, and ties) 1. Choose the appropriate side for venting in upflow or
SDR−26 PVC piping. A suit- downflow positions. Exhaust piping exits from the top
able hanger can be fabri- of the unit in horizontal air discharge applications. Glue
cated by using metal or the field−provided exhaust vent pipe (or provided street
FIGURE 18 ell or reducing ell in upflow or downflow applications) to
plastic strapping or a large
wire tie. the flue collar. All cement joints should be made ac-
cording to the specifications outlined in ASTM D 2855.
Refer to pipe and fittings specifications and gluing pro-
cedures.

Exhaust Pipe Offset

12" Min.

12" Min.
Upflow Application
Upflow Application Side Wall Termination
Rooftop Termination
12" Min.
12" Min.

Horizontal Application
Rooftop Termination Horizontal Application
Side Wall Termination

FIGURE 19

Page 23
 TYPICAL EXHAUST PIPE CONNECTIONS AND CONDENSATE TRAP INSTALLATION
IN UPFLOW OR DOWNFLOW DIRECT OR NON−DIRECT VENT APPLICATIONS
(Right−Hand Exit in Upflow Application Shown)
2−1/2",
3", OR
4"
PLUG PLUG 2” G51MP−045, 070
TRANSITION or 090 with
2−1/2", 3", or 4"
2” vent pipe
2”
VENT PLUG 2"
(Must be
glued in 2” 4"
place)
2”
2−1/2", REDUCER
PLUG 3", OR (use only if
4" pipe is
4"
required)
CONDENSATE TRANSITION 3"
TRAP
(Must be installed
on same side as 2"***
exhaust piping)
2"*
2”* 3"**

*2" diameter street elbow provided. G51MP−110 with G51MP−110−1, −2 units with G51MP−135 with
**3" diameter reducing elbow provided. 2” vent pipe 2−1/2", 3", OR 4" vent pipe 3" OR 4" vent pipe
***Limit pipe length to 2".
FIGURE 20
TYPICAL EXHAUST PIPE CONNECTIONS
HORIZONTAL DIRECT OR IMPORTANT
NON−DIRECT VENT APPLICATIONS
(Horizontal Right−Hand Air Discharge Application Shown) Exhaust piping and condensate trap must be
installed on the same side of the unit for upflow
and downflow positions.
*Limit pipe length to 2"
G51MP−24B−045
2. All horizontal runs of exhaust pipe must slope back to-
in G51MP−110 and −135 2−1/2", G51MP−36B−045 ward unit. A minimum of 1/4" (6mm) drop for each 12"
applications. 3", OR G51MP−36B−070
4" (305mm) of horizontal run is mandatory for drainage.
G51MP−36C−090
G51MP−48C−090 Horizontal runs of exhaust piping must be supported ev-
TRANSITION
G51MP−60C−090 ery 5 feet (1.52m) using hangers.
G51MP−48C−110*
G51MP−60C−110* NOTE − Exhaust piping should be checked carefully to
2"* G51MP−60D−135*
make sure there are no sags or low spots.
3. On the opposite side of the cabinet, glue the provided
2"
2" 2" vent plug into the unused flue collar.
4. Route piping to outside of structure. Continue with
G51MP−24B−045
DO NOT transition from G51MP−36B−045 installation following instructions given in piping ter-
smaller to larger pipe 2" G51MP−36B−070
size in horizontal runs.
mination section.
G51MP−36C−090
G51MP−48C−090
G51MP−60C−090
G51MP−48C−110
G51MP−60C−110 CAUTION
Do not discharge exhaust into an existing stack or
stack that also serves another gas appliance. If verti-
cal discharge through an existing unused stack is re-
quired, insert PVC pipe inside the stack until the end
is even with the top or outlet end of the metal stack.

CAUTION
The exhaust vent pipe operates under positive pres-
sure and must be completely sealed to prevent leak-
age of combustion products into the living space.
FIGURE 21
Intake Piping

Page 24
The G51MP furnace may be installed in either direct vent 1 − Cement intake piping in slip connector located on the
or non−direct vent applications. In non−direct vent applica- side of the burner box.
tions, when intake air will be drawn into the furnace from the 2 − Use a sheet metal screw to secure the intake pipe to the
surrounding space, the indoor air quality must be consid-
connector, if desired. A pilot indentation is provided in the
ered and guidelines listed in Combustion, Dilution and Ven-
slip connector to assist in locating and starting the fasten-
tilation Air section must be followed.
The G51MP unit is designed for either left−side or right−side er.
air intake connections in either upflow or downflow applica- 3 − Glue the provided 2" plug into the unused air intake con-
tions. In horizontal applications, air intake must be brought nector on the opposite side of the cabinet.
in through the top. Intake air piping is independent of ex- 4 − Route piping to outside of structure. Continue with installa-
haust piping. tion following instructions given in general guide lines for
Follow the next four steps when installing the unit in Direct piping terminations and in intake and exhaust piping ter-
Vent applications, where combustion air is taken from out- minations for direct vent sections. Refer to figure 22 for
doors and flue gases are discharged outdoors. The provided pipe sizes.
air intake debris screen must not be used in direct vent ap-
plications.

TYPICAL AIR INTAKE PIPE CONNECTIONS

UPFLOW OR DOWNFLOW DIRECT VENT APPLICATIONS 2−1/2",
(Right−Hand Exit in Upflow Application Shown) 3" OR
4

TRANSITION 2−1/2",
3" OR
2
2* 4
TRANSITION

2 2* 2"*
2 2

PLUG
(Must be G51MP−24B−045 G51MP−24B−045 G51MP−24B−045
glued in G51MP−36B−045 G51MP−36B−045 G51MP−36B−045
place) G51MP−36B−070 G51MP−36B−070 G51MP−36B−070
G51MP−36C−090 G51MP−36C−090 G51MP−36C−090
G51MP−48C−090 G51MP−48C−090 G51MP−48C−090
G51MP−60C−090 G51MP−60C−090 G51MP−60C−090
G51MP−48C−110 G51MP−48C−110* G51MP−48C−110*
G51MP−60C−110 G51MP−60C−110* G51MP−60C−110*
G51MP−60D−135*

*Limit pipe length to 2"

in G51MP−110 and −135
applications.

FIGURE 22

Page 25
 Follow the next three steps when installing the unit in Non-
TYPICAL AIR INTAKE PIPE CONNECTIONS
HORIZONTAL DIRECT VENT APPLICATIONS
Direct Vent applications where combustion air is taken
(Horizontal Right−Hand Air Discharge Application Shown) from indoors and flue gases are discharged outdoors.

G51MP−24B−045
G51MP−36B−045
2−1/2”,
*Limit pipe G51MP−36B−070
G51MP−36C−090 3” OR 4” TYPICAL AIR INTAKE PIPE CONNECTIONS
length to 2" in
G51MP−110 G51MP−48C−090 UPFLOW OR HORIZONTAL NON−DIRECT
and −135
G51MP−60C−090 VENT APPLICATIONS
G51MP−48C−110* REDUCER (Right−Hand Exit in Upflow Application Shown)
applications. G51MP−60C−110*
G51MP−60D−135*
2”*
2−1/2”, 6 in. Max.
G51MP−24B−045 3” OR 4”
2”*
G51MP−36B−045
G51MP−36B−070 2”
G51MP−36C−090
G51MP−48C−090 TRANSITION PLUG
G51MP−60C−090 (Must be
2”* glued in
G51MP−48C−110* place)
G51MP−60C−110* INTAKE
G51MP−24B−045 DEBRIS
2” SCREEN
G51MP−36B−045
2” (Provided)
G51MP−36B−070
G51MP−36C−090
G51MP−48C−090
G51MP−60C−090
2”
G51MP−48C−110
G51MP−60C−110

NOTE − Debris screen and elbow may be rotated, so that

screen may be positioned to face forward, backward or
downward.
FIGURE 24

FIGURE 23

TYPICAL AIR INTAKE PIPE CONNECTIONS

DOWNFLOW NON−DIRECT VENT APPLICATIONS
(Right−Hand Exit in Downflow Applications Shown)

2" SWEEP
ELL
INTAKE
DEBRIS
SCREEN
(Provided)

6 in. Max.
PLUG
(Must be PLUG
glued in (Must be
place) glued in
place) 2"
18 in.

INTAKE DEBRIS 2" SWEEP ELL

SCREEN
(Provided)
Downflow Additive Flloor Base
Downflow
Evaporator NOTE − Debris screen and sweep ell may be rotated, so that
Coil screen may be positioned to face forward, backward or to the side.

FIGURE 25

Page 26
1 − Use field−provided materials and the factory−provided 5 − Turn on clothes dryers and any appliances not con-
air intake screen to route the intake piping as shown in nected to the venting system. Turn on any exhaust
figures 24 and 25. Maintain a minimum clearance of 3" fans, such as range hoods and bathroom exhausts, so
(76mm) around the air intake opening. The air intake they will operate at maximum speed. Do not operate a
summer exhaust fan.
opening (with the protective screen) should always be
6 − Follow the lighting instruction to place the appliance
directed either downward or straight out. Use 2" pipe
being inspected into operation. Adjust thermostat so
and fittings only and make sure that the air intake does appliance will operate continuously.
not extend more than 6" beyond the G51MP cabinet. 7 − Use the flame of match or candle to test for spillage of
The air intake connector must not be located near flue gases at the draft hood relief opening after 5 min-
the floor. To avoid this complication in downflow utes of main burner operation.
applications which do not include a downflow 8 − If improper venting is observed during any of the above
evaporator coil, the intake air routing should be modi- tests, the venting system must be corrected or suffi-
fied as shown in figure 25. cient combustion/make-up air must be provided. The
venting system should be re-sized to approach the
2 − Use a sheet metal screw to secure the intake pipe to the minimum size as determined by using the appropriate
connector, if desired. A pilot indentation is provided in the tables in appendix G in the current standards of the Na-
slip connector to assist in locating and starting the fasten- tional Fuel Gas Code ANSI−Z223.1/NPFA 54 in the
er. U.S.A., and the appropriate Natural Gas and Propane
appliances venting sizing tables in the current standard
3 − Glue the provided 2" plug into the unused air intake con- of the CSA−B149 Natural Gas and Propane Installation
nector on the opposite side of the cabinet. Codes in Canada.
Testing for Proper Venting and Sufficient Combustion Air 9 − After determining that each appliance remaining
connected to the common venting system properly
(Non−Direct Vent Applications Only) vents when tested as indicated in step 3, return doors,
windows, exhaust fans, fireplace dampers and any
other gas-burning appliance to their previous condi-
tion of use.
WARNING General Guidelines for Vent Terminations for Non-Direct
Vent Installations.
CARBON MONOXIDE POISONING HAZARD!
In Non-Direct Vent applications, combustion air is taken
Failure to follow the steps outlined below for each ap- from indoors and the flue gases are discharged to the out-
pliance connected to the venting system being
placed into operation could result in carbon monox- doors. The G51MP is then classified as a non-direct vent,
ide poisoning or death. Category IV gas furnace. In Non-Direct Vent applications,
The following steps shall be followed for each ap- the vent termination is limited by local building codes. In
pliance connected to the venting system being the absence of local codes, refer to the current National
placed into operation, while all other appliances con- Fuel Gas Code ANSI Z223−1/NFPA 54 in U.S.A., and cur-
nected to the venting system are not in operation.
rent CSA−B149 Natural Gas and Propane Installation
Codes in Canada for details.
After the G51MP gas furnace has been started, the follow- Position termination end according to location given in fig-
ing test should be conducted to ensure proper venting and ure 26. In addition, position termination end so it is free from
sufficient combustion air has been provided to the G51MP, any obstructions and above the level of snow accumulation
as well as to other gas-fired appliances which are separate- (where applicable). The termination should be at least 12
ly vented. The test should be conducted while all appliances inches (305mm) from any opening through which flue prod-
(both in operation and those not in operation) are connected ucts could enter the building.
to the venting system being tested. If the venting system
At vent termination, care must be taken to maintain
has been installed improperly, or if provisions have not been
protective coatings over building materials (prolonged
made for sufficient amounts of combustion air, corrections
exposure to exhaust condensate can destroy protective
must be made as outlined in the previous section.
coatings). It is recommended that the exhaust outlet not be
1 − Seal any unused openings in the venting system. located within 6 feet (1.8m) of a condensing unit because
2 − Visually inspect the venting system for proper size and the condensate can damage the painted coating.
horizontal pitch. Determine there is no blockage or re- NOTE − If winter design temperature is below 32°F (0°C),
striction, leakage, corrosion, or other deficiencies exhaust piping should be insulated with 1/2" (13mm), Arma-
which could cause an unsafe condition.
flex or equivalent when run through unheated space. Do not
3 − To the extent that it is practical, close all building doors and leave any surface area of exhaust pipe open to outside air;
windows and all doors between the space in which the ap- exterior exhaust pipe should be insulated with 1/2" (13mm)
pliances connected to the venting system are located and Armaflex or equivalent.
other spaces of the building. In extreme cold climate areas, 3/4" (19mm) Armaflex or
4 − Close fireplace dampers. equivalent may be necessary. Insulation on outside runs of

