Lennox G60UH, G60UHX Installation Instructions Manual

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Page 1

INSTALLATION

E 2008 Lennox Industries Inc.

Dallas, Texas, USA

RETAIN THESE INSTRUCTIONS

FOR FUTURE REFERENCE

INSTRUCTIONS

G60UH(X) Series

GAS FURNACE

506176−01 1/2010 Supersedes 10/2009

Table of Contents

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

G60UH(X) Parts Arrangement 3. . . . . . . . . . . . . . . . . . . . .

G60UH(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. . . . . . . . . . . . . .

Setting Equipment 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filters 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Duct System 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Venting 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gas Piping 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Integrated Control 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unit Start−Up 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gas Pressure Adjustment 31. . . . . . . . . . . . . . . . . . . . . . .

High Altitude Information 31. . . . . . . . . . . . . . . . . . . . . . . .

Other Unit Adjustments 32. . . . . . . . . . . . . . . . . . . . . . . . . .

Blower Performance 33. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heating Sequence of Operation 35. . . . . . . . . . . . . . . . . .

Service 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Planned Service 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Integrated Control Diagnostic Codes 38. . . . . . . . . . . . . .

Troubleshooting 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair Parts List 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start−Up & Performance Check List 46. . . . . . . . . . . . . . .

Litho U.S.A.

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.

01/10

*2P0110*

WARNING

FIRE OR EXPLOSION HAZARD.

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

WHAT TO DO IF YOU SMELL GAS:

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

use any phone in your building.

D Leave the building immediately. 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.

Page 1

*P506176-01*

506176−01

Page 2

G60UH(X) Unit Dimensions − inches (mm)

*NOTE − 60C and 60D units that require air volumes over 1800 cfm (850 L/s) must have one of the following:

1. Return air from single side with transition which will accommodate 20 x 25 x 1 in. (508 x 635 x 25 mm) cleanable air filter. (Required to maintain proper air velocity.)

2. Return air from single side with optional RAB Return Air Base.

3. Return air from bottom.

4. Return air from both sides.

5. Return air from bottom and

one side.

Refer to Engineering Handbook for additional information.

**Flue outlet may be horizontal but furnace must be vented vertically Optional external side return air filter kit cannot be used with the optional RAB Return Air Base.

B 9/16 (14)

OPTIONAL

EXTERNAL

SIDE RETURN

AIR FILTER KIT

(Either Side)

(1016)

3−3/4 (95)

FLUE OUTLET

(Top)

OPTIONAL

EXTERNAL

SIDE RETURN

AIR FILTER KIT

(Either Side)

3−1/4 (83) Right

8−1/8 (206) Left

14 (356) Right

13−1/4 (337) Left

4−7/8 (124) Right

2−1/4 (57) Left

TOP VIEW

3−3/4 (95)

SUPPLY AIR

OPENING

23-3/4 (603)

25 (635)

TOP VIEW

28−1/2

(724)

19−7/16

(494)

**FLUE OUTLET

(Either Side)

ELECTRICAL INLET

(Either Side)

GAS PIPING INLET

(Either Side)

ELECTRICAL INLET

(Either Side)

9/16

(14)

14−3/4

AIR FLOW

3/4 (19)

*Bottom Return

Air Opening

FRONT VIEW SIDE VIEW

Model No.

G60UH−24A−070, G60UH−36A−070

G60UH−36B−090, G60UH−48B−090

G60UH−36C−110, G60UH−48C−110, G60UH−60C−110

G60UH−60D−135 24−1/2 622 23−3/8 546 23 584 9−1/2 241

14−1/2 368 13−3/8 340 13 330 4−1/2 11 4

17−1/2 446 16−3/8 416 16 406 6 152

A B C D

in. mm in. mm in. mm in. mm

21 533 19−7/8 454 19−1/2 495 7−3/4 197

506176−01 01/2010

(375)

(406)

5/8 (16)

Page 2

(102)

4−1/4 (108)

(584)

*Side Return

Air Opening

(Either Side)

23−1/2

(597)

*Bottom Return

Air Opening

(356)

1−15/16 (49)

Page 3

G60UH(X) Parts Arrangement

Gasket

Flue

Transition

Flame Sensor

Flame Rollout Switches*

Flame Rollout Bracket

Gas Valve

Flue Box Gasket

Combustion Air

Orifice

Combustion Air

Pressure Switch Assembly

(two switches)

Combustion Air Inducer

Primary

Limit

(NOx Units Only)

Flue

Collector

Box

Limit Shield

NOx Insert

Air Deflector

G60UH−60C−110

Units Only

Heat Exchanger

Burners

Gas Orifices

Ignitor Bracket

Burner Bottom Shield

Control Transformer

Circuit Breaker

Two−Stage Integrated

Control

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

Ignitor

Secondary Limit(s)

Blower Motor

Capacitor

Door Interlock Switch

FIGURE 1

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G60UH Series

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G60UH(X) Gas Furnace

The G60UH(X) gas furnace is equipped with a two−stage integrated control. Each G60UH(X) unit is shipped ready for installation in the upflow or horizontal position (left or right). The furnace is shipped with the bottom panel in place. The bottom panel must be removed if the unit is to be installed in a horizontal application. The panel may also be removed in upflow applications.

Shipping and Packing List

Package 1 of 1 contains

1 − Assembled G60UH(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 − Hanging bracket (for horizontal installations) 1 − Propane/LP changeover kit 1 − Return air base 1 − High altitude kit 1 − Side filter 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.

Safety Information

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 G60UH 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.

G60UH(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 Natural Gas and Propane Installation Code, 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 figures 6 and 11. Accessibility and service clearances must take precedence over fire protection clearances.

NOTE − For installation on combustible floors, the furnace shall not be installed directly on carpeting, tile, or other combustible material other than wood flooring.

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.

506176−01 01/2010

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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.

This G60UH(X) furnace must be installed so that its electrical components are protected from water.

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 G60UH(X) furnace may be installed in alcoves, closets, attics, basements, garages, and utility rooms in the upflow or horizontal 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 G60UH(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.

G60UH(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 system,

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 G60UH(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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G60UH Series

Page 6

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 G60UH(X) furnaces to ensure efficient and safe operation. You must consider combustion air needs and requirements for exhaust vents and gas piping. 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 standard CSA B149 installation code.

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 m3) 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

506176−01 01/2010

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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 m3) 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

CHIMNEY

OR GAS

VENT

FURNACE

NOTE − Each opening shall have a free area of at least one square inch (645 mm2) 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 mm2).

SPACE ALL AIR FROM INSIDE

WATER

HEATER

OPENINGS (To Adjacent

Room)

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 mm2). 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 mm2) 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 mm2) 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.

FIGURE 2

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G60UH Series

Page 8

CHIMNEY OR

GAS VENT

FURNACE

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

VENTILATION LOUVERS

(Each end of attic)

EQUIPMENT IN CONFINED SPACE

ALL AIR FROM OUTSIDE

OUTLET

AIR

WATER

HEATER

CHIMNEY

OR GAS

VENT

FURNACE

VENTILATION

LOUVERS

(For unheated crawl space)

INLET

AIR

NOTE−The inlet and outlet air openings shall each have a free area of at least one square inch (645 mm2) per 4,000 Btu (1.17 kW) per hour of the total input rating of all equipment in the enclosure.

