Lennox G60UH, G60UHX, G60UH−24A−045, G60UH−24A−070, G60UH−36A−070 Service Manual

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Page 1

Corp. 0204−L2

Revised 09−2006

G60UH(X)

Service Literature

G60UH(X) SERIES UNITS

G60UH(X) series units are mid−efficiency gas furnaces used for upflow or horizontal applications only, manufactured with Lennox Duralok Plus heat exchangers formed of aluminized steel. G60UH(X) units are available in heating capacities of 44,000 to 132,000 Btuh and cooling applications up to 5 tons. Refer to Engineering Handbook for proper sizing.

Units are factory equipped for use with natural gas. Kits are available for conversion to LPG operation. G60UH(X) model units are equipped with the Two−Stage / Variable Speed Integrated SureLight control. G60UH(X) unit meets the California Nitrogen Oxides (NO

) Standards and California Seasonal Efficiency requirements. All units use a redundant gas valve to assure safety shut−off as required by C.S.A.

All specifications in this manual are subject to change. Procedures outlined in this manual are presented as a recommendation only and do not supersede or replace local or state codes. In the absence of local or state codes, the guidelines and procedures outlined in this manual (except where noted) are recommendations only and do not constitute code.

TABLE OF CONTENTS

Introduction 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blower Data 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High Altitude 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts Identification 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I Unit Components 12. . . . . . . . . . . . . . . . . . . . . . . . . . . .

II Installation 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

III Start Up 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IV Heating System Service Checks 20. . . . . . . . . . . . . .

V Typical Operating Characteristics 22. . . . . . . . . . . . . .

VI Maintenance 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VII Wiring and Sequence of Operation 25. . . . . . . . . . .

VIII Field Wiring and Jumper Setting 33. . . . . . . . . . . . .

IX Control Board Troubleshooting 35. . . . . . . . . . . . . . .

G60UH−1 MODEL SHOWN

IMPORTANT

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

WARNING

Electric shock hazard. Can cause injury or death. Before attempting to perform any service or maintenance, turn the electrical power to unit OFF at disconnect switch(es). Unit may have multiple power supplies.

WARNING

Sharp edges. Be careful when servicing unit to avoid sharp edges which may result in personal injury.

Page 2

SPECIFICATIONS

Gas Heating Performance

ModelNo. G60UH−24A−045 G60UH−24A−070 G60UH−36A−070

Low NOx Model No. G60UH−24A−045X − − − G60UH−36A−070X

Input− Btuh (kW) low fire 30,000 (8.8) 45,000 (13.2) 45,000 (13.2)

Output− Btuh (kW) low fire 24,000 (7.0) 36,000 (10.6) 36,000 (10.6)

Input− Btuh (kW) high fire 44,000 (12.9) 66,000 (19.3) 66,000 (19.3)

Output− Btuh (kW) high fire 36,000 (10.5) 54,000 (15.8) 54,000 (15.8)

AFUE 80.0% 80.0% 80.0%

California Seasonal Efficiency 73.1 74.2 73.9

Highstatic(AGA/CGA)− in.w.g. (Pa) .50 (124) .50 (124) .50 (124)

Temperature rise range − F (C) low fire 15 − 45 (8 − 25) 20 − 50 (11 − 28) 20 − 50 (11 − 28)

Temperature rise range − F (C) high fire 35 − 65 (19 − 36) 40 − 70 (22 − 39) 40 − 70 (22 − 39)

Connections

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

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

Indoor

Wheelnominaldiameter xwidth −in. (mm) 10 x 7 (254 x 178) 10 x 7 (254 x 178) 10 x 8 (254 x 203)

ower

Motoroutput − hp (W) 1/5 (149) 1/5 (149) 1/3 (249)

Tons(kW) ofadd-oncooling 2 (7.0) 2 (7.0) 2 − 3 (7.0 − 10.6)

Shippingweight − 1 package 121 lbs. (55 kg) 127 lbs. (58 kg) 132 lbs. (60 kg)

Matching Coils

Up−flow cased C33−18A−2F, C33−24A−2F, C33−30A−2F, C33−36A−2F, C33−38A−2F

Horizontal CH33−18A−2F, CH33−24/30A−2F, CH33−36A−2F

Electricalcharacteristics 120 volts − 60 hertz − 1 phase (less than 12 amps)

OPTIONAL ACCESSORIES - MUST BE ORDERED EXTRA

 Air Filter and Rack Kit

Horizontal (end) 87L95 − (1) 14 x 25 x 1 in. (356 x 635 x 25 mm)

Numb

er and size of

filt

ers

Side Return Single (44J22) or Ten Pack (66K63) − (1) 16 x 25 x 1 in. (406 x 635 x 25 mm)

EZ Filter Base

Catalog Number − Shipping Weight 73P55 − 6 lbs. (3 kg)

Dimensions − H x W x D 4 x 14−1/4 x 28−5/8 in. (102 x 362 x 727 mm)

Number and size of filter (field provided) 14 x 25 x 1 in. (356 x 635 x 25 mm)

Horizontal Support Frame Kit − Shipping Weight 56J18  18 lbs. (8 kg)

Vent Adaptor − 6 in. 152 (mm) connection size 18M79 − 2 lbs. (1 kg) 18M79 − 2 lbs. (1 kg) 18M79 − 2 lbs. (1 kg)

High Altitude See Page 10

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

Page 3

SPECIFICATIONS Cont.

Gas Heating Performance

ModelNo. G60UH−36B−090 G60UH−48B−070 G60UH−48B−090 G60UH−36C−110

Low NOx Model No. − − − − − − G60UH−48B−090X − − −

Input− Btuh (kW) low fire 60,000 (17.6) 45,000 (13.2) 60,000 (17.6) 75,000 (22.0)

Output− Btuh (kW) low fire 48,000 (14.1) 36,000 (10.6) 49,000 (14.4) 61,000 (17.9)

Input− Btuh (kW) high fire 88,000 (25.8) 66,000 (19.3) 88,000 (25.8) 110,000 (32.2)

Output− Btuh (kW) high fire 72,000 (21.1) 54,000 (15.8) 72,000 (21.1) 90,000 (26.4)

AFUE 80.0% 80.0% 80.0% 80.0%

California Seasonal Efficiency 73.8% 73.1% 74.6% 74.2%

Highstatic(AGA/CGA)− in.w.g. (Pa) .50 (124) .50 (124) .50 (124) .50 (124)

Temperature rise range − F (C) low fire 20 − 50 (11 − 28) 15 − 45 (8 − 25) −1, −2 units 20 − 50

(11 − 28)

−4 units 15 − 45 (8.3 − 25)

25 − 55 (14 − 31)

Temperature rise range − F (C) high fire 40 − 70 (22 − 39) 25 − 55 (15 − 33) −1, −2 units 40 − 70

(22 − 39)

−4 units 35 − 65

(19 − 36)

50 − 80 (28 − 44)

Connections

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

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

Indoor

Wheelnominaldiameter xwidth −in. 10 x 8 10 x 10 10 x 10 10 x 8

ower

mm 254 x 203 254 x 254 254 x 254 254 x 203

Motoroutput − hp (W) 1/3 (249) 1/2 (373) 1/2 (373) 1/3 (249)

Tons(kW) ofadd-oncooling 2 − 3 (7.0 − 10.6) 2 − 4 (7.0 − 14.1) 2 − 4 (7.0 − 14.1) 2 − 3 (7.0 − 10.6)

Shippingweight − 1 package 146 lbs. (66 kg) 147 lbs (67 kg) 153 lbs (69 kg) 166 lbs. (75 kg)

Matching Coils

Up−flow cased C33−24B−2F, C33−30B−2F, C33−36B−2F, C33−38B−2F,

C33−42B−2F, C33−48B−2F

C33−36C−2F, C33−48C−2F,

C33−50/60C−2F,

Horizontal CH33−36B−2F, CH33−42B−2F, CH33−44/48B−2F CH33−36C−2F,

CH33−48C−2F,

CH33−50/60C−2F

Electricalcharacteristics 120 volts − 60 hertz − 1 phase (less than 12 amps)

OPTIONAL ACCESSORIES - MUST BE ORDERED EXTRA

 Air Filter and Rack Kit Number and size of filters

Horizontal (end) 87L96 − (1) 18 x 25 x 1 in. (457 x 635 x 25 mm) 87L97 − (1) 20 x 25 x 1 in.

(508 x 635 x 25 mm)

Side Return Single 44J22 or Ten Pack (66K63) − (1) 16 x 25 x 1 in. (406 x 635 x 25 mm)

EZ Filter

Catalog Number − Shipping Weight 73P56 − 7 lbs. (3 kg) 73P57 − 8 lbs. (4 kg)

ase

Dimensions − H x W x D 4 x 17−5/8 x 28−5/8 in. (102 x 448 x 727 mm) 4 x 21−5/8 x 28−5/8 in.

(102 x 549 x 727 mm)

Number & size of field provided filter 16 x 25 x 1 in. (406 x 635 x 25 mm) 20 x 25 x 1 in.

(508 x 635 x25 mm)

Horizontal Support Frame Kit − Shipping Weight 56J18 − 18 lbs. (8 kg) 56J18 − 18 lbs. (8 kg) 56J18 − 18 lbs. (8 kg) 56J18 − 18 lbs. (8 kg)

LPG/Propane Kit

4501−7500 ft. (1372−2286 m) 59M13 59M13 59M13 59M13

7501−10,000 ft. (2286−3048 m) 59M14 59M14 59M14 59M14

Vent Adaptor − 6 in. 152 (mm) connection size 18M79 − 2 lbs. (1 kg) 18M79 − 2 lbs. (1 kg) 18M79 − 2 lbs. (1 kg) 18M79 − 2 lbs. (1 kg)

High Altitude See Page 10

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

Annual Fuel Utilization Efficiency based on DOE test procedures and according to FTC labeling regulations. Isolated combustion system rating for non-weatherized furnaces. NOTE − Filters and provisions for mounting are not furnished and must be field provided.  The same C33 uncased models match the furnaces shown but require an optional adaptor base or field fabricated transition. See C33 coil bulletin for additional information.  Cleanable polyurethane frame type filter.

Page 4

SPECIFICATIONS Cont.

Gas

ModelNo. G60UH−48C−110 G60UH−60C−110 G60UH−60D−135 Heating Performance

Low NOx Model No. − − − G60UH−60C−110X − − −

Input− Btuh (kW) low fire 75,000 (22.0) 75,000 (22.0) 90,000 (26.4)

Output− Btuh (kW) low fire 60,000 (17.6) 61,000 (17.9) 73,000 (21.4)

Input− Btuh (kW) high fire 110,000 (32.2) 110,000 (32.2) 132,000 (38.7)

Output− Btuh (kW) high fire 90,000 (26.4) 90,000 (26.4) 108,000 (31.6)

AFUE 80.0% 80.0% 80.0%

California Seasonal Efficiency 74.9 75.1 74.9

Highstatic(AGA/CGA)− in.w.g.

(Pa)

.50 (124)

.50 (124) .50 (124)

Temperature rise range − F (C) low fire 20 − 50 (11 − 28)

−1, −2, −3 units

25 − 55 (14 − 31)

−4 units 20 − 50 (11 − 28)

25 − 55 (14 − 31)

Temperature rise range − F (C) high fire 40 − 70 (22 − 39) 35 − 65 (19 − 36) 45 − 75 (25 − 42)

Connections

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

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

Indoor Blower

Wheelnominaldiameter xwidth −in.

