Lennox G60DFV-36A-070X, G60DFV-36A-070, G60DFV-36B-090, G60DFV-60C-090, G60DFV-60C-090X Unit Information

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Page 1

Corp. 0211−L3

G60DFV(X)

Service Literature

Revised 08−2007

G60DFV(X) SERIES UNITS

G60DFV 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 66,000 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. G60DFV model

units are equipped with the two−stage variable speed inte-

grated SureLight control. G60DFV model units meet the

California Nitrogen Oxides (NO

) Standards and California

Seasonal Efficiency 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. Pro-

cedures outlined in this manual are presented as a recom-

mendation 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 consti-

tute code.

TABLE OF CONTENTS

Specifications Page 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blower Data Page 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High Altitude Page 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts Identification Page 7. . . . . . . . . . . . . . . . . . . . . . . . .

I Unit Components Page 8. . . . . . . . . . . . . . . . . . . . . . . .

II Installation Page 30. . . . . . . . . . . . . . . . . . . . . . . . . . . .

III Start Up Page 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IV Heating System Service Checks Page 31. . . . . . . . .

V Typical Operating Characteristics Page 33. . . . . . . . .

VI Maintenance Page 33. . . . . . . . . . . . . . . . . . . . . . . . . .

VII Wiring and Sequence of Operation Page 37. . . . . .

VIII Field Wiring and Jumper Settings Page 52. . . . . . .

IX Integrated Control Board Troubleshooting Page 57.

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

Gas

ModelNo. G60DFV−36A−070 G60DFV−36B−090 G60DFV−60C−090

Heating

Low NO

Model No. G60DFV−36A−070X − − − G60DFV−60C−090X

Perf

ormance

Input− Btuh (kW) low fire 45,000 (13.2) 60,000 (17.6) 60,000 (17.6)

Output− Btuh (kW) low fire 36,000 (10.5) 48,000 (14.1) 48,000 (14.1)

Input− Btuh (kW) high fire 66,000 (19.3) 88,000 (25.8) 88,000 (25.8)

Output− Btuh (kW) high fire 54,000 (15.8) 72,000 (21.1) 72,000 (21.1)

lAFUE 80.0% 80.0% 80.0%

California Seasonal Efficiency 77.0% 77.1% 77.0%

Highstatic− in.w.g. (Pa) .80 (200) .80 (200) .80 (200)

Temperature rise range − _F (_C) low fire 20 − 50 (11 − 28) 25 − 55 (14 − 31) 20 − 50 (11 − 28)

Temperature rise range − _F (_C) high fire 35 − 65 (19 − 36) 45 − 75 (25 − 42) 30 − 60 (17 − 33)

Connections GaspipesizeIPS− 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

Wheelnominaldiameter xwidth −in. 10 x 8 10 x 8 11−1/2 x 10

Blower

mm 254 x 203 254 x 203 292 x 254

Motoroutput − hp (W) 1/2 (373) 1/2 (373) 1 (746)

Tons(kW) ofadd-oncooling 2 − 3 (7.0 − 10.6) 2 − 3.5 (7.0 − 12.3) 3.5 − 5 (12.3 − 17.6)

Shippingweight − 1 package 132 lbs. (60 kg) 154 lbs. (70 kg) 172 lbs. (78 kg)

Matching Coils CR26−18N−F, CR26−30N−F,

CR26−36N−F

CR26−36W−F,

CR26−48N−F

CR26−48N−F,

CR26−60N−F

Electricalcharacteristics 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) 11M 60 − 10 (5) 11M 61 − 11 (5)

High Altitude See Page 6

LPG/Propane Kit See Page 6

Propane/Natural Gas Kit 0 to 7500 ft. (0 to 2286 m) 59M87 59M87 59M87

lAnnual 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

ModelNo. G60DFV−60C−110 G60DFV−60D−135

Heating

Low NOx Model No. G60DFV−60C−110X − − − −

Perf

ormance

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)

lAFUE 80.0% 80.0%

California Seasonal Efficiency 75.8% 76.5%

Highstatic− in.w.g. (Pa) .80 (200) .80 (200)

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

GaspipesizeIPS− in. (mm) 1/2 (12.7) 1/2 (12.7)

Flue connection − in. (mm) round 4 (102) 4 (102)

Indoor Blower

Wheelnominaldiameter xwidth −in. 11−1/2 x 10 11−1/2 x 10

Blower

mm 292 x 254 292 x 254

Motoroutput − hp (W) 1 (746) 1 (746)

Tons(kW) ofadd-oncooling 3.5 − 5 (12.3 − 17.6) 4 − 5 (14.1 − 17.6)

Shippingweight − 1 package 184 lbs. (83 kg) 198 lbs. (76 kg)

Matching Coils CR26−48N−F,

CR26−60N−F

CR26−48W−F, CR26−60W−F

Electricalcharacteristics 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) 11M 62 − 13 (6)

High Altitude Page 6

LPG/Propane Kit Page 6

Propane/Natural Gas Kit 0 to 7500 ft. (0 to 2286 m) 59M87 59M87

Page 4

BLOWER DATA

G60DFV−36A−070 BLOWER PERFORMANCE

0 through 0.80 in. w.g. (0 Through 200 Pa) External Static Pressure Range Blower Control Factory Settings ADJUST − NORM

HEAT − 2 COOL − 4

Speed Switch Positions

ADJUST"

2nd Stage HEAT" Speed 2nd Stage COOL" Speed

Switch

Position

1 2 3 4 1 2 3 4

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

+" (Plus) 880 415 1025 485 1135 535 1320 625 1045 495 1210 570 1300 615 1400 660

NORM (Normal) 800 380 930 440 1035 490 1200 565 950 450 1100 520 1180 555 1275 600

" (Minus) 720 340 835 395 930 440 1080 510 855 405 990 465 1060 500 1145 540

ADJUST"

1st Stage HEAT" Speed 1st Stage COOL" Speed

ADJUST

Switch

1 2 3 4 1 2 3 4

Switch

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

+" (Plus) 815 385 945 445 1055 500 1210 570 700 330 785 370 840 395 900 425

NORM (Normal) 740 350 860 405 960 455 1100 520 640 300 715 335 765 360 820 385

" (Minus) 665 315 775 365 865 410 990 465 575 270 645 305 690 325 735 350

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

1st stage HEAT is approximately 91% of the same 2nd stage

HEAT speed position.

1st stage COOL (two speed air conditioning units only) is approximately 70% (65% for units built prior to 09−2002) of the same 2nd stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same 2nd stage COOL speed position − minimum 500 cfm (235 L/s). Lennox Harmony IIt zone control applications − Minimum blower heating speed is approximately 75% of the 1st stage HEAT speed position. Lennox Harmony IIt zone control applications − Minimum blower cooling speed is approximately 45% of the 2nd stage COOL speed position.

G60DFV−36B−090 BLOWER PERFORMANCE

0 through 0.80 in. w.g. (0 Through 200 Pa) External Static Pressure Range

Blower Control Factory Settings ADJUST − NORM

HEAT − 2 COOL − 4

Speed Switch Positions

ADJUST"

2nd Stage HEAT" Speed 2nd Stage COOL" Speed

Switch

Positions

1 2 3 4 1 2 3 4

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

+" (Plus) N/A N/A 111 0 525 1295 610 1350 635 1075 505 1240 585 1345 635 1475 695

NORM (Normal) N/A N/A 1005 475 1180 555 1225 580 975 460 1130 530 1220 575 1345 635

" (Minus) N/A N/A 905 430 1060 500 1105 520 880 415 1015 480 1100 520 1210 570

ADJUST"

1st Stage HEAT" Speed 1st Stage COOL" Speed

ADJUST

Switch

1 2 3 4 1 2 3 4

Switch

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

+" (Plus) N/A N/A 956 450 1175 555 1210 570 800 377 870 410 930 438 1000 471

NORM (Normal) N/A N/A 870 410 1070 505 1110 525 725 3423 800 377 845 398 910 429

" (Minus) N/A N/A 780 370 960 455 995 470 650 306 720 339 770 363 825 389

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

1st stage HEAT is approximately 91% of the same 2nd stage HEAT speed position. 1st stage COOL (two speed air conditioning units only) is approximately 70% (65% for units built prior to 09−2002) of the same 2nd stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same 2nd stage COOL speed position − minimum 500 cfm (235 L/s). Lennox Harmony IIt zone control applications − Minimum blower heating speed is approximately 75% of the 1st stage HEAT speed position. Lennox Harmony IIt zone control applications − Minimum blower cooling speed is approximately 45% of the 2nd stage COOL speed position. N/A − 1st stage and 2nd stage HEAT, speed position 1, cannot be used with this model.

Page 5

BLOWER DATA

G60DFV−60C−090 BLOWER PERFORMANCE

0 through 0.80 in. w.g. (0 Through 200 Pa) External Static Pressure Range Bottom Return Air, Side Return Air with Optional RAB Return Air Base, Return Air from Both Sides or

Return Air from Bottom and One Side. Blower Control Factory Settings ADJUST − NORM

HEAT − 2 COOL − 4

Speed Switch Positions

ADJUST"

2nd Stage HEAT" Speed 2nd Stage COOL" Speed

Switch

Positions

1 2 3 4 1 2 3 4

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

+" (Plus) 1525 720 1730 815 1850 870 2130 1005 1670 790 1805 850 2035 960 2275 1075

NORM (Normal) 1385 655 1575 745 1770 835 1935 915 1520 715 1640 775 1850 870 2070 975

" (Minus) 1245 590 1415 670 1595 750 1745 825 1365 645 1475 695 1665 785 1860 880

ADJUST"

1st Stage HEAT" Speed 1st Stage COOL" Speed

ADJUST

Switch

1 2 3 4 1 2 3 4

Switch

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

+" (Plus) 1380 650 1580 745 1800 850 1980 935 1070 504 1270 599 1385 653 1545 729

NORM (Normal) 1255 590 1440 680 1635 775 1800 850 955 450 1075 507 1240 585 1370 646

" (Minus) 1130 535 1295 610 1475 695 1620 765 865 408 910 429 1110 523 1220 575

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

1st stage HEAT is approximately 91% of the same 2nd stage HEAT speed position. 1st stage COOL (two speed air conditioning units only) is approximately 70% (60% for units built prior to 09−2002) of the same 2nd stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same 2nd stage COOL speed position. Lennox Harmony IIt zone control applications − Minimum blower heating speed is approximately 75% of the 1st stage HEAT speed position. Lennox Harmony IIt zone control applications − Minimum blower cooling speed is approximately 42% of the 2nd stage COOL speed position.

G60DFV−60C−110 BLOWER PERFORMANCE

0 through 0.80 in. w.g. (0 Through 200 Pa) External Static Pressure Range Bottom Return Air, Side Return Air with Optional RAB Return Air Base, Return Air from Both Sides or

Return Air from Bottom and One Side. Blower Control Factory Settings ADJUST − NORM

HEAT − 2 COOL − 4

Speed Switch Positions

ADJUST"

2nd Stage HEAT" Speed 2nd Stage COOL" Speed

Switch

ositions

1 2 3 4 1 2 3 4

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

+" (Plus) 1530 720 1720 810 1955 925 2145 1010 1665 785 1810 855 2030 960 2300 1085

NORM (Normal) 1390 655 1565 740 1780 840 1950 920 1510 715 1645 775 1845 870 2090 985

" (Minus) 1250 590 1405 665 1600 755 1755 830 1360 640 1480 700 1660 785 1885 890

ADJUST"

1st Stage HEAT" Speed 1st Stage COOL" Speed

ADJUST

Switch

1 2 3 4 1 2 3 4

Switch

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

+" (Plus) 1375 650 1555 735 1795 850 1960 925 1035 488 1035 488 1300 613 1445 681

NORM (Normal) 1250 590 1410 665 1635 770 1785 840 950 448 1030 486 1180 556 1315 620

" (Minus) 1125 530 1270 600 1470 695 1605 755 855 403 925 436 1065 502 1195 563

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

Page 6

BLOWER DATA

G60DFV−60D−135 BLOWER PERFORMANCE

0 through 0.80 in. w.g. (0 Through 200 Pa) External Static Pressure Range Bottom Return Air, Side Return Air with Optional RAB Return Air Base, Return Air from Both Sides or

Return Air from Bottom and One Side. Blower Control Factory Settings ADJUST − NORM

HEAT − 2 COOL − 4

Speed Switch Positions

ADJUST"

2nd Stage HEAT" Speed 2nd Stage COOL" Speed

Switch

Position

1 2 3 4 1 2 3 4

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

+" (Plus) 1545 730 1775 840 1985 935 2175 1025 1710 805 1850 875 2080 980 2300 1085

NORM (Normal) 1405 665 1615 760 1805 850 1980 935 1555 735 1680 795 1890 890 2095 990

" (Minus) N/A N/A 1455 685 1625 765 1780 840 1400 660 1515 715 1700 805 1885 890

ADJUST"

1st Stage HEAT" Speed 1st Stage COOL" Speed

ADJUST

Switch

1 2 3 4 1 2 3 4

Switch

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

+" (Plus) 1400 660 1620 765 1825 860 2020 955 1090 514 1175 554 1350 637 1500 707

NORM (Normal) 1275 600 1475 695 1660 785 1835 865 1000 471 1090 514 1230 580 1375 648

" (Minus) N/A N/A 1325 625 1495 705 1650 780 885 417 975 460 1100 519 1230 580

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

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 0.44 110

 Data is for 1 inch (25 mm) cleanable filter (field provided).

HIGH ALTITUDE / MANIFOLD PRESSURE INFORMATION

Altitude

Manifold Pressure

Model

Gas

0 − 4500 ft.

(0 − 1372 m)

4,501 − 7500 ft.

(1373 − 2286 m)

7501−10,000 ft.

(2286 − 3048 m)

at all altitudes

Input

Size

Gas

Required

Pressure

Required

Pressure

Required

Pressure

Low Fire High Fire

onversion

Kit

Pressure

Switch

onversion

Kit

Pressure

Switch

onversion

Kit

Pressure

Switch

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

Nat. No Change No Change No Change No Change 59M16 18M64 1.7 0.42 3.5 0.87

045/070−1

to −

LPG 59M13 No Change 59M13 No Change 59M14 18M64 4.9 1.22 10.0 2.5

Nat. No Change No Change No Change 18M61 59M16 18M64 1.7 0.42 3.5 0.87

090−1

to −

LPG 59M13 No Change 59M13 18M61 59M14 18M64 4.9 1.22 10.0 2.5

Nat. No Change No Change No Change 18M63 59M16 18M61 1.7 0.42 3.5 0.87

110/−135−1

to−−

LPG 59M13 No Change 59M13 18M63 59M14 18M61 4.9 1.22 10.0 2.5

045/070−7 and

Nat. No Change No Change No Change No Change 59M17 18M64 1.7 0.42 3.5 0.87

045/070 7 and

later

LPG 59M13 No Change 59M13 No Change 59M14 18M64 4.9 1.22 10.0 2.5

Nat. No Change No Change No Change 18M61 59M17 18M64 1.7 0.42 3.5 0.87

090−7

and later

LPG 59M13 No Change 59M13 18M61 59M14 18M64 4.9 1.22 10.0 2.5

110/135−7 and

Nat. No Change No Change No Change 18M63 59M17 18M61 1.7 0.42 3.5 0.87

110/135 7 and

later

LPG 59M13 No Change 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).

