Lennox G60DF−36B−090, G60DF−24A−045, G60DF−36A−070, G60DF−48C−090, G60DF−24A−045X Installation Instructions Manual
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Page 1
© 2002 Lennox Industries Inc.
Corp. 0210−L3
G60DF(X)
Service Literature
Revised 08−2007
G60DF(X) SERIES UNITS
G60DF series units are mid−efficiency gas furnaces used
for downflow applications only, manufactured with Lennox
Duralok Plus heat exchangers formed of aluminized steel.
Units are available in heating capacities of 44,000 to
132,000 Btuh and cooling applications up to 5 tons. Refer
to Engineering Handbook for proper sizing.
Units are factory equipped for use with natural gas. Kits are
available for conversion to LPG operation. G60DF model
units are equipped with the Lennox two−stage integrated
SureLight control. G60DF units meets the California Nitro-
gen Oxides (NO
x
) Standards and California Seasonal Effi-
ciency requirements. All units use a redundant gas valve to
assure safety shut−off as required by C.S.A.
All specifications in this manual are subject to change. Procedures outlined in this manual are presented as a recommendation only and do not supersede or replace local or
state codes. In the absence of local or state codes, the
guidelines and procedures outlined in this manual (except
where noted) are recommendations only and do not constitute code.
TABLE OF CONTENTS
Specifications Page 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Data Page 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Altitude Page 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Identification Page 9. . . . . . . . . . . . . . . . . . . . . . . . .
I Unit Components Page 10. . . . . . . . . . . . . . . . . . . . . . .
II Installation Page 23. . . . . . . . . . . . . . . . . . . . . . . . . . . .
III Start Up Page 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IV Heating System Service Checks Page 24. . . . . . . . .
V Typical Operating Characteristics Page 26. . . . . . . . .
VI Maintenance Page 27. . . . . . . . . . . . . . . . . . . . . . . . . .
VII Wiring and Sequence of Operation Page 30. . . . . .
VIII Field Wiring and Jumper Settings Page 46. . . . . . .
IX Control Board Troubleshooting Page 50. . . . . . . . . .
G60DF−1 MODEL SHOWN
IMPORTANT
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 qualified installer, service agency
or the gas supplier.
WARNING
Electric shock hazard. Can cause injury
or death. Before attempting to perform
any service or maintenance, turn the
electrical power to unit OFF at disconnect switch(es). Unit may have multiple
power supplies.
WARNING
Sharp edges.
Be careful when servicing unit to avoid sharp edges
which may result in personal injury.
Page 2
SPECIFICATIONS G60DF(X) Models
Gas
Heating
Performance
ModelNo. G60DF−24A−045 G60DF−36A−070 G60DF−36B−090 G60DF−48C−090
Low NO
x
Model No. G60DF−24A−045X G60DF−36A−070X − − − G60DF−48C−090X
Input− Btuh (kW) low fire 30,000 (8.8) 45,000 (13.2) 60,000 (17.6) 60,000 (17.6)
Output− Btuh (kW) low fire 24,000 (7.0) 36,000 (10.5) 48,000 (14.1) 49,000 (14.4)
Input− Btuh (kW) high fire 44,000 (12.8) 66,000 (19.3) 88,000 (25.8) 88,000 (25.8)
Output− Btuh (kW) high fire 36,000 (10.5) 54,000 (15.8) 72,000 (21.1) 72,000 (21.1)
AFUE 80.0% 80.0% 80.0% 80.0%
California Seasonal Efficiency 73.3% 74.5% 75.0% 74.4%
Highstatic− in.w.g. (Pa) .50 (124) .50 (124) .50 (124) .50 (124)
Temperature rise range − F (C) low fire 15 − 45 (8 − 25) −1, −2, units
20 − 50 (11 − 28)
−4 units 15 − 45
(6 − 25)
−1, −2, units
25 − 55 (14 − 31)
−4 units 20 − 50
(11 − 28)
20 − 50 (11 − 28)
Temperature rise range − F (C) high fire 30 − 60 (17 − 33) 35 − 65 (19 − 36) 45 − 75 (25 − 42) 35 − 65 (19 − 36)
Connections
GaspipesizeIPS− in. (mm) 1/2 (12.7) 1/2 (12.7) 1/2 (12.7) 1/2 (12.7)
Flue connection − in. (mm) round 4 (102) 4 (102) 4 (102) 4 (102)
Indoor
Blower
Wheelnominaldiameter xwidth −in. 10 x 8 10 x 8 10 x 8 10 x 10
mm 254 x 203 254 x 203 254 x 203 254 x 254
Motoroutput − hp (W) 1/5 (149) 1/3 (249) 1/3 (249) 1/2 (373)
Tons(kW) ofadd-oncooling 1.5 − 2 (5.3 − 7.0) 1.5 − 3 (5.3 − 10.6) 1.5 − 3 (5.3 − 10.6) 2 − 4 (7.0 − 14.1)
Shippingweight − 1 package 121 lbs. (55 kg) 132 lbs. (60 kg) 146 lbs. (66 kg) 153 (69)
Matching Coils CR26−18N−F,
CR26−30N−F,
CR26−36N−F
CR26−18N−F,
CR26−30N−F,
CR26−36N−F
CR26−36W−F,
CR26−48N−F
CR26−36W−F,
CR26−48N−F,
CR26−60N−F
Electricalcharacteristics 120 volts − 60 hertz − 1 phase (less than 12 amps)
OPTIONAL ACCESSORIES − MUST BE ORDERED EXTRA
Down−Flow Additive Base − Shipping Weight − lbs. (kg) 11M59 − 9 (4) 11M59 − 9 (4) 11M 60 − 10 (5) 11M 61 − 11 (5)
High Altitude See Page 8
Propane/Natural Gas Kit 0 to 7500 ft. (0 to 2286 m) 59M87
Annual Fuel Utilization Efficiency based on DOE test procedures and according to FTC labeling regulations. Isolated combustion system rating for non-weatherized furnaces.
