Lennox G60UHV, G60UHVX Service Manual

Page 1

Corp. 0124−L11

G60UHV(X)

Service Literature

Revised 1−2009

G60UHV(X) SERIES UNITS

G60UHV(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 66,000 to 132,000 Btuh and cooling applications up to 5 tons. Refer to Engineering Handbook for proper sizing.

Units are factory equipped for use with natural gas. Kits are available for conversion to LPG operation. 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 Page 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications Page 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blower Data Page 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High Altitude Page 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I Unit Components Page 9. . . . . . . . . . . . . . . . . . . . . . . .

II Installation Page 32. . . . . . . . . . . . . . . . . . . . . . . . . . . .

III Start Up Page 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IV Heating System Service Checks Page 33. . . . . . . . .

V Typical Operating Characteristics Page 35. . . . . . . . .

VI Maintenance Page 36. . . . . . . . . . . . . . . . . . . . . . . . . .

VII Wiring and Sequence of Operation Page 38. . . . . .

VIII Field Wiring and Jumper Settings Page 53. . . . . . .

IX Troubleshooting Page 58. . . . . . . . . . . . . . . . . . . . . . .

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. G60UHV−36A−070 G60UHV−36B−090 G60UHV−60C−090

Low NOx Model No. G60UHV−36A−070X − − − G60UHV−60C−090X

Input− Btuh (kW) low fire 45,000 (13.2) 60,000 (17.6) 60,000 (17.6)

Output− Btuh (kW) low fire 36,000 (10.5) 48,000 (14.1) 48,000 (14.1)

Input− Btuh (kW) high fire 66,000 (19.3) 88,000 (5.8) 88,000 (25.8)

Output− Btuh (kW) high fire 54,000 (15.8) 72,000 (21.0) 72,000 (21.1)

AFUE 80.0% 80.0% 80.0%

California Seasonal Efficiency 77.2% 77.1% 76.8%

Highstatic(CSA)− in.w.g. (Pa) .80 (200) .80 (200) .80 (200)

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)

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

Temperature rise range − F (C) high fire 40 − 70 (22 − 39) 40 − 70 (22 − 39) 30 − 60 (17 − 33)

Indoor Blower

Wheelnominaldiameter xwidth −in. (mm) 10 x 8 (254 x 203) 10 x 8 (254 x 203) 11−1/2 x 10 (292 x 254)

Motoroutput − hp (W) 1/2 (373) 1/2 (373) 1 (746)

Tons(kW) ofadd-oncooling 2 − 3 (7.0 − 10.6) 2 − 3 (7.0 − 10.6) 4 − 5 (14.1 − 17.6)

Shippingweight − 1 package 137 (62) 154 (70) 172 (78)

Matching Coils Up−flow cased C33−18A−2F,

C33−24A−2F, C33−30A−2F, C33−36A−2F,

C33−38A−2F

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 CH33−18A−2F,

CH33−24/30A−2F,

CH33−36A−2F

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) 87L95 − (1) 14 x 25 x 1 in.

(356 x 635 x 25 mm)

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 Base Catalog Number − Shipping Weight 73P55 − 6 lbs. (3 kg) 73P56 − 7 lbs. (3 kg) 73P57 − 8 lbs. (4 kg)

Dimensions − H x W x D 4 x 14−1/4 x 28−5/8 in.

(102 x 362 x 727 mm)

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

635 x 25 mm)

16 x 25 x 1 in. (406 x

635 x 25 mm)

20 x 25 x 1 in. (508 x

635 x25 mm)

CCB1 Efficiency Plust Humidity Control System 35H00 35H00 35H00

High Altitude Pressure Switch Kit See Page 7

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

LPG/Propane Kit See Page 7

RAB Return Air Base − − − − − − RAB60C (12M71)

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

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.  Not for use with RAB Return Air Base or with 60C and 60D size units with 2nd stage heating air flow requirements of 1800 cfm (850 L/s) or greater. See Blower Performance

Tables for additional information.

Page 3

SPECIFICATIONS

Gas Heating Performance

ModelNo. G60UHV−60C−110 G60UHV−60D−135

Low NOx Model No. G60UHV−60C−110X − − −

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

Output− Btuh (kW) low fire 60,000 (17.6) 72,000 (21.1)

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

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

AFUE 80.0% 80.0%

California Seasonal Efficiency 77.2% 77.5%

Highstatic(CSA)− in.w.g. (Pa) .80 (200) .80 (200)

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

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

Temperature rise range − F (C) low fire 25 − 55 (14 − 31) 25 − 55 (14 − 31)

Temperature rise range − F (C) high fire 35 − 65 (19 − 36) 45 − 75 (25 − 42)

Indoor Blower

Wheelnominaldiameter xwidth −in. (mm) 11−1/2 x 10 (292 x 254) 11−1/2 x 10 (292 x 254)

Motoroutput − hp (W) 1 (746) 1 (746)

Tons(kW) ofadd-oncooling 4 − 5 (14.1 − 17.6) 4 − 5 (14.1 − 17.6)

Shippingweight − 1 package 184 (83) 198 (90)

Matching Coils

Up−flow cased

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

CH33−60D−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)

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

(1) 24 x 24 x 1 in. (610 x 610 x 25

mm)

CCB1 Efficiency Plust Humidity Control System 35H00 35H00

High Altitude Pressure Switch Kit See Page 7

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

LPG/Propane Kit See Page 7

RAB Return Air Base RAB60C (12M71) RAB60D (12M72)

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

 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 2nd stage heating air flow requirements of 1800 cfm (850 L/s) or greater. See Blower Performance Tables for additional information.

Page 4

BLOWER DATA

G60UHV−36A−070 BLOWER PERFORMANCE

0 through 0.80 in. w.g. (0 Through 200 Pa) External Static Pressure Range

Blower Control Factory Settings ADJUST − NORM

HEAT − 2 COOL − 4

ADJUST"

Switch

Positions

Speed Switch Positions

2nd Stage HEAT" Speed 2nd Stage COOL" Speed

1 2 3 4 1 2 3 4

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

+" (Plus) 910 430 1055 495 1305 615 1350 635 1045 495 1230 580 1315 620 1420 670

NORM (Normal) 830 390 940 445 1165 550 1215 575 945 445 1100 520 1190 560 1300 615

" (Minus) 745 350 845 400 1030 485 1070 505 850 400 975 460 1035 485 1130 535

ADJUST"

Switch

Positions

1st Stage HEAT" Speed 1st Stage COOL" Speed

1 2 3 4 1 2 3 4

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

+" (Plus) 840 395 965 455 1195 565 1235 585 730 344 800 377 860 405 994 469

NORM (Normal) 765 360 865 410 1055 495 1105 520 680 320 745 351 780 368 850 401

" (Minus) 700 330 785 370 955 450 985 465 620 292 685 323 725 342 760 358

NOTES − The effect of static pressure and filter resistance is included in air volumes shown.