Page 7

FIGURE 1

G60DFV(X) PARTS ARRANGEMENT

Combustion Air Pres-

sure Switch Assembly

(Two switches)

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

SureLightt Two−Stage

Variable Spee Integrated

Control Board

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

Secondary Limit

(not shown)

Page 8

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 G60DFV

Transformer

SureLightt Two−Stage

Integrated Control Board

Door

Interlock Switch

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) Board 18M99

G60DFV units are equipped with the Lennox two−stage, variable speed integrated SureLight control board. The system consists of a ignition / blower control board (figure 4 with control terminal designations in tables 1 through 4) and ignitor (figure 12). 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 two LED lights, DS1 and DS2 for troubleshooting and four LED lights (DS3, DS6, DS7 and DS8) to show furnace status. The board also has two accessory terminals rated at (1) one amp each. See table 5 for status code and table 6 for troubleshooting diagnostic codes.

Electronic Ignition

At the beginning of each heating 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 allow first stage heat only. However if the second stage prove switch closes during the first stage pre− purge, the control WILL respond to second stage heat call. 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 9

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 3 (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 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.

TW0−STAGE, VARIABLE SPEED INTEGRATED

CONTROL BOARD

FIGURE 4

DIP

SWITCHES

1 − 3

DIP

SWITCHES

5 − 12

DIAGNOSTIC

LEDs

ON−BOARD

JUMPER W951

(cut when heat pump

is used with FM21)

ON−BOARD

JUMPER W914

(cut when CCB1,

Harmony II or

SignatureStat are used)

LEDs

LED

FACTORY−

INSTALLED

JUMPER

THERMOSTAT CONNECTIONS (TB1)

DIP SWITCH FUNCTIONS

DIP SWITCH(ES) FUNCTION

1 and 2 Blower Off Delay

3 Second Stage ON Delay (Single−stage t’stat)

4 Not used 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

E20

JUMPER

16 PIN BLOWER

CONTROL TERMINALS

DS8

DS7

DS3

DS6

Page 10

TABLE 1

Two Stage Ignition / Blower Control Terminals

120VAC Neutral

LINE Line 120VAC Neutral

XFMR Transformer 120VAC Neutral

EAC Electronic Air Cleaner 120VAC Neutral

CIRC Indoor Blower 120VAC Neutral

HUM Humidifier 120VAC Neutral

120VAC Line

HUM Humidifier 120VAC Hot

XMFR Transformer 120VAC Hot

LINE Line 120VAC Hot

CIRC Indoor Blower 120VAC Hot

EAC Electronic Air Cleaner 120VAC Hot

TABLE 2

SureLight Board 12Pin Terminal Designation

PIN # Function

1 Gas Valve 2nd. Stage (High Fire)

2 Second Stage Pressure 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 Pressure Switch

TABLE 3

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 4

SureLight Board 16 Pin Blower Control Terminals

PIN # Function

1 Ground

2 Low Heat Speed

3 Ground

4 DELAY" Dip Switch Selection

5 COOL" Dip Switch Selection

6 Y1" Signal

7 ADJUST" Dip Switch Selection

8 Ground

9 o" From Thermostat

10 DS" Output Signal

11 HEAT" Dip Switch Selection

12 24 VAC

13 HIGH HEAT Speed

14 Y2" Signal

15 G"

16 CFM LED

Page 11

TABLE 5

STATUS CODES

STATUS LED COLOR FUNCTION

DS3

ON / OFF ’

GREEN

DS3−ON indicates that the motor has a demand to operate. (This LED must be on in all modes).

DS6

CFM"

GREEN

DS6−blinking indicates the airflow (CFM) demand in the motor. The air flow is determined by counting blinks between two (2) second pauses. One blink equals roughly 100 CFM.

DS7

HI / LO"

YELLOW

DS7−ON indicaties the DS to R" jumper has not been cut. When the jumper is cut the system will be operating with LENNOX HARMONY IIt (See Harmony Installation Instructions) or with the CCB1 Efficiency Plus control. CCB1: When ON, a 24 VAC is being applied and when OFF, it has been removed. This on/off operation varies the indoor blower’s performance so dehumidification can be enhanced.

DS8

HEAT"

YELLOW DS8−ON indicates the system is in HEAT mode.

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 pressure 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

ONONON

OFF

Circuit board failure or control wired incorrectly. Check 24 and 115 volts to board.

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 12

Dip Switch Settings Switches 1 and 2 − 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 1 and 2 on the integrated control board. 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.The table below provides the blower off timings that will result from different switch settings.

TABLE 7

Blower Off Delay Switch Settings

Blower Off 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 − Not used

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 blower data tables at the front of this manual for corresponding cfm values.

TABLE 8

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 blower data tables at the front of this manual for corresponding cfm values.

TABLE 9

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. The table below 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. See unit nameplate for manufacturing date.

TABLE 10

Cooling Mode Blower Speed Ramping

Ramping Option

Switch 9 Switch 10

A (Factory) Off Off

B On Off C Off On D On On

Page 13

G60DFV units manufactured before April 2003

Ramping Option A (Factory Selection)

D Motor runs at 50% for 1/2 minute. 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 1/2 min-

ute.

D Motor ramps down to off.

OFF

1/2 MIN 50% CFM

COOLING DEMAND

7−1/2 MIN 82% CFM

100% CFM

1/2 MIN 50% CFM

Ramping Option B

D Motor runs at 50% for 1/2 minute. 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 ramps down to off.

OFF

1/2 MIN 50% CFM

7−1/2 MIN 82% CFM

100% CFM

COOLING DEMAND

Ramping Option C

D Motor runs at 82% for approximately 7−1/2 minutes. D If demand has not been satisfied after 7−1/2 minutes,

the motor runs at 100% until demand is satisfied.

D Once demand is met, motor ramps down to off.

OFF

82%CFM

100% CFM

COOLING DEMAND

7−1/2 MIN

Ramping Option D

D Motor runs at 100% until demand is satisfied. D Once demand is met, motor ramps down to off.

OFFOFF

100% CFM

COOLING DEMAND

G60DFV units manufactured April 2003 and later

Ramping Option A (Factory Selection)

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

utes. If demand has not been satisfied after 7−1/2 minutes.

S Motor runs at 100% until demand is satisfied. S Once demand is met, motor runs at 50% for 30 sec-

onds then −

S 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 −

S 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,

S ramps down to stop.

OFF

100% CFM

COOLING DEMAND

G60DFV units date coded prior to 2−2006 will delay 60 seconds

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

Page 14

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 blower data tables at the front of this manual for corresponding cfm values.

TABLE 11

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 Jumper W914

On−board jumper W914, which connects terminals DS and R on the integrated control board, must be cut when the furnace is installed with the Harmony II zone control board, the CCB1 EfficiencyPlus humidity control or Lennox SignatureStatt. Refer to table 21 for operation sequence in applications including a G60DF, CCB1 and single−speed outdoor unit. Table 22 gives the operation sequence in applications with a two−speed outdoor unit. Refer to table 23 for operation sequence in applications including a G60DF, SignatureStat and single−speed outdoor unit. Table 24 gives the operation sequence in applications with a two− speed outdoor unit.

On−Board Jumper W951

Factory−Installed Jumper Y1 to Y2

A factory−installed jumper from Y1 to Y2 terminals on the integrated control board terminal strip must be removed if two−stage cooling will be used.

Diagnostic LEDs (DS1 and DS2)

Two diagnostic LEDs are located on the two−stage, variable speed integrated control just to the left of the first bank of dip switches. These lights’ flashes correspond with diagnostic codes detailed on in table 6.

Status LEDs (HEAT, HI/LO, ON/OFF and CFM)

The integrated control includes four LEDs which indicate operating status. The green ON/OFF LED is lit any time the blower is operating. The green CFM LED indicates the blower motor speed. Count the number of blinks between the two−second pauses to determine the CFM. Each blink represents approximately 100 CFM. The yellow HI/LO LED is lit when the W914 (DS to R) jumper has not

been clipped for CCB1, SignatureStat or Harmony operation. The yellow HEAT LED is lit when the indoor blower is operating at the HEATING speed.

Page 15

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) Board 100870

Beggining with the G60DFV−7, units are equipped with the Lennox two−stage, variable speed integrated SureLight control board. The system consists of a ignition / blower control board (figures 5 and 6) with control pin designations in tables 12, 13 and 14 and ignitor (figure 13). 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 15 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. Two green LEDs show indoor blower status and CFM. See Page 20 for more detail. The board also has two 120 volt accessory terminals rated at (1) one amp each. In addition there is a 24 volt accessory terminal located on TB1.

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.

NOTE − Board 100870 provides 95 volts regulated to the ignitor.

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 4) 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 factory default 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 16

TWO−STAGE, VARIABLE SPEED INTEGRATED CONTROL BOARD

FIGURE 5

THERMOSTAT CONNECTIONS (TB1)

1/4" QUICK CONNECT TERMINALS

DIP SWITCH FUNCTIONS

INDOOR

BLOWER DIP

SWITCHES

HEATING

DIP

SWITCHES

DIAGNOSTIC

LEDs

ON−BOARD

JUMPERS

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

NEUTRALS= 120 VAC NEUTRAL

W914

W951

W915

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

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

TABLE 12

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 13

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

TABLE 14

SureLight Board 16 Pin Blower Control Terminals

PIN # Function

1 Ground

2 Low Heat Speed

3 Ground

4 DELAY" Dip Switch Selection

5 COOL" Dip Switch Selection

6 Y1" Signal

7 ADJUST" Dip Switch Selection

8 Ground

9 0" From Thermostat

10 DS" Output Signal

11 HEAT" Dip Switch Selection

12 24 VAC

13 HIGH HEAT Speed

14 Y2" Signal

15 G"

16 CFM LED

Page 17

FIGURE 6

TWO−STAGE, VARIABLE SPEED INTEGRATED CONTROL BOARD

Page 18

TABLE 15

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 19

Dip Switch Settings

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 board. 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 16 provides the blower off timings that will result from different switch settings.

TABLE 16

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 blower tables at the front of this manual for corresponding cfm values.

TABLE 17

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 blower tables at the front of this manual for corresponding cfm values.

TABLE 18

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 19 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 Page 13 under units manufactured April 2003 and later".

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

TABLE 19

Cooling Mode Blower Speed Ramping

Ramping Option

Switch 9 Switch 10

A (Factory) Off Off

B On Off C Off On D On On

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 blower tables at the front of this manual for corresponding cfm values.

Page 20

TABLE 20

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 Jumper W914

On−board jumper W914, which connects terminals DS and R on the integrated control board, must be cut when the furnace is installed with either the Harmony III zone control board or a thermostat which features humidity control. If the jumper is left intact the PWM signal from the HARMONY III control will be blocked and also lead to control damage. Refer to table 21 (CCB1) and table 23 (SignatureStat) for operation sequence in applications including G60DFV, a thermostat which features humidity control and a single− speed outdoor unit. Table 22 (CCB1) and table 24 (SignatureStatt) gives the operation sequence in applications with a two−speed outdoor unit.

On−Board Jumper W951

On−board jumper W951, which connects terminals R and O on the integrated control board, 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 jumper is left intact, terminal O" will remain energized eliminating the HEAT MODE in the heat pump.

On−Board Jumper W915

On−board jumper W915, which connects terminals Y1 and Y2 on the integrated control board, must be cut if two−stage cooling will be used. If the jumper is not cut the outdoor unit will operate in second−stage cooling only.

Status LEDs (SPEED, CFM, 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 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.

TABLE 21

G60DFV, CCB1 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 CCB1 control. Indoor blower speed reduced by CCB1 control.

Dehumidification demand satisfied

during cooling demand.

Humidity level falls below set-

point. 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 call for

None

Humidity level above setpoint.

Demand initiated.

Off

Dehumidification mode begins when relative hu-

humidity

removal.

Humidity level above setpoint.

Demand initiated.

60%/65% of COOL

Dehumidification mode begins when relative hu

midity is greater than setpoint.

Humidity demand satisfied between

None Over setpoint (1 or more) Off

While unit is not operating (no thermostat de-

thermostat demands (unit

off cycle).

Y1 Change to acceptable COOL

mand), slide switch is moved down and 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 21

TABLE 22

G60DFV, CCB1 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%/49

% of HIGH

COOL

Compressor demand and indoor

blower speed controlled by

Y2 No demand. Acceptable High HIGH COOL

thermostat demand

Y1 No demand. Acceptable Low

**42%/46%/49

% of HIGH

COOL

Call for humidity

removal during

Humidity level rises slightly

(1) above setpoint. Demand

initiated.

Low

**42%/46%/49

% of HIGH

COOL

Dehumidification mode does not begin

until after initial thermostat demand is

1st−stage cooling

demand

Demand

satisfied

Humidity level remains

slightly (1) above setpoint.

Demand continues.

Off

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%/49

% of HIGH

COOL

If humidity rises significantly above setpoint, 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

Humidity demand

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

CFM in order to hasten the end of the

cycle. Unit can only shift out of high

thermostat demand

No demand. Acceptable

Low

**42%/46%/49

% 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

Call for 1st stage

cooling after call for

humidity removal.

Humidity level is slightly (1)

above setpoint.

