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Lennox G25MV Series User manual

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Page 1 1995 Lennox Industries Inc.
LITHO U.S.A.
Corp. 9505–L2
G25MV
Service Literature
G25MV SERIES UNITS
G25MV series units are mid–efficiency gas furnaces
manufactured with tubular steel heat exchangers
formed of aluminized steel. G25MV units are available
in heating capacities of 60,000 to 120,000 Btuh (17.6 to
35.2 kW) and cooling applications from 1.5 through 5
tons (3.5 through 17.6 kW). Refer to Engineering Hand-
book for proper sizing.
Units are factory equipped for use with natural gas. All
G25MV units use a hot surface ignition system. The
G25MV units meet the California Nitrogen Oxides (NOx)
Standards and California Seasonal Efficiency require-
ments. All units use a two stage gas valve along with a
two stage induced draft blower assembly. The gas valve
is redundant to assure safety shut–off as required by
A.G.A. or C.G.A.
All G25MV units are equipped with an electronic vari-
able speed (VSM) fan motor. The VSM motor maintains
a specified air volume throughout the entire external
static range.
Units may be installed in upflow, downflow or horizon-
tal position. The heat exchanger is designed for upright
or horizontal use only. When the unit is installed in the
downflow position, the heat exchanger is field re-
moved and reinstalled so it is upright when the cabinet
is inverted. No field conversion is required when the
unit is installed in the horizontal position.
The heat exchanger, burners and manifold assembly
can easily be removed for inspection and service by sim-
ply disconnecting gas, unplugging wiring harnesses
and removing four screws holding the heat exchanger in
place. The heat exchanger slides out of the cabinet.
Information contained in this manual is intended for use
by Lennox service technicians only. All specifications
are subject to change. Procedures outlined in this manu-
al are presented as a recommendation only and do not
supersede or replace local or state codes.
G25MV
Page 2
SPECIFICATIONS
Model No. G25MV3-60 G25MV3-75 G25MV5-100 G25MV5-120
Input Btuh (kW) high fire 60,000 17.6) 75,000 (22.0) 100,000 (29.3) 120,000 (35.2)
Output Btuh (kW) high fire 48,000 (14.1) 60,000 (17.6) 80,000 (23.4) 96,000 (28.1)
A.F.U.E. 80.0% 80.0% 80.0% 80.0%
Input Btuh (kW) low fire 40,800 (12.0) 51,000 (15.0) 68,000 (20.0) 81,600 (24.0)
Flue size connection diameter — in. (mm) round 3 (76) 4 (102) 4 (102) 4 (102)
Temperature rise range — F (C) 30 – 60 (17 – 33) low fire
40 – 70 (22 – 39) high fire
High static certified by A.G.A./C.G.A. — in wg. (Pa) .80 (200) .80 (200) .80 (200) .80 (200)
Gas Piping Size I.P.S. Natural gas only 1/2 (13) 1/2 (13) 1/2 (13) 1/2 (13)
Blower wheel nominal
di id h
in. 10 x 7 10 x 7 12 x 9 12 x 9
diameter x width mm 254 x 178 254 x 178 305 x 229 305 x 229
Blower motor output — hp (W) 1/2 (373) 1/2 (373) 1 (746) 1 (746)
Unit minimum circuit ampacity (amps) 12.2 18.2
Unit maximum fuse or circuit breaker size 15.0 20.0
Electrical characteristics 120 volts — 60 hertz — 1 phase
Nominal cooling
hbddd
Tons 2, 2-1/2 or 3 2, 2-1/2 or 3 3-1/2, 4 or 5 3-1/2, 4 or 5
g
that can be added kW 7.0, 8.8 or 10.6 7.0, 8.8 or 10.6 12.3, 14.1 or 17.6 12.3, 14.1 or 17.6
Up-flow/Horizontal Filter Kit (furnished) — filter size (1) 16 x 20 x 1 (406 x 508 x 25) (1) 20 x 20 x 1 (508 x 508 x 25)
Shipping weight — lbs. (kg) 1 package 135 (61) 135 (61) 175 (79) 175 (79)
Optional Accessories (Must Be Ordered Extra) 
Down-flow
Fil Ki
Catalog No. LB-69843A (32J01) — 3 lbs. (1 kg)
Filter Kit No. & Size of Filters — in. (mm) (2) 16 x 20 x 1 (406 x 508 x 25)
Down-flow Combustible Floor Base LB-79239A (67J91) — 10 lbs. (4 kg) LB-79239B (67J92) — 10 lbs. (4 kg)
Hanging Bracket Kit LB-69957 (46J66) — 15 lbs. (7 kg)
Annual Fuel Utilization Efficiency based on U.S. DOE test procedures and according to FTC labeling regulations. Isolated combustion system rating for non-weatherized
furnaces.
Filters are not furnished with kit and must be ordered extra. Polyurethane frame type filter is furnished with kit.
2 in. x 3 in. (51 mm x 76 mm) flue adaptor furnished with -60 input furnaces for connection to furnace induced draft blower.
2 in. x 4 in. (51 mm x102 mm) flue adaptor furnished with -75, -100 & -120 input furnaces for connection to furnace induced draft blower.
BLOWER PERFORMANCE DATA
G25MV3-60 & G25MV3-75 BLOWER PERFORMANCE
0 through 0.80 in. w.g. (0 Through 200 Pa) External Static Pressure Range
VSP2-1 Blower Control — Factory Settings
G25MV3-60 = Low Speed — 1 / High Speed — 4 / Heat Speed — 1
G25MV3-75 = Low Speed — 3 / High Speed — 4 / Heat Speed — 2
“ADJUST”
VSP2-1 Jumper Speed Positions
“ADJUST”
Jumper
“LOW” Speed (Cool Or Continuous Fan) “HIGH” Speed (Cool) “HEAT” Speed
Jumper
Setting 1 2 3 4 1 2 3 4 1 2 3 4
g
cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s
NORM 640 300 740 350 890 420 1030 485 1060 500 1100 520 1260 595 1340 630 850 400 1050 495 1280 605 1370 645
—600 285 680 320 810 380 920 435 930 440 1020 480 1130 535 1200 565 780 370 945 445 1160 545 1240 585
NOTE — The effect of static pressure and filter resistance is included in the air volumes listed.
G25MV5-100 & G25MV5-120 BLOWER PERFORMANCE
0 through 0.80 in. w.g. (0 Through 200 Pa) External Static Pressure Range
VSP2-1 Blower Control — Factory Settings
G25MV5-100 = Low Speed — 2 / High Speed — 4 / Heat Speed — 1
G25MV5-120 = Low Speed — 3 / High Speed — 4 / Heat Speed — 2
“ADJUST”
VSP2-1 Jumper Speed Positions
“ADJUST”
Jumper
“LOW” Speed (Cool Or Continuous Fan) “HIGH” Speed (Cool) “HEAT” Speed
Jumper
Setting 1 2 3 4 1 2 3 4 1 2 3 4
g
cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s
NORM 690 325 1170 550 1440 680 1480 700 1620 765 1820 860 2000 945 2100 990 1420 970 1720 810 2030 960 2150 1015
—580 275 1050 495 1280 605 1360 640 1350 635 1550 730 1700 800 1800 850 1280 605 1550 730 1800 850 1900 895
NOTE — The effect of static pressure and filter resistance is included in the air volumes listed.
NOTE — Do not adjust jumper settings (CFM) below tap# 2 “NORMAL” for both “LOW” speed and “HEAT” speed for the G25MV5–120 units only.
Page 3
FIGURE 1
G25MV
PARTS IDENTIFICATION
VENT ADAPTER CABINET TOP
G25MV
CABINET
CABINET
BOTTOM
HEAT EXCHANGER
ASSEMBLY
BURNER
ASSEMBLY
BLOWER
ASSEMBLY
COMBUSTION AIR
BLOWER
FLUE BOX
SECONDARY
LIMITS
FRONT LOUVERED
PANEL
DOOR INTERLOCK SWITCH
BURNER
CONTROL
BOARD
TRANSFORMER
PRESSURE
SWITCHES
NOx
TURBULATOR
VSP2
BOARD
FLUE THERMOSTAT
VARIABLE SPEED
BLOWER MOTOR
PRIMARY
LIMIT
G25MV BLOWER DOOR COMPONENTS – BLOWER ACCESS
FIGURE 2
W
W
BRN
BRN
BLK
BURNER
CONTROL (A3)
VSP2
CONTROL (A24)
TRANSFORMER
(T1)
DOOR INTERLOCK
SWITCH (S51)
TRANSFORMER
CIRCUIT BREAKER (CB8)
G25MV SHOWN
IN UPFLOW
POSITION
Page 4
I–UNIT COMPONENTS (Figure 1)
G25MV unit components are shown in figure 1. The
blower controls, gas valve and burners can be accessed
by removing the front access panel. A separate blower
access door is located behind the front access panel.
Electrical control components are mounted to the
blower access door. Units are factory equipped with
bottom return air panels
A–Blower Door Components (Figure 2)
Electrical burner control and blower control components
are located on the outside surface of the blower access
door. Jackplugs allow the blower door to be easily re-
moved for blower service.
Located on the blower door are the unit transformer
(T1), burner control (A3), VSP2 blower control board
(A24), and door interlock switch (S51).
1– Control Transformer (T1)
A transformer located on the blower door provides power
to the low voltage section of the unit. Transformers on all
models are rated 50VA with a 120V primary and a 24V
secondary. The transformer is protected by a 3.0 amp
circuit breaker.
2–Door Interlock Switch (S51)
A door interlock switch rated 16A at 125VAC is located
on the blower access door. The switch is wired in series
with line voltage. When the blower door is removed the
unit will shut down.
3– Burner Control (A3)
All G25MV units utilize a burner control manufactured
by RAM Electronics Corporation. The “RAM” board is
a printed circuit board which controls the gas valve,
combustion air blower and ignition. It also monitors
the flame, limit and gas valve operation. The board
utilizesboth120and24VAC.Seefigure3.Theboardis
equipped with a diagnostic LED for use when trouble-
shooting the unit.
Whenthe furnaceis idle(blower offand noheating or
cooling demand), the diagnostic LED flashes at a
slow steady rate. On a call for heat, the diagnostic
LED begins flashing at a fast rate and the combustion
air blower is energized. The LED flashes different
codes to indicate problem conditions. The diagnostic
LED lights red (not flashing) to indicate control board fail-
ure. Table 1 shows how to interpret the other LED modes.
Pre-Purge
On a call for heat, the combustion air blower begins
operating. If the combustion air prove switch closes,
the combustion air blower continues to operate for
30seconds (pre-purge) before allowing ignition. Pre-
purge allows the heat exchanger to be cleared of
combustion products and to introduce fresh air for
combustion. If the combustion air prove switch does
notclose,the combustionair blower continues torun
indefinitely (until the prove switch closes).
Post-Purge
After a demand, the combustion air blower continues
to operate for 5 seconds (post-purge) before stopping.
Post-purge allows the heat exchanger to be cleared of
combustion products.
Ignition Control
The ignition control is a hot surface ignition control
module integral to the burner control. See table 2 and
figure 3. When there is a call for heat, the control delays
ignition until combustion air blower operation has been
proved and pre-purge period has elapsed. It then ener-
gizes a hot surface for 35 seconds. At the end of the 35
seconds the main gas valve opens on high fire. Trial for
ignition lasts for 7 seconds. At the same time, the control
begins monitoring the flame sensor. If the flame current
is too weak (less than 1 microamp) or if the burners do
not ignite (within the 7 second ignition trial), the control
will shut off the hot surface ignitor and the combustion
air blower and de-energize the gas valve. Flame current
should be between 1 and 5 microamps to keep the gas
valve open.
The control will attempt to ignite the burners up to two
more times. Each time the control restarts the ignition
sequence, it begins with a 30 second pre-purge. If flame
is not sensed after the third trial, the control locks out.
Lockout means that the control shuts off the gas valve,
spark and combustion air blower for 60 minutes. At the
end of 60 minutes the control completely resets and
will attempt ignition up to three times. The control
can be manually reset before the end of 60 minutes
by momentarily turning off power to the unit.
When flame is sensed, the indoor blower starts after a
45 second delay. Gas valve remains open and blower
continues to run until demand stops, flame sensor
senses loss of flame, a limit opens or the combustion
air prove switch opens. If any of these events occur
during a thermostat demand, the gas valve closes
and the diagnostic LED registers the error condition.
Page 5
G25MV BURNER CONTROL (A3)
FIGURE 3
LINE VOLTAGE
TERMINAL
CONNECTIONS
24VAC VOLT
TERMINAL
CONNECTIONS
THERMOSTAT
CONNECTIONS (TB1)
DIAGNOSTIC
LED
See Table 3 for
Terminal
Functions
PLUG P20
12
1
See Table 2 for
Terminal
Functions
3
Diagnostic LED
The burner control is equipped with a diagnostic LED
used for troubleshooting the unit and the control. LED
functions are shown in table 1.
TABLE 1
Burner Control A3 Diagnostic LED
LED State Meaning Remedy
Steady On Control Failure Replace Control
Slow Flash Normal Operation
and No Call For Heat - - - -
Fast Flash Normal Operation
with Call For Heat - - - -
Two
Flashes Control Lockout
Failed to Sense or Sustain
Flame. Check Gas Valve,
Burners, Hot Surface Ignitor
and Wire, Flame Sensor.
Replace Control If All OK.
Three
Flashes Pressure Switch Open
Failed to Prove Combustion
Blower Operation or
Blocked Vent. Repair or
Replace as Necessary.
Four
Flashes Open Limit
Check Primary Limit, Rollout
Switches and Secondary
Limits. Find source of Over
temperature. If all OK, Reset
or Replace Limits as
Necessary.
Five
Flashes Flame Sensed and Gas
Valve Not Energized. Check Gas Valve. If OK,
Check Flame Sensor.
Six
Flashes Failed Hot Surface
Ignitor
Check Hot Surface Ignitor
Voltage. If OK,
Replace Ignitor
DANGER
Shock hazard.
Disconnect power before servicing. Control is not
field repairable. If control is inoperable, simply
replace entire control.
Can cause injury or death. Unsafe operation will
result if repair is attempted.
TABLE 2
BURNER CONTROL JACK/PLUG 20 TERMINAL DESIGNATIONS
Pin # Function
1High Fire Pressure Switch Output
2Low Valve Output
3Low Fire Pressure Switch Output
4Blank
5Limits Input
6High Limit Input
7Flame Sensor
8Limits Output
9Valve Return
10 Blank
11 Ignitor Return
12 Ignitor Output
Page 6
TABLE 3
BURNER CONTROL A3 TERMINAL DESIGNATIONS
Terminal Type Function
24VAC OUT 1/4” Spade 24VAC Out To VSP2
24VAC HOT 1/4” Spade 24VAC In From Transformer
24VAC RTN 1/4” Spade 24VAC In From VSP2
GROUND 1/4” Spade To Cabinet Ground
GScrew Strip Blower Demand
DS Screw Strip Input Harmony Zone Control
Y1 Screw Strip First Stage Cooling Demand
Y2 Screw Strip Second Stage Cooling Demand
CScrew Strip 24VAC Common
W2 Screw Strip Second Stage Heating Demand
W1 Screw Strip First Stage Heating Demand
RScrew Strip 24VAC to Thermostat
G1/4” Spade Blower Demand to VSP2
DS 1/4” Spade Harmony Zone To VSP2
IDR HI 1/4” Spade 120VAC Out To High Speed
Combustion Air Blower (B6)
IDR LO 1/4” Spade 120VAC Out To Lo Speed
Combustion Air Blower (B6)
120VAC RTN 1/4” Spade 120VAC Return From
Combustion Air Blower (B6)
120VAC RTN 1/4” Spade 120VAC Return From (T1)
120VAC HOT 1/4” Spade 120VAC In From Door
Interlock Switch (S51)
120VAC HOT 1/4” Spade 120VAC Output To Control
Transformer (T1)
120VAC HOT 1/4” Spade 120VAC To Blower Motor (B3)
ACCA 1/4” Spade Accessory Cooling Terminal
ACCH 1/4” Spade Accessory Heating Terminal
TERM #12 1/4” Spade 24VAC Accessory Input
S102 IN 1/4” Spade 24VAC In From High Fire
Pressure Switch
HI VLV 1/4” Spade 24VAC Out To Gas Valve (GV1)
S101 IN 1/4” Spade 24VAC In From Flue Thermostat
S101 OUT 1/4” Spade 24VAC Out To Flue Thermostat
VSP #3 1/4” Spade Second Stage Heat Output–VSP2
VSP #5 1/4” Spade Limit Output To VSP2
4–VSP2 Blower Control Board (A24)
G25MV units are equipped with a variable speed motor
that is capable of maintaining a specified CFM through-
out the external static range. The unit uses the VSP2–1
variable speed control board, located on the blower
access door, which controls the blower speed and
provides diagnostic LEDs. The control has both a
non–adjustable, factory preset “ON” fan timing delay and
an adjustable “OFF” fan timing delay (see figure 6).
The VSP2–1 also senses limit trip condition and turns on
the blower. The G25MV limit switch is located in the
middle of the vestibule wall. When excess heat is sensed
in the heat exchanger, the limit switch will open and
interrupt the current to the gas valve, while at the same
time the VSP2–1 energizes the blower on heating speed.
The limit automatically resets when the unit temperature
returns to normal and the blower is de–energized.
Diagnostic LEDs located on the VSP2–1 control board are
provided to aid in identifying the unit’s mode of operation.
Certain scenarios will arise depending on the jumper
positions. Refer to figure 4 for identification.
IMPORTANT
24 VAC half wave rectified (DC pulse), when
measured with a meter, may appear as a lower
or higher voltage depending on the make of
the meter. Rather than attempting to measure
the output voltage of A24, see G25MV BLOWER
& VSP2 BLOWER CONTROL BOARD TROUBLE-
SHOOTING FLOW CHART in the TROUBLE-
SHOOTING section of this manual.
JP2
HIGH LOW ADJUST HEAT
CFM
HI/LOW
ON/OFF
HEAT
HTG.
BLOWER
12
DS2
DS3
DS1
DS4
1
2
3
4
1
2
3
4
1
2
3
4
TEST
–
+
NORM
210
150
90
270
JP1
VSP2–1 VARIABLE SPEED CONTROL BOARD SELECTIONS
FIGURE 4
DIAGNOSTIC
DS LEDS
FAN “OFF”
TIMING PINS
JP46
13 PIN PLUG
(BOARD TO MOTOR)
HEATING STAGE
JUMPER SELECTOR PINS
JP73
15 PIN PLUG
(BOARD TO VARIOUS
POINTS IN FURNACE)
HIGH SPEED
SELECTOR PINS
(COOLING ONLY)
LOW SPEED
SELECTOR PINS
(COOLING AND HEATING)
HEATING SPEED
SELECTOR PINS
OPERATIONAL
SELECTOR PINS
(Affects both heating
and cooling modes)
1
1
Page 7
FIGURE 5
VSP2 BLOWER CONTROL BOARD (A24)
VOLTAGES INTO VSP2
VOLTAGES FROM VSP2 TO ELECTRONICALLY
CONTROLLED BLOWER MOTOR
34 volts
–34 volts
0 volts
Voltage across J73 pins 13 to 1 and 6 to 1 is 24VAC as shown here.
Refer to unit wiring diagram.
Voltage across J46 pins 6 to 3 and 1 to 3 is half-rectified AC as shown here.
Refer to unit wiring diagram.
Voltage across J73 pins 4 to 1 is approximately 15-20VDC (straight voltage) if
CCB is used. If Harmony is used a voltage of 0–25VDC should be present.
If CCB or Harmony is not used, pin 4 to 1 voltage is 21VAC.
Approx.
34 volts
0 volts
Voltage across J46 pins 8 and 9 to 3, is approximately 15-20VDC if CCB is used. If CCB
or Harmony is not used, pins 8 and 9 to 3 voltage is approximately 21VAC. If Harmony
is used a voltage of 0–25VDC should be present.
24VAC @ 60Hz.
24VAC Half-Rectified (DC Pulse)
@ 60Hz.
J46
HIGH LOW ADJUST HEAT
CFM
HI/LOW
ON/OFF
HEAT
HTG.
BLOWER
12
DS2
DS3
DS1
DS4
1
2
3
4
1
2
3
4
1
2
3
4
TEST
–
+
NORM
210
150
90
270
J73
1
1
J73
PIN 1 - C - 24 VAC common.
PIN 2 - G - Input signal from thermostat’s fan signal.
PIN 3 - W2 - Input signal for second stage heat from the thermostat.
PIN 4 - DS - Input signal for the blower speed regulation.
PIN 5 - Limit - Input signal from the external limit.
PIN 6 - R - 24 VAC power to the thermostat.
PIN 7 - C - 24 VAC common.
Pin 8 - C - 24 VAC common.
PIN 9 - CI - Input signal from the fan limit control.
PIN 10 - CO - Output signal to the burner control.
PIN 11 - HT - Input signal from the fan limit control.
PIN 12 - ACC - 24 VAC accessory output.
PIN 13 - 24V - Input 24 VAC power for the VSP2-1.
PIN 14 - 24V - Input 24 VAC power for the VSP2-1.
PIN 15 - V - Input signal from the gas line.
J46
PIN 1 - Heat - Heat speed input signal to the ICM2 motor.
PIN 2 - C - 24 VAC common.
PIN 3 - C - 24 VAC common.
PIN 4 - High Tap - High Speed programming input.
PIN 5 - Low Tap - Low speed programming input.
PIN 6 - On / Off - On / off output signal to the ICM2 motor.
PIN 7 - Adjust Tap - ICM2 mode selection.
PIN 8 - Hi / Low - Speed regulate input signal to the ICM2 motor.
PIN 9 - Hi / Low - Speed regulate input signal to the ICM2 motor.
PIN 10 - Ref. V - ICM2 reference voltage.
PIN 11 - Heat Tap - Heating blower speed programming.
PIN 12 - C - 24 VAC common.
PIN 13 - cfm - Motor speed diagnostic signal.
Diagnostic LED Lights
 
ON/OFF–DS3 indicates there is a demand for the blower
motor to run. When the ON/OFF LED–DS3 is lit, a demand
is being sent to the motor. In heating mode only, there is a
45 second fan “ON” delay in energizing ON/OFF
LED–DS3. The light will not go off until adjustable fan
“OFF” delay has expired.
If ON/OFF LED–DS3 is on and both HIGH/LOW LED–DS1
& HEAT LED–DS2 are off, the motor will operate in
low speed.
 
If HEAT LED–DS2 is on, the blower is running in the heat
speed according to the “HEAT” jumper setting. The
HEAT LED–DS2 comes on instantaneous and switches
off when the call for heat is satisfied.
NOTE–When the blower is in “OFF” delay mode, the
motor runs at low speed, therefore the HEAT LED–DS2
is off. It switches off when the call for heat is satisfied.
 
HIGH/LOW LED–DS1 indicates whether the blower is
operating in high or low speed. When the light is off, the
blower is running in low speed according to the “LOW”
jumper setting. When HIGH/LOW LED–DS1 is on, the
blower is operating in high speed according to the
“HIGH” jumper setting.
 
CFM LED–DS4 indicates the CFM the unit is operating,
according to the jumper settings. The light flashes
once for approximately every 100 CFM. For example, if
the unit is operating at 1000 CFM, CFM LED–DS4 will
flash 10 times. If the CFM is 2050, CFM LED–DS4 will
flash 20 full times plus one fast or half flash.
At times the light may appear to flicker or glow. This
takes place when the control is communicating with the
motor between cycles. This is normal operation.
The appropriate speed according to application and
CFM need is selected by moving jumper pins.
NOTE–On Harmony II zoning applications in the heating
mode, the highest speed obtainable is the same as the
highest cooling speed selection. Also, the heating speed
(heat jumper position) is only used when the primary limit
has been tripped. In non–zoning applications, refer to the
section on the VSP2–1 control.
Jumper Settings
IMPORTANT
Before changing jumper setting, make sure the
motor has completely stopped. Any jumper
setting change will not take place while the
motor is running.
Page 8
To change jumper positions, gently pull the jumper off the
pins and place it on the desired set of pins. The following
section outlines the different jumper selections available
and conditions associated with each one. Refer to figure 4
for identification.
After the CFM for each application has been determined,
the jumper settings must be adjusted to reflect those
given in the tables on page 2. Using the tables, determine
which row of CFM volumes most closely matches the
desired CFM. Once a specific row has been chosen
(NORMALor–),CFMvolumes from other rowscannot
be used. Below are the descriptions of each of the
jumper selections.
Refer to table 4 for factory settings. Refer to the tables on
page 2 for the approximate air volume for each setting.
TABLE 4
MODEL
NUMBER
G25MV3-60
G25MV3-75
VSP2–1 FACTORY SETTINGS
HIGH LOW HEAT
141
243
ADJUST
NORM
NORM
G25MV5-100 241
243
NORM
NORM
G25MV5-120
 
The ADJUST pins allow the motor to run at normal speed
or approximately 10% lower than normal speed. The
tables on page 2 give two rows (NORMAL and –) with
their respective CFM volumes. The + adjustment setting
is not operable. Notice that the normal adjustment
setting for heat speed position #3 is 2030 CFM (960
L/s). After the adjustment setting has been determined,
chose the remaining speed jumper settings from
those offered in the table.
The TEST pin is available to bypass the VSP2–1 control
and run the motor at approximately 70% to test that the
motor is operational. This is beneficial primarily in
troubleshooting. G must be energized for motor to run.
  
For G25MV units, place the   jumper
across the second and third pins (position #2).
When W1 is energized, the  jumper selections are
activated. The HEAT jumper selections are activated
when W2 is energized.
NOTE–In Harmony II zoning applications, HEATING
BLOWER jumper must be in position #2.
 
The HEAT jumper is used to set the blower speed to
obtain the required CFM as outlined in HEAT SPEED
section of the tables on page 2.
The HEAT jumper selections are activated with a call for
second-stage heating (W2).
IMPORTANT
Before changing jumper setting, make sure the
motor has completely stopped. Any jumper set-
ting change will not take place while the motor
is running.
 
The HIGH jumper is used to determine the CFM during
cooling speed. These jumper selections are activated
when G and DS terminals are energized.
 
The LOW jumper is used to determine CFM during low
speed cooling. These jumper selections are activated
when G is energized. The LOW jumper may also be used
for low speed heating. See the “HEAT” section for details.
 
Fan “OFF” timings (time that the blower operates after
the heat demand has been satisfied) are determined by
the arrangement of a jumper on the VSP2–1 board. See
figure 6. To adjust fan “OFF” timings, gently disconnect
the jumper and reposition it across pins corresponding
with the new timing. Fan “OFF” time is factory set at
270 seconds. The control has a non–adjustable, factory
preset “on” fan timing (45 seconds).
      
    
FIGURE 6
FAN-OFF TIME ADJUSTMENT
270 210
150 90
To adjust fan–off timings:
Remove jumper from VSP2–1 and
select one of the other pin com-
binations to achieve the desired
time.
TIMING
JUMPER
TIMING PINS (seconds)
Leave jumper off to achieve
330 second fan–off timing.
Fan-off timing is factory
set at 270 seconds
NOTE—If fan “OFF” time is too low, residual heat in
heat exchanger may cause primary limit S10 to trip
resulting in frequent cycling of blower. If this occurs,
adjust blower to longer time setting.
Table 5 outlines the operation of the variable speed
motor in relation to specific modes of operation. Some
information has been repeated from the previous section
to provide an example. Refer to each diagnostic LED or
jumper settings section for more information.
Page 9
TABLE 5
VSP2–1 OPERATION
HEATING MODE COOLING MODE
UNITS WITH
SINGLE–STAGE HEATING
UNITS WITH
TWO–STAGE HEATING
UNITS WITH SINGLE–
SPEED COMPRESSOR
UNITS WITH TWO–SPEED
COMPRESSOR
NON–ZONED
APPLICATIONS
When a single-stage thermostat is
used and full heating input of the
unit is required, jump terminals W1
and W2 on the burner control
board.
The HEAT LED-DS2 is lit when the
thermostat calls for heat. The ON/
OFF LED-DS3 is lit after 110 seconds
(65 seconds pre-purge and 45 se-
conds fan “ON” time) from the time
a call for heat is made. This indicates
the blower is operating in heating
speed.
NON–ZONED
APPLICATIONS
Using a two-stage thermostat with
first-stage (W1) calling, the ON/OFF
LED-DS3 is lit to indicate the blower
is operating in low speed.
When the ON/OFF LED-DS3 and
HEAT LED-DS2 are lit, the blower is
operating in heating speed and se-
cond-stage (W2) heating is calling.
HEAT LED-DS2 is lit with a call for
heat from the thermostat. ON/OFF
LED-DS3 is lit after 110 seconds
from the time a call for heat is made.
NOTE—In two-stage operation and
when there is a call for first-stage
only, the unit will always start on
high heat (second-stage) and will
automatically switch to first-stage
operation after initial unit warm-up.
NON–ZONED
APPLICATIONS
The terminals “DS” and “Y” must be
jumpered together. With a call for
cooling, terminals G, Y and DS on
the unit control board are energized
from the thermostat. HI/LOW LED–
DS1 and ON/OFF LED–DS3 are lit to
indicate the blower is operating on
high speed.
NOTE—“Y” and “DS” must be
jumpered for single-stage cooling,
non-zoned applications.
NON–ZONED
APPLICATIONS
The ON/OFF LED–DS3 is lit to indicate
the blower is operating in first stage
cooling. This LED is energized on
when a 24VAC thermostat demand is
supplied to the control (terminal “G”
on the control box terminal strip).
In second stage, the ON/OFF LED–
DS3 and HI/LOW LED–DS1 are lit to
indicate the blower is operating on
high speed (24VAC is supplied to the
unit terminal strip “Y2” from “Y2”
on the thermostat).
NOTE—“Y2” must be jumpered to
“DS” in two–speed, non–zoned
applications.
HARMONY ZONED
APPLICATIONS
The blower speed is controlled by
the PWM (pulse width modulation)
signal sent from the control center
of the zoning system to the terminal
strip’s “DS” terminal. HI/LOW LED–
DS1 and ON/OFF LED–DS3 are lit to
indicate the blower is operating.
NOTE–In Harmony II zoning ap-
plications, HTG. BLOWER jumper
must be in position #2.
HARMONY ZONED
APPLICATIONS
The blower speed is controlled by
the PWM (pulse width modulation)
signal sent from the control center
of the zoning system to the terminal
strip’s “DS” terminal. HI/LOW LED–
DS1 and ON/OFF LED–DS3 are lit to
indicate the blower is operating.
NOTE–In Harmony II zoning ap-
plications, HTG. BLOWER jumper
must be in position #2.
HARMONY ZONED
APPLICATIONS
The blower speed is controlled by
the PWM (pulse width modulation)
signal sent from the control center
of the zoning system to the terminal
strip’s “DS” terminal. HI/LOW LED–
DS1 and ON/OFF LED–DS3 are lit to
indicate the blower is operating.
HARMONY ZONED
APPLICATIONS
The blower speed is controlled by
the PWM (pulse width modulation)
signal sent from the control center
of the zoning system to the terminal
strip’s “DS” terminal. HI/LOW LED–
DS1 and ON/OFF LED–DS3 are lit to
indicate the blower is operating.
NOTE: For zone applications with Harmony, remove wire from VSP #3 terminal on burner control board, insulate end and secure
to prevent from shorting.
B–Blower Compartment (Figure 8)
Located inside the blower compartment are the variable
speed blower motor (B3), coil choke (L13), and the
secondary limit switches [(1)S21 and (2)S21]. To access
the blower compartment follow the steps outlined below:
1– Remove the two screws holding the blower panel to
the unit.
2– Remove the two screws (located in the middle of the
blower panel) holding the grommet for the VSP2
JP46 wires.
3– Disconnect the jack (J46) from the VSP2 and feed it
through the blower panel.
4– Disconnect thermostat wires from the terminal strip
(TB1) on the burner control board.
5– Disconnect the 120VAC (black) wire from the burner
control board going to the coil choke and feed
through the blower panel grommet.
6– Disconnect line voltage wire (white) and feed through
the blower panel grommet.
7– Lift panel up and disconnect jack plugs JP1 and JP2
(brown wires) found in the blower compartment.
8– Remove wires from the wire clips located on the
blower panel allowing more wire for movement.
9– Place panel to the side, while servicing blower.
FIGURE 7
G25MV BLOWER DOOR COMPONENTS –
BLOWER ACCESS
W
W
BRN
BRN
BLK
G25MV
SHOWN
IN UPFLOW
POSITION
5
67
8
1
2
3
4
1
1– Blower Motor (B3)
G25MV units use a three-phase, electronically controlled
D.C. brushless motor (controller converts single phase
a.c. to three phase D.C.), with a permanent-magnet-type
rotor (figure 9). Because this motor has a permanent
Page 10
magnet rotor it does not need brushes like conventional
D.C. motors. Internal components are shown in figure 10.
The stator windings are split into three poles which are
electrically connected to the controller. This arrangement
allows motor windings to turn on and off in sequence
by the controller.
FIGURE 8
SUPPLY AIR BLOWER
AND SECONDARY LIMITS
BLOWER
MOTOR (B6)
To Remove Blower From Unit: Remove Bolts and
Wiring Jackplugs. Then Slide Out Front of Unit.
COIL
CHOKE (L13)
SECONDARY
LIMITS [(1)S21]
BLOWER
WHEEL
SECONDARY
LIMITS [(2)S21]
FIGURE 9
G25MV BLOWER MOTOR B3
MOTOR
CONTROLLER
SHAFT
J49
J48
G25MV BLOWER MOTOR COMPONENTS
FIGURE 10
STATOR
(WINDINGS)
OUTPUT
SHAFT
BEARING
ROTOR
A solid-state controller is permanently attached to
the motor. The controller is primarily an A.C. to D.C.
converter. Converted D.C. power is used to drive the
motor. The controller contains a microprocessor
which monitors varying conditions inside the motor
(such as motor workload).
The controller uses sensing devices to sense what posi-
tion the rotor is in at any given time. By sensing the posi-
tion of the rotor and then switching the motor windings
on and off in sequence, the rotor shaft turns the blower.
G25MV series blower motorratings are listed in table
6. All G25MV blower motors use single phase power.
An external run capacitor is not used. The motor uses
permanently lubricated ball-type bearings.
TABLE 6
ELECTRONICALLY CONTROLLED BLOWER MOTOR
CCW ROTATION
Unit Volts Phase HP
G25MV3 120 1
1
1/2
1G25MV5 120
Internal Operation
Each time the controller switches a stator winding (figure
10) on and off, it is called a “pulse.” The length of time
each pulse stays on is called the “pulse width.” By varying
the pulse width (figure 11), the controller varies motor
speed (called “pulse-width modulation”). This allows for
precise control of motor speed and allows the motor to
compensate for varying load conditions as sensed by the
controller. In this case, the controller monitors the static
workload on the motor and varies motor rpm in order to
maintain constant airflow (cfm).
The motor is equipped with 11 incremental taps which are
driven by the integral controller. The controller is capable
of controlling three of the 11 taps.
The motor controller is driven by the VSP2. The VSP2
receives its demand (PWM signal or fixed 24 VAC or
VDC signal) from optional controls such as the Harmony
zone control system, Efficiency Plus Humidity Control
(CCB1) or a conventional thermostat.
Motor rpm is continually adjusted internally to maintain
constant static pressure against the blower wheel. The
controller monitors the static work load on the motor and
motor amp-draw to determine the amount of rpm adjust-
ment. Blower rpm may be adjusted any amount in order
to maintain a constant cfm as shown in Blower Ratings
Tables. The amount of adjustment is determined by the
incremental taps which are used and the amount of motor
loading sensed internally. The cfm remains relatively
stable over a broad range of static pressure. Since the
blower constantly adjusts rpm to maintain a specified
cfm, motor rpm is not rated. Hence, the terms “blower
speed” and “speed tap” in this manual, on the unit wiring
diagram and on blower B3 refer to blower cfm regardless
of motor rpm.
When Harmony is used, speed taps are overridden and a
PWM signal generated by the Harmony controller contin-
uously varies motor speed based upon zone demands.
Initial Power Up
When line voltage is applied to B3, there will be a large
inrush of power lasting less than 1/4 second. This inrush
charges a bank of DC filter capacitors inside the controller.
If the disconnect switch is bounced when the disconnect
is closed, the disconnect contacts may become welded.
Try not to bounce the disconnect switch when applying
power to the unit.