FIGURE 3

EQUIPMENT IN CONFINED SPACE

ALL AIR FROM OUTSIDE

(All Air Through Ventilated Attic)

VENTILATION LOUVERS

(Each end of attic)

OUTLET

AIR

above bottom)

INLET AIR

(Ends 12 in.

WATER

HEATER

FURNACE

CHIMNEY

OR GAS

VENT

CONFINED SPACE

WATER

HEATER

OUTLET AIR

INLET AIR

EQUIPMENT IN

ALL AIR FROM

OUTSIDE

FIGURE 4

506176−01 01/2010

NOTE − Each air duct opening shall have a free area of at least one square inch (645 mm2) 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 mm2) per 4,000 Btu (1.17 kW) per hour of the total input rating of all other equipment in the enclosure.

FIGURE 5

Page 8

Page 9

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.

The G60UH(X) gas furnace can be installed as shipped in either the upflow position or the horizontal position, with right-hand or left-hand air discharge. 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 − 1/3 hp blower motors are equipped with four flexible mounting legs. 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.

Upflow Applications

Allow for clearances to combustible materials as indicated on the unit nameplate. Minimum clearances for closet or alcove installations are shown in figure 6.

Upflow Application Installation Clearances

Top

Left Side

Bottom

Type of Vent

Connector

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 0‡ 0‡

*Front clearance in alcove installation must be 24 in. (610 mm). Maintain a minimum of 24 in. (610 mm) for front service access. ‡For installation on a combustible floor, do not install the furnace directly on carpeting, tile or other combustible materials other than wood flooring. †Left side requires 3 inches if a single wall vent is used on 14−1/2 inch cabinets, or 2 inches if a single wall vent is used on 17−1/2 inch cabinets.

Type C Type B1

Right Side

FIGURE 6

Page 9

G60UH Series

Page 10

Return Air −− Upflow Applications

Return air can be brought in through the bottom or either side of the furnace installed in an upflow application. If the furnace is installed on a platform with bottom return, make an airtight seal between the bottom of the furnace and the platform to ensure that the furnace operates properly and safely. The furnace is equipped with a removable bottom panel to facilitate installation.

Markings are provided on both sides of the furnace cabinet for installations that require side return air. Cut the furnace cabinet at the maximum dimensions shown on page 2.

NOTE − When air volumes over 1800 cfm (850 L/s) are required with 60C or 60D models in an upflow application, the following return air options are available:

1 − Return air from single side with transition which will

accommodate 20 x 25 x 1 in. (508 x 635 x 25 mm) cleanable air filter. (Required to maintain proper air velocity.) See figure 7.

2 − Return air from single side with optional RAB Return

Air Base. See figure 8.

3 − Return air from bottom.

4 − Return air from both sides.

5 − Return air from bottom and

one side.

Refer to Engineering Handbook for additional information.

Side Return Air

(with transition and filter)

20" X 25" X 1"

(508mm X635mm X 25mm)

Filter

Return Air

Plenum

Transition

FIGURE 7

Optional Return Air Base

(Upflow Applications Only −− For use with B, C and D cabinets only)

23 (584)

Overall

(Maximum)

Unit side return air

Opening

SIDE RETURN AIR

5−5/8 (143)

OPENINGS

(Either Side)

23 (584)

27−5/8 (702)

SIDE VIEW

Minimum 11 (279)

Maximum

14 (356)

22−7−16

(570)

Overall

(Maximum)

AIR FLOW

17−1/2 (446) RAB−B (98M60)

21 (533) RAB−C (98M58)

24−1/2 (622) RAB−D (98M59)

FURNACE

FRONT

7−1/4 (184)

OPTIONAL RAB

RETURN AIR BASE

(102)

(356)

7/8

(22)

FRONT VIEW

NOTE− Optional Side Return Air Filter Kits are not for use with RAB Return Air Base.

Both the unit return air opening and the base return air opening must be covered by a single plenum or IAQ cabinet. Minimum unit side return air opening dimensions for units requiring 1800 cfm or more of air (W x H): 23 x 11 in. (584 x 279 mm). The opening can be cut as needed to accommodate plenum or IAQ cabinet while maintaining dimensions shown. Side return air openings must be cut in the field. There are cutting guides stenciled on the cabinet for the side return air opening. The size of the opening must not extend beyond the markings on the furnace cabinet..

To minimize pressure drop, the largest opening height possible (up to 14 inches) is preferred.

NOTE− Optional Side Return Air Filter Kits are not for use with RAB Return Air Base.

3/4

(19)

506176−01 01/2010

FIGURE 8

Page 10

Page 11

Removing the Bottom Panel

Remove the two screws that secure the bottom cap to the furnace. Pivot the bottom cap down to release the bottom panel. Once the bottom panel has been removed, reinstall the bottom cap. See figure 9.

Removing the Bottom Panel

Leveling Bolt Installation

Furnace Front

3/8

(10)

3/8

(10)

Inches (mm)

1−3/4

(44)

Screw

Bottom Panel

Leveling an Upflow Unit

FIGURE 9

Bottom Cap

1−3/4

(44)

Furnace

Leveling Bolt

Locations

Bottom

Leveling Bolt

Locations

3/8

(10)

1−3/4

(44)

1−3/4 (44)

3/8

(10)

FIGURE 10

Horizontal Applications

The G60UH(X) furnace can be installed in horizontal applications.

Allow for clearances to combustible materials as indicated on the unit nameplate. Minimum clearances for closet or alcove installations are shown in figure 11.

Horizontal Application

Installation Clearances

Top

When the side return air inlets are used in an upflow application, it may be necessary to install leveling bolts on the bottom of the furnace. Use field−supplied corrosion−resistant 5/16 inch machine bolts (4) and nuts (8). See figure 10.

NOTE − The maximum length of the bolt is 1−1/2 inches.

1 − Lie the furnace on its back and drill a 5/16 inch diame-

ter hole in each corner of the furnace’s bottom. See figure 10 for the correct location of the holes. Drill through the bottom panel and the bottom flange of the cabinet.

2 − Install one bolt and two nuts into each hole. Screw the

first nut onto a bolt and then insert the bolt into a hole. A flat washer may be added between the nut and the bottom of the unit.

3 − Screw another nut onto the bolt on the inside of the fur-

nace base. A flat washer may be added between the nut and the bottom of the unit.

4 − Adjust the outside nut to the appropriate height and

tighten the inside nut to secure the arrangement.

Left End

Bottom

Vent Connector

Type

Top 0 0

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

Back 0 0

Ends 2 in. (51 mm) 2 in. (51 mm)

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

Bottom 0‡ 0‡

*Front clearance in alcove installation must be 24 in. (610 mm). Maintain a minimum of 24 in. (610 mm) for front service access. ‡For installations on a combustible floor, do not install the furnace directly on carpeting, tile or other combustible materials other than wood flooring.

Type C Type B1

Right End

FIGURE 11

Page 11

G60UH Series

Page 12

This furnace may be installed in either an attic or a crawlspace. Either suspend the furnace from roof rafters or floor joists, as shown in figure 12, or install the furnace on a platform, as shown in figure 13. The unit must be supported at both ends and beneath the blower deck to prevent sagging.

Typical Horizontal Application

Unit Suspended in Attic or Crawlspace

Leave sufficient clearance between rod and unit to remove access panel.

