Lennox G60DF(X) Series, 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.
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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.
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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.
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