Lennox G60DF(X), G60DF(X)−36A−070, G60DF−36B−090, G60DF(X)−48C−110 Installation Instructions Manual

Page 1

05/09

*2P0509*

506178−01

*P506178-01*

E 2008 Lennox Industries Inc.

Dallas, Texas, USA

RETAIN THESE INSTRUCTIONS

FOR FUTURE REFERENCE

INSTALLATION
INSTRUCTIONS

G60DF(X) Series

GAS FURNACE

506178−01
05/2009
Supersedes 10/2008

Table of Contents

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

G60DF(X) Parts Arrangement 3. . . . . . . . . . . . . . . . . . . . .

G60DF(X) Gas Furnace 4. . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Use of Furnace as a Construction Heater 5. . . . . . . . . . .

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

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

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

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

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

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

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

Gas Piping 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Integrated Control 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unit Start−Up 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gas Pressure Adjustment 28. . . . . . . . . . . . . . . . . . . . . . . .

High Altitude Information 28. . . . . . . . . . . . . . . . . . . . . . . . .

Other Unit Adjustments 29. . . . . . . . . . . . . . . . . . . . . . . . . .

Blower Performance 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heating Sequence of Operation 31. . . . . . . . . . . . . . . . . . .

Service 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Planned Service 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ignition Control Diagnostic Codes 34. . . . . . . . . . . . . . . . .

Troubleshooting 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair Parts List 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start−Up & Performance Check List 42. . . . . . . . . . . . . . . .

WHAT TO DO IF YOU SMELL GAS:

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

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

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

use any phone in your building.

D Immediately call your gas supplier from a

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

D If you cannot reach your gas supplier, call

the fire department.

FIRE OR EXPLOSION HAZARD.

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

WARNING

D Leave the building immediately.

Litho U.S.A.

Page 2

506178−01 05/2009

G60DF(X) Unit Dimensions − inches (mm)

GAS PIPING INLET

(Either Side)

FLUE OUTLET

(Top)

ELECTRICAL INLET

(Either Side)

RETURN AIR

OPENING

FRONT VIEW SIDE VIEW

TOP VIEW

A

B

C

D

3/4

(19)

3/4

(19)

28−1/2

(724)

19−1/2

(495)

19−1/4

(489)

9−1/4
(235)

4−7/8 (124) Right

2−1/4 (57) Left

40

(1016)

3−3/4 (95)

5/8

(16)

AIR FLOW

5/8

(16)

3/4

(19)

19−1/2

(495)

5/8

(16)

B

5/8 (16)

5/8 (16)

Supply

Air

Supply

Air

A B C D

Model No.

in. mm in. mm in. mm in. mm
G60DF(X)−36A−070 14−1/2 368 13−1/4 337 13 330 4−1/2 114
G60DF−36B−090 17−1/2 446 16−1/4 413 16 406 6 152

G60DF(X)−48C−110

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

Page 3

G60DF Series

G60DF(X) Parts Arrangement

FIGURE 1

Blower Assembly

Blower Motor

Capacitor

Internal Flue Pipe

Assembly

Flue Box Gasket

Flue Collector Box

Gasket

Combustion Air Inducer

Gasket

Primary

Limit

Heat Exchanger

Combustion Air

Pressure Switch

Assembly

(Two Switches)

Combustion

Air Orifice

Transformer

Two−Stage

Integrated Control

Flue

Chase

Gasket

Door

Interlock Switch

Limit
Shield

Circuit Breaker

Flame Sensor

Gas Valve

Burners

Ignitor

Flame Rollout Switches*

Flame Rollout Bracket

Gas Orifices

Ignitor Bracket

Burner Bottom Shield

*Flame rollout switches are
located on brackets on the
inner sides.

Page 4

506178−01 05/2009

G60DF(X) Gas Furnace

The G60DF(X) gas furnace is equipped with a two−stage
integrated control. Each G60DF(X) unit is shipped ready
for installation in the downflow position.

Shipping and Packing List

Package 1 of 1 contains

1 − Assembled G60DF(X) unit
1 − Bag assembly containing the following:

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

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

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

DANGER

Danger of explosion.

There are circumstances in which odorant used with
LP/propane gas can lose its scent. In case of a leak,
LP/propane gas will settle close to the floor and may
be difficult to smell. An LP/propane leak detector
should be installed in all LP applications.

Requirements

WARNING

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

CAUTION

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

The G60DF is designed for installation as a Non−Direct
Vent gas central furnace.

NOTE − In Non−Direct Vent installations, combustion air is
taken from indoors and flue gases are discharged out−
doors.

Use only the type of gas approved for use with this furnace.
Refer to unit nameplate.

G60DF(X) units are CSA International certified to ANSI
Z21.47 and CSA 2.3 standards.

In the USA, installation of gas furnaces must conform with
local building codes. In the absence of local codes, units
must be installed according to the current National Fuel
Gas Code (ANSI Z223.1/NFPA 54). The National Fuel Gas
Code is available from the following address:

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

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

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

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

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

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

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

This G60DF(X) furnace must be installed so that its electri­cal components are protected from water.

Page 5

G60DF Series

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

When installed, this furnace must be electrically grounded
according to local codes. In addition, in the United States,
installation must conform with the current National Electric
Code, ANSI/NFPA No. 70. The National Electric Code
(ANSI/NFPA No. 70) is available from the following ad­dress:

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

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

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

The G60DF(X) furnace may be installed in alcoves, clos­ets, attics, basements, garages, and utility rooms in the
downflow position.

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

Never use an open flame to test for gas leaks. Check all
connections using a commercially available soap solution
made specifically for leak detection.

Use of Furnace as a Construction Heater

Lennox does not recommend the use of G60DF(X) units as
a construction heater during any phase of construction.
Very low return air temperatures, harmful vapors and op­eration of the unit with clogged or misplaced filters will dam­age the unit.

G60DF(X) units may be used for heating of buildings or
structures under construction, if the following conditions
are met:

D The vent system must be permanently installed per

these installation instructions.

D A room thermostat must control the furnace. The use of

fixed jumpers that will provide continuous heating is not
allowed.

D The return air duct must be provided and sealed to the

furnace.

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

80°F (27°C) must be maintained.

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

maintained during construction.

D Air filters must be replaced upon construction comple-

tion.

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

furnace rating plate.

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

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

D The furnace heat exchanger, components, duct sys-

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

D All furnace operating conditions (including ignition, in-

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

NOTE − The Commonwealth of Massachusetts stipu­lates these additional requirements:

D Gas furnaces shall be installed by a licensed plumb-

er or gas fitter only.

D The gas cock must be T handle" type.
D When a furnace is installed in an attic, the passage-

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

General

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

In addition to the requirements outlined previously, the fol­lowing general recommendations must be considered
when installing a G60DF(X) furnace:

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

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

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

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

D Do not block the furnace combustion air openings with

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

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

lated space, keep insulation away from the furnace.

Page 6

506178−01 05/2009

WARNING

Product contains fiberglass wool.

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

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

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

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

Combustion, Dilution & Ventilation Air

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

In the absence of local codes concerning air for combus­tion and ventilation, use the guidelines and procedures in
this section to install G60DF(X) furnaces to ensure efficient
and safe operation. You must consider combustion air
needs and requirements for exhaust vents. A portion of this
information has been reprinted with permission from the
National Fuel Gas Code (ANSI Z223.1/NFPA 54). This re­printed material is not the complete and official position of
the ANSI on the referenced subject, which is represented
only by the standard in its entirety.