1st stage HEAT is approximately 91% of the same 2nd stage

HEAT speed position.

1st stage COOL (two speed air conditioning units only) is approximately 70% (65% for units built prior to 09−2002) of the same 2nd stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same 2nd stage COOL speed position − minimum 500 cfm (235 L/s). Lennox Harmony II zone control applications − Minimum blower heating speed is approximately 75% of the 1st stage HEAT speed position. Lennox Harmony II zone control applications − Minimum blower cooling speed is approximately 45% of the 2nd stage COOL speed position.

G60UHV−36B−090 BLOWER PERFORMANCE

0 through 0.80 in. w.g. (0 Through 200 Pa) External Static Pressure Range

Blower Control Factory Settings ADJUST − NORM

HEAT − 2 COOL − 4

ADJUST"

Switch

Positions

Speed Switch Positions

2nd Stage HEAT" Speed 2nd Stage COOL" Speed

1 2 3 4 1 2 3 4

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

+" (Plus) N/A N/A 1035 490 1280 605 1335 630 1010 475 1175 555 1275 600 1400 660

NORM (Normal) N/A N/A 930 440 1150 540 1190 560 935 440 1055 495 1130 535 1250 590

" (Minus) N/A N/A 830 390 1020 480 1050 495 830 390 940 445 1005 475 1090 515

ADJUST"

Switch

Positions

1st Stage HEAT" Speed 1st Stage COOL" Speed

1 2 3 4 1 2 3 4

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

+" (Plus) N/A N/A 935 440 1150 540 1195 565 740 349 800 377 850 401 910 429

NORM (Normal) N/A N/A 840 395 1035 490 1070 505 675 318 740 349 780 368 845 398

" (Minus) N/A N/A 755 355 930 440 965 455 615 290 690 325 715 337 750 353

NOTES − The effect of static pressure and filter resistance is included in air volumes shown.

1st stage HEAT is approximately 91% of the same 2nd stage HEAT speed position. 1st stage COOL (two speed air conditioning units only) is approximately 70% (65% for units built prior to 09−2002) of the same 2nd stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same 2nd stage COOL speed position − minimum 500 cfm (235 L/s). Lennox Harmony II zone control applications − Minimum blower heating speed is approximately 75% of the 1st stage HEAT speed position. Lennox Harmony II zone control applications − Minimum blower cooling speed is approximately 45% of the 2nd stage COOL speed position. N/A − 1st stage HEAT, speed position 1, cannot be used with this model.

G60UHV−60C−090 BLOWER PERFORMANCE

0 through 0.80 in. w.g. (0 Through 200 Pa) External Static Pressure Range

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

Blower Control Factory Settings ADJUST − NORM

HEAT − 2 COOL − 4

ADJUST"

Switch

Positions

Speed Switch Positions

2nd Stage HEAT" Speed 2nd Stage COOL" Speed

1 2 3 4 1 2 3 4

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

+" (Plus) 1525 720 1715 810 1935 915 2125 1005 1630 770 1760 830 1960 925 2185 1030

NORM (Normal) 1385 655 1560 735 1760 830 1930 910 1480 700 1600 755 1785 840 1985 935

" (Minus) 1245 590 1400 660 1580 745 1740 820 1335 630 1440 680 1605 755 1785 845

ADJUST"

Switch

Positions

1st Stage HEAT" Speed 1st Stage COOL" Speed

1 2 3 4 1 2 3 4

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

+" (Plus) 1395 660 1580 745 1780 840 1960 925 1120 528 1200 566 1370 646 1550 731

NORM (Normal) 1265 595 1440 680 1615 760 1780 840 1000 471 1100 519 1250 589 1375 648

" (Minus) 1140 540 1295 610 1465 690 1605 755 900 424 975 460 1120 528 1230 580

NOTES − The effect of static pressure and filter resistance is included in air volumes shown.

1st stage HEAT is approximately 91% of the same 2nd stage HEAT speed position. 1st stage COOL (two speed air conditioning units only) is approximately 70% (60% for units built prior to 09−2002) of the same 2nd stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same 2nd stage COOL speed position. Lennox Harmony II zone control applications − Minimum blower heating speed is approximately 75% of the 1st stage HEAT speed position. Lennox Harmony II zone control applications − Minimum blower cooling speed is approximately 42% of the 2nd stage COOL speed position.

Page 5

BLOWER DATA

G60UHV−60C−090 BLOWER PERFORMANCE

0 through 0.80 in. w.g. (0 Through 200 Pa) External Static Pressure Range

Single Side Return Air − Air volumes in bold require field fabricated transition to accommodate 20 x 25 x 1 in. (508 x 635 x 25 mm) cleanable air filter in order to maintain proper air velocity across the filter.

Blower Control Factory Settings ADJUST − NORM

HEAT − 2 COOL − 4

ADJUST"

Switch

Positions

Speed Switch Positions

2nd Stage HEAT" Speed 2nd Stage COOL" Speed

1 2 3 4 1 2 3 4

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

+" (Plus) 1475 695 1665 785 1870 880 2050 965 1580 745 1700 800 1920 905 2110 995

NORM (Normal) 1340 630 1515 715 1700 800 1865 880 1435 675 1545 730 1745 825 1920 905

" (Minus) 1205 570 1365 645 1530 720 1680 790 1290 610 1390 655 1570 740 1730 815

ADJUST"

Switch

Positions

1st Stage HEAT" Speed 1st Stage COOL" Speed

1 2 3 4 1 2 3 4

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

+" (Plus) 1355 640 1535 725 1710 805 1890 890 1070 504 1160 547 1325 625 1490 703

NORM (Normal) 1230 580 1395 660 1555 735 1720 810 955 450 1060 500 1210 570 1325 625

" (Minus) 1105 520 1255 590 1400 660 1550 730 860 405 935 441 1085 512 1185 559

NOTES − The effect of static pressure and filter resistance is included in air volumes shown.

G60UHV−60C−110 BLOWER PERFORMANCE

0 through 0.80 in. w.g. (0 Through 200 Pa) External Static Pressure Range

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

Blower Control Factory Settings ADJUST − NORM

HEAT − 2 COOL − 4

ADJUST"

Switch

Positions

Speed Switch Positions

2nd Stage HEAT" Speed 2nd Stage COOL" Speed

1 2 3 4 1 2 3 4

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

+" (Plus) 1485 700 1695 800 1910 900 2130 1005 1630 770 1750 825 1980 935 2185 1030

NORM (Normal) 1350 635 1540 730 1735 820 1935 915 1480 700 1590 750 1800 850 1985 940

" (Minus) 1215 575 1390 655 1560 735 1740 820 1335 630 1435 675 1620 765 1790 845

ADJUST"

Switch

Positions

1st Stage HEAT" Speed 1st Stage COOL" Speed

1 2 3 4 1 2 3 4

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

+" (Plus) 1365 645 1550 730 1735 820 1925 910 1080 509 1075 507 1315 620 1445 681

NORM (Normal) 1240 585 1410 665 1575 745 1750 825 990 467 1050 495 1195 563 1315 620

" (Minus) 1115 525 1270 600 1420 670 1575 745 890 419 940 443 1075 507 1195 563

NOTES − The effect of static pressure and filter resistance is included in air volumes shown.