Low

**42%/46%/49

% 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 CCB1 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 49% for ALL model units manufactured September 2002 and later. (Earlier date code − 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 22

TABLE 23

G60FDV, SignatureStatt and SINGLE STAGE OUTDOOR UNIT

OPERATING

SEQUENCE

SYSTEM DEMAND SYSTEM RESPONSE

Thermostat Demand Relative Humidity

Blower

Syst

Condition

Step

Y1 O G

Status D

ompres-

sor

Blower

CFM

(COOL)

Comments

NO CALL FOR DEHUMIDIFICATION

Normal Operation 1 On On On Acceptable

VAC

High 100%

Compressor and indoor blower follow thermostat demand

BASIC MODE (only active on a Y1 thermostat demand)

Normal Operation 1 On On On Acceptable

VAC

High 100%

SignatureStat energizes

Dehumidification

Call

2 On On On On Demand

VAC

High

60%, 65%,

70%*

and de−energizes D on

a call for de−humidification

PRECISION MODE (operates independent of a Y1 thermostat demand)

Normal Operation 1 On On On Acceptable

VAC

High 100%

Dehumidification mode

Dehumidification

call

2 On On On Demand

VAC

High

60%, 65%,

70%*

begi

ns when hum

idity i

greater than set point

Dehumidification

call ONLY

1 On On On Demand

VAC

High

60%, 65%,

70%*

SignatureStat will try to maintain room humidity set

oint by allowing the

Jumpers at indoor unit with a single stage outdoor unit

setpoint by allowing the

room space to maintain a

Jumpers at indoor unit with a single stage outdoor unit

With Condensing unit − Cut W914 (R to DS) on SureLight board

room space to maintain a

cooler room thermostat

With Condensing unit Cut W914 (R to DS) on SureLight board

With Heat Pump − Cut W914 (R to DS) & W951 (R to O) on SureLight board

setpoint**

Dave Lennox SignatureStat to use for this application − 51M26 1 heat / 1 cool or 51M28 − 2 heat / 2 cool for heat pumps *Dehumidification blower speed is 65% of COOL speed for 36A & 36B units and 60% COOL speed for 60C & 60D units manufactured before 09−2002. Dehumidification blower speed is 70% of COOL speed for all units manufactured 09−2002 and later. **In Precision mode, SignatureStats built before 10−2003 will maintain room temperature up to 3°F(1.8°C) cooler than room setting. Signature Stats built 10−2003 and later will maintain room temperature up to 2 °F (1.2°C) cooler than room setting.

Page 23

TABLE 24

G60DFV, SignatureStatt and TWO STAGE OUTDOOR UNIT

OPERATING

SEQUENCE

SYSTEM DEMAND SYSTEM RESPONSE

Thermostat Demand Relative Humidity

Blower

Syst

Condition

Step

Y1 Y2 O G

W1W

Status D

Compressor

Blower

CFM

(COOL)

Comments

NO CALL FOR DEHUMIDIFICATION

Normal Operation −

1 On On On Acceptable

VAC

Low

60%, 65%

70%*

Compressor and indoor

Normal Operation −

2 On On On On Acceptable

VAC

High 100%

ower follow thermosta

demand

ROOM THERMOSTAT CALLS FOR FIRST STAGE COOLING

BASIC MODE (only active on a Y1 thermostat demand)

Normal Operation 1 On On On Acceptable

VAC

Low

60%, 65%

70%*

SignatureStat energizes

Dehumidification

Call

2 On On On On Demand

VAC

High

60%, 65%

70%**

and de−energizes D on

a call for de−humidification

PRECISION MODE (operates independent of a Y1 thermostat demand)

Normal Operation 1 On On On Acceptable

VAC

Low

60% 65%

70%*

Dehumidification mode be-

Dehumidification

call

2 On On On On Demand

VAC

High

60% 65%

70%**

gins when hum

idity i

greater than set point

Dehumidification

call ONLY

1 On On On On Demand

VAC

High

60% 65%

70%**

SignatureStat will try to maintain room humidity setpoint by allowing the room space to maintain a cooler room thermostat setpoint***

ROOM THERMOSTAT CALLS FOR FIRST AND SECOND STAGE COOLING

BASIC MODE (only active on a Y1 thermostat demand)

Normal Operation 1 On On On On Acceptable

VAC

High 100%

SignatureStat energizes

Dehumidification

Call

2 On On On On Demand

VAC

High

60% 65%

70%**

and de−energizes D on

a call for de−humidification

PRECISION MODE (operates independent of a Y1 thermostat demand)

Normal Operation 1 On On On Acceptable

VAC

Low

60% 65%

70%*

Dehumidification mode be-

Dehumidification

call

2 On On On On Demand

VAC

High

60% 65%

70%**

gins when hum

idity i

greater than set point

Dehumidification

call ONLY

1 On On On On Demand

VAC

High

60% 65%

70%**

SignatureStat will try to maintain room humidity

Jumpers at indoor unit with a two stage outdoor unit

setpoint by allowing the room s

ace to maintain a

Cut factory jumper from Y1 to Y2 or cut W915 (Y1 to Y2) With Condensin

unit − Cut W914 (R to DS) on SureLight board

room space to maintain a

cooler room thermostat

With Condensing unit

−

Cut W914 (R to DS) on SureLight board

With Heat Pump − Cut W914 (R to DS) & W951 (R to O) on SureLight board

setpoint***

Dave Lennox SignatureStat to use for this application − 51M27 2 heat / 2 cool or 51M28 − 2 heat / 2 cool for heat pumps *Normal operation first stage cooling blower speed is as follows for units built before 09−2002: 65% of COOL for 36A, 36B, 60% COOL for 60C, 60D units. ALL units built 09−2002 and later first stage blower speed is 70% COOL speed. **Dehumidification blower speed is as follows for units built before 09−2002: 65% of COOL for 36A, 36B 60% of COOL for 60C, 60D. ALL units built 09−2002 and later, reduced blower speed is 70% of COOL. ***In Precision mode, Signature Stats built before 10−2003 will maintain room temperature up to 3°F(1.8°C) cooler than room setting. Signature Stats built 10−2003 and later will maintain room temperature up to 2 °F (1.2°C) cooler than room setting.

Page 24

6. Blower Motor

FIGURE 7

SUPPLY AIR BLOWER

BLOWER

MOTOR (B6)

POWER

CHOKE

(L13)

BLOWER

WHEEL

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.

Blower Motor (B3)

G60DFV units use a three-phase, electronically controlled D.C. brushless motor (controller converts single phase a.c. to three phase D.C.), with a permanent-magnet-type rotor (figure 8). Because this motor has a permanent magnet rotor it does not need brushes like conventional D.C. motors. Internal components are shown in figure 9. The stator windings are split into three poles which are electrically connected to the controller. This arrangement allows m o t o r windings t o turn on and off in sequence by the controller.

FIGURE 8

G60DFV BLOWER MOTOR B3

MOTOR

CONTROLLER

SHAFT

J49

J48

G60DFV BLOWER MOTOR COMPONENTS

FIGURE 9

STATOR

(WINDINGS)

OUTPUT

SHAFT

BEARING

ROTOR

A solid-state controller is permanently attached to the motor. The controller is primarily an A.C. to D.C. converter. Converted D.C. power is used to drive the motor. The controller contains a microprocessor which monitors varying conditions inside the motor (such as motor workload).

The controller uses sensing devices to sense what position the rotor is in at any given time. By sensing the position of the rotor and then switching the motor windings on and off in sequence, the rotor shaft turns the blower.

All G60DFV blower motors use single phase power. An external run capacitor is not used. The motor uses permanently lubricated ball-type bearings.

Internal Operation

Each time the controller switches a stator winding (figure 9) on and off, it is called a pulse." The length of time each pulse stays on is called the pulse width." By varying the pulse width (figure 11), the controller varies motor speed (called pulsewidth modulation"). This allows for precise control of motor speed and allows the motor to compensate for varying load conditions as sensed by the controller. In this case, the controller monitors the static workload on the motor and varies motor rpm in order to maintain constant airflow (cfm).

The motor is equipped with 11 incremental taps which are driven by the integral controller. The controller is capable of controlling three of the 11 taps.

The motor controller is driven by the Two−stage Variable Speed Integrated control board. The board receives its demand (PWM signal or fixed 24 VAC or VDC signal) from optional controls such as the Harmony zone control system, Efficiency Plus Humidity Control (CCB1) or a conventional thermostat.

Motor rpm is continually adjusted internally to maintain constant static pressure against the blower wheel. The controller monitors the static work load on the motor and motor ampdraw to determine the amount of rpm adjustment. Blower rpm may be adjusted any amount in order to maintain a constant cfm as shown in Blower Ratings Tables. The amount of adjustment is determined by the incremental taps which are used and the amount of motor loading sensed internally. The cfm remains relatively stable over a broad range of static pressure. Since the blower constantly adjusts rpm to maintain a specified cfm, motor rpm is not rated. Hence, the terms cool speed" , heat speed " or speed tap" in this manual, on the unit wiring diagram and on blower B3, refer to blower cfm regardless of motor rpm.

When Harmony is used, speed taps are overridden and a PWM signal generated by the Harmony controller continuously varies motor speed based upon zone demands.

Page 25

Initial Power Up

When line voltage is applied to B3, there will be a large inrush of power lasting less than 1/4 second. This inrush charges a bank of DC filter capacitors inside the controller. If the disconnect switch is bounced when the disconnect is closed, the disconnect contacts may become welded. Try not to bounce the disconnect switch when applying power to the unit.

Motor Start-Up

When B3 begins start-up, the motor gently vibrates back and forth for a moment. This is normal. During this time the electronic controller is determining the exact position of the rotor. Once the motor begins turning, the controller slowly eases the motor up to speed (this is called soft-start"). The motor may take as long as 10-15 seconds to reach full speed. If the motor does not reach 200rpm within 13 seconds, the motor shuts down. Then the motor will immediately attempt a restart. The shutdown feature provides protection in case of a frozen bearing or blocked blower wheel. The motor may attempt to start eight times. If the motor does not start after the eighth try, the controller locks out. Reset controller by momentarily turning off power to unit.

The DC filter capacitors inside the controller are connected electrically to the speed tap wires. The capacitors take approximately 5 minutes to discharge when the disconnect is opened. For this reason it is necessary to wait at least 5 minutes after turning off power to the unit before attempting to change speed taps.

DANGER

Disconnect power from unit and wait at least five minutes to allow capacitors to discharge before attempting to adjust motor speed tap settings. Failure to wait may cause personal injury or death.

External Operation (Speed Tap Priority)

Figure 10 shows the two quick-connect jacks (J48 and J49) which connect the motor to the G60DF. Jack J48 is the power plug and jack J49 connects the unit controls to the motor.

Line voltage must be applied to J48 pin 5 in order for the motor to operate. When using 120VAC pins 1 and 2 must be jumpered. When control voltage is applied to J49 pin 3 and 15, the motor is energized on the continuous fan mode.

When voltage is applied to J49 pin 2 in addition to pin 3 and 15 (first stage heating), the blower is energized on the low speed heating tap. When voltage is applied to J49 pin 13 in addition to pin 3 and 15 (second stage heating), the blower

is energized on the high speed heating tap. The motor assigns priority to J49 pin 2 so that if a call for cooling and a call for heating are concurrent, heating call overrides and the blower operates on high speed heating tap.

FIGURE 10

POWER

CONNECTOR J48

CONTROL

CONNECTOR J49

BLOWER B3 HARNESS CONNECTORS

J49 PIN 1 - C1 PIN 2 - W / W1 PIN 3 - C2 PIN 4 − Delay PIN 5 - Cool PIN 6 - Y1 PIN 7 - Adjust PIN 8 - 0ut PIN 9 - 0 PIN 10 - DS(PWM) PIN 11 - Heat PIN 12 - R PIN 13 - EM / W2 PIN 14 - Y / Y2 PIN 15 - G PIN 16 - Out +

J48 PIN 1 - Jumper PIN 1 to PIN2 for 120VAC line input only. PIN 2 - Jumper PIN 1 to PIN2 for 120VAC line input only. PIN 3 - Ground PIN 4 - AC Line PIN 5 - AC Line

Power Choke (L13)

A choke coil is used on G60DFV 5 ton 1 hp units. The ch oke i s located on the blower housing and is used to block radio frequency interference.

Precautions

If the G60DF V or its electronically controlled blower motor is improperly or inadequately grounded, it may cause television interference (commonly known as RFI or radio frequency interference).

This interference is caused by internal switching frequencies of the motor controller. TV interference may show u p as s mall s p ecks o r line s which randomly appear on the TV screen accompanied by pops or clicks in the sound. Before attempting any service, make sure the indoor unit is causing the interference. To check, disconnect power to indoor unit then check TV for continued signs of interference.

TV interference may be stopped by making sure the motor is solidly grounded to the cabinet (metal to metal) and by making sure the cabinet is solidly grounded. If TV inte rferenc e per s ists, make sure the television (and all affected RF appliances) are moved away from the G60DFV. Also make sure affected appliances are connected to a separate electrical circuit.

Page 26

One revolution

FIGURE 11

HIGH SPEED COOL (output from controller to motor windings)

MOTOR SPEED CONTROL WITH D.C. PULSE-WIDTH MODULATION

WINDING #1

WINDING #2

WINDING #3

LOW SPEED HEAT/COOL (output from controller to motor windings)

HIGH SPEED HEAT (output from controller to motor windings)

O volts

325VDC

One revolution

O volts

325VDC

O volts

325VDC

WINDING #1

WINDING #2

WINDING #3

O volts

325VDC

O volts

325VDC

O volts

325VDC

WINDING #1

WINDING #2

WINDING #3

O volts

325VDC

O volts

325VDC

O volts

325VDC

Motor speed is determined by the size of the electrical pulse sent to

the motor windings. The longer the pulse, the faster the motor.

One

Pulse

ON PULSE

OFF PULSE

WINDINGS TURNED OFF

The frequency of the pulses to the windings is 20KHz.

DO NOT ATTEMPT TO MEASURE THESE VOLTAGES.

WINDINGS TURNED ON

OUTPUT FROM CONTROLLER TO MOTOR WINDINGS

One revolution

Page 27

7. Ignitor

The SureLight ignitor is made of durable silicon nitride. Ignitor longevity is enhanced by controlling voltage to the ignitor. Board 18M99 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 100870 provides a regulated 95 volts to the ignitor for a consistent ignition and long ignitor life. Ohm value for ignitors with SureLight board 18M99 should be 10.9 to 19.7. Ohm value for ignitors with board 100870 should be 25 to

47. See figure 12 and 13 (make note of control board used) for ignitor location. Ignitors are not interchangeable between boards.

NOTE − The G60DFV(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 14 and 15 (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.

FIGURE 12

5/16"

13/32’

5/8 "

SureLight Board 18M99 Ignitor Location

BURNERS TOP VIEW

BURNERS FRONT VIEW

MEASUREMENT IS TO I.D. OF RETENTION RING

IGNITOR

BRACKET

FIGURE 13

21/64"

7/32’

5/8 "

SureLight Board 100870 Ignitor Location

BURNERS TOP VIEW

BURNERS FRONT VIEW

MEASUREMENT IS TO I.D. OF RETENTION RING

IGNITOR

BRACKET

FIGURE 14

NORMAL FLAME SIGNAL > 0.23 MICROAMPS LOW FLAME SIGNAL < 0.22 MICROAMPS DROP OUT SIGNAL = 0.16 MICROAMPS

5/16"

SureLight Board 18M99 Sensor

FIGURE 15

NORMAL FLAME SIGNAL > 1.50 MICROAMPS LOW FLAME SIGNAL <

1.40 MICROAMPS

DROP OUT SIGNAL = 0.20 MICROAMPS

5/16"

SureLight Board 100870 Sensor

Page 28

9. Combustion Air Inducer (B6)

All units use a two−stage combustion air inducer to move air through the burners and heat exchanger during heating operation. The blower uses a 120VAC motor. The motor operates during all heating operation and is controlled by furnace / blower control A92. The inducer also operates for 15 seconds before burner ignition (pre-purge) and for 5 seconds after the gas valve closes (post-purge). The inducer operates on low speed during first−stage heat, then switches to high speed for second stage heat.