In Canada, refer to the current CSA B149 standards.

CAUTION

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

CAUTION

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

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

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

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

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

Unconfined Space

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

3

) per 1,000 Btu (.29 kW) per hour of the com­bined input rating of all appliances installed in that space.
This space also includes adjacent rooms which are not
separated by a door. Though an area may appear to be un­confined, it might be necessary to bring in outdoor air for
combustion if the structure does not provide enough air by

Page 7

G60DF Series

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

Confined Space

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

3

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

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

EQUIPMENT IN CONFINED

SPACE ALL AIR FROM INSIDE

CHIMNEY

OR GAS

VENT

FURNACE

WATER

HEATER

OPENINGS

(To Adjacent

Room)

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

2

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

2

).

FIGURE 2

Air from Inside

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

2

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

Air from Outside

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

2

) per 4,000 Btu (1.17

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

2

) per

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

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

Page 8

506178−01 05/2009

EQUIPMENT IN CONFINED SPACE

ALL AIR FROM OUTSIDE

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

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

2

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

VENTILATION LOUVERS

(Each end of attic)

OUTLET

AIR

WATER

HEATER

INLET

AIR

CHIMNEY OR

GAS VENT

FURNACE

VENTILATION

LOUVERS

(For unheated crawl space)

FIGURE 3

EQUIPMENT IN CONFINED SPACE

ALL AIR FROM OUTSIDE

(All Air Through Ventilated Attic)

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

2

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

CHIMNEY

OR GAS

VENT

WATER

HEATER

OUTLET

AIR

VENTILATION LOUVERS

(Each end of attic)

INLET AIR

(Ends 12 in.

above bottom)

FURNACE

FIGURE 4

EQUIPMENT IN

CONFINED SPACE

ALL AIR FROM

OUTSIDE

OUTLET AIR

INLET AIR

WATER

HEATER

CHIMNEY

OR GAS

VENT

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

2

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

2

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

FURNACE

FIGURE 5

Page 9

G60DF Series

Downflow Installation

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

Installation on Non−Combustible Flooring

1 − Cut floor opening keeping in mind clearances listed on

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

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

opening.

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

the unit.

3 − Ensure that the seal is adequate.

TABLE 1

NON−COMBUSTIBLE FLOOR OPENING SIZE

Front to Rear Side to Side

Model N

o.

in. mm in. mm

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

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

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

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

Installation on Combustible Flooring

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

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

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

See table 2 for opening size to cut in floor.

CAUTION

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

TABLE 2

ADDITIVE BASE FLOOR OPENING SIZE

Front to Rear Side to Side

Model N

o.

in. mm in. mm

A Cabinet (14.5")

22 559 15 − 3/4 400

B Cabinet (17.5")

22 559 18 − 3/4 476

C Cabinet (21")

22 559 22 − 3/4 578

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

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

3 − Check fiberglass strips on additive base to make sure

they are properly glued and positioned.

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

num flanges seal against fiberglass strips.

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

5 − Set the furnace over the plenum.

6 − Ensure that the seal between the furnace and plenum

is adequate.

G60DF(X)UNIT

SUPPLY AIR PLENUM

ADDITIVE BASE

PROPERLY

SIZED FLOOR

OPENING

FIGURE 6

Installation on Cooling Cabinet

1 − Refer to reverse−flow coil installation instructions for

correctly sized opening in floor and installation of cabi­net.

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

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

3 − Seal the cabinet and check for air leaks.

Return Air Opening −− Downflow Units

The following steps should be taken when installing ple­num:

1 − Bottom edge of plenum should be flanged with a

hemmed edge (See figure 7).

SECURE FROM

OUTSIDE CABINET

HEMMED EDGE

PLENUM

FIBERGLASS
SEALING STRIP
(Field Provided)

CABINET SIDE PANEL

Side View

FIGURE 7

2 − Fiberglass sealing strips should be used.

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

of furnace with sheet metal screws.

Page 10

506178−01 05/2009

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

sheet metal screws from the outside. In this case,
make plenum with a removable front and install
screws from the inside (See figure 8).

5 − Make certain that an adequate seal is made.

SECURE FROM IN-

SIDE CABINET

HEMMED EDGE

FIBERGLASS

SEALING STRIP

(Field Provided)

CABINET SIDE

PANEL

PLENUM

Side View

FIGURE 8

Setting Equipment

WARNING

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

Install the G60DF(X) gas furnace as shipped. Do not
install the furnace horizontally.

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

NOTE − Units with 1/2 hp blower motors are equipped with
three flexible legs and one rigid leg. The rigid leg is
equipped with a shipping bolt and a flat white plastic wash­er (rather than the rubber mounting grommet used with a
flexible mounting leg). The bolt and washer must be re-
moved before the furnace is placed into operation. Af­ter the bolt and washer have been removed, the rigid leg
will not touch the blower housing.

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

Downflow Application Installation Clearances

Top

Bottom

Left Side

Right Side

Type of Vent

Connector

Type C Type B1

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

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

Back 0 0

Sides 0† 0

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

Floor NC†† NC††

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

FIGURE 9

WARNING

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

Page 11

G60DF Series

WARNING

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

Filters

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

TABLE 3

Furnace

Cabinet Width

Return Air Filter Size (inches)

14−1/2" 14 X 25 X 1 (1)

17−1/2" 16 X 25 X 1 (1)

21" 20 X 25 X 1 (1)

Duct System

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

NOTE − Do not operate the furnace with an external static
pressure that exceeds 0.5 inches w.c. Higher external stat­ic pressures may cause erratic limit operation.

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

Return Air Plenum

NOTE − Return air must not be drawn from a room
where this furnace, or any other gas−fueled appliance
(i.e., water heater), or carbon monoxide−producing de­vice (i.e., wood fireplace) is installed.

When return air is drawn from a room, a negative pressure
is created in the room. If a gas appliance is operating in a
room with negative pressure, the flue products can be
pulled back down the vent pipe and into the room. This re­verse flow of the flue gas may result in incomplete combus­tion and the formation of carbon monoxide gas. This toxic
gas might then be distributed throughout the house by the
furnace duct system.

Venting

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

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

tion.

The G60DF(X) series units are classified as fan−assisted
Category I furnaces when vertically vented according to
the latest edition of National Fuel Gas Code (ANSI
Z223.1/NFPA 54) in the USA and the current standards of
the CSA B149 Natural Gas and Propane Installation Codes
in Canada. A fan−assisted Category I furnace is an ap­pliance equipped with an integral mechanical means to ei­ther draw or force combustion products through the com­bustion chamber and/or heat exchanger.

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

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

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

IMPORTANT

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

WARNING

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

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

FLUE TRANSITION

COLLAR

VENT CONNECTION

VENT

PIPE

FURNACE

FIGURE 10

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

Page 12

506178−01 05/2009

Venting Using a Masonry Chimney

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

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

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

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

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

Insulation for the flexible vent pipe must be an encapsu­lated fiberglass sleeve recommended by the flexible vent
pipe manufacturer. See figure 11.

IMPORTANT

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

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

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

S The chimney is currently serving at least one drafthood

equipped appliance

S The vent connectors and chimney are sized according

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

Common Venting Using Metal−Lined Masonry Chimney

4 in. (102 mm)

minimum

MIN. LENGTH −− AS

SHORT AS PRACTICAL

MAX. LENGTH

−− SEE NOTE 1
BELOW.