Page 6

BLOWER DATA

G60UHV−60C−110 BLOWER PERFORMANCE

0 through 0.80 in. w.g. (0 Through 200 Pa) External Static Pressure Range

Blower Control Factory Settings ADJUST − NORM

HEAT − 2 COOL − 4

ADJUST"

Switch

Positions

Speed Switch Positions

2nd Stage HEAT" Speed 2nd Stage COOL" Speed

1 2 3 4 1 2 3 4

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

+" (Plus) 1430 675 1615 765 1835 865 2040 965 1530 720 1660 785 1875 885 2100 990

NORM (Normal) 1300 615 1470 695 1665 785 1855 875 1390 655 1510 715 1705 805 1910 900

" (Minus) 1170 550 1325 625 1500 710 1670 790 1250 590 1360 640 1535 725 1720 810

ADJUST"

Switch

Positions

1st Stage HEAT" Speed 1st Stage COOL" Speed

1 2 3 4 1 2 3 4

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

+" (Plus) 1305 615 1480 700 1680 790 1865 880 965 455 1060 500 1205 568 1345 634

NORM (Normal) 1185 560 1345 635 1525 720 1695 800 885 417 965 455 995 469 1225 578

" (Minus) 1065 505 1210 570 1375 650 1525 720 795 375 875 412 985 464 111 5 526

NOTES − The effect of static pressure and filter resistance is included in air volumes shown.

G60UHV−60D−135 BLOWER PERFORMANCE

0 through 0.80 in. w.g. (0 Through 200 Pa) External Static Pressure Range

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

Blower Control Factory Settings ADJUST − NORM

HEAT − 2 COOL − 4

ADJUST"

Switch

Positions

Speed Switch Positions

2nd Stage HEAT" Speed 2nd Stage COOL" Speed

1 2 3 4 1 2 3 4

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

+" (Plus) 1520 715 1725 815 1940 915 2130 1005 1630 770 1760 830 1985 935 2200 1040

NORM (Normal) 1385 655 1570 740 1765 835 1940 915 1480 700 1600 755 1805 850 2000 945

" (Minus) N/A N/A 1410 665 1590 750 1745 825 1335 630 1440 680 1625 765 1800 850

ADJUST"

Switch

Positions

1st Stage HEAT" Speed 1st Stage COOL" Speed

1 2 3 4 1 2 3 4

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

+" (Plus) 1395 660 1580 745 1760 830 1960 925 1090 514 1170 552 1315 620 1450 684

NORM (Normal) 1265 595 1435 675 1600 755 1785 840 995 469 1060 500 1200 566 1320 622

" (Minus) N/A N/A 1295 610 1440 680 1605 755 895 422 950 448 1080 509 1200 566

NOTES − The effect of static pressure and filter resistance is included in air volumes shown.

1st stage HEAT is approximately 91% of the same 2nd stage HEAT speed position. 1st stage COOL (two speed air conditioning units only) is approximately 70% (65% for units built prior to 09−2009) of the same 2nd stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same 2nd stage COOL speed position. Lennox Harmony II zone control applications − Minimum blower heating speed is approximately 75% of the 1st stage HEAT speed position. Lennox Harmony II zone control applications − Minimum blower cooling speed is approximately 45% of the 2nd stage COOL speed position. N/A − 1st stage HEAT, speed position 1 with " (Minus) Adjust" setting, cannot be used with this model.

Page 7

BLOWER DATA

G60UHV−60D−135 BLOWER PERFORMANCE

0 through 0.80 in. w.g. (0 Through 200 Pa) External Static Pressure Range

Blower Control Factory Settings ADJUST − NORM

HEAT − 2 COOL − 4

ADJUST"

Switch

Positions

Speed Switch Positions

2nd Stage HEAT" Speed 2nd Stage COOL" Speed

1 2 3 4 1 2 3 4

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

+" (Plus) 1415 665 1625 765 1820 860 2015 950 1525 720 1650 780 1875 885 2095 990

NORM (Normal) 1285 605 1475 695 1655 780 1830 865 1385 655 1500 710 1705 805 1905 900

" (Minus) N/A N/A 1330 625 1490 705 1645 775 1245 590 1350 635 1535 725 1715 810

ADJUST"

Switch

Positions

1st Stage HEAT" Speed 1st Stage COOL" Speed

1 2 3 4 1 2 3 4

cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s

+" (Plus) 1300 615 1480 700 1660 785 1850 875 965 455 1070 504 1215 573 1345 634

NORM (Normal) 1180 555 1345 635 1510 715 1680 795 885 417 975 460 1105 521 1225 578

" (Minus) N/A N/A 1210 570 1360 640 1510 715 795 375 870 410 995 469 111 5 526

NOTES − The effect of static pressure and filter resistance is included in air volumes shown.

1st stage HEAT is approximately 91% of the same 2nd stage HEAT speed position. 1st stage COOL (two speed air conditioning units only) is approximately 70% (65% for units built prior to 09−2002) of the same 2nd stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same 2nd stage COOL speed position. Lennox Harmony II zone control applications − Minimum blower heating speed is approximately 75% of the 1st stage HEAT speed position. Lennox Harmony II zone control applications − Minimum blower cooling speed is approximately 45% of the 2nd stage COOL speed position. N/A − 1st stage HEAT, speed position 1 with " (Minus) Adjust" setting, cannot be used with this model.

FILTER AIR RESISTANCE

cfm L/s in. w.g. Pa

0 0 0.00 0

200 95 0.01 0

400 190 0.03 5

600 285 0.04 10

800 380 0.06 15

1000 470 0.09 20

1200 565 0.12 30

1400 660 0.15 35

1600 755 0.19 45

1800 850 0.23 55

2000 945 0.27 65

2200 1040 0.33 80

2400 1130 0.38 95

2600 1225 0.44 110

HIGH ALTITUDE

Model

Input

Size

Gas

Altitude

Manifold Pressure

at all altitudes

0 − 4500 ft.

(0 − 1372 m)

4,501 − 7500 ft.

(1373 − 2286 m)

7501−10,000 ft.

