Lennox G60DFV-36B-090, G60DFV-36A-070, G60DFVX-36A-070, G60DFVX-36B-090, G60DFV-60C-090 Installation Instructions Manual

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Page 1

10/08

*2P1008*

506179−01

*P506179-01*

E 2008 Lennox Industries Inc.

Dallas, Texas, USA

RETAIN THESE INSTRUCTIONS

FOR FUTURE REFERENCE

INSTALLATION INSTRUCTIONS

G60DFV(X) Series

GAS FURNACE

506179−01 10/2008 Supersedes 505,126M

Table of Contents

Unit Dimensions 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G60DFV(X) Parts Arrangement 3. . . . . . . . . . . . . . . . . . .

G60DFV(X) Gas Furnace 4. . . . . . . . . . . . . . . . . . . . . . . .

Shipping and Packing List 4. . . . . . . . . . . . . . . . . . . . . . . .

Safety Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Combustion, Dilution & Ventilation Air 6. . . . . . . . . . . . . .

Downflow Installation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting Equipment 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filters 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Duct System 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Venting 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gas Piping 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Integrated Control 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unit Start−Up 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gas Pressure Adjustment 32. . . . . . . . . . . . . . . . . . . . . . . .

High Altitude Information 32. . . . . . . . . . . . . . . . . . . . . . . . .

Other Unit Adjustments 32. . . . . . . . . . . . . . . . . . . . . . . . . .

Heating Sequence of Operation 33. . . . . . . . . . . . . . . . . . .

Service 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Planned Service 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair Parts List 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Integrated Control Diagnostic Codes 37. . . . . . . . . . . . . . .

Troubleshooting 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start−Up & Performance Check List 44. . . . . . . . . . . . . . . .

WHAT TO DO IF YOU SMELL GAS:

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

Installation and service must be performed by a qualified installer, service agency or the gas supplier.

D Do not try to light any appliance. D Do not touch any electrical switch; do not

use any phone in your building.

D Immediately call your gas supplier from a

neighbor’s phone. Follow the gas supplier’s instructions.

D If you cannot reach your gas supplier, call

the fire department.

FIRE OR EXPLOSION HAZARD.

Failure to follow safety warnings exactly could result in serious injury, death, or property damage.

WARNING

D Leave the building immediately.

Litho U.S.A.

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G60DFV(X) Unit Dimensions − inches (mm)

GAS PIPING INLET

(Either Side)

FLUE OUTLET

(Top)

ELECTRICAL INLET

(Either Side)

RETURN AIR

OPENING

FRONT VIEW SIDE VIEW

TOP VIEW

3/4

(19)

3/4

(19)

28−1/2

(724)

19−1/2

(495)

19−1/4

(489)

9−1/4 (235)

4−7/8 (124) Right

2−1/4 (57) Left

(1016)

3−3/4 (95)

5/8

(16)

AIR FLOW

5/8

(16)

3/4

(19)

19−1/2

(495)

5/8

(16)

5/8 (16)

Supply

Air

Supply

Air

A B C D

Model No.

in. mm in. mm in. mm in. mm G60DFV(X)−36A−070 14−1/2 368 13−1/4 337 13 330 4−1/2 114 G60DFV(X)−36B−090 17−1/2 446 16−1/4 413 16 406 6 152 G60DFV(X)−60C−090,

G50DFV(X)−60C−110

21 533 19−1/4 502 19−1/2 495 7−3/4 197

G60DFV(X)−60D−135 24−1/2 622 23−1/4 591 23 584 9−1/2 241

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G60DFV(X) Parts Arrangement

Combustion Air Pres-

sure Switch Assembly

(Two switches)

FIGURE 1

Blower Assembly

Variable

Speed

Blower Motor

Internal Flue Pipe

Assembly

Flue Box Gasket

Flue Collector Box

Gasket

Combustion Air Inducer

Gasket

Primary

Limit

Heat Exchanger

Combustion

Air Orifice

Transformer

Two−Stage

Integrated Control

Flue

Chase

Gasket

Door

Interlock Switch

Flame Sensor

Gas

Valve

Burners

Ignitor

Gas

Orifices

Ignitor

Bracket

Burner Box Bottom

Flame Rollout Switches

Air Intake

Cover

Air Baffle

Gasket

Limit Shield

Burner Box Cover

Power Choke

(1HP Only)

Circuit

Breaker

Sight Glass

Burner Box Top

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G60DFV(X) Gas Furnace

The G60DFV(X) gas furnace is equipped with a two−stage, variable speed integrated control. This control ensures compatibility with Lennox’ Harmony III zone control system, as well as a thermostat which provides humidity control. Each G60DFV(X) unit is shipped ready for installation in the downflow position.

Shipping and Packing List

Package 1 of 1 contains

1 − Assembled G60DFV(X) unit 1 − Bag assembly containing the following:

2 − Screws 3 − Wire nuts 1 − Snap bushing 1 − Snap plug 1 − Wire tie 1 − Vent warning label 1 − Owner’s manual and warranty card

The following items may be ordered separately: 1 − Thermostat 1 − Propane/LP changeover kit 1 − Additive base 1 − High altitude kit

Check equipment for shipping damage. If you find any damage, immediately contact the last carrier.

Safety Information

WARNING

Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Installation and service must be performed by a licensed professional installer (or equivalent), service agency or the gas supplier.

CAUTION

As with any mechanical equipment, personal injury can result from contact with sharp sheet metal edges. Be careful when you handle this equipment.

G60DFV(X) units are CSA International certified to ANSI Z21.47 and CSA 2.3 standard.

In the USA, installation of gas furnaces must conform with local building codes. In the absence of local codes, units must be installed according to the current National Fuel Gas Code (ANSI-Z223.1). The National Fuel Gas Code is available from the following address:

American National Standards Institute, Inc. 11 West 42nd Street New York, NY 10036

In Canada, installation must conform with current National Standard of Canada CSA-B149 installation codes for natural gas burning appliances and equipment, local plumbing or waste water codes and other applicable local codes.

Adequate clearance must be made around the air openings into the vestibule area. In order to ensure proper unit operation, combustion and ventilation air supply must be provided according to the current National Fuel Gas Code or CSA-B149 standards.

Vent installations must be consistent with the venting tables (in this instruction) and applicable provisions of local building codes.

This furnace is CSA International certified for installation clearances to combustible material as listed on the unit nameplate and in the tables in figure 9. Accessibility and service clearances must take precedence over fire protection clearances.

For installation in a residential garage, the furnace must be installed so that the burner(s) and the ignition source are located no less than 18 inches (457 mm) above the floor. The furnace must be located or protected to avoid physical damage by vehicles. When a furnace is installed in a public garage, hangar, or other building that has a hazardous atmosphere, the furnace must be installed according to recommended good practice requirements and current National Fuel Gas Code or CSA B149 standards.

NOTE − Furnace must be adjusted to obtain a temperature rise(high and low fire) within the range(s) specified on the unit nameplate. Failure to do so may cause erratic limit operation and may also result in premature heat exchanger failure.

This G60DFV(X) furnace must be installed so that its electrical components are protected from water.

When this furnace is used with cooling units, it shall be installed in parallel with, or on the upstream side of, cooling units to avoid condensation in the heating compartment. With a parallel flow arrangement, a damper (or other means to control the flow of air) must adequately prevent chilled air from entering the furnace. If the damper is manually operated, it must be equipped to prevent operation of either the heating or the cooling unit, unless it is in the full HEAT or COOL setting.

When installed, this furnace must be electrically grounded according to local codes. In addition, in the United States,

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installation must conform with the current National Electric Code, ANSI/NFPA No. 70. The National Electric Code (ANSI/NFPA No. 70) is available from the following address:

National Fire Protection Association 1 Battery March Park Quincy, MA 02269

In Canada, all electrical wiring and grounding for the unit must be installed according to the current regulations of the Canadian Electrical Code Part I (CSA Standard C22.1) and/or local codes.

NOTE − This furnace is designed for a minimum continuous return air temperature of 60°F (16°C) or an intermittent operation down to 55°F (13°C) dry bulb for cases where a night setback thermostat is used. Return air temperature must not exceed 85°F (29°C) dry bulb.

The G60DFV(X) furnace may be installed in alcoves, closets, attics, basements, garages, and utility rooms in the downflow position.

This furnace design has not been CSA International certified for installation in mobile homes, recreational vehicles, or outdoors.

Lennox does not recommend the use of G60DFV(X) units as a construction heater during any phase of construction. Very low return air temperatures, harmful vapors and operation of the unit with clogged or misplaced filters will damage the unit.

G60DFV(X) units may be used for heating of buildings or structures under construction, if the following conditions are met:

D The vent system must be permanently installed per

these installation instructions.

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

furnace.

D Return air temperature range between 60°F (16°C) and

80°F (27°C) must be maintained.

D Air filters must be installed in the system and must be

maintained during construction.

D Air filters must be replaced upon construction comple-

tion.

D The input rate and temperature rise must be set per the

furnace rating plate.

D One hundred percent (100%) outdoor air must be pro-

vided for combustion air requirements during construction. Temporary ducting may supply outdoor air to the furnace. Do not connect duct directly to the furnace. Size the temporary duct following these instructions in section for Combustion, Dilution and Ventilation Air in a confined space with air from outside.

D The furnace heat exchanger, components, duct sys-

tem, air filters and evaporator coils must be thoroughly cleaned following final construction clean−up.

D All furnace operating conditions (including ignition, in-

put rate, temperature rise and venting) must be verified according to these installation instructions.

NOTE − The Commonwealth of Massachusetts stipulates these additional requirements:

D Gas furnaces shall be installed by a licensed plumb-

er or gas fitter only.

D The gas cock must be T handle" type.

D When a furnace is installed in an attic, the passage-

way to and service area surrounding the equipment shall be floored.

General

These instructions are intended as a general guide and do not supersede local codes in any way. Consult authorities having jurisdiction before installation.

In addition to the requirements outlined previously, the following general recommendations must be considered when installing a G60DFV(X) furnace:

D Place the furnace as close to the center of the air dis-

tribution system as possible. The furnace should also be located close to the chimney or vent termination point.

D Do not install the furnace where drafts might blow direct-

ly into it. This could cause improper combustion and unsafe operation.

D Do not block the furnace combustion air openings with

clothing, boxes, doors, etc. Air is needed for proper combustion and safe unit operation.

D When the furnace is installed in an attic or other insu-

lated space, keep insulation away from the furnace.

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WARNING

Product contains fiberglass wool.

Disturbing the insulation in this product during installation, maintenance, or repair will expose you to fiberglass wool. Breathing this may cause lung cancer. (Fiberglass wool is known to the State of California to cause cancer.)

Fiberglass wool may also cause respiratory, skin, and eye irritation.

To reduce exposure to this substance or for further information, consult material safety data sheets available from address shown below, or contact your supervisor.

Lennox Industries Inc. P.O. Box 799900 Dallas, TX 75379−9900

Combustion, Dilution & Ventilation Air

In the past, there was no problem in bringing in sufficient outdoor air for combustion. Infiltration provided all the air that was needed. In today’s homes, tight construction practices make it necessary to bring in air from outside for combustion. Take into account that exhaust fans, appliance vents, chimneys, and fireplaces force additional air that could be used for combustion out of the house. Unless outside air is brought into the house for combustion, negative pressure (outside pressure is greater than inside pressure) will build to the point that a downdraft can occur in the furnace vent pipe or chimney. As a result, combustion gases enter the living space creating a potentially dangerous situation.

In the absence of local codes concerning air for combustion and ventilation, use the guidelines and procedures in this section to install G60DFV(X) furnaces to ensure efficient and safe operation. You must consider combustion air needs and requirements for exhaust vents. A portion of this information has been reprinted with permission from the National Fuel Gas Code (ANSI-Z223.1). This reprinted material is not the complete and official position of the ANSI on the referenced subject, which is represented only by the standard in its entirety.

In Canada, refer to the standard CSA B149 installation codes.

CAUTION

Do not install the furnace in a corrosive or contaminated atmosphere. Meet all combustion and ventilation air requirements, as well as all local codes.

CAUTION

Insufficient combustion air can cause headaches, nausea, dizziness or asphyxiation. It will also cause excess water in the heat exchanger resulting in rusting and premature heat exchanger failure. Excessive exposure to contaminated combustion air will result in safety and performance related problems. Avoid exposure to the following substances in the combustion air supply:

Permanent wave solutions Chlorinated waxes and cleaners Chlorine base swimming pool chemicals Water softening chemicals De-icing salts or chemicals Carbon tetrachloride Halogen type refrigerants Cleaning solvents (such as perchloroethylene) Printing inks, paint removers, varnishes, etc. Hydrochloric acid Cements and glues Antistatic fabric softeners for clothes dryers Masonry acid washing materials

All gas-fired appliances require air for the combustion process. If sufficient combustion air is not available, the furnace or other appliances will operate inefficiently and unsafely. Enough air must be provided to meet the needs of all fuel-burning appliances and appliances such as exhaust fans which force air out of the house. When fireplaces, exhaust fans, or clothes dryers are used at the same time as the furnace, much more air is necessary to ensure proper combustion and to prevent a downdraft. Insufficient air causes incomplete combustion which can result in carbon monoxide.

In addition to providing combustion air, fresh outdoor air dilutes contaminants in the indoor air. These contaminants may include bleaches, adhesives, detergents, solvents and other contaminants which can corrode furnace components.

The requirements for providing air for combustion and ventilation depend largely on whether the furnace is installed in an unconfined or a confined space.