(mm)

10 x 10 (254 x 254) 11−1/2 x 10 (292 x 254) 11−1/2 x 10 (292 x 254)

Motoroutput − hp (W) 1/2 (373)

1 (746)

−1, −2 models 3/4 (560)

1 (746)

−1, −2 models 3/4 (560)

Tons(kW) ofadd-oncooling 2 − 4 (7.0 − 14.1) 5 (17.6) 5 (17.6)

Shippingweight − 1 package 169 lbs. (77 kg) 172 lbs. (78 kg) 192 lbs. (87 kg)

Matching Coils

Up−flow cased

C33−36C−2F, C33−48C−2F,

C33−50/60C−2F,

C33−36C−2F, C33−48C−2F,

C33−50/60C−2F,

C33−60D−2F, C33−62D−2F

Horizontal

CH33−36C−2F, CH33−48C−2F,

CH33−50/60C−2F

CH33−36C−2F, CH33−48C−2F,

CH33−50/60C−2F

CH33−60D−2F,

CH33−62D−2F

Electricalcharacteristics 120 volts − 60 hertz − 1 phase (less than 12 amps)

OPTIONAL ACCESSORIES - MUST BE ORDERED EXTRA

 Air Filter and Rack Kit Number and size of filters

Horizontal (end)

87L97 − (1) 20 x 25 x 1 in. (508 x 635 x 25 mm)

87L97

(1) 20 x 25 x 1 in. (508 x 635 x 25 mm)

87L98

(1) 25 x 25 x 1 in.

(635 x 635 x 25 mm)

Side Return Single 44J22 or Ten Pack (66K63) − (1) 16 x 25 x 1 (406 x 635 x 25)

EZ Filter Base

Catalog Number − Shipping Weight 73P57 − 8 lbs. (4 kg) 73P58 − 10 lbs. (5 kg)

Dimensions − H x W x D 4 x 21−5/8 x 28−5/8 in. (102 x 549 x 727 mm)

4 x 24−5/8 x 28−5/8 in. (102 x 625 x 727 mm)

Number and size of field provided

filter

20 x 25 x 1 in. (508 x 635 x25 mm)

24 x 24 x 1 in.

(610 x 610 x 25 mm)

Horizontal Support Frame Kit − Shipping Weight 56J18 − 18 lbs. (8 kg) 56J18 − 18 lbs. (8 kg) 56J18 − 18 lbs. (8 kg)

RAB Return Air Base Not Required RAB60C (12M71) RAB60D (12M72)

Vent Adaptor − 6 in. 152 (mm) connection size 18M79 − 2 lbs. (1 kg) 18M79 − 2 lbs. (1 kg) 18M79 − 2 lbs. (1 kg)

High Altitude See Page 10

Propane / Natural Kit 59M87

 The same C33 uncased models match the furnaces shown but require an optional adaptor base or field fabricated transition. See C33 coil bulletin for additional information.  Cleanable polyurethane frame type filter.  Flue connection on the unit is 4 in. (102 mm) diameter. Most applications will require 5 in. (127 mm) venting and field supplied 4 x 5 in. (102 x 127 mm) adaptor. See Venting Tables

in the Installation Instructions for detailed information.  Not for use with RAB Return Air Base or with 60C and 60D size units with air flow requirements of 1800 cfm (850 L/s) or greater. See Blower Performance Tables for additional information.

Page 5

BLOWER DATA

G60UH−24A−045 PERFORMANCE

External Static

Air Volume / Watts at Various Blower Speeds

External Static

Pressure

High Medium Low

in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts

0.00 0 1090 515 460 905 425 390 725 340 300

0.05 12 1080 510 450 900 425 390 720 340 300

0.10 25 1065 505 445 895 420 385 710 335 295

0.15 37 1050 495 435 895 420 380 700 330 290

0.20 50 1030 485 425 890 420 375 690 325 290

0.25 62 1015 480 415 875 415 370 680 320 285

0.30 75 995 470 410 860 405 365 665 315 280

0.40 100 960 455 395 840 395 350 650 305 270

0.50 125 910 430 380 795 375 335 610 290 260

0.60 150 840 395 355 750 355 315 540 255 245

0.70 175 770 365 340 665 315 295 490 230 235

0.80 200 660 310 315 555 260 275 420 200 225

0.90 225 560 265 295 480 225 260 355 170 210

NOTE − All air data is measured external to unit with 1 in. (25 mm) cleanable filter (not furnished − field provided) in place. Also see Filter Air Resistance table. NOTE − Air volumes based on bottom return air. Actual air volume may vary on side return air applications.

G60UH−24A−070 PERFORMANCE

External Static

Air Volume / Watts at Various Blower Speeds

External Static

Pressure

High Medium Low

in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts

0.00 0 1075 505 445 905 425 375 730 345 290

0.05 12 1070 505 445 900 425 375 725 340 290

0.10 25 1065 505 440 895 420 370 720 340 285

0.15 37 1060 500 435 890 420 365 715 335 285

0.20 50 1055 500 430 885 420 360 710 335 280

0.25 62 1045 495 425 880 415 360 700 330 280

0.30 75 1030 485 415 875 415 355 690 325 270

0.40 100 1010 475 400 860 405 350 675 320 270

0.50 125 975 460 390 840 395 340 660 310 265

0.60 150 940 445 375 805 380 325 640 300 255

0.70 175 890 420 360 755 355 305 605 285 240

0.80 200 830 390 340 700 330 285 565 265 225

0.90 225 765 360 305 640 300 265 515 245 205

G60UH−36A−070 PERFORMANCE

External Static

Air Volume / Watts at Various Blower Speeds

External Static

Pressure

High Medium−High Medium−Low Low

in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts

0.00 0 1500 710 705 1290 610 565 985 465 455 830 390 375

0.05 12 1475 695 695 1275 600 555 980 465 445 820 385 365

0.10 25 1450 685 680 1255 590 545 970 460 440 810 380 360

0.15 37 1425 675 670 1240 585 535 965 455 430 805 380 355

0.20 50 1400 660 655 1225 580 525 955 450 425 795 375 350

0.25 62 1370 645 645 1205 570 510 945 445 415 790 375 345

0.30 75 1340 630 630 1180 555 500 930 440 405 780 370 335

0.40 100 1285 605 610 1140 540 475 900 425 390 745 350 325

0.50 125 1215 575 580 1080 510 450 865 410 375 705 335 310

0.60 150 1150 545 560 1015 480 430 810 380 355 655 310 290

0.70 175 1060 500 535 940 445 405 730 345 330 585 275 270

0.80 200 955 450 515 800 375 370 655 310 305 480 225 260

0.90 225 785 370 475 605 285 325 585 275 270 410 195 255

Page 6

BLOWER DATA Cont.

G60UH−36B−090 PERFORMANCE

External Static

Air Volume / Watts at Various Blower Speeds

External Static

Pressure

High Medium−High Medium−Low Low

in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts

0.00 0 1500 710 720 1255 590 595 1040 490 460 900 425 370

0.05 12 1485 700 705 1250 590 580 1040 490 450 895 420 365

0.10 25 1465 690 685 1240 585 570 1035 490 445 890 420 360

0.15 37 1450 685 675 1235 585 555 1035 490 440 885 420 355

0.20 50 1435 675 660 1225 580 545 1030 485 435 880 415 350

0.25 62 1420 670 645 1215 575 530 1025 485 425 875 415 345

0.30 75 1400 660 630 1200 565 520 1020 480 415 870 410 340

0.40 100 1345 635 595 1170 550 495 1000 470 400 855 405 330

0.50 125 1300 615 575 1135 535 475 965 455 380 830 390 300

0.60 150 1235 585 545 1080 510 445 930 440 360 780 370 290

0.70 175 1165 550 510 1020 480 415 870 410 340 740 350 280

0.80 200 1080 510 480 940 445 385 800 380 315 670 315 260

0.90 225 985 465 445 840 395 355 710 335 290 600 285 245

G60UH−36C−110 PERFORMANCE

External Static

Air Volume / Watts at Various Blower Speeds

External Static

Pressure

High Medium−High Medium−Low Low

in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts

0.00 0 1555 735 715 1335 630 575 1085 510 460 925 435 365

0.05 12 1540 725 705 1330 630 555 1080 510 450 920 435 360

0.10 25 1525 720 690 1320 625 545 1075 505 440 915 430 355

0.15 37 1510 715 680 1310 620 535 1070 505 430 910 430 350

0.20 50 1490 705 670 1295 610 525 1065 505 420 900 425 340

0.25 62 1465 690 655 1280 605 510 1060 500 415 890 420 335

0.30 75 1440 680 645 1260 595 495 1050 495 405 880 415 330

0.40 100 1385 655 615 1230 580 485 1030 485 390 865 410 320

0.50 125 1320 625 590 1190 560 460 995 470 375 835 395 300

0.60 150 1260 595 570 1135 535 430 960 455 355 815 385 295

0.70 175 1190 560 545 1075 505 410 915 430 345 775 365 285

0.80 200 1090 515 515 970 460 385 860 405 325 760 360 280

0.90 225 975 460 485 880 415 360 790 375 305 705 335 275

G60UH−48B−070 PERFORMANCE

External Static

Air Volume / Watts at Different Blower Speeds

External Static

Pressure

High Medium−High Medium−Low Low

in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts

.00 0 2080 980 846 1810 855 764 1535 725 634 1295 610 519

.10 25 2030 955 810 1790 845 714 1520 715 600 1285 605 492

.20 50 1955 920 767 1760 830 675 1515 715 566 1275 600 477

.30 75 1885 890 732 1710 805 640 1505 710 555 1265 595 459

.40 100 1820 860 699 1670 790 611 1470 695 525 1255 590 443

.50 125 1740 820 664 1600 755 575 1420 670 496 1215 575 414

.60 150 1635 770 624 1530 720 544 1350 635 464 1175 555 400

.70 175 1545 730 597 1420 670 501 1270 600 432 1080 510 368

.80 200 1400 660 554 1295 610 462 1135 535 392 990 465 343

.90 225 1250 590 512 1125 530 419 1050 495 372 875 410 310

NOTES − All air data is measured external to unit with 1 in. (25 mm) cleanable filter (not furnished − field provided) in place. Also see Filter Air Resistance table.

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

Page 7

BLOWER DATA Cont.

G60UH−48B−090 PERFORMANCE

External Static

Air Volume / Watts at Various Blower Speeds

External Static

Pressure

High Medium−High Medium−Low Low

in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts

0.00 0 1970 930 790 1810 855 735 1585 750 670 1340 630 565

0.05 12 1940 915 780 1785 840 715 1580 745 650 1335 630 555

0.10 25 1915 905 765 1760 830 695 1570 740 630 1325 625 540

0.15 37 1880 885 745 1730 815 660 1560 735 615 1325 625 530

0.20 50 1840 870 730 1700 800 620 1545 730 600 1320 625 520

0.25 62 1805 850 715 1670 790 625 1520 715 585 1310 620 510

0.30 75 1765 835 695 1640 775 625 1490 705 565 1295 610 500

0.40 100 1695 800 670 1570 740 595 1440 680 540 1260 595 480

0.50 125 1600 755 635 1490 705 560 1360 640 505 1195 565 450

0.60 150 1505 710 600 1400 660 530 1285 605 480 1140 540 425

0.70 175 1395 660 565 1265 595 485 1170 550 440 990 465 380

0.80 200 1250 590 520 1100 520 445 975 460 390 905 425 355

0.90 225 1005 475 460 870 410 385 900 425 365 810 380 325

G60UH−48C−110 PERFORMANCE

External Static

Air Volume / Watts at Various Blower Speeds

External Static

Pressure

High Medium−High Medium−Low Low

in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts

0.00 0 2015 950 895 1620 765 780 1340 630 640 1150 545 525

0.05 12 1990 940 870 1615 760 760 1340 630 640 1150 545 525

0.10 25 1965 925 850 1610 760 745 1340 630 640 1150 545 525

0.15 37 1930 910 825 1605 755 725 1335 630 630 1150 545 525

0.20 50 1895 895 805 1600 755 710 1335 630 615 1150 545 525

0.25 62 1860 880 785 1590 750 695 1330 630 605 1150 545 520

0.30 75 1820 860 765 1580 745 675 1330 630 590 1145 540 515

0.40 100 1740 820 725 1530 720 635 1320 625 560 1140 540 490

0.50 125 1665 785 695 1475 695 600 1285 605 525 1120 530 470

0.60 150 1575 745 650 1405 665 555 1230 580 490 1075 505 445

0.70 175 1475 695 610 1310 620 515 1165 550 470 1015 480 415

0.80 200 1350 635 560 1210 570 485 1080 510 430 930 440 380

0.90 225 1210 570 520 1070 505 430 870 410 365 740 350 325

G60UH−60C−110 with 3/4 hp PERFORMANCE − 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.

External Static

Air Volume / Watts at Various Blower Speeds

External Static

Pressure

High Medium−High Medium−Low Low

in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts

0.00 0 2450 1155 1220 2300 1085 1060 2056 970 905 1725 815 735

0.05 12 2410 1135 1205 2265 1070 1045 2040 965 895 1715 810 725

0.10 25 2370 1120 1195 2230 1050 1030 2020 955 890 1710 810 720

0.15 37 2325 1095 1175 2200 1040 1015 1995 940 875 1700 800 715

0.20 50 2280 1075 1165 2170 1025 1005 1975 935 870 1695 800 710

0.25 62 2245 1060 1150 2130 1005 990 1950 920 855 1680 795 705

0.30 75 2205 1040 1135 2095 990 975 1925 910 845 1665 785 700

0.40 100 2115 995 1105 2010 950 940 1860 875 820 1625 770 685

0.50 125 2025 955 1060 1945 920 920 1810 855 805 1605 755 675

0.60 150 1910 900 1015 1850 875 885 1715 810 780 1540 730 670

0.70 175 1835 865 1005 1775 840 865 1655 780 765 1495 705 655

0.80 200 1745 825 975 1655 780 835 1540 725 730 1400 660 635

0.90 225 1610 760 945 1540 725 805 1475 695 715 1310 620 615

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

Page 8

BLOWER DATA Cont.

G60UH−60C−110 with 3/4 hp PERFORMANCE − Single Side Return Air − Air volumes in bold require field fabricated transition to accommodate 20 x 25 x 1 in. (508 x 635 x25 mm) cleanable air filter in order to maintain proper air velocity across the filter.

External Static

Air Volume / Watts at Various Blower Speeds

External Static

Pressure

High Medium−High Medium−Low Low

in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts

0.00 0 2395 1130 1230 2260 1065 1085 2015 950 920 1730 815 750

0.05 12 2365 1115 1220 2230 1050 1070 1985 935 905 1720 810 745

0.10 25 2330 1100 1205 2200 1040 1060 1960 925 890 1705 805 750

0.15 37 2285 1080 1190 2170 1025 1045 1030 485 880 1695 800 740

0.20 50 2245 1060 1170 2135 1010 1030 1905 900 870 1675 790 735

0.25 62 2200 1040 1160 2100 990 1020 1890 890 860 1665 785 730

0.30 75 2170 1025 1145 2070 980 1005 1870 880 850 1655 780 720

0.40 100 2085 985 1110 1990 940 975 1825 860 835 1610 760 705

0.50 125 1980 935 1075 1910 900 945 1755 830 810 1555 735 690

0.60 150 1890 890 1045 1835 865 915 1670 790 780 1515 715 680

0.70 175 1800 850 1020 1725 815 885 1615 760 770 1445 685 655

0.80 200 1700 805 995 1645 775 855 1525 720 745 1380 650 645

0.90 225 1590 750 980 1520 720 820 1410 665 710 1300 615 625

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

G60UH−60D−135 with 3/4 hp PERFORMANCE − 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.

External Static

Air Volume / Watts at Various Blower Speeds

External Static

Pressure

High Medium−High Medium−Low Low

in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts

0.00 0 2465 1165 1205 2325 1100 1060 2155 1015 930 1895 895 780

0.05 12 2430 1145 1195 2295 1085 1050 2125 1000 920 1875 885 770

0.10 25 2395 1130 1180 2265 1070 1040 2095 990 910 1855 875 765

0.15 37 2350 1110 1165 2230 1050 1025 2070 975 900 1830 865 755

0.20 50 2310 1090 1150 2195 1035 1010 2045 965 890 1805 850 745

0.25 62 2265 1070 1135 2155 1015 995 2010 950 875 1785 840 735

0.30 75 2220 1050 1120 2115 1000 980 1975 930 865 1765 830 730

0.40 100 2120 1000 1080 2035 960 950 1915 905 845 1715 810 720

0.50 125 2050 970 1055 1955 925 925 1830 865 815 1645 775 700

0.60 150 1930 910 1015 1860 880 895 1745 825 795 1585 745 680

0.70 175 1835 865 985 1775 840 870 1655 780 770 1530 720 670

0.80 200 1720 810 955 1645 775 830 1560 735 745 1445 685 650

0.90 225 1595 755 925 1535 725 800 1455 685 720 1310 620 620

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

G60UH−60D−135 with 3/4 hp PERFORMANCE − Single Side Return Air − Air volumes in bold require field fabricated transition to accommodate 20 x 25 x 1 in. (508 x 635 x25 mm) cleanable air filter in order to maintain proper air velocity across the filter.

External Static

Air Volume / Watts at Various Blower Speeds

External Static

Pressure

High Medium−High Medium−Low Low

in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts

0.00 0 2350 1110 1180 2225 1050 1035 2055 970 905 1855 875 775

0.05 12 2310 1090 1170 2195 1035 1025 2035 960 895 1835 865 765

0.10 25 2275 1075 1155 2165 1020 1010 2010 950 885 1815 855 760

0.15 37 2235 1055 1140 2130 1005 1000 1980 935 875 1795 845 755

0.20 50 2195 1035 1130 2100 990 985 1945 920 865 1775 835 750

0.25 62 2155 1020 1115 2055 970 970 1915 905 855 1750 825 740

0.30 75 2115 1000 1100 2010 950 950 1885 890 845 1725 815 735

0.40 100 2010 950 1055 1940 915 930 1830 865 830 1665 785 720

0.50 125 1930 910 1035 1860 880 905 1745 825 805 1600 755 705

0.60 150 1830 865 1005 1770 835 880 1655 780 775 1530 720 685

0.70 175 1735 820 985 1655 780 845 1595 755 765 1480 700 675

0.80 200 1645 775 955 1545 730 815 1480 700 735 1375 650 650

0.90 225 1515 715 925 1435 675 785 1385 655 710 1290 610 630

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

Page 9

BLOWER DATA Cont.

G60UH−60C−110 with 1 hp PERFORMANCE − 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.

External Static

Air Volume / Watts at Different Blower Speeds

External Static

Pressure

High Medium−High Medium−Low Low

in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts

.00 0 2555 1205 1378 2300 1085 1027 1985 935 863 1655 780 678

.10 25 2490 1175 1354 2265 1070 1002 1980 935 839 1640 775 667

.20 50 2420 1140 1330 2225 1050 980 1975 930 832 1635 770 660

.30 75 2355 111 0 1300 2175 1025 957 1945 915 810 1625 765 653

.40 100 2275 1075 1265 2115 1000 934 1915 905 785 1620 765 639

.50 125 2175 1025 1229 2040 960 903 1860 875 762 1595 750 623

.60 150 2085 985 1199 1965 925 873 1800 850 733 1565 740 608

.70 175 1990 940 1140 1870 880 843 1730 815 714 1525 720 590

.80 200 1890 890 1105 1770 835 807 1630 770 676 1455 685 567

.90 225 1760 830 1067 1655 780 777 1535 725 649 1370 645 541

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

G60UH−60C−110 with 1 hp PERFORMANCE − Single Side Return Air − Air volumes in bold require field fabricated transition to accommodate 20 x 25 x 1 in. (508 x 635 x25 mm) cleanable air filter in order to maintain proper air velocity.

External Static

Air Volume / Watts at Different Blower Speeds

External Static

Pressure

High Medium−High Medium−Low Low

in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts

.00 0 2385 1125 1296 2185 1030 981 1915 905 836 1650 780 686

.10 25 2330 1100 1274 2150 1015 961 1900 895 815 1635 770 677

.20 50 2255 1065 1234 2095 990 930 1885 890 794 1625 765 664

.30 75 2190 1035 1207 2035 960 902 1855 875 769 1620 765 651

.40 100 2115 1000 1179 1970 930 876 1820 860 751 1605 755 639

.50 125 2055 970 1156 1905 900 853 1760 830 725 1575 745 622

.60 150 1985 935 1141 1830 865 827 1705 805 704 1525 720 602

.70 175 1910 900 1119 1745 825 797 1635 770 680 1475 695 582

.80 200 1810 855 1088 1650 780 772 1560 735 659 1430 675 571

.90 225 1715 810 1058 1570 740 751 1485 700 638 1355 640 549

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

G60UH−60D−135 with 1 hp PERFORMANCE − 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.

External Static

Air Volume / Watts at Different Blower Speeds

External Static

Pressure

High Medium−High Medium−Low Low

in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts

.00 0 2715 1280 1407 2255 1065 1070 1910 900 850 1660 785 674

.10 25 2640 1245 1403 2250 1060 1030 1900 895 834 1645 775 668

.20 50 2540 1200 1355 2245 1060 1006 1890 890 821 1630 770 665

.30 75 2480 1170 1319 2200 1040 975 1890 890 781 1625 765 656

.40 100 2390 1125 1282 2155 1015 940 1885 890 775 1615 760 642

.50 125 2320 1095 1251 2085 985 904 1860 875 758 1605 755 631

.60 150 2205 1040 1210 2020 955 876 1815 855 731 1595 750 611

.70 175 2080 980 1161 1935 915 839 1760 830 707 1545 730 588

.80 200 2010 950 1122 1855 875 810 1690 795 679 1495 705 568

.90 225 1880 885 1071 1755 830 781 1585 745 646 1430 675 545

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

Page 10

BLOWER DATA Cont.

G60UH−60D−135 with 1 hp PERFORMANCE − Single Side Return Air − Air volumes in bold require field fabricated transition to accommodate 20 x 25 x 1 in. (508 x 635 x25 mm) cleanable air filter in order to maintain proper air velocity.

External Static

Air Volume / Watts at Different Blower Speeds

External Static

Pressure

High Medium−High Medium−Low Low

in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts

.00 0 2455 1160 1336 2170 1025 1019 1850 875 829 1555 735 673

.10 25 2380 1125 1299 2140 1010 974 1840 870 812 1550 730 664

.20 50 2305 1085 1266 2105 995 947 1830 865 791 1545 730 656

.30 75 2235 1055 1234 2045 965 914 1820 860 774 1540 725 642

.40 100 2160 1020 1240 1985 935 886 1800 850 755 1540 725 628

.50 125 2065 975 1170 1925 910 863 1745 825 726 1535 725 614

.60 150 1990 940 1146 1870 880 844 1700 800 706 1505 710 599

.70 175 1895 895 1111 1775 835 808 1655 780 689 1465 690 573

.80 200 1805 850 1074 1680 790 779 1565 740 656 1425 670 562

.90 225 1695 800 1042 1590 750 752 1480 700 630 1335 630 533

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

HIGH ALTITUDE

HIGH ALTITUDE / MANIFOLD PRESSURE INFORMATION

Altitude

Manifold Pressure

Model

0 − 4500 ft.

(0 − 1372 m)

4,501 − 7500 ft.

(1373 − 2286 m)

7501−10,000 ft.

(2286 − 3048 m)

at all altitudes

Input

Size

Required

Pressure

Required

Pressure

Required

Pressure

Low Fire High Fire

onversion

Kit

Pressure

Switch

onversion

Kit

Pressure

Switch

onversion

Kit

Pressure

Switch

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

045/070−1

Nat. N/A N/A N/A N/A 59M16 18M64 1.7 0.42 3.5 0.87

045/070−1

to −6

LPG 59M13 N/A 59M13 N/A 59M14 18M64 4.9 1.22 10.0 2.5

045/070−7

Nat. N/A N/A N/A N/A 59M17 18M64 1.7 0.42 3.5 0.87

045/070−7

and later

LPG 59M13 N/A 59M13 N/A 59M14 18M64 4.9 1.22 10.0 2.5

Nat. N/A N/A N/A 18M61 59M16 18M64 1.7 0.42 3.5 0.87

090−1 to −6

LPG 59M13 N/A 59M13 18M61 59M14 18M64 4.9 1.22 10.0 2.5

090−7 and

Nat. N/A N/A N/A 18M61 59M17 18M64 1.7 0.42 3.5 0.87

090−7 and

later

LPG 59M13 N/A 59M13 18M61 59M14 18M64 4.9 1.22 10.0 2.5

110/135−1

Nat. N/A N/A N/A 18M63 59M16 18M61 1.7 0.42 3.5 0.87

110/135−1

to −6

LPG 59M13 N/A 59M13 18M63 59M14 18M61 4.9 1.22 10.0 2.5

110/135−7

Nat. N/A N/A N/A 18M63 59M17 18M61 1.7 0.42 3.5 0.87

110/135−7

and later

LPG 59M13 N/A 59M13 18M63 59M14 18M61 4.9 1.22 10.0 2.5

Pressure switch is factory set. No adjustment necessary. All models use the factory installed pressure switch from 0−4500 feet (0−1372 m). 1 − Conversion requires 2 pressure switches

Page 11

Flue

Transition

Combustion Air Inducer

Combustion Air

Orifice

Combustion Air

Pressure Switch Assembly

(two switches)

Flue

Collector

Box

Heat Exchanger

Insert

Primary

Limit

Door Interlock Switch

SureLight

Two−Stage

Integrated Control Board

Control Transformer

Circuit Breaker

Gasket

Flue Box Gasket

Limit Shield

Secondary Limit(s)

(NOx Units Only)

Air Deflector

G60UH−60C−110

Units Only

Blower Motor

Capacitor

Flame Sensor

Gas Valve

Burners

Ignitor

Flame Rollout Switches*

Flame Rollout Bracket

Gas Orifices

Ignitor Bracket

Burner Bottom Shield

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

FIGURE 1

PARTS ARRANGEMENT

NOTE − G60UH−1, −2 and −3 unit models are equipped with a fully enclosed burner box. See figure 16.

Page 12

I−UNIT COMPONENTS

G60UH(X) unit components are shown in figure 1. The gas valve, combustion air inducer and burners can be accessed by removing the burner access panel. Electrical components are in the control box (figure 2) found in the blower section. G60UH(X) units are factory equipped with a bottom return air

panel in place. The panel is designed to be field removed as required for bottom air return. Markings are provided for side return air and may be cut out in the field.

CAUTION

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

ELECTROSTATIC DISCHARGE (ESD)

Precautions and Procedures

1. Control Transformer (T1)

A transformer located in the control box provides power to the low voltage section of the unit. Transformers on all models are rated 40VA with a 120V primary and a 24V secondary.

2. Door Interlock Switch (S51)

A door interlock switch rated 14A at 125VAC is wired in series with line voltage. When the blower door is removed the unit will shut down.

FIGURE 2

CONTROL BOX G60UH(X)

SURELIGHT

CONTROL

BOARD

TRANSFORMER

CIRCUIT BREAKER

DOOR INTERLOCK

SWITCH

3. Circuit Breaker (CB8)

A 24V circuit breaker is also located in the control box. The switch provides overcurrent protection to the transformer (T1). The breaker is rated 3A at 32V. If the current exceeds this limit the breaker will trip and all unit operation will shutdown. The breaker can be manually reset by pressing the button on the face. See figure 3.

FIGURE 3

CIRCUIT BREAKER CB8

PRESS TO RESET

WARNING

Shock hazard. Disconnect power before servicing. Integrated

Control Board is not field repairable. If control is inoperable, simply replace entire control.

Can cause injury or death. Unsafe operation will result if repair is attempted.

4. Integrated Control Board(A92)

All G60UH units are equipped with the Lennox Two−Stage Integrated control board. The system consists of a ignition control board (figure 4 with control terminal designations in tables 3, 4 and 5). and ignitor (figure 7). The board and ignitor work in combination to ensure furnace ignition and ignitor durability. The board controls all major furnace operations. The board features two LED lights, DS1 and DS2 for troubleshooting. The board also has two accessory terminals rated at (1) one amp. See table 6 for troubleshooting diagnostic codes.

Electronic Ignition

At the beginning of the heat cycle, SureLight control monitors the first stage and second stage combustion air inducer prove switch. The control will not begin the heating cycle if the first stage prove switch is closed (by−passed). Likewise the control will not begin the second stage heating cycle if the second stage prove switch is closed, and will allow first stage heat only. However if the second stage prove switch closes during the first stage pre−purge, the control will respond to second stage heat. Once the first stage prove switch is determined to be open, the combustion air inducer is energized on low (first stage) heat speed. When the differential in the prove switch is great enough, the prove switch closes and a 15−second pre−purge begins. If the switch is not proven within 2−1/2 minutes, the control goes into Watchguard−Pressure Switch mode for a 5−minute re−set period. After the 15−second pre−purge period, the SureLight ignitor warms up for 20 seconds after which the gas valve opens for a 4−second trial for ignition. The ignitor energizes during the trial until flame is sensed. If ignition is not proved during the 4−second period, the control will try four more times with an inter purge and warm−up time between trials of 35 sec-

Page 13

onds. After a total of five trials for ignition (including the initial trial), the control goes into Watchguard−Flame Failure mode. After a 60−minute reset period, the control will begin the ignition sequence again. The SureLight control board has an added feature that prolongs the life of the ignitor. After a successful ignition, the SureLight control utilizes less power to energize the ignitor on successive calls for heat. The control continues to ramp down the voltage to the ignitor until it finds the lowest amount of power that will provide a successful ignition. This amount of power is used for 255 cycles. On the 256th call for heat, the control will again ramp down until the lowest power is determined and the cycle begins again.

Two Stage Operation / Thermostat Selection Jumper

The control can be utilized in two modes: SINGLE−STAGE thermostat or TWO−STAGE thermostat. The thermostat selection jumper E20, located just below dip switches 1 through 4 (figure 4), must be positioned for the particular application. The jumper is factory set on TWO" for use with a two−stage thermostat with two stage heat. Re−position jumper to SINGLE" for use with a single stage thermostat with two stage heat. While in the single−stage thermostat mode (single jumper setting), the burners will always fire on first−stage heat. The combustion air inducer will operate on low speed and indoor blower will operate on low heat speed. After a 10 minute recognition period, the unit will switch to second stage heat. While in the two−stage thermostat mode (two jumper setting) the burners will fire on first−stage heat. The combustion air inducer will operate on low speed and indoor blower will operate on low heat speed. The unit will switch to second−stage heat on call from the indoor thermostat. If there is a simultaneous call for first and second stage heat, the unit will fire on first stage heat and switch to second stage heat after 30 seconds of operation. See Sequence of Operation flow charts in the back of this manual for more detail.

Dip Switch Settings

Dip Switches 1 and 2 − Heating Fan off Delay − The fan on

time of 45 seconds is not adjustable. Fan off time (time that the blower operates after the heat demand has been satisfied) can be adjusted by flipping the dip switches 1 and 2 located on the SureLight integrated control. The unit is shipped with a factory fan off setting of 90 seconds. Fan off time will affect comfort and is adjustable to satisfy individual applications. For customized comfort, monitor the supply air temperature once the heat demand is satisfied. Note the supply air temperature at the instant the blower is de−energized. Adjust the fan−off delay to achieve a supply air temperature between 90° − 110° at the instant the blower is de− energized. (Longer delay times allow for lower air temperature, shorter delay times allow for higher air temperature). See table 1 for dip switch settings.

TABLE 1

Heating Fan Off Delay

Delay (Seconds)

Switch 1 Switch 2

60 Off Off

90 Off On

120 On Off

180 On On

Switch 3 − Second Stage Delay (Used with Single−Stage

Thermostat Only) −− This switch is used to determine the

second stage on delay when a single−stage thermostat is

being used. The switch is factory−set in the ON position,

which provides a 10−minute delay before second−stage

heat is initiated. If the switch is toggled to the OFF position,

it will provide a 15−minute delay before second−stage heat

is initiated. This switch is only activated when the thermo-

stat selector jumper is positioned for SINGLE−stage ther-

mostat use.

Switch 4 − Cooling Fan off Delay − The fan on delay time

of 2 seconds is not adjustable. Fan off time (time that the

blower operates after the cool demand has been satisfied)

can be adjusted by flipping dip switch 4. The unit is shipped

with a factory fan off setting of 45 seconds. Fan off time will

affect comfort and is adjustable to satisfy individual ap-

plications. See table 2 for cool fan off time settings.

TABLE 2

Cooling Fan Off Delay

Delay (Seconds)

Switch 4

2 Off

45 On

Diagnostic LED’s (DS1 and DS2)

Two diagnostic LED’S are located on the two−stage inte-

grated control board. See figure 4. These light flashes cor-

respond with the codes detailed in table 6.

Factory Installed Jumper Y1 to Y2

A factory−installed jumper from Y1 to Y2 terminals on the

integrated control board terminal strip must be clipped for

two−stage cooling.

Page 14

TWO−STAGE INTEGRATED CONTROL BOARD

FIGURE 4

THERMOSTAT CONNECTIONS (TB1)

DIP

SWITCHES

1 − 4

LEDs

FACTORY−

INSTALLED

JUMPER

DIP SWITCH(ES) FUNCTION

1 and 2 Blower Off Delay (Heating Mode)

3 Second Stage ON Delay (Single−stage t’stat) 4 Blower Off Delay (Cooling Mode)

TABLE 3

Integrated Control Board Terminals

120VAC Neutral

LINE Line

XFMR Transformer

EAC Electronic Air Cleaner

CIRC Indoor Blower

HUM Humidifier

120VAC Line

HUM Humidifier

XMFR Transformer

LINE Line

PARK For Unused Leads

COOL Cooling Speed

EAC Electronic Air Cleaner

HI HEAT HIigh Heat Speed

LO HEAT Low Heat, Low Cool and Continuous Fan

Speed

TABLE 4

Integrated Control Board 5 Pin Terminal

PIN # Function

1 Ignitor

2 Combustion Air Inducer High Speed

3 Combustion Air Inducer Low Speed

4 Combustion Air Inducer Neutral

5 Ignitor Neutral

TABLE 5

Integrated Control Board 12Pin Terminal

PIN # Function

1 Gas Valve 2nd Stage (High Fire)

2 Second Stage Prove Switch

3 Not Used

4 Ground

5 24V Hot

6 Primary Limit In

7 Gas Valve 1st stage (Low Fire)

8 Gas Valve Common

9 24V Neutral

10 Ground

11 Primary Limit Out

12 1st Stage Prove Switch

Page 15

TABLE 6

DIAGNOSTIC CODES

Diagnostic LEDs are labeled DS1 and DS2. See figure 4 for location of diagnostic LEDs.

DS1 DS2 DESCRIPTION

SIMULTANEOUS

SLOW FLASH

SIMULTANEOUS

SLOW FLASH

Power on − Normal operation. Also signaled during cooling and continuous fan.

SIMULTANEOUS

FAST FLASH

SIMULTANEOUS

FAST FLASH

Normal operation − signaled when heating demand initiated at thermostat.

SLOW FLASH ON

Primary, secondary or rollout limit switch open. Limits must close within 3 minutes or unit goes into 1 hour Watchguard.

OFF SLOW FLASH

Low pressure switch open; OR: Blocked inlet/exhaust vent; OR: Low pressure switch closed prior to activation of combustion air inducer.

OFF FAST FLASH

High pressure switch open; OR: Blocked inlet/exhaust vent; OR: High pressure switch closed prior to activation of combustion air inducer.

ALTERNATING

SLOW FLASH

ALTERNATING

SLOW FLASH

Watchguard −− burners failed to ignite; OR limit open more than 3 minutes; OR lost flame sense 5 times in one heating cycle; OR pressure switch opened 5 times in one heating cycle.

SLOW FLASH OFF Flame sensed without gas valve energized.

ON ON

ONONON

OFF

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

OFF ON

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

FAST FLASH SLOW FLASH Main power polarity reversed. Switch line and neutral.

SLOW FLASH FAST FLASH Low flame signal. Measures below 0.23 microAmps. Replace flame sense rod.

ALTERNATING

FAST FLASH

ALTERNATING

FAST FLASH

The following conditions are sensed during the ignitor warm−up period only:

1) Improper main ground;

2) Broken ignitor; OR: Open ignitor circuit;

3) Line voltage below 75 volts. (If voltage lower than 75 volts prior to ignitor warm-up, control will signal waiting on call from thermostat, and will not respond.

NOTE − Slow flash rate equals 1 Hz (one flash per second). Fast flash rate equals 3 Hz (three flashes per second). Low flame sense current = 0.17−0.22 microAmps.

5. Blower Motors and Capacitors

All G60UH(X) units use direct drive blower motors. All motors are 120V permanent split capacitor motors to ensure maximum efficiency. Ratings for capacitors will be on motor nameplate. See SPECIFICATIONS section for motor specifications.

NOTE − Shafts on 1 HP motors have 2 flat sides and are matched with blower wheels with 2 set screws.

FIGURE 5

SUPPLY AIR BLOWER

AND SECONDARY LIMIT (S)

SECONDARY

LIMIT (S)

CAPACITOR

MOTOR/BLOWER

ASSEMBLY

To Remove Blower From Unit: Disconnect Power, Remove Control

Box, Remove Bolts and Unplug Motor Wires From Control Board.

Then Slide Out Front of Unit.

Page 16

6. Flame Sensor

A flame sensor is located on the left side of the burner support. See figure 6. The sensor is mounted on the flame rollout plate and the tip protrudes into the flame envelope of the left−most burner. The sensor can be removed for service without removing any part of the burners. During operation, flame is sensed by current passed through the flame and sensing electrode. The SureLight control allows the gas valve to remain open as long as flame signal is sensed.

FIGURE 6

NORMAL FLAME SIGNAL > 0.23 MICROAMPS LOW FLAME SIGNAL <

0.22 MICROAMPS

DROP OUT SIGNAL = 0.16 MICROAMPS

5/16"

7. Ignitor

The SureLight ignitor is made of durable silicon nitride. Ignitor longevity is enhanced by controlling voltage to the ignitor. The board finds the lowest ignitor temperature which will successfully light the burner, thus increasing the life of the ignitor. Due to this feature of the board, voltage cannot be measured so ignitor must be ohmed. Ohme value should be 10.9 to 19.7. See 7 for ignitor location.

NOTE − The G60UH(X) furnace contains electronic components that are polarity sensitive. Make sure that the furnace is wired correctly and is properly grounded.

FIGURE 7

5/16"

13/32’

5/8"

SureLight Ignitor Location

BURNERS TOP VIEWBURNERS FRONT VIEW

MEASUREMENT IS TO I.D. OF RETENTION RING

IGNITOR

BRACKET

Page 17

8. Combustion Air Inducer (B6)

All G60UH(X) units use a two−stage combustion air inducer to move air through the burners and heat exchanger during heating operation. The blower uses a 120VAC motor. The motor operates during all heating operation and is controlled by furnace / blower control A92. The inducer also operates for 15 seconds before burner ignition (pre-purge) and for 5 seconds after the gas valve closes (post-purge). The inducer operates on low speed during first−stage heat, then switches to high speed for second stage heat.

A proving switch connected to the combustion air inducer orifice plate is used to prove inducer operation. The combustion air inducer orifice will be different for each model. See table 7 for orifice sizes. The switch monitors air pressure in the inducer housing. During normal operation, the pressure in the housing is negative. If pressure becomes less negative (signifying an obstruction) the proving switch opens. When the proving switch opens, the furnace control (A92) immediately closes the gas valve to prevent burner operation.

TABLE 7

G60UH(X) Unit

C.A.I. Orifice Size

−045−1, −2 1.25"

−070−1, −2, −3 1.5"

−070−4 and later 1.438"

−090 all units 1.75"

−110−1, −2, −3 2.0"

−110−4 and later 1.875"

−135−1, −2, −3 2.25"

−135−4 and later 2.156"

Horizontal Applications

The G60UH(X) furnace can be installed in horizontal ap-

plications.

The combustion air inducer may be rotated clockwise or

counterclockwise by 90° to allow for vertical vent discharge

in a horizontal application. Remove the four mounting

screws, rotate the assembly (assembly consists of orifice

plate, proving switch, gasket and combustion air inducer),

then reinstall the mounting screws. See figure 8. 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. Use sheet metal shears to

remove the cut out from the side of the cabinet. See figure

9. Use the two provided sheet metal screws to install the cut

out on the top cap to cover the original flue outlet opening.

Combustion Air Inducer

(Upflow Position)

Mounting Screws

MOUNTING SCREWS

90°

(Remove)

Power Leads

Flue Transition

(Do not remove

)

FIGURE 8

Flue Outlet Hole

(

Reattach

Cutout Here)

Supply Air

Opening

Top View of Furnace

Top Cap

Cut out

Optional

Flue Outlet

Optional Flue Outlet

(Horizontal Installation)

FIGURE 9

9. Flame Rollout Switches (S47)

On all G60UH −1, −2 and −3 units, flame rollout switch is a high temperature limit located on top of the burner box. Each furnace is equipped with two identical switches. One switch is located over the leftmost burner and the other switch is located over the rightmost burner. On G60UH−4 and later model units, the switches are located on a bracket inside the burner box. The limits are N.C. SPST manual-reset limits connected in series with the primary limit S10. When S47 senses rollout, the circuit breaks and the ignition control immediately stops ignition and closes the gas valve. If unit is running and flame rollout is detected, the gas valve will close and ignition control will be disabled. Rollout can be caused by a blocked heat exchanger, flue or lack of combustion air. The switch is factory set to trip (open) at 210°F and cannot be adjusted. The switch can be manually reset. To manually reset a tripped switch, push the reset button located on the control.

Page 18

10. Primary Limit Control (S10)

The primary limit (S10) on G60UH(X) units is located in the heating vestibule panel. When excess heat is sensed in the heat exchanger, the limit will open. If the limit is open, the furnace control energizes the supply air blower and closes the gas valve.The limit automatically resets when unit temperature returns to normal. The switch must reset within three minutes or the SureLight board will go into Watch guard for one hour. If the limit opens during a second stage heat call, the blower will operate on high heat for 30 seconds and then switch to low heat speed for the remainder of the 3 minute period. The switch is factory set (see face of switch) and cannot be adjusted. Replace switch with exact length and set point.

11. Secondary Limit Controls (S21)

The secondary limit (S21) on G60UH(X) units is located in the blower compartment on the back side of the blower housing. See figure 5. Blower speed chart on the wiring diagram show secondary limit quantities per unit. When excess heat is sensed in the blower compartment, the limit will open. If the limit is open, the furnace control energizes the supply air blower and closes the gas valve. The limit automatically resets when unit temperature returns to normal. G60UH−1 through −4 units use surface type limts factory set to open at 125°F. G60UH−5 units and later use air stream type limts factory set to open at 135°. The secondary limit cannot be adjusted.

12. Gas Valve

The G60UH(X) uses a two−stage gas valve manufactured by Honeywell (figure 11). The valve is internally redundant to assure safety shut−off. If the gas valve must be replaced, the same type valve must be used.

24VAC terminals and gas control knob or switch are located on the valve. All terminals on the gas valve are connected to wires from the electronic ignition control. 24V applied to the terminals energizes the valve.

Inlet and outlet pressure taps are located on the valve. A regulator adjustment screw is located on the valve.

LPG change over kit s are available from Lennox. Kits include burner orifices and a gas valve regulator conversion kit.

13. Combustion Air Inducer Prove Switch (S18)

G60UH(X) series units are equipped with a dual combustion air proving switch (first and second stage) located on the combustion air inducer orifice bracket. The switch is connected to the combustion air inducer housing by means of a flexible silicone hose. It monitors negative air pressure in the combustion air inducer housing.

The switches are a single-pole single-throw proving switch electrically connected to the furnace control. The purpose of the switch is to prevent burner operation if the combustion air inducer is not operating or if the flue becomes obstructed.

On heat demand (first or second stage) the switch senses that the combustion air inducer is operating. It closes a circuit to the furnace control when pressure inside the combustion air inducer decreases to a certain set point. Set points vary depending on unit size. See tables 8, 9 and

10. The pressure sensed by the switch is negative relative to atmospheric pressure. If the flue becomes obstructed during operation, the switch senses a loss of negative pressure (pressure becomes more equal with atmospheric pressure) and opens the circuit to the furnace control and gas valve. A bleed port on the switch allows relatively dry air in the vestibule to purge switch tubing, to prevent condensate build up. The switch is factory set and is not field adjustable. It is a safety shut-down control in the furnace and must not be by− passed for any reason. If switch is closed or by−passed, the control will not initiate ignition at start up.

FIGURE 10

DUAL COMBUSTION AIR PROVE SWITCH

BRACKET

TAP

LOW FIRE SWITCH

HIGH FIRE SWITCH

TABLE 8

0’ to 4500’

G60UH(X) Unit

Set Point High

Heat

Set Point Low

Heat

−045 0.40" 0.20"

−070 0.40" 0.20"

−090 0.45" 0.20"

−110 0.50" 0.20"

−135 0.50" 0.20"

TABLE 9*

4501’ to 7500’

G60UH(X) Unit

Set Point High

Heat

Set Point Low

Heat

−045 0.40" 0.20"

−070 0.40" 0.20"

−090 0.40" 0.20"

−110 0.45" 0.20"

−135 0.45" 0.20"

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

Page 19

TABLE 10*

7501’ to 10,000’

G60UH(X) Unit

Set Point High

Heat

Set Point Low

Heat

−045 0.35" 0.20"

−070 0.35" 0.20"

−090 0.35" 0.20"

−110 0.40" 0.20"

−135 0.40" 0.20"

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

II−PLACEMENT AND INSTALLATION

Make sure unit is installed in accordance with installation instructions and applicable codes.

III−START-UP A−Preliminary and Seasonal Checks

1 − Inspect electrical wiring, both field and factory installed

for loose connections. Tighten as required.

2 − Check voltage at disconnect switch. Voltage must be

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

B−Heating Start-Up

WARNING

Shock and burn hazard.

G60UH(X) units are equipped with a hot surface ignition system. Do not attempt to light manually.

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

this section.

2 − Set the thermostat to the lowest setting.

3 − Turn off all electrical power to the unit. 4 − This furnace is equipped with an ignition device which

automatically lights the burners. Do not try to light the

burners by hand. 5 − Remove the upper access panel. 6 − Honeywell VR8205 Gas Valve − Turn knob on gas

valve clockwise

to OFF. Do not force. See figure

11.

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 instruc-

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

FIGURE 11

HONEYWELL VR8205 Series Gas Valve

GAS VALVE SHOWN IN OFF POSITION

MANIFOLD

PRESSURE

TAP

lOW FIRE

ADJUSTMENT

SCREW

(under cap)

INLET PRESSURE TAP

HIGH FIRE

ADJUSTMENT

SCREW

(under cap)

8 −Honeywell VR8205 Gas Valve − Turn knob on gas valve

counterclockwise

to ON. Do not force. See figure

11.

9 − Replace the upper access panel.

10− Turn on all electrical power to the unit.

11− Set the thermostat to desired setting.

NOTE − When unit is initially started, steps 1 through 11 may need to be repeated to purge air from gas line.

Turning Off Gas To Unit

1 − Set thermostat to lowest setting.

2 − Turn off all electrical power to unit if service is to be per-

formed.

3 − Remove access panel.

4 − Turn knob on Honeywell valve clockwise

to OFF. Do

not force.

5 − Replace access panel.

C−Safety or Emergency Shutdown

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

D−Extended Period Shutdown

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

Page 20

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

All units are C.S.A. (formally A.G.A. and C.G.A. combined) design certified without modifications. Refer to the G60UH(X) Installation Instruction.

B−Gas Piping

CAUTION

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

WARNING

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

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

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

C−Testing Gas Piping

IMPORTANT

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

When pressure testing gas lines, the gas valve must be disconnected and isolated. Gas valves can be damaged if subjected to more than 0.5psig (14" W.C.). See figure 12.

FIGURE 12

MANUAL MAIN SHUT−OFF VALVE

GAS VALVE

CAP

GAS PIPING TEST PROCEDURE

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

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

D−Testing Gas Supply Pressure

When testing supply gas pressure, connect test gauge to inlet pressure tap on the unit gas valve (GV1). See figure

11. Check gas line pressure with unit firing at maximum rate. Low pressure may result in erratic operation or underfire. High pressure can result in permanent damage to gas valve or overfire. See table 11 for operating pressure at unit gas connection (line).

On multiple unit installations, each unit should be checked separately, with and without units operating. Supply pressure must fall within range listed in table 11.

E−Check Manifold Pressure

After line pressure has been checked and adjusted, check manifold pressure. Move pressure gauge to outlet pressure tap located on unit gas valve (GV1). Checks of manifold pressure are made as verification of proper regulator adjustment. Manifold pressure for the G60UH(X) can be measured at any time the gas valve is open and is supplying gas to the unit. See table 11 for normal operating manifold pressure. See HIGH ALTITUDE table (table of contents) for high altitude manifold pressures.

TABLE 11

All G60UHV Units

Natural LP

Line Pressure WC" 4.5 − 10.5 11.0 − 13.0

Manifold Pressure High

Heat WC"

3.5 10.0

Manifold Pressure Low

Heat WC"

1.7 4.9

IMPORTANT

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

Page 21

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

Manifold Adjustment Procedure:

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

valve. See figure 11 for tap location. Start unit and allow

5 minutes for unit to reach steady state.

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

Flame should be stable and should not lift from burner.

Natural gas should burn blue. L.P. gas should burn

mostly blue with some orange streaks.

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

manifold pressure.

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

F− Proper Gas Flow (Approximate)

Furnace should operate at least 5 minutes before checking gas flow. Determine time in seconds for two revolutions of gas through the meter. (Two revolutions assures a more accurate time.) Divide by two and compare to time in table 12 below. If manifold pressure matches table 11 and rate is incorrect, check gas orifices for proper size and restriction.

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

TABLE 12

GAS METER CLOCKING CHART

Seconds for One Revolution

G60UH

Natural LP

G60UH

Unit

1 cu ft

Dial

2 cu ft

Dial

1 cu ft

Dial

2 cu ft

DIAL

−45 82 164 205 410

−70 55 11 0 136 272

−90 41 82 102 204

−110 33 66 82 164

−135 27 54 68 136

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

IMPORTANT

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

G− Proper Combustion

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

TABLE 13 High Heat

Unit

CO2%

For Nat

CO2%

For L.P.

G60UH−24A−045(X) 6.5 − 7.5 7.3 − 8.3

G60UH−24A−070 6.8 − 7.8 8.3 − 9.3

G60UH−36A−070(X) 7.2 − 8.2 8.0 − 9.0

G60UH−48B−070 7.2 − 8.2 8.0 − 9.0

G60UH−36B−090 7.5 − 8.5 8.5 − 9.5

G60UH−48B−090(X) 8.0 − 9.0 8.7 − 9.7

G60UH−36C−110 7.5 − 8.5 8.7 − 9.7

G60UH−48C−110 7.5 − 8.5 8.7 − 9.7

G60UH−60C−110(X) 7.3 − 8.3 8.5 − 9.5

G60UH−60D−135 7.5 − 8.5 8.5 − 9.5

TABLE 14

Low Heat

Unit

CO2%

For Nat

CO2%

For L.P.

G60UH−24A−045(X) 4.0 − 5.0 4.0 − 5.0

G60UH−24A−070 4.2 − 5.2 5.0 − 6.0

G60UH−36A−070(X) 4.2 − 5.2 5.0 − 6.0

G60UH−48B−070 4.2 − 5.2 5.0 − 6.0

G60UH−36B−090 4.7 − 5.7 5.0 − 6.0

G60UH−48B−090(X) 4.8 − 5.8 5.2 − 6.2

G60UH−36C−110 4.5 − 5.5 5.3 − 6.3

G60UH−48C−110 4.7 − 5.7 5.3 − 6.3

G60UH−60C−110(X) 4.5 − 5.5 5.5 − 6.5

G60UH−60D−135 4.7 − 5.7 5.5 − 6.5

Page 22

FIGURE 13

TRANSDUCER

(PART #78H5401)

FIGURE 15

STATIC PRESSURE TEST

Page 22

H−Flame Signal

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

To Measure Flame Signal − Ignition Control:

A transducer (Part #78H5401 available from Lennox Repair Parts) is required to measure flame signal if meter used will not read a low micro amp signal. Seefigure13. The transducer converts microamps to volts on a 1:1 conversion. Flame signal for the SureLight control should read 0.23 or greater microamps with a lockout signal of 0.16 microamps. A digital readout meter must be used. The transducer plugs into most meters. See figure 14 for proper use of transducer.

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

transducer into the VDC and common inputs. Observe correct polarities. Failure to do so results in negative (−) values.

2 − Turn off supply voltage to control.

3 − Disconnect ignition control flame sensor wire from the

flame sensor.

4 − Connect (−) lead of the transducer to flame sensor.

5 − Connect (+) lead of transducer to the ignition control sen-

sor wire.

6 − Turn supply voltage on and close thermostat contacts to

cycle system.

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

reading. Remember 1 DC volt = 1 DC microamp.

SET DIAL TO MEASURE

VDC

(+)

(−) TO

FLAME SENSOR

NOTE−MUST USE DIGITAL METER

RED COLLAR

INDICATES

POSITIVE

LEAD

(+) TO

IGNITION

CONTROL

SENSOR

WIRE

FIGURE 14

(−)

V−TYPICAL OPERATING CHARACTERISTICS A−Blower Operation and Adjustment

1 − Blower operation is dependent on thermostat control

system.

2 − Generally, blower operation is set at thermostat sub-

base fan switch. With fan switch in ON position, blower operates continuously. With fan switch in AUTO position, blower cycles with demand or runs continuously while heating or cooling circuit cycles.

3 − Depending on the type of indoor thermostat, blower

and entire unit will be off when the system switch is in OFF position.

B−Temperature Rise

Temperature rise for G60UH(X) units depends on unit input, blower speed, blower horsepower and static pressure as marked on the unit rating plate. The blower speed must be set for unit operation within the range of TEMP. RISE °F" listed on the unit rating plate.

To Measure Temperature Rise:

1 − Place plenum thermometers in the supply and return air

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

2 − Set thermostat to highest setting.

3 − After plenum thermometers have reached their high-

est and steadiest readings, subtract the two readings. The difference should be in the range listed on the unit rating plate. If the temperature is too low, decrease blower speed. If temperature is too high, first check the firing rate. Provided the firing rate is acceptable, increase blower speed to reduce temperature. To change blower speed taps see the Blower Speed Taps section in this manual.

C−External Static Pressure

1 − Tap locations shown in figure 15.

2 − Punch a 1/4" diameter hole

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

3 − With only the blower motor running and the evaporator

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

4 − External static pressure drop must not be more than

0.5" W.C.

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

Page 23

D−Blower Speed Taps

Blower speed tap changes are made on the SureLight control board. See figure 4. The unused tap must be secured on dummy terminals "PARK " on the SureLight board. The high heating tap is connected to the "HI HEAT " terminal and the low heating / continuous blower tap is connected to the "LO HEAT" terminal. The cooling tap is connected to the COOL" tap. To change existing heat tap, turn off power then switch out speed tap on "HI HEAT" or LO HEAT" with tap connected to "PARK ". See table 15 for blower motor tap colors for each speed.

TABLE 15

VI−MAINTENANCE

WARNING

Disconnect power before servicing unit.

CAUTION

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

At the beginning of each heating season, a qualified technician should check the system as follows:

A−Blower

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

WARNING

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

B−Filters

All 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.

C−Flue And Chimney

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

D−Electrical

1 − Check all wiring for loose connections.

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

operating).

3 − Check amp−draw on the blower motor.

Motor Nameplate__________Actual__________

E−Heat Exchanger and Burners

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

Cleaning the heat exchanger requires a steel spring snake," a reversible drill and a vacuum cleaner. The steel spring snake may be constructed 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.

4 − Remove the collector box located behind the combus-

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

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

then disconnect them.

6 − Remove the four screws securing the burner box cover

and remove the cover.

Page 24

G60UH(X) BURNER & HEAT EXCHANGER REMOVAL

FIGURE 16

HEAT EXCHANGER

BURNER BOX

ASSEMBLY

(−1, −2, −3 units only)

GAS VALVE

ASSEMBLY

GASKET

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

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

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

the NOx insert to the corbel at the entrance to each heat exchanger section. Carefully remove the NOx insert from each section. See figure 17.

9 − 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. 10− Repeat procedure for each heat exchanger section. 11− 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. 12− Remove the cable from the heat exchanger. Use a vac-

uum cleaner to remove debris knocked loose during

cleaning.

NOTE − Safety glasses and surgical mask should

be worn when using vacuum cleaner.

13− 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.

14− 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.

NOx INSERTS

(X models only)

FIGURE 17

NOx INSERT

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

brush attachment over the face of burners. Visually inspect inside the burners and crossovers for any blockage caused by foreign matter. Remove any blockage.

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

bels at the entrance to each heat exchanger opening. See figure 17.

17− Re−install gasket and burner box / manifold assembly

onto the vestibule panel. Replace burner box cover and re−secure using screws.

NOTE − Gasket must be replaced if it was damaged during disassembly.

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

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

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

tion air inducer outlet.

20− Reconnect gas supply piping.

21− Turn on power and gas supply to unit.

22− Set thermostat and check for proper operation.

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

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

CAUTION

Some soaps used for leak detection are corrosive to certain metals. Carefully rinse piping thoroughly after leak test has been completed. Do not use matches, candles, flame or other sources of ignition to check for gas leaks.

24− If a leak is detected, shut gas and electricity off and

repair leak.

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

26− Replace front access panel.

Page 25

VII− Wiring and Sequence of Operation

G60UH−1, −2, −3

Page 26

G60UH−4, −5

Page 27

Sequence of Operation

Sequence depends on type thermostat used. G60UH units are applicable for single stage or two stage thermostats. Both type thermostats are described below. Thermostat jumper E20 dictates which mode unit will operate in. See flow chart for more sequence detail.

SureLight Control Self Check

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

Two−Stage Thermostat, Two Stage Heat. Jumper E20

set at TWO".

1− SureLight control energizes combustion air inducer B6

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

2− SureLight control begins 20 second ignitor warm up

period.

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

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

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

ignitor de−energizes.

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

on low heat speed.

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

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

ond stage recognition period begins.

7− The combustion air inducer ramps up to high heat

speed.

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

energizes second stage heat.

9− B3 indoor blower energizes on high heat speed.

Single−Stage Thermostat, Two Stage Heat. Jumper

E20 set at SINGLE"

1− SureLight control energizes combustion air inducer B6

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

2− SureLight control begins 20 second ignitor warm up

period.

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

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

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

ignitor de−energizes.

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

on low heat speed.

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

stage heat delay period begins.

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

high heat speed.

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

energizes second stage heat.

9− B3 indoor blower energizes on high heat speed.

Page 28

HEATING SEQUENCE OF OPERATION

NORMAL AND ABNORMAL HEATING MODE

CONTROL SELF−CHECK OKAY?

YES

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF. (RESET CONTROL BY

TURNING MAIN POWER OFF.) DS1 ON, DS2 ON

POLARITY REVERSED.

DS1 −− FAST FLASH

DS2 −− SLOW FLASH

POWER ON

POLARITY OKAY?

SIGNAL HOLDS UNTIL UNIT IS PROPERLY GROUNDED.

DS1 AND DS2 ALTERNATING FAST FLASH.

IS THERE A

PROPER GROUND?

IS VOLTAGE

ABOVE 75 VOLTS?

SIGNAL HOLDS UNTIL VOLTAGE RISES ABOVE 75 VOLTS.

DS1 AND DS2 ALTERNATING FAST FLASH.

YES

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF. INDOOR BLOWER OFF. CHECK FOR BROKEN IGNITOR OR OPEN IGNITER CIRCUIT. DS1 AND DS2 ALTERNATING FAST FLASH.

