INSTALLATION

©2006 Lennox Industries Inc.

INSTRUCTIONS
Dallas, Texas, USA

G40UH(X) Series
GAS FURNACE
505,181M
03/2006
Supersedes 505,011M
Litho U.S.A.

Table of Contents
Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
G40UH(X) Parts Arrangement . . . . . . . . . . . . . . . . . . . . . 3
G40UH(X) Gas Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Shipping and Packing List . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Combustion, Dilution & Ventilation Air . . . . . . . . . . . . . . 5
Setting Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Duct System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Unit Start−Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Gas Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . 26
High Altitude Information . . . . . . . . . . . . . . . . . . . . . . . . 27
Other Unit Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Repair Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
RETAIN THESE INSTRUCTIONS Ignition Control Board Diagnostic Codes . . . . . . . . . . . 31
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
FOR FUTURE REFERENCE Start−Up & Performance Check List . . . . . . . . . . . . . . . 35

WARNING
FIRE OR EXPLOSION HAZARD.
Failure to follow safety warnings exact-
ly could result in serious injury, death,
or property damage.

Do not store or use gasoline or other

WHAT TO DO IF YOU SMELL GAS:
flammable vapors and liquids in the D Do not try to light any appliance.
vicinity of this or any other ap- D Do not touch any electrical switch; do not
pliance. use any phone in your building.
D Leave the building immediately.
Installation and service must be D Immediately call your gas supplier from a
performed by a qualified installer, neighbor’s phone. Follow the gas supplier’s
service agency or the gas supplier. instructions.
D If you cannot reach your gas supplier, call
the fire department.

03/06 505,181M
*2P0306* Page 1 *P505181M*
G40UH(X) Unit Dimensions − inches (mm)
*NOTE − 60C and 60D units that require air volumes 3−3/4 (95)
over 1800 cfm (850 L/s) must have one of the following:
1. Return air from single side with transition which will
accommodate 20 x 25 x 1 in. (508 x 635 x 25 mm) D
cleanable air filter. (Required to maintain proper air
velocity.)
2. Return air from single side with optional RAB Return SUPPLY AIR
Air Base. FLUE OUTLET OPENING
3. Return air from bottom. (Top)
4. Return air from both sides.
5. Return air from bottom and one side.
Refer to Engineering Handbook for additional information.

OPTIONAL
EXTERNAL
**Flue outlet may be horizontal but furnace must be SIDE RETURN 23-3/4 (603)
vented vertically AIR FILTER KIT

Optional external side return air filter kit cannot be used (Either Side) 25 (635)
with the optional RAB Return Air Base. TOP VIEW
TOP VIEW
3−1/4 (83) Right 28−1/2
A (724)
8−1/8 (206) Left 3−3/4 9/16
B 9/16 (14) (95) 19−7/16 (14)
(494)

**FLUE OUTLET
(Either Side)

14 (356) Right ELECTRICAL INLET

13−1/4 (337) Left (Either Side)

OPTIONAL
EXTERNAL GAS PIPING INLET
SIDE RETURN (Either Side)
AIR FILTER KIT
(Either Side) 4−7/8 (124) Right
40 2−1/4 (57) Left
(1016) ELECTRICAL INLET
(Either Side)

14−3/4 4 23
(375) (102) (584)
16 14
*Side Return (356)
(406) Air Opening
(Either Side)
AIR FLOW
1−15/16 (49)
5/8 (16)
23−1/2
3/4 (19) C 3/4 (19) (597)
*Bottom Return 4−1/4 *Bottom Return
Air Opening (108) Air Opening
FRONT VIEW SIDE VIEW
A B C D
Model No.
No
in. mm in. mm in. mm in. mm
G40UH−24A−045,
G40UH−24A−070, 14−1/2 368 13−3/8 340 13 330 4−1/2 114
G40UH−36A−045,
G40UH−36A−070
G40UH−36B−090,
G40UH−48B−070, 17−1/2 446 16−3/8 416 16 406 6 152
G40UH−48B−090
G40UH−36B−110,
G40UH−48C−110, 21 533 19−7/8 454 19−1/2 495 7−3/4 197
G40UH−48C−135,
G40UH−60C−110
G40UH−60D−135 24−1/2 622 23−3/8 546 23 584 9−1/2 241
G40UH−60D−155

Page 2
G40UH(X) Parts Arrangement

Air Deflector
G40UH−48C−135,
G40UH−60C−110, &
G40UH−60D−155
Flue Box Gasket Units Only
Heat Exchanger
Gasket
Flue Collector Box

Flue Transition
Combustion Air
Orifice

Combustion Air
Pressure Switch

Combustion Air Inducer

Flame Sensor Limit Shield

Flame Rollout Switches*

Flame Rollout Bracket Primary Limit

Gas Valve

NOx Insert
(NOx Units Only)

Burners
Gas Orifices
Igniter Bracket Igniter
Secondary Limit

Burner Bottom Shield

Blower Assembly
Door Interlock Switch
Capacitor
*135 and 155 kBtuh units only −−
Flame rollout switches are located
on brackets on the inner sides (one
on the left and one on the right) of
the burner box.
Integrated Ignition
Control Board
Control Transformer

FIGURE 1

Page 3
G40UH(X) Gas Furnace In Canada, installation must conform with current CSA
B149 Natural Gas and Propane Installation Codes, local
The G40UH(X) gas furnace is shipped ready for installa- plumbing or waste water codes and other applicable local
tion in the upflow and horizontal position (left or right) codes.
fueled by natural gas. A conversion kit (ordered separate- Adequate clearance must be made around the air open-
ly) is required for use in propane/LP gas applications. The ings into the vestibule area. In order to ensure proper unit
furnace is shipped with the bottom panel in place. The bot- operation, combustion and ventilation air supply must be
tom panel must be removed if the unit is to be installed in a provided according to the current National Fuel Gas Code
horizontal application. The panel may also be removed in or CSA B149 standards.
upflow applications. Vent installations must be consistent with the venting
tables (in this instruction) and applicable provisions of local
Shipping and Packing List building codes.
This furnace is CSA International certified for installation
Package 1 of 1 contains clearances to combustible material as listed on the unit
1 − Assembled G40UH(X) unit nameplate and in the tables in figures 6 and 11. Accessibility
1 − Bag assembly containing the following: and service clearances must take precedence over fire
2 − Screws protection clearances.
3 − Wire nuts NOTE − For installation on combustible floors, the furnace
1 − Snap bushing shall not be installed directly on carpeting, tile, or other
1 − Snap plug combustible material other than wood flooring.
1 − Wire tie For installation in a residential garage, the furnace must
1 − Vent warning label be installed so that the burner(s) and the ignition source
1 − Owner’s manual and warranty card are located no less than 18 inches (457 mm) above the
The following items may also be ordered separately: floor. The furnace must be located or protected to avoid
1 − Thermostat physical damage by vehicles. When a furnace is installed
1 − Hanging bracket (for horizontal installations) in a public garage, hangar, or other building that has a haz-
1 − Propane/LP changeover kit ardous atmosphere, the furnace must be installed accord-
ing to recommended good practice requirements and cur-
Check equipment for shipping damage. If you find any
rent National Fuel Gas Code or CSA B149 standards.
damage, immediately contact the last carrier.
NOTE − Furnace must be adjusted to obtain a temperature
rise within the range specified on the unit nameplate. Failure
Safety Information to do so may cause erratic limit operation and premature heat
exchanger failure.
This G40UH(X) furnace must be installed so that its electri-
WARNING cal components are protected from water.
Improper installation, adjustment, alteration, service When this furnace is used with cooling units, it shall be
or maintenance can cause property damage, person- installed in parallel with, or on the upstream side of, cooling
al injury or loss of life. Installation and service must units to avoid condensation in the heating compartment.
be performed by a qualified installer, service agency With a parallel flow arrangement, a damper (or other means
or the gas supplier. to control the flow of air) must adequately prevent chilled air
from entering the furnace. If the damper is manually oper-
ated, it must be equipped to prevent operation of either the
heating or the cooling unit, unless it is in the full HEAT or
CAUTION COOL setting.
As with any mechanical equipment, personal injury When installed, this furnace must be electrically grounded
can result from contact with sharp sheet metal according to local codes. In addition, in the United States,
edges. Be careful when you handle this equipment. installation must conform with the current National Electric
Code, ANSI/NFPA No. 70. The National Electric Code
G40UH(X) units are CSA International certified to ANSI (ANSI/NFPA No. 70) is available from the following ad-
Z21.47 and CSA 2.3 standards. dress:
In the USA, installation of gas furnaces must conform with lo- National Fire Protection Association
cal building codes. In the absence of local codes, units must 1 Battery March Park
be installed according to the current National Fuel Gas Code Quincy, MA 02269
(ANSI-Z223.1). The National Fuel Gas Code is available
from the following address: In Canada, all electrical wiring and grounding for the unit
American National Standards Institute, Inc. must be installed according to the current regulations of the
11 West 42nd Street Canadian Electrical Code Part I (CSA Standard C22.1)
New York, NY 10036 and/or local codes.

Page 4
NOTE − This furnace is designed for a minimum continu- D Gas furnaces shall be installed by a licensed plumb-
ous return air temperature of 60°F (16°C) or an intermit- er or gas fittter only.
tent operation down to 55°F (13°C) dry bulb for cases D The gas cock must be
T handle" type.
where a night setback thermostat is used. Return air tem- D When a furnace is installed in an attic, the passage-
perature must not exceed 85°F (29°C) dry bulb. way to and service area surrounding the equipment
NOTE − G40UH(X) series units should not be installed as shall be floored.
a unit heater. General
The G40UH(X) furnace may be installed in alcoves, clos-
ets, attics, basements, garages, and utility rooms in the up- These instructions are intended as a general guide and do
flow or horizontal position. not supersede local codes in any way. Consult authorities
having jurisdiction before installation.
This furnace design has not been CSA International certi-
In addition to the requirements outlined previously, the fol-
fied for installation in mobile homes, recreational vehicles,
lowing general recommendations must be considered
or outdoors.
when installing a G40UH(X) furnace:
Lennox does not recommend the use of G40UH(X) units as
• Place the furnace as close to the center of the air dis-
a construction heater during any phase of construction.
tribution system as possible. The furnace should also be
Very low return air temperatures, harmful vapors and op- located close to the chimney or vent termination point.
eration of the unit with clogged or misplaced filters will dam- • Do not install the furnace where drafts might blow direct-
age the unit. ly into it. This could cause improper combustion and un-
G40UH(X) units may be used for heating of buildings or safe operation.
structures under construction, if the following conditions • Do not block the furnace combustion air openings with
are met: clothing, boxes, doors, etc. Air is needed for proper
D The vent system must be permanently installed per combustion and safe unit operation.
these installation instructions. • When the furnace is installed in an attic or other insu-
lated space, keep insulation away from the furnace.
D A room thermostat must control the furnace. The use of
fixed jumpers that will provide continuous heating is not
allowed.
D The return air duct must be provided and sealed to the
WARNING
furnace. Product contains fiberglass wool.
D Return air temperature range between 60°F (16°C) and Disturbing the insulation in this product during
80°F (27°C) must be maintained. installation, maintenance, or repair will expose you
to fiberglass wool. Breathing this may cause lung
D Air filters must be installed in the system and must be
cancer. (Fiberglass wool is known to the State of Cal-
maintained during construction. ifornia to cause cancer.)
D Air filters must be replaced upon construction comple-
Fiberglass wool may also cause respiratory, skin,
tion. and eye irritation.
D The input rate and temperature rise must be set per the To reduce exposure to this substance or for further
furnace rating plate. information, consult material safety data sheets
D One hundred percent (100%) outdoor air must be pro- available from address shown below, or contact your
vided for combustion air requirements during construc- supervisor.
tion. Temporary ducting may supply outdoor air to the Lennox Industries Inc.
furnace. Do not connect duct directly to the furnace. P.O. Box 799900
Size the temporary duct following these instructions in Dallas, TX 75379−9900
section for Combustion, Dilution and Ventilation Air in a
confined space with air from outside. Combustion, Dilution & Ventilation Air
D The furnace heat exchanger, components, duct system,
air filters and evaporator coils must be thoroughly In the past, there was no problem in bringing in sufficient out-
cleaned following final construction clean−up. door air for combustion. Infiltration provided all the air that
was needed. In today’s homes, tight construction practices
D All furnace operating conditions (including ignition, in-
make it necessary to bring in air from outside for combus-
put rate, temperature rise and venting) must be verified tion. Take into account that exhaust fans, appliance vents,
according to these installation instructions. chimneys, and fireplaces force additional air that could be
NOTE − The Commonwealth of Massachusetts stipu- used for combustion out of the house. Unless outside air is
lates these additional requirements: brought into the house for combustion, negative pressure

Page 5
(outside pressure is greater than inside pressure) will build fans which force air out of the house. When fireplaces, ex-
to the point that a downdraft can occur in the furnace vent haust fans, or clothes dryers are used at the same time as
pipe or chimney. As a result, combustion gases enter the liv- the furnace, much more air is necessary to ensure proper
ing space creating a potentially dangerous situation. combustion and to prevent a downdraft. Insufficient air
In the absence of local codes concerning air for combus- causes incomplete combustion which can result in carbon
tion and ventilation, use the guidelines and procedures in monoxide.
this section to install G40UH(X) furnaces to ensure efficient
In addition to providing combustion air, fresh outdoor air
and safe operation. You must consider combustion air
needs and requirements for exhaust vents and gas piping. dilutes contaminants in the indoor air. These contami-
A portion of this information has been reprinted with per- nants may include bleaches, adhesives, detergents, sol-
mission from the National Fuel Gas Code (ANSI-Z223.1). vents and other contaminants which can corrode furnace
This reprinted material is not the complete and official posi- components.
tion of the ANSI on the referenced subject, which is repre- The requirements for providing air for combustion and ven-
sented only by the standard in its entirety. tilation depend largely on whether the furnace is installed in
In Canada, refer to the CSA B149 installation codes. an unconfined or a confined space.
Unconfined Space
CAUTION An unconfined space is an area such as a basement or
large equipment room with a volume greater than 50 cubic
Do not install the furnace in a corrosive or contami-
nated atmosphere. Meet all combustion and ventila- feet (1.42 m3) per 1,000 Btu (.29 kW) per hour of the com-
tion air requirements, as well as all local codes. bined input rating of all appliances installed in that space.
This space also includes adjacent rooms which are not
separated by a door. Though an area may appear to be un-
CAUTION confined, it might be necessary to bring in outdoor air for
Insufficient combustion air can cause headaches, combustion if the structure does not provide enough air by
nausea, dizziness or asphyxiation. It will also cause infiltration. If the furnace is located in a building of tight
excess water in the heat exchanger resulting in rust- construction with weather stripping and caulking around
ing and premature heat exchanger failure. Excessive the windows and doors, follow the procedures in the air
exposure to contaminated combustion air will result
in safety and performance related problems. Avoid from outside section.
exposure to the following substances in the combus- Confined Space
tion air supply: A confined space is an area with a volume less than 50 cu-
Permanent wave solutions
bic feet (1.42 m3) per 1,000 Btu (.29 kW) per hour of the
Chlorinated waxes and cleaners
Chlorine base swimming pool chemicals combined input rating of all appliances installed in that
Water softening chemicals space. This definition includes furnace closets or small
De-icing salts or chemicals equipment rooms.
Carbon tetrachloride When the furnace is installed so that supply ducts carry air
Halogen type refrigerants
circulated by the furnace to areas outside the space con-
Cleaning solvents (such as perchloroethylene)
Printing inks, paint removers, varnishes, etc. taining the furnace, the return air must be handled by ducts
Hydrochloric acid which are sealed to the furnace casing and which terminate
Cements and glues outside the space containing the furnace. This is especially
Antistatic fabric softeners for clothes dryers important when the furnace is mounted on a platform in a
Masonry acid washing materials confined space such as a closet or small equipment room.
All gas-fired appliances require air for the combustion pro- Even a small leak around the base of the unit at the platform
cess. If sufficient combustion air is not available, the fur- or at the return air duct connection can cause a potentially
nace or other appliances will operate inefficiently and un- negative pressure condition. Air for combustion and dan-
safely. Enough air must be provided to meet the needs of all gerous ventilation can be brought into the confined space
fuel-burning appliances and appliances such as exhaust either from inside the building or from outside.

Page 6
 EQUIPMENT IN CONFINED mm) of the top of the enclosure and one opening within 12
CHIMNEY SPACE ALL AIR FROM INSIDE inches (305 mm) of the bottom. See figure 2.
OR GAS
VENT Air from Outside
If air from outside is brought in for combustion and ventila-
tion, the confined space must have two permanent open-
ings. One opening shall be within 12 inches (305 mm) of the
WATER top of the enclosure and one opening within 12 inches (305
HEATER
FURNACE mm) of the bottom. These openings must communicate di-
rectly or by ducts with the outdoors or spaces (crawl or at-
OPENINGS tic) that freely communicate with the outdoors or indirectly
(To Adjacent
Room) through vertical ducts. Each opening shall have a minimum
free area of 1 square inch (645 mm2) per 4,000 Btu (1.17
kW) per hour of total input rating of all equipment in the en-
closure. See figures 3 and 4. When communicating with
the outdoors through horizontal ducts, each opening shall
NOTE−Each opening shall have a free area of at least one square have a minimum free area of 1 square inch (645 mm2) per
inch (645 mm2) per 1,000 Btu (.29 kW) per hour of the total input rat- 2,000 Btu (.56 kW) per total input rating of all equipment in
ing of all equipment in the enclosure, but not less than 100 square
inches (64516 mm 2).
the enclosure. See figure 5.
When ducts are used, they shall be of the same cross−sec-
tional area as the free area of the openings to which they
FIGURE 2 connect. The minimum dimension of rectangular air ducts
Air from Inside shall be no less than 3 inches (75 mm). In calculating free
If the confined space that houses the furnace adjoins a area, the blocking effect of louvers, grilles, or screens must
space categorized as unconfined, air can be brought in by be considered. If the design and free area of protective cov-
providing two permanent openings between the two ering is not known for calculating the size opening required,
spaces. Each opening must have a minimum free area of 1 it may be assumed that wood louvers will have 20 to 25 per-
square inch (645 mm2) per 1,000 Btu (.29 kW) per hour of cent free area and metal louvers and grilles will have 60 to
total input rating of all gas−fired equipment in the confined 75 percent free area. Louvers and grilles must be fixed in the
space. Each opening must be at least 100 square inches open position or interlocked with the equipment so that they
(64516 mm2). One opening shall be within 12 inches (305 are opened automatically during equipment operation.

EQUIPMENT IN CONFINED SPACE

ALL AIR FROM OUTSIDE
(Inlet Air from Crawlspace and Outlet Air to Ventilated Attic)
CHIMNEY OR
GAS VENT

VENTILATION LOUVERS
(Each end of attic)

OUTLET
FURNACE AIR WATER
HEATER

VENTILATION INLET
LOUVERS AIR
(For unheated crawl space)

NOTE−The inlet and outlet air openings shall each have a free area of at least one square inch (645 mm2)
per 4,000 Btu (1.17 kW) per hour of the total input rating of all equipment in the enclosure.

FIGURE 3

Page 7
 The G40UH(X) gas furnace can be installed as shipped
EQUIPMENT IN CONFINED SPACE in either the upflow position or the horizontal position,
ALL AIR FROM OUTSIDE with right-hand or left-hand air discharge.
CHIMNEY (All Air Through Ventilated Attic)
OR GAS
VENT Select a location that allows for the required clearances
VENTILATION LOUVERS
(Each end of attic) that are listed on the unit nameplate. Also consider gas
supply connections, electrical supply, vent connection,
OUTLET
AIR
and installation and service clearances [24 inches (610
mm) at unit front]. The unit must be level.

FURNACE
NOTE − 1/3 hp blower motors are equipped with four flex-
INLET AIR
(Ends 12 in.
above bottom)
ible mounting legs, and 1/2 hp blower motors are equipped
with three flexible legs and one rigid leg. The rigid leg is
equipped with a shipping bolt and a flat white plastic wash-
WATER
HEATER
er (rather than the rubber mounting grommet used with a
flexible mounting leg). The bolt and washer must be re-
moved before the furnace is placed into operation. Af-
ter the bolt and washer have been removed, the rigid leg
NOTE−The inlet and outlet air openings shall each have a
free area of at least one square inch (645 mm2) per 4,000 will not touch the blower housing.
Btu (1.17 kW) per hour of the total input rating of all equip-
ment in the enclosure. Upflow Applications
Allow for clearances to combustible materials as indicated
on the unit nameplate. Minimum clearances for closet or al-
FIGURE 4
cove installations are shown in figure 6.
EQUIPMENT IN
CONFINED SPACE Upflow Application Installation Clearances
ALL AIR FROM
OUTSIDE Top
CHIMNEY
OR GAS
VENT WATER
HEATER

OUTLET AIR
Left Side Right Side

FURNACE

INLET AIR
Bottom
Type of Vent
Type C Type B1
NOTE − Each air duct opening shall have a free area of at least Connector
one square inch (645 mm 2) per 2,000 Btu (.59 kW) per hour of
the total input rating of all equipment in the enclosure. If the Top 1 in. (25 mm) 1 in. (25 mm)
equipment room is located against an outside wall and the air
*Front 3 in. (76 mm) 3 in. (76 mm)
openings communicate directly with the outdoors, each open-
ing shall have a free area of at least one square inch (645 mm2) Back 0 0
per 4,000 Btu (1.17 kW) per hour of the total input rating of all
other equipment in the enclosure. Sides 0† 0
FIGURE 5 Vent 6 in. (152 mm) 1 in. (25 mm)

Setting Equipment Floor 0‡ 0‡

*Front clearance in alcove installation must be 24 in. (610 mm).