Unconfined Space

An unconfined space is an area such as a basement or large equipment room with a volume greater than 50 cubic feet (1.42 m

) per 1,000 Btu (.29 kW) per hour of the combined 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 unconfined, it might be necessary to bring in outdoor air for combustion if the structure does not provide enough air by

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infiltration. If the furnace is located in a building of tight construction with weather stripping and caulking around the windows and doors, follow the procedures in the air from outside section.

Confined Space

A confined space is an area with a volume less than 50 cubic feet (1.42 m

) per 1,000 Btu (.29 kW) per hour of the combined input rating of all appliances installed in that space. This definition includes furnace closets or small equipment rooms.

When the furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air must be handled by ducts which are sealed to the furnace casing and which terminate outside the space containing the furnace. This is especially important when the furnace is mounted on a platform in a confined space such as a closet or small equipment room. Even a small leak around the base of the unit at the platform or at the return air duct connection can cause a potentially dangerous negative pressure condition. Air for combustion and ventilation can be brought into the confined space either from inside the building or from outside.

EQUIPMENT IN CONFINED

SPACE ALL AIR FROM INSIDE

CHIMNEY

OR GAS

VENT

FURNACE

WATER

HEATER

OPENINGS (To Adjacent

Room)

NOTE − Each opening shall have a free area of at least one square inch (645 mm

) per 1,000 Btu (.29 kW) per hour of the total input rating of all equipment in the enclosure, but not less than 100 square inches (64516 mm

FIGURE 2

Air from Inside

If the confined space that houses the furnace adjoins a space categorized as unconfined, air can be brought in by providing two permanent openings between the two spaces. Each opening must have a minimum free area of 1 square inch (645 mm2) per 1,000 Btu (.29 kW) per hour of total input rating of all gas−fired equipment in the confined space. Each opening must be at least 100 square inches (64516 mm

). One opening shall be within 12 inches (305 mm) of the top of the enclosure and one opening within 12 inches (305 mm) of the bottom. See figure 2.

Air from Outside

If air from outside is brought in for combustion and ventilation, the confined space must have two permanent openings. One opening shall be within 12 inches (305 mm) of the top of the enclosure and one opening within 12 inches (305 mm) of the bottom. These openings must communicate directly or by ducts with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors or indirectly through vertical ducts. Each opening shall have a minimum free area of 1 square inch (645 mm

) per 4,000 Btu (1.17

kW) per hour of total input rating of all equipment in the enclosure. See figures 3 and 4. When communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 square inch (645 mm

) per

2,000 Btu (.56 kW) per total input rating of all equipment in the enclosure. See figure 5.

When ducts are used, they shall be of the same cross−sectional area as the free area of the openings to which they connect. The minimum dimension of rectangular air ducts shall be no less than 3 inches (75 mm). In calculating free area, the blocking effect of louvers, grilles, or screens must be considered. If the design and free area of protective covering is not known for calculating the size opening required, it may be assumed that wood louvers will have 20 to 25 percent free area and metal louvers and grilles will have 60 to 75 percent free area. Louvers and grilles must be fixed in the open position or interlocked with the equipment so that they are opened automatically during equipment operation.

Page 8

EQUIPMENT IN CONFINED SPACE

ALL AIR FROM OUTSIDE

(Inlet Air from Crawlspace and Outlet Air to Ventilated Attic)

NOTE−The inlet and outlet air openings shall each have a free area of at least one square inch (645 mm

) per 4,000 Btu (1.17 kW) per hour of the total input rating of all equipment in the enclosure.

VENTILATION LOUVERS

(Each end of attic)

OUTLET

AIR

WATER

HEATER

INLET

AIR

CHIMNEY OR

GAS VENT

FURNACE

VENTILATION

LOUVERS

(For unheated crawl space)

FIGURE 3

EQUIPMENT IN CONFINED SPACE

ALL AIR FROM OUTSIDE

(All Air Through Ventilated Attic)

NOTE−The inlet and outlet air openings shall each have a free area of at least one square inch (645 mm

) per 4,000 Btu (1.17 kW) per hour of the total input rating of all equipment in the enclosure.

CHIMNEY

OR GAS

VENT

WATER

HEATER

OUTLET

AIR

VENTILATION LOUVERS

(Each end of attic)

INLET AIR

(Ends 12 in.

above bottom)

FURNACE

FIGURE 4

EQUIPMENT IN

CONFINED SPACE

ALL AIR FROM

OUTSIDE

OUTLET AIR

INLET AIR

WATER

HEATER

CHIMNEY

OR GAS

VENT

NOTE − Each air duct opening shall have a free area of at least one square inch (645 mm

) per 2,000 Btu (.59 kW) per hour of the total input rating of all equipment in the enclosure. If the equipment room is located against an outside wall and the air openings communicate directly with the outdoors, each opening shall have a free area of at least one square inch (645 mm

) per 4,000 Btu (1.17 kW) per hour of the total input rating of all other equipment in the enclosure.

FURNACE

FIGURE 5

Page 9

Downflow Installation

Downflow unit installs in three ways: on non−combustible flooring, on combustible flooring using an additive base, or on a reverse−flow cooling cabinet. Do not drag the unit across the floor.

Installation on Non−Combustible Flooring

1 − Cut floor opening keeping in mind clearances listed on

unit rating plate. Also keep in mind gas supply connections, electrical supply, flue and air intake connections and sufficient installation and servicing clearances. See table 1 for correct floor opening size.

2 − Flange warm air plenum and lower the plenum into the

opening.

3 − Set the unit over the plenum and seal the plenum to

the unit.

3 − Ensure that the seal is adequate.

TABLE 1

NON−COMBUSTIBLE FLOOR OPENING SIZE

Front to Rear Side to Side

Model No.

in. mm in. mm

A Cabinet (14.5") 19 − 3/4 502 13 − 1/4 337

B Cabinet (17.5") 19 − 3/4 502 16 − 1/4 413

C Cabinet (21") 19 − 3/4 502 19 − 3/4 502

D Cabinet (24.5") 19 − 3/4 502 23 − 1/4 591

NOTE − Floor opening dimensions listed are 1/4 inch (6 mm) larger than the unit opening. See unit dimensions on page 2.

Installation on Combustible Flooring

1 − When unit is installed on a combustible floor, an addi-

tive base must be installed between the furnace and the floor. The base must be ordered separately for the following cabinet sizes:

D A cabinet 14.5" − # 11M59 D B cabinet 17.5" − # 11M60 D C cabinet −21" # 11M60 D D cabinet 24.5" − # 11M61

See table 2 for opening size to cut in floor.

CAUTION

The furnace and additive base shall not be installed directly on carpeting, tile, or other combustible material other than wood flooring.

TABLE 2

ADDITIVE BASE FLOOR OPENING SIZE

Front to Rear Side to Side

Model No.

in. mm in. mm

A Cabinet (14.5")

22 559 15 − 3/4 400

B Cabinet (17.5")

22 559 18 − 3/4 476

C Cabinet (21")

22 559 22 − 3/4 578

D Cabinet (24.5")

22 559 25 − 3/4 654

NOTE − Floor opening dimensions listed are 1/4 inch (6 mm) larger than unit opening. See unit dimensions on page 2.

2 − After opening is cut, set additive base into opening.

3 − Check fiberglass strips on additive base to make sure

they are properly glued and positioned.

4 − Lower supply air plenum into additive base until ple-

num flanges seal against fiberglass strips.

NOTE − Be careful not to damage fiberglass strips. Check for a tight seal.

5 − Set the furnace over the plenum.

6 − Ensure that the seal between the furnace and plenum

is adequate.

G60DFV(X)UNIT

SUPPLY AIR PLENUM

ADDITIVE BASE

PROPERLY

SIZED FLOOR

OPENING

FIGURE 6

Installation on Cooling Cabinet

1 − Refer to reverse−flow coil installation instructions for

correctly sized opening in floor and installation of cabinet.

2 − When cooling cabinet is in place, set and secure the

furnace according to the instructions that are provided with the cooling coil. Secure the furnace to the cabinet.

3 − Seal the cabinet and check for air leaks.

Return Air Opening −− Downflow Units

The following steps should be taken when installing plenum:

1 − Bottom edge of plenum should be flanged with a

hemmed edge (See figure 7).

SECURE FROM

OUTSIDE CABINET

HEMMED EDGE

PLENUM

FIBERGLASS SEALING STRIP (Field Provided)

CABINET SIDE PANEL

Side View

FIGURE 7

2 − Fiberglass sealing strips should be used.

3 − In all cases, plenum should be secured to top flanges

of furnace with sheet metal screws.

Page 10

SECURE FROM IN-

SIDE CABINET

HEMMED EDGE

FIBERGLASS SEALING STRIP (Field Provided)

CABINET SIDE

PANEL

PLENUM

Side View

FIGURE 8

4 − In closet installations, it may be impossible to install

sheet metal screws from the outside. In this case,

make plenum with a removable front and install

screws from the inside (See figure 8).

5 − Make certain that an adequate seal is made.

Setting Equipment

WARNING

Do not install the furnace on its front or its back. Do not connect the return air ducts to the back of the furnace. Doing so will adversely affect the operation of the safety control devices, which could result in personal injury or death.

Install the G60DFV(X) gas furnace as shipped. Do not install the furnace horizontally.

Select a location that allows for the required clearances that are listed on the unit nameplate. Also consider gas supply connections, electrical supply, vent connection, and installation and service clearances [24 inches (610 mm) at unit front]. The unit must be level.

NOTE − Units with 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 washer (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. After the bolt and washer have been removed, the rigid leg will not touch the blower housing.

NOTE − G60DFV−60D−135 units are equipped with a shipping pad under the blower housing. Remove the shipping pad prior to operation.

WARNING

The blower access panel must be securely in place when the blower and burners are operating. Gas fumes, which could contain carbon monoxide, can be drawn into living space resulting in personal injury or death.

Downflow Application Allow for clearances to combustible materials as indicated on the unit nameplate. Minimum clearances for closet or alcove installations are shown in figure 9.

Downflow Application Installation Clearances

Top

Bottom

Left Side

Right Side

Type of Vent

Connector

Type C Type B1

Top 1 in. (25 mm) 1 in. (25 mm)

*Front 3 in. (76 mm) 3 in. (76 mm)

Back 0 0

Sides 0† 0

Vent 6 in. (152 mm) 1 in. (25 mm)

Floor NC†† NC††

*Front clearance in alcove installation must be 24 in. (610 mm). Maintain a minimum of 24 in. (610 mm) for front service access. †Left side requires 3 in. if a single wall vent is used on 14 −1/2 in. cabinets, or 2 in. if a single wall vent is used on 17 − 1/2 in. cabinets. ††The furnace may be installed on a combustible wood floor if an optional additive base is installed between the furnace and the combustible floor.

FIGURE 9

WARNING

Improper installation of the furnace can result in personal injury or death. Combustion and flue products must never be allowed to enter the return air system or the living space. Use screws and joint tape to seal the return air system to the furnace. In platform installations with bottom return air, the furnace should be sealed airtight to the return air plenum. A door must never be used as a portion of the return air duct system. The base must provide a stable support and an airtight seal to the furnace. Allow absolutely no sagging, cracks, gaps, etc. The return and supply air duct systems must never be connected to or from other heating devices such as a fireplace or stove, etc. Fire, explosion, carbon monoxide poisoning, personal injury and/or property damage could result.

Page 11

Filters

This unit is not equipped with a filter or rack. A field−provided high−velocity filter is required for the unit to operate properly. Table 3 lists recommended filter sizes. A filter must be in place any time the unit is operating.

TABLE 3

Furnace

Cabinet Width

Return Air Filter Size (inches)

14−1/2" 14 X 25 X 1 (1)

17−1/2" 16 X 25 X 1 (1)

21" 20 X 25 X 1 (1)

24−1/2" 24 X 25 X 1 (1)

Duct System

Use industry-approved standards (such as those published by Air Conditioning Contractors of America or American Society of Heating, Refrigerating and Air Conditioning Engineers) to size and install the supply and return air duct system. This will result in a quiet and low-static system that has uniform air distribution.

NOTE − Do not operate the furnace with an external static pressure that exceeds 0.8 inches w.c. Higher external static pressures may cause erratic limit operation.

Ensure that you have made a seal between the supply air plenum and the furnace and between the furnace and the return air plenum.

Return Air Plenum

Return air must not be drawn from a room where this furnace, or any other gas appliance (ie., a water heater), is installed. When return air is drawn from a room, a

negative pressure is created in the room. If a gas appliance is operating in a room with negative pressure, the flue products can be pulled back down the vent pipe and into the room. This reverse flow of the flue gas may result 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.

Venting

A 4−inch diameter flue transition is factory-installed on all models. Modifying or removing the flue transition will

cause the unit to operate unsafely and will void the unit certification. The vent connector does not require insula-

tion. The G60DFV(X) series units are classified as fan−assisted

Category I furnaces when vertically vented according to the latest edition of National Fuel Gas Code (NFPA 54 / ANSI Z223.1) in the USA and the current standards of CSA B149 Natural Gas and Propane Installation Code in Canada. A fan−assisted Category I furnace is an appliance equipped with an integral mechanical means to either draw or force combustion products through the combustion chamber and/or heat exchanger.

NOTE − Use these instructions as a guide. They do not supersede local codes. This furnace must be vented according to all local codes, these installation instructions, and the provided venting tables in these instructions

The venting tables in this manual were extracted from the National Fuel Gas Code (NFPA 54 / ANSI Z223.1) and are provided as a guide for proper vent installation. Proper application, termination, construction and location of vents must conform to local codes having jurisdiction. In the absence of local codes, the NFGC serves as the defining document.

Refer to the tables and the venting information contained in these instructions to properly size and install the venting system.

IMPORTANT

Once the venting system is installed, attach the Disconnected Vent" warning sticker to a visible area of the plenum near the vent pipe. The warning sticker is provided in the bag assembly.

WARNING

Asphyxiation hazard. The exhaust vent for this furnace must be securely connected to the furnace flue transition at all times.

FLUE

TRANSITION

COLLAR

VENT CONNECTION

VENT

PIPE

FURNACE

FIGURE 10

Use self−drilling sheet metal screws or a mechanical fastener to firmly secure the vent pipe to the round collar of the flue transition. If self−drilling screws are used to attach the vent pipe, it is recommended that three be used. Drive one self−drilling screw through the front and one through each side of the vent pipe and collar. See figure 10.

Install the first vent connector elbow at a minimum of six inches (152 mm) from the furnace vent outlet.

Venting Using a Masonry Chimney

The following additional requirements apply when a lined masonry chimney is used to vent this furnace.

Masonry chimneys used to vent Category I central furnaces must be either tile-lined or lined with a listed metal lining system or dedicated gas vent. Unlined masonry chimneys are prohibited. See figures 11 and 12 for common venting.

Page 12

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

MINIMUM LENGTH = AS SHORT AS PRACTICAL. FOR MAXIMUM LENGTH SEE NOTE TO LEFT

INTERIOR TILE−LINED MASONRY CHIMNEY

NOTE − the chimney must be properly sized per provided venting tables or lined with listed metal lining system.

PERMANENTLY SEALED FIREPLACE OPENING

VENT

CONNECTOR

SEE NOTE 1 BELOW

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

NOTE− Refer to provided venting tables for installations in the USA and the venting tables in current CSA−B149 for installations in Canada.

FURNACE

OTHER

APPLIANCE

FIGURE 11

A chimney with one or more sides exposed to the outside of the structure is considered to be an exterior chimney.

An exterior masonry chimney that is not tile−lined must be lined with B1 vent or a listed insulated flexible metal vent. An exterior tile−lined chimney that is sealed and capped may be lined with a listed uninsulated flexible metal vent.

If the existing chimney will not accommodate a listed metal liner, either the chimney must be rebuilt to accommodate one of these liners or an alternate approved venting method must be found.

Insulation for the flexible vent pipe must be an encapsulated fiberglass sleeve recommended by the flexible vent pipe manufacturer. See figure 12.

Common Venting Using Metal−Lined Masonry Chimney

4 in. (102 mm)

minimum

MIN. LENGTH −− AS

SHORT AS PRACTICAL

MAX. LENGTH

−− SEE NOTE 1 BELOW.

SEALED

PERMANENTLY

SEALED FIREPLACE

OPENING

EXTERIOR

CHIMNEY WITH

METAL

LINER

VENT CONNECTOR

SEE NOTE 2

NOTE 1 − Refer to the provided venting tables for installations in the USA and the venting tables in CSA−B149 for installations Canada. NOTE 2 − Either single-walled or double-walled vent connector may be 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.

OTHER

APPLIANCE

FURNACE

FIGURE 12

5 ft. (1.5 m)

minimum

DO NOT insulate the space between the liner and the chimney wall with puffed mica or any other loose granular insulating material

IMPORTANT

SINGLE appliance venting of a fan-assisted furnace into a tile-lined masonry chimney (interior or outside wall) is PROHIBITED. The chimney must first be lined with either type B1 vent or an insulated single wall flexible vent lining system which has been sized according to the provided venting tables and the vent pipe manufacturer’s instructions.

A fan−assisted furnace may be commonly vented into an existing lined masonry chimney if the following conditions are met:

S The chimney is currently serving at least one drafthood

equipped appliance

S The vent connectors and chimney are sized according

to the provided venting tables for the USA, and the appropriate venting tables in the standards of the CSA B149 Natural Gas and Propane Installation Codes in

Canada. If type B1 double-wall vent is used inside a chimney, no other appliance can be vented into the chimney. The outer wall of type B1 vent pipe must not be exposed to flue products. A type B1 vent or masonry chimney liner shall terminate above the roof surface with a listed cap or a listed roof assembly according to the terms of their respective listings and the vent manufacturer’s instructions. When inspection reveals that an existing chimney is not safe for the intended purpose, it shall be rebuilt to conform to nationally recognized standards, lined or relined with suitable materials, or replaced with a gas vent or chimney suitable for venting G60DFV(X) series units. The chimney passageway must be checked periodically to ensure that it is clear and free of obstructions. Do not install a manual damper, barometric draft regulator, or flue restrictor between the furnace and the chimney.

Page 13

Never connect a Category I appliance to a chimney that is servicing a solid−fuel appliance. If a fireplace chimney flue is used to vent this appliance, the fireplace opening must be permanently sealed.

A type B or listed chimney lining system that passes through an unused masonry chimney flue is not considered to be exposed to the outdoors.

General Venting Requirements

Vent all G60DFV(X) furnaces according to these instructions:

1 − Vent diameter recommendations and maximum allow-

able piping runs are found in the provided venting tables for the USA, and the appropriate venting tables in the standards of the CSA B149 Natural Gas and Propane Installation Codes for Canada.

2 − In no case should the vent or vent connector diameter

be less than the diameter specified in the provided venting tables for the USA, and the appropriate venting tables in the standards of the CSA B149 Natural Gas and Propane Installation Codes for Canada.

3 − The minimum vent capacity determined by the sizing

tables must be less than the low fire input rating and the maximum vent capacity must be greater than the high fire input rating.

4 − Single appliance vents − If the vertical vent or tile-lined

chimney has a larger diameter or flow area than the vent connector, use the vertical vent diameter to determine the minimum vent capacity and the vent

connector diameter to determine the maximum vent capacity. The flow area of the vertical vent, however,

shall not exceed 7 times the flow area of the listed appliance categorized vent area, drafthood outlet area or flue collar area unless designed according to approved engineering methods.

5 − Multiple appliance vents − The flow area of the largest

section of vertical vent or chimney shall not exceed 7 times the smallest listed appliance categorized vent area, drafthood outlet area or flue collar area unless designed according to approved engineering methods.

6 − The entire length of single wall metal vent connector

shall be readily accessible for inspection, cleaning, and replacement.

7 − Single appliance venting configurations with zero lat-

eral lengths (tables 5 and 6) 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% (0.90 x maximum listed capacity).

8 − The common venting tables (7, 8, 9, and 10) were gen-

erated using a maximum horizontal vent connector length of 1−1/2 feet (.46 m) for each inch (25 mm) of connector diameter as follows:

TABLE 4

Connector Diameter

inches (mm)

Maximum Horizontal

Connector Length feet (m)

3 (76) 4−1/2 (1.37)

4 (102) 6 (1.83)

5 (127) 7−1/2 (2.29)

6 (152) 9 (2.74)

7 (178) 10−1/2 (3.20)

9 − If the common vertical vent is offset, the maximum

common vent capacity listed in the common venting tables should be reduced by 20%, the equivalent of two 90° elbows (0.80 x maximum common vent capacity). The horizontal length of the offset shall not exceed 1-1/2 feet (.46 m) for each inch (25 mm) of common vent diameter.

10 − The vent pipe should be as short as possible with the

least number of elbows and angles required to complete the job. Route the vent connector to the vent using the shortest possible route.

11 − A vent connector shall be supported without any dips

or sags and shall slope a minimum of 1/4 inch (6.4 mm) per linear foot (305 mm) of connector, back toward the appliance.

12 − Vent connectors shall be firmly attached to the furnace

flue collar by self−drilling screws or other approved means, except vent connectors of listed type B vent material which shall be assembled according to the manufacturer’s instructions. Joints between sections of single wall connector piping shall be fastened by screws or other approved means.

13 − When the vent connector used for Category I ap-

pliances must be located in or pass through a crawlspace or other areas which may be cold, that portion of the vent connector shall be constructed of listed double-wall type B vent material or material having equivalent insulation qualities.

14 − All venting pipe passing through floors, walls, and ceil-

ings must be installed with the listed clearance to combustible materials and be fire stopped according to local codes. In absence of local codes, refer to NFGC (Z223.1).

15 − No portion of the venting system can extend into, or

pass through any circulation air duct or plenum.

16 − Vent connectors serving Category I appliances shall

not be connected to any portion of mechanical draft systems operating under positive pressure such as Category III or IV venting systems.

Page 14

17 − If vent connectors are combined prior to entering the

common vent, the maximum common vent capacity listed in the common venting tables must be reduced by 10%, the equivalent of one 90° elbow (0.90 x maximum common vent capacity).

18 − The common vent diameter must always be at least as

large as the largest vent connector diameter.

19 − In no case, shall the vent connector be sized more than

two consecutive table size diameters over the size of the draft hood outlet or flue collar outlet.

20 − Do not install a manual damper, barometric draft regu-

lator or flue restrictor between the furnace and the

chimney.

21 − When connecting this appliance to an existing dedi-

cated or common venting system, you must inspect the

venting system’s general condition and look for signs

of corrosion. The existing vent pipe size must conform

to these instructions and the provided venting tables

for the USA, and the appropriate venting tables in the

standards of the CSA B149 Natural Gas and Propane

Installation Codes for Canada. If the existing venting

system does not meet these requirements, it must be

resized.

TABLE 5

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

(

feet

)L(

feet

)

Appliance Input Rating in Thousands of Btu Per Hour

(feet)

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

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

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

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

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

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

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 maximum listed capacity).

Page 15

TABLE 6

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

(

feet

)L(

feet

)

Appliance Input Rating in Thousands of Btu Per Hour

(feet)

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

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

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

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

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

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

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

Page 16

TABLE 7

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

Height

onnector

Rise

3 Inch 4 Inch 5 Inch 6 Inch

Height

Rise

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

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

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

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

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

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

2 21 64 33 118 47 190 62 299

3 22 66 34 123 48 198 64 309

TABLE 8

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

Height

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 17

TABLE 9

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

Height

onnector

Rise

3 Inch 4 Inch 5 Inch 6 Inch

Height

Rise

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

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

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

2 50 62 81 115 117 185 177 290

3 54 64 85 119 122 193 185 300

TABLE 10

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

Height

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

In the event that an existing furnace is removed from a venting system commonly run with separate gas appliances, the venting system is likely to be too large to properly vent the remaining attached appliances.

Conduct the following test while each appliance is operating and the other appliances (which are not operating) remain connected to the common venting system. If the venting system has been installed improperly, you must correct the system as indicated in the general venting requirements section.

1 − Seal any unused openings in the common venting sys-

tem.

2 − Inspect the venting system for proper size and horizon-

tal pitch. Determine that there is no blockage, restriction, leakage, corrosion, or other deficiencies which could cause an unsafe condition.

3 − Close all building doors and windows and all doors be-

tween the space in which the appliances remaining connected to the common venting system are located

and other spaces of the building. Turn on clothes dryers and any appliances not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

4 − Follow the lighting instructions. Turn on the appliance

that is being inspected. Adjust the thermostat so that the appliance operates continuously.

5 − After the main burner has operated for 5 minutes, test

for leaks of flue gases at the draft hood relief opening. Use the flame of a match or candle, or smoke from a cigarette, cigar, or pipe.

6 − After determining that each appliance connected to the

common venting system is venting properly, (step 3) return all doors, widows, exhaust fans, fireplace dampers, and any other gas−burning appliances to their previous mode of operation.

7 − If a venting problem is found during any of the preced-

ing tests, the common venting system must be modified to correct the problem.

Page 18

Resize the common venting system to the minimum vent pipe size determined by using the appropriate tables in Appendix G. (These are in the current standards of the National Fuel Gas Code ANSI Z223.1 in the USA, and the appropriate Category 1 Natural Gas and Propane appliances venting sizing tables in the current standards of the CSA B149 Natural Gas and Propane Installation Codes in Canada.)

Gas Piping

CAUTION

If a flexible gas connector is required or allowed by the authority that has jurisdiction, black iron pipe shall be installed at the gas valve and extend outside the furnace cabinet.

Gas Supply

1 − This unit is shipped standard for left or right side instal-

lation of gas piping. Connect the gas supply to the piping assembly.

2 − When connecting the gas supply piping, consider fac-

tors such as length of run, number of fittings, and furnace rating to avoid excessive pressure drop. Table 11 lists recommended pipe sizes for typical applications.

3 − The gas piping must not run in or through air ducts,

clothes chutes, gas vents or chimneys, dumb waiters,

or elevator shafts.

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

[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 − A 1/8" N.P.T. plugged tap or pressure post is located

on the gas valve to facilitate test gauge connection. See figures 20 and 21.

6 − In some localities, codes may require the installation of

a manual main shut-off valve and union (furnished by

the installer) external to the unit. The union must be of

the ground joint type.

IMPORTANT

Compounds used on threaded joints of gas piping must be resistant to the actions of liquified petroleum gases.

NOTE − If emergency shutoff is necessary, shut off the main manual gas valve and disconnect main power to the furnace. The installer should properly label these devices.