A proving switch connected to the combustion air inducer orifice plate is used to prove inducer operation. The combustion air inducer orifice will be different for each model. See table 25 for orifice sizes. The switch monitors air pressure in the inducer housing. During normal operation, the pressure in the housing is negative. If pressure becomes less negative (signifying an obstruction) the proving switch opens. When the proving switch opens, the furnace control (A92) immediately closes the gas valve to prevent burner operation.

TABLE 25

G60DFV Unit

C.A.I. Orifice Size

−070 1.563"

−090 1.875

−110 2.156"

−135 2.600"

10. Flame Rollout Switches (S47)

Flame rollout switch is a high temperature limit located on top of the burner box. Each furnace is equipped with two identical switches (−045 model has one switch located in the center). One switch is located over the leftmost burner and the other switch is located over the rightmost burner. The limit is a N.C. SPST manual-reset limit connected in series with the primary limit S10. When S47 senses rollout, the circuit breaks and the ignition control immediately stops ignition and closes the gas valve. If unit is running and flame rollout is detected, the gas valve will close and ignition control will be disabled. Rollout can be caused by a blocked heat exchanger, flue or lack of combustion air. The switch is factory set to trip (open) at 210°F and cannot be adjusted. The switch can be manually reset. To manually reset a tripped switch, push the reset button located on the control.

11. Primary Limit Control (S10)

The primary limit (S10) is located in the heating vestibule pan-

el. When excess heat is sensed in the heat exchanger, the

limit will open. If the limit is open, the furnace control energizes

the supply air blower and closes the gas valve. The limit auto-

matically resets when unit temperature returns to normal. The

switch must reset within three minutes or the SureLight board

will go into Watch guard for one hour. The switch is factory

set and cannot be adjusted. The switch may have a different

set point for each unit model number. If limit switch must be

replaced, see Lennox Repair Parts Handbook for correct

length and set point.

12. Secondary Limit Controls (S21)

The secondary limit (S21) is located in the blower compart-

ment on the back side of the blower housing. When excess

heat is sensed in the blower compartment, the limit will open. If

the limit is open, the furnace control energizes the supply air

blower and closes the gas valve. The limit automatically resets

when unit temperature returns to normal. G60DFV−1 and −2

units use a surface type limit factory set to open at 125°F.

G60DFV−3 units and later use an airstream type limit factory

set to open at 135°. The secondary limit cannot be adjusted.

13. Gas Valve

All units use a two−stage gas valve manufactured by

Honeywell (figure 17). The valve is internally redundant to

assure safety shut−off. If the gas valve must be replaced,

the same type valve must be used.

24VAC terminals and gas control knob are located on the

valve. All terminals on the gas valve are connected to wires

from the electronic ignition control. 24V applied to the terminals

energizes the valve.

Inlet and outlet pressure taps are located on the valve. A regu-

lator adjustment screw is located on the valve.

LPG change over kits are available from Lennox. Kits include

burner orifices and a gas valve regulator conversion kit.

Page 29

14. Combustion Air Inducer Prove Switch (S18)

S18 is a dual combustion air proving switch (first and second stage) located on the combustion air inducer orifice bracket. The switch is connected to the combustion air inducer housing by means of a flexible silicone hose. It monitors negative air pressure in the combustion air inducer housing. The switches are a single-pole single-throw proving switch electrically connected to the furnace control. The purpose of the switch is to prevent burner operation if the combustion air inducer is not operating or if the flue becomes obstructed. On heat demand (first or second stage) the switch senses that the combustion air inducer is operating. It closes a circuit to the furnace control when pressure inside the combustion air inducer decreases to a certain set point. Set points vary depending on unit size. See tables 26, 27 and 28. The pressure sensed by the switch is negative relative to atmospheric pressure. If the flue becomes obstructed during operation, the switch senses a loss of negative pressure (pressure becomes more equal with atmospheric pressure) and opens the circuit to the furnace control and gas valve. A bleed port on the switch allows relatively dry air in the vestibule to purge switch tubing, to prevent condensate build up. The switch is factory set and is not field adjustable. It is a safety shut-down control in the furnace and must not be by− passed for any reason. If switch is closed or by−passed, the control will not initiate ignition at start up.

FIGURE 16

DUAL COMBUSTION AIR PROVE SWITCH

BRACKET

TAP

LOW FIRE SWITCH

HIGH FIRE SWITCH

TABLE 26

0’ to 4500’

G60DFV Unit

Set Point High

Heat

Set Point Low

Heat

−070 0.40" 0.20"

−090 0.45" 0.20"

−110 0.50" 0.20"

−135 0.50" 0.20"

TABLE 27*

4501’ to 7500’

G60DFV Unit

Set Point High

Heat

Set Point Low

Heat

−070 0.40" 0.20"

−090 0.40" 0.20"

−110 0.45" 0.20"

−135 0.45" 0.20"

*Unit requires conversion kit at this altitude. See High Altitude table.

TABLE 28*

7501’ to 10,000’

G60DFV Unit

Set Point High

Heat

Set Point Low

Heat

−070 0.35" 0.20"

−090 0.35" 0.20"

−110 0.40" 0.20"

−135 0.40" 0.20"

*Unit requires conversion kit at this altitude. See High Altitude table.

Page 30

II−PLACEMENT AND INSTALLATION

Make sure unit is installed in accordance with installation

instructions and applicable codes.

III−START-UP

A−Preliminary and Seasonal Checks

1 − Inspect electrical wiring, both field and factory installed

for loose connections. Tighten as required.

2 − Check voltage at disconnect switch. Voltage must be

within range listed on the nameplate. If not, consult the power company and have voltage condition corrected before starting unit.

B−Heating Start-Up

WARNING

Shock and burn hazard.

G60DF units are equipped with a hot surface ignition system. Do not attempt to light manually.

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 − Honeywell VR8205 Gas Valve − Turn knob on gas

valve clockwise

to OFF. Do not force. See figure

17.

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

FIGURE 17

HONEYWELL VR8205 Series Gas Valve

GAS VALVE SHOWN IN OFF POSITION

MANIFOLD PRESSURE

TAP

lOW FIRE

ADJUSTMENT

SCREW

(under cap)

iNLET PRESSURE TAP

HIGH FIRE

ADJUSTMENT

SCREW

(under cap)

8 − Honeywell VR8205 Gas Valve − Turn knob on gas

valve counterclockwise

to ON. Do not force. See

figure 17.

9 − Replace the upper access panel.

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

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.

Turning Off Gas To Unit

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

formed.

3 − Remove access panel.

4 − Turn knob on Honeywell valve clockwise

to OFF. Do

not force.

5 − Replace access panel.

C−Safety or Emergency Shutdown

Turn off unit power. Close manual and main gas valves.

D−Extended Period Shutdown

Turn off thermostat or set to UNOCCUPIED" mode. Close all gas valves (both internal and external to unit) to guarantee no gas leak into combustion chamber. Turn off power to unit. All access panels and covers must be in place and secured.

Page 31

IV−HEATING SYSTEM SERVICE CHECKS A−C.S.A. Certification

All units are C.S.A. (formally A.G.A. and C.G.A. combined) design certified without modifications. Refer to the G60DFV Installation Instruction.

B−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.

WARNING

Do not exceed 600 in−lbs (50 ft−lbs) torque when attaching the gas piping to the gas valve.

Gas supply piping should not allow more than 0.5"W.C. drop in pressure between gas meter and unit. Supply gas pipe must not be smaller than unit gas connection.

Compounds used on gas piping threaded joints should be resistant to action of liquefied petroleum gases.

C−Testing Gas Piping

IMPORTANT

In case emergency shutdown is required, turn off the main shut-off valve and disconnect the main power to unit. These controls should be properly labeled by the installer.

When pressure testing gas lines, the gas valve must be disconnected and isolated. Gas valves can be damaged if subjected to more than 0.5psig (14" W.C.). See figure 18. If the pressure is equal to or less than 0.5psig (14"W.C.), use the manual shut−off valve before pressure testing to isolate furnace from gas supply.

FIGURE 18

MANUAL MAIN SHUT−OFF VALVE

WILL NOT HOLD TEST PRESSURE

IN EXCESS OF 0.5 PSIG (14"W.C.)

GAS VALVE

CAP

GAS PIPING TEST PROCEDURE

FIELD PROVIDED

LINE PRESSURE TAP

When checking piping connections for gas leaks, use preferred means. Kitchen detergents can cause harmful corrosion on various metals used in gas piping. Use of a specialty Gas Leak Detector is strongly recommended. It is available through Lennox under part number 31B2001. See Corp. 8411−L10, for further details.

Do not use matches, candles, flame or any other source of ignition to check for gas leaks.

D−Testing Gas Supply Pressure

When testing supply gas pressure, connect test gauge to inlet pressure tap (field provided). See figure 18. Check gas line pressure with unit firing at maximum rate. Low pressure may result in erratic operation or underfire. High pressure can result in permanent damage to gas valve or overfire. See table 29 for operating pressure at unit gas connection (line).

On multiple unit installations, each unit should be checked separately, with and without units operating. Supply pressure must fall within range listed in table 29.

E−Check Manifold Pressure

After line pressure has been checked and adjusted, check manifold pressure. Move pressure gauge to outlet pressure tap located on unit gas valve (GV1). Checks of manifold pressure are made as verification of proper regulator adjustment. Manifold pressure can be measured at any time the gas valve is open and is supplying gas to the unit. See table 29 for normal operating manifold pressure. See HIGH ALTITUDE table (table of contents) for high altitude manifold pressures.

Page 32

TABLE 29

All G60DFV Units

Natural LP

Line Pressure WC" 4.5 − 10.5 11.0 − 13.0

Manifold Pressure High

Heat WC"

3.5 10.0

Manifold Pressure Low

Heat WC"

1.7 4.9

IMPORTANT

For safety, connect a shut-off valve between the manometer and the gas tap to permit shut off of gas pressure to the manometer.

The gas valve is factory set and should not require adjustment. All gas valves are factory regulated.

Manifold Adjustment Procedure:

1 − Connect a test gauge to manifold pressure tap on gas

valve. See figure or 17 for tap location. Start unit and allow 5 minutes for unit to reach steady state.

2 − While waiting for the unit to stabilize, notice the flame.

Flame should be stable and should not lift from burner. Natural gas should burn blue. L.P. gas should burn mostly blue with some orange streaks.

3 − After allowing unit to stabilize for 5 minutes, record

manifold pressure.

NOTE−Shut unit off and remove manometer as soon as an accurate reading has been obtained. Take care to replace pressure tap plug.

F− Proper Gas Flow (Approximate)

Furnace should operate at least 5 minutes before checking gas flow. Determine time in seconds for two revolutions of gas through the meter. (Two revolutions assures a more accurate time.) Divide by two and compare to time in table 30 below. If manifold pressure matches table 29 and rate is incorrect, check gas orifices for proper size and restriction.

NOTE− To obtain accurate reading, shut off all other gas appliances connected to meter.

TABLE 30

GAS METER CLOCKING CHART

Seconds for One Revolution

G60DFV

Natural LP

G60DFV

Unit

1 cu ft

Dial

2 cu ft

Dial

1 cu ft

Dial

2 cu ft

DIAL

−70 55 11 0 136 272

−90 41 82 102 204

−110 33 66 82 164

−135 27 54 68 136

Natural−1000 btu/cu ft LP−2500 btu/cu ft

IMPORTANT

For safety, shut unit off and remove manometer as soon as an accurate reading has been obtained. Take care to replace pressure tap plug.

G− Proper Combustion

Furnace should operate minimum 15 minutes with correct manifold pressure and gas flow rate before checking combustion. See sections E− and F−. Take combustion sample beyond the flue outlet and compare to the tables below. The maximum carbon monoxide reading should not exceed 100 ppm.

TABLE 31 High Heat

Unit Btuh

CO2%

For Nat

CO2%

For L.P.

−070 6.7 − 7.7 7.0 − 8.0

−090 6.7 − 7.7 8.0 − 9.0

−110 7.0 − 8.0 8.3 − 9.3

−135 6.7 − 7.7 7.5 − 8.5

TABLE 32

Low Heat

Unit Btuh

CO2%

For Nat

CO2%

For L.P.

−070 4.3 − 5.3 4.7 − 5.7

−090 4.5 − 5.5 4.9 − 5.9

−110 4.7 − 5.7 5.2 − 6.2

−135 4.5 − 5.5 5.0 − 6.0

Page 33

FIGURE 19

TRANSDUCER

(PART #78H5401)

Page 33

H−Flame Signal

A microamp DC meter is needed to check the flame signal on the ignition control. Flame (microamp) signal is an electrical current which passes from the furnace control through the sensor during unit operation. Current passes from the sensor through the flame to ground to complete a safety circuit.

To Measure Flame Signal − Ignition Control:

A transducer (Part #78H5401 available from Lennox Repair Parts) is required to measure flame signal if meter used will not read a low micro amp signal. Seefigure19. The transducer converts microamps to volts on a 1:1 conversion. See figures 14 and 15 for flame signal. A digital readout meter must be u s e d . T h e transducer plugs into most meters. See figure 20 for proper use of transducer.

1 − Set the volt meter to the DC voltage scale. Insert

transducer into the VDC and common inputs. Observe correct polarities. Failure to do so results in

negative (−) values. 2 − Turn off supply voltage to control. 3 − Disconnect ignition control flame sensor wire from the

flame sensor. 4 − Connect (−) lead of the transducer to flame sensor. 5 − Connect (+) lead of transducer to the ignition control sen-

sor wire. 6 − Turn supply voltage on and close thermostat contacts to

cycle system. 7 − When main burners are in operation for two minutes, take

reading. Remember 1 DC volt = 1 DC microamp.

SET DIAL TO MEASURE

VDC

(+)

(−) TO

FLAME SENSOR

NOTE−MUST USE DIGITAL METER

RED COLLAR

INDICATES

POSITIVE

LEAD

(+) TO

IGNITION

CONTROL

SENSOR

WIRE

FIGURE 20

(−)

V−TYPICAL OPERATING CHARACTERISTICS A−Blower Operation and Adjustment

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 cooling or heating demand.

When the G60DFV is running in the heating mode, the indoor blower will run on the heating speed designated by the positions of dip switches 11 and 12.

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.

B−Temperature Rise

Temperature rise for G60DFV units depends on unit input, blower speed, blower horsepower and static pressure as marked on the unit rating plate. The blower speed must be set for unit operation within the range of TEMP. RISE °F" listed on the unit rating plate.

To Measure Temperature Rise:

1 − Place plenum thermometers in the supply and return air

plenums. Locate supply air thermometer in the first horizontal run of the plenum where it will not pick up radiant

heat from the heat exchanger. 2 − Set thermostat to highest setting. 3 − After plenum thermometers have reached their high-

est and steadiest readings, subtract the two readings.

The difference should be in the range listed on the unit

rating plate. If the temperature is too low, decrease

blower speed. If temperature is too high, first check the

firing rate. Provided the firing rate is acceptable, in-

crease blower speed to reduce temperature.

Page 34

FIGURE 21

STATIC PRESSURE TEST

Page 34

C−External Static Pressure

1 − Tap locations shown in figure 21.

2 − Punch a 1/4" diameter hole

in supply and return air plenums. Insert manometer hose flush with inside edge of hole or insulation. Seal around the hose with permagum. Connect the zero end of the manometer to the discharge (supply) side of the system. On ducted systems, connect the other end of manometer to the return duct as above. For systems with non−ducted returns, leave the other end of the manometer open to the atmosphere.

3 − With only the blower motor running and the evaporator

coil dry, observe the manometer reading. Adjust blower motor speed to deliver the air desired according to the job requirements.

4 − External static pressure drop must not be more than

0.8" W.C.

5 − Seal around the hole when the check is complete.

VI−MAINTENANCE

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 qualified technician should check the system as follows:

A−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

The blower access panel and vent pipe 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.

B−Filters

All 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.

C−Flue and Chimney

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

D−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__________

E−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 using 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 supplies to the furnace.

Remove the furnace access panels.

2 −Remove the three screws that secure the vent pipe to

the flue collar.

3 −Remove the screw that secures the internal flue pipe to

the combustion air inducer. See figure 22.

4 −Scrape away the silicone sealant that is between the

internal flue pipe and the combustion air inducer. 5 −Pull the internal flue pipe into the chase. 6 −Label and disconnect the pressure switch wires. 7 − Remove the four screws that secure the combustion

air inducer. Carefully remove the combustion air induc-

er to avoid damaging the blower gasket. If the gasket is

damaged, it must be replaced to prevent leakage. See

figure 23. 8 −Remove the collector box located behind the combus-

tion air inducer. Be careful with the collector box gas-

ket. If the gasket is damaged, it must be replaced to

prevent leakage. 9 −Label the wires from gas valve and rollout switches,

then disconnect them. 10 −Disconnect gas supply piping. Remove four screws

securing the burner manifold assembly to the vestibule

panel and remove the assembly from the unit.

Page 35

G60DFV(X) Internal Flue Pipe and Chase

FIGURE 22

Unit Top Cap

Internal Flue

Pipe

with Adaptor

Flue Chase

with Gaskets

Screw (1)

Internal

Flue Pipe

RTV

Silicone

Sealant

Combustion

Air Inducer

FIGURE 23

G60DFV(X) CAI & Burner Box Removal

Burner Box Assembly

Heat Exchanger

Combustion Air Inducer

11 −NOx units only − Remove the three screws that attach

the NO

insert to the corbel at the entrance to each

heat exchanger section. Carefully remove the NO

in-

sert from each section. See figure 24.

12 −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.

13 −Repeat procedure for each heat exchanger section.

14 −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 12.

15 −Remove the cable from the heat exchanger. Use a

vacuum cleaner to remove debris knocked loose during cleaning.

NOTE − Take care to not inhale loose debris and avoid eye contact. Safety glasses and surgical mask should be worn when using vacuum cleaner.

INSERTS

(X models only)

FIGURE 24

NOx INSERT

Page 36

16 −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.

17 −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.

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

brush attachment over the face of burners. Inspect inside the burners and crossovers for any blockage. Clean the inside of the burner if necessary.

19 −NO

Units − Reattach the NOx inserts to the corbels at

the entrance to each heat exchanger opening. See figure 24.

20 −Reinstall the burner/manifold assembly on the vesti-

bule panel.

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

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

22 −Use screws to resecure the junction box to the cabinet.

23 −Apply RTV/high temperature silicone sealant between

the internal flue pipe and the combustion air inducer.

24 −Use one screw to resecure the internal flue pipe to the

combustion air inducer.

25 −Use three screws to resecure the vent pipe to the flue

collar.

WARNING

26 −Reconnect the gas supply piping.

27 −Turn on power and gas supply to the unit.

28 −Set thermostat and check for proper operation.

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

leaks. Use a leak detecting solution or other preferred

means.

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.

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

pair leak.

31 −Replace front access panels.

Page 37

VII− Wiring and Sequence of Operation A−G60DFV with SureLight Board 18M99

Page 38

B−Sequence of Operation.

Sequence depends on type thermostat used. Units are applicable for single stage or two stage thermostats. Both type thermostats are described below. Thermostat jumper E20 dictates which mode unit will operate in. See flow chart for more sequence detail.

SureLight Control Self Check

When there is a call for heat, the SureLight integrated control runs a self check. The control checks for S10 primary limit, S21 secondary limit (s) and S47 rollout switch normally closed contacts. The control also checks for S102 high heat and S128 low heat prove switch normally open contacts. Once self check is complete and all safety switches are operational, heat call can continue.

Two−Stage Thermostat, Two Stage Heat. Jumper E20

set at TWO".

1− SureLight control energizes combustion air inducer B6

on low heat speed. Combustion air inducer runs until S128 low heat prove switch contacts close (switch must close within 2 1/2 minutes or control goes into Watchguard Pressure Switch mode. High heat prove switch S102 may also close). A 15 second pre−purge follows once S128 closes.

2− SureLight control begins 20 second ignitor warm up

period.

3− Gas valve opens on first stage for a 4 second trial for

ignition. Ignitor stays energized during the trial or until flame sensed.

4− Flame is sensed, gas valve remains on first stage heat,

ignitor de−energizes.

5− After 45 second delay, indoor blower B3 is energized

on low heat speed.

The furnace will stay in this mode until first stage demand is satisfied OR a second stage heat demand is initiated.

6− Second stage heat demand initiated. A 30 second sec-

ond stage recognition period begins.

7− The combustion air inducer ramps up to high heat

speed.

8− S102 high heat prove switch closes and the gas valve

energizes second stage heat.

9− B3 indoor blower ramps up to high heat speed.

Single−Stage Thermostat, Two Stage Heat. Jumper

E20 set at SINGLE"

1− SureLight control energizes combustion air inducer B6

on low heat speed. Combustion air inducer runs until

S128 low heat prove switch contacts close (switch

must close within 2 1/2 minutes or control goes into

Watchguard Pressure Switch mode. High heat prove

switch S102 may also close). A 15 second pre−purge

follows once S128 closes.

2− SureLight control begins 20 second ignitor warm up

period.

3− Gas valve opens on first stage for a 4 second trial for

ignition. Ignitor stays energized during the trial or until

flame sensed.

4− Flame is sensed, gas valve remains on first stage heat,

ignitor de−energizes.

5− After 45 second delay, indoor blower B3 is energized

on low heat speed.

6− A 10 minute (factory set) or 15 minute (field set) second

stage heat delay period begins.

7− The combustion air inducer ramps up to high heat

speed.

8− S102 high heat prove switch closes and the gas valve

energizes second stage heat.

9− B3 indoor blower ramps up to high heat speed.

Page 39

C−Flow Chart SureLight Board 18M99

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.) DS1 ON, DS2 ON

POLARITY REVERSED.

DS 1 −− FAST FLASH

DS 2 −− SLOW FLASH

POWER ON

POLARITY OKAY?

SIGNAL HOLDS UNTIL UNIT IS PROPERLY GROUNDED.

DS1 AND DS2 ALTERNATING FAST FLASH.

IS THERE A

PROPER GROUND?

IS VOLTAGE

ABOVE 75 VOLTS?

SIGNAL HOLDS UNTIL VOLTAGE RISES ABOVE 75 VOLTS.

DS1 AND DS2 ALTERNATING FAST FLASH.

YES

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF. INDOOR BLOWER OFF. CHECK FOR BROKEN IGNITOR OR OPEN IGNITER CIRCUIT. DS 1 AND DS 2 ALTERNATING FAST FLASH.

BURNER OFF?

(CONTINUOUS FLAME CHECK)

YES

GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

INDOOR BLOWER ON HEATING SPEED.

DS1 SLOW FLASH, DS2 OFF,

ON/OFF LED OFF

NORMAL OPERATION:

DS 1 −− SIMULTANEOUS SLOW FLASH DS 2 −− SIMULTANEOUS SLOW FLASH

THERMOSTAT CALLS FOR HEAT:

DS 1 −− SIMULTANEOUS FAST FLASH DS 2 −− SIMULTANEOUS FAST FLASH

YES

PRIMARY AND SECONDARY LIMIT

SWITCHES CLOSED?

YES

COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER ON. HAS PRIMARY OR

SECONDARY LIMIT RESET WITHIN 3 MINUTES?

DS1 SLOW FLASH, DS2 ON,

ON/OFF LED ON, HEAT LED ON.

ROLLOUT SWITCH CLOSED?

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

HAS MANUAL ROLLOUT SWITCH(ES) BEEN

RESET (CLOSED) WITHIN 3 MINUTES?

DS1 SLOW FLASH, DS2 ON,

ON/OFF LED ON, HEAT LED ON.

YES

FIRST (LOW) STAGE PROVE SWITCH

CONTACTS OPEN?

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF. CONTROL REMAINS UNTIL

PRESSURE SWITCH IS DETECTED OPEN.

DS1 OFF, DS2 SLOW FLASH,

ON/OFF LED OFF, HEAT LED OFF.

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.

DS1 OFF, DS2 FAST FLASH,

ON/OFF LED OFF, HEAT LED ON.

TWO−STAGE OR SINGLE−STAGE THERMOSTAT

CALL FOR HEAT

COMBUSTION AIR INDUCER ON LOW SPEED.

DS1 AND DS2 SIMULTANEOUS FAST FLASH

CONTINUED ON NEXT PAGE

60−MINUTE LIMIT WATCHGUARD MODE.

GAS VALVE OFF, COMBUSTION AIR INDUCER

OFF, INDOOR BLOWER OFF WITH DELAY.

DS1 AND DS2 ALTERNATING SLOW FLASH,

ON/OFF LED OFF, HEAT LED ON.

YES

SECOND (HIGH) STAGE PROVE SWITCH CONTACTS

OPEN?

Page 40

HEATING SEQUENCE OF OPERATION

FIRST−STAGE (LOW FIRE) PROVE

SWITCH CLOSED WITHIN 2.5 MINUTES?

GAS VALVE OFF. COMBUSTION AIR INDUCER

OFF. INDOOR BLOWER OFF. UNIT WILL RETRY

AFTER 5−MINUTE WAIT PERIOD.

DS1 OFF, DS2 SLOW FLASH,

ON/OFF LED OFF, HEAT LED OFF.

YES

15−SECOND COMBUSTION AIR INDUCER

PRE−PURGE INITIATED BY CLOSED FIRST−STAGE

PROVE SWITCH (or 15 SECOND INTER−PURGE

PERIOD.)

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

IGNITOR WARM−UP (20 SECONDS)

DS1 AND DS2 SIMULTANEOUS FAST FLASH

IS VOLTAGE ABOVE 75 VOLTS?

COMBUSTION AIR INDUCER OFF, IGNITER OFF.

SIGNAL HOLDS UNTIL VOLTAGE RISES ABOVE 75 VOLTS.

DS1 AND DS2 ALTERNATING FAST FLASH.

YES

IS THERE A PROPER GROUND?

COMBUSTION AIR INDUCER OFF, IGNITER OFF.

SIGNAL HOLDS UNTIL UNIT IS PROPERLY GROUNDED.

DS1 AND DS2 ALTERNATING FAST FLASH.

COMBUSTION AIR INDUCER OFF, IGNITOR OFF.

SIGNAL HOLDS UNTIL IGNITOR IS REPLACED

OR RECONNECTED.

DS1 AND DS2 ALTERNATING FAST FLASH.

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.

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

YES

4−SECOND FLAME STABILIZATION PERIOD.

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

FLAME RECTIFICATION CURRENT CHECK

CAN FLAME BE PROVEN WITHIN 4

SECONDS AFTER GAS VALVE OPENS?

(u0.16 microamps)

GAS VALVE OFF. COMBUSTION AIR

INDUCER ON. INDOOR BLOWER OFF.

DS1 SLOW FLASH, DS2 FAST FLASH,

ON/OFF LED OFF, HEAT LED 0N.

HAS CONTROL FAILED TO SENSE

FLAME FOR FIVE CONSECUTIVE TRIES

DURING A SINGLE HEAT DEMAND?

YES

THERMOSTAT CALLS FOR HEAT

DS1 AND DS2 SIMULTANEOUS FAST FLASH

(Refer to box A on previous page)

YES

FLAME PRESENT?

HAS CONTROL RESET IGNITION SEQUENCE

FOUR (4) TIMES?

DS1 SLOW FLASH, DS2 FAST FLASH,

ON/OFF LED OFF, HEAT LED ON .

YES

CONTINUED ON NEXT PAGE

YES

CONTINUED

IS IGNITOR INTACT AND CONNECTED?

WATCHGUARD MODE. GAS VALVE OFF,

COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF.

DS1 AND DS2 ALTERNATING SLOW FLASH.

ON/OFF LED 0FF, HEAT LED OFF.

IS 60−MINUTE RESET PERIOD COMPLETE?

Page 41

HEATING SEQUENCE OF OPERATION

LOW FLAME SIGNAL

(Does not affect control operation)

DS1 SLOW FLASH, DS2 FAST FLASH.

FLAME SIGNAL ABOVE

0.23 microamps)

YES

CONTINUED ON NEXT PAGE

YES

SINGLE−STAGE THERMOSTAT MODE

(E20 SET AT SINGLE")

TWO STAGE THERMOSTAT MODE

(E20 SET AT TWO")

YES

START SECOND−STAGE RECOGNITION

ON DELAY (10 OR 15 MINUTES).

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

45−SECOND INDOOR BLOWER ON DELAY BEGINS.

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

YES

PRIMARY AND SECONDARY LIMITS AND ROLLOUT

SWITCHES CLOSED?

GAS VALVE OFF, COMBUSTION AIR INDUCER OFF,

INDOOR BLOWER ON. DS1 SLOW FLASH, DS2 ON,

ON/OFF LED ON, HEAT LED ON.

HAS PRIMARY, SECONDARY OR ROLLOUT

SWITCH CLOSED WITHIN 3 MINUTES?

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

YES

FIRST−STAGE (LOW FIRE)

PROVE SWITCH CLOSED?

LIMIT SWITCH WATCHGUARD MODE.

GAS VALVE OFF, COMBUSTION AIR INDUCER OFF,

INDOOR BLOWER OFF WITH DELAY.

DS1 AND DS2 ALTERNATING SLOW FLASH,

ON/OFF LED OFF, HEAT LED OFF.

IS 60−MINUTE RESET PERIOD COMPLETE?

THERMOSTAT CALLS FOR HEAT.