Page 27
exhaust pipe must be painted or wrapped to protect insula-
tion from deterioration. Exhaust pipe insulation may not be
necessary in some specific applications.
IMPORTANT
NOTE − During extremely cold temperatures, below approx- Do not use screens or perforated metal in exhaust ter-
minations. Doing so will cause freeze−ups and may
imately 20°F (6.7°C), units with long runs of vent pipe
block the terminations.
through unconditioned space, even when insulated, may
form ice in the exhaust termination that prevents the unit
from operating properly. Longer run times of at least 5 min-
utes will alleviate most icing problems. Also, a heating cable
IMPORTANT
may be installed on exhaust piping and termination to pre- For Canadian Installations Only:
vent freeze−ups. Heating cable installation kit is available In accordance to CSA International B149 installation
from Lennox. See Condensate Piping section for part num- codes, the minimum allowed distance between the
bers. combustion air intake inlet and the exhaust outlet of
other appliances shall not be less than 12 inches
(305mm).

VENT TERMINATION CLEARANCES

FOR INSTALLATIONS IN THE USA AND CANADA*

− G51MP VENT TERMINATION

− AIR INLET OF OTHER APPLIANCE

less than
10 ft (3.048M)

D
F

D
E
G

A − Clearance above grade − 12 in. (305mm) minimum. E − Clearance to non−mechanical air supply inlet or outlet
B − Clearance to window or door that may be opened − for vent installations in USA − 48 in. (1219mm) minimum
for vent installations in USA − 12 in. (305mm) minimum. horizontal and below, 12 in. (305mm) minimum above.
for vent installations in Canada − 12 in. (305mm) minimum for vent installations in Canada − 12 in. (305mm) minimum
for appliances  100,000 Btuh (30 kW); for appliances  100,000 Btuh (30 kW);
36 in. (0.9m) minimum for appliances > 100,000 Btuh (30 36 in. (0.9m) minimum for appliances > 100,000 Btuh (30
kW). kW).
C − Do not position terminations directly under roof eaves. F − Clearance to mechanical air supply inlet −−
for vent installations in USA − 36 in. minimum (914mm).
D − Clearance to electric meters, gas meters, regulators, and
relief equipment − G − Clearance to mechanical air supply inlet −−
for vent installations in USA − 48 in (1219mm) minimum. for vent installations in Canada − 72 in. (1829mm) mini-
for vent installations in Canada − see current edition of CSA mum.
B149 Code. H − Do not point terminations into recessed areas such as win-
dow wells, stairwells or alcoves.
J − Do not position terminations directly above a walkway.

* Note −
(I) Dimensions are from the current edition of The National Fuel Gas Code − ANSI-Z223.1/NFPA 54 for USA installa-
tions. In Canada, refer to current edition of CSA B149 installation codes. Local codes or regulations may require dif-
ferent clearances.

(II) In Non-Direct Vent installations, combustion air is taken from indoors and the flue gases are discharged to the outdoors.

FIGURE 26

Page 28
Details of Intake and Exhaust Piping Terminations for 1/2 (13) ARMAFLEX
12 (305) MAX.
(unless supported)
Direct Vent Installations INSULATION IN
UNCONDITIONED SPACE
NOTE − In Direct Vent installations, combustion air is taken from 1/2" (13)
outdoors and flue gases are discharged to outdoors. ARMAFLEX
INSULATION
Intake and exhaust pipes may be routed either horizontally
FIELD−
through an outside wall or vertically through the roof. In at- PROVIDED 1−1/2 (38) PVC
tic or closet installations, vertical termination through the REDUCER MAY
BE REQUIRED
roof is preferred. Figures 27 through 35 show typical ter- TO ADAPT 6 (152) SIZE
MAXIMUM TERMINATION
minations. LARGER VENT
PIPE PER
PIPE SIZE TO
1. Exhaust and intake exits must be in same pressure TERMINATION TABLE 15.
zone. Do not exit one through the roof and one on the 2 (51) PVC
side. Also, do not exit the intake on one side and the COUPLING

exhaust on another side of the house or structure.

OUTSIDE 8 (203)
2. Intake and exhaust pipes should be placed as close to- WALL MINIMUM
gether as possible at termination end (refer to illustra- Inches (mm) TOP VIEWWALL RING KIT
tions). Maximum separation is 3" (76mm) on roof ter- (15J74)
minations and 6" (152mm) on side wall terminations. FIGURE 28
3. If necessary, install a field−provided reducer to adapt 6. On field supplied terminations for side wall exits, ex-
larger vent pipe size to termination pipe size.
haust piping should extend a minimum of 12 inches
4. On roof terminations, the intake piping should termi-
nate straight down using two 90° elbows (See figure (305mm) beyond the outside wall unless supported. In-
27). take piping should be as short as possible. See figure
5. Exhaust piping must terminate straight out or up as 28.
shown. In rooftop applications, a reducer may be re- 7. On field supplied terminations, a minimum separation
quired on the exhaust piping at the point where it exits distance between the end of the exhaust pipe and the
the structure to improve the velocity of exhaust away end of the intake pipe is 8 inches (203mm).
from the intake piping. See table 15.
8. If intake and exhaust piping must be run up a side wall
NOTE − Care must be taken to avoid recirculation of ex-
to position above snow accumulation or other obstruc-
haust back into intake pipe.
TABLE 15 tions, piping must be supported every 3 ft. (.9m) as
EXHAUST PIPE TERMINATION SIZE REDUCTION shown in figure 18. Refer to figure 31 for proper piping
G51MP method. In addition, WTK wall termination kit must be
MODEL Exhaust Pipe Size Termination Pipe Size extended for use in this application. See figure 34.
045 and 070 2", 2−1/2", 3" or 4" 1−1/2" When exhaust and intake piping must be run up an out-
090 2", 2−1/2", 3" or 4" 2" side wall, the exhaust piping must be terminated with
110 2 , 2−1/2", 3" or 4" 2"* pipe sized per table 15. The intake piping may be
135 3" or 4" 2"* equipped with a 90° elbow turndown. Using turndown
*Approved 3" concentric termination kit terminates with 2−5/8" ID pipe. will add 5 feet (1.5m) to the equivalent length of the
3(76) MAX. pipe.
Inches(mm) SIZE TERMINATION
PIPE PER TABLE 15. 9. Based on the recommendation of the manufacturer, a
multiple furnace installation may use a group of up to
UNCONDITIONED
ATTIC SPACE four termination kits WTK assembled together horizon-
8" (203) MIN
1/2" (13) FOAM tally, as shown in figure 33.
INSULATION IN
12" (305) ABOVE UNCONDITIONED
AVERAGE SNOW SPACE
ACCUMULATION

3" (76) OR
2" (51) PVC

PROVIDE SUPPORT
FOR INTAKE AND
EXHAUST LINES

DIRECT VENT ROOF TERMINATION KIT

(15F75 or 44J41)

FIGURE 27

Page 29
 EXHAUST VENT
EXHAUST 12" (305) ABOVE
TERMINATION AVERAGE SNOW
ACCUMULATION
Inches (mm) INTAKE Front View
VENT
INTAKE
TERMINATION
1/2" (13) Foam Insulation
in Unconditioned Space Side View
FIELD−PROVIDED FIELD−
REDUCER MAY BE REQUIRED PROVIDED EXHAUST VENT
TO ADAPT LARGER VENT REDUCER MAY
PIPE SIZE TO TERMINATION BE REQUIRED
TO ADAPT
LARGER VENT
EXHAUST INTAKE
PIPE SIZE TO
TERMINATION
DIRECT VENT CONCENTRIC ROOFTOP TERMINATION INTAKE VENT
(71M80, 69M29 or 60L46) Inches (mm) OUTSIDE WALL

FIGURE 29 DIRECT VENT WALL TERMINATION KIT

(22G44, 44J40, 30G28 or 81J20)
FIGURE 32
Inches (mm) INTAKE
TERMINATION
EXHAUST
EXHAUST TERMINATION 12"
EXHAUST (305)
VENT 5" 5−1/2"
(127) (140)
INTAKE INTAKE
12" (305) Min. VENT
FIELD−PROVIDED 18" MAX.
above grade. (457) Front View
REDUCER MAY
BE REQUIRED TO
ADAPT LARGER EXHAUST VENT
VENT PIPE SIZE
TO TERMINATION

Inches (mm) INTAKE

DIRECT VENT CONCENTRIC WALL TERMINATION
(71M80, 69M29 or 60L46) VENT
Side View
FIGURE 30
OPTIONAL VENT TERMINATION FOR MULTIPLE UNIT
12" (305) MAX. for 2" (51) INSTALLATION OF DIRECT VENT WALL TERMINATION KIT WTK
Inches(mm) (unless supported)
UNCONDITIONED FIGURE 33
SPACE
8 (203)
OUTSIDE WALL
MIN.

SIZE
PROVIDE SUPPORT TERMINATION
FOR INTAKE AND PIPE PER
EXHAUST LINES EVERY TABLE 15.
36" (914)
12" (305) ABOVE
FIELD−PROVIDED
AVERAGE SNOW
REDUCER MAY
ACCUMULATION
BE REQUIRED TO
ADAPT LARGER
VENT PIPE SIZE
TO TERMINATION
1/2" (13) FOAM
INSULATION IN
UNCONDITIONED 1/2" (13) FOAM
SPACE INSULATION
SIDE VIEW
DIRECT VENT WALL RING TERMINATION
(15F74)
See venting table 13 for maximum venting lengths with
this arrangement.