TABLE 11

Gas Pipe Capacity − ft

/hr (m3/hr)

Nominal

Iron Pipe

Internal

Length of Pipe − feet (m)

Iron Pipe

Size

inches

(mm)

Diameter

inches

(mm)

(3.048)20(6.096)30(9.144)40(12.192)50(15.240)60(18.288)70(21.336)80(24.384)90(27.432)

100

(30.480)

3/8

(9.53)

.493

(12.522)95(2.69)

(1.84)

(1.47)

(1.27)

(1.13)

(1.02)

(.73)

(.88)

(.82)

(.76)

1/2

(12.7)

.622

(17.799)

175

(4.96)

120

(3.40)

(2.75)

(2.32)

(2.07)

(1.87)

(1.73)

(1.61)

(1.50)

(1.42)

3/4

(19.05)

.824

(20.930)

360

(10.19)

250

(7.08)

200

(5.66)

170

(4.81)

151

(4.28)

138

(3.91)

125

(3.54)

118

(3.34)

110

(3.11)

103

(2.92)

(25.4)

1.049

(26.645)

680

(919.25)

465

(13.17)

375

(10.62)

320

(9.06)

285

(8.07)

260

(7.36)

240

(6.80)

220

(6.23)

205

(5.80)

195

(5.52)

1−1/4

(31.75)

1.380

(35.052)

1400

(39.64)

950

(26.90)

770

(21.80)

660

(18.69)

580

(16.42)

530

(15.01)

490

(13.87)

460

(13.03)

430

(12.18)

400

(11.33)

1−1/2

(38.1)

1.610

(40.894)

2100

(59.46)

460

(41.34)

1180

(33.41)

990

(28.03)

900

(25.48)

810

(22.94)

750

(21.24)

690

(19.54)

650

(18.41)

620

(17.56)

(50.8)

2.067

(52.502)

3950

(111.85)

2750

(77.87)

2200

(62.30)

1900

(53.80)

1680

(47.57)

1520

(43.04)

1400

(39.64)

1300

(36.81)

1220

(34.55)

1150

(32.56)

2−1/2

(63.5)

2.469

(67.713)

6300

(178.39)

4350

(123.17)

3520

(99.67)

3000

(84.95

2650

(75.04)

2400

(67.96)

2250

(63.71)

2050

(58.05)

1950

(55.22)

1850

(52.38)

(76.2)

3.068

(77.927)

11000

(311.48)

7700

(218.03)

6250

(176.98)

5300

(150.07)

4750

(134.50)

4300

(121.76)

3900

(110.43)

3700

(104.77)

3450

(97.69)

3250

(92.03)

NOTE − Capacity given in cubic feet (m3 ) of gas per hour and based on 0.60 specific gravity gas.

Page 19

GROUND

JOINT

UNION

AUTOMATIC GAS VALVE (with manual

shut−off valve)

FIELD

PROVIDED

AND INSTALLED

GROUND

JOINT

UNION

Left Side Piping

(Standard)

Right Side Piping

(Alternate)

AUTOMATIC

GAS VALVE (with manual

shut−off valve)

DRIP LEG

MANUAL

MAIN SHUT−OFF

VALVE

MANUAL

MAIN SHUT−OFF

VALVE

FIGURE 13

Leak Check

After gas piping is completed, carefully check all piping connections (factory− and field−installed) for gas leaks. Use 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 furnace. The installer should properly label these devices.

CAUTION

Some soaps used for leak detection are corrosive to certain metals. Carefully rinse piping thoroughly after leak test has been completed. Do not use matches, candles, flame or other sources of ignition to check for gas leaks.

The furnace must be isolated from the gas supply system by closing its individual manual shut-off valve during any pressure testing of the gas supply system at pressures less than or equal to 1/2 psig (3.48 kPa, 14 inches w.c.).

IMPORTANT

When testing pressure of gas lines, gas valve must be disconnected and isolated. See figure 14. Gas valves can be damaged if subjected to pressures greater than 1/2 psig (3.48 kPa, 14 inches w.c.).

MANUAL MAIN

SHUT−OFF VALVE

WILL NOT HOLD

NORMAL TEST

PRESSURE

CAP

ISOLATE

GAS VALVE

FURNACE

FIGURE 14

Electrical

ELECTROSTATIC DISCHARGE (ESD)

Precautions and Procedures

CAUTION

Electrostatic discharge can affect electronic components. Take precautions during furnace installation and service to protect the furnace’s electronic controls. Precautions will help to avoid control exposure to electrostatic discharge by putting the furnace, the control and the technician at the same electrostatic potential. Neutralize electrostatic charge by touching hand and all tools on an unpainted unit surface, such as the gas valve or blower deck, before performing any service procedure.

The unit is equipped with a field make−up box. The make− up box may be moved to the right side of the furnace to facilitate installation. Secure the excess wire to the existing harness to protect it from damage.

INTERIOR MAKE−UP BOX INSTALLATION

(Left Side)

FIGURE 15

MAKE−UP

BOX

Page 20

INTERIOR MAKE−UP BOX INSTALLATION

(Right Side)

FIGURE 16

MAKE−UP

BOX

Refer to figure 17 for schematic wiring diagram and troubleshooting and table 12 and figure 18 for field wiring.

1 − Select circuit protection and wire size according to the

unit nameplate. The power supply wiring must meet Class I restrictions.

2 − Holes are on both sides of the furnace cabinet to facili-

tate wiring.

3 − Install a separate disconnect switch (protected by ei-

ther fuse or circuit breaker) near the furnace so that power can be turned off for servicing.

4 − Before connecting the thermostat or the power wiring,

check to make sure the wires will be long enough for servicing at a later date. Remove the blower access panel to check the length of the wire.

5 − Complete the wiring connections to the equipment.

Use the provided unit wiring diagram and the field wiring diagrams shown in table 12 and figure 18. Use 18−gauge wire or larger that is suitable for Class II rating for thermostat connections.

6 − Electrically ground the unit according to local codes or,

in the absence of local codes, according to the current National Electric Code (ANSI/NFPA No. 70) for the

USA and current Canadian Electric Code part 1 (CSA

standard C22.1) for Canada. A green ground wire is

provided in the field make−up box.

NOTE − The G60DFV(X) furnace contains electronic

components that are polarity sensitive. Make sure

that the furnace is wired correctly and is properly

grounded.

7 − One line voltage EAC" 1/4" spade terminal is provided

on the furnace integrated control. Any electronic air

cleaner rated up to one amp can be connected to this

terminal with the neutral leg of the circuit being con-

nected to the one of the provided neutral terminals.

See figure 19 for control configuration. This terminal is

energized when the indoor blower is operating.

8 − One line voltage HUM" 1/4" spade terminal is pro-

vided on the furnace integrated control. Any humidifier

rated up to one amp can be connected to this terminal

with the neutral leg of the circuit being connected to

one of the provided neutral terminals. See figure 19 for

control configuration. This terminal is energized in the

heating mode whenever the combustion air inducer is

operating.

9 − One 24V H" terminal is provided on the furnace control

terminal block. Any humidifier rated up to 0.5 amp can

be connected to this terminal with the ground leg of the

circuit being connected to either ground or the C" ter-

minal. See figure 19 for control configuration.

10 −Install the room thermostat according to the instruc-

tions provided with the thermostat. See table 12 for

field wiring connections in varying applications. If the

furnace is being matched with a heat pump, refer to the

instruction packaged with the dual fuel thermostat.

Indoor Blower Speeds

1 − When the thermostat is set to FAN ON," the indoor

blower will run continuously at approximately 38% of

the second−stage cooling speed when there is no cool-

ing or heating demand.

2 − When the G60DFV(X) is running in the heating mode,

the indoor blower will run on the heating speed desig-

nated by the positions of dip switches 11 and 12.

3 − When there is a cooling demand, the indoor blower will

run on the cooling speed designated by the positions

of dip switches 5 and 6.

Page 21

TABLE 12

Field Wiring Applications

DIP Switch Setting and On−Board Links (See figure 19)

Thermostat

DIP Switch 1

W915

Two−Stage

Cooling

W914 Dehu-

midification or Harmony

III

W951

Heat Pumps

Wiring Connections

1 Heat / 1 Cool

NOTE − Use DIP switch 2 to set second−stage heat ON delay. OFF−10 minutes. ON−15 minutes.

ON Intact Intact Intact

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

1 Heat / 2 Cool

NOTE − Use DIP switch 2 to set second−stage heat ON delay. OFF−10 minutes. ON−15 minutes.

ON Cut Intact Intact

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

1 Heat / 2 Cool with t’stat with humidity control

NOTE − Use DIP switch 2 to set second−stage heat ON delay. OFF−10 minutes. ON−15 minutes.

ON Cut Cut Intact

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

Page 22

TABLE 12

Field Wiring Applications (Continued)

DIP Switch Setting and On−Board Links (See figure 19)

Thermostat

DIP Switch 1

W915

Two−Stage

Cooling

W914 Dehumidification or Harmony

III

W951

Heat Pumps

Wiring Connections

2 Heat / 2 Cool OFF Cut Intact Intact

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

2 Heat / 2 Cool with t’stat with humidity control

OFF Cut Cut Intact

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

2 Heat / 1 Cool OFF Intact Intact Intact

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

Page 23

G60DFV(X) Schematic Wiring Diagram

FIGURE 17

Page 24

FIELD INSTALLED CLASS II 24V FIELD INSTALLED LINE VOLTAGE

TYPICAL G60DFV(X) FIELD WIRING DIAGRAM

FIGURE 18

TWO−STAGE, VARIABLE SPEED INTEGRATED CONTROL

HTG DIP SWITCH(ES) FUNCTION

5 and 6 Cooling Mode Blower Speed 7 and 8 Blower Speed Adjustment

9 and 10 Cooling Mode Blower Ramping Profile

11 and 12 Heating Mode Blower Speed

INDOOR

BLOWER DIP

SWITCHES

HEATING

DIP

SWITCHES

DIAGNOSTIC

LEDs

ON−BOARD

LINKS

1 T’stat Heat Stages (single or two−stage) 2 Second Stage ON Delay (single−stage t’stat)

3 and 4 Heating Fan OFF Delay

INDOOR BLOWER

DIP SWITCH(ES)

FUNCTION

W914

W951

W915

DIP SWITCH FUNCTIONS

THERMOSTAT CONNECTIONS (TB1)

1/4" QUICK CONNECT TERMINALS

H= 24V HUMIDIFIER OUTPUT L= LENNOX SYSTEM OPERATION MONITOR 1= FUTURE USE

NEUTRALS= 120 VAC NEUTRAL

FIGURE 19

Page 25

Integrated Control

G60DFV units are equipped with a two−stage, variable speed integrated control. This control manages ignition timing, heating mode fan off delays and indoor blower speeds based on selections made using the control DIP switches. The control includes an internal watchguard feature which automatically resets the integrated control when it has been locked out. After one hour of continuous thermostat demand for heat, the watchguard will break and remake thermostat demand to the furnace and automatically reset the control to relight the furnace.

Heating Operation DIP Switch Settings Switch 1 −− Thermostat Selection −− This unit may be

used with either a single−stage or two−stage thermostat. The thermostat selection is made using a DIP switch which must be properly positioned for the particular application. TheDIP switch is factory−positioned for use with a two− stage thermostat. If a single−stage thermostat is to be used, the DIP switch must be repositioned.

a − Select OFF" for two−stage heating operation con-

trolled by a two−stage heating thermostat (factory setting);

b − Select ON" for two−stage heating operation con-

trolled by a single−stage heating thermostat. This setting provides a timed delay before second−stage heat is initiated.

Switch 2 −− Second Stage Delay (Used with Single− Stage Thermostat Only) −− This switch is used to deter-

mine the second stage on delay when a single−stage thermostat is being used. The switch is factory−set in the OFF position, which provides a 10−minute delay before second− stage heat is initiated. If the switch is toggled to the ON position, it will provide a 15−minute delay before second− stage heat is initiated. This switch is only activated when the thermostat selector jumper is positioned for SINGLE− stage thermostat use.

Switches 3 and 4 −− Blower−Off Delay −− The blower−on delay of 45 seconds is not adjustable. The blower−off delay (time that the blower operates after the heating demand has been satisfied) can be adjusted by moving switches 3 and 4 on the integrated control. The unit is shipped from the factory with a blower−off delay of 90 seconds. The blower off delay affects comfort and is adjustable to satisfy individual applications. Adjust the blower off delay to achieve a supply air temperature between 90° and 110°F at the exact moment that the blower is de−energized. Longer off delay settings provide lower supply air temperatures; shorter settings provide higher supply air temperatures.Table 13 provides the blower off timings that will result from different switch settings.

TABLE 13

Blower Off Delay Switch Settings

Blower Off Delay

(Seconds)

Switch 3 Switch 4

60 Off On

90 Off Off 120 On Off 180 On On

Indoor Blower Operation DIP Switch Settings Switches 5 and 6 −− Cooling Mode Blower Speed −−

Switches 5 and 6 are used to select cooling blower motor speed. The unit is shipped from the factory with the dip switches positioned for high speed (4) indoor blower motor operation during the cooling mode. The table below provides the cooling mode blower speeds that will result from different switch settings. Refer to tables 18 through 22 for corresponding cfm values.

TABLE 14

Cooling Mode Blower Speeds

Speed

Switch 5 Switch 6

1 − Low On On

2 − Medium Low Off On

3 − Medium High On Off

4 − High (Factory) Off Off

Switches 7 and 8 −− Blower Speed Adjustment −−

Switches 7 and 8 are used to select blower speed adjustment settings. The unit is shipped from the factory with the dip switches positioned for NORMAL (no) adjustment. The dip switches may be positioned to adjust the blower speed by +10% or −10% to better suit the application. The table below provides blower speed adjustments that will result from different switch settings. Refer to tables 18 through 22 for corresponding cfm values.

TABLE 15

Blower Speed Adjustment

Adjustment

Switch 7 Switch 8

+10% (approx.) On Off

NORMAL (Factory) Off Off

−10% (approx.) Off On

Switches 9 and 10 −− Cooling Mode Blower Speed Ramping −− Switches 9 and 10 are used to select cooling

mode blower speed ramping options. Blower speed ramping may be used to enhance dehumidification performance. The switches are factory set at option A which has the greatest effect on blower motor performance. Table 16 provides the cooling mode blower speed ramping options that will result from different switch settings. The cooling mode blower speed ramping options are detailed on the next page.

NOTE − The off portion of the selected ramp profile also applies during heat pump operation in dual fuel applications.

Page 26

TABLE 16

Cooling Mode Blower Speed Ramping

Ramping Option

Switch 9 Switch 10

A (Factory) Off Off

B On Off C Off On D On On

Ramping Option A (Factory Selection)

D Motor runs at 50% for 30 seconds. D Motor then runs at 82% for approximately 7−1/2 min-

utes.

D If demand has not been satisfied after 7−1/2 minutes,

motor runs at 100% until demand is satisfied.

D Once demand is met, motor runs at 50% for 30 sec-

onds then ramps down to stop.

OFF

1/2 MIN 50% CFM

COOLING DEMAND

7 1/2 MIN 82% CFM

100% CFM

1/2 MIN 50% CFM

Ramping Option B

S Motor runs at 82% for approximately 7−1/2 minutes. If

demand has not been satisfied after 7−1/2 minutes, motor runs at 100% until demand is satisfied.

S Once demand is met, motor ramps down to stop.

OFF

82%CFM

100% CFM

COOLING DEMAND

7 1/2 MIN

Ramping Option C

S Motor runs at 100% until demand is satisfied.

S Once demand is met, motor runs at 100% for 45 sec-

onds then ramps down to stop.

OFF

100% CFM

DEMAND

45 SEC.

Ramping Option D

S Motor runs at 100% until demand is satisfied.

S Once demand is met, motor ramps down to stop.

OFFOFF

100% CFM

COOLING DEMAND

Switches 11 and 12 −− Heating Mode Blower Speed −−

Switches 11 and 12 are used to select heating mode blower motor speed. The unit is shipped from the factory with the dip switches positioned for medium low (2) speed indoor blower motor operation during the heating mode. The table below provides the heating mode blower speeds that will result from different switch settings. Refer to tables 18 through 22 for corresponding cfm values.

TABLE 17

Heating Mode Blower Speeds

Speed

Switch 11 Switch 12

1 − Low On On

2 − Medium Low

(Factory)

Off On

3 − Medium High On Off

4 − High Off Off

On−Board Link W914

On−board link W914, is a clippable connection between terminals DS and R on the integrated control. W914 must be cut when the furnace is installed with either the Harmony IIIt zone control or a thermostat which features humidity control. If the link is left intact the PMW signal from the Harmony III control will be blocked and also lead to control damage. Refer to table 23 for operation sequence in applications including G60DFV, a thermostat which features humidity control and a single−speed outdoor unit. Table 24 gives the operation sequence in applications with a two− speed outdoor unit.

On−Board Link W951

On−board link W951 is a clippable connection between terminals R and O on the integrated control. W951 must be cut when the furnace is installed in applications which include a heat pump unit and a thermostat which features dual fuel use. If the link is left intact, terminal O" will remain energized eliminating the HEAT MODE in the heat pump.

On−Board Link W915

On−board link W915 is a clippable connection between terminals Y1 and Y2 on the integrated control. W915 must be cut if two−stage cooling will be used. If the link is not cut the outdoor unit will operate in second−stage cooling only.

Status LEDs (SPEED, CFM, STATUS, E−COM)

The green SPEED LED indicates circulating blower speed in response to the DS signal. The LED is lit during normal blower operation and is off during a dehumidification demand. In Harmony III applications, the brightness of the LED indicates the requested blower speed.

The green CFM LED indicates the blower air flow. Count the number of blinks between the two−second pauses to determine the CFM. Each blink represents approximately 100 CFM.

The STATUS LED flashes diagnostic codes, which are detailed on page 38.

The green E−COM LED indicates that the control is receiving and processing of commands and inputs. The LED may flash rapidly or may display a single flash, depending upon the activity.

Page 27

TABLE 18

G60DFV−36A−070 BLOWER MOTOR PERFORMANCE

0.0" to 0.8" w.g. (0 through 200 Pa) External Static Pressure Range

Factory Settings: Heating Speed − 2; Cooling Speed − 4; Speed Adjust − NORM

Speed Switch Positions

ADJUST"

Second Stage HEAT" Speed Second Stage COOL" Speed

Switch

Positions

2 3 4 1 2 3

Positions

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

945 445 1105 525 1375 650 1425 670 1105 520 1290 610 1390 655 1505 710

NORM 855 405 995 470 1240 585 1285 605 1010 475 1140 540 1240 585 1360 645

 785

370 885 420 1090 515 1125 530 875 415 1025 485 1090 515 1195 565



First Stage HEAT" Speed First Stage COOL" Speed

ADJUST"

Switch

2 3 4 1 2 3

Stc

Positions

cfm

L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

855 405 1005 475 1240 585 1295 610 765 360 855 405 910 430 1000 470

NORM 795 375 900 425 1110 525 1165 550 710 335 790 375 840 395 905 430



730 345 810 385 990 465 1025 485 660 310 725 345 765 360 810 385

Factory default jumper setting.

NOTES − The effect of static pressure is included in air volumes shown.

Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 426 cfm (201 L/s).

TABLE 19

G60DFV−36B−090 BLOWER MOTOR PERFORMANCE

0.0" to 0.8" w.g. (0 through 200 Pa) External Static Pressure Range

Factory Settings: Heating Speed − 2; Cooling Speed − 4; Speed Adjust − NORM

Speed Switch Positions

ADJUST"

Second Stage HEAT" Speed Second Stage COOL" Speed

Switch

Positions

2 3 4 1 2 3

Positions

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

1005 475 1165 550 1435 680 1495 705 1145 540 1330 625 1425 675 1555 735

NORM 920 435 1055 495 1295 610 1350 635 1040 490 1195 565 1285 605 1405 660

 N/A

N/A 935 440 1150 540 1185 560 920 435 1060 500 1140 540 1235 585



First Stage HEAT" Speed First Stage COOL" Speed

ADJUST"

Switch

2 3 4 1 2 3

Stc

Positions

cfm

L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

915 430 1060 500 1300 615 1350 640 805 380 910 430 970 455 1055 495

NORM 840 395 955 450 1170 555 1210 570 745 350 825 390 875 410 950 450



N/A N/A 860 405 1040 490 1080 510 695 330 765 360 800 380 860 405

Factory default jumper setting. N/A − First and second stage HEAT positions shown cannot be used on this model. NOTES − The effect of static pressure is included in air volumes shown.

Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 523 cfm (245 L/s).

Page 28

TABLE 20

G60DFV−60C−090 BLOWER MOTOR PERFORMANCE

0.0" to 0.8" w.g. (0 through 200 Pa) External Static Pressure Range

Factory Settings: Heating Speed − 2; Cooling Speed − 4; Speed Adjust − NORM.

Speed Switch Positions

ADJUST"

Second Stage HEAT" Speed Second Stage COOL" Speed

Switch

Positions

2 3 4 1 2 3

Positions

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

1620 765 1820 860 2030 960 2260 1065 1750 825 1860 880 2100 990 2365 1115

NORM 1465 690 1660 785 1865 880 2060 975 1565 740 1685 795 1905 900 2130 1005

 1300

615 1475 695 1675 790 1845 870 1390 655 1505 710 1710 810 1920 905



First Stage HEAT" Speed First Stage COOL" Speed

ADJUST"

Switch

2 3 4 1 2 3

Stc

Positions

cfm

L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

1470 695 1685 795 1885 890 2060 970 1200 565 1280 605 1460 690 1665 785

NORM 1325 625 1515 715 1725 815 1885 890 1090 515 1165 550 1315 620 1475 695



1200 565 1335 630 1520 715 1695 800 970 455 1050 495 1190 560 1315 620

Factory default jumper setting.

NOTES − The effect of static pressure is included in air volumes shown.

Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 520 cfm (245 L/s).

TABLE 21

G60DFV−60C−110 BLOWER MOTOR PERFORMANCE

0.0" to 0.8" w.g. (0 through 200 Pa) External Static Pressure Range

Factory Settings: Heating Speed − 2; Cooling Speed − 4; Speed Adjust − NORM.

Speed Switch Positions

ADJUST"

Second Stage HEAT" Speed Second Stage COOL" Speed

Switch

Positions

2 3 4 1 2 3

Positions

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

1565 740 1765 835 1980 935 2210 1040 1685 795 1800 850 2035 960 2295 1080

NORM 1400 660 1620 765 1805 850 1995 940 1510 715 1645 775 1855 875 2075 980

 N/A

N/A 1415 670 1615 760 1780 840 1340 630 1450 685 1670 790 1845 870



First Stage HEAT" Speed First Stage COOL" Speed

ADJUST"

Switch

2 3 4 1 2 3

Stc

Positions

cfm

L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

1415 670 1625 765 1815 860 2000 945 1150 545 1235 580 1400 660 1585 745

NORM 1280 605 1465 690 1655 780 1830 865 1045 495 1130 530 1265 595 1420 670



N/A N/A 1290 610 1465 690 1645 775 930 440 1000 470 1135 535 1265 595

Factory default jumper setting. N/A − First and second stage HEAT positions shown cannot be used on this model. NOTES − The effect of static pressure is included in air volumes shown.

Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 475 cfm (225 L/s).

Page 29

TABLE 22

G60DFV−60D−135 BLOWER MOTOR PERFORMANCE

0.0" to 0.8" w.g. (0 through 200 Pa) External Static Pressure Range

Factory Settings: Heating Speed − 2; Cooling Speed − 4; Speed Adjust − NORM.

Speed Switch Positions

ADJUST"

Second Stage HEAT" Speed Second Stage COOL" Speed

Switch

Positions

2 3 4 1 2 3

Positions

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

1570 740 1785 845 2000 945 2235 1055 1680 795 1810 855 2050 970 2310 1090

NORM 1410 665 1610 760 1825 860 2020 955 1500 710 1645 775 1865 880 2095 990

− N/A

N/A 1420 670 1620 765 1805 850 1340 630 1440 680 1670 790 1865 880



First Stage HEAT" Speed First Stage COOL" Speed

ADJUST"

Switch

2 3 4 1 2 3

Stc

Positions

cfm

L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

1415 670 1630 770 1840 670 2030 955 1160 550 1235 580 1400 660 1595 750

NORM 1280 605 1465 690 1665 785 1850 875 1045 495 1125 530 1265 600 1420 670



N/A N/A 1295 610 1475 695 1645 775 935 440 1005 475 1145 540 1270 600

Factory default jumper setting. N/A − First and second stage HEAT positions shown cannot be used on this model. NOTES − The effect of static pressure is included in air volumes shown.

Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 477 cfm (225 L/s).

TABLE 23

OPERATING SEQUENCE

G60DFV, Thermostat with Humidity Control Feature and Single−Speed Outdoor Unit

OPERATING MODE SYSTEM DEMAND SYSTEM RESPONSE

System Condition

Thermostat

Demand

*Relative Humidity

(EfficiencyPlus Lights)

Blower

CFM

(COOL)

Comments

Normal operation Y1

No demand. Humidity

level is acceptable

COOL

Compressor demand and indoor blower speed controlled by thermostat demand.

*Call for humidity

removal during

cooling demand

Humidity level rises

above setpoint. Demand

initiated.

60%/65% of COOL

Call for dehumidification initiated by thermostat. Indoor blower speed reduced by thermostat.

Dehumidification demand satisfied

during cooling de-

mand.

Humidity level falls below

setpoint. No demand

COOL

When humidity demand is satisfied, blower speed immediately increases to the COOL CFM to hasten the end of the cycle.

Call for cooling after

None

Humidity level above set-

point. Demand initiated.

Off

Dehumidification mode begins when rela-

call for humidity

removal.

Humidity level above set-

point. Demand initiated.

60%/65% of COOL

Dehumidification mode begins when rela

tive humidity is greater than setpoint.

Humidity demand satisfied between

None Over setpoint (1 or more) Off

While unit is not operating (no thermostat

satisfied between

thermostat demands

(unit off cycle).

Y1 Change to acceptable COOL

emand), s

lid

e switch is moved down an

back up. Blower operates at COOL CFM.

NOTE − When changing unit mode of operation from cooling to heating, indicating lights that are on will stay on until the first thermostat heating demand. * Reduced blower speed is 65% of COOL for the −36A and −36B units; 60% of COOL for −60C and −60D series units.

Page 30

TABLE 24

OPERATING SEQUENCE

G60DFV, Thermostat with Humidity Control Feature and Two−Speed Outdoor Unit

OPERATING MODE SYSTEM DEMAND SYSTEM RESPONSE

System

Condition

Thermostat

Demand

*Relative Humidity

(EfficiencyPlus Lights)

****Compressor

Speed

Blower CFM

(COOL)

Comments

Normal operation

Y1 No demand. Acceptable Low

**42%/46% of

HIGH COOL

Compressor demand and indoor

blower s

eed controlled by

Normal operation

Y2 No demand. Acceptable High HIGH COOL

blower speed controlled by

thermostat demand

Y1 No demand. Acceptable Low

**42%/46% of

HIGH COOL

Call for humidity

Humidity level rises slightly

(1) above setpoint. Demand

initiated.