NOTE − Filters and provisions for mounting are not furnished and must be field provided.
Page 3
SPECIFICATIONS Cont.
Gas
Heating
Performance
ModelNo. G60DF−48C−110 G60DF−60C−110 G60DF−60D−135
Low NOx Model No. − − − − G60DF−60C−110X − − − −
Input− Btuh (kW) low fire 75,000 (22.0) 75,000 (22.0) 90,000 (26.4)
Output− Btuh (kW) low fire 61,000 (17.9) 61,000 (17.9) 73,000 (21.4)
Input− Btuh (kW) high fire 110,000 (32.2) 110,000 (32.2) 132,000 (38.7)
Output− Btuh (kW) high fire 90,000 (26.4) 91,000 (26.7) 109,000 (31.9)
AFUE 80.0% 80.0% 80.0%
California Seasonal Efficiency 75.4% 74.6% 75.3%
Highstatic− in.w.g. (Pa) .50 (124) .50 (124) .50 (124)
Temperature rise range − F (C) low fire −1, −2 units
25 − 55 (14 − 31)
−4 units 20 − 50 (11 − 28)
20 − 50 (11 − 28) 25 − 55 (14 − 31)
Temperature rise range − F (C) high fire 45 − 75 (25 − 42) 30 − 60 (17 − 33) 40 − 70 (22 − 39)
Connections
GaspipesizeIPS− in. (mm) 1/2 (12.7) 1/2 (12.7) 1/2 (12.7)
Flue connection − in. (mm) round 4 (102) 4 (102) 4 (102)
Indoor
Blower
Wheelnominaldiameter xwidth −in. 10 x 10 11−1/2 x 10 11−1/2 x 10
mm 254 x 254 292 x 254 292 x 254
Motoroutput − hp (W) 1/2 (373) 3/4 (560) 3/4 (560)
Tons(kW) ofadd-oncooling 2 − 4 (7.0 − 14.1) 4 − 5 (14.1 − 17.6) 4 − 5 (14.1 − 17.6)
Shippingweight − 1 package 169 lbs. (77 kg) 169 lbs. (77 kg) 192 lbs. (87 kg)
Matching Coils CR26−36W−F,
CR26−48N−F,
CR26−60N−F
CR26−48N−F,
CR26−60N−F
CR26−48W−F,
CR26−60W−F
Electricalcharacteristics 120 volts − 60 hertz − 1 phase (less than 12 amps)
OPTIONAL ACCESSORIES − MUST BE ORDERED EXTRA
Down−Flow Additive Base − Shipping Weight − lbs. (kg) 11M 61 − 11 (5) 11M6 1 − 11 (5) 11M6 2 − 13 (6)
High Altitude See Page 8
Propane/Natural Gas Kit 0 to 7500 ft. (0 to 2286 m) 59M87
Annual Fuel Utilization Efficiency based on DOE test procedures and according to FTC labeling regulations. Isolated combustion system rating for non-weatherized furnaces.
NOTE − Filters and provisions for mounting are not furnished and must be field provided.
Page 4
SPECIFICATIONS Cont.
Gas
Heating
Performance
ModelNo. G60DF−60C−110 G60DF−60D−135
Low NOx Model No. G60DF−60C−110X − − − −
Input− Btuh (kW) low fire 75,000 (22.0) 90,000 (26.4)
Output− Btuh (kW) low fire 61,000 (17.9) 73,000 (21.4)
Input− Btuh (kW) high fire 110,000 (32.2) 132,000 (38.7)
Output− Btuh (kW) high fire 91,000 (26.7) 109,000 (31.9)
AFUE 80.0% 80.0%
California Seasonal Efficiency 74.6% 75.3%
Highstatic− in.w.g. (Pa) .50 (124) .50 (124)
Temperature rise range − F (C) low fire 20 − 50 (11 − 28) 25 − 55 (14 − 31)
Temperature rise range − F (C) high fire 30 − 60 (17 − 33) 40 − 70 (22 − 39)
Connections
GaspipesizeIPS− in. (mm) 1/2 (12.7) 1/2 (12.7)
Flue connection − in. (mm) round 4 (102) 4 (102)
Indoor
Blower
Wheelnominaldiameter xwidth −in. 11−1/2 x 10 11−1/2 x 10
mm 292 x 254 292 x 254
Motoroutput − hp (W)
1 (746)
−1, −2 models 3/4 (560)
1 (746)
−1, −2 models 3/4 (560)
Tons(kW) ofadd-oncooling 4 − 5 (14.1 − 17.6) 4 − 5 (14.1 − 17.6)
Shippingweight − 1 package 172 lbs. (78 kg) 195 lbs. (88 kg)
Matching Coils CR26−48N−F,
CR26−60N−F
CR26−48W−F,
CR26−60W−F
Electricalcharacteristics 120 volts − 60 hertz − 1 phase (less than 12 amps)
OPTIONAL ACCESSORIES − MUST BE ORDERED EXTRA
Down−Flow Additive Base − Shipping Weight − lbs. (kg) 11M 61 − 11 (5) 11 M62 − 13 (6)
High Altitude See Page 8
Propane/Natural Gas Kit 0 to 7500ft (0 − 2286m) 59M87
Annual Fuel Utilization Efficiency based on DOE test procedures and according to FTC labeling regulations. Isolated combustion system rating for non-weatherized furnaces.
NOTE − Filters and provisions for mounting are not furnished and must be field provided.
BLOWER DATA
G60DF−24A−045 PERFORMANCE
External Static
Pressure
Air Volume / Watts at Different Blower Speeds
High Medium Low
in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts
0.00 0 1202 565 417 1058 500 367 828 390 278
0.05 12 1185 560 410 1041 490 360 819 385 274
0.10 25 1167 550 402 1024 482 353 809 380 270
0.15 37 1147 540 396 1008 475 346 793 375 265
0.20 50 1127 530 390 991 470 338 776 365 260
0.25 62 1104 520 382 979 460 335 764 360 257
0.30 75 1081 510 374 966 455 331 752 355 254
0.40 100 1018 480 357 922 435 319 712 335 244
0.50 125 960 455 342 873 410 306 651 305 234
0.60 150 901 425 330 811 385 290 618 290 231
0.70 175 815 385 313 691 325 272 564 265 221
0.80 200 685 325 289 619 290 259 465 220 203
0.90 225 558 265 271 510 240 238 395 185 190
NOTE − All air data is measured external to unit with 1 in. (25 mm) cleanable filter (not furnished − field provided) in place. Also see Filter Air Resistance table.
Page 5
BLOWER DATA Cont.
G60DF−36A−070 PERFORMANCE
External Static
Pressure
Air Volume / Watts at Different Blower Speeds
High Medium−High Medium−Low Low
in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts
0.00 0 1475 695 616 1343 635 554 1151 545 495 989 465 415
0.05 12 1449 685 606 1321 625 543 1139 540 481 983 465 407
0.10 25 1423 670 595 1298 615 532 1127 530 466 976 460 398
0.15 37 1397 660 585 1276 600 521 111 5 525 452 970 460 390
0.20 50 1371 645 574 1253 590 510 1103 520 437 963 455 381
0.25 62 1345 635 563 1228 580 494 1090 515 428 953 450 371
0.30 75 1318 620 552 1203 570 478 1077 510 418 943 445 360
0.40 100 1249 590 528 1151 545 455 1039 490 395 918 435 346
0.50 125 1200 565 508 1094 515 432 998 470 374 882 415 331
0.60 150 1112 525 475 1033 490 409 951 450 354 831 390 313
0.70 175 1032 485 455 968 455 390 856 405 338 722 340 280
0.80 200 959 455 434 876 415 359 737 350 299 666 315 266
0.90 225 770 365 389 715 335 321 667 315 278 591 280 244
NOTE − All air data is measured external to unit with 1 in. (25 mm) cleanable filter (not furnished − field provided) in place. Also see Filter Air Resistance table.
G60DF−36B−090 PERFORMANCE
External Static
Pressure
Air Volume / Watts at Different Blower Speeds
High Medium−High Medium−Low Low
in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts
0.00 0 1598 755 608 1408 665 526 1166 550 436 963 455 355
0.05 12 1579 745 599 1398 660 518 1164 550 428 966 455 351
0.10 25 1559 735 589 1388 655 509 1161 550 420 968 455 346
0.15 37 1528 720 573 1369 645 497 1156 545 413 966 455 341
0.20 50 1497 705 556 1350 635 485 1150 545 406 964 455 335
0.25 62 1465 690 544 1326 625 473 1137 535 398 955 450 329
0.30 75 1432 675 532 1301 615 460 1124 530 389 945 445 323
0.40 100 1370 645 509 1248 590 438 1093 515 373 933 440 313
0.50 125 1294 610 482 1198 565 420 1055 500 355 902 425 302
0.60 150 1213 575 456 1141 540 397 1012 480 343 862 405 285
0.70 175 1139 540 437 1054 495 371 917 435 313 802 380 272
0.80 200 1002 475 401 948 445 342 850 400 295 728 345 251
0.90 225 901 425 374 822 390 313 740 350 272 − − − − − − − − −
NOTE − All air data is measured external to unit with 1 in. (25 mm) cleanable filter (not furnished − field provided) in place. Also see Filter Air Resistance table.
Page 6
BLOWER DATA Cont.
G60DF−48C−090 PERFORMANCE
External Static
Pressure
Air Volume / Watts at Different Blower Speeds
High Medium−High Medium−Low Low
in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts
0.00 0 2039 960 749 1852 875 657 1595 755 562 1325 625 466
0.05 12 1998 945 727 1826 860 638 1576 745 547 1338 632 460
0.10 25 1956 925 704 1800 850 619 1556 735 532 1351 640 453
0.15 37 1921 905 692 1770 835 602 1541 725 518 1340 630 441
0.20 50 1885 890 679 1739 820 585 1526 720 503 1329 625 428
0.25 62 1844 870 662 1701 805 568 1502 710 488 1301 615 414
0.30 75 1802 850 645 1663 785 551 1477 695 473 1272 600 399
0.40 100 1693 800 606 1583 745 517 1415 670 448 1226 580 378
0.50 125 1600 755 570 1491 705 485 1334 630 414 1170 550 360
0.60 150 1494 705 540 1406 665 457 1248 590 389 111 0 525 337
0.70 175 1378 650 509 1300 615 426 1166 550 367 1026 485 316
0.80 200 1248 590 478 1161 550 390 1027 485 331 − − − − − − − − −
0.90 225 1097 520 439 1028 485 360 925 435 307 − − − − − − − − −
NOTE − All air data is measured external to unit with 1 in. (25 mm) cleanable filter (not furnished − field provided) in place. Also see Filter Air Resistance table.
G60DF−48C−110 PERFORMANCE
External Static
Pressure
Air Volume / Watts at Different Blower Speeds
High Medium−High Medium−Low Low
in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts
0.00 0 2034 960 846 1790 845 712 1508 710 595 1226 580 477
0.05 12 2001 945 825 1761 830 694 1493 705 581 1224 580 470
0.10 25 1968 930 803 1731 815 675 1477 695 567 1222 575 463
0.15 37 1924 910 781 1708 805 657 1470 695 555 1219 575 455
0.20 50 1879 885 758 1685 795 638 1463 690 542 1216 575 447
0.25 62 1837 865 736 1654 780 618 1442 680 528 1201 565 437
0.30 75 1794 845 714 1623 765 597 1420 670 514 1186 560 427
0.40 100 1681 795 669 1548 730 564 1361 640 483 1134 535 400
0.50 125 1622 765 630 1445 680 524 1280 605 447 1065 505 371
0.60 150 1447 685 592 1312 620 479 1165 550 404 1000 470 343
0.70 175 1289 610 545 1178 555 434 1056 500 369 907 430 319
0.80 200 1157 545 502 1067 505 406 956 450 348 816 385 296
0.90 225 1012 480 472 931 440 372 840 395 320 690 325 265
NOTE − All air data is measured external to unit with 1 in. (25 mm) cleanable filter (not furnished − field provided) in place. Also see Filter Air Resistance table.
G60DF−60C−110 with 3/4 hp PERFORMANCE
External Static
Pressure
Air Volume / Watts at Different Blower Speeds
High Medium−High Medium−Low Low
in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts
.00 0 2450 1155 1170 2355 111 0 1005 2145 1015 840 1845 870 705
.05 10 2430 1150 1165 2340 1105 995 2130 1005 835 1840 870 695
.10 25 2380 1120 1145 2315 1090 985 2105 995 825 1830 865 690
.15 35 2350 1110 1135 2260 1065 965 2085 985 815 1815 855 680
.20 50 2300 1085 1115 2235 1055 955 2060 975 805 1805 850 675
.25 60 2270 1070 1105 2205 1040 945 2015 950 785 1780 840 665
.30 75 2245 1060 1100 2150 1015 925 1995 940 775 1770 835 655
.40 100 2135 1010 1060 2070 975 895 1925 910 750 1730 815 640
.50 125 2055 970 1035 1990 940 870 1855 875 725 1695 800 625
.60 150 1975 930 1010 1910 900 845 1785 845 705 1650 775 605
.70 175 1870 880 980 1830 865 820 1695 800 680 1575 745 585
.80 200 1760 830 950 1720 815 795 1605 755 655 1505 710 570
.90 225 1625 765 915 1560 735 755 1515 715 640 1435 675 555
NOTE − All air data is measured external to unit with 1 in. (25 mm) cleanable filter (not furnished − field provided) in place. Also see Filter Air Resistance table.
Page 7
BLOWER DATA Cont.
G60DF−60D−135 with 3/4 hp PERFORMANCE
External Static
Pressure
Air Volume / Watts at Different Blower Speeds
High Medium−High Medium−Low Low
in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts
0.00 0 2845 1345 1143 2692 1270 961 2451 1155 818 2054 970 686
0.05 12 2774 1310 1128 2628 1240 948 2354 1110 809 2022 955 680
0.10 25 2702 1275 1112 2564 1210 935 2256 1065 799 1989 940 674
0.15 37 2629 1240 1095 2494 1175 918 2203 1040 784 1933 910 666
0.20 50 2556 1205 1077 2424 1145 901 2150 1015 769 1877 885 657
0.25 62 2471 1165 1061 2309 1090 890 2089 985 759 1835 865 649
0.30 75 2385 1125 1045 2194 1035 878 2028 955 749 1792 845 640
0.40 100 2184 1030 1022 2066 975 851 1900 895 727 1697 800 626
0.50 125 2019 955 990 1917 905 830 1779 840 707 1584 750 602
0.60 150 1865 880 957 1760 830 796 1630 770 676 1491 705 583
0.70 175 1697 800 927 1592 750 768 1475 695 656 1364 645 557
0.80 200 1513 715 897 1485 700 740 1378 650 627 1266 600 538
0.90 225 1385 655 863 1305 615 712 1206 570 598 1120 530 516
NOTE − All air data is measured external to unit with 1 in. (25 mm) cleanable filter (not furnished − field provided) in place. Also see Filter Air Resistance table.
G60DF−60C−110 with 1 hp PERFORMANCE
External Static
Pressure
Air Volume / Watts at Different Blower Speeds
High Medium−High Medium−Low Low
in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts
.00 0 2475 1170 1276 2280 1075 987 1995 940 845 1690 795 698
.10 25 2390 1125 1248 2235 1055 955 1990 940 829 1675 790 690
.20 50 2330 1100 1223 2180 1030 945 1975 930 809 1665 785 675
.30 75 2245 1060 1192 2125 1000 911 1940 915 786 1660 785 657
.40 100 2175 1025 1187 2050 965 880 1895 895 757 1650 780 636
.50 125 2085 985 1145 1970 930 849 1835 870 734 1625 765 619
.60 150 2020 955 1129 1880 885 815 1750 825 695 1580 745 599
.70 175 1920 905 1094 1775 835 785 1660 785 669 1525 720 579
.80 200 1785 840 1052 1685 795 762 1585 745 645 1440 680 556
.90 225 1670 790 1020 1600 755 741 1520 715 633 1370 645 538
NOTE − All air data is measured external to unit with 1 in. (25 mm) cleanable filter (not furnished − field provided) in place. Also see Filter Air Resistance table.
Page 8
BLOWER DATA Cont.
G60DF−60D−135 with 1 hp PERFORMANCE
External Static
Pressure
Air Volume / Watts at Different Blower Speeds
High Medium−High Medium−Low Low
in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts
.00 0 2660 1255 1379 2325 1095 1059 1960 925 864 1655 780 684
.10 25 2560 1210 1353 2310 1090 1030 1945 915 840 1640 775 667
.20 50 2490 1175 1325 2280 1075 1000 1940 915 824 1630 770 661
.30 75 2415 1140 1293 2225 1050 972 1930 910 801 1625 765 649
.40 100 2345 1105 1264 2170 1025 941 1910 900 779 1620 760 638
.50 125 2265 1070 1235 2115 1000 918 1870 880 754 1615 760 624
.60 150 2165 1020 1199 2020 955 880 1830 865 733 1585 745 604
.70 175 2050 965 1160 1940 915 854 1755 830 705 1570 740 604
.80 200 1955 920 1112 1865 880 828 1680 790 683 1515 715 584
.90 225 1865 880 1096 1760 830 797 1605 755 656 1465 690 567
NOTE − All air data is measured external to unit with 1 in. (25 mm) cleanable filter (not furnished − field provided) in place. Also see Filter Air Resistance table.
FILTER AIR RESISTANCE
cfm L/s in. w.g. Pa cfm L/s in. w.g. Pa
0 0 0.00 0 1400 660 0.15 35
200 95 0.01 0 1600 755 0.19 45
400 190 0.03 5 1800 850 0.23 55
600 285 0.04 10 2000 945 0.27 65
800 380 0.06 15 2200 1040 0.33 80
1000 470 0.09 20 2400 1130 0.38 95
1200 565 0.12 30 2600 1225 0.44 11 0
Data is for 1 inch (25 mm) cleanable filter (field provided).
HIGH ALTITUDE / MANIFOLD PRESSURE INFORMATION
Model
Input
Size
Gas
Altitude
Manifold Pressure
at all altitudes
0 − 4500 ft.
(0 − 1372 m)
4,501 − 7500 ft.
(1373 − 2286 m)
7501−10,000 ft.
(2286 − 3048 m)
Required
Conversion
Kit
Pressure
Switch
Required
Conversion
Kit
1
Pressure
Switch
Required
Conversion
Kit
1
Pressure
Switch
Low Fire High Fire
in. w.g. kPa in. w.g. kPa
045/070−1 to
−6
Nat. no change
no change
no change N/A 59M16 18M64 1.7 0.42 3.5 0.87
LPG 59M13 59M13 N/A 59M14 18M64 4.9 1.22 10.0 2.5
045/070−7
and later
Nat. no change
no change
no change N/A 59M17 18M64 1.7 0.42 3.5 0.87
LPG 59M13 59M13 N/A 59M14 18M64 4.9 1.22 10.0 2.5
090−1 to −6
Nat. no change
no change
no change 18M61 59M16 18M64 1.7 0.42 3.5 0.87
LPG 59M13 59M13 18M61 59M14 18M64 4.9 1.22 10.0 2.5
090−7 and
later
Nat. no change
no change
no change 18M61 59M17 18M64 1.7 0.42 3.5 0.87
LPG 59M13 59M13 18M61 59M14 18M64 4.9 1.22 10.0 2.5
110/135−1 to
−6
Nat. no change
no change
no change 18M63 59M16 18M61 1.7 0.42 3.5 0.87
LPG 59M13 59M13 18M63 59M14 18M61 4.9 1.22 10.0 2.5
110/135−7
and later
Nat. no change
no change
no change 18M63 59M17 18M61 1.7 0.42 3.5 0.87
LPG 59M13 59M13 18M63 59M14 18M61 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 0−4500 feet (0−1372 m).
1 − Conversion requires 2 pressure switches
Page 9
FIGURE 1
Blower Assembly
Blower Motor
Capacitor
Internal Flue Pipe
Assembly
Flue Box Gasket
Flue Collector Box
Gasket
Combustion Air Inducer
Gasket
Primary
Limit
Heat Exchanger
Combustion Air
Prove Switch
Assembly
(Two Switches)
Combustion
Air Orifice
Transformer
SureLight
®
Two−Stage
Integrated Control Board
Flue
Chase
Gasket
Door
Interlock Switch
Limit
Shield
Circuit Breaker
Flame Sensor
Gas Valve
Burners
Ignitor
Flame Rollout Switches*
Flame Rollout Bracket
Gas Orifices
Ignitor Bracket
Burner Bottom Shield
*Flame rollout switches are
located on brackets on the
inner sides.
PARTS ARRANGEMENT
NOTE − G60DF−1, −2 and −3 model units are
equipped with a fully covered burner box.
Page 10
I−UNIT COMPONENTS
Unit components are shown in figure 1. The gas valve,
combustion air inducer and burners can be accessed by removing the burner access panel. Electrical components
are in the control box (figure 2) found in the blower section.
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.
ELECTROSTATIC DISCHARGE (ESD)
Precautions and Procedures
1. Control Transformer (T1)
A transformer located in the control box provides power to
the low voltage section of the unit. Transformers on all
models are rated 40VA with a 120V primary and a 24V secondary.
2. Door Interlock Switch (S51)
A door interlock switch rated 14A at 125VAC is wired in series with line voltage. When the blower door is removed the
unit will shut down.
FIGURE 2
CONTROL BOX G60DF
Door Interlock Switch
Two−Stage Integrated
Control Board
Control Transformer
Circuit Breaker
3. Circuit Breaker (CB8)
A 24V circuit breaker is also located in the control box.
The switch provides overcurrent protection to the transformer (T1). The breaker is rated 3A at 32V. If the current
exceeds this limit the breaker will trip and all unit operation will shutdown. The breaker can be manually reset
by pressing the button on the face. See figure 3.
FIGURE 3
CIRCUIT BREAKER CB8
PRESS TO RESET
WARNING
Shock hazard.
Disconnect power before servicing. Integrated
Control Board is not field repairable. If control is
inoperable, simply replace entire control.
Can cause injury or death. Unsafe operation will
result if repair is attempted.
4. Integrated Control Board(A92)
SureLight
®
Board 18M34
All G60DF units are equipped with the Lennox two−stage
integrated SureLight control board. The system consists
of a ignition control board (figure 4 with control terminal
designations in tables 3,
4 and 5) and ignitor (figure 8).
The board and ignitor work in combination to ensure furnace ignition and ignitor durability. The board controls all
major furnace operations. The board features two LED
lights, DS1 and DS2 for troubleshooting. The board also
has two accessory terminals rated at (1) one amp each.
See table 6 for troubleshooting diagnostic codes.
Electronic Ignition
At the beginning of each heat cycle, SureLight control monitors the first stage and second stage combustion air inducer prove switch. The control will not begin the heating cycle
if the first stage prove switch is closed (by−passed). Likewise the control will not begin the second stage heating
cycle if the second stage prove switch is closed and will allow first stage heat only. However if the second stage prove
switch closes during the first stage pre−purge, the control
will still respond to second stage heat. Once the first stage
prove switch is determined to be open, the combustion air
inducer is energized on low (first stage) heat speed. When
the differential in the prove switch is great enough, the
prove switch closes and a 15−second pre−purge begins. If
the switch is not proven within 2−1/2 minutes, the control
goes into Watchguard−Pressure Switch mode for a 5−minute re−set period.
Page 11
After the 15−second pre−purge period, the SureLight ignitor
warms up for 20 seconds after which the gas valve opens
for a 4−second trial for ignition. The ignitor energizes during
the trial until flame is sensed. If ignition is not proved during
the 4−second period, the control will try four more times with
an inter purge and warm−up time between trials of 35 seconds. After a total of five trials for ignition (including the initial trial), the control goes into Watchguard−Flame Failure
mode. After a 60−minute reset period, the control will begin
the ignition sequence again.
The SureLight control board has an added feature that prolongs the life of the ignitor. After a successful ignition, the
SureLight control utilizes less power to energize the ignitor
on successive calls for heat. The control continues to ramp
down the voltage to the ignitor until it finds the lowest
amount of power that will provide a successful ignition. This
amount of power is used for 255 cycles. On the 256th call
for heat, the control will again ramp down until the lowest
power is determined and the cycle begins again.
Two Stage Operation / Thermostat Selection Jumper
The control can be utilized in two modes: SINGLE−STAGE
thermostat or TWO−STAGE thermostat. The thermostat
selection jumper E20, located just below dip switches 1
through 4 (figure 4), must be positioned for the particular
application. The jumper is factory set on TWO" for use
with a two−stage thermostat with two stage heat. Re−position jumper to SINGLE" for use with a single stage thermostat with two stage heat.
While in the single−stage thermostat mode (single jumper
setting), the burners will always fire on first−stage heat. The
combustion air inducer will operate on low speed and indoor blower will operate on low heat speed. After a field selectable 10 or 15 minute delay (dip switch 3), the unit will
switch to second stage heat. While in the two−stage thermostat mode (two jumper setting) the burners will fire on
first−stage heat. The combustion air inducer will operate on
low speed and indoor blower will operate on low heat
speed. The unit will switch to second−stage heat on call
from the indoor thermostat. If there is a simultaneous call
for W1 and W2 (first and second stage heat) the unit will fire
on first stage heat and will switch to second stage heat after
30 seconds of operation. See Sequence of Operation flow
charts in the back of this manual for more detail.
Dip Switch Settings
Dip Switches 1 and 2 − Heating Fan off Delay − The fan on
time of 45 seconds is not adjustable. Fan off time (time that
the blower operates after the heat demand has been satisfied) can be adjusted by flipping the dip switches 1 and 2
located on the SureLight integrated control. The unit is
shipped with a factory fan off setting of 90 seconds. Fan off
time will affect comfort and is adjustable to satisfy individual
applications.
For customized comfort, monitor the supply air temperature once the heat demand is satisfied. Note the supply air
temperature at the instant the blower is de−energized. Adjust the fan−off delay to achieve a supply air temperature
between 90° − 110° at the instant the blower is de−energized. (Longer delay times allow for lower air temperature,
shorter delay times allow for higher air temperature). See
table 1 for dip switch settings.
TABLE 1
Heating Fan Off Delay
Delay (Seconds)
Switch 1 Switch 2
60 Off Off
90 Off On
120 On Off
180 On On
Switch 3 − Second Stage Delay (Used with Single−Stage
Thermostat Only) −− This switch is used to determine the
second stage on delay when a single−stage thermostat is
being used. The switch is factory−set in the ON position,
which provides a 10−minute delay before second−stage
heat is initiated. If the switch is toggled to the OFF 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.
Switch 4 − Cooling Fan off Delay − The fan on delay time
of 2 seconds is not adjustable. Fan off time (time that the
blower operates after the cool demand has been satisfied)
can be adjusted by flipping dip switch 4. The unit is shipped
with a factory fan off setting of 45 seconds. Fan off time will
affect comfort and is adjustable to satisfy individual applications. See table 2 for cool fan off time settings.
TABLE 2
Cooling Fan Off Delay
Delay (Seconds)
Switch 4
2 Off
45 On
Diagnostic LED’s (DS1 and DS2)
Two diagnostic LED’S are located on the two−stage integrated control board. See figure 4. These light flashes correspond with the codes detailed in table 6.
Factory Installed Jumper Y1 to Y2
A factory−installed jumper from Y1 to Y2 terminals on the
integrated control board terminal strip must be clipped for
two−stage cooling.
Page 12
TWO−STAGE CONTROL BOARD 18M34
FIGURE 4
THERMOSTAT CONNECTIONS (TB1)
DIP
SWITCHES
1 − 4
LEDs
FACTORY−
INSTALLED
JUMPER
DIP SWITCH(ES) FUNCTION
1 and 2 Blower Off Delay (Heating Mode)
3 Second Stage ON Delay (Single−stage t’stat)
4 Blower Off Delay (Cooling Mode)
SENSOR
TABLE 3
Integrated Control Board Terminals
120VAC Neutral
LINE Line
XFMR Transformer
EAC Electronic Air Cleaner
CIRC Indoor Blower
HUM Humidifier
120VAC Line
HUM Humidifier
XMFR Transformer
LINE Line
PARK For Unused Leads
COOL Cooling Speed
EAC Electronic Air Cleaner
HI HEAT High Heat Speed
LO HEAT Low Heat, Low Cool and Continuous Fan
Speed
TABLE 4
Integrated Control Board 5 Pin Terminal
PIN # Function
1 Ignitor
2 Combustion Air Inducer High Speed
3 Combustion Air Inducer Low Speed
4 Combustion Air Inducer Neutral
5 Ignitor Neutral
TABLE 5
Integrated Control Board 12Pin Terminal
PIN # Function
1 Gas Valve 2nd Stage (High Fire)
2 Second Stage Prove Switch
3 Not Used
4 Ground
5 24V Hot
6 Primary Limit In
7 Gas Valve 1st stage (Low Fire)
8 Gas Valve Common
9 24V Neutral
10 Ground
11 Primary Limit Out
12 1st Stage Prove Switch
Page 13
TABLE 6
DIAGNOSTIC CODES
Diagnostic LEDs are labeled DS1 and DS2. See figure 4 for location of diagnostic LEDs.
DS1 DS2 DESCRIPTION
SIMULTANEOUS
SLOW FLASH
SIMULTANEOUS
SLOW FLASH
Power on − Normal operation.
Also signaled during cooling and continuous fan.
SIMULTANEOUS
FAST FLASH
SIMULTANEOUS
FAST FLASH
Normal operation − signaled when heating demand initiated at thermostat.
SLOW FLASH ON
Primary, secondary or rollout limit switch open. Limits must close within 3 minutes
or unit goes into 1 hour Watchguard.
OFF SLOW FLASH
Low prove switch open;
OR: Blocked inlet/exhaust vent;
OR: Low prove switch closed prior to activation of combustion air inducer.
OFF FAST FLASH
High prove switch open;
OR: Blocked inlet/exhaust vent;
OR: High prove switch closed prior to activation of combustion air inducer.
ALTERNATING
SLOW FLASH
ALTERNATING
SLOW FLASH
Watchguard −− burners failed to ignite; OR limit open more than 3 minutes;
OR lost flame sense 5 times in one heating cycle;
OR pressure switch opened 5 times in one heating cycle.
SLOW FLASH OFF Flame sensed without gas valve energized.
ON
ON
OFF
ON
OFF
ON
Circuit board failure or control wired incorrectly. Check 24 and 115 volts to board.
FAST FLASH SLOW FLASH Main power polarity reversed. Switch line and neutral.
SLOW FLASH FAST FLASH Low flame signal. Measures below 0.23 microAmps. Replace flame sense rod.
ALTERNATING
FAST FLASH
ALTERNATING
FAST FLASH
The following conditions are sensed during the ignitor warm−up period only:
1) Improper main ground;
2) Broken ignitor; OR: Open ignitor circuit;
3) Line voltage below 75 volts.
(If voltage lower than 75 volts prior to ignitor warm-up, control will signal waiting on
call from thermostat, and will not respond.
NOTE − Slow flash rate equals 1 Hz (one flash per second). Fast flash rate equals 3 Hz (three flashes per second).
Low flame sense current = 0.17−0.22 microAmps.
Page 14
WARNING
Shock hazard.
Disconnect power before servicing. Integrated
Control Board is not field repairable. If control is
inoperable, simply replace entire control.
Can cause injury or death. Unsafe operation will
result if repair is attempted.
5. Integrated Control Board(A92)
SureLight Board 100869
G60DF units are equipped with the Lennox two−stage integrated SureLight control board. The system consists of
a ignition / blower control board (figures 5 and 6) with control pin designations in tables 8 and 9 and and ignitor (figure 9). The board and ignitor work in combination to ensure furnace ignition and ignitor durability. The SureLight
integrated board controls all major furnace operations.
The board features a red LED light, for furnace status and
troubleshooting. The LED flashes in X" + Y" codes. For
example using table 10 under PRESSURE SWITCH
CODES", if the red LED flashes 2 times, then off for 2 seconds then flashes 3 times, the low pressure switch is failed
open. The board also has two 120 volt accessory terminals rated at (1) one amp each and one 24 volt accessory
terminal rated at 0.5.
Electronic Ignition
At the beginning of the heat cycle the SureLight control
monitors the first stage and second stage combustion air
inducer prove switch. The control will not begin the heating
cycle if the first stage prove switch is closed (by−passed).
Likewise the control will not begin the second stage heating
cycle if the second stage prove switch is closed, and will remain in first stage heat. However, if the second stage prove
switch closes during the first stage heat pre−purge, the control will allow second stage heat. Once the first stage prove
switch is determined to be open, the combustion air inducer is energized on low (first stage) heat speed. When the
differential in the prove switch is great enough, the prove
switch closes and a 15−second pre−purge begins. If the
switch is not proven within 2−1/2 minutes, the control goes
into Watchguard−Pressure Switch mode for a 5−minute re−
set period.
After the 15−second pre−purge period, the SureLight ignitor
warms up for 20 seconds after which the gas valve opens
for a 4−second trial for ignition. The ignitor energizes during
the trial until flame is sensed. If ignition is not proved during
the 4−second period, the control will try four more times with
an inter purge and warm−up time between trials of 35 seconds. After a total of five trials for ignition (including the initial trial), the control goes into Watchguard−Flame Failure
mode. After a 60−minute reset period, the control will begin
the ignition sequence again.
NOTE − Board 100869 DOES NOT ramp down voltage
to the ignitor. A regulated 95 volts is provided to the ig-
niter at ignition.
Two Stage Operation / Thermostat Selection Jumper
The control can be utilized in two modes: SINGLE−STAGE
thermostat or TWO−STAGE thermostat. The thermostat
selection is made using a dip switch (figure NO TAG) and
must be positioned for the particular application. The dip
switch is factory set on TWO" for use with a two−stage
thermostat with two stage heat. Re−position dip switch to
SINGLE" for use with a single stage thermostat with two
stage heat.
While in the single−stage thermostat mode (single dip
switch setting), the burners will always fire on first−stage
heat. The combustion air inducer will operate on low speed
and indoor blower will operate on low heat speed. After a
10 minute recognition period, the unit will switch to second
stage heat. While in the two−stage thermostat mode (two
dip switch setting) the burners will fire on first−stage heat.
The combustion air inducer will operate on low speed and
indoor blower will operate on low heat speed. The unit will
switch to second−stage heat on call from the indoor thermostat. If there is a simultaneous call for first and second stage
heat, the unit will fire an first stage heat and switch to second stage heat after 30 seconds of operation. See Sequence of Operation flow charts in the back of this manual
for more detail.
Page 15
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 −− Heating Blower−Off Delay −− The
heating blower−on delay of 45 seconds is not adjustable.
The heating 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
board. The unit is shipped from the factory with a heating
blower−off delay of 90 seconds. The heating 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 7 provides the blower off timings that will result from different
switch settings.
TABLE 7
Heating 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
Switch 5 −− Cooling Blower−Off Delay −− The cooling
blower−off delay (time that the blower operates after the
cooling demand has been satisfied) can be adjusted by
moving switch 5 on the integrated control board. The
switch is factory−set in the OFF position, which provides a
cooling blower−off delay of 45 seconds. If the switch is
toggled to the ON position, it will provide a 2−second cooling blower−off delay
On−Board Link W951
On−board link W951 is a clippable connection which connects terminals R and O on the integrated control board.
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 which connects terminals Y1 and Y2 on the integrated control board.
W915 must be cut if two−stage cooling will be used. If the
link is not cut the outdoor unit will operate in first−stage cooling only.
Page 16
CONTROL BOARD 100869
FIGURE 5
THERMOSTAT CONNECTIONS (TB1)
1/4" QUICK CONNECT TERMINALS
DIP SWITCH FUNCTIONS
DIP
SWITCHES
DIAGNOSTIC
LEDs
ON−BOARD
LINKS
1= ERROR CODE RECALL
H= 24V HUMIDIFIER OUTPUT
L= LENNOX SYSTEM OPERATION MONITOR
SENSE = 120 VAC OUTPUT TO FLAME SENSER
NEUTRALS= 120 VAC NEUTRAL
PARK = DEAD TERMINAL FOR UNUSED BLOWER LEAD
HEAT LOW = 120 VAC OUTPUT TO CIRC BLWR −− LOW HT SPEED
HEAT HIGH/ COOL LOW = 120 VAC OUTPUT TO CIRC BLWR −−
HIGH HEAT AND LOW COOL SPEED
COOL HIGH = 120 VAC OUTPUT TO CIRC BLWR −− HIGH COOL SPEED
DIP SWITCH(ES) FUNCTION
1 −− 2 Stage T’stat Selects t/stat type (single or two−stage)
2 −− 2nd Stage Delay Second stage ON delay (single−stage t’stat)
3 & 4 −− Heat Off Delay Heating fan OFF delay
5 −− Cool Off Delay Cooling fan OFF delay
W915
W951
TABLE 8
SureLight Board 5 Pin Terminal Designation
PIN # Function
1 Ignitor
2 Combustion Air Inducer High Speed
3 Combustion Air Inducer Low Speed
4 Combustion Air Inducer Neutral
5 Ignitor Neutral
TABLE 9
SureLight Board 12Pin Terminal Designation
PIN # Function
1 Gas Valve High Fire
2 Second Stage Prove Switch
3 Rollout In
4 Ground
5 24V Hot
6 Primary Limit In
7 Gas Valve Low Stage
8 Gas Valve Common
9 24V Neutral
10 Ground
11 Rollout Switch Out
12 1st Stage Prove Switch
Page 17
CONTROL BOARD 100869
FIGURE 6
Page 18
TABLE 10
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.
Error Code Storage
The ignition control stores the last ten error codes in
memory. The codes are retained in case of power loss.
Error Code Review
1 − Short R (2) to (1). Within 1/2 second, the STATUS LED
will stay lit continuously to indicate that the short was
sensed.
2 − Continue to hold the short between R (2) to (1). After 5
seconds, STATUS LED will go from being continuously
lit to off. This indicates that error code review is pending.
3 − Remove R (2) to (1) short within ten seconds of STA-
TUS LED turning off. This activates error code review.
4 − Last ten error codes will be flashed on the STATUS
LED.
5 − After final error code is indicated, STATUS LED will
flash to indicate normal operation.
Clearing Error Codes
1 − Short R (2) to (1). Within 1/2 second, the STATUS LED
will stay lit continuously to indicate that the short was
sensed.
2 − Continue to hold the short between R (2) to (1). After 5
seconds, STATUS LED will go from being continuously
lit to off.
3 − Continue to hold the short between R (2) to (1) beyond
ten seconds after STATUS LED has turned off. STATUS LED will turn on, indicating that error codes have
been cleared.
4 − Remove R (2) to (1) short. STATUS LED will flash to in-
dicate normal operation.
Page 19
6. Blower Motors and Capacitors
All G60DFunits use direct drive blower motors. All motors
are 120V permanent split capacitor motors to ensure maxi-
mum efficiency. Ratings for capacitors will be on motor
nameplate. See SPECIFICATIONS section for motor speci-
fications. Follow the steps in figure 7 for blower removal.
NOTE − Shafts on 1 HP motors have 2 flat sides and are
matched with blower wheels with 2 set screws.
FIGURE 7
SUPPLY AIR BLOWER
AND SECONDARY LIMIT (S)
To Remove Blower From Unit:
1. Disconnect Power, 2. Remove internal flue pipe and
chase (Section VI− Heat exchanger and Burners). 3. Re-
move Control Box, 4. Remove Bolts. 5. Unplug Motor
Wires From Control Board. Then Slide Out Front of Unit.
SECONDARY
LIMIT
CAPACITOR
MOTOR/BLOWER
ASSEMBLY
7. Ignitor
The SureLight ignitor is made of durable silicon nitride. Ignitor longevity is enhanced by controlling voltage to the ignitor. Board 18M34 finds the lowest ignitor temperature
which will successfully light the burner, thus increasing the
life of the ignitor. Due to this feature of the board, voltage
cannot be measured so ignitor must be ohmed. Board
100869 provides a regulated 95 volts to the ignitor for consistent ignition and long ignitor life. Ohm value for ignitors
with SureLight board 18M34 should be 10.9 to 19.7. Ohm
value for ignitors with board 100869 should be 25 to 47.
See figure 8 and 9 (make note of control board used) for
ignitor location.
NOTE − The G60DF(X) furnace contains electronic
components that are polarity sensitive. Make sure that
the furnace is wired correctly and is properly grounded.
8. Flame Sensor
A flame sensor is located on the left side of the burner support. See figure 10 and 11 (make note of control board
used). The sensor is mounted on the flame rollout plate and
the tip protrudes into the flame envelope of the left−most
burner. The sensor can be removed for service without removing any part of the burners. During operation, flame is
sensed by current passed through the flame and sensing
electrode. The SureLight control allows the gas valve to remain open as long as flame signal is sensed.
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