(2286 − 3048 m)

Required

Conversion

Kit

Pressure

Switch

Required

Conversion

Kit

Pressure

Switch

Required

Conversion

Kit

Pressure

Switch

Low Fire High Fire

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

070−1 to −6

Nat. N/A No Change N/A No Change 59M16 18M64 1.7 0.42 3.5 0.87

LPG 59M13 No Change 59M13 No Change 59M14 18M64 4.9 1.22 10.0 2.5

090−1 to −6

Nat. N/A No Change N/A 18M61 59M16 18M64 1.7 0.42 3.5 0.87

LPG 59M13 No Change 59M13 18M61 59M14 18M64 4.9 1.22 10.0 2.5

110/135−1 to

−6

Nat. N/A No Change N/A 18M63 59M16 18M61 1.7 0.42 3.5 0.87

LPG 59M13 No Change 59M13 18M63 59M14 18M61 4.9 1.22 10.0 2.5

070−7 and

later

Nat. N/A No Change N/A No Change 59M17 18M64 1.7 0.42 3.5 0.87

LPG 59M13 No Change 59M13 No Change 59M14 18M64 4.9 1.22 10.0 2.5

090−7 and

later

Nat. N/A No Change N/A 18M61 59M17 18M64 1.7 0.42 3.5 0.87

LPG 59M13 No Change 59M13 18M61 59M14 18M64 4.9 1.22 10.0 2.5

110/135−7

and later

Nat. N/A No Change N/A 18M63 59M17 18M61 1.7 0.42 3.5 0.87

LPG 59M13 No Change 59M13 18M63 59M14 18M61 4.9 1.22 10.0 2.5

Pressure switch is factory set. No adjustment necessary. All models use the factory installed pressure switch from 0−4500 feet (0−1370 m).

Page 8

FIGURE 1

Flue

Transition

Combustion Air Inducer

Combustion Air

Orifice

Combustion Air

Prove Switch Assembly

(two switches)

Flue

Collector

Box

Heat Exchanger

Flame Sensor

Gas Valve

Burners

Ignitor

Insert

Primary

Limit

Door Interlock Switch

SureLight Two−Stage,

Variable Speed

Integrated Control Board

Control Transformer

Circuit Breaker

Gasket

Flue Box Gasket

Gas

Orifices

Ignitor

Bracket

Burner Box Bottom

Limit Shield

Secondary Limit(s)

(NOx Units Only)

Air Deflector

G60UH−60C−110

Units Only

Variable Speed

Blower Motor

Flame Rollout Switches

Air Intake

Cover

Air Baffle

Gasket

Burner

Box Cover

Power Choke

(1 hp Only)

Sight

Glass

Burner

Box Top

G60UHV(X) PARTS ARRANGEMENT

Page 9

I−UNIT COMPONENTS

G60UHV(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. G60UHV(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 G60UHV(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) Boards 18M99 and 49M59

All G60UHV units are equipped with the Lennox two− stage, variable speed integrated SureLight control board. The system consists of a ignition / blower control board (figure 4 with control terminal designations in tables 1 through 4) and ignitor (figure 12). The board and ignitor work in combination to ensure furnace ignition and ignitor durability. The SureLight integrated board controls all major furnace operations. The board features two LED lights, DS1 and DS2 for troubleshooting and four LED lights (DS3, DS6, DS7 and DS8) to show furnace status. The board also has two accessory terminals rated at (1) one amp each. See table 5 for status code and table 6 for troubleshooting diagnostic codes.

Electronic Ignition

At the beginning of the heat cycle the SureLight control monitors the first stage and second stage combustion air inducer prove switch. The control will not begin the heating cycle if the first stage prove switch is closed (by−passed). Likewise the control will not begin the second stage heating cycle if the second stage prove switch is closed, and will remain in first stage heat. However, if the second stage prove switch closes during the first stage heat pre−purge, the control will allow second stage heat. Once the first stage prove switch is determined to be open, the combustion air inducer is energized on low (first stage) heat speed. When the differential in the prove switch is great enough, the prove switch closes and a 15−second pre−purge begins. If the switch is not proven within 2−1/2 minutes, the control goes into Watchguard−Pressure Switch mode for a 5−minute re− set period.

Page 10

After the 15−second pre−purge period, the SureLight ignitor warms up for 20 seconds after which the gas valve opens for a 4−second trial for ignition. The ignitor energizes during the trial until flame is sensed. If ignition is not proved during the 4−second period, the control will try four more times with an inter purge and warm−up time between trials of 35 seconds. After a total of five trials for ignition (including the initial trial), the control goes into Watchguard−Flame Failure mode. After a 60−minute reset period, the control will begin the ignition sequence again. The SureLight control board has an added feature that prolongs the life of the ignitor. After a successful ignition, the SureLight control utilizes less power to energize the ignitor on successive calls for heat. The control continues to ramp down the voltage to the ignitor until it finds the lowest amount of power that will provide a successful ignition. This amount of power is used for 255 cycles. On the 256th call for heat, the control will again ramp down until the lowest power is determined and the cycle begins again.

Two Stage Operation / Thermostat Selection Jumper

The control can be utilized in two modes: SINGLE−STAGE thermostat or TWO−STAGE thermostat. The thermostat selection jumper E20, located just below dip switches 1 through 3 (figure 4), must be positioned for the particular application. The jumper is factory set on TWO" for use with a two−stage thermostat with two stage heat. Re−position jumper to SINGLE" for use with a single stage thermostat with two stage heat. While in the single−stage thermostat mode (single jumper setting), the burners will always fire on first−stage heat. The combustion air inducer will operate on low speed and indoor blower will operate on low heat speed. After a 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 an first stage heat and switch to second stage heat after 30 seconds of operation. See Sequence of Operation flow charts in the back of this manual for more detail.

TW0−STAGE, VARIABLE SPEED INTEGRATED

CONTROL BOARD

FIGURE 4

DIP

SWITCHES

1 − 3

DIP

SWITCHES

5 − 12

DIAGNOSTIC

LEDs

ON−BOARD

JUMPER W951

(cut when heat pump

is used with FM21)

ON−BOARD

JUMPER W914

(cut when SignatureStat,

CCB1 or Harmony II are used)

LEDs

LED

FACTORY−

INSTALLED

JUMPER

THERMOSTAT CONNECTIONS (TB1)

DIP SWITCH FUNCTIONS

DIP SWITCH(ES) FUNCTION

1 and 2 Blower Off Delay

3 Second Stage ON Delay (Single−stage t’stat) 4 Not used

5 and 6 Cooling Mode Blower Speed 7 and 8 Blower Speed Adjustment

9 and 10 Cooling Mode Blower Ramping Profile

11 and 12 Heating Mode Blower Speed

E20

JUMPER

16 PIN BLOWER

CONTROL TERMINALS

DS8

DS7

DS3

DS6

Page 11

TABLE 1

Two Stage Ignition / Blower Control Terminals

LINE Line 120VAC Neutral

XFMR Transformer 120VAC Neutral

EAC Electronic Air Cleaner 120VAC Neutral

CIRC Indoor Blower 120VAC Neutral

HUM Humidifier 120VAC Neutral

HUM Humidifier 120VAC Hot

XMFR Transformer 120VAC Hot

LINE Line 120VAC Hot

CIRC Indoor Blower 120VAC Hot

EAC Electronic Air Cleaner 120VAC Hot

TABLE 2

SureLight Board 5 Pin Terminal Designation

PIN # Function

1 Ignitor

2 Combustion Air Inducer High Speed

3 Combustion Air Inducer Low Speed

4 Combustion Air Inducer Neutral

5 Ignitor Neutral

TABLE 3

SureLight Board 12Pin Terminal Designation

PIN # Function

1 Gas Valve High Fire

2 Second Stage Pressure Switch

3 Not Used

4 Ground

5 24V Hot

6 Primary Limit In

7 Gas Valve Low Stage

8 Gas Valve Common

9 24V Neutral

10 Ground

11 Primary Limit Out

12 1st Stage Pressure Switch

TABLE 4

SureLight Board 16 Pin Blower Control Terminals

PIN # Function

1 Ground

2 Low Heat Speed

3 Ground

4 DELAY" Dip Switch Selection

5 COOL" Dip Switch Selection

6 Y1" Signal

7 ADJUST" Dip Switch Selection

8 Ground

9 0" From Thermostat

10 DS" Output Signal

11 HEAT" Dip Switch Selection

12 24 VAC

13 HIGH HEAT Speed

14 Y2" Signal

15 G"

16 CFM LED

Page 12

TABLE 5

STATUS CODES

STATUS LED COLOR FUNCTION

DS3

ON / OFF ’

GREEN

DS3−ON indicates that the motor has a demand to operate. (This LED must be on in all modes).

DS6

CFM"

GREEN

DS6−blinking indicates the airflow (CFM) demand in the motor. The air flow is determine by counting blinks between two (2) second pauses. One blink equals roughly 100 CFM.

DS7

HI / LO"

YELLOW

DS7−ON indicaties the DS to R" jumper has not been cut. When the jumper is cut the system will be operating with LENNOX HARMONY II (See Harmony Installation Instructions) or with the CCB1 Efficiency Plus control. CCB1: When ON, a 24 VAC is being applied and when OFF, it has been removed. This on/off operation varies the indoor blower’s performance so dehumidification can be enhanced.

DS8

HEAT"

YELLOW DS8−ON indicates the sytem is in HEAT mode.

TABLE 6

DIAGNOSTIC CODES

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

DS1 DS2 DESCRIPTION

SIMULTANEOUS

SLOW FLASH

SIMULTANEOUS

SLOW FLASH

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

SIMULTANEOUS

FAST FLASH

SIMULTANEOUS

FAST FLASH

Normal operation − signaled when heating demand initiated at thermostat.

SLOW FLASH ON

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

OFF SLOW FLASH

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

OFF FAST FLASH

High prove switch open; OR: Blocked inlet/exhaust vent; OR: High prove 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 prove switch opened 5 times in one heating cycle.

SLOW FLASH OFF Flame sensed without gas valve energized.

ON ON

OFF

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 − .22 microAmps.

Page 13

Dip Switch Settings Switches 1 and 2 −− Blower Off Delay −− The blower−on

delay of 45 seconds is not adjustable. The blower−off delay (time that the blower operates after the heating demand has been satisfied) can be adjusted by moving switches 1 and 2 on the integrated control board. The unit is shipped from the factory with a blower−off delay of 90 seconds. The blower off delay affects comfort and is adjustable to satisfy individual applications. Adjust the blower off delay to achieve a supply air temperature between 90° and 110°F at the exact moment that the blower is de−energized. Longer off delay settings provide lower supply air temperatures; shorter settings provide higher supply air temperatures.The table below provides the blower off timings that will result from different switch settings.

TABLE 7

Blower Off Delay Switch Settings

Blower Off Delay

(Seconds)

Switch 1 Switch 2

60 Off Off

90 Off On 120 On Off 180 On On

Switch 3 −− Second Stage Delay (Used with Single− Stage Thermostat Only) −− This switch is used to deter-

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

Switch 4 −− Not used in G60UHV application.

Switches 5 and 6 −− Cooling Mode Blower Speed −−

Switches 5 and 6 are used to select cooling blower motor speed. The unit is shipped from the factory with the dip switches positioned for high speed (4) indoor blower motor operation during the cooling mode. The table below provides the cooling mode blower speeds that will result from different switch settings. Refer to blower data tables at the front of this manual for corresponding cfm values.

TABLE 8

Cooling Mode Blower Speeds

Speed

Switch 5 Switch 6

1 − Low On On 2 − Medium Low Off On 3 − Medium High On Off

4 − High (Factory) Off Off

Switches 7 and 8 −− Blower Speed Adjustment −−

Switches 7 and 8 are used to select blower speed adjustment settings. The unit is shipped from the factory with the dip switches positioned for NORMAL (no) adjustment. The dip switches may be positioned to adjust the blower speed by +10% or −10% to better suit the application. The table below provides blower speed adjustments that will result from different switch settings. Refer to blower data tables at the front of this manual for corresponding cfm values.

TABLE 9

Blower Speed Adjustment

Adjustment

Switch 7 Switch 8

+10% (approx.) On Off

NORMAL (Factory) Off Off

−10% (approx.) Off On

Switches 9 and 10 −− Cooling Mode Blower Speed Ramping −− Switches 9 and 10 are used to select cooling

mode blower speed ramping options. Blower speed ramping may be used to enhance dehumidification performance. The switches are factory set at option A which has the greatest effect on blower motor performance. The table below provides the cooling mode blower speed ramping options that will result from different switch settings. The cooling mode blower speed ramping options are detailed on Page 14. See unit nameplate for manufacturing date.

TABLE 10

Cooling Mode Blower Speed Ramping

Ramping Option

Switch 9 Switch 10

A (Factory) Off Off

B On Off

C Off On

D* On On

*Only option for CCB1

Page 14

G60UHV units manufactured before April 2003

Ramping Option A (Factory Selection)

 Motor runs at 50% for 1/2 minute.  Motor then runs at 82% for approximately 7−1/2 min-

utes.

 If demand has not been satisfied after 7−1/2 minutes,

motor runs at 100% until demand is satisfied.

 Once demand is met, motor runs at 50% for 1/2 min-

ute.

 Motor ramps down to off.

OFF

1/2 MIN 50% CFM

COOLING DEMAND

7−1/2 MIN 82% CFM

100% CFM

1/2 MIN 50% CFM

Ramping Option B

 Motor runs at 50% for 1/2 minute.  Motor then runs at 82% for approximately 7−1/2 min-

utes.