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

SEE BOX A.

YES

GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

INDOOR BLOWER OFF AFTER DELAY.

DS1 OFF, DS 2 SLOW FLASH,

ON/OFF LED OFF, HEAT LED ON.

YES

FIRST−STAGE HEAT DEMAND SATISFIED?

DS1 AND DS2 SIMULTANEOUS SLOW FLASH.

GAS VALVE OFF, COMBUSTION AIR INDUCER

OFF FOLLOWING POST PURGE.

INDOOR BLOWER OFF WITH DELAY

DS1 AND DS2 SIMULTANEOUS SLOW FLASH

YES

SECOND−STAGE HEAT DEMAND.

SECOND−STAGE HEAT DEMAND REQUIRED?

DS1 AND DS2 SIMUTANEOUS SLOW FLASH.

SECOND STAGE PROVE SWITCH CLOSED?

ABNORMAL FLASH CODE.

NOTE − IF SECOND−STAGE PROVE SWITCH

WAS ORIGINALLY FOUND CLOSED,

ABNORMAL CODE WILL FLASH.

SECOND−STAGE PROVE SWITCH CLOSED

AT BEGINNING OF HEAT DEMAND?

DS1 OFF, DS2 SLOW FLASH,

ON/OFF LED ON, HEAT LED ON.

YES

SECOND−STAGE 30−SECOND DELAY ON BEGINS.

DS1 AND DS2 SIMULTANEOUS FAST FLASH

SECOND−STAGE COMBUSTION AIR INDUCER

ON. SECOND−STAGE GAS VALVE ON. HIGH

HEAT INDOOR BLOWER SPEED ON.

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

ON/OFF LED ON.

YES

SECOND−STAGE PROVE SWITCH CLOSED

IN LESS THAN TEN (10) SECONDS?

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

YES

RETURNS TO FIRST−STAGE HEAT MODE WHICH

CONTINUES UNTIL SECOND−STAGE PROVE

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

NORMAL OPERATION.

DS1 AND DS2 SIMULTANEOUS SLOW FLASH.

SECOND STAGE HEAT DEMAND

DS1 AND DS2 SIMULTANEOUS SLOW FLASH.

YES

CONTINUED

Page 42

HEATING SEQUENCE OF OPERATION

IS PRIMARY AND SECONDARY LIMIT

AND ROLLOUT SWITCH CLOSED?

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER ON.

DS1 SLOW FLASH, DS2 ON,

ON/OFF LED ON, HEAT LED 0N.

HAS PRIMARY, SECONDARY OR ROLLOUT

SWITCH CLOSED WITHIN 3 MINUTES?

LIMIT SWITCH WATCHGUARD MODE. GAS VALVE

OFF. COMBUSTION AIR INDUCER OFF. INDOOR BLOWER OFF WITH DELAY. IS 60−MINUTE RESET PERIOD COMPLETE? DS SLOW FLASH, DS2 ON,

ON/OFF LED OFF, HEAT LED OFF.

SEE BOX B

THERMOSTAT CALLS FOR HEAT

DS 1 AND DS 2 SIMULTANEOUS FAST FLASH

YES

FIRST−STAGE (LOW FIRE) HEAT

PRESSURE SWITCH CLOSED?

SEE BOX A

NORMAL OPERATION

DS1 AND DS2 SIMULTANEOUS SLOW FLASH.

YES

GAS VALVE OFF, COMBUSTION AIR INDUCER OFF

AFTER 15 SECOND POST PURGE, INDOOR

BLOWER OFF AFTER DELAY.

DS1 OFF, DS2 FAST FLASH,

ON/OFF LED ON, HEAT LED ON.

RETURN TO HEAT DEMAND?

YES

RETURN TO FIRST−STAGE HEAT MODE. FIRST−STAGE CONTINUES UNTIL SECOND− STAGE PROVE SWITCH CAN BE PROVEN or

HEAT DEMAND IS SATISFIED. A FIVE (5) MIN-

UTE 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?

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

YES

TWO STAGE THERMOSTAT MODE?

(E20 SET AT TWO")

SINGLE−STAGE THERMOSTAT MODE

(E20 SET AT SINGLE")

YES

HEAT DEMAND SATISFIED?

DS1 AND DS2

SIMULTANEOUS FAST FLASH.

FIRST AND SECOND STAGE HEAT

DEMAND SATISFIED SIMULTANEOUSLY.

DS1 & DS2 SIMULTANEOUS FAST FLASH.

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.

DS1 AND DS2

SIMULTANEOUS FAST FLASH

DEMAND FOR HEAT SATISFIED.

POWER ON STAND BY.

DS1 AND DS2

SIMULTANEOUS SLOW FLASH

YES

SECOND STAGE HEAT

DEMAND SATISFIED?

DS1 AND DS2

SIMULTANEOUS FAST FLASH.

GAS VALVE, COMBUSTION AIR INDUCER

AND INDOOR BLOWER RETURN TO FIRST−

STAGE OPERATION.

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

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.

DS1 & DS2 SIMULTANEOUS FAST FLASH.

CONTINUED

SECOND−STAGE (HIGH FIRE) HEAT

PROVE SWITCH CLOSED?

Page 43

COOLING SEQUENCE OF OPERATION

SIGNAL POLARITY REVERSED.

DS1 FAST FLASH, DS2 SLOW FLASH.

POWER ON

YES

IS POLARITY REVERSED?

THERMOSTAT CALLS FOR FIRST−STAGE COOL.

COMPRESSOR AND CONDENSER FAN

ENERGIZED.

IS THERE

PROPER GROUND?

IS VOLTAGE

ABOVE 75 VOLTS?

LOW VOLTAGE SIGNAL AT DS HOLDS

UNTIL VOLTAGE RISES ABOVE 75 VOLTS.

YES

SIGNAL IMPROPER

GROUND AT DS.

SIGNAL HOLDS

UNTIL UNIT IS

PROPERLY

GROUNDED.

INDOOR BLOWER ENERGIZED ON FIRST−STAGE

COOL SPEED AFTER 2 SECOND DELAY.

FIRST−STAGE DEMAND FOR COOL SATISFIED?

THERMOSTAT CALLS FOR SECOND−STAGE COOL.

YES

COMPRESSOR AND CONDENSER FAN DE−ENERGIZED.

INDOOR BLOWER DE−ENERGIZED AFTER

FIELD−SELECTED BLOWER OFF DELAY.

YES

INDOOR BLOWER RAMPS UP TO SECOND−STAGE COOL SPEED.

SECOND−STAGE COOL DEMAND SATISFIED?

YES

UNIT RETURNS TO FIRST−STAGE COOL.

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

D−G60DFV with SureLight Board 100870

Page 45

E−Sequence of Operation

Sequence depends on type thermostat used. G60DFV units are applicable for single stage or two stage thermostats. Both type thermostats are described below. Thermostat dip switch selection dictates which mode unit will operate in. See flow chart for more sequence detail.

SureLight Control Self Check

Two−Stage Thermostat, Two Stage Heat. Dip Switch

set at TWO".

10− SureLight control energizes combustion air inducer B6

11− SureLight control begins 20 second ignitor warm up

period.

12− Gas valve opens on first stage for a 4 second trial for

ignition. Ignitor stays energized during the trial or until flame sensed.

13− Flame is sensed, gas valve remains on first stage heat,

ignitor de−energizes.

14− After 45 second delay, indoor blower B3 is energized

on low heat speed.

The furnace will stay in this mode until first stage demand is satisfied OR a second stage heat demand is initiated.

15− Second stage heat demand initiated. A 30 second sec-

ond stage recognition period begins.

16− The combustion air inducer ramps up to high heat

speed.

17− S102 high heat prove switch closes and the gas valve

energizes second stage heat.

18− B3 indoor blower ramps up to high heat speed.

Single−Stage Thermostat, Two Stage Heat. Dip

Switch set at SINGLE"

1− SureLight control energizes combustion air inducer B6

2− SureLight control begins 20 second ignitor warm up

period.

3− Gas valve opens on first stage for a 4 second trial for

ignition. Ignitor stays energized during the trial or until flame sensed.

4− Flame is sensed, gas valve remains on first stage heat,

ignitor de−energizes.

5− After 45 second delay, indoor blower B3 is energized

on low heat speed.

6− A 10 minute (factory set) or 15 minute (field set) second

stage heat delay period begins.

7− After the delay the combustion air inducer ramps up to

high heat speed.

8− S102 high heat prove switch closes and the gas valve

energizes second stage heat.

9− B3 indoor blower ramps up to high heat speed.

Page 46

F−Flow Chart SureLight Board 100870

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 47

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 48

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 49

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 50

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 51

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 52

VIII− Field Wiring & Jumper Settings

A−SureLight Board 18M99

TABLE 33

Field Wiring Applications

Jumper Settings (See figure 4)

Thermostat

E20 W915 W914 W951

Wiring Connections

1 Heat / 1 Cool

NOTE − Use dip switch 3 to set second−stage heat ON delay. ON−10 minutes. OFF−15 minutes.

SINGLE Intact Intact Intact

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

HSXB15

(LSOM)

51M26 SignatureStat

NOTE − Use dip switch 3 to set second−stage heat ON delay. ON−10 minutes. OFF−15 minutes.

SINGLE Intact Cut Intact

51M26

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

HSXB15

(LSOM)

1 Heat / 1 Cool with CCB1

NOTE − Use dip switch 3 to set second−stage heat ON delay. ON−10 minutes. OFF−15 minutes.

SINGLE Intact Cut Intact

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

CCB1

HSXB15

(LSOM)

1 Heat / 2 Cool

NOTE − Use dip switch 3 to set second−stage heat ON delay. ON−10 minutes. OFF−15 minutes.

SINGLE Cut Intact Intact

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

HSXA19

(LSOM)

Page 53

TABLE 33

Field Wiring Applications (Continued)

Jumper Settings (See figure 4)

Thermostat

E20 W915 W914 W951

Wiring Connections

1 Heat / 2 Cool with CCB1

NOTE − Use dip switch 3 to set second−stage heat ON delay. ON−10 minutes. OFF−15 minutes.

SINGLE Cut Cut Intact

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

CCB1

HSXA19

(LSOM)

2 Heat / 2 Cool TWO Cut Intact Intact

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

HSXA19

(LSOM)

51M27 SignatureStat TWO Cut Cut Intact

CONTROL

TERM. STRIP

OUTDOOR

UNIT

CCB1

HSXA19

(LSOM)

2 Heat / 2 Cool with CCB1

TWO Cut Cut Intact

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

CCB1

HSXA19

(LSOM)

Page 54

TABLE 33

Field Wiring Applications (Continued)

Jumper Settings (See figure 4)

Thermostat

E20 W915 W914 W951

Wiring Connections

2 Heat / 1 Cool TWO Intact Intact Intact

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

HSXB15

(LSOM)

FM21 Heat Pump / 1 Cool

SINGLE Intact Intact Cut

CONTROL

TERM. STRIP

FM21

75VA, 24V

TRANSFORM-

ER*

*Disconnect existing furnace transformer and replace with 75VA, 24V transformer if defrost option to be used.

NOTE − Wiring connections to outdoor unit and thermostat made at FM21 control board per FM21 instructions.

NOTE − Remove Y1/Y2 jumper for two−stage cooling.

Page 55

B−SureLight Board 100870

Jumper Settings (See figure 5)

Thermostat

DIP Switch 1

W915

Two−Stage

Cooling

W914 Dehumidification or Harmony

III

W951

Heat Pumps

Wiring Connections

1Heat / 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 56

Jumper Settings (See figure 5)

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 57

IX− Troubleshooting SureLight Board 18M99

UPON INITIAL POWER UP, REMOVE ALL THERMOSTAT DEMANDS TO THE UNIT

PROBLEM: 1 UNIT FAILS TO OPERATE IN THE COOLING, HEATING, OR CONTINUOUS FAN MODE

Condition Possible Cause Corrective Action / Comments

1.1

− Both diagnostic lights fail to light up.

1.1.1

Main voltage 120V not supplied to unit.

ACTION 1 − Check 120V main voltage. Determine cause of main power failure.

LED#1−Off LED#2−Off

1.1.2

Miswiring of furnace or improper connections.

ACTION 1 − Check for correct wiring of 120V to power make up box and transformer.

ACTION 2 − Check 24V wiring to control board.

1.1.3

Circuit breaker tripped or fails to close.

ACTION 1 − Replace circuit breaker if it is reset but does not have continuity. ACTION 2 − If circuit breaker still trips, check for short.

1.1.4

Door interlock switch failure.

ACTION 1 − Check that door switch is activated when door is closed. ACTION 2 − Check wire connections to switch, replace loose connectors. ACTION 3 − Check continuity of switch in closed position. Replace if defective.

1.1.5

Transformer Failure.

ACTION 1 − Check that transformer output is 24V. Replace if defective.

1.1.6

Failed control board.

ACTION 1 − If all the above items have been checked, replace board.

1.2

− Diagnostic lights flash the reverse

ag ost c g ts as t e e e se

polarity code.

1.2.1

120V main power polarity reversed.

ACTION 1 − Check the 120V has line and neutral correctly input into control. ACTION 2 − Reverse the line and neutral at the

LED#1−Fast Flash, LED#2−Slow Flash.

ppy

120V field

connection.

1.3

− Diagnostic lights flash the improper

1.3.1

Improper ground to the unit.

ACTION 1 − Check that the unit is properly ground. ACTION 2 − Install a proper main ground to the unit

main ground.

1.3.2

Open ignitor circuit.

ACTION 1 − Check for correct wiring and loose connections in the ignitor circuit. Check mult−plug connections for correct installation.

LED#1−Alternating Fast Flash LED#2−Alternating Fast Flash

1.3.3

Broken or failed ignitor.

ACTION 1 − Unplug ignitor and read resistance across ignitor. If resistance does not read between

10.9 and 19.7 ohms, replace the ignitor.

1.3.4

Line voltage is below 75V.

ACTION 1 − Check that the line voltage is above 75V. Determine cause of voltage drop and supply correct voltage to the control.

Page 58

PROBLEM 2: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR INDUCER DOES

NOT ENERGIZE

Condition Possible Cause Corrective Action / Comments

2.1

− Unit operates with a cooling or contin-

uous fan demand.

− Combustion air inducer will not start with a Heating demand.

− Diagnostic lights flash the limit failure

2.1.1

Primary Limit or secondary limit (if

equipped ) or rollout switch open.

ACTION 1 − Check continuity across switch(es). Switches reset automatically upon cool down.

Rollout switch must be reset manually. ACTION 2 − Check for restrictions on blower inlet

air (including filter) and outlet air. Determine cause for limit activation before placing unit back in operation.

mode.

LED#1−Slow Flash, LED#2−On

2.1.2

Miswiring of furnace or improper con-

nections at limit switch(es).

ACTION 1 − Check for correct wiring and loose connections. Correct wiring and/or replace any loose connections.

2.2

− Unit operates with a cooling and continuous fan demand.

− Combustion air inducer will not start with a Heating demand.

− Dia

nostic lights flash the pressure

2.2.1

Miswiring of furnace or improper con-

nections to combustion air inducer.

ACTION 1 − Check for correct wiring and loose connections. Correct wiring and/or replace any loose connections.

−

Diagnostic lights flash the pressure

switch failure code.

LED#1−Off, LED#2−Slow Flash

2.2.2

Pressure switch stuck closed.

ACTION 1 − Check that the pressure switch is open without the combustion air inducer operating. Replace if defective.

2.3

− Unit operates with a cooling and continuous fan demand.

− Combustion air inducer will not start with a Heating demand.

− Diagnostic lights flash the pressure

2.3.1

Miswiring of furnace or improper con-

nections to combustion air inducer.

ACTION 1 − Check for correct wiring and loose connections. Correct wiring and/or replace any loose connections.

switch failure code 2.5 minutes after heating demand.

LED#1−Off, LED#2−Slow Flash

2.3.2

Combustion air inducer failure.

ACTION 1 − If there is 120V to combustion air inducer and it does not operate, replace combustion air inducer.

Page 59

PROBLEM 3: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR BLOWER

ENERGIZES, IGNITOR IS NOT ENERGIZED.

Condition Possible Cause Corrective Action/Comments

3.1

− Unit operates with a cooling and

continuous fan demand.

− Combustion air inducer energizes

3.1.1

Pressure switch does not close due

to incorrect routing of the pressure

switch line.

ACTION 1 − Check that the pressure switch line is correctly routed. Correctly route pressure switch line.

with a heating demand.

− Diagnostic lights flash the pressure switch failure code 2.5 minutes after heating demand.

3.1.2

Pressure switch does not close due

to obstructions in the pressure switch

line.

ACTION 1 − Remove any obstructions from the the pressure switch line and/or taps.

LED#1−Off LED#2−Slow Flash

3.1.3

Pressure switch line damaged

ACTION 1 − Check pressure switch line for leaks. Replace broken line if required.

LED#2 Slow Flash

3.1.4

Condensate in pressure switch line.

ACTION 1 − Check pressure switch line for condensate. Remove condensate from line.

3.1.5

Pressure switch does not close due to a low differential pressure across

the pressure switch.

ACTION 1 − Check the differential pressure across the pressure switch. This pressure should exceed the set point listed on the switch. ACTION 2 − Check for restricted inlet vent. Remove all blockage. ACTION 3 − Check for proper vent sizing and run length. See installation instructions.

3.1.6

Wrong pressure switch installed in the

unit, or pressure switch is out of cal-

ibration.

ACTION 1 − Check that the proper pressure switch is installed in the unit. Replace pressure switch if necessary.

3.1.7

Miswiring of furnace or improper con-

nections at pressure switch.

ACTION 1 − Check for correct wiring and loose connections. Correct wiring and/or replace any loose connections.

3.1.8

Pressure switch failure.

ACTION 1 − If all the above modes of failure have been checked, the pressure switch may have failed. Replace pressure switch and determine if unit will operate.

Page 60

PROBLEM 4: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR BLOWER

ENERGIZES, IGNITOR IS ENERGIZED.

Condition Possible Cause Corrective Action/Comments

4.1

− Unit operates with a cooling and continuous fan demand.

4.1.1

Check that gas is being supplied to

the unit.

ACTION 1 − Check line pressure at the gas valve. Pressure should not exceed 13" WC for both natural and propane. Line pressure should read a minimum 4.5" WC for natural and 11.0"WC for propane.

− Combustion air inducer energizes with Heating demand.

− Ignitor is energized but unit fails to light.

4.1.2

Miswiring of gas valve or loose con-

nections at multi−pin control amp

plugs or valve.

ACTION 1 − Check for correct wiring and loose connections. Correct wiring and/or replace any loose connections.

LED#1−Alternating Slow Flash LED#2−Alternating Slow Flash

4.1.3

Defective gas valve or ignition con-

trol.

ACTION 1 − Check that 24V is supplied to the gas valve approximately 35 seconds after heat demand is initiated. ACTION 2 − Replace the valve if 24V is supplied but valve does not open. ACTION 3 − Replace the control board if 24V is not supplied to valve.

PROBLEM 5: BURNERS LIGHT WITH A HEATING DEMAND BUT UNIT SHUTS DOWN

PREMATURELY

Condition Possible Cause Corrective Action/Comments

5.1

− Burners fire with a heating demand.

− Burners light but unit shuts off prior to satisfying T−stat demand.

− Diagnostic lights flash the pressure switch code.

LED#1−Off LED#2−Slow Flash

5.1.1

Low pressure differential at the pres-

sure switch.

ACTION 1 − Check for restricted exhaust vent. Remove all blockage. ACTION 2: Check for proper vent sizing. See installation instructions.

5.2

− Combustion air inducer energizes with a heating demand.

5.2.1

Sensor or sense wire is improperly

installed.

ACTION 1 − Check that sensor is properly located and that the sense wire is properly attached to both the sensor and the control.

− Burners light but fail to stay lit.

− After 5 tries the control diagnostics flash the watchguard burners failed to ignite code.

5.2.2

Sensor or sense wire is broken.

ACTION 1 − Check for a broken sensor. ACTION 2 − Test continuity across the sense

wire. If wire or sensor are damaged replace the component.

ignite code.

LED#1−Alternating Slow Flash LED#2−Alternating Slow Flash

5.2.3

Sensor or sensor wire is grounded to

the unit.

ACTION 1 − Check for resistance between the sensor rod and the unit ground. ACTION 2 − Check for resistance between the sensor wire and the unit ground.

ACTION 3 − Correct any shorts found in circuit.

5.2.4

Control does not sense flame.

ACTION 1 − Check the microamp signal from the burner flame. If the microamp signal is below normal, check the sense rod for proper location or contamination. ACTION 2 − Replace, clean, or relocate flame sense rod. If rod is to be cleaned, use steel wool or replace sensor. DO NOT CLEAN ROD WITH SAND PAPER. SAND PAPER WILL CONTRIBUTE TO THE CONTAMINATION PROBLEM. NOTE: Do not attempt to bend sense rod. ACTION 3 − Check that there is proper ground to burner box. Repair as necessary.

Page 61

PROBLEM 5: BURNERS LIGHT WITH HEATING DEMAND BUT UNIT SHUTS DOWN

PREMATURELY (CONT.)

Condition Possible Cause Corrective Action/Comments

5.3

− Combustion air inducer energizes with a heating demand.

− Burners light.

− Roll−out switch trips during the heating demand.

5.3.1

Unit is firing above 100% of the

nameplate input.

ACTION 1 − Check that the manifold pressure matches value listed on nameplate. See installation instructions for proper procedure. ACTION 2 − Verify that the installed orifice size match the size listed on the nameplate or installation instructions. ACTION 3 − Check the input rate to verify rate matches value listed on nameplate.

− Diagnostic lights flash limit / roll−out switch failure.

LED#1−Slow Flash

5.3.2

Gas orifices leak at the manifold con-

nection.

ACTION 1 − Tighten orifice until leak is sealed. NOTE: Be careful not to strip orifice threads. ACTION 2 − Check for gas leakage at the

threaded orifice connection. Use approved method for leak detection (see unit instructions).

LED#1 Slow Flash

LED#2−On

5.3.3

Insufficient flow through the heat ex-

changer caused by a sooted or re-

stricted heat exchanger.

ACTION 1 − Check for sooting deposits or other restrictions in the heat exchanger assembly. Clean assembly as outlined in instruction manual. ACTION 2 − Check for proper combustion. See IV−Heating System Service Checks section G−.

5.3.4

Burners are not properly located in

the burner box.

ACTION 1 − Check that the burners are firing into the center of the heat exchanger openings. Correct the location of the burners if necessary.

5.3.5

Poor Venting

ACTION 1 −Check vent pipe and remove any obstructions ACTION 2 − Check for correct exhaust vent installation. See instructions

5.3.6

Improper burner cross−overs

ACTION 1 − Remove burner and inspect the cross−overs for burrs, or any restriction or if crossover is warped. Remove restriction or replace burners.

5.4

− Combustion air inducer energizes

with a heating demand.

− Burners light roughly and the unit

5.4.1

Poor Venting

ACTION 1 −Check vent pipe and remove any obstructions ACTION 2 − Check for correct exhaust vent installation. See instructions

Burners light roughly and the unit

fails to stay lit.

− Diagnostic lights flash watchguard flame failure.

5.4.2

Improper burner cross−overs

ACTION 1 − Remove burner and inspect the cross−overs for burrs, or any restriction or if crossover is warped. Remove restriction or replace burners.

LED#1−Alternating Slow Flash LED#2−Alternating Slow Flash

5.4.3

Burrs in gas orifices

ACTION 1 − Remove gas orifices and inspect. Remove any burrs that are present or replace orifice.

Page 62

PROBLEM 5: BURNERS LIGHT WITH HEATING DEMAND BUT UNIT SHUTS DOWN

PREMATURELY (CONT.)

5.5

− Combustion air inducer energizes with a heating demand.

− Burners light.

− Dia

nostic lights flash watch guard

5.5.1

Loose sensor wire connection causes

intermittent loss of flame signal.

ACTION 1 − Check that the sensor is properly located. ACTION 2 − Check that the sense wire is properly attached to both the sensor and the control. Pay extra attention to the pin connectors.

−

Diagnostic lights flash watch guard

flame failure.

− NOTE" Unit might go into 60 minute Watchguard mode depending on in-

5.5.2

Poor ground to burner box

ACTION 1 − Check for proper ground and repair as necessary.

erm

ittent

nature of sensor signal.

LED#1−Alternating Slow Flash LED#2−Alternating Slow Flash

5.5.3

Prove Switch opens 5 times during a

single demand

ACTION 1 − Inspect vent pipe installation and for any restriction. Remove restriction.

ACTION 2 − Check prove switch reliability.

PROBLEM 6: CONTROL SIGNALS LOW FLAME SENSE DURING HEATING MODE

Condition Possible Cause Corrective Action/Comments

6.0

− Unit operates correctly but the diagnostic lights flash low flame sense

6.1.1

Sense rod is improperly located on

the burner.

ACTION 1 − Check the sense rod for proper location on the burner. Properly locate the sense rod or replace if rod cannot be located correctly.

code

LED#1−Slow Flash LED#2−Fast Flash

6.1.2

Sense rod is contaminated.

ACTION 1 − Check sense rod for contamination or coated surface. Clean the sense rod with steel wool or replace sensor. DO NOT USE SAND PAPER TO CLEAN ROD. SAND PAPER WILL CONTRIBUTE TO THE CONTAMINATION PROBLEM.

PROBLEM 7: INDOOR BLOWER FAILS TO OPERATE IN COOLING, HEATING, OR CONTINUOUS

FAN MODE

Condition Possible Cause Corrective Action/Comments

7.0

− Indoor blower fails to operate in continuous fan, cooling, or heating mode.

7.1.1

Miswiring of furnace or improper con-

nections at control or indoor blower

motor.

ACTION 1− Correct wiring and/or replace any loose connections. Check for correct wiring and loose connections.

7.1.2

120V is not being supplied to the in-

door air blower or blower motor fail-

ure.

ACTION 1 − Check for 120V at the various calls for indoor blower by energizing "Y", "G", and "W" individually on the low voltage terminal strip. Note that when "W’ is energized, the blower is delayed 45 seconds. If there is 120V to each motor tap but the blower does not operate, replace the motor.

7.1.3

Defective control board

ACTION 1 − If there is not 120V when "Y", "G", or "W" is energized, replace the control.

Page 63

Two Stage Variable Speed Control Board 100870

UPON INITIAL POWER UP, REMOVE ALL THERMOSTAT DEMANDS TO THE UNIT

PROBLEM: 1 UNIT FAILS TO OPERATE IN THE COOLING, HEATING, OR CONTINUOUS FAN MODE

Flash Code

LED X + Y

Possible Cause Corrective Action / Comments

1.1

− Diagnostic lights fail to light up.

1.1.1

Main voltage 120V not supplied to unit.

ACTION 1 − Check 120V main voltage. Determine cause of main power failure.

LED OFF

1.1.2

Miswiring of furnace or improper connections.

ACTION 1 − Check for correct wiring of 120V to power make up box and transformer.

ACTION 2 − Check 24V wiring to control board.

1.1.3

Circuit breaker tripped or fails to close.

ACTION 1 − Replace circuit breaker if it is reset but does not have continuity. ACTION 2 − If circuit breaker still trips, check for short.

1.1.4

Door interlock switch failure.

1.1.5

Transformer Failure.

ACTION 1 − Check that transformer output is 24V. Replace if defective.

1.1.6

Failed control board.

ACTION 1 − If all the above items have been checked, replace board.

1.2

−

Diagnostic light flashes the reverse

polarity code.

1.2.1

120V main power polarity reversed.

ACTION 1

− Check the

120V h

as line and neutra

correctly input into control. ACTION 2 − Reverse the line and neutral at the

LED 5 + 4

120V main power polarity reversed.

120V field connection.

1.3

− Diagnostic light flash the improper

main ground.

LED 5 + 3

1.3.1

Improper ground to the unit.

ACTION 1 − Check that the unit is properly ground. ACTION 2 − Install a proper main ground to the unit

1.4

− Diagnostic light flashes ignitor

circuit fault.

1.4.1

Open ignitor circuit.

ACTION 1 − Check for correct wiring and loose connections in the ignitor circuit. Check mult−plug connections for correct installation.

circuit fault

LED 4 + 7

1.4.2

Broken or failed ignitor.

ACTION 1 − Unplug ignitor and read resistance across ignitor. If resistance does not read between 25 and 47 ohms, replace the ignitor.

1.5

− Diagnostic light flashes low

line voltage

LED 4 + 8

1.5.1

Line voltage is below 90V.

ACTION 1 − Check that the line voltage is above 90V. Determine cause of voltage drop and supply correct voltage to the control.

Page 64

PROBLEM 2: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR BLOWER DOES NOT

ENERGIZE

Flash Code

LED X + Y

Possible Cause

Corrective Action / Comments

2.1

Unit operates with a cooling or

continuous fan demand.

Combustion air inducer will not start

with a Heating demand.

2.1.1

Primary Limit or secondary limit

(if equipped ) open.

ACTION 1 − Check continuity across switch(es). Switches reset automatically upon cool down. ACTION 2 − Check for restrictions on blower inlet air (including filter) and outlet air. Determine cause for limit activation before placing unit back in operation.

Diagnostic lights flash the limit failure

mode.

LED 3 + 1

2.1.2

Miswiring of furnace or improper con-

nections at limit switch(es).

ACTION 1 − Check for correct wiring and loose connections. Correct wiring and/or replace any loose connections.

2.2

Unit operates with a cooling and

continuous fan demand.

Combustion air inducer will not start

with a Heating demand.

2.2.1

Miswiring of furnace or improper con-

nections to combustion air inducer.

ACTION 1 − Check for correct wiring and loose connections. Correct wiring and/or replace any loose connections.

Diagnostic lights flash the pressure

switch failure code.

LED 2 +4

2.2.2

Prove switch stuck closed.

ACTION 1 − Check that the prove switch is open without the combustion air inducer operating. Replace if defective.

2.3

Unit operates with a cooling or

continuous fan demand.

Combustion air inducer will not start

with a Heating demand.

Diagnostic lights flash the open

rollout failure mode.

LED 5 + 1

2.3.1

Rollout Switch Open.

ACTION 1 − Check continuity across rollout switches. Rollout switches must be manually reset. ACTION 2 − Look for restrictions in vent pipe or combustion air inlet or heat exchanger. Determine cause before placing unit in operation.

PROBLEM 3: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR INDUCER DOES

NOT ENERGIZE

Condition Possible Cause Corrective Action/Comments

3.3

Unit operates with a cooling and

continuous fan demand.

Combustion air inducer will not start

with a Heating demand.

Dia

nostic lights flash the pressure

3.3.1

Miswiring of furnace or improper con-

nections to combustion air inducer.

ACTION 1 − Check for correct wiring and loose connections. Correct wiring and/or replace any loose connections.

Diagnostic lights flash the pressure

switch failure code 2.5 minutes after

heating demand.

LED 2 + 3

3.3.2

Combustion air inducer failure.

ACTION 1 − If there is 120V to combustion air inducer and it does not operate, replace combustion air inducer.

Page 65

PROBLEM 4: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR INDUCER

ENERGIZES, IGNITOR IS NOT ENERGIZED.

Flash Code

LED X + Y

Possible Cause Corrective Action/Comments

4.1

− Unit operates with a cooling and

continuous fan demand.

4.1.1

Prove switch does not close due to

obstruction in vent pipe.

ACTION 1 − Check for restricted vent. Remove all blockage. ACTION 2: Check for proper vent sizing. See installation instructions.

− Combustion air inducer energizes

with a heating demand.

− Diagnostic lights flash the pressure switch failure code 2.5 minutes after

heating demand.

4.1.2

Prove switch does not close due to

incorrect routing of the prove switch

line.

ACTION 1 − Check that the prove switch line is correctly routed. Correctly route prove switch line.

LED 2 + 3

4.1.3

Prove switch does not close due to

obstructions in the prove switch line.

ACTION 1 − Remove any obstructions from the the prove switch line and/or taps.

4.1.4

Prove switch line damaged

ACTION 1 − Check prove switch line for leaks. Replace broken line if required.

4.1.5

Condensate in prove switch line.

ACTION 1 − Check prove switch line for condensate. Remove condensate from line.

4.1.6

Prove switch does not close due to a

low differential pressure across the

prove switch.

ACTION 1 − Check the differential pressure across the prove switch. This pressure should exceed the set point listed on the switch. ACTION 2 − Check for restricted inlet vent. Remove all blockage. ACTION 3 − Check for proper vent sizing and run length. See installation instructions.

4.1.7

Wrong prove switch installed in the

unit, or prove switch is out of calibra-

tion.

ACTION 1 − Check that the correct prove switch is installed in the unit. Replace prove switch if necessary.

4.1.8

Miswiring of furnace or improper con-

nections at prove switch.

ACTION 1 − Check for correct wiring and loose connections. Correct wiring and/or replace any loose connections.

4.1.9

Prove switch failure.

ACTION 1 − If all the above modes of failure have been checked, the prove switch may have failed. Replace prove switch and determine if unit will operate.

Page 66

PROBLEM 5: UNIT FIRES ON LOW FIRE, FAILS TO GO TO HIGH FIRE OPERATION

Flash Code

LED X + Y

Possible Cause Corrective Action/Comments

5.1

− Unit light s normally during low fire

− Call for high fire inducer switches to

5.1.1

Prove switch does not close due to

obstruction in vent pipe.

ACTION 1 − Check for restricted vent. Remove all blockage. ACTION 2: Check for proper vent sizing. See installation instructions.

high fire for 10 seconds then back to

low fire.

− Diagnostic lights flash the high pressure switch failure to close.

5.1.2

Prove switch does not close due to

incorrect routing of the prove switch

line.

ACTION 1 − Check that the prove switch line is correctly routed. Correctly route prove switch line.

LED 2 + 5

5.1.3

Prove switch does not close due to

obstructions in the prove switch line.

ACTION 1 − Remove any obstructions from the the prove switch line and/or taps.

5.1.4

Prove switch line damaged

ACTION 1 − Check prove switch line for leaks. Replace broken line if required.

5.1.5

Condensate in prove switch line.

ACTION 1 − Check prove switch line for condensate. Remove condensate from line.

5.1.6

Prove switch does not close due to a

low differential prove across the

prove switch.

5.1.7

Wrong prove switch installed in the

unit, or prove switch is out of calibra-

tion.

ACTION 1 − Check that the correct prove switch is installed in the unit. Replace prove switch if necessary.

5.1.8

Miswiring of furnace or improper con-

nections at prove switch.

ACTION 1 − Check for correct wiring and loose connections. Correct wiring and/or replace any loose connections.

5.1.9

Prove switch failure.

ACTION 1 − If all the above modes of failure have been checked, the prove switch may have failed. Replace prove switch and determine if unit will operate.

Page 67

PROBLEM 6: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR BLOWER

ENERGIZES, IGNITOR IS ENERGIZED.

Flash Code

LED X + Y

Possible Cause Corrective Action/Comments

6.1

Unit operates with a cooling and

continuous fan demand.

6.1.1

Check that gas is being supplied to

the unit.

ACTION 1 − Check line pressure at the gas valve. Pressure should not exceed 13" WC for both natural and propane. Line pressure should read a minimum 4.5" WC for natural and 8.0"WC for propane.

Combustion air inducer energizes

with Heating demand.

Ignitor is energized but unit fails to

light.

6.1.2

Miswiring of gas valve or loose con-

nections at multi−pin control amp

plugs or valve.

ACTION 1 − Check for correct wiring and loose connections. Correct wiring and/or replace any loose connections.

LED 4 + 1

6.1.3

Defective gas valve or ignition con-

trol.

PROBLEM 7: BURNERS LIGHT WITH A HEATING DEMAND BUT UNIT SHUTS DOWN

PREMATURELY

Flash Code

LED X + Y

Possible Cause Corrective Action/Comments

7.1

Burners fire with a heating demand.

Burners light but unit shuts off prior

to satisfying T−stat demand.

Diagnostic lights flash the prove

switch code.

LED 2 + 7

7.1.1

Low pressure differential at the prove

switch.

ACTION 1 − Check for restricted exhaust vent. Remove all blockage. ACTION 2: Check for proper vent sizing. See installation instructions.

7.2

Combustion air inducer energizes

with a heating demand.

7.2.1

Sensor or sense wire is improperly

installed.

ACTION 1 − Check that sensor is properly located and that the sense wire is properly attached to both the sensor and the control.

Burners light but fail to stay lit.

After 5 tries the control diagnostics

flash the watchguard burners failed to

ignite code.

7.2.2

Sensor or sense wire is broken.

ACTION 1 − Check for a broken sensor. ACTION 2 − Test continuity across the sense

wire. If wire or sensor are damaged replace the component.

ignite code.

LED 4 + 3

7.2.3

Sensor or sensor wire is grounded to

the unit.

ACTION 1 − Check for resistance between the sensor rod and the unit ground. ACTION 2 − Check for resistance between the sensor wire and the unit ground.

ACTION 3 − Correct any shorts found in circuit.

7.2.4

Control does not sense flame.

ACTION 1 − Check the microamp signal from the burner flame. If the microamp signal is below normal microamps, check the sense rod for proper location or contamination. ACTION 2 − Replace, clean, or relocate flame sense rod. If rod is to be cleaned, use steel wool or replace sensor. DO NOT CLEAN ROD WITH SAND PAPER. SAND PAPER WILL CONTRIBUTE TO THE CONTAMINATION PROBLEM. NOTE: Do not attempt to bend sense rod. ACTION 3 − Check that there is proper ground to burner box. Repair as necessary.

Page 68

PROBLEM 7: BURNERS LIGHT WITH HEATING DEMAND BUT UNIT SHUTS DOWN

PREMATURELY (CONT.)

Flash Code

LED X + Y

Possible Cause Corrective Action/Comments

7.3

Combustion air inducer energizes

with a heating demand.

Burners light.

Roll−out switch trips during the

heating demand.

7.3.1

Unit is firing above 100% of the

nameplate input.

Diagnostic lights flash roll−out switch

failure.

LED 5 + 1

7.3.2

Gas orifices leak at the manifold con-

nection.

ACTION 1 − Tighten orifice until leak is sealed. NOTE: Be careful not to strip orifice threads. ACTION 2 − Check for gas leakage at the

threaded orifice connection. Use approved method for leak detection (see unit instructions).

LED 5 + 1

7.3.3

Insufficient flow through the heat ex-

changer caused by a sooted or re-

stricted heat exchanger.

7.3.4

Burners are not properly located in

the burner box.

ACTION 1 − Check that the burners are firing into the center of the heat exchanger openings. Correct the location of the burners if necessary.

7.3.5

Poor Venting

ACTION 1 −Check vent pipe and remove any obstructions ACTION 2 − Check for correct exhaust vent installation. See instructions

7.3.6

Improper burner cross−overs

ACTION 1 − Remove burner and inspect the cross−overs for burrs, or any restriction or if crossover is warped. Remove restriction or replace burners.

7.4

Combustion air inducer energizes

with a heating demand.

7.4.1

Poor Venting

ACTION 1 −Check vent pipe and remove any obstructions ACTION 2 − Check for correct exhaust vent installation. See instructions

Burners light roughly and the unit

fails to stay lit.

Diagnostic lights flash watchguard

flame failure.

7.4.2

Improper burner cross−overs

ACTION 1 − Remove burner and inspect the cross−overs for burrs, or any restriction or if crossover is warped. Remove restriction or replace burners.

LED 4 + 3

7.4.3

Burrs in gas orifices

ACTION 1 − Remove gas orifices and inspect. Remove any burrs that are present or replace orifice.

Page 69

PROBLEM 7: BURNERS LIGHT WITH HEATING DEMAND BUT UNIT SHUTS DOWN

PREMATURELY (CONT.)

Flash Code

LED X + Y

Possible Cause Corrective Action/Comments

7.5

Combustion air inducer energizes

with a heating demand.

− Burners light.

Diagnostic lights flash watch guard

flame failure.

7.5.1

Loose sensor wire connection causes

intermittent loss of flame signal.

ACTION 1 − Check that the sensor is properly located. ACTION 2 − Check that the sense wire is properly attached to both the sensor and the control. Pay extra attention to the pin connectors.

NOTE Unit might go into 60 minute

Watchguard mode depending on

intermittent nature of sensor signal.

LED 4 + 3

7.5.2

Poor ground to burner box

ACTION 1 − Check for proper ground and repair as necessary.

PROBLEM 8: CONTROL SIGNALS LOW FLAME SENSE DURING HEATING MODE

Condition Possible Cause Corrective Action/Comments

8.0

Unit operates correctly but the

diagnostic lights flash low flame

8.1.1

Sense rod is improperly located on

the burner.

ACTION 1 − Check the sense rod for proper location on the burner. Properly locate the sense rod or replace if rod cannot be located correctly.

sense code.

LED 1 + 2

8.1.2

Sense rod is contaminated.

PROBLEM 9: INDOOR BLOWER FAILS TO OPERATE IN COOLING, HEATING, OR CONTINUOUS

FAN MODE

Condition Possible Cause Corrective Action/Comments

9.0

− Indoor blower fails to operate in continuous fan, cooling, or heating mode.

9.1.1

Miswiring of furnace or improper con-

nections at control or indoor blower

motor.

ACTION 1− Correct wiring and/or replace any loose connections. Check for correct wiring and loose connections.

9.1.2

120V is not being supplied to the in-

door air blower or blower motor fail-

ure.

ACTION 1 − PSC MOTORS Check for 120V at the various calls for indoor blower by energizing "Y", "G", and "W" individually on the low voltage terminal strip. Note that when "W’ is energized, the blower is delayed 45 seconds. If there is 120V to each motor tap but the blower does not operate, replace the motor.

ACTION 1 − VARIABLE SPEED MOTORS for operation of the VSM see Page 24

9.1.3

Defective control board

ACTION 1 − PSC MOTORS If there is not 120V when "Y", "G", or "W" is energized, replace the control.

Page 70

LOW

HEAT

SPEED

J46

5 Disconnect power to unit. 6 Connect voltage source as shown above.

7 Turn on power to unit. Blower should operate at high cool speed.

11 Disconnect power to unit. 12 Connect voltage source as shown above.

13 Turn on power to unit. Blower should operate at high heat speed.

REMOVE PLUG FROM BOARD

120V to the motor must not be interrupted. All connections for check out will be from the voltage source below (battery or 24V) to plug J46, after disconnecting from blower control board.

ICM−2 WITH TWO STAGE VARIABLE SPEED CONTROL BOARD

LOW

COOL

SPEED

1 Disconnect power to unit. 2 Disconnect plug J46 from P46 located on the blower control board. 3 Connect voltage source as shown above. 4 Turn on power to unit. Blower should operate at low cool speed.

J46

8 Disconnect power to unit. 9 Connect voltage source as shown above.

10 Turn on power to unit. Blower should operate at low heat speed.

HIGH

COOL

SPEED

J46

LOW

HEAT

SPEED

J46

5 Disconnect power to unit. 6 Connect voltage source as shown above.

7 Turn on power to unit. Blower should operate at high cool speed.

11 Disconnect power to unit. 12 Connect voltage source as shown above.

13 Turn on power to unit. Blower should operate at high heat speed.

LOW

COOL

SPEED

J46

8 Disconnect power to unit. 9 Connect voltage source as shown above.

10 Turn on power to unit. Blower should operate at low heat speed.

HIGH

COOL

SPEED

J46

HIGH

HEAT

SPEED

HIGH

HEAT

SPEED

J46J46

CHECK−OUT PROCEDURE USING BATTERY

An ordinary 9 volt battery with maximum DC 20volts is recommended. A 9 volt battery will last for about one day of normal operation.

Unit transformer T1 with a maximum AC 30 volts may be used in lieu of a battery. If transformer T1 is used, double check all wiring connections before placing unit back in operation.

CHECK−OUT PROCEDURE USING 24V SOURCE

Lennox G60DFV-36A-070X, G60DFV-36A-070, G60DFV-36B-090, G60DFV-60C-090, G60DFV-60C-090X Unit Information

Specifications and Main Features

Frequently Asked Questions

User Manual