WARNING Maintain a minimum of 24 in. (610 mm) for front service access.
‡For installations on a combustible floor, do not install the furnace
directly on carpeting, tile or other combustible materials other
Do not install the furnace on its front or its back. Do than wood flooring.
not connect the return air ducts to the back of the fur- †Left side requires 3 inches if a single wall vent is used on 14−1/2
nace. Doing so will adversely affect the operation of inch cabinets, or 2 inches if a single wall vent is used on 17−1/2
inch cabinets.
the safety control devices, which could result in per-
sonal injury or death. FIGURE 6

Page 8
 Return Air −− Upflow Applications 5 − Return air from bottom and one side.
Return air can be brought in through the bottom or either Refer to Engineering Handbook for additional information.
side of the furnace installed in an upflow application. If the Side Return Air
furnace is installed on a platform with bottom return, make (with transition and filter)
an airtight seal between the bottom of the furnace and the
platform to ensure that the furnace operates properly and
safely. The furnace is equipped with a removable bottom
panel to facilitate installation. 20" X 25" X 1"
Markings are provided on both sides of the furnace cabinet (508mm X635mm X 25mm)
for installations that require side return air. Cut the furnace Cleanable Filter
cabinet at the maximum dimensions shown on page 2.
NOTE − When air volumes over 1800 cfm (850 L/s) are
required with 60C or 60D models in an upflow applica-
tion, the following return air options are available:
1 − Return air from single side with transition which will Return Air
accommodate 20 x 25 x 1 in. (508 x 635 x 25 mm) clean- Plenum
able air filter. (Required to maintain proper air velocity.)
See figure 7.
2 − Return air from single side with optional RAB Return
Air Base. See figure 8.
Transition
3 − Return air from bottom.
4 − Return air from both sides. FIGURE 7
Optional Return Air Base
(Upflow Applications Only −− For use with B, C and D cabinets only)

1
23 (584)
4
(102) Overall 1 Minimum
14 (Maximum) 11 (279)
(356) 2 122−7−16
1 Unit side return air Maximum
14 (356) (570)
AIR FLOW Opening Overall
FURNACE
(Maximum)
FRONT
5−5/8 SIDE RETURN
7−1/4 (184) (143) AIR OPENINGS
(Either Side)

OPTIONAL RAB 23 (584) 3/4

17−1/2 (446) RAB−B (98M60) RETURN AIR BASE (19)
21 (533) RAB−C (98M58) 7/8
27−5/8 (702)
24−1/2 (622) RAB−D (98M59) (22)
SIDE VIEW
FRONT VIEW
NOTE− Optional Side Return Air Filter Kits are not for use with RAB Return Air Base.
1 Both the unit return air opening and the base return air opening must be covered by a single plenum or IAQ cabinet.
Minimum unit side return air opening dimensions for units requiring 1800 cfm or more of air (W x H): 23 x 11 in.
(584 x 279 mm).
The opening can be cut as needed to accommodate plenum or IAQ cabinet while maintaining dimensions shown.
Side return air openings must be cut in the field. There are cutting guides stenciled on the cabinet for the side return
air opening. The size of the opening must not extend beyond the markings on the furnace cabinet..
2 To minimize pressure drop, the largest opening height possible (up to 14 inches) is preferred.
NOTE− Optional Side Return Air Filter Kits are not for use with RAB Return Air Base.

FIGURE 8

Page 9
 Removing the Bottom Panel
Leveling Bolt Installation
Remove the two screws that secure the bottom cap to the Inches (mm)
furnace. Pivot the bottom cap down to release the bottom 3/8
(10)
panel. Once the bottom panel has been removed, reinstall Furnace Front
the bottom cap. See figure 9.
3/8 1−3/4
(10) (44)
Removing the Bottom Panel

1−3/4
(44) Leveling Bolts
Furnace
Bottom
Leveling Bolts 3/8
(10)

3/8 1−3/4
(10) (44)

1−3/4 (44)

FIGURE 10
Screw
Horizontal Applications
The G40UH(X) furnace can be installed in horizontal ap-
plications.
Bottom Cap
Allow for clearances to combustible materials as indicated
Bottom Panel on the unit nameplate. Minimum clearances for closet or al-
cove installations are shown in figure 11.
FIGURE 9 Horizontal Application
Leveling an Upflow Unit Installation Clearances

When the side return air inlets are used in an upflow ap- Top
plication, it may be necessary to install leveling bolts on the
bottom of the furnace. Use field−supplied corrosion−resist-
Left End Right End
ant 5/16 inch machine bolts (4) and nuts (8). See figure 10.
NOTE − The maximum length of the bolt is 1−1/2 inches.
Bottom
1 − Lie the furnace on its back and drill a 5/16 inch diame-
Vent Connector
ter hole in each corner of the furnace’s bottom. See fig- Type C Type B1
Type
ure 10 for the correct location of the holes. Drill through
Top 0 0
the bottom panel and the bottom flange of the cabinet.
2 − Install one bolt and two nuts into each hole. Screw the *Front 3 in. (76 mm) 3 in. (76 mm)
first nut onto a bolt and then insert the bolt into a hole. A Back 0 0
flat washer may be added between the nut and the bot-
Ends 2 in. (51 mm) 2 in. (51 mm)
tom of the unit.
Vent 6 in. (152 mm) 1 in. (25 mm)
3 − Screw another nut onto the bolt on the inside of the fur-
nace base. A flat washer may be added between the Floor 0‡ 0‡
nut and the bottom of the unit. *Front clearance in alcove installation must be 24 in. (610 mm).
4 − Adjust the outside nut to the appropriate height and Maintain a minimum of 24 in. (610 mm) for front service access.
‡For installations on a combustible floor, do not install the furnace
tighten the inside nut to secure the arrangement. directly on carpeting, tile or other combustible materials other
NOTE − The unit may be tilted back−to−front a maximum of than wood flooring.

1". This will ensure proper draining of the heat exchanger. FIGURE 11

Page 10
This furnace may be installed in either an attic or a crawl-
Horizontal Application
space. Either suspend the furnace from roof rafters or Unit Installed on Platform
floor joists, as shown in figure 12, or install the furnace on NOTE − Line contact is permis-
a platform, as shown in figure 13. The unit must be sup- sible. See the unit nameplate for
clearances.
ported at both ends and beneath the blower deck to pre-
vent sagging.
NOTE − In horizontal applications, the unit must be lev-
el side to side. The unit may be tilted back to front a maxi- GAS
ENTRY
mum of 1". This will ensure proper draining of the heat ex- VENT
changer. PIPE

Typical Horizontal Application

Unit Suspended in Attic or Crawlspace
Leave sufficient clearance between rod and unit to
remove access panel. WORKING
PLATFORM

FIGURE 13

1/4 in. ROD WARNING

Improper installation of the furnace can result in per-
ANGLE sonal injury or death. Combustion and flue products
IRON must never be allowed to enter the return air system
U−CHANNELS
or the living space. Use screws and joint tape to seal
the return air system to the furnace.
FIGURE 12 In platform installations with bottom return air, the
NOTE − Heavy gauge perforated sheet metal straps furnace should be sealed airtight to the return air ple-
(plumbers’ straps) may be used to suspend the unit from num. A door must never be used as a portion of the
roof rafters or ceiling joists. When straps are used to sus- return air duct system. The base must provide a
pend the unit in this way, support must be provided for both stable support and an airtight seal to the furnace. Al-
the ends and the middle of the furnace to prevent sagging. low absolutely no sagging, cracks, gaps, etc.
The straps must not interfere with the plenum or exhaust The return and supply air duct systems must never
piping installation. Securing screws should be 1/2 inch be connected to or from other heating devices such
from the top edge and 1−1/2 inch from the side edge in all as a fireplace or stove, etc. Fire, explosion, carbon
cases. Cooling coils and supply and return air plenums monoxide poisoning, personal injury and/or proper-
must be supported separately. ty damage could result.
NOTE − When the furnace is installed on a platform in a
crawlspace, it must be elevated enough to avoid water
damage and to allow the evaporator coil to drain.
Return Air −− Horizontal Applications
WARNING
The blower access panel must be securely in place
Return air can be brought in through the end of a furnace when the blower and burners are operating. Gas
installed in a horizontal application. The furnace is fumes, which could contain carbon monoxide, can
equipped with a removable bottom panel to facilitate be drawn into living space resulting in personal inju-
installation. See figure 9. ry or death.

Page 11
 Filters Venting
This unit is not equipped with a filter or rack. A field−pro- A 4−inch diameter flue transition is factory-installed on the
vided high−velocity filter is required for the unit to operate combustion air inducer outlet of all models. Modifying or
removing the flue transition will cause the unit to oper-
properly. Table 1 lists recommended filter sizes.
ate unsafely and will void the unit certification. The
A filter must be in place whenever the unit is operating. vent connector does not require insulation.
TABLE 1 The combustion air inducer may be rotated clockwise or
Furnace Filter Size counterclockwise by 90° to allow for vertical vent dis-
Cabinet Size Side Return Bottom Return charge. Remove the four mounting screws, rotate the as-
14−1/2" 16 X 25 X 1 (1) 14 X 25 X 1 (1) sembly (including the gasket), then reinstall the mounting
17−1/2" 16 X 25 X 1 (1) 16 X 25 X 1 (1) screws. See figure 14. Use the provided wire tie to bundle
the pressure switch wires with the inducer motor power
21" 16 X 25 X 1 (1) 20 X 25 X 1 (1)
leads. Route the power leads away from any moving
24−1/2" 16 X 25 X 1 (2) 24 X 25 X 1 (1)
parts to prevent damage to the wires.

Duct System Combustion Air Inducer

90° 90°
Use industry-approved standards to size and install the
MOUNTING SCREWS
supply and return air duct system. This will result in a quiet (Remove)
and low-static system that has uniform air distribution.
NOTE − Do not operate the furnace with an external static
pressure that exceeds 0.5 inches w.c. Higher external stat-
ic pressures may cause erratic limit operation. Flue Transition
(Do not remove)
Supply Air Plenum
If the furnace is installed without a cooling coil, a removable
access panel must be installed in the supply air duct. The
access panel should be large enough to permit inspection
(either by smoke or reflected light) of the heat exchanger
for leaks after the furnace is installed. The furnace access
Mounting Screws Power Leads
panel must always be in place when the furnace is operat- (Remove)
ing and it must not allow leaks into the supply air duct sys-
tem. FIGURE 14

Return Air Plenum Optional Flue Outlet

Return air must not be drawn from a room where this
furnace, or any other gas appliance (ie., a water heat- Top Cap
er), is installed. When return air is drawn from a room, a
negative pressure is created in the room. If a gas ap- Supply Air
pliance is operating in a room with negative pressure, the Opening
(Top View)
flue products can be pulled back down the vent pipe and Flue Outlet Hole
(Reattach
into the room. This reverse flow of the flue gas may result Cutout Here)
in incomplete combustion and the formation of carbon
monoxide gas. This toxic gas might then be distributed
throughout the house by the furnace duct system.
In upflow applications, the return air can be brought in Cut out
through the bottom or either side of the furnace. If a furnace
with bottom return air is installed on a platform, make an air- Optional Flue Outlet
(Side View)
tight seal between the bottom of the furnace and the plat-
form to ensure that the unit operates properly and safely.
Use fiberglass sealing strips, caulking, or equivalent seal-
ing method between the plenum and the furnace cabinet to
ensure a tight seal. If a filter is installed, size the return air
duct to fit the filter frame. FIGURE 15

Page 12
Use sheet metal shears to remove the cut out from the side Use self−drilling sheet metal screws or a mechanical fas-
of the cabinet. Use the two provided sheet metal screws to tener to firmly secure the vent pipe to the round collar of the
install the cut out on the top cap to cover the original flue flue transition. If self−drilling screws are used to attach the
outlet opening. See figure 15. vent pipe, it is recommended that three be used. Drive one
The G40UH(X) series units are classified as fan−assisted self−drilling screw through the front and one through each
Category I furnaces when vertically vented according to side of the vent pipe and collar. See figure 16.
the latest edition of the National Fuel Gas Code (NFPA 54/ Install the first vent connector elbow at a minimum of six
ANSI Z223.1) in the USA and the current CSA B149 Natu- inches (152 mm) from the furnace vent outlet.
ral Gas and Propane Installation Codes in Canada. A fan− Venting Using a Masonry Chimney
assisted Category I furnace is an appliance equipped with The following additional requirements apply when a lined
an integral mechanical means to either draw or force com- masonry chimney is used to vent this furnace.
bustion products through the combustion chamber and/or Masonry chimneys used to vent Category I central fur-
heat exchanger. naces must be either tile-lined or lined with a listed metal
NOTE − Use these instructions as a guide. They do not su- lining system or dedicated gas vent. Unlined masonry
persede local codes. This furnace must be vented accord- chimneys are prohibited. See figures 17 and 18 for com-
ing to all local codes these installation instructions, and the mon venting.
provided venting tables in these instructions A chimney with one or more sides exposed to the outside of
The venting tables in this manual were extracted from the the structure is considered to be an exterior chimney.
National Fuel Gas Code (NFPA 54 / ANSI Z223.1) and are An exterior masonry chimney that is not tile−lined must be
provided as a guide for proper vent installation. Proper ap- lined with B1 vent or a listed insulated flexible metal vent.
plication, termination, construction and location of vents An exterior tile−lined chimney that is sealed and capped
must conform to local codes having jurisdiction. In the ab- may be lined with a listed uninsulated flexible metal vent.
sence of local codes, the NFGC serves as the defining doc- If the existing chimney will not accommodate a listed metal
ument. liner, either the chimney must be rebuilt to accommodate
Refer to the tables and the venting information contained in one of these liners or an alternate approved venting meth-
these instructions to properly size and install the venting od must be found.
system. Insulation for the flexible vent pipe must be an encapsu-
lated fiberglass sleeve recommended by the flexible vent
IMPORTANT pipe manufacturer. See figure 17.
Once the venting system is installed, attach the
Dis- DO NOT insulate the space between the liner and the
connected Vent" warning sticker to a visible area of chimney wall with puffed mica or any other loose gran-
the plenum near the vent pipe. The warning sticker ular insulating material
is provided in the bag assembly.
Common Venting Using Metal−Lined Masonry Chimney
SEALED

WARNING MAX. LENGTH

−− SEE NOTE 1
Asphyxiation hazard. The exhaust vent for this fur- 5 ft. (1.5 m)
BELOW.
MIN. LENGTH −− AS
nace must be securely connected to the furnace flue minimum SHORT AS PRACTICAL
EXTERIOR
CHIMNEY WITH
transition at all times. METAL
LINER
VENT CONNECTOR
SEE NOTE 2
VENT CONNECTION
4 in. (102 mm)
minimum
VENT
PIPE

FURNACE

OTHER
APPLIANCE
PERMANENTLY
SEALED FIREPLACE
OPENING

FURNACE NOTE 1 − Refer to the provided venting tables for installations in the USA
and the venting tables in CSA−B149 for installations Canada.
FLUE TRANSITION NOTE 2 − Either single-walled or double-walled vent connector may be
COLLAR used. Refer to the capacity requirements shown in the provided venting
tables for installations in USA and the venting tables in current CSA−
B149 for installations in Canada.

FIGURE 16 FIGURE 17

Page 13
 Common Venting Using Tile−Lined Interior Masonry Chimney and Combined Vent Connector

MINIMUM LENGTH = AS SHORT AS PRACTICAL. INTERIOR TILE−LINED

FOR MAXIMUM LENGTH SEE NOTE TO LEFT MASONRY CHIMNEY
NOTE− Refer to provided venting tables
for installations in the USA and the
venting tables in current CSA−B149 for
installations in Canada.
NOTE − the chimney must be properly
sized per provided venting tables or
lined with listed metal lining system.

FURNACE VENT
CONNECTOR
OTHER SEE NOTE 1 BELOW PERMANENTLY
APPLIANCE SEALED FIREPLACE
OPENING

Note − Either single-walled or double-walled vent connector may be used. Refer to the capacity requirements as shown in the pro-
vided venting tables for installations in USA and the venting tables in current CSA−B149 for installations in Canada.

FIGURE 18

Never connect a Category I appliance to a chimney that is

IMPORTANT servicing a solid−fuel appliance. If a fireplace chimney flue
is used to vent this appliance, the fireplace opening must
SINGLE appliance venting of a fan-assisted furnace be permanently sealed.
into a tile-lined masonry chimney (interior or outside A type B or listed chimney lining system that passes
wall) is PROHIBITED. The chimney must first be lined through an unused masonry chimney flue is not considered
with either type B1 vent or an insulated single wall to be exposed to the outdoors.
flexible vent lining system which has been sized ac-
cording to the provided venting tables and the vent General Venting Requirements
pipe manufacturer’s instructions. Vent all G40UH(X) furnaces according to these instruc-
tions:
A fan−assisted furnace may be commonly vented into an 1 − Vent diameter recommendations and maximum allow-
existing lined masonry chimney if the following conditions able piping runs are found in the provided venting tables
are met: for the USA, and the appropriate venting tables in the
• The chimney is currently serving at least one drafthood standards of CSA B149 Natural Gas and Propane
equipped appliance. Installation Codes for Canada.
S The vent connectors and chimney are sized according 2 − In no case should the vent or vent connector diameter
to the provided venting tables for the USA, and the ap- be less than the diameter specified in the provided
propriate venting tables in the standards of CSA B149 venting tables for the USA, and the appropriate venting
Natural Gas and Propane Installation Codes in Canada tables in the standards of CSA B149 Natural Gas and
If type B1 double-wall vent is used inside a chimney, no oth- Propane Installation Code for Canada.
er appliance can be vented into the chimney. The outer wall 3 − Single appliance vents − If the vertical vent or tile-lined
of type B1 vent pipe must not be exposed to flue products. chimney has a larger diameter or flow area than the
A type B1 vent or masonry chimney liner shall terminate vent connector, use the vertical vent diameter to de-
above the roof surface with a listed cap or a listed roof as- termine the minimum vent capacity and the vent
sembly according to the terms of their respective listings connector diameter to determine the maximum vent
and the vent manufacturer’s instructions. capacity. The flow area of the vertical vent, however,
When inspection reveals that an existing chimney is not shall not exceed 7 times the flow area of the listed ap-
safe for the intended purpose, it shall be rebuilt to conform pliance categorized vent area, drafthood outlet area or
to nationally recognized standards, lined or relined with flue collar area unless designed according to approved
suitable materials, or replaced with a gas vent or chimney engineering methods.
suitable for venting G40UH(X) series units. The chimney 4 − Multiple appliance vents − The flow area of the largest
passageway must be checked periodically to ensure that it section of vertical vent or chimney shall not exceed 7
is clear and free of obstructions. times the smallest listed appliance categorized vent
Do not install a manual damper, barometric draft regulator, area, drafthood outlet area or flue collar area unless de-
or flue restrictor between the furnace and the chimney. signed according to approved engineering methods.

Page 14
5 − The entire length of single wall metal vent connector mended) or other approved means, except vent con-
shall be readily accessible for inspection, cleaning, nectors of listed type B vent material which shall be as-
and replacement. sembled according to the manufacturer’s instructions.
Joints between sections of single wall connector piping
6 − Single appliance venting configurations with zero lat-
shall be fastened by screws or other approved means.
eral lengths (tables 3 and 4), are assumed to have no
12 − When the vent connector used for Category I ap-
elbows in the vent system. For all other vent configura-
pliances must be located in or pass through a crawl-
tions, the vent system is assumed to have two 90° el-
space or other areas which may be cold, that portion of
bows. For each additional 90° elbow or equivalent (for
the vent connector shall be constructed of listed
example two 45° elbows equal one 90° elbow) beyond
double-wall type B vent material or material having
two, the maximum capacity listed in the venting table
equivalent insulation qualities.
should be reduced by 10% (0.90 x maximum listed ca-
pacity). 13 − All venting pipe passing through floors, walls, and ceil-
ings must be installed with the listed clearance to com-
7 − The common venting tables (5, 6, 7, and 8) were gen- bustible materials and be fire stopped according to lo-
erated using a maximum horizontal vent connector cal codes. In absence of local codes, refer to NFGC
length of 1−1/2 feet (.46 m) for each inch (25 mm) of
(Z223.1).
connector diameter as follows:
14 − No portion of the venting system can extend into, or pass
TABLE 2 through any circulation air duct or plenum.
Connector Diameter Maximum Horizontal 15 − Vent connectors serving Category I appliances shall
inches (mm) Connector Length feet (m) not be connected to any portion of mechanical draft
3 (76) 4−1/2 (1.37) systems operating under positive pressure such as
Category III or IV venting systems.
4 (102) 6 (1.83)
16 −If vent connectors are combined prior to entering the
5 (127) 7−1/2 (2.29)
common vent, the maximum common vent capacity
6 (152) 9 (2.74) listed in the common venting tables must be reduced by
7 (178) 10−1/2 (3.20) 10%, the equivalent of one 90° elbow (0.90 x maximum
common vent capacity).
8 − If the common vertical vent is offset, the maximum
17 −The common vent diameter must always be at least as
common vent capacity listed in the common venting
large as the largest vent connector diameter.
tables should be reduced by 20%, the equivalent of two
18 −In no case, shall the vent connector be sized more than
90° elbows (0.80 x maximum common vent capacity).
two consecutive table size diameters over the size of
The horizontal length of the offset shall not exceed
the draft hood outlet or flue collar outlet.
1-1/2 feet (.46 m) for each inch (25 mm) of common
19 − Do not install a manual damper, barometric draft regu-
vent diameter.
lator or flue restrictor between the furnace and the
9 − The vent pipe should be as short as possible with the chimney.
least number of elbows and angles required to com- 20 − When connecting this appliance to an existing dedicated
plete the job. Route the vent connector to the vent us- or common venting system, you must inspect the venting
ing the shortest possible route. system’s general condition and look for signs of corro-
10 − A vent connector shall be supported without any dips sion. The existing vent pipe size must conform to these
or sags and shall slope a minimum of 1/4 inch (6.4 mm) instructions and the provided venting tables for the USA,
per linear foot (305 mm) of connector, back toward the and the appropriate venting tables in the standards of
appliance. CSA B149 Natural Gas and Propane Installation Codes
11 − Vent connectors shall be firmly attached to the furnace for Canada. If the existing venting system does not meet
flue collars by self−drilling screws (three recom- these requirements, it must be resized.

Page 15
 TABLE 3
Capacity of Type B Double−Wall Vents with Type B Double−Wall Connectors
Serving a Single Category I Appliance
Vent and Connector Diameter − D (inches)
Height Lateral 3 Inch 4 Inch 5 Inch 6 Inch
H L
(feet) (feet) Appliance Input Rating in Thousands of Btu Per Hour
MIN MAX MIN MAX MIN MAX MIN MAX
0 0 78 0 152 0 251 0 375
2 13 51 18 97 27 157 32 232
6
4 21 49 30 94 39 153 50 227
6 25 46 36 91 47 149 59 223
0 0 84 0 165 0 276 0 415
2 12 57 16 109 25 178 28 263
8
5 23 53 32 103 42 171 53 255
8 28 49 39 98 51 164 64 247
0 0 88 0 175 0 295 0 447
2 12 61 17 118 23 194 26 289
10
5 23 57 32 113 41 187 52 280
10 30 51 41 104 54 176 67 267
0 0 94 0 191 0 327 0 502
2 11 69 15 136 20 226 22 339
15 5 22 65 30 130 39 219 49 330
10 29 59 40 121 51 206 64 315
15 35 53 48 112 61 195 76 301
0 0 97 0 202 0 349 0 540
2 10 75 14 149 18 250 20 377
5 21 71 29 143 38 242 47 367
20
10 28 64 38 133 50 229 62 351
15 34 58 46 124 59 217 73 337
20 48 52 55 116 69 206 84 322
0 0 100 0 213 0 374 0 587
2 9 81 13 166 14 283 18 432
5 21 77 28 160 36 275 45 421
30 10 27 70 37 150 48 262 59 405
15 33 64 44 141 57 249 70 389
20 56 58 53 132 66 237 80 374
30 NR NR 73 113 88 214 104 346
NOTE − Single appliance venting configurations with zero lateral lengths are assumed to have no elbows in the vent system. For all other
vent configurations, the vent system is assumed to have two 90° elbows. For each additional 90° elbow or equivalent (for example two 45°
elbows equal one 90° elbow) beyond two, the maximum capacity listed in the venting table should be reduced by 10 percent (0.90 x maxi-
mum listed capacity).

Page 16
 TABLE 4
Capacity of Type B Double−Wall Vents with Single−Wall Metal Connectors
Serving a Single Category I Appliance
Vent and Connector Diameter − D (inches)
Height Lateral 3 Inch 4 Inch 5 Inch 6 Inch
H L
(feet) (feet) Appliance Input Rating in Thousands of Btu Per Hour
MIN MAX MIN MAX MIN MAX MIN MAX
0 38 77 59 151 85 249 126 373
2 39 51 60 96 85 156 123 231
6
4 NR NR 74 92 102 152 146 225
6 NR NR 83 89 114 147 163 220
0 37 83 58 164 83 273 123 412
2 39 56 59 108 83 176 121 261
8
5 NR NR 77 102 107 168 151 252
8 NR NR 90 95 122 161 175 243
0 37 87 57 174 82 293 120 444
2 39 61 59 117 82 193 119 287
10
5 52 56 76 111 105 185 148 277
10 NR NR 97 100 132 171 188 261
0 36 93 56 190 80 325 116 499
2 38 69 57 136 80 225 115 337
15 5 51 63 75 128 102 216 144 326
10 NR NR 95 116 128 201 182 308
15 NR NR NR NR 158 186 220 290
0 35 96 54 200 78 346 114 537
2 37 74 56 148 78 248 113 375
5 50 68 73 140 100 239 141 363
20
10 NR NR 93 129 125 223 177 344
15 NR NR NR NR 155 208 216 325
20 NR NR NR NR 186 192 254 306
0 34 99 53 211 76 372 110 584
2 37 80 55 164 76 281 109 429
5 49 74 72 157 98 271 136 417
30 10 NR NR 91 144 122 255 171 397
15 NR NR 115 131 151 239 208 377
20 NR NR NR NR 181 223 246 357
30 NR NR NR NR NR NR NR NR
NOTE − Single appliance venting configurations with zero lateral lengths are assumed to have no elbows in the vent system. For all other
vent configurations, the vent system is assumed to have two 90° elbows. For each additional 90° elbow or equivalent (for example two 45°
elbows equal one 90° elbow) beyond two, the maximum capacity listed in the venting table should be reduced by 10 percent (0.90 x maxi-
mum listed capacity).

Page 17
 TABLE 5
Vent Connector Capacity
Type B Double−Wall Vents with Type B Double−Wall Connectors
Serving Two or More Category I Appliances
Vent and Connector Diameter − D (inches)
Vent Connector
Height Rise 3 Inch 4 Inch 5 Inch 6 Inch
H R Appliance Input Rating in Thousands of Btu Per Hour
(feet) (feet)
MIN MAX MIN MAX MIN MAX MIN MAX
1 22 37 35 66 46 106 58 164
6 2 23 41 37 75 48 121 60 183
3 24 44 38 81 49 132 62 199
1 22 40 35 72 49 114 64 176
8 2 23 44 36 80 51 128 66 195
3 24 47 37 87 53 139 67 210
1 22 43 34 78 49 123 65 189
10 2 23 47 36 86 51 136 67 206
3 24 50 37 92 52 146 69 220
1 21 50 33 89 47 142 64 220
15 2 22 53 35 96 49 153 66 235
3 24 55 36 102 51 163 68 248
1 21 54 33 99 46 157 62 246
20 2 22 57 34 105 48 167 64 259
3 23 60 35 110 50 176 66 271
1 20 62 31 113 45 181 60 288
30 2 21 64 33 118 47 190 62 299
3 22 66 34 123 48 198 64 309

TABLE 6
Common Vent Capacity
Type B Double−Wall Vents with Type B Double−Wall Connectors
Serving Two or More Category I Appliances
Common Vent Diameter − D (inches)
Vent
Height 4 Inch 5 Inch 6 Inch 7 Inch
H Appliance Input Rating in Thousands of Btu Per Hour
(feet)
FAN + FAN FAN + NAT FAN + FAN FAN + NAT FAN + FAN FAN + NAT FAN + FAN FAN + NAT
6 92 81 140 116 204 161 309 248
8 101 90 155 129 224 178 339 275
10 110 97 169 141 243 194 367 299
15 125 112 195 164 283 228 427 352
20 136 123 215 183 314 255 475 394
30 152 138 244 210 361 297 547 459

Page 18
 TABLE 7
Vent Connector Capacity
Type B Double−Wall Vents with Single−Wall Metal Connectors
Serving Two or More Category I Appliances
Vent and Connector Diameter − D (inches)
Vent Connector
Height Rise 3 Inch 4 Inch 5 Inch 6 Inch
H R Appliance Input Rating in Thousands of Btu Per Hour
(feet) (feet)
MIN MAX MIN MAX MIN MAX MIN MAX
1 NR NR NR NR NR NR NR NR
6 2 NR NR NR NR NR NR 168 182
3 NR NR NR NR 121 131 174 198
1 NR NR 79 87 116 138 177 214
15 2 NR NR 83 94 121 150 185 230
3 NR NR 87 100 127 160 193 243
1 47 60 77 110 113 175 169 278
30 2 50 62 81 115 117 185 177 290
3 54 64 85 119 122 193 185 300

TABLE 8
Common Vent Capacity
Type B Double−Wall Vents with Single−Wall Metal Connectors
Serving Two or More Category I Appliances
Common Vent Diameter − D (inches)
Vent
Height 4 Inch 5 Inch 6 Inch 7 Inch
H Appliance Input Rating in Thousands of Btu Per Hour
(feet)
FAN + FAN FAN + NAT FAN + FAN FAN + NAT FAN + FAN FAN + NAT FAN + FAN FAN + NAT
6 89 78 136 113 200 158 304 244
8 98 87 151 126 218 173 331 269
10 106 94 163 137 237 189 357 292
15 121 108 189 159 275 221 416 343
20 131 118 208 177 305 247 463 383
30 145 132 236 202 350 286 533 446

Removal of the Furnace from Common Vent and other spaces of the building. Turn on clothes dry-
In the event that an existing furnace is removed from a ers and any appliances not connected to the common
venting system commonly run with separate gas ap- venting system. Turn on any exhaust fans, such as
pliances, the venting system is likely to be too large to range hoods and bathroom exhausts, so they will oper-
properly vent the remaining attached appliances. ate at maximum speed. Do not operate a summer ex-
haust fan. Close fireplace dampers.
Conduct the following test while each appliance is operat-
4− Follow the lighting instructions. Turn on the appliance
ing and the other appliances (which are not operating) re-
that is being inspected. Adjust the thermostat so that
main connected to the common venting system. If the
the appliance operates continuously.
venting system has been installed improperly, you must
correct the system as indicated in the general venting re- 5− After the main burner has operated for five minutes,
quirements section. test for leaks of flue gases at the draft hood relief open-
ing. Use the flame of a match or candle, or smoke from
1 − Seal any unused openings in the common venting sys-
a cigarette, cigar, or pipe.
tem.
6− After determining that each appliance connected to the
2 − Inspect the venting system for proper size and horizontal common venting system is venting properly, (step 3)
pitch. Determine that there is no blockage, restriction, return all doors, widows, exhaust fans, fireplace damp-
leakage, corrosion, or other deficiencies which could ers, and any other gas−burning appliances to their pre-
cause an unsafe condition. vious mode of operation.
3 − Close all building doors and windows and all doors be- 7− If a venting problem is found during any of the preced-
tween the space in which the appliances remaining ing tests, the common venting system must be modi-
connected to the common venting system are located fied to correct the problem.

Page 19
 Resize the common venting system to the minimum 2 − When connecting the gas supply piping, consider fac-
size determined by using the appropriate tables in ap- tors such as length of run, number of fittings, and fur-
pendix G. (These are in the current standards of the nace rating to avoid excessive pressure drop. Table 9
National Fuel Gas Code ANSI Z223.1 in the USA, and lists recommended pipe sizes for typical applications.
the appropriate Category 1 Natural Gas and Propane 3 − The gas piping must not run in or through air ducts,
appliances venting sizing tables in the current stan- clothes chutes, gas vents or chimneys, dumb waiters,
dards of the CSA B149 Natural Gas and Propane or elevator shafts.
Installation Codes in Canada.) 4 − The piping should be sloped 1/4 inch (6.4 mm) per 15
feet (4.57 m) upward toward the meter from the fur-
nace. The piping must be supported at proper intervals
Gas Piping
[every 8 to 10 feet (2.44 to 3.01 m)] with suitable hang-
ers or straps. Install a drip leg inside vertical pipe runs
to the unit.
5 − In some localities, codes may require the installation of
CAUTION a manual main shut-off valve and union (furnished by
If a flexible gas connector is required or allowed by the installer) external to the unit. The union must be of
the authority that has jurisdiction, black iron pipe the ground joint type.
shall be installed at the gas valve and extend outside
the furnace cabinet.
IMPORTANT
Compounds used on threaded joints of gas piping
WARNING must be resistant to the actions of liquified petro-
leum gases.
Do not exceed 600 in−lbs (50 ft−lbs) torque when at-
taching the gas piping to the gas valve. NOTE − Install a 1/8 inch NPT plugged tap in the field piping
upstream of the gas supply connection to the unit. The tap
Gas Supply must be accessible for test gauge connection. See figure 19.
1 − This unit is shipped standard for left or right side instal- NOTE − If emergency shutoff is necessary, shut off the main
lation of gas piping (or top entry in horizontal applica- manual gas valve and disconnect main power to the fur-
tions). Connect the gas supply to the piping assembly. nace. The installer should properly label these devices.
TABLE 9
Gas Pipe Capacity − ft3/hr (m3/hr)
Nominal Internal Length of Pipe − feet (m)
Iron Pipe Diameter
Size inches
inches 10 20 30 40 50 60 70 80 90 100
(mm) (3.048) (6.096) (9.144) (12.192) (15.240) (18.288) (21.336) (24.384) (27.432) (30.480)
(mm)
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) (919.25) (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)
NOTE − Capacity given in cubic feet (m 3 ) of gas per hour and based on 0.60 specific gravity gas.

Page 20
 Left Side Piping AUTOMATIC MANUAL
(Standard) GAS VALVE MAIN SHUT−OFF
MANUAL AUTOMATIC (with manual VALVE
MAIN SHUT−OFF GAS VALVE shut−off valve) (With 1/8 in. NPT
VALVE (with manual Plugged Tap
(With 1/8 in. NPT shut−off valve) Shown)
Plugged Tap Shown) GROUND
JOINT
UNION

GROUND
JOINT
UNION DRIP LEG

FIELD
Right Side Piping
PROVIDED (Alternate)
DRIP LEG AND INSTALLED

FIGURE 19
Leak Check Electrical
After gas piping is completed, carefully check all piping ELECTROSTATIC DISCHARGE (ESD)
connections (factory− and field−installed) for gas leaks. Use Precautions and Procedures
a leak detecting solution or other preferred means.
NOTE − If emergency shutoff is necessary, shut off the main
manual gas valve and disconnect the main power to the CAUTION
furnace. The installer should properly label these devices. Electrostatic discharge can affect electronic com-
ponents. Take precautions during furnace installa-
tion and service to protect the furnace’s electronic
CAUTION controls. Precautions will help to avoid control ex-
posure to electrostatic discharge by putting the fur-
Some soaps used for leak detection are corrosive to nace, the control and the technician at the same
certain metals. Carefully rinse piping thoroughly af- electrostatic potential. Neutralize electrostatic
ter leak test has been completed. Do not use charge by touching hand and all tools on an un-
matches, candles, flame or other sources of ignition painted unit surface, such as the gas valve or blow-
to check for gas leaks. er deck, before performing any service procedure.
The unit is equipped with a field make−up box. The make−
The furnace must be isolated from the gas supply system
up box may be moved to the right side of the furnace to fa-
by closing its individual manual shut-off valve during any
cilitate installation. If the make−up box is moved to the right
pressure testing of the gas supply system at pressures less
side, the excess wire must be pulled into the blower
than or equal to 1/2 psig (3.48 kPa, 14 inches w.c.).
compartment. Secure the excess wire to the existing harn-
ess to protect it from damage.
IMPORTANT INTERIOR MAKE−UP BOX INSTALLATION
When testing pressure of gas lines, gas valve must MAKE−UP
be disconnected and isolated. See figure 20. Gas BOX
valves can be damaged if subjected to pressures
greater than 1/2 psig (3.48 kPa, 14 inches w.c.).

MANUAL MAIN ISOLATE

SHUT−OFF VALVE GAS VALVE Right Side
WILL NOT HOLD
NORMAL TEST FURNACE
PRESSURE

CAP

FIGURE 20
FIGURE 21

Page 21
 NOTE − The G40UH(X) furnace contains electronic
INTERIOR MAKE−UP BOX INSTALLATION
components that are polarity sensitive. Make sure
MAKE−UP that the furnace is wired correctly and is properly
Left side BOX
grounded.
7 − One line voltage
EAC" accessory terminal is provided
on the furnace control board. Any electronic air cleaner
rated up to one amp can be connected to this terminal
with the neutral leg of the circuit being connected to the
any of the
NEUTRAL" terminals. See figure 25 for con-
trol board configuration. This terminal is energized
whenever the blower is operating.
8 − One line voltage
HUM" accessory terminal is provided
on the furnace control board. Any humidifier rated up
to one amp can be connected to this terminal with the
neutral leg of the circuit being connected to any of the

NEUTRAL" terminals. See figure 25 for control board
configuration. This terminal is energized in the heating
mode whenever the combustion air inducer is operat-
ing.
9 − Install the room thermostat according to the instruc-
FIGURE 22 tions provided with the thermostat. See figure 23 for
thermostat designations. If the furnace is being
Refer to figure 24 for field wiring and figure 26 for schematic matched with a heat pump, refer to the FM21 installa-
wiring diagram and troubleshooting. tion instruction.
1 − Select circuit protection and wire size according to the
unit nameplate. The power supply wiring must meet G40UH(X) and CONDENSING UNIT
THERMOSTAT DESIGNATIONS
Class I restrictions. (Refer to specific thermostat and outdoor unit.)
2 − Holes are on both sides of the furnace cabinet to facili-
tate wiring. Thermostat G40UH(X) Condensing
Furnace Unit
3 − Install a separate disconnect switch (protected by ei-
POWER
ther fuse or circuit breaker) near the furnace so that R R

power can be turned off for servicing. W1

HEAT
W
CONDENSING
4 − Before connecting the thermostat or the power wiring, COOLING UNIT
Y Y
check to make sure the wires will be long enough for
INDOOR BLOWER
servicing at a later date. Remove the blower access G G
CONDENSING
panel to check the length of the wire. C
COMMON
C
UNIT COMMON

5 − Complete the wiring connections to the equipment.

Use the provided unit wiring diagram and the field wir- FIGURE 23
ing diagram shown in figure 24. Use 18−gauge wire or
larger that is suitable for Class II rating for thermostat Indoor Blower Speeds
connections. 1 − When the thermostat is set to
FAN ON," the indoor
6 − Electrically ground the unit according to local codes or, blower will run continuously on the heating speed
in the absence of local codes, according to the current when there is no cooling or heating demand.
National Electric Code (ANSI/NFPA No. 70) for the 2 − When the G40UH(X) is running in the heating mode,
USA and current Canadian Electric Code part 1 (CSA the indoor blower will run on the heating speed.
standard C22.1) for Canada. A green ground wire is 3 − When there is a cooling demand, the indoor blower will
provided in the field make−up box. run on the cooling speed.

Page 22
 TYPICAL G40UH(X) FIELD WIRING DIAGRAM

FIGURE 24

INTEGRATED CONTROL BOARD

(Automatic Hot Surface Ignition System)

TERMINAL DESIGNATIONS
HUM Humidifier (120VAC)
LINE Input (120VAC)
XFMR Transformer (120VAC)
EAC Electronic Air Cleaner (120VAC)
COOL Blower − Cooling Speed (120VAC)
HEAT Blower − Heating Speed (120VAC)
PARK Dead terminals to park alternate spd taps
FLAME Flame senser
NEUTRALS Neutral terminals (120VAC)

3 AMP, 32 VAC FUSE

BLOWER OFF
DELAY JUMPER

FIGURE 25

Page 23
G40UH(X) Schematic Wiring Diagram

FIGURE 26

Page 24
 Unit Start−Up 3 − Turn off all electrical power to the unit.
4 − This furnace is equipped with an ignition device which
FOR YOUR SAFETY READ BEFORE LIGHTING automatically lights the burners. Do not try to light the
burners by hand.
5 − Remove the upper access panel.
WARNING 6 − Honeywell VR8205 Gas Valve with ON/OFF Switch
Do not use this furnace if any part has been underwa- − Move gas valve switch to OFF. See figure 27.
ter. Immediately call a qualified service technician to Honeywell VR8205 Gas Valve with Control Knob −
inspect the furnace and to replace any part of the Turn knob on gas valve clockwise to OFF. Do not
control system and any gas control which has been force. See figure 28.
under water. White Rodgers 36G Gas Valve − Move gas valve
switch to OFF. See figure 29.
7 − Wait five minutes to clear out any gas. If you then smell
WARNING gas, STOP! Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s instruc-
If overheating occurs or if gas supply fails to shut off, tions. If you do not smell gas go to next step.
shut off the manual gas valve to the appliance before
shutting off electrical supply. Honeywell VR8205 Series Gas Valve
MANIFOLD (With On/Off Switch)
PRESSURE
ADJUSTMENT MANIFOLD
CAUTION SCREW
(under cap)
PRESSURE
OUTLET
Before attempting to perform any service or mainte-
nance, turn the electrical power to unit OFF at dis-
connect switch.
BEFORE LIGHTING smell all around the appliance area for
GAS VALVE ON/OFF SWITCH SHOWN IN OFF POSITION
gas. Be sure to smell next to the floor because some gas is
heavier than air and will settle on the floor. FIGURE 27
The gas valve on the G40UH(X) unit may be equipped with
Honeywell VR8205 Series Gas Valve
either a gas control knob or gas control lever. Use only your
with Gas Control Knob
hand to push the lever or to turn the gas control knob. Never MANIFOLD MANIFOLD
use tools. If the knob will not turn or if the lever will not move PRESSURE PRESSURE
by hand, do not try to repair it. Call a qualified service tech- ADJUSTMENT OUTLET
SCREW
nician. Force or attempted repair may result in a fire or ex-
plosion.
Placing the furnace into operation: ON

G40UH(X) units are equipped with an automatic hot sur-

OFF
face ignition system. Do not attempt to manually light
burners on these furnaces. Each time the thermostat calls GAS VALVE SHOWN IN OFF POSITION
for heat, the burners will automatically light. The igniter FIGURE 28
does not get hot when there is no call for heat on units with
this ignition system. White Rodgers 36G Series Gas Valve
OUTLET
PRESSURE
WARNING POST MANIFOLD
PRESSURE
If you do not follow these instructions exactly, a fire ADJUSTMENT
or explosion may result causing property damage, SCREW
(Under cover
personal injury or death. screw)
Gas Valve Operation (Figures 27, 28 and 29) INLET
PRESSURE
1 − STOP! Read the safety information at the beginning of POST
GAS VALVE SHOWN IN OFF POSITION
this section.
2 − Set the thermostat to the lowest setting. FIGURE 29

Page 25
8 − Honeywell VR8205 Gas Valve with ON/OFF Switch Gas Pressure Adjustment
− Move gas valve switch to ON. See figure 27.
Honeywell VR8205 Gas Valve with Control Knob − Gas Flow (Approximate)
Turn knob on gas valve counterclockwise to ON. 1 − Operate unit at least 15 minutes before checking gas
Do not force. See figure 28. flow. Determine the time in seconds for one revolu-
White Rodgers 36G Gas Valve − Move gas valve tions of gas through the meter. A portable LP gas me-
switch to ON. See figure 29.
ter (17Y44) is available for LP applications.
9 − Replace the upper access panel. 2 − Compare the number of seconds and the gas meter
10− Turn on all electrical power to to the unit. size in table 10 to determine the gas flow rate. Multiply
the gas flow rate by the heating value to determine the
11− Set the thermostat to desired setting.
unit input rate. If manifold pressure is correct and the
NOTE − When unit is initially started, steps 1 through 11 unit input rate is incorrect, check gas orifices for proper
may need to be repeated to purge air from gas line. size and restriction.
12− If the appliance will not operate, follow the instructions 3 − Remove temporary gas meter if installed.

Turning Off Gas to Unit" and call your service techni- NOTE − To obtain accurate reading, shut off all other gas
cian or gas supplier. appliances connected to meter.
Turning Off Gas to Unit TABLE 10
1 − Set the thermostat to the lowest setting. Gas Flow Rate (Ft.3/Hr.)
2 − Turn off all electrical power to the unit if service is to be Seconds for 1 Gas Meter Size
performed. Revolution 1/2 cu ft Dial 1 cu ft Dial
10 180 360
3 − Remove the upper access panel.
12 150 300
4 − Honeywell VR8205 Gas Valve with ON/OFF Switch 14 129 257
− Move gas valve switch to OFF. See figure 27. 16 113 225
Honeywell VR8205 Gas Valve with Control Knob − 18 100 200
Turn knob on gas valve clockwise to OFF. Do not 20 90 180
force. See figure 28. 22 82 164
White Rodgers 36G Gas Valve − Move gas valve 24 75 150
switch to OFF. See figure 29. 26 69 138
5 − Replace the upper access panel. 28 64 129
30 60 120
Heating Sequence Of Operation
32 56 113
1 − When thermostat calls for heat, combustion air inducer 34 53 106
starts. 36 50 100
2 − Combustion air pressure switch proves blower opera- 38 47 95
tion. Switch is factory set and requires no adjustment. 40 45 90
42 43 86
3 − After a 15−second prepurge, the hot surface igniter en- 44 41 82
ergizes. 46 39 78
4 − After a 20−second igniter warm−up period, the gas 48 38 75
valve solenoid opens. 50 36 72
5 − Gas is ignited, flame sensor proves the flame, and the 52 35 69
combustion process continues. 54 33 67
56 32 64
6 − If flame is not detected after first ignition trial, the igni- 58 31 62
tion control will repeat steps 3 and 4 four more times 60 30 60
before locking out the gas valve (
WATCHGUARD"
flame failure mode). The ignition control will then auto-
matically repeat steps 1 through 6 after 60 minutes. IMPORTANT
7 − To interrupt the 60−minute
WATCHGUARD" period, For safety, shut unit off and remove manometer as
move thermostat from
Heat" to
OFF" then back to soon as an accurate reading has been obtained.

Heat". Heating sequence then restarts at step 1. Take care to replace pressure tap plug.

Page 26
Gas Pressure Other Unit Adjustments
1 − Check the gas line pressure with the unit firing at maxi-
mum rate. A minimum of 4.5 in. w.c. for natural gas or Primary and Secondary Limits
11.0 in. w.c. for LP/propane gas should be maintained. The primary limit is located on the heating compartment
2 − After the line pressure has been checked and ad- vestibule panel. The secondary limits (if equipped) are lo-
justed, check the manifold pressure. A natural gas to cated in the blower compartment, attached to the back side
LP/propane gas changeover kit is required to convert of the blower. These limits are factory set and require no
the unit. Manifold pressure for all units is given in table adjustment.
11. See figures 27, 28 and 29 for the location of the Flame Rollout Switches (Two)
manifold pressure adjustment screws. These manually reset switches are located on (or inside of)
the burner box. If tripped, check for adequate combustion
High Altitude Information air before resetting.
Pressure Switch
NOTE − In Canada, certification for installations at eleva-
The pressure switch is located in the heating compartment
tions over 4500 feet (1372 m) is the jurisdiction of local au-
adjacent to the combustion air inducer. This switch checks
thorities. for proper combustion air inducer operation before allow-
The manifold pressure may require adjustment to ensure ing ignition trial. The switch is factory−set and requires no
proper operation at higher altitudes. See table 11 for proper adjustment.
manifold pressure settings at varying altitudes. Temperature Rise
TABLE 11 Place the unit into operation with a heating demand. After
Manifold Pressure (Outlet) inches w.c. supply and return air temperatures have stabilized, check
Altitude (feet) the temperature rise. If necessary, adjust the blower speed
F l
Fuel to maintain the temperature rise within the range shown on
0−4500 4501−5500 5501−6500 6501−7500
the unit nameplate. Increase the blower speed to decrease
Nat.
3.5 3.3 3.2 3.1 the temperature rise. Decrease the blower speed to in-
Gas
L.P. crease the temperature rise. Failure to adjust the tempera-
10.0 10.0 10.0 10.0 ture rise may cause erratic limit operation.
Gas
Fan Control
NOTE − A natural to L.P. propane gas changeover kit is nec-
There is no cooling mode fan on delay; however, there is a
essary to convert this unit. L.P. conversion kit 45L60 is used
cooling fan off delay of 45 seconds. This delay is not adjust-
with all units installed at altitudes up to 7,500 feet. L.P. con- able.
version kit 47M81 is used with all units installed at altitudes The heating mode fan on delay of 45 seconds is not adjust-
from 7,501 to 10,000 feet above sea level. Refer to the able. The heating mode fan off delay (amount of time that
changeover kit installation instruction for the conversion the blower operates after the heat demand has been satis-
procedure. fied) may be adjusted by changing the jumper position
NOTE − Units fueled by natural gas and installed at alti- across the five pins on the integrated control. The unit is
tudes of 7501−10,000 feet above sea level require installa- shipped with a factory fan off setting of 90 seconds. The fan
tion of a high altitude orifice kit (47M82). off delay affects comfort and is adjustable to satisfy individ-
ual applications. Adjust the fan off delay to achieve a supply
The combustion air pressure switches are factory−set and
air temperature between 90° and 110°F at the exact mo-
require no adjustment. Table 12 lists the replacement pres- ment that the blower is de−energized. Longer off delay set-
sure switch required for G40UH(X) units installed at alti- tings provide lower return air temperatures; shorter set-
tudes above 4,500 feet above sea level. tings provide higher return air temperatures. See figure 30.
TABLE 12 FAN-OFF TIME ADJUSTMENT
Altitude (feet)
4501−7500 7501−10000
Model Pres. Switch Pres. Switch
Replacement Replacement
Required Required
G40UH(X)−045−070 56L32 56L32 To adjust fan−off timing, reposition jumper across pins to
G40UH(X)−090−110 49L90 15M22 achieve desired setting.
G40UH(X)−135−155 49L90 15M22 FIGURE 30

Page 27
Thermostat Heat Anticipation 5 − Is the filter dirty or plugged? Dirty or plugged filters will
Set the heat anticipator setting (if adjustable) according to cause the limit control to shut the unit off.
the amp draw listed on the wiring diagram that is attached 6 − Is gas turned on at the meter?
to the unit. 7 − Is the manual main shut-off valve open?
8 − Is the internal manual shut-off valve open?
Electrical
9 − Is the unit ignition system in lock out? If the unit locks out
1 − Check all wiring for loose connections. again, call the service technician to inspect the unit for
2 − Check for the correct voltage at the furnace (furnace blockages.
operating).
3 − Check amp-draw on the blower motor.
Service
Motor Nameplate__________Actual__________
NOTE − Do not secure the electrical conduit directly to the WARNING
air ducts or structure. Disconnect power before servicing unit.
Blower Speeds
NOTE − CFM readings are taken external to unit with a dry
evaporator coil and without accessories.
CAUTION
1 − Turn off electrical power to furnace. Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and dan-
2 − Remove blower access panel. gerous operation. Verify proper operation after ser-
3 − Disconnect existing speed tap at control board speed vicing.
terminal. At the beginning of each heating season, a qualified techni-
NOTE − Termination of any unused motor leads must be insu- cian should check the system as follows:
lated. Blower
4 − Refer to blower speed selection chart on unit wiring dia- Check the blower wheel for debris and clean if necessary.
gram for desired heating or cooling speed. The blower motors are prelubricated for extended bearing
5 − Connect selected speed tap at control board speed life. No further lubrication is needed.
terminal.
6 − Resecure blower access panel.
7 − Turn on electrical power to furnace. WARNING
Electronic Ignition The blower access panel must be securely in place
The integrated ignition control has an added feature of an when the blower and burners are operating. Gas
internal Watchguard control. The feature serves as an auto- fumes, which could contain carbon monoxide, can
matic reset device for ignition control lockout because the be drawn into living space resulting in personal inju-
burner has failed to ignite. This type of lockout is usually due ry or death.
to low gas line pressure. After one hour of continuous ther- Filters
mostat demand for heat, the Watchguard will break and re-
make thermostat demand to the furnace and automatically All G40UH(X) filters are installed external to the unit. Fil-
reset the control to begin the ignition sequence. ters should be inspected monthly. Clean or replace the fil-
ters when necessary to ensure proper furnace operation.
Flue And Chimney Replacement filters must be rated for high velocity airflow.
1 − Check flue pipe, chimney and all connections for tight- Table 1 lists recommended filter sizes.
ness and to make sure there is no blockage. Flue And Chimney
2 − Check unit for proper draft.
Check the flue pipe, chimney and all connections for tight-
3 − Is pressure switch closed? Obstructed flue will cause
ness and to make sure there is no blockage.
unit to shut off at pressure switch. Check flue and outlet
for blockages. Electrical
4 − Reset manual flame rollout switches on burner box 1 − Check all wiring for loose connections.
cover. 2 − Check for the correct voltage at the furnace (furnace
Failure To Operate operating).
If the unit fails to operate, check the following: 3 − Check amp−draw on the blower motor.
1 − Is the thermostat calling for heat? Motor Nameplate__________Actual__________
2 − Are access panels securely in place? Cleaning the Heat Exchanger and Burners
3 − Is the main disconnect switch closed? NOTE − Use papers or protective covering in front of the fur-
4 − Is there a blown fuse? nace while you clean furnace.

Page 28
Cleaning the heat exchanger requires a steel spring
NOx INSERTS

snake," a reversible drill and a vacuum cleaner. The steel
(X models only)
spring snake may be constructed by purchasing a 4 ft. long
by 1/4 inch diameter steel wire cable and a 1/4 inch diame-
ter wire brush. These items are available at a hardware
store. Insert wire end of brush into the open end of the
spring cable. Crimp the cable around the brush so that the
brush is secured and will not come off during cleaning. At-
tach the other end of the cable to the reversible drill to com-
plete the tool for cleaning the heat exchanger.
1 − Turn off both electrical and gas power supplies to fur-
nace.
2 − Remove flue pipe and top cap from the unit. Label the
pressure switch wires, then disconnect them.
3 − Remove the four screws that secure the combustion air
NOx INSERTS
inducer. Carefully remove the combustion air inducer to
avoid damaging blower gasket. If gasket is damaged, it
must be replaced to prevent leakage. See figure 31.

G40UH(X) BURNER & HEAT FIGURE 32

EXCHANGER REMOVAL 7 − NOx units only − remove the three screws that attach
the NOx insert to the corbel at the entrance to each
heat exchanger section. Carefully remove the NOx in-
sert from each section. See figure 32.
8 − Insert the brush end of cable snake into the top of one
of the heat exchanger openings. Do not force the
HEAT EXCHANGER cable into the heat exchanger. Insert the cable and
operate the drill on slow speed. Move the cable in and
BURNER BOX ASSEMBLY
out of the heat exchanger section three or four times or
until sufficient cleaning is accomplished. Reverse drill
and slowly work the cable out of opening.
9− Repeat procedure for each heat exchanger section.
10− After each of the top heat exchanger sections has been
cleaned, insert the brush end of the cable snake into
the bottom openings of each of the heat exchanger
sections. Clean the bottom opening as described in
step 8.
11− Remove cable from heat exchanger. Use a vacuum
cleaner to remove debris knocked loose during clean-
FIGURE 31 ing from each heat exchanger section.
12− Attach the exhaust end (positive pressure) of the vacu-
4 − Remove the collector box located behind the combus- um cleaner to the top of the heat exchanger section.
tion air inducer. Be careful with the collector box gas- Any loose debris will be forced to the bottom of the heat
ket. If the gasket is damaged you must replace it to pre- exchanger section. Vacuum debris from bottom open-
vent leakage. ings.
5 − Label the wires from gas valve and rollout switches, 13− Replace collector box and combustion air inducer.
then disconnect them. Check gaskets for damage. Damaged gaskets must be
6 − Disconnect gas supply piping. Remove four screws se- replaced to avoid heat exchanger leaks. Replace all
curing the burner manifold assembly to the vestibule screws to the collector box and combustion air inducer.
panel and remove the assembly from the unit. Failure to replace all screws may cause leaks.

Page 29
14− To clean the burner, run a vacuum cleaner with a soft 21− Set thermostat and check for proper operation.
brush attachment over the face of burners. Visually in- 22− Check all piping connections, factory and field, for gas
spect inside the burners and crossovers for any blockage leaks. Use a leak detecting solution or other preferred
caused by foreign matter. Remove any blockage. means.
15− NOx Units − Reattach the NOx inserts to the corbels
at the entrance to each heat exchanger opening. See
figure 32. CAUTION
16− Replace burner/manifold assembly onto the vestibule Some soaps used for leak detection are corrosive to
panel. certain metals. Carefully rinse piping thoroughly af-
ter leak test has been completed. Do not use
17− Reconnect wires to pressure switch, roll−out switches, matches, candles, flame or other sources of ignition
gas valve and combustion air inducer. Refer to unit wir- to check for gas leaks.
ing diagram.
23− If a leak is detected, shut gas and electricity off and
18− Reconnect vent pipe to combustion air inducer outlet. repair leak.
19− Reconnect gas supply piping. 24− Repeat steps 23 and 24 until no leaks are detected.
20− Turn on power and gas supply to unit. 25− Replace front access panel.
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 nameplate −− Example: G40UH(X)−24A−045−1.
Cabinet Parts Heating Parts
Upper access panel Flame sensor
Blower panel Heat exchanger assembly
Top cap Gas manifold
Control Panel Parts Combustion air inducer
Transformer Gas valve
Integrated ignition control board Main burner cluster
Door interlock switch Main burner orifices
Circuit breaker Pressure switch
Blower Parts Igniter
Blower wheel Primary limit control
Motor Flame rollout switch
Motor mounting frame Secondary limit (not used on 24A−45−1)
Motor capacitor
Blower housing cutoff plate

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Ignition Control Board Diagnostic Codes
DIAGNOSTIC CODES
Make sure to Identify LED’S Correctly.
Refer to figure NO TAG for control board layout.

LED #1 (Red) LED #2 (Green) DESCRIPTION

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
SLOW FLASH ON
goes into 1 hour Watchguard.
Pressure prove switch open.
OFF SLOW FLASH OR: Blocked inlet/exhaust vent;
OR: Pressure switch closed prior to activation of combustion air inducer.
ALTERNATING ALTERNATING Watchguard −− burners failed to ignite or lost flame 5 times during single heating
SLOW FLASH SLOW FLASH demand.
SLOW FLASH OFF Flame sensed without gas valve energized.
ON SLOW FLASH Rollout switch open. OR: 12-pin connector improperly attached.
ON ON
ON OFF Circuit board failure or control wired incorrectly.
y
OFF ON
FAST FLASH SLOW FLASH Main power polarity reversed. Switch line and neutral.
SLOW FLASH FAST FLASH Low flame signal. Measures below 1.5 microamps. Replace flame sense rod.
ALTERNATING ALTERNATING Improper main ground.
FAST FLASH FAST FLASH OR: Line voltage below 90 volts.

NOTE − Slow flash rate equals 1 Hz (one flash per second). Fast flash rate equals 3 Hz (three flashes per second).
Minimum flame sense current = 0.5 microAmps.

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Troubleshooting

HEATING SEQUENCE OF OPERATION

NORMAL HEATING MODE ABNORMAL HEATING MODE

POWER ON
GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.
NO INDOOR BLOWER DELAY OFF.
CONTROL SELF−CHECK OKAY? LED #1 ON
LED #2 ON
(RESET CONTROL BY TURNING MAIN POWER OFF.)

YES NO POLARITY REVERSED.

IS POLARITY CORRECT? LED #1 −− FAST FLASH
LED #2 −− SLOW FLASH
YES
NO IMPROPER GROUND.
IS THERE A PROPER GROUND? LED #1 −− ALTERNATING FAST FLASH
LED #2 −− ALTERNATING FAST FLASH
YES

NO LEDs SIGNAL FAST ALTERNATING FLASH.

IS VOLTAGE CONTROL WILL NOT RESPOND TO A CALL FOR
ABOVE 90 VOLTS? HEATING UNTIL VOLTAGE RISES ABOVE 95 VOLTS.

YES GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

NO
INDOOR BLOWER ON.
ROLLOUT SWITCH CLOSED? LED #1 −− ON. LED #2 −− SLOW FLASH.
SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES
YES AND POWER IS RESET OR T’STAT IS INTERRUPTED
FOR MINIMUM OF 1 SECOND.

GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

NO
BURNER OFF? INDOOR BLOWER ON HEATING SPEED.
(CONTINUOUS FLAME CHECK) LED #1 −− SLOW FLASH
LED #2 −− OFF
YES
NO NORMAL OPERATION:
LED #1 −− SLOW FLASH
LED #2 −− SLOW FLASH
YES
COMBUSTION AIR INDUCER OFF.
THERMOSTAT CALLS FOR HEAT:
INDOOR BLOWER ON
LED #1 −− FAST FLASH
LED #1 SLOW FLASH RATE
LED #2 −− FAST FLASH
NO LED #2 −− ON
YES
PRIMARY AND SECONDARY LIMIT SWITCH.
CLOSED?
GAS VALVE OFF.
YES COMBUSTION AIR INDUCER OFF.
NO INDOOR BLOWER OFF WITH DELAY.
IS COMBUSTION AIR LED #1 OFF
PRESSURE SWITCH OPEN? LED #2 SLOW FLASH
YES (Sequence holds until pressure switch
opens or thermostat resets control.)
IS COMBUSTION AIR INDUCER
ENERGIZED?
YES
PRESSURE SWITCH IS IN WATCHGUARD MODE. YES
HAS COMBUSTION AIR PRESSURE NO GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.
SWITCH CLOSED IN 2.5 MINUTES? INDOOR BLOWER OFF WITH DELAY.
LED #1 −− OFF. LED #2 −− SLOW FLASH.
YES
IS 5-MINUTE RESET PERIOD COMPLETE?

CONTINUED NEXT PAGE

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Troubleshooting

HEATING SEQUENCE CONTINUED

NORMAL HEATING MODE ABNORMAL HEATING MODE

15-SECOND COMBUSTION AIR INDUCER PREPURGE

INITIATED BY CLOSED PRESSURE SWITCH.
YES LEDS SIGNAL
NO ALTERNATING
NO FAST FLASH UNTIL
IGNITER WARM-UP −− 20 SECONDS. IS VOLTAGE ABOVE 90 VOLTS?
VOLTAGE IS ABOVE
YES YES 95 VOLTS, THEN
RESTARTS HEATING
4-SECOND TRIAL FOR IGNITION. SEQUENCE.
GAS VALVE OPENS. IGNITER ENERGIZED FOR
UP TO 4 SECONDS.
GAS VALVE OFF. COMBUSTION AIR INDUCER ON.
YES INDOOR BLOWER OFF. NO
NO HAS CONTROL FAILED TO SENSE FLAME FOR
FLAME STABILIZATION PERIOD. FIVE CONSECUTIVE TRIES DURING A SINGLE
HEAT DEMAND?
4 SECONDS
YES
FLAME RECTIFICATION CURRENT 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
(0.5 microamps) LEDs SIGNAL WATCHGUARD FAILURE CODE.
IS 60-MINUTE RESET PERIOD COMPLETE?
YES
YES
NO NO
FLAME PRESENT? HAS CONTROL RESET IGNITION
SEQUENCE FOUR TIMES?
YES
YES

NO LOW FLAME SIGNAL LIMIT SWITCH WATCHGUARD

MODE. GAS VALVE, COMB. AIR
(Does not affect operation of control)
FLAME SIGNAL 1.5 MICROAMPS OR GREATER? LED #1 −− SLOW FLASH INDUCER AND INDOOR BLOW-
YES LED #2 −− FAST FLASH ER OFF. LEDs SIGNAL LIMIT
SWITCH OPEN UNTIL MAIN
INDOOR BLOWER ON POWER IS
AFTER 45−SECOND DELAY INTERRUPTED OR
GAS VALVE DE−ENERGIZED.
YES COMBUSTION AIR INDUCER DE−ENERGIZED. T’STAT IS CYCLED
OFF/ON FOR 1
PRIMARY AND SECONDARY LIMIT NO INDOOR BLOWER ON UNTIL SWITCH CLOSES.
LED #1 −− SLOW FLASH. LED #2 −− ON. SEC. MINIMUM.
SWITCHES CLOSED? IS LIMIT SWITCH CLOSED? 60−MINUTE WATCH-
GUARD PERIOD
YES STARTS AT TIME
HAS PRIMARY / SECONDARY YES LIMIT CLOSES.
LIMIT RESET TIME IS 60−MIN. PERIOD
YES COMPLETE?
EXCEEDED 3 MINUTES?
NO

NO GAS VALVE POWER OFF.

COMBUSTION AIR INDUCER POWER ON.
ROLLOUT SWITCH CLOSED? INDOOR BLOWER ON
LED #1 −− ON. LED #2 −− SLOW FLASH.
YES
SEQUENCE HOLDS UNTIL ROLLOUT SWITCH IS RESET
AND MAIN POWER IS INTERRUPTED OR
COMBUSTION AIR PRESSURE NO THERMOSTAT IS CYCLED OFF/ON FOR 1 SEC. MINIMUM.
SWITCH CLOSED?
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.
NO
YES
COMB. AIR INDUCER CONTINUES 5-SECOND 5-MINUTE PRESSURE SWITCH
POST PURGE AFTER T’STAT DEMAND IS SATISFIED. WATCHGUARD MODE.
INDOOR AIR BLOWER COMPLETES SELECTED

OFF" DELAY BEFORE SHUTTING OFF.

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Troubleshooting

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
NO SIGNAL IMPROPER GROUND AT LED.
IS THERE A PROPER GROUND? CONTROL WILL CONTINUE TO CALL FOR COOLING
IN THIS CONDITION.
YES
NO SIGNAL POLARITY REVERSED AT LED. CONTROL
IS POLARITY CORRECT? WILL CONTINUE TO CALL FOR COOLING IN THIS
CONDITION.
YES
NO
IS VOLTAGE LED SIGNALS LOW VOLTAGE. CONTROL WILL
ABOVE 90 VOLTS? CONTINUE TO CALL FOR COOLING
IN THIS CONDITION.
YES
GAS VALVE OFF. COMBUSTION AIR INDUCER ON.
NO INDOOR BLOWER ON.
ROLLOUT SWITCH MONITORED CONTINUOUSLY. SIGNAL ROLL-OUT SWITCH OPEN AT LED.
IS ROLLOUT SWITCH CLOSED? SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES
AND MAIN POWER IS INTERRUPTED OR THERMOSTAT
IS CYCLED OFF/ON FOR 1 SEC. MINIMUM.
YES

LED: SLOW FLASH RATE REMAINS UNCHANGED

THROUGHOUT COOLING CYCLE.

THERMOSTAT CALLS FOR COOLING.

COMPRESSOR CONTACTOR AND SYSTEM FAN

ENERGIZED WITH 2-SECOND DELAY
(COOLING SPEED). EAC TERM. ENERGIZED.

THERMOSTAT OPENS.

COMPRESSOR OFF.

SYSTEM FAN AND EAC TERM. OFF

WITH 45-SECOND DELAY.

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Troubleshooting

CONTINUOUS HEAT SPEED FAN SEQUENCE OF OPERATION

LED: SLOW FLASH RATE REMAINS

UNCHANGED THROUGHOUT SEQUENCE.

MANUAL FAN SELECTION MADE AT THERMOSTAT.

CONTROL (G) ENERGIZES SYSTEM FAN AT HEAT
SPEED. EAC TERMINAL IS ENERGIZED.

HUM TERM. ENERGIZES

THERMOSTAT CALLS FOR HEAT (W). WITH COMB. AIR INDUCER.
NO YES

THERMOSTAT CALLS FOR COOLING. SYSTEM FAN REMAINS ON

YES NO HEATING SPEED.
SYSTEM FAN SWITCHED TO COOL SPEED.
EAC TERM. REMAINS ON. THERMOSTAT OPENS.

THERMOSTAT OPENS. HUM TERM. DE−ENERGIZES

WITH COMB. AIR INDUCER
MANUAL FAN SELECTION MADE AT THERMOSTAT.
CONTROL (G) ENERGIZES SYSTEM FAN AT HEAT SYSTEM FAN REMAINS ON
SPEED. EAC TERM. ENERGIZED. HEATING SPEED.

G40UH(X) Start−Up & Performance Check List

Job Name Job No. Date

Job Location City State
Installer City State
Unit Model No. Technician
Serial No.
Heating Section
Electrical Connections Tight? Supply Voltage Blower Motor H.P.
Blower Motor Amps Gas Piping Connections Tight & Leak−Tested?
Fuel Type: Natural Gas? LP/Propane Gas?
Furnace Btu Input Line Pressure
Regulator Pressure w.c. − Nat.: w.c. − LP/Propane
Flue Connections Tight? Proper Draft?
Combustion Gas Tested? CO2 CO
Fan Control Setting (45 Seconds Fixed On) Temperature Rise
Fan Control Off Setting
Filter Clean & Secure? Vent Clear?
Thermostat
Calibrated? Heat Anticipator Properly Set? Level?

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