FIGURE 31

Page 30
 12" (305) MAX. for 2" (51)
20" (508) MAX. for 3" (76)
(unless supported) Inches (mm) 12" COVER EXHAUST
(305) VENT WITH
EXHAUST 1/2" (13)
AIR FOAM
8" (203) INSULATION
INTAKE INTAKE
AIR Minimum AIR
EXHAUST
12" (305) AIR
Minimum 5" 12" MIN.
ABOVE GRADE (127) (305)
Above Grade

ÉÉÉÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉÉÉÉ
5-1/2"
(140)

ÉÉÉÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉÉÉÉ
GRADE Side View GRADE
Front View
DIRECT VENT TERMINATION
WALL TERMINATION KIT (22G44, 44J40, 30G28 or 81J20) EXTENDED VENT FOR GRADE CLEARANCE

FIGURE 34
haust piping should extend a maximum of 12 inches
G51MP DIRECT VENT APPLICATION
STRAIGHT−CUT OR (305mm) beyond the outside wall, unless support is
USING EXISTING CHIMNEY ANGLE−CUT IN DIRECTION
OF ROOF SLOPE * provided in the horizontal section. See figure 37.

8" − 12"
3" − 8"
(76mm−
EXHAUST VENT
1/2" (13mm)
Inches(mm) SIZE TERMINATION
203mm)
(203mm − 305mm) WEATHERPROOF PIPE PER TABLE
INSULATION 15.
12" (305mm)
INTAKE PIPE SHOULDER OF FITTINGS ABOVE AVE.
INSULATION (optional) PROVIDE SUPPORT SNOW
OF PIPE ON TOP PLATE
SHEET
ALTERNATE
ACCUMULATION
METAL TOP
PLATE INTAKE PIPE

MINIMUM 12"
(305mm) ABOVE
ROOF 3" − 8" 3" (76) OR
(76mm−
2" (51) PVC UNCONDITIONED
203mm)
INSULATE EXTERIOR ATTIC SPACE
TO FORM PORTION OF
SEAL CHIMNEY PROVIDE SUPPORT
FOR EXHAUST LINES
*SIZE TERMINATION
PIPE PER TABLE 15.

NOTE − Do not discharge exhaust gases directly into any chimney or vent stack. If ver-
tical discharge through an existing unused chimney or stack is required, insert piping NON−DIRECT VENT ROOF TERMINATION KIT
inside chimney until the pipe open end is above top of chimney and terminate as illus- (15F75 or 44J41)
trated. In any exterior portion of chimney, the exhaust vent must be insulated.
FIGURE 36
FIGURE 35

12" (305) Max. for 2" (51)

Unless Supported
Details of Exhaust Piping Terminations for Non-Direct 1/2" (13) ARMAFLEX
INSULATION IN
Vent Applications UNCONDITIONED SPACE 1/2" (13)
ARMAFLEX
Exhaust pipes may be routed either horizontally through an INSULATION
FIELD−PROVIDED
REDUCER MAY
outside wall or vertically through the roof. In attic or closet BE REQUIRED TO
installations, vertical termination through the roof is pre- ADAPT LARGER
VENT PIPE SIZE
ferred. Figures 36 through 39 show typical terminations. TO TERMINATION PVC REDUCER

1. Exhaust piping must terminate straight out or up as

Inches (mm) SIZE TERMINATION
shown. The termination pipe must be sized as listed in PIPE PER TABLE 15.
table 15.The specified pipe size ensures proper veloc-
TOP VIEW
ity required to move the exhaust gases away from the NON−DIRECT VENT WALL RING KIT
building. (15F74)

2. On field supplied terminations for side wall exits, ex- FIGURE 37

Page 31
3. If exhaust piping must be run up a side wall to position
CONDENSATE TRAP LOCATIONS
above snow accumulation or other obstructions, piping (Unit shown in upflow position)
must be supported every 3 feet (.9m) as shown in fig-
ure 18. Refer to figure 38 for proper piping method. Horizontal Horizontal
When exhaust piping must be run up an outside wall, left and right and
any reduction in exhaust pipe size must be done after optional optional
downflow downflow
the final elbow.

12" (305) Max. for 2" (51)

Inches(mm) Unless Supported

UNCONDITIONED
SPACE
Optional Optional
OUTSIDE WALL upflow upflow
SIZE TERMINATION
PROVIDE SUPPORT PIPE PER TABLE 15.
FOR EXHAUST LINES
EVERY 36" (914) 12" (305) ABOVE
AVERAGE SNOW
FIELD−PROVIDED ACCUMULATION
REDUCER MAY BE
REQUIRED TO
ADAPT LARGER
VENT PIPE SIZE TO NOTE − In upflow applications where side return
TERMINATION air filter is installed on same side as the conden-
1/2" (13) FOAM sate trap, filter rack must be installed beyond
INSULATION IN
UNCONDITIONED 1/2" (13) FOAM condensate trap to avoid interference.
SPACE INSULATION
SIDE VIEW FIGURE 40
NON−DIRECT VENT WALL RING TERMINATION 1 − Determine which side condensate piping will exit the
(15F74)
unit. Remove plugs from the condensate collar at the
FIGURE 38 appropriate location on the side of the unit.
NOTE − The condensate trap is factory−shipped with
G51MP NON−DIRECT VENT APPLICATION two rubber O−rings and two rubber clean−out caps
USING EXISTING CHIMNEY installed. Check to make sure that these items are in
SIZE TERMINATION STRAIGHT−CUT OR
ANGLE−CUT IN DIRECTION place before installing the trap assembly.
PIPE PER TABLE 15. OF ROOF SLOPE
2 − Install condensate trap onto the condensate collar. Use
3" − 8" EXHAUST VENT
provided HI/LO screws to secure two upper flanges of
(76mm−
203mm)
1/2" (13mm)
WEATHERPROOF
the trap to the collar. Use provided sheet metal screw to
MINIMUM
MINIMUM12" INSULATION
(305mm) ABOVE
12" (304mm)
ABOVE AVERAGE
secure bottom trap flange to side of unit. See figure 41.
AVERAGE SNOW
SNOW ACCUMULATION
ACCUMULATION SHOULDER OF FITTINGS
PROVIDE SUPPORT
NOTE − In upflow and downflow applications, condensate
OF PIPE ON TOP PLATE
SHEET trap must be installed on the same side as the exhaust pip-
METAL TOP
PLATE ing. The optional
Condensate Trap Alternate Location Kit #
7620M" is available for those installations where the trap
3" − 8"
(76mm−
203mm)
cannot be mounted on the same side as the exhaust.
INSULATE
TO FORM EXTERIOR
SEAL PORTION OF
CHIMNEY
CAUTION
DO NOT use a power driver to tighten screws which
secure condensate trap to cabinet. Screws should be
NOTE − Do not discharge exhaust gases directly into any chimney or vent stack. If ver- hand−tightened using a screw driver to avoid the pos-
tical discharge through an existing unused chimney or stack is required, insert piping
inside chimney until the pipe open end is above top of chimney and terminate as illus- sibility of damage to the trap assembly.
trated. In any exterior portion of chimney, the exhaust vent must be insulated.
3 − Glue the field−provided coupling or pipe to the trap.
FIGURE 39 Install a tee and vent pipe near the trap.
Condensate Piping NOTE − The condensate trap drain stubs (both sides)
This unit is designed for either right- or left-side exit of con- have an outer diameter which will accept a standard
densate piping in either upflow or downflow applications; 3/4" PVC coupling. The inner diameter of each stub will
however, it must be installed on the same side of the unit as accept standard 1/2" diameter PVC pipe.
the exhaust piping . In horizontal applications, the conden- NOTE − Vinyl tubing may be used for condensate drain.
sate trap should extend below the unit. A 5−1/2" service Tubing must be 1−1/4" OD X 1" ID and should be at-
clearance is required for the condensate trap. Refer to fig- tached to the drain stubs on the trap using a hose
ure 40 for condensate trap locations. clamp.

Page 32
4 − Glue the field−provided drain line to the tee. Route the III−START-UP
drain line to an open drain. As an alternate, clear vinyl
A−Preliminary and Seasonal Checks
tubing may be used to drain condensate away from the
1 − Inspect electrical wiring, both field and factory installed for
trap. Secure the vinyl tubing to the drain stubs on the loose connections. Tighten as required.
trap using a hose clamp. Do not overtighten the hose 2 − Check voltage at disconnect switch. Voltage must be within
clamp. range listed on the nameplate. If not, consult the power
Condensate line must be sloped downward away from company and have voltage condition corrected be-
condensate trap to drain. If drain level is above con- fore starting unit.
densate trap, condensate pump must be used. Con- 3 − Inspect condition of condensate traps and drain as-
densate drain line should be routed within the condi- sembly. Disassemble and clean seasonally.
tioned space to avoid freezing of condensate and B−Heating Start-Up
blockage of drain line. If this is not possible, a heat
BEFORE LIGHTING the unit, smell all around the furnace
cable kit may be used on the condensate trap and line.
area for gas. Be sure to smell next to the floor because
Heating cable kit is available from Lennox in various
some gas is heavier than air and will settle on the floor.
lengths; 6 ft. (1.8m) − kit no. 26K68; 24 ft. (7.3m) − kit no.
The gas valve on the G51MP may be equipped with either
26K69; and 50 ft. (15.2m) − kit no. 26K70.
a gas control knob or gas control lever. Use only your
hand to push the lever or turn the gas control knob. Never
CAUTION use tools. If the the lever will not move or the knob will not
Do not use copper tubing or existing copper con- push in or turn by hand, replace the valve. Do not try to re-
densate lines for drain line. pair it. Force or attempted repair may result in a fire or ex-
plosion.
5 − If unit will be started immediately upon completion of
Placing the furnace into operation:
installation, prime trap per procedure outlined in Unit
Start−Up section. G51MP units are equipped with a SureLight® hot surface
ignition system. Do not attempt to manually light burners
6 − Glue the provided cap onto the unused condensate
on this furnace. Each time the thermostat calls for heat,
drain line stub.
the burners will automatically light The ignitor does not
get hot when there is no call for heat on units with Sur-
CONDENSATE ASSEMBLY
eLight® hot surface ignition system.
HI/LO SCREWS Priming Condensate Trap
O−RINGS (DO NOT use power VENT The condensate trap should be primed with water prior to
driver. Hand−tighten
using screw driver.)
start−up to ensure proper condensate drainage. Either
NIPPLE
pour 10 fl. oz. (300 ml) of water into the trap, or follow
these steps to prime the trap:
1 − Follow the lighting instructions to place the unit into op-
eration.
TEE 2 − Set the thermostat to initiate a heating demand.
CAP NIPPLE
3 − Allow the burners to fire for approximately 3 minutes.
4 − Adjust the thermostat to deactivate the heating de-
COUPLING mand.
CLEAN−OUT ACCESS 5 − Wait for the combustion air inducer to stop. Set the ther-
(both sides) mostat to initiate a heating demand and again allow the
CONDENSATE TRAP
burners to fire for approximately 3 minutes.
6 − Adjust the thermostat to deactivate the heating demand
SCREW
and again wait for the combustion air inducer to stop. At
FIGURE 41 this point, the trap should be primed with sufficient wa-
ter to ensure proper condensate drain operation.

WARNING
If you do not follow these instructions exactly, a fire
or explosion may result causing property damage,
personal injury or death.
Gas Valve Operation
1 − STOP! Read the safety information at the beginning of
this section.
2 − Set the thermostat to the lowest setting.