SEALED

PERMANENTLY

SEALED FIREPLACE

OPENING

EXTERIOR

CHIMNEY WITH

METAL

LINER

VENT CONNECTOR

SEE NOTE 2

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

OTHER

APPLIANCE

FURNACE

FIGURE 11

5 ft. (1.5 m)

minimum

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

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

INTERIOR TILE−LINED
MASONRY CHIMNEY

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

PERMANENTLY
SEALED FIREPLACE
OPENING

VENT

CONNECTOR

SEE NOTE 1 BELOW

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

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

FURNACE

OTHER

APPLIANCE

FIGURE 12

Page 13

G60DF Series

If type B1 double-wall vent is used inside a chimney, no oth­er appliance can be vented into the chimney. The outer wall
of type B1 vent pipe must not be exposed to flue products.

A type B1 vent or masonry chimney liner shall terminate
above the roof surface with a listed cap or a listed roof as­sembly according to the terms of their respective listings
and the vent manufacturer’s instructions.

When inspection reveals that an existing chimney is not
safe for the intended purpose, it shall be rebuilt to conform
to nationally recognized standards, lined or relined with
suitable materials, or replaced with a gas vent or chimney
suitable for venting G60DF(X) series units. The chimney
passageway must be checked periodically to ensure that it
is clear and free of obstructions.

Do not install a manual damper, barometric draft regulator,
or flue restrictor between the furnace and the chimney.
Never connect a Category I appliance to a chimney that is
servicing a solid−fuel appliance. If a fireplace chimney flue
is used to vent this appliance, the fireplace opening must
be permanently sealed.
A type B or listed chimney lining system that passes
through an unused masonry chimney flue is not considered
to be exposed to the outdoors.

General Venting Requirements

Vent all G60DF(X) furnaces according to these instruc­tions:

1 − Vent diameter recommendations and maximum allow-

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

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

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

3 − The minimum vent capacity determined by the sizing

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

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

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

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

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

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

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

6 − The entire length of single wall metal vent connector

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

7 − Single appliance venting configurations with zero lat-

eral lengths (tables 5 and 6) are assumed to have no
elbows in the vent system. For all other vent configura­tions, the vent system is assumed to have two 90° el­bows. For each additional 90° elbow or equivalent (for
example two 45° elbows equal one 90° elbow) beyond
two, the maximum capacity listed in the venting table
should be reduced by 10% (0.90 x maximum listed ca­pacity).

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

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

TABLE 4

Connector Diameter

inches (mm)

Maximum Horizontal

Connector Length feet (m)

3 (76) 4−1/2 (1.37)

4 (102) 6 (1.83)

5 (127) 7−1/2 (2.29)

6 (152) 9 (2.74)

7 (178) 10−1/2 (3.20)

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

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

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

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

11 − A vent connector shall be supported without any dips

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

Page 14

506178−01 05/2009

12 − Vent connectors shall be firmly attached to the furnace

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

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

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

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

ings must be installed with the listed clearance to com­bustible materials and be fire stopped according to lo­cal codes. In absence of local codes, refer to NFGC
(ANSI Z223.1/NFPA 54).

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

pass through any circulation air duct or plenum.

16 − Vent connectors serving Category I appliances shall

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

17 − If vent connectors are combined prior to entering the

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

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

large as the largest vent connector diameter.

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

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

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

lator or flue restrictor between the furnace and the
chimney.

21 − When connecting this appliance to an existing dedi-

cated or common venting system, you must inspect the
venting system’s general condition and look for signs
of corrosion. The existing vent pipe size must conform
to these instructions and the provided venting tables
for the USA, and the appropriate venting tables in the
standards of CSA B149 Natural Gas and Propane
Installation Codes for Canada. If the existing venting
system does not meet these requirements, it must be
resized.

Page 15

G60DF Series

TABLE 5

Capacity of Type B Double−Wall Vents with Type B Double−Wall Connectors

Serving a Single Category I Appliance

Vent and Connector Diameter − D (inches)

Height

Lateral

3 Inch 4 Inch 5 Inch 6 Inch

H

(

feet

)L(

feet

)

Appliance Input Rating in Thousands of Btu Per Hour

(feet)

(feet)

MIN MAX MIN MAX MIN MAX MIN MAX

0 0 78 0 152 0 251 0 375

2 13 51 18 97 27 157 32 232

6

4 21 49 30 94 39 153 50 227

6 25 46 36 91 47 149 59 223

0 0 84 0 165 0 276 0 415

2 12 57 16 109 25 178 28 263

8

5 23 53 32 103 42 171 53 255

8 28 49 39 98 51 164 64 247

0 0 88 0 175 0 295 0 447

2 12 61 17 118 23 194 26 289

10

5 23 57 32 113 41 187 52 280

10 30 51 41 104 54 176 67 267

0 0 94 0 191 0 327 0 502

2 11 69 15 136 20 226 22 339

15

5 22 65 30 130 39 219 49 330

10 29 59 40 121 51 206 64 315

15 35 53 48 112 61 195 76 301

0 0 97 0 202 0 349 0 540

2 10 75 14 149 18 250 20 377

5 21 71 29 143 38 242 47 367

20

10 28 64 38 133 50 229 62 351

15 34 58 46 124 59 217 73 337

20 48 52 55 116 69 206 84 322

0 0 100 0 213 0 374 0 587

2 9 81 13 166 14 283 18 432

5 21 77 28 160 36 275 45 421

30

10 27 70 37 150 48 262 59 405

15 33 64 44 141 57 249 70 389

20 56 58 53 132 66 237 80 374

30 NR NR 73 113 88 214 104 346

NOTE − Single appliance venting configurations with zero lateral lengths are assumed to have no elbows in the vent system. For all other
vent configurations, the vent system is assumed to have two 90° elbows. For each additional 90° elbow or equivalent (for example two 45°
elbows equal one 90° elbow) beyond two, the maximum capacity listed in the venting table should be reduced by 10 percent (0.90 x maxi­mum listed capacity).

Page 16

506178−01 05/2009

TABLE 6

Capacity of Type B Double−Wall Vents with Single−Wall Metal Connectors

Serving a Single Category I Appliance

Vent and Connector Diameter − D (inches)

Height

Lateral

3 Inch 4 Inch 5 Inch 6 Inch

H

(

feet

)L(

feet

)

Appliance Input Rating in Thousands of Btu Per Hour

(feet)

(feet)

MIN MAX MIN MAX MIN MAX MIN MAX

0 38 77 59 151 85 249 126 373

2 39 51 60 96 85 156 123 231

6

4 NR NR 74 92 102 152 146 225

6 NR NR 83 89 114 147 163 220

0 37 83 58 164 83 273 123 412

2 39 56 59 108 83 176 121 261

8

5 NR NR 77 102 107 168 151 252

8 NR NR 90 95 122 161 175 243

0 37 87 57 174 82 293 120 444

2 39 61 59 117 82 193 119 287

10

5 52 56 76 111 105 185 148 277

10 NR NR 97 100 132 171 188 261

0 36 93 56 190 80 325 116 499

2 38 69 57 136 80 225 115 337

15

5 51 63 75 128 102 216 144 326

10 NR NR 95 116 128 201 182 308

15 NR NR NR NR 158 186 220 290

0 35 96 54 200 78 346 114 537

2 37 74 56 148 78 248 113 375

5 50 68 73 140 100 239 141 363

20

10 NR NR 93 129 125 223 177 344

15 NR NR NR NR 155 208 216 325

20 NR NR NR NR 186 192 254 306

0 34 99 53 211 76 372 110 584

2 37 80 55 164 76 281 109 429

5 49 74 72 157 98 271 136 417

30

10 NR NR 91 144 122 255 171 397

15 NR NR 115 131 151 239 208 377

20 NR NR NR NR 181 223 246 357

30 NR NR NR NR NR NR NR NR

NOTE − Single appliance venting configurations with zero lateral lengths are assumed to have no elbows in the vent system. For all other
vent configurations, the vent system is assumed to have two 90° elbows. For each additional 90° elbow or equivalent (for example two 45°
elbows equal one 90° elbow) beyond two, the maximum capacity listed in the venting table should be reduced by 10 percent (0.90 x maxi­mum listed capacity).