Low

**42%/46% of

HIGH COOL

Dehumidification mode does not begin

removal during

1st−stage cooling

demand

Demand

satisfied

Humidity level remains

slightly (1) above setpoint.

Demand continues.

Off

until after initial thermostat demand is

satisfied and new cooling demand is

initiated.

Humidity level remains

slightly (1) above setpoint.

Demand continues.

High

***65%/60% of

HIGH COOL

Significant increase in

No demand. Acceptable

Low

**42%/46% of

HIGH COOL

If humidity rises significantly above set-

point, or if slide switch is moved signifi-

humidity duri

thermostat cooling

demand.

Humidity level rises signifi-

cantly (2 or more) above

setpoint. Demand initiated.

High

***65%/60% of

HIGH COOL

point, or if slide switch is moved signifi

cantly, unit will immediately go into de-

humidification mode (in presence of

thermostat demand).

Humidity level

above setpoint.

High

***65%/60% of

HIGH COOL

When humidity demand is satisfied,

Humidity demand

satisfied durin

Humidity level falls below

setpoint. No demand.

High

HIGH COOL

When humidity demand is satisfied,

blower immediately shifts to the COOL

CFM in order to hasten the end of the

satisfied during

thermostat demand.

None

No demand. Acceptable

Off

cycle. Unit can only shift out of high

speed compressor operation at begin-

No demand. Acceptable

Low

**42%/46% of

HIGH COOL

speed compressor operation at begin

ning of next cycle.

No demand. Acceptable

High

HIGH COOL

Call for humidity

removal during 2nd

stage thermostat

Humidity level rises slightly

(1) above setpoint. Demand

initiated.

High

***65%/60% of

HIGH COOL

Blower immediately changes speed in

response to thermostat demand.

eman

No demand. Acceptable

High

HIGH COOL

*Call for 1st stage

None

Humidity level is slightly (1)

above setpoint.

Off

Dehumidification mode (high speed

compressor) begins with next thermo-

cooling after call for

humidity removal.

Humidity level is slightly (1)

above setpoint.

Low

**42%/46% of

HIGH COOL

compressor) begins with next thermo

stat demand after initial demand is sat-

isfied.

Call for 2nd stage

None

Humidity level is slightly (1)

above setpoint.

Off

Reduced blower speed (dehumidifica-

cooling after call for

humidity removal

Humidity level is slightly (1)

above setpoint.

High

***65%/60% of

HIGH COOL

tion speed) begins immediately with

thermostat demand

Call for cooling after

None

Humidity level is significantly

above setpoint (2 or more).

Off

If humidity increases significantly over

setpoint, or if slide switch is moved,

significant increase in

humidity

Y1 or Y2

Humidity level is significantly

above setpoint (2 or more).

High

***65%/60% of

HIGH COOL

unit immediately goes into dehumidifi-

cation mode (in presence of thermostat

demand).

Humidity demand satisfied between

None

Humidity level is slightly (1)

above setpoint.

Off

While unit is not operating (no thermo-

stat demand), slide switch is moved

satisfied between

thermostat demands

(unit off cycle).

Y1 or Y2

Humidity level falls below

setpoint. No demand.

High

HIGH COOL

down and back up. Blower and com-

pressor operate at high speed until

next thermostat demand.

NOTE − When changing unit mode of operation from cooling to heating, indicating lights that are on will stay on until the first thermostat heating demand.

*IMPORTANT - If power to unit is turned on with thermostat calling for humidity removal, outdoor unit may be locked into high speed indefinitely. To reset, move humidity slide switch all the way down then back up to desired setpoint (with unit running) ** Reduced blower speed is 42% of HIGH COOL for −36A and −36B units; 46% of HIGH COOL for −60C and −60D series units. *** Reduced blower speed is 65% of HIGH COOL for −36A and −36B units; 60% of HIGH COOL for −60C and −60D series units. ****If the two−speed control on a two−speed outdoor unit is set for LATCH 2 (15 minutes) or LATCH 3 (30 minutes), the compressor will latch into high speed after a Y1 demand has occurred for that period of time.

Page 31

Unit Start−Up

FOR YOUR SAFETY READ BEFORE LIGHTING

WARNING

Do not use this furnace if any part has been underwater. Immediately call a licensed professional service technician (or equivalent) to inspect the furnace and to replace any part of the control system and any gas control which has been under water.

WARNING

If overheating occurs or if gas supply fails to shut off, shut off the manual gas valve to the appliance before shutting off electrical supply.

CAUTION

Before attempting to perform any service or maintenance, turn the electrical power to unit OFF at disconnect switch.

WARNING

During blower operation, the ECM motor emits energy that may interfere with pacemaker operation. Interference is reduced by both the sheet metal cabinet and distance.

BEFORE LIGHTING smell all around the appliance area

for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

The gas valve on the G60DFV(X) unit may be equipped with either a gas control knob or gas control switch. Use only your hand to move the control switch or to turn the gas control knob. Never use tools. If the knob will not turn or if the switch will not move by hand, do not try to repair it. Call a licensed professional service technician (or equivalent). Force or attempted repair may result in a fire or explosion.

Placing the furnace into operation:

G60DFV(X) units are equipped with an automatic ignition system. Do not attempt to manually light burners on these furnaces. Each time the thermostat calls for heat, the burners will automatically light. The ignitor does not get hot when there is no call for heat on units with an automatic ignition system.

WARNING

If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or death.

Gas Valve Operation (Figures 20 and 21)

1 − STOP! Read the safety information at the beginning of

this section.

2 − Set the thermostat to the lowest setting.

3 − Turn off all electrical power to the unit. 4 − This furnace is equipped with an ignition device which

automatically lights the burners. Do not try to light the

burners by hand. 5 − Remove the upper access panel. 6 − White Rodgers 36E Gas Valve − Move gas valve con-

trol switch to OFF. See figure 20.

Honeywell VR8205 Gas Valve − Turn knob on gas

valve clockwise

to OFF. Do not force. See figure

21.

7 − Wait five minutes to clear out any gas. If you then smell

gas, STOP! Immediately call your gas supplier from a

neighbor’s phone. Follow the gas supplier’s instruc-

tions. If you do not smell gas go to next step.

WHITE RODGERS 36E SERIES GAS VALVE

GAS VALVE SHOWN IN OFF POSITION

HIGH FIRE MANIFOLD PRESSURE

ADJUSTMENT

ON SIDE

(under cap)

MANIFOLD

PRESSURE

TAP ON SIDE

INLET PRESSURE

TAP ON SIDE

LOW FIRE MANIFOLD

PRESSURE ADJUSTMENT

ON SIDE (under cap)

FIGURE 20

HONEYWELL VR8205 SERIES GAS VALVE

GAS VALVE SHOWN IN OFF POSITION

MANIFOLD

PRESSURE

TAP

HIGH FIRE

ADJUSTING SCREW

(under cap)

INLET PRESSURE

TAP

LOW FIRE

ADJUSTING SCREW

(under cap)

FIGURE 21

8 − White Rodgers 36E Gas Valve − Move gas valve con-

trol switch to ON. See figure 20. Honeywell VR8205 Gas Valve − Turn knob on gas

valve counterclockwise

to ON. Do not force. See

figure 21.

9 − Replace the upper access panel.

10 − Turn on all electrical power to to the unit.

Page 32

11 − Set the thermostat to desired setting.

NOTE − When unit is initially started, steps 1 through 11 may need to be repeated to purge air from gas line.

12− If the appliance will not operate, follow the instructions

Turning Off Gas to Unit" and call your service technician or gas supplier.

Turning Off Gas to Unit

1 − Set the thermostat to the lowest setting. 2 − Turn off all electrical power to the unit if service is to be

performed. 3 − Remove the upper access panel. 4 − White Rodgers 36E Gas Valve − Move gas valve con-

trol switch to OFF.

Honeywell VR8205 Gas Valve − Turn knob on gas

valve clockwise

to OFF. Do not force.

5 − Replace the upper access panel.

Gas Pressure Adjustment

Gas Flow

To check for proper gas flow to the combustion chamber, determine the Btu (kW) input from the unit nameplate. Divide this input rating by the Btu (kW) per cubic foot (cubic meter) of available gas. The result is the required number of cubic feet (cubic meter) per hour. Determine the flow of gas through the gas meter for two minutes and multiply by 30 to get the hourly flow of gas.

Gas Pressure

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

11.0 in. w.c. for LP/propane gas should be maintained.

2 − After the line pressure has been checked and ad-

justed, check the low fire and high fire manifold pres-

sures. See figures 20 and 21 for the location of the

manifold pressure adjustment screws. Low and high

fire manifold pressures are given in table 25. A natural

gas to LP/propane gas changeover kit is required to

convert the unit.

High Altitude Information

Refer to table 25 for high altitude requirements and manifold pressure settings at all altitudes.

NOTE − In Canada, certification for installations at elevations over 4500 feet (1372 m) is the jurisdiction of local authorities.

NOTE − A natural to L.P. propane gas changeover kit is necessary to convert this unit. Refer to the changeover kit installation instruction for the conversion procedure.

Other Unit Adjustments

Primary and Secondary Limits

The primary limit is located on the heating compartment vestibule panel. The secondary limits (if equipped) are located in the blower compartment, attached to the back side of the blower. These limits are factory set and require no adjustment.

Flame Rollout Switches (Two)

These manually reset switches are located on (or inside of) the burner box. If tripped, check for adequate combustion air before resetting.

Pressure Switches

The pressure switch assembly (includes two switches) is located in the heating compartment adjacent to the combustion air inducer. These switches check for proper combustion air inducer operation before allowing ignition trial. The switches are factory−set and require no adjustment.

Temperature Rise

Place the unit into operation with a second−stage heating demand. After supply and return air temperatures have stabilized, check the temperature rise. If necessary, adjust the heating blower speed to maintain the temperature rise within the range shown on the unit nameplate. Increase the blower speed to decrease the temperature rise. Decrease the blower speed to increase the temperature rise. Failure to properly adjust the temperature rise may cause erratic limit operation and may result in premature heat exchanger failure.

Thermostat Heat Anticipation

Set the heat anticipator setting (if adjustable) according to the amp draw listed on the wiring diagram that is attached to the unit.

TABLE 25

High Altitude Requirements / Manifold Pressure Settings

Altitude

Model

Input

Gas

0 − 7500 ft.

(0 − 2285 m)

7501−10,000 ft.

(2286 − 3048 m)

Manifold Pressure

at all altitudes

Input

Size

Gas

Required Pressure Required Pressure

Low Fire High Fire

Required

Conversion Kit

Pressure

Switch

Required

Conversion Kit

Pressure

Switch

in. w.g. kPa in. w.g. kPa

−070, −090,

Nat. N/A No Change 44W51 44W31 1.7 0.42 3.5 0.87

−070, −090

−110, −135

LPG 44W48 No Change 44W50 44W31 4.9 1.22 10.0 2.5

Pressure switch is factory set. No adjustment necessary. All models use the factory installed pressure switch from 0−7500 feet (0−2285 m).

Page 33

Electrical

1 − Check all wiring for loose connections. 2 − Check for the correct voltage at the furnace (furnace

operating).

3 − Check amp-draw on the blower motor.

Motor Nameplate__________Actual__________

NOTE − Do not secure the electrical conduit directly to the air ducts or structure.

Electronic Ignition

The two−stage, variable speed integrated control used in G60DFV units has an added feature of an internal Watchguard control. The feature serves as an automatic reset device for ignition control lockout caused by ignition failure. This type of lockout is usually due to low gas line pressure. After one hour of continuous thermostat demand for heat, the Watchguard will break and remake thermostat demand to the furnace and automatically reset the control to begin the ignition sequence.

Flue And Chimney

1 − Check flue pipe, chimney and all connections for tight-

ness and to make sure there is no blockage. 2 − Check unit for proper draft. 3 − Is pressure switch closed? Obstructed flue will cause

unit to shut off at pressure switch. Check flue and outlet

for blockages. 4 − Reset manual flame rollout switches on burner box.

Failure To Operate

If the unit fails to operate, check the following: 1 − Is the thermostat calling for heat? 2 − Are access panels securely in place? 3 − Is the main disconnect switch closed? 4 − Is there a blown fuse or tripped circuit breaker? 5 − Is the filter dirty or plugged? Dirty or plugged filters will

cause the limit control to shut the unit off. 6 − Is gas turned on at the meter? 7 − Is the manual main shut-off valve open? 8 − Is the internal manual shut-off valve open? 9 − Is the unit ignition system in lock out? If the unit locks

out again, call the service technician to inspect the unit

for blockages.

Heating Sequence of Operation

NOTE − The integrated control thermostat selection DIP switch is factory−set in the TWO−STAGE" position.

Applications Using a Two−Stage Thermostat

A − Heating Sequence −− Control Thermostat Selection DIP Switch in Two−Stage" Position (Factory Setting)

1 − On a call for heat, thermostat first−stage contacts close

sending a signal to the integrated control. The integrated control runs a self-diagnostic program and checks high temperature limit switches for normally closed contacts and pressure switches for normally open contacts.The combustion air inducer is energized at low speed and the 120 VAC humidifier terminal is energized.

2 − Once the control receives a signal that the low pres-

sure switch has closed, the combustion air inducer begins a 15−second pre−purge in low speed.

3 − After the pre−purge is complete, a 20−second initial ig-

nitor warm−up period begins. The combustion air inducer continues to operate at low speed.