Page 33
3 − Turn off all electrical power to the unit. Turning Off Gas to Unit
4 − This furnace is equipped with an ignition device which 1 − Set the thermostat to the lowest setting.
automatically lights the burners. Do not try to light the 2 − Turn off all electrical power to the unit if service is to be
burners by hand. performed.
5 − Remove the upper access panel. 3 − Remove the upper access panel.
6 − White Rodgers 36G Gas Valve − Switch gas valve le- 4 − White Rodgers 36G Gas Valve − Switch gas valve le-
ver to OFF. See figure 42. ver to OFF.
Honeywell VR8205 Gas Valve − Turn knob on gas Honeywell VR8205 Gas Valve − Turn knob on gas
valve clockwise to OFF. Do not force. See figure valve clockwise to OFF. Do not force.
43. 5 − Replace the upper access panel.
7 − Wait five minutes to clear out any gas. If you then smell
IV−HEATING SYSTEM SERVICE CHECKS
gas, STOP! Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s instruc-
tions. If you do not smell gas go to next step. IMPORTANT
In case emergency shutdown is required, turn off
White Rodgers 36G Series Gas Valve the main shut-off valve and disconnect the main
MANIFOLD power to unit. These controls should be properly
PRESSURE labeled by the installer.
OUTLET POST
A−C.S.A. Certification
MANIFOLD All units are C.S.A. design certified without modifications.
PRESSURE Refer to the G51MP Operation and Installation Instruction
ADJUSTMENT
INLET SCREW Manual Information.
PRESSURE
POST GAS VALVE SHOWN IN OFF POSITION B−Gas Piping
FIGURE 42 Gas supply piping should not allow more than 0.5"W.C. drop
in pressure between gas meter and unit. Supply gas pipe
Honeywell VR8205 Series Gas Valve must not be smaller than unit gas connection. See table 16 if
MANIFOLD MANIFOLD gas pipe is suspect.
PRESSURE PRESSURE
ADJUSTMENT OUTLET Compounds used on gas piping threaded joints should be re-
SCREW sistant to action of liquefied petroleum gases.
C−Testing Gas Piping
ON When pressure testing gas lines, the gas valve must be dis-
INLET LINE connected and isolated. Gas valves can be damaged if sub-
PRESSURE OFF
jected to more than 0.5psig (14" W.C.). See figure 44.
GAS VALVE SHOWN IN OFF POSITION
FIGURE 43 GAS PIPING TEST PROCEDURE (Typical)
8 − White Rodgers 36G Gas Valve − Switch gas valve lever
to ON. MANUAL SHUTOFF VALVE FURNACE
Honeywell VR8205 Gas Valve − Turn knob on gas valve
counterclockwise to ON. Do not force. ISOLATE
9 − Replace the upper access panel. GAS VALVE

10− Turn on all electrical power to to the unit.

11− Set the thermostat to desired setting.
CAP
NOTE − When unit is initially started, steps 1 through 11 may
need to be repeated to purge air from gas line. GAS VALVE WILL NOT HOLD
TEST PRESSURE IN EXCESS
12− If the appliance will not operate, follow the instructions OF 0.5 PSIG (14"W.C.)
Turning Off Gas to Unit" and call your service techni-
cian or gas supplier. FIGURE 44

Page 34
 TABLE 16
GAS PIPE CAPACITY − FT3/HR (kL/HR)
Nominal Internal Length of Pipe−Feet(m)
Iron Pipe Size Diameter 10 20 30 40 50 60 70 80 90 100
−Inches(mm) −Inches(mm) (3.048) (6.096) (9.144) (12.192) (15.240) (18.288) (21.336) (24.384) (27.432) (30.480)

1/4 .364 43 29 24 20 18 16 15 14 13 12
(6.35) (9.246) (1.13) (.82) (.68) (.57) (.51) (.45) (.42) (.40) (.37) (.34)

3/8 .493 95 65 52 45 40 36 33 31 29 27
(9.53) (12.522) (2.69) (1.84) (1.47) (1.27) (1.13) (1.02) (.73) (.88) (.82) (.76)

1/2 .622 175 120 97 82 73 66 61 57 53 50

(12.7) (17.799) (4.96) (3.40) (2.75) (2.32) (2.07) (1.87) (1.73) (1.61) (1.50) (1.42)

3/4 .824 360 250 200 170 151 138 125 118 110 103
(19.05) (20.930) (10.19) (7.08) (5.66) (4.81) (4.28) (3.91) (3.54) (3.34) (3.11) (2.92)

1 1.049 680 465 375 320 285 260 240 220 205 195
(25.4) (26.645) (19.25) (13.17) (10.62) (9.06) (8.07) (7.36) (6.80) (6.23) (5.80) (5.52)

1−1/4 1.380 1400 950 770 660 580 530 490 460 430 400
(31.75) (35.052) (39.64) (26.90) (21.80) (18.69) (16.42) (15.01) (13.87) (13.03) (12.18) (11.33)

1−1/2 1.610 2100 460 1180 990 900 810 750 690 650 620
(38.1) (40.894) (59.46) (41.34) (33.41) (28.03) (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
(50.8) (52.502) (111.85) (77.87) (62.30) (53.80) (47.57) (43.04) (39.64) (36.81) (34.55) (32.56)

2−1/2 2.469 6300 4350 3520 3000 2650 2400 2250 2050 1950 1850
(63.5) (67.713) (178.39) (123.17) (99.67) (84.95) (75.04) (67.96) (63.71) (58.05) (55.22) (52.38)

3 3.068 11000 7700 6250 5300 4750 4300 3900 3700 3450 3250
(76.2) (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)

NOTE−Capacity given in cubic feet of gas per hour (kilo liters of gas per hour) and based on 0.60 specific gravity gas.

Check gas line pressure with unit firing at maximum rate.

IMPORTANT Low pressure may result in erratic operation or underfire.
High pressure can result in permanent damage to gas valve
The furnace must be isolated from the gas supply or overfire. For natural gas units, operating pressure at unit
piping system by closing its individual manual
shut−off valve during any pressure testing of the gas connection must be between 4.5" W.C. and 13.0" W.C.
gas supply piping system at test pressures equal For L.P. gas units, operating pressure at unit gas connection
to or less than 1/2 psig (3.45 kPa). must be between 10.5" and 13.0" W.C.
The furnace and its individual shut−off valve must On multiple unit installations, each unit should be checked
be disconnected from the gas supply piping sys- separately, with and without units operating. Supply pres-
tem during any pressure testing of the system at sure must fall within range listed in previous paragraph.
test pressures greater than 1/2 psig (3.45 kPa). See
figure 44.
E−Check Manifold Pressure
Manifold pressure is the manifold pressure measured when
When checking piping connections for gas leaks, use pre- the gas valve regulator is operating at factory preset level
ferred means. Kitchen detergents can cause harmful corro- sensing atmospheric pressure.
sion on various metals used in gas piping. Use of a specialty
Gas Leak Detector is strongly recommended. It is available
through Lennox under part number 31B2001. See Corp.
IMPORTANT
8411−L10, for further details. The White Rodgers 36G gas valve (figure 42) is
equipped with pressure posts for measuring supply
and manifold pressures. The posts provide built−in
WARNING hose connections and have an integral 3/32" Allen−
head screw. Rotate the screw counterclockwise one
Do not use matches, candles, flame or any other full turn to permit pressure measurement. Reseat the
source of ignition to check for gas leaks. screw (rotate one full turn clockwise) after measure-
ments have been taken to prevent gas leakage.
After line pressure has been checked and adjusted, check
D−Testing Gas Supply Pressure manifold pressure. Move pressure gauge to outlet pressure
When testing supply gas pressure, use the 1/8" N.P.T. tap located on unit gas valve (GV1).
plugged tap or pressure post located on the gas valve to fa- Checks of manifold pressure are made as verification of prop-
cilitate test gauge connection. See figures 42 and 43. er regulator adjustment.

Page 35
Manifold operating pressure for the G51MP can be measured G− Proper Combustion
at any time the gas valve is open and is supplying gas to the Furnace should operate at least 15 minutes with correct
unit. manifold pressure and gas flow rate before checking com-
TABLE 17 bustions. Take sample beyond the flue outlet and compare
GAS VALVE MANIFOLD PRESSURE W.C. to table 19. The maximum carbon monoxide reading
Natural 3.5 + 0.3 should not exceed 100 ppm.
L.P. 10.0 + 0.7
TABLE 19
Unit Btuh CO2% For Nat CO2% For L.P
IMPORTANT −045 6.3 − 7.3 7.4 − 8.4
For safety, connect a shut-off valve between the −070 6.5 − 7.5 7.6 − 8.6
manometer and the gas tap to permit shut off of −090
gas pressure to the manometer.
−110 7.0 − 8.0 8.2 − 9.2
−135
Manifold Pressure Measurement and Adjustment
1 − Connect test gauge to outlet tap on gas valve. H− Condensate pH Range
2 − Disconnect pressure sensing hose from the gas valve. The condensate is mildly acidic and can be measured with
Plug end of hose using tape or equivalent. Leave hose pH indicators. The pH scale is a measurement of acidity and
barb on gas valve open to atmosphere. alkalinity. The following scale shows the relative pH of some
3 − Start unit and allow 5 minutes for unit to reach steady common liquids as compared with condensate of G51MP
state. units. The concentration of the acidity of all these fluids in-
4 − While waiting for the unit to stabilize, notice the flame. cluding the condensate is very low and harmless.
Flame should be stable and should not lift from burner. pH RANGE
Natural gas should burn blue. L.P. gas should burn most- 0
ly blue with some orange streaks. 1
Increasing 2 Vinegar
5 − After allowing unit to stabilize for 5 minutes, adjust the 3 Wine G51 Condensate
Acidity
manifold pressure on the gas valve if necessary (see 4 Orange Juice pH Range
table 17). 5 Tomato Juice
6
6 − When test is complete, reconnect sensing hose to gas 7 Tap Water
valve barb. 8
Increasing 9
NOTE−Shut unit off and remove manometer as soon as Alkalinity 10
an accurate reading has been obtained. Take care to re- 11
place pressure tap plug. I−Flame Signal
F− Proper Gas Flow (Approximate) A transducer (Part #78H5401 available from Lennox Repair
Parts) is required to measure flame signal if meter used will not
Furnace should operate at least 5 minutes before checking
read a low microAmp signal.
See
figure
45. The transducer
gas flow. Determine time in seconds for two revolutions of
converts microAmps to volts on a 1:1 conversion. See table 20
gas through the meter. (Two revolutions assures a more
for flame signal. A digital readout meter must be used. The
accurate time.) Divide by two and compare to time in transducer plugs into most meters.
table 18 below. Adjust manifold pressure on gas valve to
To Measure Flame Signal:
match time needed.
1 − Set the volt meter to the DC voltage scale. Insert
NOTE− To obtain accurate reading, shut off all other gas transducer into the VDC and common inputs. Ob-
appliances connected to meter.
serve correct polarities. Failure to do so results in
TABLE 18 negative (−) values.
2 − Turn off supply voltage to control.
GAS METER CLOCKING CHART
Seconds for One Revolution
3 − Disconnect ignition control flame sensor wire from the
G51MP
Natural LP
flame sensor.
Unit
1 cu ft Dial 2 cu ft Dial 1 cu ft Dial 2 cu ft DIAL 4 − Connect (−) lead of the transducer to flame sensor.
−45 80 160 200 400 5 − Connect (+) lead of transducer to the ignition control sen-
−70 51 102 129 258 sor wire.
−90 40 80 100 200 6 − Turn supply voltage on and close thermostat contacts to
−110 33 66 82 164 cycle system.
−135 27 53 67 134 7 − When main burners are in operation for two minutes, take
Natural−1000 btu/cu ft LP−2500 btu/cu ft reading. Remember 1 DC volt = 1 DC microAmp.
Page 36
 The combustion air pressure switches are factory−set and
NOTE−MUST USE DIGITAL METER
require no adjustment.
NOTE − Pressure switch is factory set. No adjustment necessary. All mod-
SET DIAL TO els use the factory installed pressure switch from 0−4500 feet (0−1370 m).
MEASURE VDC TABLE 21
Manifold Pressure (Outlet) inches w.c.
TRANSDUCER Model Altitude (feet)
(+) PART #78H5401
Fuel Input 0− 4501− 5501− 6501− 7501−
(+) TO Sizes
IGNITION
4500 5500 6500 7500 10,000
CONTROL (−) RED COLLAR 045, 070,
SENSOR INDICATES 090, 110,
WIRE (−) TO POSITIVE
3.5 3.5 3.5 3.5 3.5*
Nat. 135
FLAME LEAD Gas
SENSOR
135−1, −2 3.5 3.3 3.2 3.1 3.5*
L.P. All sizes 10.0** 10.0** 10.0** 10.0** 10.0**
Gas
FIGURE 45
*Conversion kit required for applications at altitudes above 7501 ft.
TABLE 20 above sea level.
Flame Signal in Microamps **Conversion kit required for applications at all altitudes.
Ignition Control Normal Low Drop Out NOTE − A natural to L.P. propane gas changeover kit is nec-
69M15  0.31 0.25 − 0.30  0.24 essary to convert this unit. Refer to the changeover kit
97L48  0.61 0.21 − 0.60  0.20 installation instruction for the conversion procedure.
J−High Altitude
NOTE − In Canada, certification for installations at eleva-
tions over 4500 feet (1372 m) is the jurisdiction of local au-
thorities.
The manifold pressure may require adjustment to ensure
proper operation at higher altitudes. Refer to table 21 for
proper manifold pressure settings at varying altitudes.
Table 22 lists required pressure switch changes and con-
version kits at varying altitudes.
TABLE 22
Conversion Kit and Pressure Switch Requirements at Varying Altitudes
Altitude
Model 0 − 4500 ft. 4,501 − 7500 ft. 7501−10,000 ft.
Input Gas (0 − 1372 m) (1373 − 2286 m) (2287 − 3048 m)
Si
Size Required Pressure Required Pressure Required Pressure
Conversion Kit Switch Conversion Kit Switch Conversion Kit Switch
Nat. N/A No Change N/A No Change 59M16 56M06
045/070 1 to −6
045/070−1 6
LPG 83M74 No Change 83M74 No Change 83M75 56M06
Nat. N/A No Change N/A No Change 59M17 95M22
045/070 7 and later
045/070−7
LPG 83M74 No Change 83M74 56M05 83M75 56M06
Nat. N/A No Change N/A 75M20 59M16 56M07
090 1 to −6
−090−1 6
LPG 83M74 No Change 83M74 75M20 83M75 56M07
Nat. N/A No Change N/A 75M20 59M17 56M07
−090−7
090 7 and later
LPG 83M74 No Change 83M74 75M20 83M75 56M07
Nat. N/A No Change N/A 75M20 59M16 56M07
−110−1
110 1 to −6
6
LPG 83M74 No Change 83M74 75M20 83M75 56M07
Nat. N/A No Change N/A 75M20 59M17 56M07
−110
110 −7
7 and later
LPG 83M74 No Change 83M74 75M20 83M75 56M07
Nat. N/A No Change N/A 56M04 47M82 60M35
−135−1,
135 1 −2
2
LPG 83M74 No Change 83M74 56M04 83M75 60M35
Nat. N/A No Change N/A 56M04 59M16 60M35
135 3 to −6
−135−3 6
LPG 83M74 No Change 83M74 56M04 83M75 60M35
Nat. N/A No Change N/A 56M04 59M16 60M35
−135−3
135 3 to −6
6
LPG 83M74 No Change 83M74 56M04 83M75 60M35
Nat. N/A No Change N/A 56M04 59M17 60M35
−135−7
135 7 and later
LPG 83M74 No Change 83M74 56M04 83M75 60M35

Page 37
V−TYPICAL OPERATING CHARACTERISTICS C−External Static Pressure
1 − Measure tap locations as shown in figure 46.
A−Blower Operation and Adjustment 2 − Punch a 1/4" diameter hole in STATIC PRESSURE
supply and return air ple- TEST
NOTE− The following is a generalized procedure and nums. Insert manometer
does not apply to all thermostat controls. hose flush with inside edge of
hole or insulation. Seal
1 − Blower operation is dependent on thermostat control around the hose with perma-
system. gum. Connect the zero end of G51MP UNIT
the manometer to the dis- FIGURE 46
2 − Generally, blower operation is set at thermostat subbase charge (supply) side of the system. On ducted systems,
fan switch. With fan switch in ON position, blower oper- connect the other end of manometer to the return duct
ates continuously. With fan switch in AUTO position, as above. For systems with non−ducted returns, leave
blower cycles with demand or runs continuously while the other end of the manometer open to the atmo-
heating or cooling circuit cycles. sphere.
3 − With only the blower motor running and the evaporator
3 − In all cases, blower and entire unit will be off when the coil dry, observe the manometer reading. Adjust blower
system switch is in OFF position. motor speed to deliver the air desired according to the
job requirements.
B−Temperature Rise 4 − Static pressure must not exceed 0.5" W.C.
5 − Seal around the hole when the check is complete.
Temperature rise for G51MP units depends on unit input,
blower speed, blower horsepower, filter resistance and
D−Blower Speed Taps
installed duct system resistance. The blower speed must be (G51MP−2 & G51MP−090−3 and later units)
set for unit operation within the range of AIR TEMP. RISE Blower speed tap changes are made on the SureLight ®con-
°F" listed on the unit rating plate. trol. See figure 8. Unused taps must be secured on dummy
terminals "PARK" on the SureLight board. The heating tap is
To Measure Temperature Rise: connected to the "HEAT " terminal and the cooling tap is con-
nected to the "COOL" terminal. The continuous blower tap is
connected to the "FAN" terminal. To change existing heat tap,
1− Place plenum thermometers in the supply and return air
turn off power then switch speed tap on HEAT" terminal with
plenums. Locate supply air thermometer in the first hori-
tap connected to one of two PARK" terminals. See unit wir-
zontal run of the plenum where it will not pick up radiant
ing diagram for blower speed tap
heat from the heat exchanger.
E−Blower Speed Taps
2 − Set thermostat to highest setting. (All G51MP −1 and G51MP−090−2 units)
Blower speed tap changes are made on the SureLight ®con-
3 − After plenum thermometers have reached their highest trol. See figure 6. Unused taps must be secured on dummy
and steadiest readings, subtract the two readings. The terminals "PARK M1" and or "PARK M2" on the SureLight
difference should be in the range listed on the unit rating board. The heating tap is connected to the "ACB HEAT " ter-
plate. If the temperature is too low, decrease blower minal and the cooling tap is connected to the "ACB COOL"
speed. If temperature is too high, first check the firing terminal. The continuous blower tap is connected to the
rate. Provided the firing rate is acceptable, increase "ACB LOW" terminal. To change existing heat tap, turn off
blower speed to reduce temperature. To change blower power then switch speed tap on ACB HEAT" terminal with
speed taps see the Blower Speed Taps section in this tap connected to PARK M1" or PARK M2". See unit wiring
manual. diagram for blower speed tap

Page 38
 G51MP BLOWER REMOVAL
To Remove Blower:
Turn off line voltage power.
1 Disconnect thermostat wiring con-
nections.
2 Disconnect blower leads from control
board and secondary limit wires.
3 Disconnect secondary limit wire
plug.
4. Loosen screws (2) and remove con-
trol box from unit. Holes are slotted so
screws do not need to be removed. 3 3
5. Remove screws (2) and remove
blower from unit.

2
4 1
FIGURE 47
VI−MAINTENANCE Filters
Filters should be inspected monthly. Clean or replace the
filters when necessary to ensure proper furnace operation.
WARNING Replacement filters must be rated for high velocity airflow.
ELECTRICAL SHOCK, FIRE, Table 23 lists recommended filter sizes.
OR EXPLOSION HAZARD. TABLE 23
Failure to follow safety warnings exactly could result Furnace Filter Size
in dangerous operation, serious injury, death or prop- Cabinet Size Side Return Bottom Return
erty damage. 17−1/2" 16 X 25 X 1 (1) 16 X 25 X 1 (1)
Improper servicing could result in dangerous opera- 21" 16 X 25 X 1 (1) 20 X 25 X 1 (1)
tion, serious injury, death, or property damage. 24−1/2" 16 X 25 X 1 (2) 24 X 25 X 1 (1)
Before servicing, disconnect all electrical power to
furnace. Exhaust and air intake pipes
When servicing controls, label all wires prior to dis-
Check the exhaust and air intake pipes and all connections
connecting. Take care to reconnect wires correctly.
Verify proper operation after servicing. for tightness and to make sure there is no blockage.
Electrical
At the beginning of each heating season, system should be
checked as follows by a qualified service technician: 1 − Check all wiring for loose connections.
Blower 2 − Check for the correct voltage at the furnace (furnace
Check the blower wheel for debris and clean if necessary. operating).
The blower motors are prelubricated for extended bearing
life. No further lubrication is needed. 3 − Check amp−draw on the blower motor.
Motor Nameplate__________Actual__________
Winterizing and Condensate Trap Care
WARNING 1 − Turn off power to the unit.
The blower access panel must be securely in place 2 − Have a shallow pan ready to empty condensate water.
when the blower and burners are operating. Gas
fumes, which could contain carbon monoxide, can be 3 − Remove the drain plug from the condensate trap and
drawn into living space resulting in personal injury or empty water. Inspect the trap then reinstall the drain
death. plug.

Page 39
Cleaning Heat Exchanger 18 − Remove two screws from the front cabinet flange at the
blower deck. Spread cabinet sides slightly to allow
clearance for removal of heat exchanger.
IMPORTANT 19 − Remove screws along vestibule sides and bottom
which secure vestibule panel and heat exchanger as-
Safety glasses and surgical mask should be worn sembly to cabinet. Remove two screws from blower rail
when cleaning heat exchanger and or burner which secure bottom heat exchanger flange. Remove
assembly. heat exchanger from furnace cabinet. Do not remove
turbulators or baffles from secondary heat ex-
If cleaning the heat exchanger becomes necessary, follow
changer.
the below procedures and refer to figure 1 when disassem-
bling unit. Use papers or protective covering in front of fur- 20 − Back wash heat exchanger with soapy water solution
nace while removing heat exchanger assembly. or steam. If steam is used it must be below 275°F
(135°C) .
1 − Turn off electrical and gas supplies to the furnace.
21 − Thoroughly rinse and drain the heat exchanger. Soap
2 − Remove the upper and lower furnace access panels. solutions can be corrosive. Take care to rinse entire as-
3 − Mark all gas valve wires and disconnect them from sembly.
valve. 22 − Reinstall heat exchanger into cabinet making sure that
4 − Remove gas supply line connected to gas valve. Re- the clamshells of the heat exchanger assembly are
move gas valve/manifold assembly. resting on the support located at the rear of the cabinet.
5 − Remove sensor wire from sensor. Disconnect 2-pin Remove the indoor blower to view this area through the
plug from the ignitor. blower opening.
6 − Disconnect wires from flame roll−out switch. 23 − Re-secure the supporting screws along the vestibule
sides and bottom to the cabinet.
7 − Remove burner box front cover and remove burner box
screws at the vestibule panel. Set burner box assembly 24 − Reinstall cabinet screws on front flange at blower deck.
aside. 25 − Reinstall the primary limit on the vestibule panel.
NOTE − If necessary, clean burners at this time. Follow 26 − Route heating component wiring through hole in blow-
procedures outlined in Burner Cleaning section. er deck and reinsert strain relief bushing.
8 − Loosen three clamps and remove flexible exhaust tee. 27 − Reinstall pressure swtich and reconnect pressure
9 − Remove 3/8 inch rubber cap from condensate drain switch wiring.
plug and drain. Replace cap after draining. 28 − Carefully connect combustion air prove switch hos-
10 − Disconnect condensate drain line from the condensate ing from prove switches to proper stubs on cold end
trap. Remove condensate trap (it may be necessary to header box.
cut drain pipe). Remove screws that secure both con- 29 − Reinstall condensate collars on each side of the fur-
densate collars to either side of the furnace and re- nace. Reconnect drain tubing to collector box.
move collars. Remove drain tubes from cold end head- 30 − Reinstall condensate trap on same side as exhaust
er collector box. pipe. Reconnect condensate drain line to the conden-
11 − Disconnect condensate drain tubing from flue collar. sate trap.
Remove screws that secure both flue collars into place. 31 − Reinstall electrical junction box.
Remove flue collars. It may be necessary to cut the ex- 32 − Reinstall the combustion air inducer. Reconnect the
iting exhaust pipe for removal of the fittings. 2−pin plug to the wire harness. Reconnect the two wires
12 − Disconnect the 2-pin plug from the combustion air in- to the secondary limit, if applicable.
ducer. Disconnect the two wires to the secondary limit, 33 − Use securing screws to reinstall flue collars to either
if applicable. Remove four screws which secure com- side of the furnace. Reconnect exhaust piping and ex-
bustion air inducer to collector box Remove combus- haust drain tubing.
tion air inducer assembly. Remove ground wire from 34 − Replace flexible exhaust tee on combustion air inducer
vest panel. and flue collars. Secure using three existing hose
13 − Mark and disconnect combustion air pressure tubing clamps.
from cold end header collector box. 35 − Reinstall burner box assembly in vestibule area.
14 − Mark and remove wires from pressure switch. Remove 36 − Reconnect flame roll−out switch wires.
pressure switch. Keep tubing attached to pressure 37 − Reconnect sensor wire and reconnect 2−pin plug from
switch. ignitor.
15 − Remove electrical junction box from the side of the fur- 38 − Secure burner box assembly to vestibule panel using
nace. four existing screws. Make sure burners line up in
16 − Mark and disconnect any remaining wiring to heating center of burner ports.
compartment components. Disengage strain relief 39 − Reinstall gas valve manifold assembly. Reconnect gas
bushing and pull wiring and bushing through the hole in supply line to gas valve.
the blower deck. 40 − Reinstall burner box cover.
17 − Remove the primary limit from the vestibule panel. 41 − Reconnect wires to gas valve.
Page 40
42 − Replace the blower compartment access panel. 6 − Use the soft brush attachment on a vacuum cleaner to
43 − Refer to instruction on verifying gas and electrical con- gently clean the face of the burners. Visually inspect
nections when re−establishing supplies. the inside of the burners and crossovers for any block-
age caused by foreign matter. Remove any blockage.
44 − Follow lighting instructions to light and operate furnace
for 5 minutes to ensure that heat exchanger is clean 7 − Reconnect the sensor wire and reconnect the 2−pin
and dry and that furnace is operating properly. plug to the ignitor wiring harness.
8 − Reinstall the burner box assembly using the existing
45 − Replace heating compartment access panel.
four screws. Make sure that the burners line up in the
Cleaning the Burner Assembly center of the burner ports.
1 − Turn off electrical and gas power supplies to furnace. 9 − Reinstall the gas valve manifold assembly. Reconnect
Remove upper and lower furnace access panels. the gas supply line to the gas valve. Reinstall burner
2 − Mark all gas valve wires and disconnect them from the box cover.
valve. 10 − Reconnect the gas valve wires to the gas valve.
3 − Disconnect the gas supply line from the gas valve. Re- 11 − Replace the blower compartment access panel.
move gas valve/manifold assembly. 12 − Refer to instruction on verifying gas and electrical con-
4 − Mark and disconnect sensor wire from the sensor. Dis- nections when re−establishing supplies.
connect 2-pin plug from the ignitor at the burner box. 13 − Follow lighting instructions to light and operate furnace
5 − Remove burner box front cover and remove screws for 5 minutes to ensure that heat exchanger is clean
which secure burner box assembly to vest panel. Re- and dry and that furnace is operating properly.
move burner box from the unit. 14 − Replace heating compartment access panel.

Page 41
VII−WIRING DIAGRAM AND SEQUENCE OF OPERATION

1 − When there is a call for heat, W1 of the thermostat en- 5 − Gas valve opens for a 4−second trial for ignition
ergizes W of the furnace control with 24VAC. 6 − Flame is sensed, gas valve remains open for the heat
2 − S10 primary limit switch, S47 rollout switch and S21 call.
secondary limit are closed. Call for heat can continue. 7 − After 45−second delay, control (A92) energizes indoor
3 − Control (A92) energizes combustion air inducer B6. blower B3.
Combustion air inducer runs until S18 combustion air
8 − When heat demand is satisfied, W1 of the indoor ther-
prove switch closes (switch must close within 2−1/2
minutes or control goes into 5 minute prove switch mostat de−energizes W of the control which de−ener-
delay). Once S18 closes, a 15−second pre−purge fol- gizes the gas valve. Combustion air inducer B6 contin-
lows. ues a 5−second post−purge period, and indoor blower
4 − Control (A92) energizes ignitor. A 20−second warm−up B3 completes a selected OFF time delay.
period begins.

Page 42
1 − When there is a call for heat, W1 of the thermostat en- 5 − Gas valve opens for a 4−second trial for ignition
ergizes W of the furnace control with 24VAC. 6 − Flame is sensed, gas valve remains open for the heat
2 − S10 primary limit switch, S47 rollout switch and S21 call.
secondary limit are closed. Call for heat can continue. 7 − After 45−second delay, SureLight control (A92) ener-
3 − Control (A92) energizes combustion air inducer B6. gizes indoor blower B3.
Combustion air inducer runs until S18 combustion air
8 − When heat demand is satisfied, W1 of the indoor ther-
prove switch closes (switch must close within 2−1/2
minutes or control goes into 5 minute Watchguard mostat de−energizes W of the control which de−ener-
Pressure Switch delay). Once S18 closes, a 15−sec- gizes the gas valve. Combustion air inducer B6 contin-
ond pre−purge follows. ues a 5−second post−purge period, and indoor blower
4 − Control (A92) energizes ignitor. A 20−second warm−up B3 completes a selected OFF time delay.
period begins.

Page 43
 SURELIGHT CONTROL
HEATING SEQUENCE OF OPERATION
Control board 69M15 RED LED #1 = DS1 & GREEN LED #2 = DS2
Control board 97L48 GREEN LED #1 = DIAG1 & GREEN LED #2 = DIAG2

NORMAL HEATING MODE ABNORMAL HEATING MODE

POWER ON
GAS VALVE OFF. COMBUSTION AIR INDUCER ON.
INDOOR BLOWER ON.
CONTROL SELF−CHECK OKAY? LED #1 ALTERNATING FAST FLASH
NO LED#2 ALTERNATING FAST FLASH
CHECK FOR BROKEN IGNITOR OR
COMBUSTION AIR INDUCER ON FOR 1 SECOND. OPEN IGNITOR CIRCUIT
(Iinition control 9748 only)
GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.
YES INDOOR BLOWER DELAY OFF.
IS POLARITY REVERSED? LED #1 ON
LED #2 ON
NO (RESET CONTROL BY TURNING MAIN POWER OFF.)
LED#1 AND LED#2
ALTERNATING FAST POLARITY REVERSED.
FLASH. SIGNAL NO LED #1 −− FAST FLASH
HOLDS UNTIL UNIT IS IS THERE YES IS VOLTAGE NO LED #2 −− SLOW FLASH
PROPERLY GROUND. PROPER GROUND? ABOVE 75 VOLTS?

YES LED#1 AND LED#2 ALTERNATING FAST

NO FLASH. SIGNAL HOLDS UNTIL VOLTAGE
ROLLOUT SWITCH CLOSED? RISES ABOVE 75 VOLTS.
YES
GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.
INDOOR BLOWER OFF WITH DELAY.
NO LED #1 −− ON. LED #2 −− SLOW FLASH.
BURNER OFF?
(CONTINUOUS FLAME CHECK) SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES.

YES
NORMAL OPERATION:
LED #1 −− SLOW FLASH GAS VALVE OFF. COMBUSTION AIR INDUCER ON.
LED #2 −− SLOW FLASH INDOOR BLOWER ON HEATING SPEED.
LED #1 −− SLOW FLASH
LED #2 −− OFF
THERMOSTAT CALLS FOR HEAT:
LED #1 −− FAST FLASH
LED #2 −− FAST FLASH
GAS VALVE OFF.
YES COMBUSTION AIR INDUCER OFF.
NO INDOOR BLOWER OFF WITH DELAY.
IS COMBUSTION AIR
PROVE SWITCH OPEN? LED #1 OFF
LED #2 SLOW FLASH
YES (Sequence holds until PROVE switch
IS COMBUSTION AIR INDUCER ENERGIZED? closes or thermostat resets control.)
(ACCESSORY TERMINAL IS ENERGIZED WITH C.A.I.)
YES
PROVE SWITCH IS IN WATCHGUARD MODE.
HAS COMBUSTION AIR PROVE SWITCH NO GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.
CLOSED IN 2.5 MINUTES? INDOOR BLOWER OFF WITH DELAY.
LED #1 −− OFF. LED #2 −− SLOW FLASH.
YES IS 5-MINUTE RESET PERIOD COMPLETE?
15-SECOND COMBUSTION AIR INDUCER PREPURGE
INITIATED BY CLOSED PROVE SWITCH.
YES
CONTINUED NEXT PAGE
TABLE 24
FLAME SENSE SIGNAL
Ignition Control Normal Low Drop Out
97L48 0.61 0.21 − 0.60 0.20
69M15 0.31 0.25 − 0.30 0.24

Page 44
 NORMAL HEATING MODE ABNORMAL HEATING MODE
15-SECOND COMBUSTION AIR INDUCER PREPURGE
INITIATED BY CLOSED PRESSURE SWITCH.
IS VOLTAGE ABOVE 75 VOLTS? NO
YES
NO YES
NO LEDS SIGNAL
IGNITOR WARM-UP −− 20 SECONDS. IS THERE A PROPER GROUND? ALTERNATING
YES YES FAST FLASH
YES NO
IS IGNITOR INTACT AND CONNECTED?
4-SECOND TRIAL FOR IGNITION. GAS VALVE OPENS.
IGNITOR ENERGIZED DURING TRIAL UNTIL FLAME
SENSED. GAS VALVE OFF. COMBUSTION AIR INDUCER ON.
INDOOR BLOWER OFF.
YES NO
HAS CONTROL FAILED TO SENSE FLAME FOR
FLAME STABILIZATION PERIOD. FIVE CONSECUTIVE TRIES DURING A SINGLE
NO HEAT DEMAND?
4 SECONDS NO
YES
FLAME RECTIFICATION CURRENT IGNITION WATCHGUARD MODE. GAS VALVE OFF.
CHECK. CAN FLAME BE PROVEN WITHIN COMBUSTION AIR INDUCER OFF.
4 SECONDS AFTER GAS VALVE OPENS? INDOOR BLOWER OFF WITH DELAY
See table 24 LED 1 ALT. SLOW FLASH LED 2 ALT SLOW FLASH
IS 60-MINUTE RESET PERIOD COMPLETE?
YES YES
HAS CONTROL RESET IGNITION NO
FLAME PRESENT?
SEQUENCE FOUR TIMES?
YES
NO
FLAME SIGNAL NORMAL? LOW FLAME SIGNAL
See table 24 (Does not affect operation of control)
LED #1 −− SLOW FLASH
YES LED #2 −− FAST FLASH YES
INDOOR BLOWER ON DELAY BEGINS LIMIT SWITCH WATCH GUARD
(45 seconds.) GAS VALVE DE−ENERGIZED. MODE. GAS VALVE OFF.
COMBUSTION AIR INDUCER COMB. AIR INDUCER OFF. IN-
YES DE−ENERGIZED.INDOOR BLOWER
NO DOOR BLOWER OFF WITH
PRIMARY AND SECONDARY LIMIT ON UNTIL SWITCH CLOSES.LED #1 DELAY. LED#1−SLOW FLASH
SWITCHES CLOSED? −− SLOW FLASH. LED #2 −− ON. LED#2− ON. IS 60MINUTE RE-
IS LIMIT SWITCH CLOSED? SET PERIOD COMPLETE.?
YES

HAS PRIMARY/SECONDARY LIMIT NO

YES RESET (CLOSED) WITHIN 3
MINUTES? YES

NO GAS VALVE POWER OFF.

COMBUSTION AIR INDUCER POWER OFF.
ROLLOUT SWITCH CLOSED? INDOOR BLOWER OFF WITH DELAY
LED #1 −− ON. LED #2 −− SLOW FLASH.
YES
SEQUENCE HOLDS UNTIL ROLLOUT SWITCH IS RESET

COMBUSTION AIR PROVE NO

SWITCH CLOSED?
YES
YES GAS VALVE DE−ENERGIZED.
COMBUSTION AIR INDUCER ON. YES
THERMOSTAT DEMAND SATISFIED. INDOOR BLOWER OFF WITH DELAY
YES LED #1 −− OFF. LED #2 −− SLOW FLASH.
HAS CAB SWITCH CLOSED IN 2.5 MINUTES?
LED #1 & #2 SIMULTANEOUS SLOW FLASHES.
YES NO
COMB. AIR INDUCER CONTINUES 5-SECOND POST PURGE 5-MINUTE PRESSURE SWITCH
AFTER T’STAT DEMAND IS SATISFIED. INDOOR AIR BLOWER WATCHGUARD MODE.
COMPLETES SELECTED OFF" DELAY BEFORE SHUTTING OFF.
HEAT SPEED, ACCESSORY AND EAC. TERMINAL OFF.

Page 45
 SURELIGHT CONTROL
COOLING SEQUENCE OF OPERATION
NORMAL COOLING MODE ABNORMAL COOLING MODE

POWER ON

IGNITION CONTROL MAIN POWER ON.

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

CONTROL SELF DIAGNOSTIC CHECK. NO INDOOR BLOWER OFF WITH NORMAL DELAY.
IS CONTROL OPERATING NORMALLY? SIGNAL CIRCUIT BOARD FAILURE AT LED.
INTERRUPT MAIN POWER TO RESET CONTROL.
YES
TURN INDUCER ON FOR 1 SECOND (ignition control 97L48)

YES
IS POLARITY REVERSED? LED#1 FAST FLASH LED#2 SLOW FLASH

NO
LED#1 AND LED#2
ALTERNATING FAST NO LED#1 AND LED#2 ALTERNATING FAST
IS THERE IS VOLTAGE NO
FLASH. SIGNAL YES FLASH. SIGNAL HOLDS UNTIL VOLTAGE
HOLDS UNTIL UNIT IS PROPER GROUND? ABOVE 75 VOLTS? RISES ABOVE 75 VOLTS.
PROPERLY GROUND.
YES THERMOSTAT OFF
GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.
NO
ROLLOUT SWITCH MONITORED CONTINUOUSLY. INDOOR BLOWER OFF WITH NORMAL DELAY.
IS ROLLOUT SWITCH CLOSED? SIGNAL CIRCUIT BOARD FAILURE AT LED.
SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES.
YES

LED: SLOW FLASH RATE REMAINS UNCHANGED

THROUGHOUT COOLING CYCLE.

THERMOSTAT CALLS FOR COOLING.

COMPRESSOR CONTACTOR AND SYSTEM FAN

ENERGIZED AFTER DELAY. COOL SPEED AND
ELECTRONIC AIR CLEANER TERMINAL IS ENERGIZED.
(ignition control 69M15, 2-second delay.
ignition control 97L48 no delay).

THERMOSTAT OPENS.

COMPRESSOR OFF.

COOLING SPEED AND ELECTRONIC AIR CLEANER

TERMINAL OFF WITH FIELD ADJUSTABLE DELAY
(ignition control 69M15, 2 or 45 second delay.
ignition control 97L48 no delay).

Page 46
 SURELIGHT CONTROL
CONTINUOUS FAN SEQUENCE OF OPERATION

LED: SLOW FLASH RATE REMAINS

UNCHANGED THROUGHOUT SEQUENCE.

MANUAL FAN SELECTION MADE AT THERMOSTAT.

CONTROL (G) ENERGIZES INDOOR BLOWER ON
CONTINUOUS BLOWER SPEED. ELECTRONIC AIR
CLEANER TERMINAL IS ENERGIZED.

HEATING ACCESSORY TERMINAL

THERMOSTAT CALLS FOR HEAT (W).
ENERGIZES WITH COMB. AIR INDUCER.
NO YES
NO
THERMOSTAT CALLS FOR COOLING (Y). INDOOR BLOWER SWITCHES TO HEAT SPEED AFTER
YES NORMAL DELAY.
(blower remains energized during continuous fan mode)
INDOOR BLOWER SWITCHES TO COOL SPEED.

THERMOSTAT OPENS. COMBUSTION AIR INDUCER AND

HEATING ACCESSORY TERMINAL ARE DE−ENERGIZED.
THERMOSTAT OPENS.

INDOOR BLOWER SELECTED TIME OFF DELAY BEGINS.

AFTER DELAY HEAT SPEED DE−ENERGIZED.
(blower remains energized during continuous fan mode).

INDOOR BLOWER SWITCHES TO

CONTINUOUS BLOWER. ELECTRONIC AIR
CLEANER TERMINAL IS ENERGIZED.

Page 47
VIII−INTEGRATED IGNITION CONTROL TROUBLESHOOTING CHART
UPON INITIAL POWER UP, REMOVE ALL THERMOSTAT DEMANDS TO THE UNIT

PROBLEM: 1 UNIT FAILS TO OPERATE IN THE COOLING, HEATING, OR CONTINUOUS FAN MODE
Condition Possible Cause Corrective Action / Comments
1.1 1.1.1
ACTION 1 − Check 120V main voltage.
− Both diagnostic lights fail to light up. Main voltage 120V not supplied to unit. Determine cause of main power failure.

1.1.2 ACTION 1 − Check for correct wiring of 120V to

LED#1−Off
Miswiring of furnace or improper con- power make up box and transformer.
LED#2−Off ACTION 2 − Check 24V wiring to control board.
nections.
1.1.3 ACTION 1 − Replace fuse.
Blown fuse ACTION 2 − If fuse still blows, check for short.

ACTION 1 − Check that door switch is activated

when door is closed.
1.1.4 ACTION 2 − Check wire connections to switch, re-
Door interlock switch failure. place loose connectors.
ACTION 3 − Check continuity of switch in closed
position. Replace if defective.

1.1.5 ACTION 1 − Check that transformer output is

Transformer Failure. 24V. Replace if defective.

1.1.6 ACTION 1 − If all the above items have been

checked, replace board.
Failed control board.
1.2 ACTION 1 − Manually reset the roll−out switch
1.2.1 by pushing the top button.
− Diagnostic lights flash the roll−out Roll−out switch open. ACTION 2 − Determine the cause of the roll−out
switch activation before leaving furnace.
code.
1.2.2 ACTION 1 − Check continuity across roll−out
switch. Replace roll−out switch if switch is reset
Roll−out switch failure. but does not have continuity.
LED#1−On,
LED#1 O
1.2.3
LED#2 Slow Flash
LED#2−Slow ACTION 1 − Check wiring connections to switch.
switch
Mis iring or improper connections at
Miswiring
roll−out switch.
ACTION 1 − Check pin connector for proper
1.2.4 connection to control board.
Low voltage pin connector failure ACTION 2 − Check continuity of the multi plug
pin.

1.3
− On initial power−up the comb. air in-
ducer does not energize.
ACTION 1 − Check the 120V has line and neutral
− Diagnostic lights flash the reverse po- 1.3.1 correctly input into control.
larity code. ACTION 2 − Reverse the line and neutral at the
120V main power polarity reversed.
120V field connection.

LED#1−Fast Flash,
LED#2−Slow Flash.
1.4
1.4.1 ACTION 1 − Check for 120V to combustion air
− On initial power up the combustion air
Open combustion air inducer motor cir- inducer. If no power, check wire and connec-
inducer does not energize. tions.
− Diagnostic lights flash normal power cuit.
on operation.

1.4.2 ACTION 1 − If power is present at blower, replace

LED#1−Slow Flash Failed combustion air inducer motor. blower.
LED#2−Slow Flash

Page 48
 PROBLEM 1: UNIT FAILS TO OPERATE IN THE COOLING, HEATING, OR CONTINUOUS FAN MODE
Condition Possible Cause Corrective Action / Comments
1.5 ACTION 1 − Check that the unit is properly
1.5.1 ground.
− Diagnostic lights flash the improper Improper ground to the unit. ACTION 2 − Install a proper main ground to the
main ground.
g unit

1.5.2
High voltage pin connector is ACTION 1 − Check pin connector for proper instal-
LED#1−Alternating Fast Flash lation. Correctly insert connector into control.
LED#2−Alternating Fast Flash improperly attached to the circuit
board.
1.5.3 ACTION 1 − Check that the line voltage is above
75V. Determine cause of voltage drop and supply
Line voltage is below 75V. correct voltage to the control.

1.5.4 ACTION 1 − Check for correct wiring and loose

connections in the ignitor circuit. Check mult−plug
Open ignitor circuit. connections for correct installation.

1.5.5 ACTION 1 − Unplug ignitor and read resistance

across ignitor. If resistance does not read be-
Broken or failed ignitor. tween 10.9 and 19.7 ohms, replace the ignitor.

PROBLEM 2: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR BLOWER DOES NOT
ENERGIZE
Condition Possible Cause Corrective Action / Comments
2.1
ACTION 1 − Check continuity across switch(es).
− Unit operates with a cooling or contin- 2.1.1 Switches reset automatically upon cool down.
uous fan demand. ACTION 2 − Check for restrictions on blower inlet
Primary or secondary (if equipped ) air (including filter) and outlet air. Determine
− Combustion air inducer will not start
limit open. cause for limit activation before placing unit back
with a Heating demand. in operation.
− Diagnostic
g lights
g flash the limit failure
d
mode.
2.1.2 ACTION 1 − Check for correct wiring and loose
Miswiring of furnace or improper connections. Correct wiring and/or replace any
LED#1−Slow Flash, connections at limit switch(es). loose connections.
LED#2−On
2.2
− Unit operates with a cooling and con- 2.2.1
ACTION 1 − Check for correct wiring and loose
tinuous fan demand. Miswiring of furnace or improper connections. Correct wiring and/or replace any
− Combustion air inducer will not start connections to combustion air loose connections.
with a Heating demand. inducer.
− Diagnostic lights flash the pressure
switch failure code
code.
2.2.2 ACTION 1 − Check that the prove switch is open
without the combustion air inducer operating. Re-
LED#1−Off, Prove switch stuck closed. place if defective.
LED#2−Slow Flash

Page 49
PROBLEM 2: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR INDUCER DOES NOT
ENERGIZE (CONT.).
Condition Possible Cause Corrective Action/Comments
2.3
− Unit operates with a cooling and con- 2.3.1 ACTION 1 − Check for correct wiring and loose
tinuous fan demand. connections. Correct wiring and/or replace any
− Combustion air inducer will not start Miswiring of furnace or improper
loose connections.
with a Heating demand. connections to combustion air inducer.
− Diagnostic lights flash the pressure
switch failure code 2.5
2 5 minutes after
heating demand.
2.3.2 ACTION 1 − If there is 120V to combustion air in-
ducer and it does not operate, replace combus-
Combustion air inducer failure. tion air inducer.
LED#1−Off,
LED#2−Slow Flash
PROBLEM 3: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR INDUCER
ENERGIZES, IGNITOR IS NOT ENERGIZED.
Condition Possible Cause Corrective Action/Comments
3.1 3.1.1
ACTION 1 − Check that the prove switch lines are
− Unit operates with a cooling and Prove switch does not close due to correctly routed. Correctly route pressure switch
continuous fan demand. incorrect routing of the pressure lines.
− Combustion air inducer energizes switch lines.
with a heating demand
demand.
3.1.2
− Diagnostic lights flash the pressure ACTION 1 − Remove any obstructions from the
switch failure code 2.5 minutes after Prove switch does not close due to the pressure lines and/or taps.
heatingg demand. obstructions in the pressure lines.
3.1.3 ACTION 1 − Check prove switch lines for leaks.
Prove switch lines damaged Replace any broken lines.
LED#1 Off
LED#1−Off
LED#2−Slow Flash 3.1.4 ACTION 1 − Check prove switch lines for conden-
Condensate in prove switch line. sate. Remove condensate from lines.

ACTION 1 − Check the differential pressure

3.1.5 across the prove switch. This pressure should
exceed the set point listed on the switch.
Prove switch does not close due to a ACTION 2 − Check for restricted inlet vent. Re-
low differential pressure across the move all blockage.
prove switch. ACTION 3 − Check for proper vent sizing and
run length.

3.1.6
ACTION 1 − Check that the proper prove switch is
Wrong prove switch installed in the installed in the unit. Replace prove switch if nec-
unit, or prove switch is out of essary.
calibration.
3.1.7 ACTION 1 − Check for correct wiring and loose
Miswiring of furnace or improper connections. Correct wiring and/or replace any
loose connections.
connections at prove switch.
ACTION 1 − If all the above modes of failure have
3.1.8 been checked, the prove switch may have failed.
Prove switch failure. Replace prove switch and determine if unit will op-
erate.

Page 50
 PROBLEM 4: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR BLOWER
ENERGIZES, IGNITOR IS ENERGIZED.
Condition Possible Cause Corrective Action/Comments
4.1 ACTION 1 − Check line pressure at the gas valve.
4.1.1 Pressure should not exceed 13" WC for both nat-
− Unit operates with a cooling and Check that gas is being supplied to ural and propane. Line pressure should read a
minimum 4.5" WC for natural and 8.0"WC for pro-
continuous fan demand. the unit. pane.
− Combustion air inducer energizes
4.1.2
with Heating demand. ACTION 1 − Check for correct wiring and loose
− Ignitor is energized but unit fails to Miswiring of gas valve or loose- connections. Correct wiring and/or replace any
connections at multi−pin control amp loose connections.
light. plugs or valve.
ACTION 1 − Check that 24V is supplied to the gas
valve approximately 35 seconds after heat de-
4.1.3 mand is initiated.
LED#1−Alternating Slow Flash Defective gas valve or ignition ACTION 2 − Replace the valve if 24V is supplied
LED#2−Alternating Slow Flash but valve does not open.
control. ACTION 3 − Replace the control board if 24V is not
supplied to valve.
PROBLEM 5: BURNERS LIGHT WITH A HEATING DEMAND BUT UNIT SHUTS DOWN
PREMATURELY
Condition Possible Cause Corrective Action/Comments
5.1.1 ACTION 1 − Check for restricted intake and ex-
haust vent. Remove all blockage.
Low pressure differential at the prove ACTION 2: Check for proper vent sizing. See
5.1 switch. installation instructions.

− Burners fire with a heating demand. 5.1.2

ACTION 1 − Check vent termination kit installed.
− Burners light but unit shuts off prior Wrong concentric vent kit used for ter- See Placement and Installation section.
to satisfying T−stat demand. minating the unit.
− Diagnostic lights flash the pressure
ACTION 1 − Check condensate line for proper
switch code. 5.1.3 vent slope, and any blockage. Condensate
Condensate drain line is not draining should flow freely during operation of furnace. Re-
pair or replace any improperly installed conden-
properly. sate lines.
LED#1−Off
LED#1 Off
LED#2−Slow Flash 5.1.4 ACTION 1 − Check for restricted intake and ex-
haust. Remove all blockage.
Low pressure differential at the prove ACTION 2: Check for proper vent sizing. See
switch. installation instructions.

5.2 5.2.1 ACTION 1 − Check that sensor is properly lo-

− Combustion air inducer energizes Sensor or sense wire is improperly cated and that the sense wire is properly at-
tached to both the sensor and the control.
with a heating demand. installed.
B rners light but
− Burners b t fail to stay
sta lit.
lit ACTION 1 − Check for a broken sensor.
− After 5 tries the control diagnostics 5.2.2 ACTION 2 − Test continuity across the sense
flash the watchguard burners failed to Sensor or sense wire is broken. wire. If wire or sensor are damaged replace the
ignite code. component.
ACTION 1 − Check for resistance between the
5.2.3 sensor rod and the unit ground.
LED#1−Alternating Slow Flash Sensor or sensor wire is grounded to ACTION 2 − Check for resistance between the
sensor wire and the unit ground.
LED#2−Alternating Slow Flash the unit. ACTION 3 − Correct any shorts found in circuit.
ACTION 1 − Check the microamp signal from
the burner flame. If the microamp signal is be-
low normal, check the sense rod for proper
location or contamination.
5.2.4 ACTION 2 − Replace, clean, or relocate flame
sense rod. If rod is to be cleaned, use steel
Control does not sense flame. wool or replace sensor. DO NOT CLEAN ROD
WITH SAND PAPER. SAND PAPER WILL
CONTRIBUTE TO THE CONTAMINATION
PROBLEM. NOTE: Do not attempt to bend
sense rod.

Page 51
 PROBLEM 5: BURNERS LIGHT WITH HEATING DEMAND BUT UNIT SHUTS DOWN
PREMATURELY (CONT.)
Condition Possible Cause Corrective Action/Comments
5.3 ACTION 1 − Check that the manifold pressure
matches value listed on nameplate. See installa-
− Combustion air inducer energizes tion instructions for proper procedure.
with a heating demand. 5.3.1 ACTION 2 − Verify that the installed orifice size
− Burners light. match the size listed on the nameplate or installa-
Unit is firing above 100% of the name- tion instructions.
− Roll−out switch trips during the heat- plate input. ACTION 3 − Check gas valve sensing hose to in-
ing demand. sure no leaks are present.
− Diagnostic lights flash roll−out fail- ACTION 4 − Check the input rate to verify rate
ure. matches value listed on nameplate.
ACTION 1 − Tighten orifice until leak is sealed.
5.3.2 NOTE: Be careful not to strip orifice threads.
LED#1−On Gas orifices leak at the manifold ACTION 2 − Check for gas leakage at the
threaded orifice connection. Use approved meth-
LED#2−Slow Flash connection. od for leak detection (see unit instructions).
5.3.3 ACTION 1 − Check for air leakage at all joints in
the heat exchanger assembly. Condition will
Air leakage at the connections cause high CO2 with high CO.
between the primary heat exchanger, ACTION 2 − Seal leakage if possible, replace heat
secondary heat exchanger, and exchanger if necessary, tag and return heat ex-
combustion air blower. changer to proper Lennox personnel.

5.3.4 ACTION 1 − Check for sooting deposits or other

Insufficient flow through the heat restrictions in the heat exchanger assembly.
exchanger caused by a sooted or Clean assembly as outlined in instruction manual.
ACTION 2 − Check for proper combustion.
restricted heat exchanger.
5.3.5 ACTION 1 − Check that the burners are firing into
Burners are not properly located in the center of the heat exchanger openings. Cor-
rect the location of the burners if necessary.
the burner box.
5.4
5.4.1 ACTION 1 − Check for proper flow of exhaust
− Combustion air inducer energizes gases away from intake vent. Remove any ob-
with a heating demand. Recirculation of flue gases. This stacles in front of the intake and exhaust vent
− Burners light roughly and the unit condition causes rough ignitions and which would cause recirculation.
fails to stay lit. operation. Problem is characterized ACTION 2 − Check for correct intake and exhaust
by nuisance flame failures. vent installation. See instructions
− Diagnostic lights flash watchguard
flame failure.

ACTION 1 − Remove burner and inspect the

5.4.2 cross−overs for burrs, or any restriction or if cross-
LED#1−Alternating Slow Flash
Improper burner cross−overs over is warped. Remove restriction or replace
LED#2−Alternating Slow Flash burners.

Page 52
 PROBLEM 6: CONTROL SIGNALS LOW FLAME SENSE DURING HEATING MODE
Condition Possible Cause Corrective Action/Comments
6.0 6.1.1 ACTION 1 − Check the sensor rod for proper loca-
− Unit operates correctly but the diag- Sensor rod is improperly located on tion on the burner. Properly locate the sensor rod
nostic lights flash low flame sense or replace if rod cannot be located correctly.
the burner.
code
code.
ACTION 1 − Check sensor rod for contamination
or coated surface. Clean the sensor rod with steel
6.1.2 wool or replace sensor. DO NOT USE SAND PA-
LED#1−Slow Flash PER TO CLEAN ROD. SAND PAPER WILL
LED#2−Fast Flash Sensor rod is contaminated.
CONTRIBUTE TO THE CONTAMINATION
PROBLEM.

PROBLEM 7: INDOOR BLOWER FAILS TO OPERATE IN COOLING, HEATING, OR CONTINUOUS

FAN MODE
Condition Possible Cause Corrective Action/Comments
7.0 7.1.1
ACTION 1− Correct wiring and/or replace any
− Indoor blower fails to operate in Miswiring of furnace or improper loose connections. Check for correct wiring and
continuous fan, cooling, or heating connections at control or indoor blow- loose connections.
mode. er motor.
ACTION 1 − Check for 120V at the various calls for
7.1.2 indoor blower by energizing "Y", "G", and "W" indi-
120V is not being supplied to the vidually on the low voltage terminal strip. Note that
indoor air blower or blower motor fail- when "W’ is energized, the blower is delayed 45
seconds. If there is 120V to each motor tap but the
ure. blower does not operate, replace the motor.

7.1.3 ACTION 1 − If there is not 120V when "Y", "G", or

Defective control board "W" is energized, replace the control.

7.1.4
ACTION 1 − Replace capacitor
Defective run capacitor
PROBLEM 8: RF STATIC DURING TIME FOR IGNITION
Condition Possible Cause Corrective Action/Comments
8.0 8.1.2
ACTION 1 − Call Technical Support, Dallas.
− AM radio interference. Ignitor operation

Page 53