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

Page 1

© 2002 Lennox Industries Inc.

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

x

) 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

x

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

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 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

s

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

P

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.

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.

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

s

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.

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 45% of the 2nd stage COOL speed position.
N/A − 1st stage and 2nd stage HEAT, speed position 1 with " (Minus) adjust, cannot be used with this model.

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

In

p

ut

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

C

onversion

Kit

Pressure

Switch

C

onversion

Kit

Pressure

Switch

C

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 −

6

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 −

6

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−−

6

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

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

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

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

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

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

OFF

100% CFM

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

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 the FM21 FuelMaster control board.

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.

After the 15−second pre−purge period, the SureLight ignitor
warms up for 20 seconds after which the gas valve opens
for a 4−second trial for ignition. The ignitor energizes during
the trial until flame is sensed. If ignition is not proved during
the 4−second period, the control will try four more times with
an inter purge and warm−up time between trials of 35 sec­onds. After a total of five trials for ignition (including the ini­tial trial), the control goes into Watchguard−Flame Failure
mode. After a 60−minute reset period, the control will begin
the ignition sequence again.

NOTE − Board 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

1

16

5

12

1

4

ON

ON

9

8

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

Y1

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.

Y1

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.

Y1

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

py

thermostat demand

Y1 No demand. Acceptable Low

**42%/46%/49

% of HIGH

COOL

Call for humidity

removal during

Y1

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

Off

satisfied and new cooling demand is

initiated.

Y1

Humidity level remains

slightly (1) above setpoint.

Demand continues.

High

***65%/60% of

HIGH COOL

Significant increase in

Y1

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

ng

thermostat cooling

demand.

Y1

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).

Y1

Humidity level

above setpoint.

High

***65%/60% of

HIGH COOL

Humidity demand

Y1

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

y

satisfied during

thermostat demand.

None

No demand. Acceptable

Off

Off

CFM in order to hasten the end of the

cycle. Unit can only shift out of high

thermostat demand

.

Y1

No demand. Acceptable

Low

**42%/46%/49

% of HIGH

COOL

speed compressor operation at begin-

ning of next cycle.

Y2

No demand. Acceptable

High

HIGH COOL

Call for humidity

removal during 2nd

stage thermostat

Y2

Humidity level rises slightly

(1) above setpoint. Demand

initiated.

High

***65%/60% of

HIGH COOL

Blower immediately changes speed in

response to thermostat demand.

d

eman

d

Y2

No demand. Acceptable

High

HIGH COOL

*Call for 1st stage

None

Humidity level is slightly (1)

above setpoint.

Off

Off

Dehumidification mode (high speed

Call for 1st stage

cooling after call for

humidity removal.

Y1

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

Off

Reduced blower speed (dehumidifica-

cooling after call for

humidity removal

Y2

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

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

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.