Page 17

G60DF Series

TABLE 7

Vent Connector Capacity

Type B Double−Wall Vents with Type B Double−Wall Connectors

Serving Two or More Category I Appliances

Vent and Connector Diameter − D (inches)

Vent

Height

C

onnector

Rise

3 Inch 4 Inch 5 Inch 6 Inch

Height

H

Rise

R

Appliance Input Rating in Thousands of Btu Per Hour

(feet) (feet)

MIN MAX MIN MAX MIN MAX MIN MAX

1 22 37 35 66 46 106 58 164

6

2 23 41 37 75 48 121 60 183

6

3 24 44 38 81 49 132 62 199

1 22 40 35 72 49 114 64 176

8

2 23 44 36 80 51 128 66 195

3 24 47 37 87 53 139 67 210

1 22 43 34 78 49 123 65 189

10

2 23 47 36 86 51 136 67 206

3 24 50 37 92 52 146 69 220

1 21 50 33 89 47 142 64 220

15

2 22 53 35 96 49 153 66 235

3 24 55 36 102 51 163 68 248

1 21 54 33 99 46 157 62 246

20

2 22 57 34 105 48 167 64 259

3 23 60 35 110 50 176 66 271

1 20 62 31 113 45 181 60 288

30

2 21 64 33 118 47 190 62 299

3 22 66 34 123 48 198 64 309

TABLE 8

Common Vent Capacity

Type B Double−Wall Vents with Type B Double−Wall Connectors

Serving Two or More Category I Appliances

Common Vent Diameter − D (inches)

Vent

Height

4 Inch 5 Inch 6 Inch 7 Inch

Height

H

Appliance Input Rating in Thousands of Btu Per Hour

(feet)

FAN + FAN FAN + NAT FAN + FAN FAN + NAT FAN + FAN FAN + NAT FAN + FAN FAN + NAT

6 92 81 140 116 204 161 309 248

8 101 90 155 129 224 178 339 275

10 110 97 169 141 243 194 367 299

15 125 112 195 164 283 228 427 352

20 136 123 215 183 314 255 475 394

30 152 138 244 210 361 297 547 459

Page 18

506178−01 05/2009

TABLE 9

Vent Connector Capacity

Type B Double−Wall Vents with Single−Wall Metal Connectors

Serving Two or More Category I Appliances

Vent and Connector Diameter − D (inches)

Vent

Height

C

onnector

Rise

3 Inch 4 Inch 5 Inch 6 Inch

Height

H

Rise

R

Appliance Input Rating in Thousands of Btu Per Hour

(feet) (feet)

MIN MAX MIN MAX MIN MAX MIN MAX

1 NR NR NR NR NR NR NR NR

6

2 NR NR NR NR NR NR 168 182

6

3 NR NR NR NR 121 131 174 198

1 NR NR 79 87 116 138 177 214

15

2 NR NR 83 94 121 150 185 230

3 NR NR 87 100 127 160 193 243

1 47 60 77 110 113 175 169 278

30

2 50 62 81 115 117 185 177 290

3 54 64 85 119 122 193 185 300

TABLE 10

Common Vent Capacity

Type B Double−Wall Vents with Single−Wall Metal Connectors

Serving Two or More Category I Appliances

Common Vent Diameter − D (inches)

Vent

Height

4 Inch 5 Inch 6 Inch 7 Inch

Height

H

Appliance Input Rating in Thousands of Btu Per Hour

(feet)

FAN + FAN FAN + NAT FAN + FAN FAN + NAT FAN + FAN FAN + NAT FAN + FAN FAN + NAT

6 89 78 136 113 200 158 304 244

8 98 87 151 126 218 173 331 269

10 106 94 163 137 237 189 357 292

15 121 108 189 159 275 221 416 343

20 131 118 208 177 305 247 463 383

30 145 132 236 202 350 286 533 446

Removal of the Furnace from Common Vent

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

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

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

tem.

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

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

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

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

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

4 − Follow the lighting instructions. Turn on the appliance

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

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

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

6 − After determining that each appliance connected to the

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

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

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

Page 19

G60DF Series

Resize the common venting system to the minimum
vent pipe size determined by using the appropriate
tables in Appendix G. (These are in the current stan­dards of the National Fuel Gas Code ANSI
Z223.1/NFPA 54 in the USA, and the appropriate
Category 1 Natural Gas and Propane appliances vent­ing sizing tables in the current standards of the CSA
B149 Natural Gas and Propane Installation Codes in
Canada.)

Gas Piping

CAUTION

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

Gas Supply

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

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

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

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

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

clothes chutes, gas vents or chimneys, dumb waiters,
or elevator shafts.

4 − The piping should be sloped 1/4 inch (6.4 mm) per 15

feet (4.57 m) upward toward the meter from the fur­nace. The piping must be supported at proper intervals
[every 8 to 10 feet (2.44 to 3.01 m)] with suitable hang­ers or straps. Install a drip leg inside vertical pipe runs
to the unit.

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

a manual main shut-off valve and union (furnished by
the installer) external to the unit. The union must be of
the ground joint type.

IMPORTANT

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

NOTE − Install a 1/8 inch NPT plugged tap in the field piping
upstream of the gas supply connection to the unit. The tap
must be accessible for test gauge connection. See figure

13.

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

TABLE 11

Gas Pipe Capacity − ft

3

/hr (m3/hr)

Nominal

Iron Pipe

Internal

Length of Pipe − feet (m)

Iron Pipe

Size

inches

(mm)

Diameter

inches

(mm)

10

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

100

(30.480)

3/8

(9.53)

.493

(12.522)95(2.69)65(1.84)

52

(1.47)

45

(1.27)

40

(1.13)

36

(1.02)

33

(.73)

31

(.88)

29

(.82)

27

(.76)

1/2

(12.7)

.622

(17.799)

175

(4.96)

120

(3.40)

97

(2.75)

82

(2.32)

73

(2.07)

66

(1.87)

61

(1.73)

57

(1.61)

53

(1.50)

50

(1.42)

3/4

(19.05)

.824

(20.930)

360

(10.19)

250

(7.08)

200

(5.66)

170

(4.81)

151

(4.28)

138

(3.91)

125

(3.54)

118

(3.34)

110

(3.11)

103

(2.92)

1

(25.4)

1.049

(26.645)

680

(919.25)

465

(13.17)

375

(10.62)

320

(9.06)

285

(8.07)

260

(7.36)

240

(6.80)

220

(6.23)

205

(5.80)

195

(5.52)

1−1/4

(31.75)

1.380

(35.052)

1400

(39.64)

950

(26.90)

770

(21.80)

660

(18.69)

580

(16.42)

530

(15.01)

490

(13.87)

460

(13.03)

430

(12.18)

400

(11.33)