4 − After the 20−second warm−up period has ended, the

gas valve is energized on low fire (first stage) and ignition occurs. At the same time, the control module sends a signal to begin an indoor blower 45−second ON−delay. When the delay ends, the indoor blower motor is energized on the low fire heating speed and the 24V humidifier terminal is energized. The furnace will continue this operation as long as the thermostat has a first−stage heating demand.

5 − If second−stage heat is required, the thermostat sec-

ond−stage heat contacts close and send a signal to the integrated control. The integrated control initiates a 30−second second−stage recognition delay.

6 − At the end of the recognition delay, the integrated con-

trol energizes the combustion air inducer at high speed. The control also checks the high fire (second stage) pressure switch to make sure it is closed.The high fire (second stage) gas valve is energized and the indoor blower motor is energized for operation at the high fire heating speed.

7 − When the demand for high fire (second stage) heat is

satisfied, thecombustion air inducer is switched to the low−fire heating speed and the high−fire (second stage) gas valve is de−energized. The low−fire (first stage) gas valve continues operation. The indoor blower motor is switched to the low−fire heating speed.

8 − When the thermostat demand for low−fire (first stage)

heat is satisfied, the gas valve is de−energized and the field−selected indoor blower off delay begins. The combustion air inducer begins a 5−second post−purge period.

9 − When the combustion air post−purge period is com-

plete, the inducer and humidifier terminals are de−energized. The indoor blower is de−energized at the end of the off delay.

Applications Using A Single−Stage Thermostat

B − Heating Sequence −− Control Thermostat Selection DIP Switch in Single−Stage" Position

NOTE − In these applications, two−stage heat will be initiated by the integrated control if heating demand has not been satisfied after the field adjustable period (10 or 15 minutes).

1 − On a call for heat, thermostat first−stage contacts close

2 − Once the control receives a signal that the low pres-

sure switch has closed, the combustion air inducer begins a 15−second pre−purge in low speed.

3 − After the pre−purge is complete, a 20−second initial ig-

nitor warm−up period begins. The combustion air inducer continues to operate at low speed.

Page 34

4 − After the 20−second warm−up period has ended, the

gas valve is energized on low fire (first stage) and ignition occurs. At the same time, the control module sends a signal to begin an indoor blower 45−second ON−delay. When the delay ends, the indoor blower motor is energized on the low fire heating speed and the 24V humidifier terminal is energized. The integrated control also initiates a second−stage on delay (factory−set at 10 minutes; adjustable to 15 minutes).

5 − If the heating demand continues beyond the second−

stage on delay, the integrated control energizes the combustion air inducer at high speed. The control also checks the high fire (second stage) pressure switch to make sure it is closed.The high fire (second stage) gas valve is energized and the indoor blower motor is energized for operation at the high fire heating speed.

6 − When the thermostat heating demand is satisfied, the-

combustion air inducer begins a 5−second low speed post−purge. The field−selected indoor blower off delay begins. The indoor blower operates at the low−fire heating speed.

7 − When the combustion air post−purge period is com-

plete, the inducer and humidifier terminals are de−energized. The indoor blower is de−energized at the end of the off delay.

Service

WARNING

Disconnect power before servicing unit.

CAUTION

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.

At the beginning of each heating season, a licensed professional technician (or equivalent) should check the system as follows:

Blower

Check the blower wheel for debris and clean if necessary. The blower motors are prelubricated for extended bearing life. No further lubrication is needed.

WARNING

Filters

All G60DFV(X) filters are installed external to the unit. Filters should be inspected monthly. Clean or replace the filters when necessary to ensure that the furnace operates properly. Replacement filters must be rated for high velocity airflow. Table 3 lists recommended filter sizes.

Flue And Chimney

Check the flue pipe, chimney and all connections for tightness and to make sure there is no blockage.

Electrical

1 − Check all wiring for loose connections.

2 − Check for the correct voltage at the furnace (furnace

operating).

3 − Check amp−draw on the blower motor.

Motor Nameplate__________Actual__________

Cleaning the Heat Exchanger and Burners

NOTE − Use papers or protective covering in front of the furnace during cleaning.

Cleaning the heat exchanger requires a steel spring snake," a reversible drill and a vacuum cleaner. The steel spring snake may be constructed by purchasing a 4 ft. long by 1/4 inch diameter steel wire cable and a 1/4 inch diameter 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. Attach the other end of the cable to the reversible drill to complete 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 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 1.

4 − Remove the collector box located behind the combus-

tion air inducer. Be careful with the collector box gasket. If the gasket is damaged, it must be replaced to prevent leakage.

5 − Label the wires from gas valve and rollout switches,

then disconnect them.

6 − Remove the four screws securing the burner box cover

and remove the cover.

7 − Disconnect gas supply piping. Remove six screws se-

curing the burner box / manifold assembly to the vestibule panel and remove the assembly from the unit. Take care not to damage the gasket.

8 − 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 insert from each section. See figure 23.

9 − Insert the brush end of cable snake into the top of one

of the heat exchanger openings. Do not force the cable into the heat exchanger. Insert the cable and operate the drill on slow speed. Move the cable in and 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.

Page 35

G60DFV(X) COMBUSTION AIR INDUCER,

BURNER BOX & HEAT EXCHANGER REMOVAL

FIGURE 22

Burner Box Assembly

Heat Exchanger

Combustion Air

Inducer

NOx INSERTS

(X models only)

FIGURE 23

NOx INSERT

10 −Repeat procedure for each heat exchanger section. 11 −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 and clean as described in step 8.

12 −Remove the cable from the heat exchanger. Use a vac-

uum cleaner to remove debris knocked loose during cleaning.

13 −Attach the exhaust end (positive pressure) of the vacu-

um cleaner to the top of the heat exchanger section. Any loose debris will be forced to the bottom of the heat exchanger section. Vacuum debris from bottom openings.

14 −Replace collector box and combustion air inducer.

Check gaskets for damage. Damaged gaskets must be replaced to avoid heat exchanger leaks. Replace all screws to the collector box and combustion air inducer. Failure to replace all screws may cause leaks.

15 −To clean the burner, run a vacuum cleaner with a soft

brush attachment over the face of burners. Visually inspect inside the burners and crossovers for any blockage caused by foreign matter. Remove any blockage.

16 −NOx units only − Reattach the NOx inserts to the cor-

bels at the entrance to each heat exchanger opening. See figure 23.

17 −Re−install gasket and burner box / manifold assembly

onto the vestibule panel. Replace burner box cover and re−secure using screws.

NOTE − Gasket must be replaced if it was damaged during disassembly.

18 −Reconnect wires to pressure switch, roll−out switches,

gas valve and combustion air inducer. Refer to unit wiring diagram.

19 −Re−install top cap and re−secure vent pipe to combus-

tion air inducer outlet.

20 −Reconnect gas supply piping.

21 −Turn on power and gas supply to unit.

22 −Set thermostat and check for proper operation.

23 −Check all piping connections, factory and field, for gas

leaks. Use a leak detecting solution or other preferred means.

CAUTION

24 − If a leak is detected, shut gas and electricity off and re-

pair leak.

25 −Repeat steps 23 and 24 until no leaks are detected.

26 −Replace front access panel.

Page 36

Planned Service

The following items should be checked during an annual inspection. Power to the unit must be shut off for the service technician’s safety.

Fresh air grilles and louvers (on the unit and in the room where the furnace is installed) − Must be open and unobstructed to provide combustion air.

Burners − Must be inspected for rust, dirt, or signs of water.

Vent pipe − Must be inspected for signs of water, damaged

or sagging pipe, or disconnected joints.

Unit appearance − Must be inspected for rust, dirt, signs of water, burnt or damaged wires, or components.

Blower access door − Must be properly in place and provide a seal between the return air and the room where the furnace is installed.

Return air duct − Must be properly attached and provide an air seal to the unit.

Operating performance − Unit must be observed during operation to monitor proper performance of the unit and the vent system.

Combustion gases − Flue products must be analyzed and compared to the unit specifications.

Problems detected during the inspection may make it necessary to temporarily shut down the furnace until the items can be repaired or replaced.

Pay attention to your furnace. Situations can arise between annual furnace inspections that may result in unsafe operation.

Repair Parts List

The following repair parts are available through independent Lennox dealers. When ordering parts, include the complete furnace model number listed on the CSA International nameplate −− Example: G60DFV(X)−36A−070−7.

Cabinet Parts

Upper access panel Blower panel Top cap

Control Panel Parts

Transformer Two−stage, variable speed integrated control Door interlock switch Circuit breaker

Blower Parts

Blower wheel Blower housing Motor Motor electronics Power choke (1 hp only) Motor mounting frame Motor capacitor Blower housing cutoff plate

Heating Parts

Flame Sensor

Heat exchanger assembly Gas manifold Two−speed combustion air inducer Two−stage gas valve Main burner cluster Main burner orifices Pressure switch Ignitor Primary limit control Flame rollout switch

Secondary limit

Page 37

Integrated Control Diagnostic Codes

FLASH CODE

(X + Y)

STATUS / ERROR DESCRIPTION

FLASH CODE DESCRIPTIONS

Pulse A 1/4 second flash followed by four seconds of off time.

Heartbeat Constant 1/2 second bright and 1/2 second dim cycles.

X + Y

LED flashes X times at 2Hz, remains off for two seconds, flashes Y times at 2Hz, remains off for four seconds, then repeats.

Pulse Power on − Standby.

Heartbeat Normal operation − signaled when heating demand initiated at thermostat.

FLAME CODES

1 + 2 Low flame current −− run mode.

1 + 3 Flame sensed out of sequence −− flame still present.

PRESSURE SWITCH CODES

2 + 3 Low pressure switch failed open.

2 + 4 Low pressure switch failed closed.

2 + 5 High pressure switch failed open.

2 + 6 High pressure switch failed closed.

2 + 7 Low pressure switch opened during ignition trial or heating demand.

LIMIT CODE

3 + 1 Limit switch open.

WATCHGUARD CODES

4 + 1 Watchguard −− Exceeded maximum number of retries.

4 + 2 Watchguard −− Exceeded maximum number of retries or last retry was due to pressure switch opening.

4 + 3 Watchguard −− Exceeded maximum number of retries or last retry was due to flame failure.

4 + 5 Watchguard −− Limit remained open longer than three minutes.

4 + 6

Watchguard −− Flame sensed out of sequence; flame signal gone.

4 + 7 Ignitor circuit fault −− Failed ignitor or triggering circuitry.

4 + 8 Low line voltage.

HARD LOCKOUT CODES

5 + 1 Hard lockout −− Rollout circuit open or previously opened.

5 + 2 Control failed self check, internal error (control will restart if error recovers).

5 + 3 No Earth ground (control will restart if error recovers).

5 + 4 Reversed line voltage polarity (control will restart if the error recovers).

5 + 6 Low secondary (24VAC) voltage.

Page 38

Troubleshooting: Heating Sequence of Operation

HEATING SEQUENCE OF OPERATION

NORMAL AND ABNORMAL HEATING MODE

CONTROL SELF−CHECK OKAY?

YES

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF. (RESET CONTROL BY

TURNING MAIN POWER OFF.)

POLARITY REVERSED.

STATUS ERROR CODE 5 + 4.

POWER ON

POLARITY OKAY?

SIGNAL HOLDS UNTIL UNIT IS PROPERLY GROUNDED.

STATUS ERROR CODE 5 + 3.

IS THERE A

PROPER GROUND?

YES

NORMAL OPERATION:

STATUS LED −− PULSE

THERMOSTAT CALLS FOR HEAT:

STATUS LED −− HEARTBEAT

YES

PRIMARY AND SECONDARY LIMIT

SWITCHES CLOSED?

YES

COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER ON. HAS PRIMARY OR

SECONDARY LIMIT RESET WITHIN 3 MINUTES?

STATUS ERROR CODE 3 + 1.

ROLLOUT SWITCH CLOSED?

GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

INDOOR BLOWER ON.

STATUS ERROR CODE 5 + 1. SEQUENCE HOLDS UNTIL ROLLOUT SWITCH IS RESET AND MAIN POWER IS INTERRUPTED OR

T’STAT IS CYCLED OFF/ON FOR 3 SEC. MINIMUM.

YES

FIRST (LOW) STAGE PRESSURE SWITCH

CONTACTS OPEN?

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF. CONTROL REMAINS UNTIL

PRESSURE SWITCH IS DETECTED OPEN.

STATUS ERROR CODE 2 + 4

YES

GAS VALVE OFF.

COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF.

CONTROL WILL NOT ATTEMPT SECOND−STAGE

OPERATION DURING THIS HEAT DEMAND.

FIRST−STAGE OPERATION WILL BE ATTEMPTED.

STATUS ERROR CODE 2 + 6.

TWO−STAGE OR SINGLE−STAGE THERMOSTAT

CALL FOR HEAT

COMBUSTION AIR INDUCER ON LOW SPEED.

STATUS LED −− HEARTBEAT

CONTINUED ON NEXT PAGE

60−MINUTE LIMIT WATCHGUARD MODE.

GAS VALVE OFF, COMBUSTION AIR

INDUCER OFF, INDOOR BLOWER OFF WITH

DELAY.

STATUS ERROR CODE 4 + 5.

YES

SECOND (HIGH) STAGE PRESSURE SWITCH

CONTACTS OPEN?

YES

Page 39

Troubleshooting: Heating Sequence of Operation (Continued)

HEATING SEQUENCE OF OPERATION

FIRST−STAGE (LOW FIRE) PRESSURE

SWITCH CLOSED WITHIN 2.5 MINUTES?

GAS VALVE OFF. COMBUSTION AIR INDUCER

OFF. INDOOR BLOWER OFF. UNIT WILL RETRY

AFTER 5−MINUTE WAIT PERIOD.

STATUS ERROR CODE 2 + 3.

YES

15−SECOND COMBUSTION AIR INDUCER

PRE−PURGE INITIATED BY CLOSED

FIRST−STAGE PRESSURE SWITCH (or 15

SECOND INTER−PURGE PERIOD.)

STATUS LED −− HEARTBEAT.

IGNITOR WARM−UP (20 SECONDS)

STATUS LED −− HEARTBEAT.

IS VOLTAGE ABOVE 90 VOLTS?

COMBUSTION AIR INDUCER OFF, IGNITER OFF.

SIGNAL HOLDS UNTIL VOLTAGE RISES ABOVE 95

VOLTS. STATUS ERROR CODE 4 + 8.

YES

COMBUSTION AIR INDUCER OFF, IGNITOR

OFF.

SIGNAL HOLDS UNTIL IGNITOR IS REPLACED

OR RECONNECTED.

STATUS ERROR CODE 4 + 7.

YES

AT END OF IGNITOR 20 SECOND WARM UP

PERIOD, 4−SECOND TRIAL FOR IGNITION.

GAS VALVE OPENS, IGNITOR ENERGIZED DURING

4−SECOND TRIAL UNTIL FLAME SENSED.

YES

4−SECOND FLAME STABILIZATION PERIOD.

FLAME RECTIFICATION CURRENT CHECK

CAN FLAME BE PROVEN WITHIN 4

SECONDS AFTER GAS VALVE OPENS?

(u0.20 microamps)

GAS VALVE OFF. COMBUSTION AIR

INDUCER ON. INDOOR BLOWER OFF.

STATUS LED −− HEARTBEAT.

HAS CONTROL FAILED TO SENSE

FLAME FOR FIVE CONSECUTIVE TRIES

DURING A SINGLE HEAT DEMAND?

YES

THERMOSTAT CALLS FOR HEAT

STATUS LED − HEARTBEAT.

(Refer to box A on previous page)

YES

FLAME PRESENT?

HAS CONTROL RESET IGNITION SEQUENCE

FOUR (4) TIMES?

WATCHGUARD MODE.

STATUS ERROR CODE 4 + 3.

YES

CONTINUED ON NEXT PAGE

YES

CONTINUED

IS IGNITOR INTACT AND CONNECTED?

WATCHGUARD MODE. GAS VALVE OFF,

COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF.

STATUS ERROR CODE 4 + 1.

IS 60−MINUTE RESET PERIOD COMPLETE?

YES

Page 40

Troubleshooting: Heating Sequence of Operation (Continued)

HEATING SEQUENCE OF OPERATION

LOW FLAME SIGNAL

(Does not affect control operation)

STATUS ERROR CODE 1 + 2.

FLAME SIGNAL ABOVE

(u1.40 microamps)

YES

CONTINUED ON NEXT PAGE

YES

SINGLE−STAGE THERMOSTAT MODE

(DIP SWITCH SET AT SINGLE")

TWO STAGE THERMOSTAT MODE

(DIP SWITCH SET AT TWO")

YES

START SECOND−STAGE RECOGNITION

ON DELAY (10 OR 15 MINUTES).

STATUS LED −− HEARTBEAT

45−SECOND INDOOR BLOWER ON DELAY BEGINS.

STATUS LED −− HEARTBEAT.

YES

PRIMARY & SECONDARY LIMIT SWITCHES

CLOSED?

GAS VALVE OFF, COMBUSTION AIR INDUCER

OFF, INDOOR BLOWER ON.

STATUS ERROR CODE 3 + 1.

HAS PRIMARY OR SECONDARY LIMIT SWITCH CLOSED WITHIN 3 MINUTES?

(Indoor blower on low speed during 3−minute period)

FIRST−STAGE (LOW FIRE)

PRESSURE SWITCH CLOSED?

LIMIT SWITCH WATCHGUARD MODE.

GAS VALVE OFF, COMBUSTION AIR INDUCER OFF,

INDOOR BLOWER OFF WITH DELAY.

STATUS ERROR CODE 4 + 5

IS 60−MINUTE RESET PERIOD COMPLETE?

THERMOSTAT CALLS FOR HEAT.

STATUS LED −− HEARTBEAT.

SEE BOX A.

YES

GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

INDOOR BLOWER OFF AFTER DELAY.

STATUS ERROR CODE 2 + 3. CONTROL RESTARTS

IGNITION SEQUENCE IF PRESSURE SWITCH

CLOSES WITHIN 2−1/2 MINUTES.

YES

FIRST−STAGE HEAT DEMAND SATISFIED?

GAS VALVE OFF, COMBUSTION AIR INDUCER

OFF FOLLOWING POST PURGE.

INDOOR BLOWER OFF WITH DELAY

STATUS LED −− PULSE

YES

SECOND−STAGE HEAT DEMAND.

SECOND−STAGE HEAT DEMAND REQUIRED?

SECOND STAGE PRESSURE SWITCH CLOSED?

ABNORMAL FLASH CODE.

NOTE − IF SECOND−STAGE PRESSURE SWITCH

WAS ORIGINALLY FOUND CLOSED,

ABNORMAL CODE WILL FLASH.

SECOND−STAGE PRESSURE SWITCH CLOSED

AT BEGINNING OF HEAT DEMAND?

STATUS ERROR CODE 2 + 6.

YES

SECOND−STAGE 30−SECOND DELAY ON BEGINS.

STATUS LED −− HEARTBEAT.

SECOND−STAGE COMBUSTION AIR INDUCER

ON. SECOND−STAGE GAS VALVE ON. HIGH

HEAT INDOOR BLOWER SPEED ON.

STATUS LED −− HEARTBEAT.

YES

SECOND−STAGE PRESSURE SWITCH CLOSED

IN LESS THAN TEN (10) SECONDS?

STATUS LED −− HEARTBEAT

YES

RETURNS TO FIRST−STAGE HEAT MODE WHICH

CONTINUES UNTIL SECOND−STAGE PRESSURE

SWITCH CAN BE PROVEN or HEAT DEMAND IS

SATISFIED. FIVE (5) MINUTE WAIT PERIOD

INITIATED BEFORE RETRY. WERE 5 ATTEMPTS

MADE FOR SECOND−STAGE HEAT?

YES

CONTINUES FIRST−STAGE HEATING

DEMAND. WILL NOT REATTEMPT

SECOND−STAGE HEATING DEMAND.

STATUS ERROR CODE 2 + 5.

SECOND STAGE HEAT DEMAND

STATUS LED −− HEARTBEAT.

YES

CONTINUED

GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

INDOOR BLOWER ON.

STATUS ERROR CODE 5 + 1. SEQUENCE HOLDS

UNTIL ROLLOUT SWITCH IS RESET AND MAIN

POWER IS INTERRUPTED OR THERMOSTAT

IS CYCLED OFF/ON FOR 3 SECOND MINIMUM.

ROLLOUT SWITCHES CLOSED?

YES

Page 41

Troubleshooting: Heating Sequence of Operation (Continued)

HEATING SEQUENCE OF OPERATION

SEE BOX B

THERMOSTAT CALLS FOR HEAT.

SEE BOX A

NORMAL OPERATION.

YES

RETURN TO FIRST−STAGE HEAT MODE.

FIRST−STAGE CONTINUES UNTIL SECOND−

STAGE PRESSURE SWITCH CAN BE PROVEN

or HEAT DEMAND IS SATISFIED. A FIVE (5)

MINUTE WAIT PERIOD IS INITIATED BEFORE

RETRY. WERE 5 ATTEMPTS MADE FOR

SECOND−STAGE HEAT?

YES

SEE BOX C

FIRST−STAGE HEAT DEMAND SATISFIED?

HEAT DEMAND SATISFIED?

STATUS LED −− HEARTBEAT.

YES

TWO STAGE THERMOSTAT MODE?

(DIP SWITCH SET AT TWO")

SINGLE−STAGE THERMOSTAT MODE

(DIP SWITCH SET AT SINGLE")

YES

FIRST AND SECOND STAGE HEAT

DEMAND SATISFIED SIMULTANEOUSLY.

STATUS LED −− HEARTBEAT.

YES

GAS VALVE OFF, COMBUSTION AIR

INDUCER OFF AFTER 5−SECOND

LOW SPEED POST PURGE PERIOD,

INDOOR BLOWER OFF DELAY

INITIATED ON LOW HEAT SPEED.

STATUS LED −− HEARTBEAT.

DEMAND FOR HEAT SATISFIED.

POWER ON STAND BY.

STATUS LED −− PULSE.

YES

SECOND STAGE HEAT

DEMAND SASTISFIED?

STATUS LED −− HEARTBEAT.

GAS VALVE, COMBUSTION AIR INDUCER

AND INDOOR BLOWER RETURN TO FIRST−

STAGE OPERATION.

STATUS LED −− HEARTBEAT.

YES

FIRST STAGE HEAT DEMAND SATISFIED?

YES

GAS VALVE OFF. COMBUSTION AIR INDUCER

OFF AFTER 5−SECOND LOW SPEED POST−

PURGE PERIOD. INDOOR BLOWER OFF. DELAY INITIATED ON LOW HEAT SPEED.

STATUS LED −− PULSE.

CONTINUED

SECOND−STAGE (HIGH FIRE) HEAT

PRESSURE SWITCH CLOSED?

Page 42

Troubleshooting: Cooling Sequence of Operation

COOLING SEQUENCE OF OPERATION

SIGNAL POLARITY REVERSED.

CONTROL WILL CONTINUE TO CALL FOR COOLING

IN THIS CONDITION.

STATUS ERROR CODE 5 + 4.

POWER ON

YES

IS POLARITY REVERSED?

THERMOSTAT CALLS FOR FIRST−STAGE COOL.

COMPRESSOR AND CONDENSER FAN

ENERGIZED.

IS THERE

PROPER GROUND?

YES

INDOOR BLOWER ENERGIZED ON FIRST STAGE

COOL SPEED AFTER 2 SECOND DELAY.

FIRST−STAGE DEMAND FOR COOL SATISFIED?

THERMOSTAT CALLS FOR SECOND−STAGE COOL.

COMPRESSOR AND CONDENSER FAN DE−ENERGIZED.

INDOOR BLOWER DE−ENEGIZED.

YES

INDOOR BLOWER RAMPS UP TO SECOND−STAGE COOL SPEED.

SECOND−STAGE DEMAND FOR COOL SATISFIED?

YES

UNIT RETURNS TO FIRST STAGE COOL

SIGNAL IMPROPER GROUND AT LED.

CONTROL WILL CONTINUE TO CALL FOR COOLING

IN THIS CONDITION.

STATUS ERROR CODE 5 + 3.

Page 43

Troubleshooting: Continuous Fan Sequence of Operation

CONTINUOUS LOW SPEED FAN SEQUENCE OF OPERATION

MANUAL FAN SELECTION MADE AT THERMOSTAT.

AFTER 2 SECOND DELAY, INDOOR BLOWER IS

ENERGIZED ON CONTINUOUS FAN SPEED.

THERMOSTAT CALLS FOR FIRST−STAGE HEAT.THERMOSTAT CALLS FOR FIRST STAGE COOL.

YES

AFTER 45−SECOND DELAY, INDOOR BLOWER

SWITCHES TO LOW HEAT SPEED.

FIRST−STAGE HEAT DEMAND SATISFIED.

YES

THERMOSTAT CALLS FOR SECOND−STAGE HEAT.

YES

INDOOR BLOWER SWITCHES TO HIGH HEAT SPEED

AFTER 30−SECOND RECOGNITION PERIOD.

SECOND−STAGE HEAT DEMAND SATISFIED.

YES

INDOOR BLOWER RAMPS DOWN TO LOW

HEAT SPEED.

INDOOR BLOWER RAMPS TO FIRST STAGE

COOLING SPEED AFTER A 2−SECOND DELAY.

FIRST−STAGE COOL DEMAND SATISFIED?

YES

SECOND STAGE COOL DEMAND SATISFIED?

INDOOR BLOWER RAMPS TO SECOND

STAGE COOL SPEED

YES

SECOND STAGE COOL DEMAND

INDOOR BLOWER RAMPS DOWN TO FIRST STAGE

COOL SPEED.

YES YES

Page 44

G60DFV(X) Start−Up & Performance Check List

w.c. − LP/Propane

Filter Clean & Secure?

Line Voltage

Electrical Connections Tight?

Job Name

Job Location

Installer

Unit Model No.

Furnace Btu Input (High fire) Line Pressure

Job No.

City

Serial No.

Date

State

Technician

Flue Connections Tight?

Heating Section

Thermostat

Heat Anticipator Setting? Thermostat Level?

Fuel Type: Natural Gas?

Blower Motor Amps

Blower Motor H.P.

Gas Piping Connections Tight & Leak−Tested?

Proper Draft?

State

Blower OFF Delay Setting (60, 90, 120 or 180)?

Blower ON delay confirmed? (45 Seconds Fixed On)

High Fire Manifold Pressure

w.c. − Nat.:

LP/Propane Gas?

Combustion Gas Tested (high fire and low fire)?

w.c. − LP/Propane

Low Fire Manifold Pressure

w.c. − Nat.:

Temperature Rise

External Static Pressure? (0.8 maximum)

Lennox G60DFV-36B-090, G60DFV-36A-070, G60DFVX-36A-070, G60DFVX-36B-090, G60DFV-60C-090 Installation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual