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G51MP Series: Gas Furnace
G51MP Series: Gas Furnace
G51MP
504,666M
08/03
SERIES
GAS FURNACE
Litho U.S.A.
WARNING
FIRE OR EXPLOSION HAZARD.
Failure to follow safety warnings exactĆ
ly could result in serious injury, death,
or property damage.
08/03 504,666M
*2P0803* *P504666M*
G51MP Parts Identification
DURALOKTM HEAT
EXCHANGER
TOP CAP ASSEMBLY
BURNERS
CABINET
UPPER ACCESS
PANEL
GAS VALVE AND
MANIFOLD
FLUE
COLLAR
SURELIGHTt
CONTROL BOARD BLOWER
MOTOR
BLOWER ACCESS
PANEL CONTROL BOX
FIGURE 1
WARNING WARNING
Product contains fiberglass wool. Do not set thermostat below 60°F (16°C) in heating
Disturbing the insulation in this product during mode. Setting thermostat below 60°F (16°C) reduces
installation, maintenance, or repair will expose you the number of heating cycles. Damage to the unit
to fiberglass wool. Breathing this may cause lung may occur that is not covered by the warranty.
cancer. (Fiberglass wool is known to the State of CalĆ
ifornia to cause cancer.)
Fiberglass wool may also cause respiratory, skin,
and eye irritation.
WARNING
To reduce exposure to this substance or for further If overheating occurs or if gas supply fails to shut off,
information, consult material safety data sheets shut off the manual gas valve to the furnace before
available from address shown below, or contact your shutting off electrical supply.
supervisor.
Lennox Industries Inc.
P.O. Box 799900
Dallas, TX 75379-9900
CAUTION
Before attempting to perform any service or mainteĆ
NOTE - This manual must be left with the equipment nance, turn the electrical power to unit OFF at the
user. disconnect switch.
Page 2
WARNING WARNING
Do not use this furnace if any part has been underĆ The blower door must be securely in place when the
water. A flood-damaged furnace is extremely danĆ blower and burners are operating. Gas fumes, which
gerous. Attempts to use the furnace can result in could contain carbon monoxide, can be drawn into
fire or explosion. Immediately call a qualified serĆ the living space resulting in personal injury or death.
vice technician to inspect the furnace and to replace
all gas controls, control system parts, and electrical Your furnace is a gas appliance. It is critical that the gas
parts that have been wet or to replace the furnace, supplied to the unit be completely burned to avoid the proĆ
if deemed necessary. duction of carbon monoxide gas. Complete combustion of
the gas requires, but is not limited to, correct gas pressure
and gas flow rate, adequate combustion, air, and proper
IMPORTANT venting.
Any additions, changes, or conversions required in
order for the appliance to satisfactorily meet the apĆ
plication needs must be made by a Lennox service WARNING
technician using factory specified and approved Carbon monoxide gas is invisible, odorless and
parts. toxic.
Page 3
The gas valve on the G51MP may be equipped with eiĆ White Rodgers 36G Series Gas Valve
ther a gas control knob or gas control lever. Use only your INLET
hand to push the lever or turn the gas control knob. Never MANIFOLD PRESSURE
PRESSURE POST
use tools. If the the lever will not move or the knob will not ADJUSTMENT
push in or turn by hand, do not try to repair it. Call a qualiĆ SCREW
fied service technician. Force or attempted repair may OUTLET
result in a fire or explosion. PRESSURE
POST
Placing the G51MP furnace into operation:
G51MP units are equipped with a SureLight® ignition
GAS VALVE SHOWN IN OFF POSITION
system. Do not attempt to manually light burners on this
FIGURE 3
furnace. Each time the thermostat calls for heat, the
burners will automatically light. The ignitor does not get Honeywell VR8205 Series Gas Valve
hot when there is no call for heat on units with SureLight® MANIFOLD MANIFOLD
PRESSURE PRESSURE
ignition system. ADJUSTMENT OUTLET
SCREW
Operating the Gas Valve (Figures 3 and 4)
1 - STOP! Read the safety information at the beginning of
this section. ON
THERMOSTATS FIGURE 4
9 - Replace the upper access panel.
10 - Turn on all electrical power to to the unit.
11 - Set the thermostat to desired setting.
NOTE - When unit is initially started, steps 1 through 11
may need to be repeated to purge air from gas line.
12- If the appliance will not operate, follow the section
Turning Off Gas to the Unit" and call your service techĆ
FIGURE 2 nician or gas supplier.
4 - This furnace is equipped with an ignition device which Turning Off Gas to the Unit
automatically lights the burners. Do not try to light the 1 - Set the thermostat to the lowest setting.
burners by hand. 2 - Turn off all electrical power to the unit if service is to be
5 - Remove the upper access panel. performed.
6 - White Rodgers 36G Gas Valve - Switch gas valve leĆ 3 - Remove the upper access panel.
ver to OFF. 4 - White Rodgers 36G Gas Valve - Switch gas valve leĆ
Honeywell VR8205 Gas Valve - Turn knob on gas ver to OFF.
valve clockwise to OFF. Do not force. See figure Honeywell VR8205 Gas Valve - Turn knob on gas
4. valve clockwise to OFF. Do not force.
7 - Wait five minutes to clear out any gas. If you then smell 5 - Replace the upper access panel.
gas, STOP! Immediately call your gas supplier from a Filters
neighbor's phone. Follow the gas supplier's instrucĆ
tions. If you do not smell gas go to next step. All G51MP filters are installed external to the unit. Filters
should be inspected monthly. Clean or replace the filters
8 - White Rodgers 36G Gas Valve - Switch gas valve lever when necessary to ensure proper furnace operation. ReĆ
to ON. See figure 3 for the White Rodgers 36G valve. placement filters must be rated for high velocity airflow.
Honeywell VR8205 Gas Valve - Turn knob on gas valve Table 1 lists recommended filter sizes.
counterclockwise to ON. Do not force. A filter must be in place whenever the unit is operating.
Page 4
TABLE 1 Inspect the furnace for obvious signs of deterioration.
Furnace Filter Size Inspect the furnace venting system to make sure it is in
Cabinet Size Side Return Bottom Return place, physically sound, and without holes, corrosion, or
17-1/2" 16 X 25 X 1 (1) 16 X 25 X 1 (1) blockage.
21" 16 X 25 X 1 (1) 20 X 25 X 1 (1) Vent pipe must be clear and free of obstructions and must
24-1/2" 16 X 25 X 1 (2) 24 X 25 X 1 (1) slope upward away from the furnace.
Inspect the furnace return air duct connection to ensure
Maintenance duct is sealed to the furnace and terminates outside the
A qualified service technician should inspect the complete space containing the furnace.
system each season (heating and cooling). The following Inspect the physical support of the furnace to guarantee
maintenance procedures should only be conducted by a that it is sound without sagging, cracks or gaps around
qualified service technician. Do not attempt to service base and it maintains seal between base and support.
the unit in any way. Inspect and clean the condensate trap and drain.
During a seasonal check the service technician will inspect
WARNING the indoor blower, burner flames and electrical connections
along with the venting system.
ELECTRICAL SHOCK, FIRE,
OR EXPLOSION HAZARD. Blower
Failure to follow safety warnings exactly could result Check the blower wheel for debris and clean if necessary.
in dangerous operation, serious injury, death or The blower motors are prelubricated for extended bearing
property damage. life. No further lubrication is needed.
Improper servicing could result in dangerous operaĆ
tion, serious injury, death, or property damage.
Before servicing, disconnect all electrical power to
furnace. WARNING
When servicing controls, label all wires prior to disĆ The blower access panel must be securely in place
connecting. Take care to reconnect wires correctly. when the blower and burners are operating. Gas
Verify proper operation after servicing. fumes, which could contain carbon monoxide, can
be drawn into living space resulting in personal injuĆ
Venting System
ry or death.
Page 5
Service Reminder Your vigilance may pay off in early detection of a problem
before either personal injury or property damage occurs.
Call your Lennox service technician if the unit will not operĆ Do not hesitate to contact a qualified service technician as
ate. Before calling, always check the following to be sure an investment in your well being.
service is required:
1 - Check that electrical disconnect switches are ON. Planned Service
2 - Check room thermostat for proper setting. You should expect a service technician to check the followĆ
3 - Replace any blown fuses or reset circuit breakers. ing items during an annual inspection. Power to the unit
4 - Gas valve should be ON. must be shut off for the service technician's safety.
5 - Air filter should not be plugged, which will limit air flow.
Fresh air grilles and louvers (on the unit and in the room
6 - Is gas turned on at meter? where the furnace is installed) - Must be open and unobĆ
7 - Is manual main shut-off valve open? structed to provide combustion air.
Record the model and serial number of the furnace. These
numbers are on the unit nameplate, which is located on the Burners - Must be inspected for rust, dirt, or signs of water.
blower deck below the combustion air inducer. Vent pipe - Must be inspected for signs of water, damaged
Serial Number __________________ or sagging pipe, or disconnected joints.
Model Number __________________ Unit appearance - Must be inspected for rust, dirt, signs
of water, burnt or damaged wires, or components.
Safety Precautions
Blower access door - Must be properly in place and proĆ
If you discover any of the following, shut down your
vide a seal between the return air and the room where the
unit, and contact a Lennox dealer for an inspection by
furnace is installed.
a qualified technician.
D If you repeatedly hear any new or unfamiliar sounds Return air duct - Must be properly attached and provide
while your unit is operating, there may be a problem. For an air seal to the unit.
example, poorly performing burners can produce unfaĆ
Operating performance - Unit must be observed during
miliar noises.
operation to monitor proper performance of the unit and the
D If you smell any unusual odors, your unit may be operatĆ
vent system.
ing improperly. For example, units can give off unfamilĆ
iar odors if components are required to operate in abĆ Combustion gases - Flue products must be analyzed and
normal conditions. compared to the unit specifications.
D Look for visible signs of a malfunctioning unit. Examples
include unusual amounts of condensate on windows inĆ Problems detected during the inspection may make it necĆ
side your house, visibly burnt components or unusual essary to temporarily shut down the furnace until the items
dirt or rust accumulations on the vent pipe or in the unit. can be repaired or replaced.
D If you experience headache, nausea, fatigue, or dizziĆ Pay attention to your furnace. Situations can arise beĆ
ness, the cause could be exposure to carbon monoxide tween annual furnace inspections that may result in unsafe
gas. This is often misdiagnosed as the flu because
operation. For instance, items innocently stored next to the
symptoms are similar. If you suffer from flu-like sympĆ
toms that are exaggerated at home, but seem to subĆ furnace may obstruct the combustion air supply. This could
side while you are away from the house, exposure to cause incomplete combustion and the production of carĆ
carbon monoxide could be the cause. bon monoxide gas.
Page 6
Repair Parts List
The following repair parts are available through Lennox dealers. When ordering parts, include the complete furnace model
number listed on the CSA International nameplate -- Example: G51MP-24B-045-1.
Cabinet Parts Heating Parts
Upper access panel Flame Sensor
Blower access panel
Top Cap Heat exchanger assembly
Gas manifold
Control Panel Parts
Combustion air inducer
Transformer
SureLight® integrated control board Gas valve
Door interlock switch Main burner cluster
Circuit Breaker Main burner orifices
Blower Parts Pressure switches
Blower wheel Ignitor
Motor Primary limit control
Motor mounting frame Secondary limit
Motor capacitor Flame rollout switches
Blower housing cutoff plate Combustion air inducer auxiliary limit
Page 7