 If demand has not been satisfied after 7−1/2 minutes,

motor runs at 100% until demand is satisfied.

 Once demand is met, motor ramps down to off.

OFF

1/2 MIN 50% CFM

7−1/2 MIN 82% CFM

100% CFM

COOLING DEMAND

Ramping Option C

 Motor runs at 82% for approximately 7−1/2 minutes.  If demand has not been satisfied after 7−1/2 minutes,

the motor runs at 100% until demand is satisfied.

 Once demand is met, motor ramps down to off.

OFF

82%CFM

100% CFM

COOLING DEMAND

7−1/2 MIN

Ramping Option D

 Motor runs at 100% until demand is satisfied.  Once demand is met, motor ramps down to off.

OFFOFF

100% CFM

COOLING DEMAND

G60UHV units manufactured April 2003 and later

Ramping Option A (Factory Selection)

S Motor runs at 50% for 30 seconds. S Motor then runs at 82% for approximately

7−1/2 minutes.

S If demand has not been satisfied after 7−1/2 minutes.

Motor runs at 100% until demand is satisfied.

S Once demand is met, motor runs at 50% for 30 sec-

onds then ramps down to stop.

OFF

1/2 MIN 50% CFM

COOLING DEMAND

7 1/2 MIN 82% CFM

100% CFM

1/2 MIN 50% CFM

Ramping Option B

S Motor runs at 82% for approximately 7−1/2 minutes. If

demand has not been satisfied after 7−1/2 minutes motor runs at 100% until demand is satisfied.

S Once demand is met, motor ramps down to stop.

OFF

82%CFM

100% CFM

COOLING DEMAND

7 1/2 MIN

Ramping Option C

S Motor runs at 100% until demand is satisfied.

S Once demand is met, motor runs at 100% for 45* sec-

onds then ramps down to stop.

OFF

100% CFM

COOLING DEMAND

* G60UHV units date coded prior to 2−2006 will delay 60 seconds

Ramping Option D

S− Motor runs at 100% until demand is satisfied.

S− Once demand is met, motor ramps down to stop.

OFFOFF

100% CFM

COOLING DEMAND

Page 15

Switches 11 and 12 −− Heating Mode Blower Speed −−

Switches 11 and 12 are used to select heating mode blower motor speed. The unit is shipped from the factory with the dip switches positioned for medium low (2) speed indoor blower motor operation during the heating mode. The table below provides the heating mode blower speeds that will result from different switch settings. Refer to blower data tables at the front of this manual for corresponding cfm values.

TABLE 11

Heating Mode Blower Speeds

Speed

Switch 11 Switch 12

1 − Low On On

2 − Medium Low

(Factory)

Off On

3 − Medium High On Off

4 − High Off Off

On−Board Jumper W914

On−board jumper W914 connects terminals DS and R on the integrated control board. W914 must be cut when the furnace is installed with either the Harmony II zone control board, the CCB1 EfficiencyPlus humidity control or Lennox SignatureStat. Refer to table 21 for operation sequence in applications including a G60UHV, CCB1 and single− speed outdoor unit. Table 22 gives the operation sequence in applications with a two−speed outdoor unit. Refer to table 23 for operation sequence in applications including a G60UHV, SignatureStat and single−speed outdoor unit. Table 24 gives the operation sequence in applications with a two−speed outdoor unit.

On−Board Jumper W951

On−board jumper W951 connects terminals R and O on the integrated control board. W951 must be cut when the furnace is installed in applications which include a heat pump unit and the FM21 FuelMaster control board.

Factory−Installed Jumper Y1 to Y2

A factory−installed jumper from Y1 to Y2 terminals on the integrated control board terminal strip must be removed if two−stage cooling will be used.

Diagnostic LEDs (DS1 and DS2)

Two diagnostic LEDs are located on the two−stage, variable speed integrated control just to the left of the first bank of dip switches. These lights’ flashes correspond with diagnostic codes detailed on in table 6.

Status LEDs (HEAT, HI/LO, ON/OFF and CFM)

The integrated control includes four LEDs which indicate operating status. The green ON/OFF LED is lit any time the blower is operating. The green CFM LED indicates the blower motor speed. Count the number of blinks between the two−second pauses to determine the CFM. Each blink represents approximately 100 CFM. The yellow HI/LO LED is lit when the W914 (DS to R) jumper has not

been clipped for SignatureStat, CCB1 or Harmony operation. The yellow HEAT LED is lit when the indoor blower is operating at the HEATING speed.

Page 16

WARNING

Shock hazard. Disconnect power before servicing. Integrated

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

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

5. Integrated Control Board(A92) Board 100870

Beginning with G60UHV−7, units are equipped with the Lennox two−stage, variable speed integrated SureLight control board. The system consists of a ignition / blower control board (figures 5 and 6) with control pin designations in tables 12, 13 and 14 and ignitor (figure 13). The board and ignitor work in combination to ensure furnace ignition and ignitor durability. The SureLight integrated board controls all major furnace operations. The board features a red LED light, for furnace status and troubleshooting. The LED flashes in X" + Y" codes. For example using table 15 under PRESSURE SWITCH CODES", if the red LED flashes 2 times, then off for 2 seconds then flashes 3 times, the low pressure switch is failed open. Two green LEDs show indoor blower status and CFM. See Page 21 for more detail. The board also has two 120 volt accessory terminals rated at (1) one amp each. In addition there is a 24 volt accessory terminal located on TB1.

Electronic Ignition

NOTE − Board 100870 provides a regulated 95 volts to to the ignitor.

Two Stage Operation / Thermostat Selection Jumper

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

Page 17

FIGURE 5

TWO−STAGE, VARIABLE SPEED INTEGRATED CONTROL BOARD

THERMOSTAT CONNECTIONS (TB1)

1/4" QUICK CONNECT TERMINALS

DIP SWITCH FUNCTIONS

INDOOR

BLOWER DIP

SWITCHES

HEATING

DIP

SWITCHES

DIAGNOSTIC

LEDs

ON−BOARD

LINKS

H= 24V HUMIDIFIER OUTPUT L= LENNOX SYSTEM OPERATION MONITOR 1= FUTURE USE

NEUTRALS= 120 VAC NEUTRAL

W914

W951

W915

HTG DIP SWITCH(ES) FUNCTION

5 and 6 Cooling Mode Blower Speed 7 and 8 Blower Speed Adjustment

9 and 10 Cooling Mode Blower Ramping Profile

11 and 12 Heating Mode Blower Speed

1 T’stat Heat Stages (single or two−stage) 2 Second Stage ON Delay (single−stage t’stat)

3 and 4 Heating Fan OFF Delay

INDOOR BLOWER

DIP SWITCH(ES)

FUNCTION

FUTURE

USE

TABLE 12

SureLight Board 5 Pin Terminal Designation

PIN # Function

1 Ignitor

2 Combustion Air Inducer High Speed

3 Combustion Air Inducer Low Speed

4 Combustion Air Inducer Neutral

5 Ignitor Neutral

TABLE 13

SureLight Board 12Pin Terminal Designation

PIN # Function

1 Gas Valve High Fire

2 Second Stage Prove Switch

3 Rollout In

4 Ground

5 24V Hot

6 Primary Limit In

7 Gas Valve Low Stage

8 Gas Valve Common

9 24V Neutral

10 Ground

11 Rollout Switch Out

12 1st Stage Prove Switch

TABLE 14

SureLight Board 16 Pin Blower Control Terminals

PIN # Function

1 Ground

2 Low Heat Speed

3 Ground

4 DELAY" Dip Switch Selection

5 COOL" Dip Switch Selection

6 Y1" Signal

7 ADJUST" Dip Switch Selection

8 Ground

9 0" From Thermostat

10 DS" Output Signal

11 HEAT" Dip Switch Selection

12 24 VAC

13 HIGH HEAT Speed

14 Y2" Signal

15 G"

16 CFM LED

Page 18

FIGURE 6

TWO−STAGE, VARIABLE SPEED INTEGRATED CONTROL BOARD

Page 19

TABLE 15

FLASH CODE

(X + Y)

STATUS / ERROR DESCRIPTION

FLASH CODE DESCRIPTIONS

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

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

X + Y

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

Pulse Power on − Standby.

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

FLAME CODES

1 + 2 Low flame current −− run mode.

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

PRESSURE SWITCH CODES

2 + 3 Low pressure switch failed open.

2 + 4 Low pressure switch failed closed.

2 + 5 High pressure switch failed open.

2 + 6 High pressure switch failed closed.

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

LIMIT CODE

3 + 1 Limit switch open.

WATCHGUARD CODES

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

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

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

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

4 + 6

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

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

4 + 8 Low line voltage.

HARD LOCKOUT CODES

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

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

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

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

5 + 6 Low secondary (24VAC) voltage.

Error Code Storage

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

Error Code Review

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

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

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

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

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

TUS LED turning off. This activates error code review.

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

LED.

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

flash to indicate normal operation.

Clearing Error Codes

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

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

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

seconds, STATUS LED will go from being continuously lit to off.

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

ten seconds after STATUS LED has turned off. STATUS LED will turn on, indicating that error codes have been cleared.

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

indicate normal operation.

Page 20

Dip Switch Settings

Heating Operation DIP Switch Settings

Switch 1 −− Thermostat Selection −− This unit may be used

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

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

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

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

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

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

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

Switches 3 and 4 −− Blower−Off Delay −− The blower−on delay of 45 seconds is not adjustable. The blower−off delay (time that the blower operates after the heating demand has been satisfied) can be adjusted by moving switches 3 and 4 on the integrated control board. The unit is shipped from the factory with a blower−off delay of 90 seconds. The blower off delay affects comfort and is adjustable to satisfy individual applications. Adjust the blower off delay to achieve a supply air temperature between 90° and 110°F at the exact moment that the blower is de−energized. Longer off delay settings provide lower supply air temperatures; shorter settings provide higher supply air temperatures.Table 16 provides the blower off timings that will result from different switch settings.

TABLE 16

Blower Off Delay Switch Settings

Blower Off Delay

(Seconds)

Switch 3 Switch 4

60 Off On

90 Off Off 120 On Off 180 On On

Indoor Blower Operation DIP Switch Settings

Switches 5 and 6 −− Cooling Mode Blower Speed −−

Switches 5 and 6 are used to select cooling blower motor speed. The unit is shipped from the factory with the DIP switches positioned for high speed (4) indoor blower motor

operation during the cooling mode. The table below provides the cooling mode blower speeds that will result from different switch settings. Refer to blower tables at the front of this manual for corresponding cfm values.

TABLE 17

Cooling Mode Blower Speeds

Speed

Switch 5 Switch 6

1 − Low On On

2 − Medium Low Off On

3 − Medium High On Off

4 − High (Factory) Off Off

Switches 7 and 8 −− Blower Speed Adjustment −−

Switches 7 and 8 are used to select blower speed adjustment settings. The unit is shipped from the factory with the DIP switches positioned for NORMAL (no) adjustment. The DIP switches may be positioned to adjust the blower speed by +10% or −10% to better suit the application. The table below provides blower speed adjustments that will result from different switch settings. Refer to blower tables at the front of this manual for corresponding cfm values.

TABLE 18

Blower Speed Adjustment

Adjustment

Switch 7 Switch 8

+10% (approx.) On Off

NORMAL (Factory) Off Off

−10% (approx.) Off On

Switches 9 and 10 −− Cooling Mode Blower Speed Ramping −− Switches 9 and 10 are used to select cooling

mode blower speed ramping options. Blower speed ramping may be used to enhance dehumidification performance. The switches are factory set at option A which has the greatest effect on blower motor performance. Table 19 provides the cooling mode blower speed ramping options that will result from different switch settings. The cooling mode blower speed ramping options are detailed on Page 14 under units manufactured April 2003 and later".

NOTE − The off portion of the selected ramp profile also applies during heat pump operation in dual fuel applications.

TABLE 19

Cooling Mode Blower Speed Ramping

Ramping Option

Switch 9 Switch 10

A (Factory) Off Off

B On Off C Off On D On On

Switches 11 and 12 −− Heating Mode Blower Speed −−

Switches 11 and 12 are used to select heating mode blower motor speed. The unit is shipped from the factory with the dip switches positioned for medium low (2) speed indoor blower motor operation during the heating mode. The table below provides the heating mode blower speeds that will result from different switch settings. Refer to blower tables at the front of this manual for corresponding cfm values.

Page 21

TABLE 20

Heating Mode Blower Speeds

Speed

Switch 11 Switch 12

1 − Low On On

2 − Medium Low

(Factory)

Off On

3 − Medium High On Off

4 − High Off Off

On−Board Link W914

On−board link W914 is a clippable connection which connects terminals DS and R on the integrated control board. W914 must be cut when the furnace is installed with either the Harmony III zone control board or a thermostat which features humidity control. If the link is left intact the PWM signal from the HARMONY III control will be blocked and also lead to control damage. Refer to table 21 (CCB1) or 23 (SignatureStat) for operation sequence in applications including G60UHV, a thermostat which features humidity control and a single−speed outdoor unit. Table 22 (CCB1) and table 24 (SignatureStata) gives the operation sequence in applications with a two−speed outdoor unit.

On−Board Link W951

On−board link W951 is a clippable connection which con-

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

On−Board Link W915

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

Status LEDs (SPEED, CFM, E−COM)

The green SPEED LED indicates circulating blower speed in response to the DS signal. The LED is lit during normal blower operation and is off during a dehumidification demand. In Harmony III applications, the brightness of the LED indicates the requested blower speed.

The green CFM LED indicates the blower air flow. Count the number of blinks between the two−second pauses to determine the CFM. Each blink represents approximately 100 CFM.

The green E−COM LED indicates that the control is receiving and processing of commands and inputs. The LED may flash rapidly or may display a single flash, depending upon the activity.

TABLE 21

G60UHV, CCB1 and Single−Speed Outdoor Unit

OPERATING MODE

SYSTEM DEMAND SYSTEM RESPONSE

System Condition

Thermostat

Demand

*Relative Humidity

(EfficiencyPlus Lights)

Blower

CFM

(COOL)

Comments

Normal operation Y1

No demand. Humidity

level is acceptable

COOL

Compressor demand and indoor blower speed controlled by thermostat demand.

*Call for humidity

removal during

cooling demand

Humidity level rises above setpoint. Demand initiated.

60%/65% of COOL

Call for dehumidification initiated by CCB1 control. Indoor blower speed reduced by CCB1 control.

Dehumidification

demand satisfied

during cooling demand.

Humidity level falls below set-

point. No demand

COOL

When humidity demand is satisfied, blower speed immediately increases to the COOL CFM to hasten the end of the cycle.

Call for cooling after call for

humidity

removal.

None

Humidity level above setpoint.

Demand initiated.

Off

Dehumidification mode begins when relative humidity is greater than setpoint.

Humidity level above setpoint.

Demand initiated.

60%/65% of

COOL

Humidity demand

satisfied between

thermostat demands (unit

off cycle).

None Over setpoint (1 or more) Off

While unit is not operating (no thermostat demand), slide switch is moved down and back up. Blower operates at COOL CFM.

Y1 Change to acceptable COOL

NOTE − When changing unit mode of operation from cooling to heating, indicating lights that are on will stay on until the first thermostat heating demand. * Reduced blower speed is 65% of COOL for the −36A and −36B units; 60% of COOL for −60C and −60D series units.

Page 22

TABLE 22

G60UHV, CCB1 and Two−Speed Outdoor Unit

OPERATING MODE SYSTEM DEMAND SYSTEM RESPONSE

System

Condition

Thermostat

Demand

*Relative Humidity

(EfficiencyPlus Lights)

****Compressor

Speed

Blower CFM

(COOL)

Comments

Normal operation

Y1 No demand. Acceptable Low

**42%/46%/49%

of HIGH COOL

Compressor demand and indoor

blower speed controlled by

thermostat demand

Y2 No demand. Acceptable High HIGH COOL

Call for humidity

removal during

1st−stage cooling

demand

Y1 No demand. Acceptable Low

**42%/46%/49%

of HIGH COOL

Dehumidification mode does not begin

until after initial thermostat demand is

satisfied and new cooling demand is

initiated.

Humidity level rises slightly

(1) above setpoint. Demand

initiated.

Low

**42%/46%/49%

of HIGH COOL

Demand satisfied

Humidity level remains

slightly (1) above setpoint.

Demand continues.

Off

Humidity level remains

slightly (1) above setpoint.

Demand continues.

High

***65%/60% of

HIGH COOL

Significant increase in

humidity during

thermostat cooling

demand.

No demand. Acceptable

Low

**42%/46%/49%

of HIGH COOL

If humidity rises significantly above setpoint, or if slide switch is moved signifi-

cantly, unit will immediately go into de-

humidification mode (in presence of

thermostat demand).

Humidity level rises signifi-

cantly (2 or more) above

setpoint. Demand initiated.

High

***65%/60% of

HIGH COOL

Humidity demand

satisfied during

thermostat demand.

Humidity level

above setpoint.

High

***65%/60% of

HIGH COOL

When humidity demand is satisfied,

blower immediately shifts to the COOL

CFM in order to hasten the end of the

cycle. Unit can only shift out of high

speed compressor operation at begin-

ning of next cycle.

Humidity level falls below

setpoint. No demand.

High

HIGH COOL

None

No demand. Acceptable

Off

No demand. Acceptable

Low

**42%/46%/49%

of HIGH COOL

Call for humidity

removal during 2nd

stage thermostat

demand

No demand. Acceptable

High

HIGH COOL

Blower immediately changes speed in

response to thermostat demand.

Humidity level rises slightly

(1) above setpoint. Demand

initiated.

High

***65%/60% of

HIGH COOL

No demand. Acceptable

High

HIGH COOL

*Call for 1st stage

cooling after call for

humidity removal.

None

Humidity level is slightly (1)

above setpoint.

Off

Dehumidification mode (high speed

compressor) begins with next thermo-

stat demand after initial demand is sat-

isfied.

Humidity level is slightly (1)

above setpoint.

Low

**42%/46%/49%

of HIGH COOL

Call for 2nd stage

cooling after call for

humidity removal

None

Humidity level is slightly (1)

above setpoint.

Off

Reduced blower speed (dehumidifica-

tion speed) begins immediately with

thermostat demand

Humidity level is slightly (1)

above setpoint.

High

***65%/60% of

HIGH COOL

Call for cooling after

significant increase in

humidity

None

Humidity level is significantly

above setpoint (2 or more).

Off

If humidity increases significantly over

setpoint, or if slide switch is moved,

unit immediately goes into dehumidifi-

cation mode (in presence of thermostat

demand).

Y1 or Y2

Humidity level is significantly

above setpoint (2 or more).

High

***65%/60% of

HIGH COOL

Humidity demand satisfied between

thermostat demands

(unit off cycle).

None

Humidity level is slightly (1)

above setpoint.

Off

While unit is not operating (no thermo-

stat demand), slide switch is moved

down and back up. Blower and com-

pressor operate at high speed until

next thermostat demand.

Y1 or Y2

Humidity level falls below

setpoint. No demand.

High

HIGH COOL

NOTE − When changing unit mode of operation from cooling to heating, indicating lights that are on will stay on until the first thermostat heating demand.

*IMPORTANT - If power to unit is turned on with CCB1 calling for humidity removal, outdoor unit may be locked into high speed indefinitely. To reset, move humidity slide switch all the way down then back up to desired setpoint (with unit running) ** Reduced blower speed for ALL model units manufactured September 2002 and later is 49% of HIGH COOL. (Earlier date code: −42% of HIGH COOL for −36A and −36B units; 46% of HIGH COOL for −60C and −60D series units) *** Reduced blower speed is 65% of HIGH COOL for −36A and −36B units; 60% of HIGH COOL for −60C and −60D series units. ****If the two−speed control on a two−speed outdoor unit is set for LATCH 2 (15 minutes) or LATCH 3 (30 minutes), the compressor will latch into high speed after a Y1 demand has occurred for that period of time.

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Lennox G60UHV, G60UHVX Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual