1. Introduction
This document provides comprehensive instructions for the installation, operation, and maintenance of the Lennox 19W94 Ignition Conversion Kit. This kit is designed to replace specific older ignition control boards, ensuring proper and safe operation of your heating system. Please read all instructions carefully before proceeding with installation or service.
2. Important Safety Information
Failure to follow these safety guidelines could result in property damage, personal injury, or death. Always adhere to local codes and regulations.
- Disconnect Power: Always ensure that all electrical power to the heating unit is disconnected at the main service panel before performing any installation, maintenance, or troubleshooting.
- Qualified Personnel: Installation and servicing of this kit should only be performed by a qualified HVAC technician or licensed electrician. Improper installation can lead to hazardous conditions.
- Electrical Hazards: Be aware of potential electrical shock hazards. Do not touch live electrical components.
- Gas Supply: Ensure the gas supply to the appliance is turned off before working on gas-related components.
- Component Handling: Handle the control board and other components with care to avoid damage from static electricity.
3. Package Contents
Verify that all components listed below are present in your kit:
- Lennox 19W94 Ignition Control Board
- Wiring Harnesses (typically two, for various connections)
- Installation Instructions/Diagrams (refer to this manual for detailed guidance)
This image displays the Lennox 19W94 Ignition Conversion Kit. It includes the main control board, which is a rectangular circuit board with various electronic components, relays, and connectors. Also visible are two wiring harnesses with multi-pin connectors, designed for connecting the new control board to the existing system wiring. A clear plastic bag containing additional wires or instructions is also present.
4. Specifications
- Product Dimensions: 8 x 8 x 8 inches
- Item Weight: 2.44 pounds
- Batteries Required: No
- Compatibility: Designed as a conversion kit for specific Lennox heating systems. Refer to your appliance's service manual for exact compatibility.
5. Installation Instructions
Warning: Installation must be performed by a qualified technician. Incorrect installation can lead to system malfunction, fire, or electrical shock.
- Power Disconnection: Turn off all electrical power to the furnace or heating unit at the main circuit breaker or fuse box. Verify power is off using a voltage meter.
- Gas Shut-off: Turn off the gas supply to the appliance.
- Access Control Board: Locate and open the access panel to the existing ignition control board.
- Document Existing Wiring: Before disconnecting any wires, take clear photographs or draw a detailed diagram of all existing wiring connections to the old control board. Note wire colors and their corresponding terminals.
- Disconnect Old Board: Carefully disconnect all wiring harnesses and individual wires from the old control board. Remove the old control board from its mounting.
- Mount New Board: Install the new Lennox 19W94 control board in the same location as the old board, using appropriate mounting hardware.
- Connect Wiring Harnesses: The conversion kit includes new wiring harnesses. These harnesses are designed to adapt the existing system wiring to the new board. Connect the provided harnesses to the new control board.
- Reconnect Wires: Based on your documented wiring, carefully reconnect the system wires to the new harnesses or directly to the new board's terminals as indicated by the kit's specific wiring diagram. Pay close attention to connections for the limit switch (2 wires), inducer motor (2 wires), and hot/neutral power wires (2 wires). Ensure all connections are secure and correct.
- Secure Wiring: Ensure all wires are routed safely and secured to prevent contact with moving parts or hot surfaces.
- Restore Gas and Power: Once all connections are verified, restore the gas supply to the appliance and then restore electrical power.
- Test Operation: Initiate a call for heat to test the system's operation. Observe the ignition sequence and ensure the furnace operates correctly.
6. Operating Instructions
The Lennox 19W94 Ignition Control Kit is an automatic component of your heating system. Once correctly installed, it manages the ignition sequence and flame supervision without direct user interaction. Ensure your thermostat is set to the desired temperature to initiate a heating cycle.
- When the thermostat calls for heat, the control board will activate the inducer motor.
- After a pre-purge period, the igniter will energize.
- Once the igniter is hot, the gas valve will open, allowing gas to flow and ignite.
- The control board monitors the flame presence. If ignition fails, it will attempt to re-ignite or enter a lockout state for safety.
7. Maintenance
The ignition control board itself requires no routine maintenance. However, regular maintenance of the overall heating system is crucial for its longevity and efficient operation.
- Annual Inspection: Have your heating system inspected annually by a qualified HVAC technician. They can check the control board's connections, wiring, and overall system performance.
- Clean Air Filters: Regularly replace or clean your furnace air filters to ensure proper airflow and prevent strain on the system.
- Clear Vents: Ensure all supply and return air vents are unobstructed.
8. Troubleshooting
If your heating system is not operating correctly after installing the Lennox 19W94 kit, consider the following common issues. Always disconnect power before inspecting components.
- No Heat/Furnace Not Starting:
- Check if the thermostat is set to heat and the temperature is above the ambient room temperature.
- Verify that the main power switch to the furnace is on and the circuit breaker has not tripped.
- Ensure the gas supply valve is open.
- Inspect all wiring connections to the new control board for looseness or incorrect placement.
- Inducer Motor Runs, No Ignition:
- Check the igniter for visible damage or cracks.
- Verify the gas valve is receiving power and opening.
- Ensure the flame sensor is clean and properly positioned in the flame path.
- Furnace Cycles On and Off Rapidly (Short Cycling):
- Check for restricted airflow (dirty filter, blocked vents).
- Inspect limit switches for proper operation.
If these steps do not resolve the issue, it is recommended to contact a qualified HVAC technician for further diagnosis and repair.
9. Warranty and Support
Warranty coverage for the Lennox 19W94 Ignition Conversion Kit is typically provided by the manufacturer or the seller at the time of purchase. Please refer to your purchase documentation or contact your supplier for specific warranty terms and conditions.
For technical support or assistance with specific issues not covered in this manual, please contact a qualified HVAC professional or the Lennox customer service department.