BURNER OFF?

(CONTINUOUS FLAME CHECK)

YES

GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

INDOOR BLOWER ON HEATING SPEED.

DS1 SLOW FLASH, DS2 OFF.

NORMAL OPERATION:

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

THERMOSTAT CALLS FOR HEAT:

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

YES

PRIMARY AND SECONDARY LIMIT

SWITCHES CLOSED?

YES

COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER ON. HAS PRIMARY OR

SECONDARY LIMIT RESET WITHIN 3 MINUTES?

DS1 SLOW FLASH, DS2 ON.

ROLLOUT SWITCH CLOSED?

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

HAS MANUAL ROLLOUT SWITCH(ES) BEEN

RESET (CLOSED) WITHIN 3 MINUTES?

DS1 SLOW FLASH, DS2 ON.

YES

FIRST (LOW) STAGE PRESSURE SWITCH

CONTACTS OPEN?

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

PRESSURE SWITCH IS DETECTED OPEN.

DS1 OFF, DS2 SLOW FLASH.

YES

GAS VALVE OFF.

COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF.

CONTROL WILL NOT ATTEMPT SECOND−STAGE

OPERATION DURING THIS HEAT DEMAND.

FIRST−STAGE OPERATION WILL BE ATTEMPTED.

DS1 OFF, DS2 FAST FLASH.

TWO−STAGE OR SINGLE−STAGE THERMOSTAT

CALL FOR HEAT

COMBUSTION AIR INDUCER ON LOW SPEED.

DS1 AND DS2 SIMULTANEOUS FAST FLASH

CONTINUED ON NEXT PAGE

60−MINUTE LIMIT WATCHGUARD MODE.

GAS VALVE OFF, COMBUSTION AIR INDUCER

OFF, INDOOR BLOWER OFF WITH DELAY.

DS1 AND DS2 ALTERNATING SLOW FLASH.

YES

SECOND (HIGH) STAGE PRESSURE SWITCH

CONTACTS OPEN?

Slow flash rate equals 1Hz (one flash per second). Fast flash rate equals 3 Hz (three flashes per second).

Page 29

HEATING SEQUENCE OF OPERATION

FIRST−STAGE (LOW FIRE) PRESSURE

SWITCH CLOSED WITHIN 2.5 MINUTES?

GAS VALVE OFF. COMBUSTION AIR INDUCER

OFF. INDOOR BLOWER OFF. UNIT WILL RETRY

AFTER 5−MINUTE WAIT PERIOD.

DS1 OFF, DS2 SLOW FLASH.

YES

15−SECOND COMBUSTION AIR INDUCER

PRE−PURGE INITIATED BY CLOSED FIRST−STAGE

PRESSURE SWITCH (or 15 SECOND

INTER−PURGE PERIOD.)

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

IGNITOR WARM−UP (20 SECONDS)

DS1 AND DS2 SIMULTANEOUS FAST FLASH

IS VOLTAGE ABOVE 75 VOLTS?

COMBUSTION AIR INDUCER OFF, IGNITER OFF.

SIGNAL HOLDS UNTIL VOLTAGE RISES ABOVE 75 VOLTS.

DS1 AND DS2 ALTERNATING FAST FLASH.

YES

IS THERE A PROPER GROUND?

COMBUSTION AIR INDUCER OFF, IGNITER OFF.

SIGNAL HOLDS UNTIL UNIT IS PROPERLY GROUNDED.

DS1 AND DS2 ALTERNATING FAST FLASH.

COMBUSTION AIR INDUCER OFF, IGNITOR OFF.

SIGNAL HOLDS UNTIL IGNITOR IS REPLACED

OR RECONNECTED.

DS1 AND DS2 ALTERNATING FAST FLASH.

YES

AT END OF IGNITOR 20 SECOND WARM UP

PERIOD, 4−SECOND TRIAL FOR IGNITION.

GAS VALVE OPENS, IGNITOR ENERGIZED DURING

4−SECOND TRIAL UNTIL FLAME SENSED.

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

YES

4−SECOND FLAME STABILIZATION PERIOD.

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

FLAME RECTIFICATION CURRENT CHECK

CAN FLAME BE PROVEN WITHIN 4

SECONDS AFTER GAS VALVE OPENS?

(u0.16 microamps)

GAS VALVE OFF. COMBUSTION AIR

INDUCER ON. INDOOR BLOWER OFF.

DS1 SLOW FLASH, DS2 FAST FLASHN.

HAS CONTROL FAILED TO SENSE

FLAME FOR FIVE CONSECUTIVE TRIES

DURING A SINGLE HEAT DEMAND?

YES

THERMOSTAT CALLS FOR HEAT

DS1 AND DS2 SIMULTANEOUS FAST FLASH

(Refer to box A on previous page)

YES

FLAME PRESENT?

HAS CONTROL RESET IGNITION SEQUENCE

FOUR (4) TIMES?

DS1 SLOW FLASH, DS2 FAST FLASH.

YES

CONTINUED ON NEXT PAGE

YES

CONTINUED

IS IGNITOR INTACT AND CONNECTED?

WATCHGUARD MODE. GAS VALVE OFF,

COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF.

DS1 AND DS2 ALTERNATING SLOW FLASH.

IS 60−MINUTE RESET PERIOD COMPLETE?

Page 30

HEATING SEQUENCE OF OPERATION

LOW FLAME SIGNAL

(Does not affect control operation)

DS1 SLOW FLASH, DS2 FAST FLASH.

FLAME SIGNAL ABOVE

0.23 microamps)

YES

CONTINUED ON NEXT PAGE

YES

SINGLE−STAGE THERMOSTAT MODE

(E20 SET AT SINGLE")

TWO STAGE THERMOSTAT MODE

(E20 SET AT TWO")

YES

START SECOND−STAGE RECOGNITION

ON DELAY (10 OR 15 MINUTES).

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

45−SECOND INDOOR BLOWER ON DELAY BEGINS.

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

YES

PRIMARY AND SECONDARY LIMITS AND ROLLOUT

SWITCHES CLOSED?

GAS VALVE OFF, COMBUSTION AIR INDUCER OFF, INDOOR BLOWER ON. DS1 SLOW FLASH, DS2 ON.

HAS PRIMARY, SECONDARY OR ROLLOUT

SWITCH CLOSED WITHIN 3 MINUTES?

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

YES

FIRST−STAGE (LOW FIRE)

PRESSURE SWITCH CLOSED?

LIMIT SWITCH WATCHGUARD MODE.

GAS VALVE OFF, COMBUSTION AIR INDUCER OFF,

INDOOR BLOWER OFF WITH DELAY.

DS1 AND DS2 ALTERNATING SLOW FLASH.

IS 60−MINUTE RESET PERIOD COMPLETE?

THERMOSTAT CALLS FOR HEAT.

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

SEE BOX A.

YES

GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

INDOOR BLOWER OFF AFTER DELAY.

DS1 OFF, DS 2 SLOW FLASH.

YES

FIRST−STAGE HEAT DEMAND SATISFIED?

DS1 AND DS2 SIMULTANEOUS SLOW FLASH.

GAS VALVE OFF, COMBUSTION AIR INDUCER

OFF FOLLOWING POST PURGE.

INDOOR BLOWER OFF WITH DELAY

DS1 AND DS2 SIMULTANEOUS SLOW FLASH

YES

SECOND−STAGE HEAT DEMAND.

SECOND−STAGE HEAT DEMAND REQUIRED?

DS1 AND DS2 SIMUTANEOUS SLOW FLASH.

SECOND STAGE PRESSURE SWITCH CLOSED?

ABNORMAL FLASH CODE.

NOTE − IF SECOND−STAGE PRESSURE SWITCH

WAS ORIGINALLY FOUND CLOSED,

ABNORMAL CODE WILL FLASH.

SECOND−STAGE PRESSURE SWITCH CLOSED

AT BEGINNING OF HEAT DEMAND?

DS1 OFF, DS2 SLOW FLASH.

YES

SECOND−STAGE 30−SECOND DELAY ON BEGINS.

DS1 AND DS2 SIMULTANEOUS FAST FLASH

SECOND−STRAGE COMBUSTION AIR INDUCER

ON. SECOND−STAGE GAS VALVE ON. HIGH

HEAT INDOOR BLOWER SPEED ON.

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

YES

SECOND−STAGE PRESSURE SWITCH CLOSED

IN LESS THAN TEN (10) SECONDS?

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

YES

RETURNS TO FIRST−STAGE HEAT MODE WHICH CONTINUES UNTIL SECOND−STAGE PRESSURE

SWITCH CAN BE PROVEN or HEAT DEMAND IS

SATISFIED. FIVE (5) MINUTE WAIT PERIOD

INITIATED BEFORE RETRY. WERE 5 ATTEMPTS

MADE FOR SECOND−STAGE HEAT?

YES

NORMAL OPERATION.

DS1 AND DS2 SIMULTANEOUS SLOW FLASH.

SECOND STAGE HEAT DEMAND

DS1 AND DS2 SIMULTANEOUS SLOW FLASH.

YES

CONTINUED

Page 31

HEATING SEQUENCE OF OPERATION

IS PRIMARY AND SECONDARY LIMIT

AND ROLLOUT SWITCH CLOSED?

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER ON.

DS1 SLOW FLASH, DS2 ON.

HAS PRIMARY, SECONDARY OR ROLLOUT

SWITCH CLOSED WITHIN 3 MINUTES?

LIMIT SWITCH WATCHGUARD MODE. GAS VALVE

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

SEE BOX B

THERMOSTAT CALLS FOR HEAT

DS 1 AND DS 2 SIMULTANEOUS FAST FLASH

YES

FIRST−STAGE (LOW FIRE) HEAT

PRESSURE SWITCH CLOSED?

SEE BOX A

NORMAL OPERATION

DS1 AND DS2 SIMULTANEOUS SLOW FLASH.

YES

GAS VALVE OFF, COMBUSTION AIR INDUCER OFF

AFTER 15 SECOND POST PURGE, INDOOR

BLOWER OFF AFTER DELAY.

DS1 OFF, DS2 FAST FLASH.

RETURN TO HEAT DEMAND?

YES

RETURN TO FIRST−STAGE HEAT MODE.

FIRST−STAGE CONTINUES UNTIL SECOND−

STAGE PRESSURE SWITCH CAN BE PROVEN

or HEAT DEMAND IS SATISFIED. A FIVE (5)

MINUTE WAIT PERIOD IS INITIATED BEFORE

RETRY. WERE 5 ATTEMPTS MADE FOR

SECOND−STAGE HEAT?

YES

SEE BOX C

FIRST−STAGE HEAT DEMAND SATISFIED?

HEAT DEMAND SATISFIED?

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

YES

TWO STAGE THERMOSTAT MODE?

(E20 SET AT TWO")

SINGLE−STAGE THERMOSTAT MODE

(E20 SET AT SINGLE")

YES

HEAT DEMAND SATISFIED?

DS1 AND DS2

SIMULTANEOUS FAST FLASH.

FIRST AND SECOND STAGE HEAT

DEMAND SATISFIED SIMULTANEOUSLY.

DS1 & DS2 SIMULTANEOUS FAST FLASH.

YES

GAS VALVE OFF, COMBUSTION AIR INDUCER OFF AFTER POST PURGE PERIOD, INDOOR BLOWER OFF AF-

TER SELECTED DELAY.

DS1 AND DS2

SIMULTANEOUS FAST FLASH

DEMAND FOR HEAT SATISFIED.

POWER ON STAND BY.

DS1 AND DS2

SIMULTANEOUS SLOW FLASH

YES

SECOND STAGE HEAT

DEMAND SASTISFIED?

DS1 AND DS2

SIMULTANEOUS FAST FLASH.

GAS VALVE, COMBUSTION AIR INDUCER

AND INDOOR BLOWER RETURN TO FIRST−

STAGE OPERATION.

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

YES

FIRST STAGE HEAT DEMAND SATISFIED?

YES

GAS VALVE OFF. COMBUSTION AIR INDUCER

OFF AFTER 5−SECOND POST−PURGE PERIOD.

INDOOR BLOWER OFF. DELAY INITIATED. DS1 & DS2 SIMULTANEOUS FAST FLASH.

CONTINUED

SECOND−STAGE (HIGH FIRE) HEAT

PRESSURE SWITCH CLOSED?

Page 32

COOLING SEQUENCE OF OPERATION

SIGNAL POLARITY REVERSED.

DS1 FAST FLASH, DS2 SLOW FLASH.

POWER ON

YES

IS POLARITY REVERSED?

THERMOSTAT CALLS FOR FIRST−STAGE COOL.

COMPRESSOR AND CONDENSER FAN

ENERGIZED.

IS THERE

PROPER GROUND?

IS LINE VOLTAGE

ABOVE 75 VOLTS?

LOW VOLTAGE SIGNAL AT DS HOLDS

UNTIL LINE VOLTAGE RISES ABOVE 75 VOLTS.

YES

SIGNAL IMPROPER

GROUND AT DS.

SIGNAL HOLDS

UNTIL UNIT IS

PROPERLY

GROUNDED.

INDOOR BLOWER ENERGIZED ON FIRST STAGE

COOL SPEED AFTER 2 SECOND DELAY.

FIRST−STAGE DEMAND FOR COOL SATISFIED?

THERMOSTAT CALLS FOR SECOND−STAGE COOL.

YES

COMPRESSOR AND CONDENSER FAN DE−ENERGIZED.

INDOOR BLOWER DE−ENERGIZED.

YES

INDOOR BLOWER RAMPS UP TO SECOND−STAGE COOL SPEED.

SECOND−STAGE DEMAND FOR COOL SATISFIED?

YES

UNIT RETURNS TO FIRST STAGE COOL

MANUAL FAN SELECTION MADE AT THERMOSTAT.

AFTER 2 SECOND DELAY, INDOOR BLOWER IS

ENERGIZED ON CONTINUOUS FAN SPEED

(LOW HEAT / LOW COOL).

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

YES

BURNERS IGNITE AND INDOOR BLOWER

CONTINUES TO OPERATE IN CONTINUOUS

LOW (LOW HEAT / LOW COOL) MODE.

FIRST−STAGE HEAT DEMAND SATISFIED.

YES

THERMOSTAT CALLS FOR SECOND−STAGE HEAT.

YES

INDOOR BLOWER SWITCHES TO HIGH HEAT SPEED

AFTER 30−SECOND RECOGNITION PERIOD.

SECOND−STAGE HEAT DEMAND SATISFIED.

YES

INDOOR BLOWER RAMPS DOWN TO LOW

HEAT SPEED.

COMPRESSOR IS ENERGIZED AND INDOOR

BLOWER CONTINUES TO OPERATE IN LOW

COOL SPEED.

FIRST−STAGE COOL DEMAND SATISFIED?

YES

SECOND STAGE COOL DEMAND SATISFIED?

INDOOR BLOWER RAMPS TO SECOND

STAGE COOL SPEED

YES

SECOND STAGE COOL DEMAND

INDOOR BLOWER RAMPS DOWN TO FIRST STAGE

COOL SPEED.

YES YES

NOTE − Continuous low speed fan and cooling low speed are equal to the low heat fan speed.

CONTINUOUS LOW SPEED FAN SEQUENCE OF OPERATION

Page 33

VIII− Field Wiring Applications and Jumper Settings

Field Wiring Applications

Jumper Settings (See figure 4)

Thermostat

E20

Term. Strip

Y1 to Y2

Wiring Connections

1 Heat / 1 Cool

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

SINGLE Leave Installed

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

HSXB15

(LSOM)

1 Heat / 2 Cool

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

SINGLE Clip

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

HSXA19

(LSOM)

2 Heat / 2 Cool TWO Clip

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

HSXA19

(LSOM)

2 Heat / 1 Cool TWO Leave Installed

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

HSXB15

(LSOM)

Page 34

Field Wiring Applications (Continued)

Jumper Settings (See figure 4)

Thermostat

E20

Term. Strip

Y1 to Y2

Wiring Connections

FM21 Heat Pump / 1 Cool

SINGLE Leave Installed

CONTROL

TERM. STRIP

FM21

75VA, 24V

TRANSFORMER*

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

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

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

Page 35

IX− Integrated Control Board Troubleshooting Guide

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

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

Condition Possible Cause Corrective Action / Comments

1.1

− Both diagnostic lights fail to light up.

1.1.1

Main voltage 120V not supplied to unit.

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

LED#1−Off LED#2−Off

1.1.2

Miswiring of furnace or improper connections.

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

ACTION 2 − Check 24V wiring to control board.

1.1.3

Circuit breaker tripped or fails to close.

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

1.1.4

Door interlock switch failure.

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

1.1.5

Transformer Failure.

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

1.1.6

Failed control board.

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

1.2

− Diagnostic lights flash the reverse

ag ost c g ts as t e e e se

polarity code.

1.2.1

120V main power polarity reversed.

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

LED#1−Fast Flash, LED#2−Slow Flash.

0 a po e po a ty e e sed

120V field

connection.

1.3

− Diagnostic lights flash the improper

1.3.1

Improper ground to the unit.

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

gg pp

main ground.

1.3.2

Open ignitor circuit.

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

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

1.3.3

Broken or failed ignitor.

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

10.9 and 19.7 ohms, replace the ignitor.

1.3.4

Line voltage is below 75V.

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

Page 36

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

ENERGIZE

Condition Possible Cause Corrective Action / Comments

2.1

− Unit operates with a cooling or contin-

uous fan demand.

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

− Diagnostic lights flash the limit failure

2.1.1

Primary Limit or secondary limit (if

equipped ) or rollout switch open.

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

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

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

mode.

LED#1−Slow Flash, LED#2−On

2.1.2

Miswiring of furnace or improper con-

nections at limit switch(es).

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

2.2

− Unit operates with a cooling and continuous fan demand.

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

− Dia

nostic lights flash the pressure

2.2.1

Miswiring of furnace or improper con-

nections to combustion air inducer.

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

−

Diagnostic lights flash the pressure

switch failure code.

LED#1−Off, LED#2−Slow Flash

2.2.2

Pressure switch stuck closed.

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

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

NOT ENERGIZE

Condition Possible Cause Corrective Action/Comments

3.3

− Unit operates with a cooling and continuous fan demand.

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

− Diagnostic lights flash the pressure

3.3.1

Miswiring of furnace or improper con-

nections to combustion air inducer.

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

switch failure code 2.5 minutes after heating demand.

LED#1−Off, LED#2−Slow Flash

3.3.2

Combustion air inducer failure.

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

Page 37

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

ENERGIZES, IGNITOR IS NOT ENERGIZED.

Condition Possible Cause Corrective Action/Comments

4.1

− Unit operates with a cooling and

continuous fan demand.

− Combustion air inducer energizes

4.1.1

Pressure switch does not close due

to incorrect routing of the pressure

switch line.

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

with a heating demand.

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

4.1.2

Pressure switch does not close due

to obstructions in the pressure switch

line.

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

LED#1−Off LED#2−Slow Flash

4.1.3

Pressure switch line damaged

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

LED#2 Slow Flash

4.1.4

Condensate in pressure switch line.

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

4.1.5

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

the pressure switch.

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

4.1.6

Wrong pressure switch installed in the

unit, or pressure switch is out of cal-

ibration.

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

4.1.7

Miswiring of furnace or improper con-

nections at pressure switch.

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

4.1.8

Pressure switch failure.

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

Page 38

PROBLEM 5: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR BLOWER

ENERGIZES, IGNITOR IS ENERGIZED.

Condition Possible Cause Corrective Action/Comments

5.1

− Unit operates with a cooling and continuous fan demand.

5.1.1

Check that gas is being supplied to

the unit.

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

− Combustion air inducer energizes with Heating demand.

− Ignitor is energized but unit fails to light.

5.1.2

Miswiring of gas valve or loose con-

nections at multi−pin control amp

plugs or valve.

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

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

5.1.3

Defective gas valve or ignition con-

trol.

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

PROBLEM 6: BURNERS LIGHT WITH A HEATING DEMAND BUT UNIT SHUTS DOWN

PREMATURELY

Condition Possible Cause Corrective Action/Comments

6.1

− Burners fire with a heating demand.

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

− Diagnostic lights flash the pressure switch code.

LED#1−Off LED#2−Slow Flash

6.1.1

Low pressure differential at the pres-

sure switch.

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

6.2

− Combustion air inducer energizes with a heating demand.

6.2.1

Sensor or sense wire is improperly

installed.

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

− Burners light but fail to stay lit.

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

6.2.2

Sensor or sense wire is broken.

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

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

ignite code.

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

6.2.3

Sensor or sensor wire is grounded to

the unit.

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

ACTION 3 − Correct any shorts found in circuit.

6.2.4

Control does not sense flame.

ACTION 1 − Check the microamp signal from the burner flame. If the microamp signal is below 0.23 microamps, check the sense rod for proper location or contamination. ACTION 2 − Replace, clean, or relocate flame sense rod. If rod is to be cleaned, use steel wool or replace sensor. DO NOT CLEAN ROD WITH SAND PAPER. SAND PAPER WILL CONTRIBUTE TO THE CONTAMINATION PROBLEM. NOTE: Do not attempt to bend sense rod. ACTION 3 − Check that there is proper ground to burner box. Repair as necessary.

Page 39

PROBLEM 6: BURNERS LIGHT WITH HEATING DEMAND BUT UNIT SHUTS DOWN

PREMATURELY (CONT.)

Condition Possible Cause Corrective Action/Comments

6.3

− Combustion air inducer energizes with a heating demand.

− Burners light.

− Roll−out switch trips during the heating demand.

6.3.1

Unit is firing above 100% of the

nameplate input.

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

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

LED#1−Slow Flash

6.3.2

Gas orifices leak at the manifold con-

nection.

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

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

LED#1 Slow Flash

LED#2−On

6.3.3

Insufficient flow through the heat ex-

changer caused by a sooted or re-

stricted heat exchanger.

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

6.3.4

Burners are not properly located in

the burner box.

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

6.3.5

Poor Venting

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

6.3.6

Improper burner cross−overs

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

6.4

− Combustion air inducer energizes

with a heating demand.

− Burners light roughly and the unit

6.4.1

Poor Venting

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

Burners light roughly and the unit

fails to stay lit.

− Diagnostic lights flash watchguard flame failure.

6.4.2

Improper burner cross−overs

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

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

6.4.3

Burrs in gas orifices

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

Page 40

PROBLEM 6: BURNERS LIGHT WITH HEATING DEMAND BUT UNIT SHUTS DOWN

PREMATURELY (CONT.)

6.5

− Combustion air inducer energizes with a heating demand.

− Burners light.

− Dia

nostic lights flash watch guard

6.5.1

Loose sensor wire connection causes

intermittent loss of flame signal.

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

−

Diagnostic lights flash watch guard

flame failure.

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

6.5.2

Poor ground to burner box

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

erm

ittent

nature of sensor signal.

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

6.5.3

Prove Switch opens 5 times during a

single demand

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

ACTION 2 − Check prove switch reliability.

PROBLEM 7: CONTROL SIGNALS LOW FLAME SENSE DURING HEATING MODE

Condition Possible Cause Corrective Action/Comments

7.0

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

7.1.1

Sense rod is improperly located on

the burner.

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

code

LED#1−Slow Flash LED#2−Fast Flash

7.1.2

Sense rod is contaminated.

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

PROBLEM 8: INDOOR BLOWER FAILS TO OPERATE IN COOLING, HEATING, OR CONTINUOUS

FAN MODE

Condition Possible Cause Corrective Action/Comments

8.0

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

8.1.1

Miswiring of furnace or improper con-

nections at control or indoor blower

motor.

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

8.1.2

120V is not being supplied to the in-

door air blower or blower motor fail-

ure.

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

8.1.3

Defective control board

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

8.1.4

Defective run capacitor

ACTION 1 − Replace capacitor

Lennox G60UH, G60UHX, G60UH−24A−045, G60UH−24A−070, G60UH−36A−070 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual