LENNOX
LENNOX
Technical _ _ _PPub,icat,ons
GAS KITS & ACCESSORIES
Litho U.S.A.
;' 2003 Lennox Industries Inc.
INSTALLATION (57M90
REPLACEMENT HEAT EXCHANGER KIT
504,767M 6/2003
Dallas, Texas, USA
INSTRUCTIONS
THROUGH
57M99)
FOR REPLACEMENT USED WITH
G51MP
HEAT EXCHANGER & G61MP
SERIES
KITS
UNITS
A,WARNING
Package 1 of I contains the following: 1 - Heat exchanger assembly
Check equipment for shipping damage. ]f damage is found, immediately contact last carrier.
A, CAUTION See table 1 for unit model numbers and corresponding replacement heat exchanger kits. TABLE 1 Unit Model Number
Kit Number
Catalog Number
LBq01518G
57M90
1 - Turn off electrical and gas supplies to the furnace.
LB-101518J
57M92
2 - Remove the upper and lower fumace access panels.
LB-101518K
57M93
3 - Mark all gas valve wires and disconnect them from valve
LB*101518L
57M94
G51MP-60D_135
LBq01518M
57M95
G61 MP-36B-045
LB-101518N
57M96
G61 MP-36B-070
LBq01518P
57M97
G61MP-48Cq G61MP*60Cq
LB-101518R
57M98
LBq01518S
57M99
G51 MP-24B-045 G51 MP*36B-045 G51 MP-36B-070 G51/61 MP-48C_090 G51/61MP-60C-090 G51MP-48Cq G51MP*60Cq
10 10
10 10
G61MP-60D_135
Refer to figure 1 or figure 2 when disassembling unit.
4-
Remove gas supply line connected to gas valve. Remove gas valve/manifold assembly.
5 - Remove sensor wire from sensor. Disconnect 2-pin plug from the ignitor. 6 - Disconnect wires from flame roll-out switches. 7 - Disconnect air intake piping from burner box. NOTE - It may be necessary to cut air intake pipe. 8 - Remove burner box cover and remove four burner box screws at the vestibule panel and remove burner box. Set burner box assembly aside. NOTE - G61MP-135 units are secured to the vestibule panel by two additional screws which are required to secure the assembly during shipping. These screws must be removed for servicing; however it is not necessary to replace these screws.
ELECTROSTATIC DISCHARGE (ESD) Precautions and Procedures
I
_
CAUTION
9 - Loosen three clamps and remove flexible exhaust tee. 10 - Remove 3/8 inch rubber cap from condensate drain plug and drain. Replace cap after draining. 11 - Disconnect condensate drain line from the condensate trap. Remove condensate trap (it may be necessary to cut drain pipe). Remove screws that secure condensate collars to either side of the furnace and remove collars. Remove drain tubes from cold end header collector box. 504,767M
06/03
IIIIIIIIIIIIIIIIIIIIIIltlllIIIIIltllllll
Page1
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12- Disconnect condensate draintubingfromfluecollar. Removescrewsthatsecurebothflue collarsinto place.Removefluecollars.It maybenecessaryto cuttheexitingexhaustpipeforremovalofthefittings. 13- Markanddisconnectall combustionair pressure tubingfromcold endheadercollectorbox.Keep tubingattachedtopressureswitches. 14- Markand removewiresfrom pressureswitches, Removepressure switches. Keeptubingattached to pressureswitches. 15-Disconnectthe 2-pin or 3-pin plug from the combustion airinducer.Disconnect thetwowiresto the back-upsecondarylimit,if applicable. Remove fourscrewswhichsecurecombustion airinducerto collector box Removecombustionair inducer assembly. Removegroundwirefromvestpanel. 16- Removeelectricaljunctionboxfromthesideofthe furnace. 17- Markanddisconnect anyremaining wiringtoheating compartment components. Disengagestrainrelief bushingandpullwiringandbushing throughthehole intheblowerdeck, 18- Removetheprimarylimitfromthevestibulepanel. 19- Removetwoscrewsfromthefrontcabinetflangeat the blowerdeck.Spreadcabinetsidesslightlyto allowclearance forremovalof heatexchanger. 20- Removescrewsalongvestibulesidesandbottom whichsecurevestibulepanelandheatexchanger assemblyto cabinet,Removetwo screwsfrom blowerrailwhich securebottomheatexchanger flange. Removeheat exchangerfrom furnace cabinet. 21-Install replacement heat exchangerinto cabinet, makingsure that clamshellsof heat exchanger assemblyare restingonthe supportlocatedat the rearofthecabinet. Remove theindoorblowertoview thisareathroughthe bloweropening. 22- Re-secure thesupporting screwsalongthevestibule sidesandbottomtothecabinet.
29- Carefullyconnectcombustionairpressureswitch hosingfrompressureswitchestoproperstubson coldendheadercollectorbox.
,&WARNING
30 - Reinstall condensate
collars on each side of the
furnace, Reconnect drain tubing to collector box. 31 - Reinstall condensate trap, Reconnect condensate drain line to the condensate trap. 32 - Use securing screws to reinstall flue collars to either side of the furnace, Reconnect exhaust piping and exhaust drain tubing. 33-Replace flexible exhaust tee on combustion air inducer and flue collars. Secure using three existing hose clamps. 34 - Reinstall burner box assembly in vestibule area. Reconnect sensor wire and reconnect 2-pin plug from ignitor. 35 - Reconnect flame roll-out switch wires. 36 - Secure burner box assembly to vestibule panel using four existing screws. Make sure burners line up in center of burner ports. NOTE - It is not necessary to reinstafl two additional screws on -!35 models. These screws are necessary shipping.
only
to secure
the assembly
during
37 - Reinstall air intake piping, 38 - Reinstall gas valve manifold assembly. Reconnect gas supply line to gas valve. Use a leak detecting solution or other preferred means to check gas connections for leaks,
,A CAUTION
23- Reinstallcabinetscrewsonfrontflangeat blower deck. 24- Reinstalltheprimarylimitonthevestibulepanel, 25- Routeheatingcomponentwiringthroughholein blowerdeckandreinsertstrainreliefbushing, 26- Reinstallelectrical junctionbox. 27- Reinstallthecombustion airinducer.Reconnect the 2-pinor 3-pinplugto thewireharness.Reconnect the two wiresto the back-upsecondarylimit, if applicable, 28- Reinstallpressureswitches andreconnect pressure switchwiring.
39 - Reinstall bumer box cover. 40 - Reconnect wires to gas valve. 41 - Replace the blower compartment access panel. 42 - Refer to instruction on verifying gas and electrical connections when re-establishing supplies. 43-Follow lighting instructions to light and operate furnace for 5 minutes to ensure that heat exchanger is clean and dry and that furnace is operating properly. 44 - Replace heating compartment access panel.
Page 2
G51MP
PARTS
SHIPPING SCREWS (-135 only)
IDENTIFICATION
DuraIokPIus TM HEAT EXCHANGER ASSEMBLY
BURNER BOX ASSEMBLY
GAS VALVE AND MANIFOLD
FLUE COLLAR
COMBUSTION AIR PRESSURE PROVE SWITCHES
WARM HEADER (COLLECTOR) BOX
COMBUSTION AIR'*'_ INDUCER CONDENSER BURNER ACCESS PANEL
PRIMARY LIMIT
/_, _ _, / _ BLOWER ACCESS DOOR
COLD HEADER (COLLECTOR) BOX
DOOR INTERLOCK SWITCH
Cb
SECONDARY LIMITS (2)
\
BLOWER ASSEMBLY
SIGHT GLASS CONTROL BOX
FIGURE 1
Page 3
COIL
G61MP
SHIPPING
PARTS
IDENTIFICATION
DuraIokPlus TM HEAT EXCHANGER ASSEMBLY
SCREWS
(-135 only)
BURNER BOX ASSEMBLY
GAS VALVE AND MANIFOLD
FLUE COLLAR
COMBUSTION AIR PRESSURE PROVE SWITCHES* COMBUSTION INDUCER
WARM HEADER (COLLECTOR) BOX AIR CONDENSER
BURNER ACCESS PANEL
PRIMARY LIMIT
COLD HEADER (COLLECTOR) BOX BLOWER ACCESS DOOR
-.....
DOOR INTERLOCK SWITCH
SECONDARY LIMITS (2)
\ *G61MP=090 shown. G61MP4145and=070 are equtpped with two sw_ches.
BLOWER ASSEMBLY
SIGHT GLASS CONTROL BOX
FIGURE 2
Page 4
COIL
Technical _ _ _PPub,icat,ons
GAS KITS & ACCESSORIES
Litho U.S.A.
;' 2003 Lennox Industries Inc.
INSTALLATION (57M90
REPLACEMENT HEAT EXCHANGER KIT
504,767M 6/2003
Dallas, Texas, USA
INSTRUCTIONS
THROUGH
57M99)
FOR REPLACEMENT USED WITH
G51MP
HEAT EXCHANGER & G61MP
SERIES
KITS
UNITS
A,WARNING
Package 1 of I contains the following: 1 - Heat exchanger assembly
Check equipment for shipping damage. ]f damage is found, immediately contact last carrier.
A, CAUTION See table 1 for unit model numbers and corresponding replacement heat exchanger kits. TABLE 1 Unit Model Number
Kit Number
Catalog Number
LBq01518G
57M90
1 - Turn off electrical and gas supplies to the furnace.
LB-101518J
57M92
2 - Remove the upper and lower fumace access panels.
LB-101518K
57M93
3 - Mark all gas valve wires and disconnect them from valve
LB*101518L
57M94
G51MP-60D_135
LBq01518M
57M95
G61 MP-36B-045
LB-101518N
57M96
G61 MP-36B-070
LBq01518P
57M97
G61MP-48Cq G61MP*60Cq
LB-101518R
57M98
LBq01518S
57M99
G51 MP-24B-045 G51 MP*36B-045 G51 MP-36B-070 G51/61 MP-48C_090 G51/61MP-60C-090 G51MP-48Cq G51MP*60Cq
10 10
10 10
G61MP-60D_135
Refer to figure 1 or figure 2 when disassembling unit.
4-
Remove gas supply line connected to gas valve. Remove gas valve/manifold assembly.
5 - Remove sensor wire from sensor. Disconnect 2-pin plug from the ignitor. 6 - Disconnect wires from flame roll-out switches. 7 - Disconnect air intake piping from burner box. NOTE - It may be necessary to cut air intake pipe. 8 - Remove burner box cover and remove four burner box screws at the vestibule panel and remove burner box. Set burner box assembly aside. NOTE - G61MP-135 units are secured to the vestibule panel by two additional screws which are required to secure the assembly during shipping. These screws must be removed for servicing; however it is not necessary to replace these screws.
ELECTROSTATIC DISCHARGE (ESD) Precautions and Procedures
I
_
CAUTION
9 - Loosen three clamps and remove flexible exhaust tee. 10 - Remove 3/8 inch rubber cap from condensate drain plug and drain. Replace cap after draining. 11 - Disconnect condensate drain line from the condensate trap. Remove condensate trap (it may be necessary to cut drain pipe). Remove screws that secure condensate collars to either side of the furnace and remove collars. Remove drain tubes from cold end header collector box. 504,767M
06/03
IIIIIIIIIIIIIIIIIIIIIIltlllIIIIIltllllll
Page1
IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII
12- Disconnect condensate draintubingfromfluecollar. Removescrewsthatsecurebothflue collarsinto place.Removefluecollars.It maybenecessaryto cuttheexitingexhaustpipeforremovalofthefittings. 13- Markanddisconnectall combustionair pressure tubingfromcold endheadercollectorbox.Keep tubingattachedtopressureswitches. 14- Markand removewiresfrom pressureswitches, Removepressure switches. Keeptubingattached to pressureswitches. 15-Disconnectthe 2-pin or 3-pin plug from the combustion airinducer.Disconnect thetwowiresto the back-upsecondarylimit,if applicable. Remove fourscrewswhichsecurecombustion airinducerto collector box Removecombustionair inducer assembly. Removegroundwirefromvestpanel. 16- Removeelectricaljunctionboxfromthesideofthe furnace. 17- Markanddisconnect anyremaining wiringtoheating compartment components. Disengagestrainrelief bushingandpullwiringandbushing throughthehole intheblowerdeck, 18- Removetheprimarylimitfromthevestibulepanel. 19- Removetwoscrewsfromthefrontcabinetflangeat the blowerdeck.Spreadcabinetsidesslightlyto allowclearance forremovalof heatexchanger. 20- Removescrewsalongvestibulesidesandbottom whichsecurevestibulepanelandheatexchanger assemblyto cabinet,Removetwo screwsfrom blowerrailwhich securebottomheatexchanger flange. Removeheat exchangerfrom furnace cabinet. 21-Install replacement heat exchangerinto cabinet, makingsure that clamshellsof heat exchanger assemblyare restingonthe supportlocatedat the rearofthecabinet. Remove theindoorblowertoview thisareathroughthe bloweropening. 22- Re-secure thesupporting screwsalongthevestibule sidesandbottomtothecabinet.
29- Carefullyconnectcombustionairpressureswitch hosingfrompressureswitchestoproperstubson coldendheadercollectorbox.
,&WARNING
30 - Reinstall condensate
collars on each side of the
furnace, Reconnect drain tubing to collector box. 31 - Reinstall condensate trap, Reconnect condensate drain line to the condensate trap. 32 - Use securing screws to reinstall flue collars to either side of the furnace, Reconnect exhaust piping and exhaust drain tubing. 33-Replace flexible exhaust tee on combustion air inducer and flue collars. Secure using three existing hose clamps. 34 - Reinstall burner box assembly in vestibule area. Reconnect sensor wire and reconnect 2-pin plug from ignitor. 35 - Reconnect flame roll-out switch wires. 36 - Secure burner box assembly to vestibule panel using four existing screws. Make sure burners line up in center of burner ports. NOTE - It is not necessary to reinstafl two additional screws on -!35 models. These screws are necessary shipping.
only
to secure
the assembly
during
37 - Reinstall air intake piping, 38 - Reinstall gas valve manifold assembly. Reconnect gas supply line to gas valve. Use a leak detecting solution or other preferred means to check gas connections for leaks,
,A CAUTION
23- Reinstallcabinetscrewsonfrontflangeat blower deck. 24- Reinstalltheprimarylimitonthevestibulepanel, 25- Routeheatingcomponentwiringthroughholein blowerdeckandreinsertstrainreliefbushing, 26- Reinstallelectrical junctionbox. 27- Reinstallthecombustion airinducer.Reconnect the 2-pinor 3-pinplugto thewireharness.Reconnect the two wiresto the back-upsecondarylimit, if applicable, 28- Reinstallpressureswitches andreconnect pressure switchwiring.
39 - Reinstall bumer box cover. 40 - Reconnect wires to gas valve. 41 - Replace the blower compartment access panel. 42 - Refer to instruction on verifying gas and electrical connections when re-establishing supplies. 43-Follow lighting instructions to light and operate furnace for 5 minutes to ensure that heat exchanger is clean and dry and that furnace is operating properly. 44 - Replace heating compartment access panel.
Page 2
G51MP
PARTS
SHIPPING SCREWS (-135 only)
IDENTIFICATION
DuraIokPIus TM HEAT EXCHANGER ASSEMBLY
BURNER BOX ASSEMBLY
GAS VALVE AND MANIFOLD
FLUE COLLAR
COMBUSTION AIR PRESSURE PROVE SWITCHES
WARM HEADER (COLLECTOR) BOX
COMBUSTION AIR'*'_ INDUCER CONDENSER BURNER ACCESS PANEL
PRIMARY LIMIT
/_, _ _, / _ BLOWER ACCESS DOOR
COLD HEADER (COLLECTOR) BOX
DOOR INTERLOCK SWITCH
Cb
SECONDARY LIMITS (2)
\
BLOWER ASSEMBLY
SIGHT GLASS CONTROL BOX
FIGURE 1
Page 3
COIL
G61MP
SHIPPING
PARTS
IDENTIFICATION
DuraIokPlus TM HEAT EXCHANGER ASSEMBLY
SCREWS
(-135 only)
BURNER BOX ASSEMBLY
GAS VALVE AND MANIFOLD
FLUE COLLAR
COMBUSTION AIR PRESSURE PROVE SWITCHES* COMBUSTION INDUCER
WARM HEADER (COLLECTOR) BOX AIR CONDENSER
BURNER ACCESS PANEL
PRIMARY LIMIT
COLD HEADER (COLLECTOR) BOX BLOWER ACCESS DOOR
-.....
DOOR INTERLOCK SWITCH
SECONDARY LIMITS (2)
\ *G61MP=090 shown. G61MP4145and=070 are equtpped with two sw_ches.
BLOWER ASSEMBLY
SIGHT GLASS CONTROL BOX
FIGURE 2
Page 4
COIL