1−1/2

(38.1)

1.610

(40.894)

2100

(59.46)

460

(41.34)

1180

(33.41)

990

(28.03)

900

(25.48)

810

(22.94)

750

(21.24)

690

(19.54)

650

(18.41)

620

(17.56)

2

(50.8)

2.067

(52.502)

3950

(111.85)

2750

(77.87)

2200

(62.30)

1900

(53.80)

1680

(47.57)

1520

(43.04)

1400

(39.64)

1300

(36.81)

1220

(34.55)

1150

(32.56)

2−1/2

(63.5)

2.469

(67.713)

6300

(178.39)

4350

(123.17)

3520

(99.67)

3000

(84.95

2650

(75.04)

2400

(67.96)

2250

(63.71)

2050

(58.05)

1950

(55.22)

1850

(52.38)

3

(76.2)

3.068

(77.927)

11000

(311.48)

7700

(218.03)

6250

(176.98)

5300

(150.07)

4750

(134.50)

4300

(121.76)

3900

(110.43)

3700

(104.77)

3450

(97.69)

3250

(92.03)

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

Page 20

506178−01 05/2009

GROUND

JOINT

UNION

AUTOMATIC

GAS VALVE
(with manual

shut−off valve)

FIELD

PROVIDED

AND INSTALLED

GROUND

JOINT

UNION

Left Side Piping

(Standard)

Right Side Piping

(Alternate)

AUTOMATIC

GAS VALVE
(with manual

shut−off valve)

DRIP LEG

DRIP LEG

MANUAL

MAIN SHUT−OFF

VALVE

(With 1/8 in. NPT

Plugged Tap Shown)

MANUAL

MAIN SHUT−OFF

VALVE

(With 1/8 in. NPT

Plugged Tap

Shown)

FIGURE 13

Leak Check

After gas piping is completed, carefully check all piping
connections (factory− and field−installed) for gas leaks. Use
a leak detecting solution or other preferred means.

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

WARNING

FIRE OR EXPLOSION HAZARD
Failure to follow the safety warnings exactly could
result in serious injury, death, or property damage.
Never use an open flame to test for gas leaks. Check
all connections using a commercially available soap
solution made specifically for leak detection.Some
soaps used for leak detection are corrosive to cer­tain metals. Carefully rinse piping thoroughly after
leak test has been completed.

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

IMPORTANT

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

MANUAL MAIN

SHUT−OFF VALVE

WILL NOT HOLD

NORMAL TEST

PRESSURE

CAP

ISOLATE

GAS VALVE

FURNACE

FIGURE 14

Electrical

ELECTROSTATIC DISCHARGE (ESD)

Precautions and Procedures

CAUTION

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

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

INTERIOR MAKE−UP BOX INSTALLATION

(Left Side)

FIGURE 15

MAKE−UP

BOX

Page 21

G60DF Series

INTERIOR MAKE−UP BOX INSTALLATION

(Right Side)

FIGURE 16

MAKE−UP

BOX

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

1 − Select circuit protection and wire size according to the

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

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

tate wiring.

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

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

4 − Before connecting the thermostat or the power wiring,

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

5 − Complete the wiring connections to the equipment.

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

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

in the absence of local codes, according to the current

National Electric Code (ANSI/NFPA No. 70) for the
USA and current Canadian Electric Code part 1 (CSA
standard C22.1) for Canada. A green ground wire is
provided in the field make−up box.

NOTE − The G60DF(X) furnace contains electronic
components that are polarity sensitive. Make sure
that the furnace is wired correctly and is properly
grounded.

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

vided on the furnace integrated control. Any humidifier
rated up to one amp can be connected to this terminal
with the neutral leg of the circuit being connected to
one of the provided neutral terminals. See figure 19 for
control configuration. This terminal is energized in the
heating mode when the combustion air inducer is oper­ating.

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

on the furnace integrated control. Any electronic air
cleaner rated up to one amp can be connected to this
terminal with the neutral leg of the circuit being con­nected to one of the provided neutral terminals. See
figure 19 for control configuration. This terminal is en­ergized when the indoor blower is operating.

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

terminal block. Any humidifier rated up to 0.5 amp can
be connected to this terminal with the ground leg of the
circuit being connected to either ground or the C" ter­minal. See figure 19 for control configuration.

10 −Install the room thermostat according to the instruc-

tions provided with the thermostat. See table 12 for
field wiring connections in varying applications. If the
furnace is being matched with a heat pump, refer to the
instruction packaged with the dual fuel thermostat.

Indoor Blower Speeds

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

blower will run continuously on the low speed when
there is no cooling or heating demand.

2 − When the G60DF(X) is operating in the high−fire or low−

fire heating mode, the indoor blower will run on the cor­responding heating speed.

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

run on the cooling speed.

Page 22

506178−01 05/2009

TABLE 12

Field Wiring Applications

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

Thermostat

DIP Switch 1

W915

(Y1 to Y2)

Two−Stage

Cooling

W951

(O to R)

Heat Pumps

Wiring Connections

1 Heat / 1 Cool

NOTE − Use DIP
switch 2 to set sec­ond−stage heat ON
delay.
OFF10 minutes.
ON−15 minutes.

ON Intact Intact

S1

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

S1

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

Page 23

G60DF Series

TABLE 12

Field Wiring Applications (Continued)

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

Thermostat

DIP Switch 1

W915

(Y1 to Y2)

Two−Stage

Cooling

W951

(O to R)

Heat Pumps

Wiring Connections

2 Heat / 2 Cool OFF Cut Intact

S1

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

2 Heat / 1 Cool OFF Intact Intact

S1

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

Page 24

506178−01 05/2009

G60DF(X) Schematic Wiring Diagram

FIGURE 17

Page 25

G60DF Series

TYPICAL FIELD WIRING DIAGRAM

FIGURE 18

TWO−STAGE INTEGRATED CONTROL

THERMOSTAT CONNECTIONS (TB1)

1/4" QUICK CONNECT TERMINALS

DIP SWITCH FUNCTIONS

DIP

SWITCHES

DIAGNOSTIC

LEDs

ON−BOARD

LINKS

1= ERROR CODE RECALL
H= 24V HUMIDIFIER OUTPUT
L= LENNOX SYSTEM OPERATION MONITOR

SENSE = 120 VAC OUTPUT TO FLAME SENSER

NEUTRALS= 120 VAC NEUTRAL

PARK = DEAD TERMINAL FOR UNUSED BLOWER LEAD
HEAT LOW = 120 VAC OUTPUT TO CIRC BLWR −− LOW HT SPEED
HEAT HIGH/ COOL LOW = 120 VAC OUTPUT TO CIRC BLWR −−

HIGH HEAT AND LOW COOL SPEED

COOL HIGH = 120 VAC OUTPUT TO CIRC BLWR −− HIGH COOL SPEED

DIP SWITCH(ES) FUNCTION

1 −− 2 Stage T’stat Selects t/stat type (single or two−stage)

2 −− 2nd Stage Delay Second stage ON delay (single−stage t’stat)

3 & 4 −− Heat Off Delay Heating fan OFF delay

5 −− Cool Off Delay Cooling fan OFF delay

W915

W951

FIGURE 19

Page 26

506178−01 05/2009

Integrated Control

G60DF units are equipped with a two−stage integrated con­trol. This control manages ignition timing and fan off delays
based on selections made using the control DIP switches.
The control includes an internal watchguard feature which
automatically resets the ignition control when it has been
locked out. After one hour of continuous thermostat de­mand for heat, the watchguard will break and remake ther­mostat demand to the furnace and automatically reset the
control to relight the furnace.

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

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

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

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

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

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

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

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

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

TABLE 13

Heating Blower−Off Delay Switch Settings

Blower Off Delay

(Seconds)

Switch 3 Switch 4

60 Off On

90 Off Off
120 On Off
180 On On

Switch 5 −− Cooling Blower−Off Delay −− The cooling
blower−off delay (time that the blower operates after the
cooling demand has been satisfied) can be adjusted by
moving switch 5 on the integrated control. The switch is fac­tory−set in the OFF position, which provides a cooling blow­er−off delay of 45 seconds. If the switch is toggled to the ON
position, it will provide a 2−second cooling blower−off delay

On−Board Link W951

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

On−Board Link W915

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

Unit Start−Up

FOR YOUR SAFETY READ BEFORE LIGHTING

WARNING

Do not use this furnace if any part has been underwa­ter. A flood−damaged furnace is extremely danger­ous. Attempts to use the furnace can result in fire or
explosion. Immediately call a licensed professional
service technician (or equivalent) to inspect the fur­nace and to replace all gas controls, control system
parts, and electrical parts that have been wet or to re­place the furnace, if deemed necessary.

WARNING

Danger of explosion. Can cause injury
or product or property damage. Should
the gas supply fail to shut off or if
overheating occurs, shut off the gas
valve to the furnace before shutting off
the electrical supply.

Page 27

G60DF Series

CAUTION

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

BEFORE LIGHTING smell all around the appliance area

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

The gas valve on the G60DF(X) unit may be equipped with
either a gas control knob or gas control switch. Use only
your hand to move the control switch or to turn the gas con­trol knob. Never use tools. If the knob will not turn or if the
control switch will not move by hand, do not try to repair it.
Call a licensed professional service technician. Force or at­tempted repair may result in a fire or explosion.

Placing the furnace into operation:

G60DF(X) units are equipped with a n automatic ignition
system. Do not attempt to manually light burners on these
furnaces. Each time the thermostat calls for heat, the burn­ers will automatically light. The ignitor does not get hot
when there is no call for heat on units with this ignition sys­tem.

WARNING

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

Gas Valve Operation (Figures 20 and 21)

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

this section.

2 − Set the thermostat to the lowest setting.

3 − Turn off all electrical power to the unit.

4 − This furnace is equipped with an ignition device which

automatically lights the burners. Do not try to light the
burners by hand.

5 − Remove the upper access panel.

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

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

valve clockwise

to OFF. Do not force. See figure

21.

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

gas, STOP! Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s instruc­tions. If you do not smell gas go to next step.

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

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

valve counterclockwise

to ON. Do not force. See

figure 21.

9 − Replace the upper access panel.

WHITE RODGERS 36E SERIES GAS VALVE

GAS VALVE SHOWN IN OFF POSITION

HIGH FIRE
MANIFOLD
PRESSURE

ADJUSTMENT

ON SIDE

(under cap)

MANIFOLD

PRESSURE

TAP ON SIDE

INLET PRESSURE

TAP ON SIDE

LOW FIRE MANIFOLD

PRESSURE ADJUSTMENT

ON SIDE (under cap)

FIGURE 20

HONEYWELL VR8205 SERIES GAS VALVE

GAS VALVE SHOWN IN OFF POSITION

MANIFOLD

PRESSURE

TAP

HIGH FIRE

ADJUSTING SCREW

(under cap)

INLET PRESSURE TAP

LOW FIRE

ADJUSTING SCREW

(under cap)

FIGURE 21

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.

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

Turning Off Gas to Unit" and call the gas supplier.

Turning Off Gas to Unit

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

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

trol switch to OFF.

Honeywell VR8205 Gas Valve − Turn knob on gas

valve clockwise

to OFF. Do not force.

5 − Replace the upper access panel.

Page 28

506178−01 05/2009

Gas Pressure Adjustment

Gas Flow (Approximate)

1 − Operate unit at least 15 minutes before checking gas

flow. Determine the time in seconds for one revolu­tions of gas through the meter. A portable LP gas me­ter (17Y44) is available for LP applications.

TABLE 14

Gas Flow Rate (Ft.3/Hr.)

Seconds for 1

Gas Meter Size

Seconds for 1

Revolution

1/2 cu ft Dial 1 cu ft Dial

10 180 360
12 150 300
14 129 257
16 113 225
18 100 200
20 90 180
22 82 164
24 75 150
26 69 138
28 64 129
30 60 120
32 56 113
34 53 106
36 50 100
38 47 95
40 45 90
42 43 86
44 41 82
46 39 78
48 38 75
50 36 72
52 35 69
54 33 67
56 32 64
58 31 62
60 30 60

2 − Compare the number of seconds and the gas meter

size in table 14 to determine the gas flow rate. Multiply
the gas flow rate by the heating value to determine the
unit input rate. If manifold pressure is correct and the
unit input rate is incorrect, check gas orifices for proper
size and restriction.

3 − Remove temporary gas meter if installed.

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

Gas Pressure

1 − Check the gas line pressure with the unit firing at maxi-

mum rate. A minimum of 4.5 in. w.c. for natural gas or

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

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

justed, check the low fire and high fire manifold pres­sures. See figures 20 and 21 for the location of the
manifold pressure adjustment screws. Low and high
fire manifold pressures are given in table 15. A natural
gas to LP/propane gas changeover kit is required to
convert the unit.

High Altitude Information

Refer to table 15 for high altitude requirements and man­ifold pressure settings at all altitudes.

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

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

TABLE 15

High Altitude Requirements / Manifold Pressure Settings

Altitude

Model

Input

Gas

0 − 7500 ft.

(0 − 2285 m)

7501−10,000 ft.

(2286 − 3048 m)

Manifold Pressure

at all altitudes

Input

Size

Gas

Required Pressure Required Pressure

Low Fire High Fire

Required

Conversion Kit

Pressure

Switch

Required

Conversion Kit

Pressure

Switch

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

−070, −090,

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

−070, −090

,

−110

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

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

Page 29

G60DF Series

Other Unit Adjustments

Primary and Secondary Limits

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

Flame Rollout Switches (Two)

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

Pressure Switches

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

Temperature Rise

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

Blower Speeds

NOTE − CFM ratings are taken external to unit with a dry
evaporator coil and without accessories. See blower per­formance data on page 30.

Thermostat Heat Anticipation

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

Electrical

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

operating).
3 − Check amp-draw on the blower motor.

Motor Nameplate__________Actual__________

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

Electronic Ignition

The two−stage integrated control used in G60DF units has
an added feature of an internal Watchguard control. The
feature serves as an automatic reset device for ignition
control lockout caused by ignition failure. This type of lock­out is usually due to low gas line pressure. After one hour of
continuous thermostat demand for heat, the Watchguard
will break and remake thermostat demand to the furnace
and automatically reset the control to begin the ignition se­quence.

Flue And Chimney

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

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

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

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

Failure To Operate

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

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

out again, inspect the unit for blockages.

Page 30

506178−01 05/2009

Blower Performance Data

G60DF−36A−070X PERFORMANCE

Air Volume / Watts at Different Blower Speeds

External

Static

Pressure

High

Medium−

High

Medium−

Low

Low

in. w.g.

cfm

Watt cfm Watt cfm Watt cfm Watt

0.00 1475 616 1345 554 1150 495 990 415

0.05 1450 606 1320 543 1140 481 985 407

0.10 1425

595 1300 532 1125 466 975 398

0.15

1395 585 1275 521 1115 452 970 390

0.20 1375 574 1255 510 1105 437 965 381

0.25 1345

563 1230 494 1090 428 955 371

0.30

1320 552 1205 478 1075 418 945 360

0.40 1250 528 1150 455 1040 395 920 346

0.50 1200

508 1095 432 1000 374 880 331

0.60

1110 475 1035 409 950 354 830 313

0.70 1030 455 970 390 855 338 720 280

0.80 960

434 875 359 735 299 665 266

0.90

770 389 715 321 665 278 590 244

G60DF−36B−090 PERFORMANCE

External

Air Volume / Watts at Different Blower Speeds

External

Static

Pressure

High

Medium−

High

Medium−

Low

Low

in. w.g. cfm Watt cfm Watt cfm Watt cfm Watt

0.00 1600 608 1410 526 1165 436 965 355

0.05 1580 599 1400 518 1165 428 965 351

0.10 1560

589 1390 509 1160 420 970 346

0.15

1530 573 1370 497 1155 413 965 341

0.20 1495 556 1350 485 1150 406 965 335

0.25 1465

544 1325 473 1135 398 955 329

0.30

1430 532 1300 460 1125 389 945 323

0.40 1370 509 1250 438 1095 373 935 313

0.50 1295

482 1200 420 1055 355 900 302

0.60

1215 456 1140 397 1010 343 860 285

0.70 1140 437 1055 371 915 313 800 272

0.80 1000

401 950 342 850 295 730 251

0.90

900 374 820 313 740 272 − − − − − −

NOTE − All air data is measured external to unit with 1 in. (25 mm) cleanable filter (not furnished − field provided) in place.

G60DF−48C−110 PERFORMANCE

External

Air Volume / Watts at Different Blower Speeds

Static

Pressure

High Medium−High Medium−Low Low

in. w.g. cfm Watts cfm Watts cfm Watts cfm Watts

0.00

2035 846 1790 712 1510 595 1225 477

0.05 2000 825 1760 694 1495 581 1225 470

0.10 1970

803 1730 675 1475 567 1220 463

0.15

1925 781 1710 657 1475 555 1220 455

0.20 1880 758 1685 638 1465 542 1215 447

0.25 1835

736 1655 618 1440 528 1200 437

0.30

1795 714 1625 597 1420 514 1185 427

0.40 1680 669 1550 564 1360 483 1135 400

0.50 1620

630 1445 524 1280 447 1065 371

0.60

1445 592 1310 479 1165 404 1000 343

0.70 1290 545 1180 434 1055 369 905 319

0.80 1155

502 1065 406 955 348 815 296

0.90

1010 472 930 372 840 320 690 265

NOTE − All air data is measured external to unit with 1 in. (25 mm) cleanable filter (not fur­nished − field provided) in place.

Page 31

G60DF Series

Heating Sequence of Operation

NOTE − The thermostat jumper on the integratred control is
factory−set in the TWO−STAGE" position.

Applications Using a Two−Stage Thermostat

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Applications Using A Single−Stage Thermostat

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

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

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

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

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

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

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

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

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

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

5 − If the heating demand continues beyond the second−

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

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

combustion air inducer begins a 5−second post−purge.
The field−selected indoor blower off delay begins.

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

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

Page 32

506178−01 05/2009

Service

WARNING

Disconnect power before servicing unit.

CAUTION

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

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

Blower

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

WARNING

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

Filters

All G60DF(X) filters are installed external to the unit. Filters
should be inspected monthly. Clean or replace the filters
when necessary to ensure that the furnace operates prop­erly. Replacement filters must be rated for high velocity air­flow. Table 3 lists recommended filter sizes.

Flue And Chimney

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

Electrical

1 − Check all wiring for loose connections.

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

operating).

3 − Check amp−draw on the blower motor.

Motor Nameplate__________Actual__________

Cleaning the Heat Exchanger and Burners

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

Cleaning the heat exchanger requires a steel spring
snake," a reversible drill and a vacuum cleaner. The steel
spring snake may be constructed by purchasing a 4 ft. long
by 1/4 inch diameter steel wire cable and a 1/4 inch diame­ter wire brush. These items are available at a hardware
store. Insert wire end of brush into the open end of the

spring cable. Crimp the cable around the brush so that the
brush is secured and will not come off during cleaning. At­tach the other end of the cable to the reversible drill to com­plete the tool for cleaning the heat exchanger.
1 − Turn off both electrical and gas power supplies to fur-

nace.

2 − Remove flue pipe and top cap from the unit. Label the

pressure switch wires, then disconnect them.

3 − Remove the four screws that secure the combustion

air inducer. Carefully remove the combustion air induc­er to avoid damaging blower gasket. If gasket is dam­aged, it must be replaced to prevent leakage. See fig­ure 1.

4 − Remove the collector box located behind the combus-

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

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

then disconnect them.

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

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

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

the NOx insert to the corbel at the entrance to each
heat exchanger section. Carefully remove the NOx in­sert from each section. See figure 23.

8 − 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.
9 − Repeat procedure for each heat exchanger section.
10− After each of the top heat exchanger sections has been

cleaned, insert the brush end of the cable snake into

the bottom openings of each of the heat exchanger

sections and clean as described in step 8.
11− Remove the cable from the heat exchanger. Use a vac-

uum cleaner to remove debris knocked loose during

cleaning.
12− 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 open-

ings.

13− 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.

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

brush attachment over the face of burners. Visually in-

spect inside the burners and crossovers for any block-

age caused by foreign matter. Remove any blockage.

Page 33

G60DF Series

G60DF(X) COMBUSTION AIR INDUCER,

BURNER & HEAT EXCHANGER REMOVAL

FIGURE 22

Burner Box Assembly

Heat Exchanger

Combustion Air

Inducer

NOx INSERTS

(X models only)

FIGURE 23

NOx INSERT

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

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

16− Re−install burner box / manifold assembly onto the ves-

tibule panel.

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

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

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

tion air inducer outlet.

19− Reconnect gas supply piping.

20− Turn on power and gas supply to unit.

21− Set thermostat and check for proper operation.

22− 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.

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

pair leak.

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

25− Replace front access panel.

Planned Service

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

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

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

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

or sagging pipe, or disconnected joints.

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

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

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

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

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

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

Instruct the homeowners to pay attention to their fur­nace. Situations can arise between annual furnace inspec-

tions that may result in unsafe operation.

Page 34

506178−01 05/2009

Integrated Control Diagnostic Codes

FLASH CODE

(X + Y)

STATUS / ERROR DESCRIPTION

FLASH CODE DESCRIPTIONS

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

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

X + Y

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

Pulse Power on − Standby.

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

FLAME CODES

1 + 2 Low flame current −− run mode.

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

PRESSURE SWITCH CODES

2 + 3 Low pressure switch failed open.

2 + 4 Low pressure switch failed closed.

2 + 5 High pressure switch failed open.

2 + 6 High pressure switch failed closed.

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

LIMIT CODE

3 + 1 Limit switch open.

WATCHGUARD CODES

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

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

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

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

4 + 6 Watchguard −− Flame sensed out of sequence; flame signal gone.

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

4 + 8 Low line voltage.

HARD LOCKOUT CODES

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

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

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

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

5 + 6 Low secondary (24VAC) voltage.

Error Code Storage

The ignition control stores the last ten error codes in
memory. The codes are retained in case of power loss.

Error Code Review

1 − Short R (2) to (1). Within 1/2 second, the STATUS LED

will stay lit continuously to indicate that the short was
sensed.

2 − Continue to hold the short between R (2) to (1). After 5

seconds, STATUS LED will go from being continuous­ly lit to off. This indicates that error code review is pend­ing.

3 − Remove R (2) to (1) short within ten seconds of STA-

TUS LED turning off. This activates error code review.

4 − Last ten error codes will be flashed on the STATUS

LED.

5 − After final error code is indicated, STATUS LED will

flash to indicate normal operation.

Clearing Error Codes

1 − Short R (2) to (1). Within 1/2 second, the STATUS LED

will stay lit continuously to indicate that the short was

sensed.

2 − Continue to hold the short between R (2) to (1). After 5

seconds, STATUS LED will go from being continuous-

ly lit to off.

3 − Continue to hold the short between R (2) to (1) beyond

ten seconds after STATUS LED has turned off. STA-

TUS LED will turn on, indicating that error codes have

been cleared.

4 − Remove R (2) to (1) short. STATUS LED will flash to

indicate normal operation.

Page 35

G60DF Series

Troubleshooting: Heating Sequence of Operation

HEATING SEQUENCE OF OPERATION

NORMAL AND ABNORMAL HEATING MODE

CONTROL SELF−CHECK OKAY?

YES

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF. (RESET CONTROL BY

TURNING MAIN POWER OFF.)

NO

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?

NO

YES

A

NORMAL OPERATION:

STATUS LED −− PULSE

B

THERMOSTAT CALLS FOR HEAT:

STATUS LED −− HEARTBEAT

YES

PRIMARY AND SECONDARY LIMIT

SWITCHES CLOSED?

YES

NO

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.

NO

YES

FIRST (LOW) STAGE PRESSURE SWITCH

CONTACTS OPEN?

NO

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.

NO

TWO−STAGE OR SINGLE−STAGE THERMOSTAT

CALL FOR HEAT

COMBUSTION AIR INDUCER ON LOW SPEED.

STATUS LED −− HEARTBEAT

CONTINUED ON NEXT PAGE

NO

NO

60−MINUTE LIMIT WATCHGUARD MODE.

GAS VALVE OFF, COMBUSTION AIR INDUCER

OFF, INDOOR BLOWER OFF WITH DELAY.

STATUS ERROR CODE 4 + 5.

YES

NO

YES

SECOND (HIGH) STAGE PRESSURE SWITCH

CONTACTS OPEN?

NO

YES

Page 36

506178−01 05/2009

Troubleshooting: Heating Sequence of Operation (Continued)

HEATING SEQUENCE OF OPERATION

FIRST−STAGE (LOW FIRE) PRESSURE

SWITCH CLOSED WITHIN 2.5 MINUTES?

GAS VALVE OFF. COMBUSTION AIR INDUCER

OFF. INDOOR BLOWER OFF. UNIT WILL RETRY

AFTER 5−MINUTE WAIT PERIOD.

STATUS ERROR CODE 2 + 3.

YES

NO

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?

NO

COMBUSTION AIR INDUCER OFF, IGNITOR OFF.

SIGNAL HOLDS UNTIL VOLTAGE RISES ABOVE 95

VOLTS. STATUS ERROR CODE 4 + 8.

YES

NO

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?

NO

HAS CONTROL RESET IGNITION SEQUENCE

FOUR (4) TIMES?

WATCHGUARD MODE.

STATUS ERROR CODE 4 + 3.

YES

CONTINUED ON NEXT PAGE

YES

NO

NO

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?

NO

YES

Page 37

G60DF Series

Troubleshooting: Heating Sequence of Operation (Continued)

HEATING SEQUENCE OF OPERATION

LOW FLAME SIGNAL

(Does not affect control operation)

STATUS ERROR CODE 1 + 2.

FLAME SIGNAL ABOVE

(u1.40 microamps)

NO

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

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

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.

NO

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.

NO

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?

NO

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

NO

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

NO

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.

NO

YES

NO

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?

NO

YES

YES

NO

YES

YES

Page 38

506178−01 05/2009

Troubleshooting: Heating Sequence of Operation (Continued)

HEATING SEQUENCE OF OPERATION

SEE BOX B

THERMOSTAT CALLS FOR HEAT.

SEE BOX A

NORMAL OPERATION.

YES

NO

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

NO

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

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.

NO

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 39

G60DF Series

Troubleshooting: Cooling Sequence of Operation

COOLING SEQUENCE OF OPERATION

SIGNAL POLARITY REVERSED.

CONTROL WILL CONTINUE TO CALL FOR COOLING

IN THIS CONDITION.

STATUS ERROR CODE 5 + 4.

POWER ON

YES

IS POLARITY REVERSED?

THERMOSTAT CALLS FOR FIRST−STAGE COOL.

COMPRESSOR AND CONDENSER FAN

ENERGIZED.

NO

IS THERE

PROPER GROUND?

YES

NO

INDOOR BLOWER ENERGIZED ON FIRST STAGE

COOL SPEED AFTER 2 SECOND DELAY.

FIRST−STAGE DEMAND FOR COOL SATISFIED?

NO

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 40

506178−01 05/2009

Troubleshooting: Continuous Fan Sequence of Operation

CONTINUOUS LOW SPEED FAN SEQUENCE OF OPERATION

MANUAL FAN SELECTION MADE AT THERMOSTAT.

AFTER 2 SECOND DELAY, INDOOR BLOWER IS

ENERGIZED ON CONTINUOUS FAN SPEED.

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

YES

YES

AFTER 45−SECOND DELAY, INDOOR BLOWER

SWITCHES TO LOW HEAT SPEED.

FIRST−STAGE HEAT DEMAND SATISFIED.

YES

NO

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

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

NO

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 41

G60DF Series

Repair Parts List

The following repair parts are available through Lennox dealers. When ordering parts, include the complete furnace model
number listed on the CSA International nameplate −− Example: G60DF(X)−36A−070−4. All service must be performed by a

licensed professional installer (or equivalent), service agency, or gas supplier.

Cabinet Parts

Upper access panel
Blower panel
Top cap

Control Panel Parts

Transformer
Two−stage integrated control
Door interlock switch
Circuit breaker

Blower Parts

Blower wheel
Blower housing
Motor
Capacitor
Motor mounting frame
Blower housing cutoff plate

Heating Parts

Flame Sensor

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

Page 42

506178−01 05/2009

G60DF(X) Start−Up & Performance Check List

w.c. − LP/Propane

Filter Clean & Secure?

Line Voltage

Electrical Connections Tight?

Job Name

Job Location

Installer

Unit Model No.

Furnace Btu Input (High fire) Line Pressure

Job No.

City

City

Serial No.

Date

State

Technician

Flue Connections Tight?

Heating Section

Thermostat

Heat Anticipator Setting? Thermostat Level?

Fuel Type: Natural Gas?

Blower Motor Amps

Blower Motor H.P.

Gas Piping Connections
Tight & Leak−Tested?

Proper Draft?

State

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

Blower ON delay confirmed?
(45 Seconds Fixed On)

High Fire Manifold Pressure

w.c. − Nat.:

LP/Propane Gas?

Combustion Gas Tested (high fire and low fire)?

CO

2

CO

w.c. − LP/Propane

Low Fire Manifold Pressure

w.c. − Nat.:

Temperature Rise

External Static Pressure?
(0.5 maximum)