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Lennox Pulse Heating Furnace Safety Notice - Heat Exchanger Inspection & Warranty Program
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• Lennox furnace safety notice, heat exchanger leak warning, free heat exchanger inspections
• Lennox furnace heat exchanger warranty program applies to furnaces sold in the U.S. & Canada
• Furnace recalls, heating system safety notices
• Lennox Pulse Furnace Warranty & Press Release
• Links to Lennox Pulse Furnace Manuals

This document describes carbon monoxide gas (CO) leak safety hazards on certain models of Lennox hot air heating furnaces and announces an inspection and recall/repair program for these systems.

Lennox Industries Inc., the maker of Lennox Pulse furnaces, announced it has set up a free program to inspect Lennox furnaces installed from 1982 to 1989 to check for carbon monoxide leaks or as the company stated: "because of "increased instances of corrosion in some Pulse furnace heat exchangers in units installed before 1990."

Readers of this document should also see HEAT EXCHANGER LEAKS. © Copyright 2009 Daniel Friedman, All Rights Reserved. Information Accuracy & Bias Pledge is at below-left. Use the links at page left to navigate this document or to go to Other Website Topics. Green links show where you are in our document & website. [Photograph courtesy Arlene Puentes.]

Lennox Furnace Inspection Program and Heat Exchanger Warranty Program

According to Bob Schjerven, president and chief operating officer for Lennox, dealers have recently reported increased instances of corrosion in some Pulse furnace heat exchangers in units installed before 1990.

As part of the inspection program, Lennox will provide a free AIM Safety carbon monoxide detector.

The Lennox company urges owners of Lennox Pulse furnaces installed between 1982 and 1989 to schedule a furnace and safety check with an independent Lennox dealer.

We agree with other writers who've complimented Lennox for making an effort to honor the warranty on these items when other product manufacturers have disappeared or even been misleading about the hazards involved (For an example see Federal Pacific Electric FPE Panel Hazards)

How To contact Lennox about a Pulse Furnace Warranty Question

We've seen a string of non-working contact numbers for Lennox, such as 800-537-4341 900-622-8000. Forget these numbers.

To find a Lennox Dealer near you go to http://www.lennox.com/residential/ and enter your zip code in the box at the web page upper right corner, OR
use the links to Lennox at the left side of this web page (supplied by Google). Contact information details for Lennox Corporation and links to some Lennox heating equipment manuals are provided at LENNOX MANUALS below.

The Lennox Pulse furnace safety inspection is (or was) free, but if the furnace has to be cleaned in order to be inspected, the customer could be charged for the cleaning.

How to Identify a Lennox Pulse Furnace that May Need a Safety Inspection

Pulse 21 Name on the Furnace Access Door: To identify a Pulse furnace, look for its name on the door. If the unit is a Pulse 21 furnace, it was manufactured after 1990 and is not part of the inspection program.

For those with Lennox furnaces without the Pulse 21 name, the next step is to remove the front door and look for the name tag. These tags are usually placed on the inside cabinet wall on the left side of the furnace.

Locate the model number on the furnace data tag (either G14 or GSR14 followed by a series of numbers and letters) and the serial number on a tag below the name tag. The photo above [courtesy Arlene Puentes] shows a model number starting G14....

Homeowners who call the 800 number with the information will be told if their furnace is eligible for this inspection program.

The original Lennox furnace safety inspection program ran through July 1, 1999. If the warranted heat exchanger needed replacing, Lennox indicated that the company would provide a new heat exchanger at no cost to the owner. Labor costs for replacement parts are not part of the Pulse furnace warranty.

Owners of Lennox furnaces in this series who discover this fact after July 1, 1999 should still have the furnace heat exchanger inspected for safety, regardless of whether a new heat exchanger will be provided under warranty. A "rusty" heat exchanger, or one which has a rust hole or crack may be unsafe and risks leaks of dangerous, even potentially fatal carbon monoxide (CO) flue gas. See HEAT EXCHANGER LEAKS for more information about heat exchanger leaks and furnace safety and see Carbon Monoxide Gas Toxicity for information about carbon monoxide.

Re inspect Lennox Pulse Furnaces Every Four Years

Some Lennox installers (and possibly the company too) recommend any Lennox Pulse furnace still in use be pressure tested every 4 years.  This almost never happens and in our opinion a visual inspection or other simpler tests of heat exchanger safety are much less reliable. Therefore, unless you are provided with pressure test information at the time of a home inspection where a Lennox Pulse Furnace has been installed, you should ALWAYS recommend a pressure test by a Lennox trained technician, and a consultation with the Lennox dealer to determine the status of the warranty of the furnace. [Thanks to Roger Hankey for this tip.] More details:

Lennox published this Service and Application Notes Feb. 1,2001, re-issued Nov. 3, 2003. With the supply of replacement heat exchangers exhausted, a new G51MP furnace will be furnished to satisfy the remaining portion of the warranty. Just as the warranty does not cover labor and shipping of the G51MP is not covered. If the homeowner wishes to upgrade to another Lennox furnace, the homeowner will be responsible for the cost difference between the two furnaces. The dealer is to order the upgrade furnace and will receive credit on the G51MP furnace only. In order to process a warranty claim of this type, the Lennox dealer must complete the attached form and have it signed by the homeowner.

According to Lennox procedure (#503594M, dated 11/97) a Lennox Pulse Furnace heat exchanger pressure test requires the heat exchanger assembly to be first plugged and then pressurized to determine if it can hold 4 psi pressure for 10 minutes. If not the heat exchanger is considered leaky and could be unsafe.

The Original Lennox Pulse Furnace Press Release is given Below

Original appearance at: Pulse Inspection Program Hotline 1-800-537-4341 [OBSOLETE NUMBER}

Lennox Heats Up Call For Consumers To Schedule Furnace Inspections - Sep 10, 1997

(DALLAS) -- Lennox Industries officials said that with cooler temperatures approaching, it is urgent that owners of Lennox Pulse furnaces installed before 1990 have those furnaces inspected.

Lennox, one of North America's leading residential and commercial heating and air conditioning equipment companies, will continue its Pulse furnace inspection program which began in April, 1997 and has already garnered over 25,000 consumer calls. The inspection program is a response to dealer reports of increased instances of corrosion in some Pulse furnace heat exchangers in units installed before 1990.

With all high-efficiency condensing furnaces, a combination of factors -- such as impurities in fuel or combustion air -- can cause corrosion of key components which could lead to potentially dangerous leaks. Furnaces which are inadequately inspected or improperly maintained can develop problems, including the possibility of carbon monoxide leaks that could be fatal.

According to Bob Schjerven, president and chief operating officer for Lennox Industries Inc., "Consumer response to the Pulse furnace inspection program has been terrific, but we need to reach everyone. We're urging all Pulse furnace owners, before they turn their thermostats from cool to heat, to call our 800 number and schedule a furnace inspection and a safety check with an independent Lennox dealer."

With each inspection, trained service technicians will perform the recommended 17-point Pulse furnace service check, conduct a visual inspection, and complete a pressure test of the unit's lifetime warranted heat exchanger. While Lennox is subsidizing participation in the inspection program, there may still be some cost to Pulse owners. Factors such as the location of the furnace, the condition of the furnace, and service unrelated to the inspection will determine the actual cost of the inspection.

If the warranted heat exchanger needs replacing, Lennox will provide a new heat exchanger at no cost to the owner. While labor costs for replacements are generally not part of the Pulse furnace warranty, Lennox will pay a reasonable allowance to the dealer for installation costs as part of this inspection program. There may be some costs to the owner, depending on the area of the country, type of installation, work required by local code requirements, and any other service required not related to the heat exchanger.

For those owners whose pre-1990 Pulse furnace has a heat exchanger which requires replacement, Lennox will provide, through the local independent Lennox dealer and at the owner's option, a $400 rebate on a new Lennox Pulse furnace. The Pulse furnace inspection program runs through July 1, 1999.

Lennox will also provide a free AIM Safety carbon monoxide detector, one of the highest quality detectors available, as part of the inspection program.

"Lennox has long been involved in a consumer carbon monoxide awareness program unrelated to this Pulse furnace inspection," explains Schjerven. "Since currently there is no device on the market that effectively shuts a furnace down if there is a carbon monoxide leak, it is important to install a carbon monoxide detector as a safeguard, in addition to annual maintenance and inspections."

Scheduling inspections: Homeowners can schedule a furnace inspection and safety check with an independent Lennox dealer by calling 1-800-537-4341. For convenience, the 800 number is staffed 24 hours a day, seven days a week. A Pulse furnace can be identified by its name on the door.

To determine whether your Pulse furnace should be inspected under this program:

1. Check for the Pulse name on the door. If the unit is a Pulse 21 furnace, it was manufactured after 1990 and is not part of this inspection program. However, as with all furnaces, annual inspections are still required.

2. Otherwise, remove the front door and look for the product identification stickers. These stickers are usually placed on the inside cabinet wall on the left side of the furnace.

3. Write down the model number that appears on the sticker (either G14 or GSR14, followed by a series of numbers and letters).

4. Write down the serial number on the product identification sticker (four numbers, followed by a letter, then five more numbers).

5. Call 1-800-537-4341 and have the model number and serial number ready.

All Furnaces Need Yearly Inspection

To maintain safety, efficiency, and reliability, Lennox recommends owners have their heating systems inspected at least once a year. The owner can extend the life of the furnace and help stop inefficient combustion and leaks, which could result in serious injuries, by:

1. Inspecting the filter monthly. Dirty filters can cause inefficient operation and could result in premature heat exchanger failure.

2. Watching for leaks and signs of deterioration. If found, call a certified service technician.

3. Insisting on a combustion efficiency test as part of the annual inspection.

Founded in 1895, Lennox Industries Inc. is an international manufacturer of air conditioning and heating equipment for residential and commercial applications. The company markets its products through a network of over 5,000 independent dealers.

Lennox Pulse Furnace Manuals - Lennox Furnace Service Manuals & Lennox Furnace User's Manuals

Contact Information for the Lennox Corporation is listed here

To assure that you have the latest and most accurate service manual or user's manual for your heating equipment we recommend checking with the manufacturer. Contact information for Lennox industries, in Dallas Texas:

Lennox Corporation
2100 Lake Park Blvd.
Richardson, TX 75080
P.O. Box 799900
Dallas, TX 75379-9900

1-800-9-LENNOX (1-800-953-6669)

To find a Lennox Dealer near you go to http://www.lennox.com/residential/ and enter your zip code in the box at the web page upper right corner, OR use the links to Lennox at the left side of this web page (supplied by Google).

To request Lennoz product literature, you can also write to Lennox Consumer Affairs, P.O. Box 799900, Dallas, TX 75379 - but primarily the company sends product brochures, not technical manuals, from this contact point.

Free, downloadable Lennox Pulse Furnace User's Manuals and Service Manuals are listed just below:

• Lennox G14 Pulse Gas Furnace User's Manual from 1990 #502.596M that supercedes Lennox 502.207M
• Lennox GSR14 Pulse Gas Furnace User's Manual from 1990, Lennox# 502.595M that supercedes Lennox 502.206M
• Lennox G21Q and G21V Lennox Pulse Gas Furnace User's Manual from 1996, Lennox #503.072M that supercedes the 1996 edition. Lennox Industries, Dallas TX
• Lennox GSR21Q and GSR21V Lennox Pulse Gas Furnace User's Manuals from 1998, supercedes the 1996 manuals, Lennox # 503.073M
• Lennox GSR21Q Lennox Pulse Furnace Manual from 1991, Lennox # 502.694M 8/91
• Lennox G24-200 Series Upflow Gas Furnace Manual, Lennox # 503.614M,1998
• Lennox G26 Series Gas Furnace Manual, 1998, #503.533M
• Lennox G32V Series Gas Furnace Manual, 2001, #504.391M
• Lennox G32Q/V Series Gas Furnace Manual, 2001, #504.392M
• Lennox G40DF (X) Series Gas Furnace User's Information Manual, 2001, #504.322M
• Lennox G50DF(X) Series Gas Furnace User's Information Manual, 2001, #504.324M
• Lennox G60DFV(X) Gas Furnace Manual, 2002, #504.577M
• Lennox G61MP Series Gas Furnace Manual, 2003, #504.741M
• Lennox 78UGF Series Gas Furnaces, User's Information Manual, 1993, supercedes the 1992 edition, Lennox # 502.840M
• Lennox 78RGF Series Gas Furnaces, User's Information Manual, 1993, supercedes 1992, #502.842M
• Lennox 90UGF Series Gas Furnace User's Information Manual, 1997, Lennox # 503.629M
• Other Lennox owners manuals for air conditioners, air handlers, furnaces, heat pumps, indoor air quality systems, packaged units, water heaters, zone controls and other controls such as thermostats, are provided by Lennox at http://www.lennox.com/support/manuals.asp
• Lennoz Pulse Furnaces, 2 IDIs and 2 Complaints (US CPSC), 5 June 1998, includes CPSC records obtained by a law firm under the FOIA Freedom of Information Act. This information includes description of gas odors, detection of gas leaks, and potential safety hazards that could be helpful to other consumers and service technicians.
• Forced Hot Air Furnaces: Troubleshooting and Repair, Roger Civi, ISBN-13: 978-0071341714, avaliable at the InspectAPedia bookstore (Amazon.com) new and used. (We recommend a number of heating system inspection, diagnosis, and repair books at this Amazon page).

Lennox Pulse Furnace Inspection Checklist

Here are seventeen inspection points suggested for Lennox Pulse Furnaces. If a simple visual inspection of your Lennox pulse furnace (or any other heating appliance) shows evidence of leaks, corrosion, or if the system is making strange noises or odors, call your heating service technician promptly as the equipment could be unsafe. Be sure that the building has working carbon monoxide detectors properly located and installed, especially where gas-fired heating equipment is in use.

1. Inspect the Lennox pulse furnace combustion air intake and exhaust PVC for condensate leaks and/or joint separations. Repair as necessary.

2. Inspect Lennox pulse furnace air diaphragm flapper material for dirt or deterioration and replace, if necessary. Air flapper material must be replaced every four years regardless of appearance.

3. Inspect Lennox pulse furnace purge blower for dirt build-up every year and clean, as necessary.

4. Inspect Lennox pulse furnace gas flapper material for dirt or deterioration. Replace entire assembly if flapper material is found to be worn.

5.Check the furnace combuation supply air blower wheel and clean, as necessary.

6. Inspect secondary heat exchanger for dirt build-up and clean, as necessary. Blower must be removed to do this check

7. Inspect Lennox pulse furnace heat exchanger assembly for any signs of corrosion or leakage. An air pressure test has been performed on the heat exchanger and exhaust venting system

8. Check all wiring for loose connections on the Lennox pulse furnace. Check for correct voltage.

9. Inspect stainless steel flexible gas connector for corrosion. Remember - Some soaps used for leak testing are corrosive to stainless steel. Failure to thoroughly rinse gas connector after leak check can lead to corrosion.

10. Inspect intake and exhaust pipe terminations to make sure they are free from obstruction.

11. Check the Lennox pulse furnace supply and manifold gas pressure. Adjust pressure, as necessary.

12. Check furnace firing rate by clocking gas meter.

13. Test oxygen/carbon dioxide level of flue gas to determine if proper combustion is taking place. For operating ranges, consult charts provided with testing instrument or unit information manual.

14. Test the Lennox pulse furnace exhaust carbon monoxide levels in flue gas. Level should never exceed 50PPM.

15. Check Lennox pulse furnace operating temperature rise and make sure proper speed is selected to match nameplate rating.

16. Check Lennox pulse furnace fan and limit controls for proper operation and setting.
(Refer to installation instructions)

17. Inspect Lennox pulse furnace condensate lines for free flow of condensate during operation.

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• Arlene Puentes is a licensed home inspector, past chapter president of the Hudson Valley chapter of the American Society of Home Inspectors, an educator, and building failures researcher in Kingston, NY who can be reached at ap@octoberhome.htm or at 845-339-7984.
• Roger Hankey is principal of Hankey and Brown home inspectors, Eden Prairie, MN. Mr. Hankey is a past chairman of the ASHI Technical Committee and the ASHI Standards Committee. Mr. Hankey serves as co-chairmain of ASHI legislative committee, and has served in other ASHI professional and leadership roles. Contact: 952 829-0044 - hankeybrown@comcast.net
• Reported Original source: ASHI Reporter, September 1997 p23, updated 12 February 2007, May 2008

More Information on Building Diagnostic Inspections and Repairs

• Carbon Dioxide Gas Toxicity
• Carbon Monoxide Gas Toxicity, exposure limits, poisoning symptoms, and inspecting buildings for CO hazards
• Dust from HVAC? An Investigation of Indoor Dust Debris Blamed on a Heating/Cooling System Reveals Carpet Dust
• Goodman Furnace High Temperature Plastic Vent HTPV safety recall US CPSC notice
• Home Heating System Should Be Checked [for proper venting and for CO Carbon Monoxide Hazards - DJF]
• Inspection Procedures for Oil-Fired Heating Systems Detailed step by step approaches for inspecting complex systems]
• Lennox Pulse Furnace Safety Inspection/Warranty Program: Carbon Monoxide Warning
• Oil Tanks - The Oil Storage Tank Information Website: Buried or Above Ground Oil Tank Inspection, Testing, Cleanup, Abandonment of Oil Tanks
• Oil Tanks Above Ground, UL Standards, guidance for home owners, buyers, and inspectors
• Plastic Heating Vent Pipe & Other Heating Safety Recall Notices
• Weil McLain Model GV Gas Boiler/gas valve CPSC recall/repair

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