1/4 in. ROD

ANGLE

IRON

U−CHANNELS

FIGURE 12

NOTE − Heavy−gauge perforated sheet metal straps (plumbers’ straps) may be used to suspend the unit from roof rafters or ceiling joists. When straps are used to suspend the unit in this way, support must be providedfor both the ends and the middle of the furnace to prevent sagging. The straps must not interfere with the plenum or exhaust piping installation. Securing screws should be 1/2 inch from the top edge and 1−1/2 inch from the side edge in all cases. Cooling coils and supply and return air ple-

nums must be supported separately.

NOTE − When the furnace is installed on a platform in a crawlspace, it must be elevated enough to avoid water damage and to allow the evaporator coil to drain.

Return Air −− Horizontal Applications

Return air can be brought in through the end of a furnace installed in a horizontal application. The furnace is equipped with a removable bottom panel to facilitate installation. See figure 9.

Horizontal Application

Unit Installed on Platform

NOTE − Line contact is permissible. See the unit nameplate for clearances.

GAS

ENTRY

VENT

PIPE

WORKING

PLATFORM

FIGURE 13

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.

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.

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Page 13

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 1 lists recommended filter sizes. A filter must be in place any time the unit is operating.

TABLE 1

Furnace

Cabinet Size

14−1/2" 16 X 25 X 1 (1) 14 X 25 X 1 (1)

17−1/2" 16 X 25 X 1 (1) 16 X 25 X 1 (1)

21" 16 X 25 X 1 (1) 20 X 25 X 1 (1)

24−1/2" 16 X 25 X 1 (2) 24 X 25 X 1 (1)

Side Return Bottom Return

Filter Size

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 0.8 inches w.c. Higher external static pressures may cause erratic limit operation.

Supply Air Plenum

If the furnace is installed without a cooling coil, a removable access panel must be installed in the supply air duct. The access panel should be large enough to permit inspection (either by smoke or reflected light) of the heat exchanger for leaks after the furnace is installed. The furnace access panel must always be in place when the furnace is operating and it must not allow leaks into the supply air duct system.

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.

In upflow applications, the return air can be brought in through the bottom or either side of the furnace. If a furnace with bottom return air is installed on a platform, make an airtight seal between the bottom of the furnace and the platform to ensure that the unit operates properly and safely. Use fiberglass sealing strips, caulking, or equivalent sealing method between the plenum and the furnace cabinet to ensure a tight seal. If a filter is installed, size the return air duct to fit the filter frame.

Venting

A 4−inch diameter flue transition is factory-installed on the combustion air inducer outlet of 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 insulation. The combustion air inducer may be rotated clockwise or

counterclockwise by 90° to allow for top or side vent discharge in all applications. When the unit is installed, the flue transition must be in the 9 o’clock, 12 o’clock or 3 o’clock position. The unit will not vent properly with the flue transition pointed down in the 6 o’clock position. Remove the four mounting screws, rotate the assembly (including the gasket), then reinstall the mounting screws.

Page 13

G60UH Series

Page 14

See figure 14. Use the provided wire tie to bundle the pressure switch wires with the inducer motor power leads.

Route the wires away from moving parts and the heat of the inducer motor to prevent damage to the wires.

Combustion Air Inducer

(Upflow Position)

90°

Flue Transition

(Do not remove)

MOUNTING SCREWS

(Remove)

90°

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.

Mounting Screws

(Remove)

FIGURE 14

Optional Flue Outlet

(Horizontal Installation)

Top View of Furnace

Top Cap

Flue Outlet

Hole

(Reattach

Supply Air

Opening

Cutout Here)

Cut out

Optional

Flue Outlet

FIGURE 15

Use sheet metal shears to remove the cut out from the side of the cabinet. Use the two provided sheet metal screws to install the cut out on the top cap to cover the original flue outlet opening. See figure 15.

The G60UH(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 CSA B149 Natural Gas and Propane Installation

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.

VENT CONNECTION

VENT

PIPE

FLUE

TRANSITION

COLLAR

FIGURE 16

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 16.

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

FURNACE

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Page 15

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

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

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.

VENT

CONNECTOR

SEE NOTE 1 BELOW

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

FIGURE 17

Venting Using a Masonry Chimney

Common Venting Using Metal−Lined 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

5 ft. (1.5 m)

minimum

MAX. LENGTH

−− SEE NOTE 1 BELOW.

MIN. LENGTH −− AS

SHORT AS PRACTICAL

chimneys are prohibited. See figures 18 and 17 for common venting.

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

4 in. (102 mm)

minimum

VENT CONNECTOR

SEE NOTE 2

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.

G60UH units installed in upflow applications may be vented into a tile−lined masonry chimney without using a listed metal liner, provided that the optional masonry chim-

OTHER

APPLIANCE

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.

FURNACE

FIGURE 18

PERMANENTLY

SEALED FIREPLACE

ney vent adapter kit (18M79) is used. Instructions provided with the kit must be followed exactly.

Insulation for the flexible vent pipe must be an encapsulated fiberglass sleeve recommended by the flexible vent pipe manufacturer. See figure 18.

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

IMPORTANT

with either type B1 vent or an insulated single wall

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

flexible vent lining system which has been sized according to the provided venting tables and the vent pipe manufacturer’s instructions.

SEALED

EXTERIOR

CHIMNEY WITH

OPENING

METAL

LINER

Page 15

G60UH Series

Page 16

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.

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 G60UH(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 G60UH(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 3 and 4) 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 (5, 6, 7, and 8) 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 2

Connector Diameter

inches (mm)

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)

Maximum Horizontal

Connector Length feet (m)

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.

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Page 16

Page 17

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.

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 (Z223.1).

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 17

G60UH Series

Page 18

TABLE 3

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

(feet)

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).

Lateral

(feet)

0 0 78 0 152 0 251 0 375

2 13 51 18 97 27 157 32 232

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

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 11 8 23 194 26 289

5 23 57 32 11 3 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

5 22 65 30 130 39 219 49 330

10 29 59 40 121 51 206 64 315

15 35 53 48 11 2 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

10 28 64 38 133 50 229 62 351

15 34 58 46 124 59 217 73 337

20 48 52 55 11 6 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

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

3 Inch 4 Inch 5 Inch 6 Inch

Appliance Input Rating in Thousands of Btu Per Hour

MIN MAX MIN MAX MIN MAX MIN MAX

506176−01 01/2010

Page 18

Page 19

TABLE 4

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

(feet)

Lateral

(feet)

0 38 77 59 151 85 249 126 373

2 39 51 60 96 85 156 123 231

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

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

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 11 6 499

2 38 69 57 136 80 225 11 5 337

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 11 4 537

2 37 74 56 148 78 248 11 3 375

5 50 68 73 140 100 239 141 363

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

10 NR NR 91 144 122 255 171 397

15 NR NR 11 5 131 151 239 208 377

20 NR NR NR NR 181 223 246 357

30 NR NR NR NR NR NR NR NR

3 Inch 4 Inch 5 Inch 6 Inch

Appliance Input Rating in Thousands of Btu Per Hour

MIN MAX MIN MAX MIN MAX MIN MAX

Page 19

G60UH Series

Page 20

Vent

Height

(feet)

TABLE 5

Vent Connector Capacity

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

Serving Two or More Category I Appliances

Connector

Rise

(feet)

1 22 37 35 66 46 106 58 164

2 23 41 37 75 48 121 60 183

3 24 44 38 81 49 132 62 199

1 22 40 35 72 49 11 4 64 176

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

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

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

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

2 21 64 33 118 47 190 62 299

3 22 66 34 123 48 198 64 309

3 Inch 4 Inch 5 Inch 6 Inch

MIN MAX MIN MAX MIN MAX MIN MAX

Vent and Connector Diameter − D (inches)

Appliance Input Rating in Thousands of Btu Per Hour

TABLE 6

Common Vent Capacity

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

Serving Two or More Category I Appliances

Vent

Height

(feet)

6 92 81 140 11 6 204 161 309 248

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

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

4 Inch 5 Inch 6 Inch 7 Inch

Appliance Input Rating in Thousands of Btu Per Hour

Common Vent Diameter − D (inches)

506176−01 01/2010

Page 20

Page 21

TABLE 7

Vent Connector Capacity

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

Serving Two or More Category I Appliances

Vent

Height

(feet)

Connector

Rise

(feet)

1 NR NR NR NR NR NR NR NR

2 NR NR NR NR NR NR 168 182

3 NR NR NR NR 121 131 174 198

1 NR NR 79 87 116 138 177 214

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

2 50 62 81 115 117 185 177 290

3 54 64 85 119 122 193 185 300

3 Inch 4 Inch 5 Inch 6 Inch

MIN MAX MIN MAX MIN MAX MIN MAX

Vent and Connector Diameter − D (inches)

Appliance Input Rating in Thousands of Btu Per Hour

TABLE 8

Common Vent Capacity

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

Serving Two or More Category I Appliances

Vent

Height

(feet)

6 89 78 136 11 3 200 158 304 244

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

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

4 Inch 5 Inch 6 Inch 7 Inch

Appliance Input Rating in Thousands of Btu Per Hour

Common Vent Diameter − D (inches)

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 horizontal

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.

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G60UH Series

Page 22

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.)

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

Gas Piping

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

CAUTION

the ground joint type.

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 (or top entry in horizontal applications). 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 9 lists recommended pipe sizes for typical applications.

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 19.

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.

IMPORTANT

TABLE 9

Gas Pipe Capacity − ft3/hr (m3/hr)

Nominal

Iron Pipe

Size

inches

(mm)

3/8

(9.53)

1/2

(12.7)

3/4

(19.05)

(25.4)

1−1/4

(31.75)

1−1/2

(38.1)

(50.8)

2−1/2

(63.5)

(76.2)

Internal

Diameter

inches

(mm)

.493

(12.522)95(2.69)65(1.84)

.622

(17.799)

.824

(20.930)

1.049

(26.645)

1.380

(35.052)

1.610

(40.894)

2.067

(52.502)

2.469

(67.713)

3.068

(77.927)

(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)

175

(4.96)

360

(10.19)

680

(919.25)

1400

(39.64)

2100

(59.46)

3950

(111.85)

6300

(178.39)

11000

(311.48)

120

(3.40)

250

(7.08)

465

(13.17)

950

(26.90)

460

(41.34)

2750

(77.87)

4350

(123.17)

7700

(218.03)

(1.47)

(2.75)

200

(5.66)

375

(10.62)

770

(21.80)

1180

(33.41)

2200

(62.30)

3520

(99.67)

6250

(176.98)

(18.69)

(28.03)

(53.80)

(84.95

(150.07)

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

Length of Pipe − feet (m)

(1.27)

(2.32)

170

(4.81)

320

(9.06)

660

990

1900

3000

5300

(1.13)

(2.07)

151

(4.28)

285

(8.07)

580

(16.42)

900

(25.48)

1680

(47.57)

2650

(75.04)

4750

(134.50)

(1.02)

(1.87)

138

(3.91)

260

(7.36)

530

(15.01)

810

(22.94)

1520

(43.04)

2400

(67.96)

4300

(121.76)

(.73)

(1.73)

125

(3.54)

240

(6.80)

490

(13.87)

750

(21.24)

1400

(39.64)

2250

(63.71)

3900

(110.43)

(.88)

(1.61)

118

(3.34)

220

(6.23)

460

(13.03)

690

(19.54)

1300

(36.81)

2050

(58.05)

3700

(104.77)

(.82)

(1.50)

110

(3.11)

205

(5.80)

430

(12.18)

650

(18.41)

1220

(34.55)

1950

(55.22)

3450

(97.69)

100

(30.480)

(.76)

(1.42)

103

(2.92)

195

(5.52)

400

(11.33)

620

(17.56)

1150

(32.56)

1850

(52.38)

3250

(92.03)

506176−01 01/2010

Page 22

Page 23

MANUAL

MAIN SHUT−OFF

VALV E

(With 1/8 in. NPT

Plugged Tap Shown)

GROUND

JOINT

UNION

Left Side Piping

(Standard)

AUTOMATIC

GAS VALVE

(with manual

shut−off valve)

AUTOMATIC

GAS VALVE

(with manual

shut−off valve)

MANUAL

MAIN SHUT−OFF

VALV E

(With 1/8 in. NPT

Plugged Tap

Shown)

GROUND

JOINT

UNION

DRIP LEG

PROVIDED

DRIP LEG

AND INSTALLED

FIGURE 19

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

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.).

FIRE OR EXPLOSION HAZARD

FIELD

Right Side Piping

(Alternate)

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. If the make−up box is moved to the right side, the excess wire must be pulled into the blower compartment. Secure the excess wire to the existing harness to protect it from damage.

IMPORTANT

When testing pressure of gas lines, gas valve must be disconnected and isolated. See figure 20. 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

FIGURE 20

ISOLATE

GAS VALVE

FURNACE

Page 23

INTERIOR MAKE−UP BOX INSTALLATION

MAKE−UP

BOX

Right Side

FIGURE 21

G60UH Series

Page 24

INTERIOR MAKE−UP BOX INSTALLATION

Left side

MAKE−UP

BOX

FIGURE 22

Refer to figure 23 for schematic wiring diagram and troubleshooting and table 10 and figure 24 for field wiring.

1 − The power supply wiring must meet Class I restric-

tions. Protected by either a fuse or circuit breaker, select circuit protection and wire size according to unit nameplate.

NOTE − Unit nameplate states maximum current draw. Maximum Over−Current Protection allowed is 20AMP.

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

tate wiring.

3 − Install a separate (properly sized) disconnect switch

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 10 and figure 24. 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 G60UH(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 provided

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 25 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 25 for control configuration. This terminal is energized when the indoor blower is operating.

9 − One 24V H" terminal is provided on the furnace inte-

grated 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 25 for control configuration.

10 −Install the room thermostat according to the instruc-

tions provided with the thermostat. See table 10 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 G60UH(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.

506176−01 01/2010

Page 24

Page 25

Thermostat

TABLE 10

Field Wiring Applications

DIP Switch Settings and On−Board Links (See figure 25)

W915

DIP Switch 1

Two−Stage

Cooling

W951

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.

1 Heat / 2 Cool

NOTE − Use DIP switch 2 to set second−stage heat ON delay. OFF−10 minutes. ON−15 minutes.

ON Intact Intact

ON Cut Intact

T’STAT

CONTROL

TERM. STRIP

CONTROL

TERM. STRIP

OUTDOOR

UNIT

OUTDOOR

UNIT

Page 25

G60UH Series

Page 26

Thermostat

TABLE 10

Field Wiring Applications (Continued)

DIP Switch Settings and On−Board Links (See figure 25)

W915

DIP Switch 1

Two−Stage

Cooling

W951

Heat Pumps

Wiring Connections

2 Heat / 2 Cool OFF Cut Intact

2 Heat / 1 Cool OFF Intact Intact

T’STAT

CONTROL

TERM. STRIP

CONTROL

TERM. STRIP

OUTDOOR

UNIT

OUTDOOR

UNIT

506176−01 01/2010

Page 26

Page 27

G60UH(X) Schematic Wiring Diagram

FIGURE 23

Page 27

G60UH Series

Page 28

USE COPPER CONDUCTORS ONLY.

FIELD INSTALLED CLASS II 24V FIELD INSTALLED LINE VOLTAGE

TYPICAL G60UH(X) FIELD WIRING DIAGRAM

FIGURE 24

DIAGNOSTIC

LEDs

DIP

SWITCHES

TWO−STAGE INTEGRATED CONTROL

1/4" QUICK CONNECT TERMINALS

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

W915

W951

HEAT HIGH/ COOL LOW = 120 VAC OUTPUT TO CIRC BLWR −−

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

THERMOSTAT CONNECTIONS (TB1)

ON−BOARD

LINKS

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

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

HIGH HEAT AND LOW COOL SPEED

DIP SWITCH FUNCTIONS

506176−01 01/2010

FIGURE 25

Page 28

Page 29

Integrated Control

G60UH 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 and jumpers. 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. The DIP 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 11 provides the blower off timings that will result from different switch settings.

Heating Blower−Off Delay Switch Settings

Blower Off Delay

(Seconds)

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.

TABLE 11

Switch 3 Switch 4

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 29

G60UH Series

Page 30

CAUTION

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

8 − White Rodgers 36E Gas Valve − Move the gas valve

control switch to ON. See figure 26. Honeywell VR8205 Gas Valve − Turn knob on gas

valve counterclockwise to ON. Do not force. See figure 27.

9 − Replace the upper access panel.

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 G60UH(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 (or equivalent). Force or attempted repair may result in a fire or explosion.

Placing the furnace into operation:

G60UH(X) units are equipped with an 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 26 and 27)

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

control switch to OFF. See figure 26. Honeywell VR8205 Gas Valve − Turn knob on gas

valve clockwise to OFF. Do not force. See figure

27.

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.

WHITE RODGERS 36E SERIES GAS VALVE

HIGH FIRE

MANIFOLD

PRESSURE

ADJUSTMENT

ON SIDE

(under cap)

MANIFOLD

PRESSURE

TAP ON SIDE

INLET PRESSURE

TAP ON SIDE

GAS VALVE SHOWN IN OFF POSITION

LOW FIRE MANIFOLD

PRESSURE ADJUSTMENT

ON SIDE (under cap)

FIGURE 26

HONEYWELL VR8205 SERIES GAS VALVE

HIGH FIRE

ADJUSTING SCREW

(under cap)

MANIFOLD

PRESSURE

TAP

LOW FIRE

ADJUSTING SCREW

(under cap)

INLET PRESSURE TAP

GAS VALVE SHOWN IN OFF POSITION

FIGURE 27

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

control switch to OFF.

Honeywell VR8205 Gas Valve − Turn knob on gas

valve clockwise to OFF. Do not force. 5 − Replace the upper access panel.

506176−01 01/2010

Page 30

Page 31

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 12

Gas Flow Rate (Ft.3/Hr.)

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

Gas Meter Size

2 − Compare the number of seconds and the gas meter

size in table 12 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 26 and 27 for the location of the manifold pressure adjustment screws. Low and high fire manifold pressures are given in table 13. A natural gas to LP/propane gas changeover kit is required to convert the unit.

High Altitude Information

Refer to table 13 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.

High Altitude Requirements / Manifold Pressure Settings

Model

Input

Size

−070, −090,

−110, −135

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

Gas

Required

Conversion Kit

Nat. N/A N/A 44W51 18M64 1.7 0.42 3.5 0.87

LPG 44W48 N/A 44W50 18M64 4.9 1.22 10.0 2.5

0 − 7500 ft.

(0 − 2285 m)

Pressure

Switch

Altitude

Conversion Kit

TABLE 13

7501−10,000 ft.

(2286 − 3048 m)

Required

Page 31

Pressure

Switch

Manifold Pressure

at all altitudes

Low Fire High Fire

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

G60UH Series

Page 32

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.

Blower Speeds

NOTE − CFM ratings are taken external to unit with a dry evaporator coil and without accessories. See blower performance data which begins on page 33.

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 SureLight® integrated control used in G60UH 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.

506176−01 01/2010

Page 32

Page 33

Blower Performance Data

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

Air volume based on bottom air return air. Actual air volume may vary on side return air applications.

G60UH−24A−070 PERFORMANCE

External

Static

Pressure

in. w.g.

Air Volume / Watts at Various Blower Speeds

High Medium Low

cfm Watts cfm Watts cfm Watts

0.00 1075 445 905 375 730 290

0.05 1070 445 900 375 725 290

0.10 1065

0.15

1060 435 890 365 715 285

440 895 370 720 285

0.20 1055 430 885 360 710 280

0.25 1045

0.30

1030 415 875 355 690 270

425 880 360 700 280

0.40 1010 400 860 350 675 270

0.50 975

0.60

940 375 805 325 640 255

390 840 340 660 265

0.70 890 360 755 305 605 240

0.80 830

0.90

765 305 640 265 515 205

340 700 285 565 225

G60UH−36B−090 PERFORMANCE

External

Static

Pressure

in. w.g.

0.00 1500 720 1255 595 1040 460 900 370

0.05 1485 705 1250 580 1040 450 895 365

0.10 1465

0.15

0.20 1435 660 1225 545 1030 435 880 350

0.25 1420

0.30

0.40 1345 595 1170 495 1000 400 855 330

0.50 1300

0.60

0.70 1165 510 1020 415 870 340 740 280

0.80 1080

0.90

Air Volume / Watts at Various Blower Speeds

High

Medium−

High

Medium−

Low

cfm Watt cfm Watt cfm Watt cfm Watt

685 1240 570 1035 445 890 360

1450 675 1235 555 1035 440 885 355

645 1215 530 1025 425 875 345

1400 630 1200 520 1020 415 870 340

575 1135 475 965 380 830 300

1235 545 1080 445 930 360 780 290

480 940 385 800 315 670 260

985 445 840 355 710 290 600 245

Low

G60UH−36A−070 PERFORMANCE

External

Static

Pressure

in. w.g.

0.00 1500 705 1290 565 985 455 830 375

0.05 1475 695 1275 555 980 445 820 365

0.10 1450

0.15

0.20 1400 655 1225 525 955 425 795 350

0.25 1370

0.30

0.40 1285 610 1140 475 900 390 745 325

0.50 1215

0.60

0.70 1060 535 940 405 730 330 585 270

0.80 955

0.90

Air Volume / Watts at Various Blower Speeds

High

Medium−

High

Medium−

Low

cfm Watt cfm Watt cfm Watt cfm Watt

680 1255 545 970 440 810 360

1425 670 1240 535 965 430 805 355

645 1205 510 945 415 790 345

1340 630 1180 500 930 405 780 335

580 1080 450 865 375 705 310

1150 560 1015 430 810 355 655 290

515 800 370 655 305 480 260

785 475 605 325 585 270 410 255

G60UH−36C−110 PERFORMANCE

External

Static

Pressure

in. w.g.

0.00 1555 715 1335 575 1085 460 925 365

0.05 1540 705 1330 555 1080 450 920 360

0.10 1525

0.15

0.20 1490 670 1295 525 1065 420 900 340

0.25 1465

0.30

0.40 1385 615 1230 485 1030 390 865 320

0.50 1320

0.60

0.70 1190 545 1075 410 915 345 775 285

0.80 1090

0.90

Air Volume / Watts at Various Blower Speeds

High

Medium−

High

Medium−

Low

cfm Watt cfm Watt cfm Watt cfm Watt

690 1320 545 1075 440 915 355

1510 680 1310 535 1070 430 910 350

655 1280 510 1060 415 890 335

1440 645 1260 495 1050 405 880 330

590 1190 460 995 375 835 300

1260 570 1135 430 960 355 815 295

515 970 385 860 325 760 280

975 485 880 360 790 305 705 275

Low

Page 33

G60UH Series

Page 34

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

Air volume based on bottom air return air. Actual air volume may vary on side return air applications.

G60UH−48B−090 PERFORMANCE

External

Static

Pressure

in. w.g.

0.00 1970 790 1810 735 1585 670 1340 565

0.05 1940 780 1785 715 1580 650 1335 555

0.10 1915

0.15

0.20 1840 730 1700 620 1545 600 1320 520

0.25 1805

0.30

0.40 1695 670 1570 595 1440 540 1260 480

0.50 1600

0.60

0.70 1395 565 1265 485 1170 440 990 380

0.80 1250

0.90

Air Volume / Watts at Various Blower Speeds

High

Medium−

High

Medium−

Low

cfm Watt cfm Watt cfm Watt cfm Watt

765 1760 695 1570 630 1325 540

1880 745 1730 660 1560 615 1325 530

715 1670 625 1520 585 1310 510

1765 695 1640 625 1490 565 1295 500

635 1490 560 1360 505 1195 450

1505 600 1400 530 1285 480 1140 425

520 1100 445 975 390 905 355

1005 460 870 385 900 365 810 325

Low

G60UH−48C−110 PERFORMANCE

External

Static

Pressure

in. w.g.

Air Volume / Watts at Various Blower Speeds

High

Medium−

High

Medium−

Low

cfm Watt cfm Watt cfm Watt cfm Watt

0.00 2015 895 1620 780 1340 640 1150 525

0.05 1990 870 1615 760 1340 640 1150 525

0.10 1965

0.15

850 1610 745 1340 640 1150 525

1930 825 1605 725 1335 630 1150 525

0.20 1895 805 1600 710 1335 615 1150 525

0.25 1860

0.30

785 1590 695 1330 605 1150 520

1820 765 1580 675 1330 590 1145 515

0.40 1740 725 1530 635 1320 560 1140 490

0.50 1665

0.60

695 1475 600 1285 525 1120 470

1575 650 1405 555 1230 490 1075 445

0.70 1475 610 1310 515 1165 470 1015 415

0.80 1350

0.90

560 1210 485 1080 430 930 380

1210 520 1070 430 870 365 740 325

G60UH−60C−100X PERFORMANCE

Air Volume / Watts at Different Blower Speeds

External

Static

Pressure

in. w.g.

Bottom Return Air, Side Return Air with Optional RAB Return Air Base, Return Air from Both Sides or Return Air from Bottom and One Side.

High Medium−High Medium−Low Low High Medium−High Medium−Low Low

Single Side Return Air − Air volumes in bold require field

fabricated transition to accommodate 20 x 25 x 1 in. air filter in order to maintain proper air velocity.

cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts

.00 2555 1378 2300 1027 1985 863 1655 678 2385 1296 2185 981 1915 836 1650 686 .10 2490 1354 2265 1002 1980 839 1640 667 2330 1274 2150 961 1900 815 1635 677 .20 2420 1330 2225 980 1975 832 1635 660 2255 1234 2095 930 1885 794 1625 664 .30 2355 1300 2175 957 1945 810 1625 653 2190 1207 2035 902 1855 769 1620 651 .40 2275 1265 2115 934 1915 785 1620 639 2115 1179 1970 876 1820 751 1605 639 .50 2175 1229 2040 903 1860 762 1595 623 2055 1156 1905 853 1760 725 1575 622 .60 2085 1199 1965 873 1800 733 1565 608 1985 1141 1830 827 1705 704 1525 602 .70 1990 1140 1870 843 1730 714 1525 590 1910 1119 1745 797 1635 680 1475 582 .80 1890 1105 1770 807 1630 676 1455 567 1810 1088 1650 772 1560 659 1430 571 .90 1760 1067 1655 777 1535 649 1370 541 1715 1058 1570 751 1485 638 1355 549

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

Low

G60UH−60D−135 PERFORMANCE

External

Static

Pressure

in. w.g.

Bottom Return Air, Side Return Air with Optional RAB Return Air Base, Return Air from Both Sides or Return Air from Bottom and One Side.

High Medium−High Medium−Low Low High Medium−High Medium−Low Low

cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts

.00

2715 1407 2255 1070 1910 850 1660 674 2455 1336 2170 1019 1850 829 1555 673

.10 2640 1403 2250 1030 1900 834 1645 668 2380 1299 2140 974 1840 812 1550 664

.20 2540 1355 2245 1006 1890 821 1630 665 2305 1266 2105 947 1830 791 1545 656

.30 2480 1319 2200 975 1890 781 1625 656 2235 1234 2045 914 1820 774 1540 642

.40 2390 1282 2155 940 1885 775 1615 642 2160 1240 1985 886 1800 755 1540 628

.50 2320 1251 2085 904 1860 758 1605 631 2065 1170 1925 863 1745 726 1535 614

.60 2205 1210 2020 876 1815 731 1595 611 1990 1146 1870 844 1700 706 1505 599

.70 2080 1161 1935 839 1760 707 1545 588 1895 1111 1775 808 1655 689 1465 573

.80 2010 1122 1855 810 1690 679 1495 568 1805 1074 1680 779 1565 656 1425 562

.90 1880 1071 1755 781 1585 646 1430 545 1695 1042 1590 752 1480 630 1335 533

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

506176−01 01/2010

Air Volume / Watts at Different Blower Speeds

Single Side Return Air − Air volumes in bold require field

fabricated transition to accommodate 20 x 25 x 1 in. air filter in order to maintain proper air velocity.

Page 34

Page 35

Heating Sequence of Operation

NOTE − The thermostat selection DIP switch on the integrated control is factory−set in the TWO−STAGE" position.

Applications Using a Two−Stage Thermostat

A − Heating Sequence −− Integrated 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

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.

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.

Page 35

G60UH Series

Page 36

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

Filters

All G60UH(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 1 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 gas-

ket. 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 vesti-

bule 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 in-

sert from each section. See figure 29.

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 blockage

caused by foreign matter. Remove any blockage.

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

bels at the entrance to each heat exchanger opening.

See figure 29.

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

tibule panel.

506176−01 01/2010

Page 36

Page 37

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

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

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

leaks. Use a leak detecting solution or other preferred means.

G60UH(X) BURNER & HEAT EXCHANGER REMOVAL

HEAT EXCHANGER

BURNER BOX ASSEMBLY

FIGURE 28

NOx INSERTS

(X models only)

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

repair 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.

NOx INSERT

FIGURE 29

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.

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 37

G60UH Series

Page 38

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

Pulse Power on − Standby.

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

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

FLAME CODES

1 + 2 Low flame current −− run mode.

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

PRESSURE SWITCH CODES

2 + 3 Low pressure switch failed open.

2 + 4 Low pressure switch failed closed.

2 + 5 High pressure switch failed open.

2 + 6 High pressure switch failed closed.

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

LIMIT CODE

3 + 1 Limit switch open.

WATCHGUARD CODES

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

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

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

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

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

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

4 + 8 Low line voltage.

HARD LOCKOUT CODES

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

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

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

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

5 + 6 Low secondary (24VAC) voltage.

Error Code Storage

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

Error Code Review

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

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

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

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

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

TUS LED turning off. This activates error code review.

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

LED.

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

flash to indicate normal operation.

Clearing Error Codes

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

will stay lit continuously to indicate that the short was

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

seconds, STATUS LED will go from being continuously

lit to off.

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

ten seconds after STATUS LED has turned off. 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 in-

dicate normal operation.

506176−01 01/2010

Page 38

Page 39

Troubleshooting: Heating Sequence of Operation

HEATING SEQUENCE OF OPERATION

NORMAL AND ABNORMAL HEATING MODE

POWER ON

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

CONTROL SELF−CHECK OKAY?

INDOOR BLOWER OFF. (RESET CONTROL BY

TURNING MAIN POWER OFF.)

POLARITY OKAY?

YES

IS THERE A

PROPER GROUND?

YES

NORMAL OPERATION:

STATUS LED −− PULSE

THERMOSTAT CALLS FOR HEAT:

STATUS LED −− HEARTBEAT

YES

PRIMARY AND SECONDARY LIMIT

SWITCHES CLOSED?

YES

ROLLOUT SWITCH CLOSED?

YES

FIRST (LOW) STAGE PRESSURE SWITCH

CONTACTS OPEN?

YES

SECOND (HIGH) STAGE PRESSURE SWITCH

CONTACTS OPEN?

YES

SIGNAL HOLDS UNTIL UNIT IS PROPERLY GROUNDED.

INDOOR BLOWER ON. HAS PRIMARY OR

SECONDARY LIMIT RESET WITHIN 3 MINUTES?

60−MINUTE LIMIT WATCHGUARD MODE.

GAS VALVE OFF, COMBUSTION AIR INDUCER

OFF, INDOOR BLOWER OFF WITH DELAY.

GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

SEQUENCE HOLDS UNTIL ROLLOUT SWITCH IS

RESET AND MAIN POWER IS INTERRUPTED OR

T’STAT IS CYCLED OFF/ON FOR 3 SEC. MINIMUM.

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF. INDOOR BLOWER OFF. CONTROL REMAINS UNTIL

PRESSURE SWITCH IS DETECTED OPEN.

POLARITY REVERSED.

STATUS ERROR CODE 5 + 4.

STATUS ERROR CODE 5 + 3.

COMBUSTION AIR INDUCER OFF.

STATUS ERROR CODE 3 + 1.

STATUS ERROR CODE 4 + 5.

INDOOR BLOWER ON.

STATUS ERROR CODE 5 + 1.

STATUS ERROR CODE 2 + 4

YES

TWO−STAGE OR SINGLE−STAGE THERMOSTAT

CALL FOR HEAT

COMBUSTION AIR INDUCER ON LOW SPEED.

STATUS LED −− HEARTBEAT

CONTINUED ON NEXT PAGE

Page 39

COMBUSTION AIR INDUCER OFF.

GAS VALVE 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.

G60UH Series

Page 40

Troubleshooting: Heating Sequence of Operation (Continued)

HEATING SEQUENCE OF OPERATION

CONTINUED

THERMOSTAT CALLS FOR HEAT

STATUS LED − HEARTBEAT.

(Refer to box A on previous page)

FIRST−STAGE (LOW FIRE) PRESSURE

SWITCH CLOSED WITHIN 2.5 MINUTES?

YES

15−SECOND COMBUSTION AIR INDUCER

PRE−PURGE INITIATED BY CLOSED FIRST−STAGE

PRESSURE SWITCH (or 15 SECOND

INTER−PURGE PERIOD.)

STATUS LED −− HEARTBEAT.

IGNITOR WARM−UP (20 SECONDS)

STATUS LED −− HEARTBEAT.

YES

IS IGNITOR INTACT AND CONNECTED?

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.

GAS VALVE OFF. COMBUSTION AIR INDUCER

OFF. INDOOR BLOWER OFF. UNIT WILL RETRY

AFTER 5−MINUTE WAIT PERIOD.

STATUS ERROR CODE 2 + 3.

COMBUSTION AIR INDUCER OFF, IGNITOR OFF.

SIGNAL HOLDS UNTIL IGNITOR IS REPLACED

OR RECONNECTED.

STATUS ERROR CODE 4 + 7.

IS VOLTAGE ABOVE 90 VOLTS?

COMBUSTION AIR INDUCER OFF, IGNITOR OFF.

SIGNAL HOLDS UNTIL VOLTAGE RISES ABOVE 95

VOLTS. STATUS ERROR CODE 4 + 8.

YES

FLAME RECTIFICATION CURRENT CHECK

CAN FLAME BE PROVEN WITHIN 4

SECONDS AFTER GAS VALVE OPENS?

(u0.20 microamps)

FLAME PRESENT?

YES

CONTINUED ON NEXT PAGE

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

WATCHGUARD MODE. GAS VALVE OFF,

COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF.

STATUS ERROR CODE 4 + 1.

IS 60−MINUTE RESET PERIOD COMPLETE?

YES

HAS CONTROL RESET IGNITION SEQUENCE

FOUR (4) TIMES?

WATCHGUARD MODE.

STATUS ERROR CODE 4 + 3.

YES

506176−01 01/2010

Page 40

Page 41

Troubleshooting: Heating Sequence of Operation (Continued)

HEATING SEQUENCE OF OPERATION

CONTINUED

FLAME SIGNAL ABOVE

(u1.40 microamps)

YES

SINGLE−STAGE THERMOSTAT MODE

(DIP SWITCH SET AT SINGLE")

YES

START SECOND−STAGE RECOGNITION

ON DELAY (10 OR 15 MINUTES).

STATUS LED −− HEARTBEAT

ROLLOUT SWITCHES CLOSED?

YES

TWO STAGE THERMOSTAT MODE

(DIP SWITCH SET AT TWO")

45−SECOND INDOOR BLOWER ON DELAY BEGINS.

YES

THERMOSTAT CALLS FOR HEAT.

STATUS LED −− HEARTBEAT.

SEE BOX A.

LOW FLAME SIGNAL

(Does not affect control operation)

STATUS ERROR CODE 1 + 2.

YES

STATUS LED −− HEARTBEAT.

YES

PRIMARY & SECONDARY LIMIT SWITCHES

CLOSED?

YES

FIRST−STAGE (LOW FIRE)

PRESSURE SWITCH CLOSED?

YES

FIRST−STAGE HEAT DEMAND SATISFIED?

YES

GAS VALVE OFF, COMBUSTION AIR INDUCER

OFF FOLLOWING POST PURGE.

INDOOR BLOWER OFF WITH DELAY

STATUS LED −− PULSE

SECOND−STAGE HEAT DEMAND.

SECOND−STAGE HEAT DEMAND REQUIRED?

YES

SECOND STAGE PRESSURE SWITCH CLOSED?

NOTE − IF SECOND−STAGE PRESSURE SWITCH

SECOND−STAGE 30−SECOND DELAY ON BEGINS.

SECOND−STAGE COMBUSTION AIR INDUCER

SECOND−STAGE PRESSURE SWITCH CLOSED

ABNORMAL FLASH CODE.

WAS ORIGINALLY FOUND CLOSED,

ABNORMAL CODE WILL FLASH.

STATUS LED −− HEARTBEAT.

YES

ON. SECOND−STAGE GAS VALVE ON. HIGH

HEAT INDOOR BLOWER SPEED ON.

STATUS LED −− HEARTBEAT.

YES

IN LESS THAN TEN (10) SECONDS?

STATUS LED −− HEARTBEAT

YES

CONTINUED ON NEXT PAGE

GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

YES

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.

GAS VALVE OFF, COMBUSTION AIR INDUCER OFF,

SWITCH CLOSED WITHIN 3 MINUTES?

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

GAS VALVE OFF, COMBUSTION AIR INDUCER OFF,

IS 60−MINUTE RESET PERIOD COMPLETE?

GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

INDOOR BLOWER OFF AFTER DELAY.

STATUS ERROR CODE 2 + 3. CONTROL RESTARTS

IGNITION SEQUENCE IF PRESSURE SWITCH

SECOND−STAGE PRESSURE SWITCH CLOSED

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

CONTINUES FIRST−STAGE HEATING DEMAND.

WILL NOT REATTEMPT SECOND−STAGE

INDOOR BLOWER ON.

STATUS ERROR CODE 3 + 1.

HAS PRIMARY OR SECONDARY LIMIT

LIMIT SWITCH WATCHGUARD MODE.

INDOOR BLOWER OFF WITH DELAY.

STATUS ERROR CODE 4 + 5

CLOSES WITHIN 2−1/2 MINUTES.

AT BEGINNING OF HEAT DEMAND?

STATUS ERROR CODE 2 + 6.

SECOND STAGE HEAT DEMAND

STATUS LED −− HEARTBEAT.

MADE FOR SECOND−STAGE HEAT?

YES

HEATING DEMAND.

STATUS ERROR CODE 2 + 5.

YES

Page 41

G60UH Series

Page 42

Troubleshooting: Heating Sequence of Operation (Continued)

HEATING SEQUENCE OF OPERATION

CONTINUED

NORMAL OPERATION.

SEE BOX A

SECOND−STAGE (HIGH FIRE) HEAT

PRESSURE SWITCH CLOSED?

YES

HEAT DEMAND SATISFIED?

STATUS LED −− HEARTBEAT.

YES

SINGLE−STAGE THERMOSTAT MODE

(DIP SWITCH SET AT SINGLE")

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.

RETURN TO FIRST−STAGE HEAT MODE.

FIRST−STAGE CONTINUES UNTIL SECOND−

YES

TWO STAGE THERMOSTAT MODE?

(DIP SWITCH SET AT TWO")

YES

FIRST AND SECOND STAGE HEAT

DEMAND SATISFIED SIMULTANEOUSLY.

STATUS LED −− HEARTBEAT.

STAGE PRESSURE SWITCH CAN BE PROVEN

or HEAT DEMAND IS SATISFIED. A FIVE (5)

MINUTE WAIT PERIOD IS INITIATED BEFORE

YES

THERMOSTAT CALLS FOR HEAT.

RETRY. WERE 5 ATTEMPTS MADE FOR

FIRST−STAGE HEAT DEMAND SATISFIED?

SEE BOX B

SECOND−STAGE HEAT?

SEE BOX C

SECOND STAGE HEAT

GAS VALVE, COMBUSTION AIR INDUCER

AND INDOOR BLOWER RETURN TO FIRST−

STATUS LED −− HEARTBEAT.

DEMAND SASTISFIED?

STATUS LED −− HEARTBEAT.

YES

STAGE OPERATION.

YES

DEMAND FOR HEAT SATISFIED.

POWER ON STAND BY. STATUS LED −− PULSE.

FIRST STAGE HEAT DEMAND SATISFIED?

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.

YES

506176−01 01/2010

Page 42

Page 43

Troubleshooting: Cooling Sequence of Operation

COOLING SEQUENCE OF OPERATION

POWER ON

YES

IS POLARITY REVERSED?

CONTROL WILL CONTINUE TO CALL FOR COOLING

SIGNAL POLARITY REVERSED.

IN THIS CONDITION.

STATUS ERROR CODE 5 + 4.

IS THERE

PROPER GROUND?

YES

THERMOSTAT CALLS FOR FIRST−STAGE COOL.

COMPRESSOR AND CONDENSER FAN

ENERGIZED.

INDOOR BLOWER ENERGIZED ON FIRST STAGE

COOL SPEED AFTER 2 SECOND DELAY.

FIRST−STAGE DEMAND FOR COOL SATISFIED?

THERMOSTAT CALLS FOR SECOND−STAGE COOL.

INDOOR BLOWER RAMPS UP TO SECOND−STAGE COOL SPEED.

YES

SIGNAL IMPROPER GROUND AT LED.

CONTROL WILL CONTINUE TO CALL FOR COOLING

IN THIS CONDITION.

STATUS ERROR CODE 5 + 3.

COMPRESSOR AND CONDENSER FAN DE−ENERGIZED.

INDOOR BLOWER DE−ENEGIZED.

SECOND−STAGE DEMAND FOR COOL SATISFIED?

YES

UNIT RETURNS TO FIRST STAGE COOL

Page 43

G60UH Series

Page 44

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.

YES YES

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

YES

INDOOR BLOWER RAMPS TO FIRST STAGE

COOLING SPEED AFTER A 2−SECOND DELAY.

AFTER 45−SECOND DELAY, INDOOR BLOWER

YES

SWITCHES TO LOW HEAT SPEED.

YES

FIRST−STAGE COOL DEMAND SATISFIED?

SECOND STAGE COOL DEMAND

INDOOR BLOWER RAMPS TO SECOND

STAGE COOL SPEED

SECOND STAGE COOL DEMAND SATISFIED?

YES

INDOOR BLOWER RAMPS DOWN TO FIRST STAGE

COOL SPEED.

FIRST−STAGE HEAT DEMAND SATISFIED.

THERMOSTAT CALLS FOR SECOND−STAGE HEAT.

YES

INDOOR BLOWER SWITCHES TO HIGH HEAT SPEED

AFTER 30−SECOND RECOGNITION PERIOD.

YES

SECOND−STAGE HEAT DEMAND SATISFIED.

YES

INDOOR BLOWER RAMPS DOWN TO LOW

HEAT SPEED.

YES

506176−01 01/2010

Page 44

Page 45

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: G60UH(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 45

G60UH Series

Page 46

G60UH(X) Start−Up & Performance Check List

Job Name

Job Location

Installer

Unit Model No.

Serial No.

Job No.

City

Technician

Heating Section

Electrical Connections Tight?

Line Voltage

Blower Motor Amps

Fuel Type: Natural Gas?

Furnace Btu Input (High fire) Line Pressure

Low Fire Manifold Pressure

High Fire Manifold Pressure

Flue Connections Tight?

Combustion Gas Tested (high fire and low fire)?

Blower ON delay confirmed? (45 Seconds Fixed On)

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

LP/Propane Gas?

w.c. − Nat.:

Blower Motor H.P.

Gas Piping Connections Tight & Leak−Tested?

w.c. − LP/Propane

Proper Draft?

External Static Pressure? (0.5 maximum)

Temperature Rise

Date

State

Filter Clean & Secure?

Thermostat

Heat Anticipator Setting? Thermostat Level?

506176−01 01/2010

Page 46

Lennox G60UH, G60UHX Installation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual