Lennox G61MP-60C-090, G61MP-36B-070, G61MP-60C-091, G61MP-48C-110, G61MP-60C-110 Installation Instructions Manual

...

Download

Page 1

INSTALLATION

E 2009 Lennox Industries Inc.

Dallas, Texas, USA

THIS MANUAL MUST BE LEFT WITH THE

HOMEOWNER FOR FUTURE REFERENCE

INSTRUCTIONS

G61MP SERIES UNITS

GAS UNITS

506406−01 08/2009

Supersedes 505,124M

Table of Contents

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

G61MP Parts Identification 3. . . . . . . . . . . . . . . . . . . . . .

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

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

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

General 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Installation − Setting Equipment 8. . . . . . . . . . . . . . . . . .

Filters 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Duct System 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pipe & Fittings Specifications 16. . . . . . . . . . . . . . . . . . . .

Vent Piping Guidelines 18. . . . . . . . . . . . . . . . . . . . . . . . .

Joint Cementing Procedure 20. . . . . . . . . . . . . . . . . . . . .

Venting Practices 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gas Piping 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Integrated Control Board 42. . . . . . . . . . . . . . . . . . . . . . .

Unit Start−Up 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gas Pressure Adjustment 44. . . . . . . . . . . . . . . . . . . . . .

High Altitude Information 45. . . . . . . . . . . . . . . . . . . . . . .

Other Unit Adjustments 46. . . . . . . . . . . . . . . . . . . . . . . . .

Service 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ignition Control Board Diagnostic Codes 56. . . . . . . . . .

Troubleshooting 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair Parts List 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vent Pipe Sizing Worksheet 63. . . . . . . . . . . . . . . . . . . . .

Start−Up & Performance Check List 63. . . . . . . . . . . . . .

Litho U.S.A.

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

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

08/09

*2P0809*

WARNING

FIRE OR EXPLOSION HAZARD.

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

WHAT TO DO IF YOU SMELL GAS:

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

use any phone in your building.

D Leave the building immediately. D Immediately call your gas supplier from a

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

D If you cannot reach your gas supplier, call

the fire department.

Page 1

*P506406-01*

506406−01

Page 2

G61MP Unit Dimensions − inches (mm)

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

1. Single side return air with transition, to accommodate 20 x 25 x 1 in. (508 x 635 x 25 mm) air filter. Required to maintain proper air velocity.

2. Single side return air with optional RAB Return Air Base

3. Bottom return air.

4. Return air from both sides.

5. Bottom and

Refer to Engineering Handbook for additional information.

**Consider sizing requirements for optional IAQ equipment before cutting side return opening.

Optional External Side Return Air Filter Kit is not for use

with the optional RAB Return Air Base.

3/4 (19)

one side return air.

B 9/16 (14)

11−5/8 (295)

Right

OPTIONAL

EXTERNAL

SIDE RETURN

AIR FILTER KIT

(Either Side)

9−3/4 (248)

Left

(1016)

14−3/4

(375)

(406)

AIR FLOW

5/8 (16)

*Bottom Return

Air Opening

3/4 (19)

FRONT VIEW SIDE VIEW

OPTIONAL

EXTERNAL

SIDE RETURN

AIR FILTER KIT

(Either Side)

5−1/2 (140)

6−1/2 (165)

4−1/8 (103)

6−3/4 (171)

4−7/8 (124) Right

2−1/4 (57) Left

2−1/2

(64)

18-3/4 (476)

6−1/2 (165)

3−1/8

(79)

(102)

4−1/4 (108)

SUPPLY AIR

OPENING

23-3/4 (603)

25 (635)

TOP VIEW

28−1/2

(724)

19−7/16

(378)

COMBUSTION AIR INTAKE

(Either Side)

EXHAUST AIR OUTLET

(Either Side)

GAS PIPING INLET

(Either Side)

CONDENSATE

TRAP CONNECTION

(Either Side)

ELECTRICAL INLET

(Either Side)

(584)

*OPTIONAL

RETURN CUTOUT

(Either Side)

1−15/16 (49)

23−1/2

(597)

*Bottom Return

Air Opening

9/16

(14)

14**

(356)

Model No.

G61MP−36B−045 G61MP−36B−070 G61MP−36B−071

G61MP−48C−090 G61MP−60C−090 G61MP−60C−091 G61MP−48C−110 G61MP−60C−110 G61MP−60C−111

G61MP−60D−135 24−1/2 622 23−3/8 546 23 584

in. mm in. mm in. mm

17−1/2 446 16−3/8 416 16 406

21 533 19−7/8 505 19−1/2 495

A B C

Page 2

Page 3

G61MP Parts Arrangement

G61MP PARTS IDENTIFICATION

TOP CAP

BURNER BOX

ASSEMBLY

GAS VALVE

AND MANIFOLD

FLUE

COLLAR

COMBUSTION

AIR PRESSURE

PROVE SWITCHES*

COMBUSTION AIR

INDUCER

DuralokPlus

HEAT EXCHANGER

ASSEMBLY

CABINET

WARM HEADER

(COLLECTOR)

BOX

CONDENSER COIL

BURNER ACCESS

PANEL

BLOWER

ACCESS

DOOR

*G61MP−090 shown.

G61MP−045 and −070

are equipped with

two switches.

SIGHT

GLASS

DOOR

INTERLOCK

SWITCH

PRIMARY LIMIT

COLD HEADER

(COLLECTOR)

BOX

SECONDARY

LIMITS (2)

BLOWER

ASSEMBLY

CONTROL BOX

FIGURE 1

Page 3

Page 4

G61MP Gas Furnace

The G61MP category IV gas furnace is shipped ready for installation in the upflow, downflow, horizontal left air discharge or horizontal right air discharge position. The furnace is shipped with the bottom panel in place. The bottom panel must be removed if the unit is to be installed in upflow applications with bottom return air. The bottom panel must also be removed and discarded in all downflow or horizontal applications.

The furnace is equipped for installation in natural gas applications. A conversion kit (ordered separately) is required for use in propane/LP gas applications.

The G61MP can be installed as either a Direct Vent or a Non−Direct Vent gas central furnace.

NOTE − In Direct Vent installations, combustion air is taken from outdoors and flue gases are discharged outdoors. In Non−Direct Vent installations, combustion air is taken from indoors and flue gases are discharged outdoors. See figure 2 for applications involving roof termination.

DIRECT VENT INSTALLATION NON−DIRECT VENT

COMBUSTION AIR INTAKE OUTSIDE OF HOUSE

EXHAUST OUTLET

INSTALLATION

EXHAUST OUTLET

COMBUSTION

AIR INTAKE INSIDE

OF HOUSE

NOTE − G61MP−48C−110, G61MP−60C−110 and G61MP−60C−111 units also include a 2" diameter PVC street elbow, which is shipped on the blower deck in the heating compartment. G61MP−60D−135 units are shipped with a 3" to 2" PVC reducing elbow.

Canadian Installations Only − Replace the provided 2" street elbow shipped with the G61MP−48C−110, G61MP−60C−110 and G61MP−60C−111 units with 2" street elbow Y0162. Replace the provided 3" X 2" reducing elbow shipped with the G61MP−60D−135 units with 3" X 2" reducing elbow 40W22. Y0162 and 40W22 meet B149 vent requirements.

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

The following items may also be ordered separately: 1 − Thermostat 1 − Propane/LP changeover kit

DANGER

Danger of explosion.

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

Safety Information

G61MP

CONDENSATE

DRAIN

G61MP

FIGURE 2

Shipping and Packing List

Package 1 of 1 contains

1 − Assembled G61MP unit 1 − Bag assembly containing the following:

3 − Screws 3 − Wire nuts 1 − Snap bushing 1 − Snap plug 1 − Wire tie 1 − Condensate trap 1 − Condensate trap cap 2 − 2" diameter vent / intake plugs 1 − 3" diameter cabinet plug (intake) 1 − 2" diameter debris screen 1 − Logo sticker (for use in downflow applications)

DRAIN

WARNING

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

CAUTION

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

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

G61MP units are CSA International certified to ANSI Z21.47 and CSA 2.3 standards.

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

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

Page 4

Page 5

In Canada, installation must conform with current National Standard of Canada CSA-B149 Natural Gas and Propane Installation Codes, local plumbing or waste water codes and other applicable local codes.

In order to ensure proper unit operation in non−direct vent applications, combustion and ventilation air supply must be provided according to the current National Fuel Gas Code or CSA-B149 standard.

This furnace is CSA International certified for installation clearances to combustible material as listed on the unit nameplate and in the tables in figures 8, 13 and 17. Accessibility and service clearances must take precedence over fire protection clearances.

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

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

NOTE − Furnace must be adjusted to obtain a temperature rise within the range specified on the unit nameplate. Failure to do so may cause erratic limit operation.

This G61MP furnace may be used as a high−static unit heater. The G61MP may also be installed in an aircraft hangar in accordance with the Standard for Aircraft Hangars (ANSI/NFPA No. 408−1990).

Installation in parking structures must be in accordance with the Standard for Parking Structures (ANSI/NFPA No. 88A−1991). Installation in repair garages must be in accordance with the Standard for Repair Garages (ANSI/NFPA No. 88B−1991).

This G61MP furnace must be installed so that its electrical components are protected from water.

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

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

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

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

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

The G61MP furnace may be installed in alcoves, closets, attics, basements, garages, and utility rooms.

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

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

Use of Furnace as Construction Heater

Lennox does not recommend the use of G61MP units as a construction heater during any phase of construction. Very low return air temperatures, harmful vapors and operation of the unit with clogged or misplaced filters will damage the unit.

G61MP units may be used for heating of buildings or structures under construction, if the following conditions are met:

D The vent system must be permanently installed per

these installation instructions.

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

fixed jumpers that will provide continuous heating is not allowed.

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

furnace.

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

80°F (27°C) must be maintained.

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

maintained during construction.

D Air filters must be replaced upon construction comple-

tion.

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

furnace rating plate.

Page 5

Page 6

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

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

D The furnace heat exchanger, components, duct system,

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

D All furnace operating conditions (including ignition, in-

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

CAUTION

G61MP unit should not be installed in areas normally subject to freezing temperatures.

Combustion, Dilution & Ventilation Air

If the G61MP is installed as a Non−Direct Vent Furnace, follow the guidelines in this section.

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

General

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

In addition to the requirements outlined previously, the following general recommendations must be considered when installing a G61MP furnace:

• Place the furnace as close to the center of the air distribution system as possible. The furnace should also be located close to the chimney or vent termination point.

• When the furnace is installed in non−direct vent applications, do not install the furnace where drafts might blow directly into it. This could cause improper combustion and unsafe operation.

• When the furnace is installed in non−direct vent applications, do not block the furnace combustion air opening with clothing, boxes, doors, etc. Air is needed for proper combustion and safe unit operation.

• When the furnace is installed in an attic or other insulated space, keep insulation away from the furnace.

• When the furnace is installed in an unconditioned space, consider provisions required to prevent freezing of condensate drain system.

WARNING

Product contains fiberglass wool.

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

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

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

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

WARNING

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

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

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

In the absence of local codes concerning air for combus− tion and ventilation, use the guidelines and procedures in this section to install G61MP furnaces to ensure efficient and safe operation. You must consider combustion air needs and requirements for exhaust vents and gas piping. A portion of this information has been reprinted with permission from the National Fuel Gas Code (ANSI−

Page 6

Page 7

Z223.1/NFPA 54). This reprinted material is not the complete and official position of the ANSI on the referenced subject, which is represented only by the standard in its entirety.

In Canada, refer to the standard CSA B149 installation codes.

CAUTION

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

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

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

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

Unconfined Space

An unconfined space is an area such as a basement or large equipment room with a volume greater than 50 cubic feet (1.42 m3) per 1,000 Btu (.29 kW) per hour of the combined input rating of all appliances installed in that space. This space also includes adjacent rooms which are not separated by a door. Though an area may appear to be unconfined, it might be necessary to bring in outdoor air for combustion if the structure does not provide enough air by infiltration. If the furnace is located in a building of tight construction with weather stripping and caulking around the windows and doors, follow the procedures in the air from outside section.

Confined Space

A confined space is an area with a volume less than 50 cubic feet (1.42 m3) per 1,000 Btu (.29 kW) per hour of the com− bined input rating of all appliances installed in that space. This definition includes furnace closets or small equipment rooms.

When the furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space containing the furnace, the return air must be handled by ducts

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

Air from Inside

If the confined space that houses the furnace adjoins a space categorized as unconfined, air can be brought in by providing two permanent openings between the two spaces. Each opening must have a minimum free area of 1 square inch (645 mm2) per 1,000 Btu (.29 kW) per hour of total input rating of all gas−fired equipment in the confined space. Each opening must be at least 100 square inches (64516 mm2). One opening shall be within 12 inches (305 mm) of the top of the enclosure and one opening within 12 inches (305 mm) of the bottom. See figure 3.

EQUIPMENT IN CONFINED SPACE − ALL AIR FROM INSIDE

ROOF TERMINATED

EXHAUST PIPE

OPENINGS

SIDE WALL

TERMINATED EX-

HAUST PIPE (ALTER-

NATE LOCATION)

NOTE − Each opening shall have a free area of at least one square inch per 1,000 Btu (645mm rating of all equipment in the enclosure, but not less than 100 square inches (64516mm.

G61MP

2).

(To Adjacent

Unconfined

Space)

per .29kW) per hour of the total input

FIGURE 3

Air from Outside

If air from outside is brought in for combustion and ventilation, the confined space shall be provided with two permanent openings. One opening shall be within 12" (305mm) of the top of the enclosure and one within 12" (305mm) of the bottom. These openings must communicate directly or by ducts with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors or indirectly through vertical ducts. Each opening shall have a minimum free area of 1 square inch per 4,000 Btu (645mm per 1.17kW) per hour of total input rating of all equipment in the enclosure. When communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 square inch per 2,000 Btu (645mm per .59kW) per total input rating of all equipment in the enclosure (See figure 4).

Page 7

Page 8

EQUIPMENT IN CONFINED SPACE − ALL AIR FROM OUTSIDE

(Inlet Air from Crawl Space and Outlet Air to Ventilated Attic)

VENTILATION LOUVERS

OUTLET

AIR

(Each end of attic)

VENTILATION

LOUVERS

(For unheated

crawl space)

per 1.17kW) per

ROOF TERMINATED

EXHAUST PIPE

SIDE WALL

TERMINATED

EXHAUST PIPE

(ALTERNATE

LOCATION)

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

G61MP

INLET

AIR

FIGURE 4

in the enclosure. See figures 4 and 5. When communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 square inch (645 mm2) per 2,000 Btu (.56 kW) per total input rating of all equipment in the enclosure. See figure 6.

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

EQUIPMENT IN CONFINED SPACE −

ALL AIR FROM OUTSIDE

ROOF TERMINATED

EXHAUST PIPE

EQUIPMENT IN CONFINED SPACE − ALL AIR FROM OUTSIDE

ROOF TERMINATED

EXHAUST PIPE

SIDE WALL

TERMINATED

EXHAUST PIPE

(ALTERNATE

LOCATION)

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

(All Air Through Ventilated Attic)

VENTILATION LOUVERS

(Each end of attic)

OUTLET

AIR

G61MP

per 1.17kW) per hour

INLET AIR

(Ends 12" above

bottom)

FIGURE 5

If air from outside is brought in for combustion and ventilation, the confined space must have two permanent openings. One opening shall be within 12 inches (305 mm) of the top of the enclosure and one opening within 12 inches (305 mm) of the bottom. These openings must communicate directly or by ducts with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors or indirectly through vertical ducts. Each opening shall have a minimum free area of 1 square inch (645 mm2) per 4,000 Btu (1.17 kW) per hour of total input rating of all equipment

OUTLET AIR

SIDE WALL

TERMINATED

EXHAUST PIPE

(ALTERNATE

LOCATION)

NOTE−Each air duct opening shall have a free area of at least one square inch per 2,000 Btu (645mm input rating of all equipment in the enclosure. If the equipment room is located against an outside wall and the air openings communicate directly with the outdoors, each opening shall have a free area of at least 1 square inch per 4,000 Btu (645mm hour of the total input rating of all other equipment in the enclosure.

G61MP

per .59kW) per hour of the total

INLET AIR

per 1.17kW) per

FIGURE 6

Installation − Setting Equipment

WARNING

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

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

Page 8

Page 9

SETTING EQUIPMENT

UPFLOW APPLICATION DOWNFLOW APPLICATION

AIR FLOW

UNIT MUST BE LEVEL SIDE−TO−SIDE IN ALL APPLICATIONS.

AIR FLOW

HORIZONTAL APPLICATION

AIR FLOW

UNIT

FRONT

FRONT VIEW

AIR FLOW

SIDE VIEW

UNIT

FRONT

1/2"

max.

UNIT SHOULD BE LEVEL FROM LEFT TO RIGHT BUT MAY BE

TILTED SLIGHTLY (MAX. 1/2") FROM BACK TO FRONT TO AID IN THE DRAINING OF THE HEAT EXCHANGER.

FRONT VIEW

The unit must be level from side to side. The unit may be tilted slightly (maximum 1/2 in.) from back to front to aid in the draining of the heat exchanger. See figure 7.

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

WARNING

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

END VIEW

FIGURE 7

Allow for clearances to combustible materials as indicated on the unit nameplate. Minimum clearances for closet or alcove installations are shown in figures 8, 13 and 17.

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

1/2"

max.

FRONT VIEW

AIR FLOW

UNIT

FRONT

SIDE VIEW

WARNING

1/2"

max.

Page 9

Page 10

Upflow Applications

The G61MP gas furnace can be installed as shipped in the upflow position. Refer to figure 8 for clearances.

Installation Clearances

Top

Left Side

Bottom (Floor)

Top/Plenum 1 in. (25 mm)

*Front 0

Back 0

Sides 0†

Vent 0

Floor 0‡

*Front clearance in alcove installation must be 24 in. (610 mm). Maintain a minimum of 24 in. (610 mm) for front service access. †Allow proper clearances to accommodate condensate trap and vent pipe installation. ‡For installations on a combustible floor, do not install the furnace directly on carpeting, tile or other combustible materials other than wood flooring.

FIGURE 8

Right Side

Return Air −− Upflow Units

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

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

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

1 − Return air from single side with transition which will

accommodate 20 x 25 x 1 in. (508 x 635 x 25 mm) air filter. (Required to maintain proper air velocity.) See figure 10.

2 − Return air from single side with optional RAB Return

Air Base. See figure 9.

3 − Return air from bottom.

4 − Return air from both sides.

5 − Return air from bottom and

one side.

Refer to Engineering Handbook for additional information.

Page 10

Page 11

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

AIR FLOW

FURNACE

7−1/4 (184)

Optional Return Air Base

(102)

(356)

FRONT

23 (584)

Overall

(Maximum)

Unit side return air

Opening

5−5/8 (143)

SIDE RETURN

AIR OPENINGS

(Either Side)

Minimum 11 (279)

Maximum

14 (356)

22−7−16

(570)

Overall

(Maximum)

17−1/2 (446) RAB−B (98M60)

21 (533) RAB−C (98M58)

24−1/2 (622) RAB−D (98M59)

OPTIONAL RAB

RETURN AIR BASE

7/8

(22)

23 (584)

27−5/8 (702)

SIDE VIEW

FRONT VIEW

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

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

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

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

FIGURE 9

G61MP applications which include side return air and a condensate trap installed on the same side of the cabinet require either a return air base or field−fabricated transition to accommodate an optional IAQ accessory taller than 14.2".

Side Return Air

Remove the two screws that secure the bottom cap to the furnace. Pivot the bottom cap down to release the bottom panel. Once the bottom panel has been removed, reinstall the bottom cap. See figure 11.

Removing the Bottom Panel

(with transition and filter)

3/4

(19)

20" X 25" X 1"

(508mm X635mm X 25mm)

Return

Air

Plenum

Transition

FIGURE 10

Air Filter

Screw

Bottom Cap

Bottom Panel

FIGURE 11

Page 11

Page 12

Setting an Upflow Unit

When the side return air inlets are used in an upflow application, it may be necessary to install leveling bolts on the bottom of the furnace. Use field−supplied corrosion−resistant 5/16 inch machine bolts (4) and nuts (8). See figure 12.

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

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

ter hole in each corner of the furnace’s bottom. See figure 12 for the correct location of the holes. Drill through the bottom panel and the bottom flange of the cabinet.

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

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

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

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

4 − Adjust the outside nut to the appropriate height and

tighten the inside nut to secure the arrangement.

NOTE − The unit may be tilted back−to−front a maximum of 1". This will ensure proper draining of the heat exchanger.

Leveling Bolt Installation

Inches (mm)

3/8

(10)

Furnace Front

3/8

(10)

1−3/4

(44)

Furnace

1−3/4

(44)

Leveling Bolt

Locations

Bottom

Leveling Bolt

Locations

3/8

(10)

1−3/4

(44)

1−3/4 (44)

3/8

(10)

FIGURE 12

Downflow Applications

The unit may be installed three ways in downflow applications: on non−combustible flooring, on combustible flooring using an additive base, or on a reverse−flow cooling cabinet. Do not drag the unit across the floor in the down-

flow position. Flange damage will result.

After unit has been properly set in place, position provided logo over existing logo and affix sticker on front panel.

Refer to figure 13 for clearances in downflow applications.

Downflow Application Installation Clearances

Top

Left Side

Bottom

Top 0

*Front 0

Back 0

Sides 0†

Vent 0

Floor NC‡

*Front clearance in alcove installation must be 24 in. (610 mm). Maintain a minimum of 24 in. (610 mm) for front service access. †Allow proper clearances to accommodate condensate trap and vent pipe installation. ‡The furnace may be installed on a combustible wood floor if an optional additive base is installed between the furnace and the combustible floor.

Right Side

FIGURE 13

Installation on Non−Combustible Flooring

1 − Cut floor opening keeping in mind clearances listed on

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

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

opening.

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

the unit.

4 − Ensure that the seal is adequate.

TABLE 1

NON−COMBUSTIBLE FLOOR OPENING SIZE

Model No.

B Cabinet (17.5") 19 − 3/4 502 16 − 5/8 422

C Cabinet (21") 19 − 3/4 502 20−1/8 511

D Cabinet (24.5") 19 − 3/4 502 23 − 5/8 600

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

Front to Rear Side to Side

in. mm in. mm

Page 12

Page 13

Installation on Combustible Flooring

(Using an Additive Base)

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

tive base must be installed between the furnace and the floor. The base must be ordered separately. See table 2 for opening size to cut in floor.

CAUTION

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

TABLE 2

ADDITIVE BASE FLOOR OPENING SIZE

Cabinet

Width

B Cabinet

(17.5")

C Cabinet

(21")

D Cabinet

(24.5")

Catalog

Number

11M60

11M61

11M62

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

3 − Check fiberglass strips on additive base to make sure

they are properly glued and positioned.

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

num flanges seal against fiberglass strips.

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

5 − Set the furnace over the plenum.

6 − Ensure that the seal between the furnace and plenum

is adequate.

Front to Rear Side to Side

in. mm in. mm

22 559 18 − 3/4 476

22 559 22 − 3/4 578

22 559 25 − 3/4 654

Installation on Cooling Coil Cabinet

1 − Refer to reverse−flow coil installation instructions for

correctly sized opening in floor and installation of cabinet.

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

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

3 − Seal the cabinet and check for air leaks.

Return Air Opening −− Downflow Units

Return air may be brought in only through the top opening of a furnace installed in the downflow position.The following steps should be taken when installing plenum:

1 − Bottom edge of plenum should be flanged with a

hemmed edge (See figure 15 or 16).

2 − Sealing strips should be used to ensure an airtight seal

between the cabinet and the plenum.

3 − In all cases, plenum should be secured to top of fur-

nace using sheet metal screws.

4 − Make certain that an adequate seal is made.

PLENUM

(Field Provided)

SEALING STRIP (Field Provided)

SECURE FROM

OUTSIDE CABINET

CABINET

SIDE PANEL

Side View

G61MP UNIT

PROPERLY

SIZED FLOOR

OPENING

FIGURE 14

SUPPLY AIR PLENUM

ADDITIVE BASE

Page 13

PLENUM

(Field Provided)

SECURE FROM

INSIDE CABINET

FIGURE 15

SEALING STRIP (Field Provided)

CABINET

SIDE PANEL

Side View

FIGURE 16

Page 14

Horizontal Applications

The G61MP furnace can be installed in horizontal applications with either right− or left−hand air discharge.

The G61MP may also be installed as a unit heater. Either suspend the furnace as shown in figure 18, or install the furnace on a field−fabricated raised platform. The unit must be supported at both ends and beneath the blower deck to prevent sagging.

Refer to figure 17 for clearances in horizontal applications.

Horizontal Application

Installation Clearances

Right−Hand Discharge

Top

Left End Right End

Bottom (Floor)**

Left−Hand Discharge

Top

3 − If unit is installed above finished space, fabricate a

drain pan fitted with a 1/2 inch or 3/4 inch N.P.T. fitting.

4 − Using 3/8 inch rods and support frame kit or field−fabri-

cated supports, fabricate suspension hangers, keeping in mind front service access clearances.

5 − Mount unit on support frame as shown in figure 18.

6 − Continue with exhaust, condensate and intake line

piping instructions.

7 − If unit is suspended above finished space, hang the

field−provided drain pan below the support frame as shown in figure 18. Leave 5−1/2 inches for service clearance below unit for condensate trap.

8 − Route auxiliary drain line so that water draining from

this outlet will be easily noticed by the homeowner. If necessary, run the condensate line into a condensate pump to meet drain line slope requirements. The pump must be rated for use with condensing furnaces. Protect the condensate discharge line from the pump to the outside to avoid freezing.

TYPICAL HORIZONTAL CEILING APPLICATION

Left End Right End

Bottom (Floor)**

Top 0

Front* 0

Back 0

Ends 0

Vent 0

Floor 0‡

*Front clearance in alcove installation must be 24 in. (610 mm). Maintain a minimum of 24 in. (610 mm) for front service access. **A 5−1/2 service clearance must be maintained below the unit to provide for servicing of the condensate trap. ‡For installations on a combustible floor, do not install the furnace directly on carpeting, tile or other combustible materials other than wood flooring.

FIGURE 17

Suspended Installation of Horizontal Unit

NOTE − If unit is suspended in attic or crawl space, horizontal support kit (Cat No. 56J18 ordered separately) must be used to ensure proper unit support and coil drainage.

1 − Select location for unit keeping in mind service and

other necessary clearances. See figure 17.

2 − Provide service platform in front of unit.

BLOWER ACCESS PANEL 3/8 in. RODS

INTAKE/EXHAUST

CONNECTION

SUPPORT FRAME

DRAIN PAN

(to protect finished space)

FIGURE 18

Platform Installation of Horizontal Unit

1 − Select location for unit keeping in mind service and

other necessary clearances. See figure 17.

2 − Construct a raised wooden frame and cover frame

with a plywood sheet. Provide a service platform in front of unit. If unit is installed above finished space, fabricate a drain pan to be installed under unit. When installing the unit in a crawl space, a proper support platform may be created using cement blocks and the horizontal support frame kit (ordered separately,

Page 14

Page 15

Lennox part number 56J18). Position the support frame on top of the blocks and install the unit on the frame. Leave 5−1/2 inches for service clearance for condensate trap.

3 − Route auxiliary drain line so that water draining from

4 − Set unit in drain pan as shown in figure 19. Leave 5−1/2

inches for service clearance below unit for condensate trap.

5 − Continue with exhaust, condensate and intake piping

installation according to instructions.

EXHAUST PIPE

INTAKE PIPE

*GAS

CONNECTOR

Unit Heater Discharge Duct Guidelines

A field−fabricated and installed discharge air duct and grille cabinet is suitable for use with the G61MP heater. Keep the following items in mind when constructing the cabinet.

1 − Outer dimensions of cabinet should match those of the

unit heater, so the duct/grille cabinet installs flush with the unit heater cabinet. See figure 20.

2 − Flange both ends of duct/grille cabinet so that screws

can be used to secure cabinet to discharge end of unit heater.

3 − To ensure proper operation, the duct/grille cabinet

must be at least 18 inches long.

4 − Use #10−16 x 1/2 inch sheet metal screws to secure

duct/grille cabinet to unit, taking care not to damage internal components of unit heater when drilling holes or installing screws. See figure 20.

5 − Use adjustable, double−deflection grille(s) to distribute

discharge air. Adjust static pressure to be in the 0.06 inch to 0.10 inch w.c. range.

*Gas connector may be used for Canadian installation if acceptable by local authority having jurisdiction.

RAISED

PLATFORM

CONDENSATE LINE

SERVICE PLATFORM

FIGURE 19

G61MP Installed in Unit Heater Applications

The G61MP may also be installed as a unit heater. Either suspend the furnace from roof rafters or floor joists, as shown in figure 18, or install the furnace on a field−fabricated raised platform, as shown in figure 19. The unit must be supported at both ends and beneath the blower deck to prevent sagging. The condensate trap must be installed where it can be serviced at a later date.

18 in.

MIN.

DRAIN PAN

(to protect

finished

space)

NOTE − When installing duct/grille cabinet, take care not to damage internal unit

heater components when drilling holes or installing screws.

FIGURE 20

Return Air −− Horizontal Applications

Return air may be brought in only through the end of a furnace installed in the horizontal position. The furnace is equipped with a removable bottom panel to facilitate installation. See figure 11.

Page 15

Page 16

Filters

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

TABLE 3

Furnace

Cabinet Width

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

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

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

Side Return Bottom Return

Filter Size

Duct System

Use industry-approved standards to size and install the supply and return air duct system. This will result in a quiet and low-static system that has uniform air distribution.

NOTE − Operation of this furnace in heating mode (indoor blower operating at selected heating speed) with an external static pressure which exceeds 0.5 inches w.c. may result in erratic limit operation.

Supply Air Plenum

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

Return Air Plenum

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

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

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

Pipe & Fittings Specifications

All pipe, fittings, primer and solvent cement must conform with American National Standard Institute and the American Society for Testing and Materials (ANSI/ASTM) standards. The solvent shall be free flowing and contain no lumps, undissolved particles or any foreign matter that adversely affects the joint strength or chemical resistance of the cement. The cement shall show no gelation, stratification, or separation that cannot be removed by stirring. Refer to the table 4 for approved piping and fitting materials.

CAUTION

Solvent cements for plastic pipe are flammable liquids and should be kept away from all sources of ignition. Do not use excessive amounts of solvent cement when making joints. Good ventilation should be maintained to reduce fire hazard and to minimize breathing of solvent vapors. Avoid contact of cement with skin and eyes.

PIPING AND FITTINGS SPECIFICATIONS

PIPE & FITTING MATERIAL

Schedule 40 PVC (Pipe) D1785 Schedule 40 PVC (Cellular Core Pipe) F891

Schedule 40 PVC (Fittings) D2466

Schedule 40 CPVC (Pipe) F441

Schedule 40 CPVC (Fittings) F438

SDR−21 PVC or SDR−26 PVC (Pipe) D2241

SDR−21 CPVC or SDR−26 CPVC (Pipe) F442

Schedule 40 ABS Cellular Core DWV (Pipe) F628

Schedule 40 ABS (Pipe) D1527

Schedule 40 ABS (Fittings) D2468

ABS−DWV (Drain Waste & Vent) (Pipe & Fittings)

PVC−DWV (Drain Waste & Vent) Pipe & Fittings)

PRIMER & SOLVENT CEMENT

PVC & CPVC Primer F656 PVC Solvent Cement D2564

CPVC Solvent Cement F493

ABS Solvent Cement D2235

PVC/CPVC/ABS All Purpose Cement For Fittings & Pipe of the same material

ABS to PVC or CPVC Transition Solvent Cement

CANADA PIPE & FITTING & SOLVENT

CEMENT

PVC & CPVC Pipe and Fittings PVC & CPVC Solvent Cement

ABS to PVC or CPVC Transition Cement

TABLE 4

ASTM

SPECIFICATION

D2661

D2665

ASTM

SPECIFICATION

D2564, D2235,

F493

D3138

MARKING

ULCS636

Page 16

Page 17

Use PVC primer and solvent cement or ABS solvent cement meeting ASTM specifications, refer to Table 4. As an alternate, use all purpose cement, to bond ABS, PVC, or CPVC pipe when using fittings and pipe made of the same materials. Use transition solvent cement when bonding ABS to either PVC or CPVC.

Low temperature solvent cement is recommended. Metal or plastic strapping may be used for vent pipe hangers. Uniformly apply a liberal coat of PVC primer for PVC or use a clean dry cloth for ABS to clean inside socket surface of fitting and male end of pipe to depth of fitting socket.

TABLE 5

OUTDOOR TERMINATION KITS AND CORRESPONDING EQUIVALENCIES

Vent Pipe Length Equivalency (feet)

Outdoor Exhaust Accel-

erator

(Dia. X

Length)

UNIT

MODEL

VENT

PIPE

DIA.

(in.)

1−1/2" X 12"

2 4

2−1/2 5

36B−045

36B−070 36B−071

48C−090 60C−090 60C−091

48C−110 60C−110 60C−111

60D−135

3 7

4 14

2 4

2−1/2 5

3 8

4 14

2−1/2

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

*Requires field−provided and installed 1−1/2" exhaust accelerator. **Requires field−provided and installed 2" exhaust accelerator.

Outdoor Ex-

haust Accel-

erator

(Dia. X

Length)

2" X 12"

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

1−1/2"

Concentric

Kit

71M80

or 44W92

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Canadian Applications Only − Pipe, fittings, primer and solvent cement used to vent (exhaust) this appliance must be certified to ULC S636 and supplied by a single manufacturer as part of an approved vent (exhaust) system. When bonding the vent system to the furnace, use ULC S636 approved One−Step Transition Cement to bond the pipe to the flue collar, or to bond the 90° elbow or reducing 90° elbow to the flue collar. In addition, the first three feet of vent pipe from the furnace flue collar must be accessible for inspection.

Table 5 lists the available exhaust termination kits, as well as vent pipe equivalencies which must be used when sizing vent pipe. All Lennox vent terminations are PVC.

2" Con-

centric Kit

69M29

or 44W92

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

3 3

6 6

12 12

6 6

12 12

Not

Allowed

Not

Allowed

 Termination kits 44W92 (includes 1−1/2" reducer), 44W93, 30G28 and 81J20 approved for use in Canadian installations.

3" Con-

centric Kit

60L46

or 44W93

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

2" Wall Plate

Kit

22G44

or 30G28

4 4* 4

5 5* 5

7 7* 7

14 14* 14

4 4* 4

5 5* 5

8 8* 8

14 14* 14

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

3" Wall Plate

Kit

44J40

or 81J20

1 1**

2 2**

4 4**

2 2

4 4

2" Wall

Ring Kit

15F74

Not

Allowed

Not

Allowed

Page 17

Page 18

Vent Piping Guidelines

The G61MP can be installed as either a Non−Direct Vent or a Direct Vent gas central furnace.

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

Intake and exhaust pipe sizing in Direct Vent applications and exhaust pipe sizing in Non-Direct Vent applications −− Size pipe according to tables 6 and 7. Table 6 lists the minimum equivalent vent pipe lengths permitted. Table 7 lists the maximum equivalent pipe lengths permitted.

Maximum vent length is defined as:

Total length (linear feet) of pipe,

Plus Equivalent length (feet) of fittings, Plus Equivalent length (feet) of termination. NOTE − Include ALL pipe and ALL fittings, both in doors and outdoors.

Regardless of the diameter of pipe used, the standard roof and wall terminations described in section Exhaust Piping Terminations should be used. Exhaust vent termination pipe is sized to optimize the velocity of the exhaust gas as it exits the termination. Refer to table 8.

*NOTE − The exhaust pipe should be offset a minimum of 12 inches to avoid the possibility of water droplets being re-

leased from the exhaust termination. The minimum exhaust vent length is 15 ft. Shorter exhaust vent lengths may result in the discharge of water droplets from the exhaust termination, in spite of the 12−inch vertical offset. See figure 21.

Each 90° elbow (including those provided with the furnace) of any diameter is equivalent to 5 feet (1.52m) of vent pipe of the same diameter. Two 45° elbows are equivalent to one 90° elbow of the same diameter. One 45° elbow is equal to 2.5 feet (.76m) of vent pipe of the same diameter.

In some applications which permit the use of several different sizes of vent pipe, a combination vent pipe may be used. Contact the Application Department for assistance in sizing vent pipe in these applications.

NOTE − The flue collar on all models is sized to accommodate 2" Schedule 40 flue pipe. When vent pipe which is larger than 2" must be used in an upflow application, a 2" elbow must be applied at the flue collar in order to properly transition to the larger diameter flue pipe. This elbow must be added to the elbow count used to determine acceptable vent lengths. Assign an equivalent feet value to this elbow according to the larger size pipe being used. Contact Lennox’ Application Department for more information concerning sizing of vent systems which include multiple pipe sizes.

*12" Min.

Upflow and Downflow Application

Rooftop Termination

*12" Min.

Horizontal Application

Rooftop Termination

*A minimum of 1/4" (6mm) drop for each 12" (305mm) of horizontal run is mandatory for drainage

Exhaust Pipe Offset

12" Min.

Upflow and Downflow Application

Side Wall Termination

*12" Min.

Horizontal Application

Side Wall Termination

FIGURE 21

Page 18

Page 19

Use the following steps to correctly size vent pipe diameter.

Refer to Vent Pipe Size Determination Worksheet on page 53.

1 − Determine the vent termination and its corresponding

equivalent feet value according to table 5.

2 − Determine the number of 90° elbows required for both

indoor and outdoor (e.g. snow riser) use. Calculate the corresponding equivalent feet of vent pipe.

3 − Determine the number of 45° elbows required for both

indoor and outdoor use. Calculate the corresponding equivalent feet of vent pipe.

4 − Determine the length of straight pipe required.

5 − Add the total equivalent feet calculated in steps 1

through 4 and compare that length to the maximum values given in table 6 for the proposed vent pipe diameter. If the total equivalent length required exceeds the maximum equivalent length listed in the appropriate table, evaluate the next larger size pipe.

TABLE 6

MINIMUM VENT PIPE LENGTHS

G61MP

MODEL

045, 070, 071, 090,

091

110, 111**

135***

*Any approved termination may be added to the minimum equivalent length listed.

**G61MP−48C−110, G61MP−60C−110 and G61MP−60C−111 must have 90° street ell (supplied or field replacment Canadian kit) installed directly into unit flue collar.

***G61MP−60D−135 must have 3" to 2" reducing ell (supplied or field replacment Canadian ki) installed directly into unit flue collar.

MIN. EQUIV.

VENT LENGTH

15 ft.*

EXAMPLE

5 ft. plus 2 elbows of 2", 2−1/2", 3"

or 4" diameter pipe

5 ft. plus 2 elbows of 2−1/2" 3" or 4"

diameter pipe

5 ft. plus 2 elbows of 3" or 4"

diameter pipe

MAXIMUM VENT PIPE LENGTHS

TABLE 7

MAXIMUM EQUIVALENT VENT

ALTITUDE

0 − 4500

(0 − 1371 m)

4501−7500

(1372−2286 m)

7501 − 10000

(2287 − 3048 m)

n/a −− Not allowed. *G61MP−48C−110, G61MP−60C−110 and G61MP−60C−111must have 90°

street ell (supplied or field replacment Canadian ki) installed directly into unit flue collar.

**G61MP−60D−135 must have 3" to 2" reducing ell (supplied or field replacment Canadian ki) installed directly into unit flue collar.

***90° elbows used in configuration of G61MP−60D−135 vent, must be limited to 3" sweep elbows.

†On G61MP−071, −091 and −111 units, sweep elbows must be used for all 90° elbows in the venting system when 2", 2−1/2" or 3" vent pipe is used. Sweep elbows are recommended for use in vent systems of other G61MP units.

G61MP

MODEL

045 59 65 77 234 070 59 65 78 214

071† 59 65 78 214

090 26 42 72 204 091† 26 42 72 204 110* n/a 32 72 179

111*† n/a 32 72 179

135**‡ n/a n/a 61 160

045 59 65 77 234

070 59 65 78 214 071† 59 65 78 214

090 26 42 72 204 091† 26 42 72 204 110* n/a 32 72 179

111*† n/a 32 72 179

135**‡ n/a n/a 46 160

045 59 65 77 234

070 59 65 78 214 071† 59 65 78 214

090 26 42 72 204 091† 26 42 72 204 110* n/a 32 72 179

111*† n/a 32 72 179

135**‡ n/a n/a 46 160

PIPE

LENGTH FEET

2−1/2"

PIPE

PIPE4"PIPE

Page 19

Page 20

Joint Cementing Procedure

All cementing of joints should be done according to the specifications outlined in ASTM D 2855.

WARNING

DANGER OF EXPLOSION!

Fumes from PVC glue may ignite during system check. Allow fumes to dissipate for at least 5 minutes before placing unit into operation.

1 − Measure and cut vent pipe to desired length.

2 − Debur and chamfer end of pipe, removing any ridges

or rough edges. If end is not chamfered, edge of pipe may remove cement from fitting socket and result in a leaking joint.

3 − Clean and dry surfaces to be joined.

4 − Test fit joint and mark depth of fitting on outside of pipe.

5 − Uniformly apply a liberal coat of PVC primer for PVC or

use a clean dry cloth for ABS to clean inside socket surface of fitting and male end of pipe to depth of fitting socket.

NOTE − Furnace flue collar and air inlet fitting are both made of ABS material. Use transition solvent cement when bonding ABS to either PVC or CPVC, refer to the procedure specified in ASTM D3138..

6 − Promptly apply solvent cement to end of pipe and in-

side socket surface of fitting. Cement should be applied lightly but uniformly to inside of socket. Take care to keep excess cement out of socket. Apply second coat to end of pipe.

NOTE − Time is critical at this stage. Do not allow primer to dry before applying cement.

7 − Immediately after applying last coat of cement to pipe,

and while both inside socket surface and end of pipe are wet with cement, forcefully insert end of pipe into socket until it bottoms out. Turn PVC pipe 1/4 turn during assembly (but not after pipe is fully inserted) to distribute cement evenly. DO NOT turn ABS or cellular core pipe.

NOTE − Assembly should be completed within 20 seconds after last application of cement. Hammer blows should not be used when inserting pipe.

8 − After assembly, wipe excess cement from pipe at end

of fitting socket. A properly made joint will show a bead around its entire perimeter. Any gaps may indicate a defective assembly due to insufficient solvent.

9 − Handle joints carefully until completely set.

Page 20

Page 21

Venting Practices

The thickness of construction through which vent pipes may be installed is 24" (610mm) maximum and 3" (76mm) minimum. If a G61MP furnace replaces a furnace which was commonly vented with another gas appliance, the size of the existing vent pipe for that gas appliance must be checked. Without the heat of the original furnace flue products, the existing vent pipe is probably oversized for the single water heater or other appliance. The vent should be checked for proper draw with the remaining appliance.

1 − Use recommended piping materials for exhaust pip-

ing.

2 − Secure all joints so that they are gas-tight using ap-

proved cement.

Suspend piping using hangers at a minimum of every 5 feet (1.52m) for schedule 40 PVC and every 3 feet (.91m) for ABS−DWV, PVC− DWV, SPR−21 PVC, and SDR−26 PVC piping. A suitable hanger can be fabricated by using metal or plastic strapping or a large wire tie.

3 − In areas where piping penetrates joists or interior

walls, hole must be large enough to allow clearance on all sides of pipe through center of hole using a hanger.

STRAPPING

(metal, plastic

or large wire

ties)

FIGURE 22

4 − Isolate piping at the point where it exits the outside wall

or roof in order to prevent transmission of vibration to the structure.

5 − When furnace is installed in a residence where unit is

shut down for an extended period of time, such as a vacation home, make provisions for draining condensate collection trap and lines.

Exhaust Piping

NOTE − A 2" diameter PVC street ell is located on the blower deck of 48C−110, 60C−110 and 60C−111 units. In upflow or downflow applications the street ell must be glued using transition solvent cement directly into the unit flue collar. See figure 23. A 3" to 2" PVC reducing ell is located on the blower deck of the 60D−135 units. In up-

flow or downflow applications, the reducing ell must be glued using transition solvent cement directly into the

unit flue collar.

1 − Choose the appropriate side for venting in upflow or

downflow positions. Exhaust piping exits from the top of the unit in horizontal air discharge applications. Glue the field−provided exhaust vent pipe (or provided street ell or reducing ell in upflow or downflow applications) to the flue collar. All PVC cement joints should be made according to the specifications outlined in ASTM D 2855. Refer to pipe and fittings specifications and gluing procedures.

TYPICAL EXHAUST PIPE CONNECTIONS AND CONDENSATE TRAP INSTALLATION

IN UPFLOW OR DOWNFLOW DIRECT OR NON−DIRECT VENT APPLICATIONS

(Right−Hand Exit in Upflow Application Shown)

PLUG

VENT PLUG

(Must be

glued in

place)

PLUG

*2" diameter street elbow provided.

**Street elbow may be used on −045, −070, 071, −090 and −091.

PLUG

CONDENSATE

TRAP

(Must be installed

on same side as

exhaust piping)

2−1/2", 3", OR

**2"

2−1/2", 3", OR

TRANSITION

*2"

G61MP−110, −111 with

2−1/2", 3", OR 4" vent

pipe

FIGURE 23

2" max

length

TRANSITION

G61MP−045,

−070, −071 or

−090, −091 with 2−1/2", 3", or 4"

vent pipe

TRANSITION (use only if 4"

pipe is

required)

G61MP−135, −110, −111

with

3" OR 4" vent pipe

45°

MAX

SIDE VIEW

2" max

length

3" to 2" REDUCING ELBOW

45°

MAX

(provided)

Page 21

Page 22

TYPICAL EXHAUST PIPE CONNECTIONS

HORIZONTAL DIRECT OR NON−DIRECT VENT

APPLICATIONS

(Horizontal Right−Hand Air

Discharge Application Shown)

* 2" maximum length

for −110, −111 −135 only

DO NOT transition from smaller to larger pipe size in horizontal runs of exhaust pipe.

2−1/2", 3", OR

TRANSITION

*2"

36B−045 36B−070 36B−071 48C−090 60C−090 60C−091

48C−110 60C−110* 60C−111* 60D−135*

36B−045 36B−070 36B−071 36C−090 60C−090 60C−091

FIGURE 24

IMPORTANT

Exhaust piping and condensate trap must be installed on the same side of the unit in upflow and dowflow applications or use alternate drain kit 76M20.

2 − All horizontal runs of exhaust pipe must slope back to-

ward unit. A minimum of 1/4" (6mm) drop for each 12" (305mm) of horizontal run is mandatory for drainage. Horizontal runs of exhaust piping must be supported every 5 feet (1.52m) using hangers.

NOTE − Exhaust piping should be checked carefully to make sure there are no sags or low spots.

3 − On the opposite side of the cabinet, glue the provided

2" ABS vent plug into the unused ABS flue collar with ABS or all purpose solvent cement.

4 − Route piping to outside of structure. Continue with

installation following instructions given in piping termination section.

CAUTION

Do not discharge exhaust into an existing stack or stack that also serves another gas appliance. If vertical discharge through an existing unused stack is required, insert PVC pipe inside the stack until the end is even with the top or outlet end of the metal stack.

CAUTION

The exhaust vent pipe operates under positive pressure and must be completely sealed to prevent leakage of combustion products into the living space.

Intake Piping

The G61MP furnace may be installed in either direct vent or non−direct vent applications. In non−direct vent applica- tions, when intake air will be drawn into the furnace from the surrounding space, the indoor air quality must be considered and guidelines listed in Combustion, Dilution and Ventilation Air section must be followed.

The G61MP unit is designed for either left−side or right−side air intake connections in either upflow or downflow applications. In horizontal applications, air intake must be brought in through the top. Intake air piping is independent of exhaust piping.

Follow the next four steps when installing the unit in direct vent applications, where combustion air is taken from outdoors and flue gases are discharged outdoors. The pro-

vided air intake screen must not be used in direct vent applications.

1 − Use transition solvent cement to connect PVC pipe to

the ABS slip connector located on the side of the burner box.

2 − Use a #7 sheet metal screw to secure the intake pipe to

the connector, if desired. A pilot indentation is provided in the slip connector to assist in locating and starting the fastener.

3 − Glue the provided 2" ABS plug into the unused ABS air

intake connector on the opposite side of the cabinet with ABS all pupose cement.

4 − Route piping to outside of structure. Continue with instal-

lation following instructions given in general guide lines for piping terminations and in intake and exhaust piping terminations for direct vent sections. Refer to figure 25 for pipe sizes.

Page 22

Page 23

TYPICAL AIR INTAKE PIPE CONNECTIONS

UPFLOW OR DOWNFLOW DIRECT VENT APPLICATIONS

(Right−Hand Exit in Upflow Application Shown)

2

PLUG

(Must be

glued in

place)

2

−36B−045−

−36B−070

−36B−071

−48C−090

−60C−090

−60C−091

2

TYPICAL AIR INTAKE PIPE CONNECTIONS

HORIZONTAL DIRECT VENT APPLICATIONS

(Horizontal Right−Hand Air Discharge Application Shown)

2−1/2",

3" OR

4

TRANSITION

2

−36B−045

−36B−070

−36B−071

−48C−090

−60C−090

−60C−091

−48C−110

−60C−110

−60C−111

*Limit pipe length to 4" in G61MP−110,

−111, −135 applications.

FIGURE 25

Follow the next three steps when installing the unit in NonDirect Vent applications where combustion air is taken

from indoors and flue gases are discharged outdoors.

TRANSITION

*2"

2−1/2",

3" OR

4

−36B−045

−36B−070

−36B−071

−48C−090

−60C−090

−60C−091

−48C−110

−60C−110*

−60C−111*

−60D−135*

*Limit pipe length to 4" in −110, −111,

−135 applications.

−36B−045

−36B−070

−36B−071

−48C−090

−60C−090

−60C−091

−48C−110

−60C−110

−60C−111

−36B−045

−36B−070

−36B−071

−48C−090

−60C−090

−60C−091

−48C−110

−60C−110*

−60C−111

−60D−135*

2”

−36B−045

−36B−070

−36B−071

−48C−090

−60C−090

−60C−091

2”

2−1/2”,

3” OR 4”

TRANSITION

*2”

2”

TRANSITION

2−1/2”,

3” OR 4”

2”

TYPICAL AIR INTAKE PIPE CONNECTIONS

UPFLOW OR HORIZONTAL NON−DIRECT

(Right−Hand Exit in Upflow Application Shown)

PLUG

(Must be

glued in

place)

NOTE − Debris screen and elbow may be rotated, so that screen may be positioned to face forward, backward or downward.

VENT APPLICATIONS

6 in. Max.

INTAKE

DEBRIS

SCREEN

(Provided)

FIGURE 26

FIGURE 27

Page 23

Page 24

TYPICAL AIR INTAKE PIPE CONNECTIONS

DOWNFLOW NON−DIRECT VENT APPLICATIONS

(Right−Hand Exit in Downflow Applications Shown)

2" SWEEP

ELL

INTAKE

DEBRIS

SCREEN

(Provided)

PLUG

(Must be

glued in

place)

6 in. Max.

INTAKE DEBRIS

SCREEN

(Provided)

Downflow

Evaporator

Coil

FIGURE 28

1 − Use field−provided materials and the factory−provided

air intake screen to route the intake piping as shown in figures 27 and 28. Maintain a minimum clearance of 3" (76mm) around the air intake opening. The air intake opening (with the protective screen) should always be directed either downward or straight out. Use 2" pipe and fittings only and make sure that the air intake does not extend more than 6" beyond the G61MP cabinet.

The air intake connector must not be located near the floor. To avoid this complication in downflow applications which do not include a downflow

PLUG

(Must be

glued in

place)

Downflow Additive Flloor Base

2" SWEEP ELL

18 in.

NOTE − Debris screen and sweep ell may be rotated, so that screen may be positioned to face forward, backward or to the side.

evaporator coil, the intake air routing should be modified as shown in figure 28.

2 − Use a #7 sheet metal screw to secure the intake pipe to

the connector, if desired. A pilot indentation is provided in the slip connector to assist in locating and starting the fastener.

3 − Glue the provided 2" ABS plug into the unused ABS air

intake connector on the opposite side of the cabinet with ABS or all purpose solvent cement.

Page 24

Page 25

General Guidelines for Vent Terminations

In Non-Direct Vent applications, combustion air is taken from indoors and the flue gases are discharged to the outdoors. The G61MP is then classified as a non-direct vent, Category IV gas furnace.

In Direct Vent applications, combustion air is taken from outdoors and the flue gases are discharged to the outdoors. The G61MP is then classified as a direct vent, Category IV gas furnace.

In both Non-Direct Vent and Direct Vent applications, the vent termination is limited by local building codes. In the absence of local codes, refer to the current National Fuel Gas Code ANSI Z223−1/NFPA 54 in U.S.A., and current CSA−B149 Natural Gas and Propane Installation Codes in Canada for details.

Position termination according to location given in figure 29 or 30. In addition, position termination so it is free from any obstructions and 12" above the average snow accumulation.

At vent termination, care must be taken to maintain protective coatings over building materials (prolonged exposure to exhaust condensate can destroy protective coatings). It is recommended that the exhaust outlet not be located within 6 feet (1.8m) of a condensing unit because the condensate can damage the painted coating.

NOTE − If winter design temperature is below 32°F (0°C), exhaust piping should be insulated with 1/2" (13mm), Armaflex or equivalent when run through unheated space. Do not leave any surface area of exhaust pipe open to outside air; exterior exhaust pipe should be insulated with 1/2"

(13mm) Armaflex or equivalent. In extreme cold climate areas, 3/4" (19mm) Armaflex or equivalent may be necessary. Insulation on outside runs of exhaust pipe must be painted or wrapped to protect insulation from deterioration. Exhaust pipe insulation may not be necessary in some specific applications.

NOTE − During extremely cold temperatures, below approximately 20°F (6.7°C), units with long runs of vent pipe through unconditioned space, even when insulated, may form ice in the exhaust termination that prevents the unit from operating properly. Longer run times of at least 5 minutes will alleviate most icing problems. Also, a heating cable may be installed on exhaust piping and termination to prevent freeze−ups. Heating cable installation kit is available from Lennox. See Condensate Piping section for part numbers.

IMPORTANT

Do not use screens or perforated metal in exhaust terminations. Doing so will cause freeze−ups and may block the terminations.

IMPORTANT

For Canadian Installations Only: In accordance to CSA International B149 installation codes, the minimum allowed distance between the combustion air intake inlet and the exhaust outlet of other appliances shall not be less than 12 inches (305mm).

Page 25

Page 26

VENT TERMINATION CLEARANCES

FOR NON−DIRECT VENT INSTALLATIONS IN THE USA AND CANADA

INSIDE CORNER

DETAIL

Fixed

Closed

Operable

VENT TERMINAL

AIR SUPPLY INLET

US Installations

A =

B =

C =

Clearance above grade, veranda,

porch, deck or balcony

Clearance to window or

door that may be opened

Clearance to permanently

12 inches (305mm) or 12 in. 305mm)

above average snow accumulation.

4 feet (1.2 m) below or to side of opening;

1 foot (30 cm) above opening

closed window

D =

Vertical clearance to ventilated soffit

located above the terminal within a

* Equal to or greater than soffit depth.

horizontal distance of 2 feet (mm)

from the center line of the terminal

E =

F =

G =

H =

I =

J =

Clearance to unventilated soffit

Clearance to outside corner

Clearance to inside corner

Clearance to each side of center line ex-

tended above meter / regulator assembly

Clearance to service regulator

vent outlet

Clearance to non−mechanical air

supply inlet to building or the com-

bustion air inlet to any other ap-

* Equal to or greater than soffit depth.

* No minimum to outside corner * No minimum to outside corner

* 3 feet (.9m) * 3 feet (.9m)

3 feet (.9m) within a height 15 feet (4.5m)

above the meter / regulator assembly

* 3 feet (.9m)

4 feet (1.2 m) below or to side of opening;

1 foot (30 cm) above opening

pliance

K =

L =

Clearance to mechanical air sup-

ply inlet

Clearance above paved sidewalk or

3 feet (.9m) above if within 10 feet

(3m) horizontally

7 feet (2.1m)

paved driveway located on public property

M =

 A vent shall not terminate directly above a sidewalk or paved driveway that is located

between two single family dwellings and serves both dwellings.  Permitted only if veranda, porch, deck or balcony is fully open on a minimum of two sides beneath the floor. Lennox recommends avoiding this location if possible.

Clearance under veranda, porch,

deck or balcony

In accordance with the current ANSI Z223.1/NFPA 54 Natural Fuel Gas Code

In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code

*12 inches (305mm)

FIGURE 29

Operable

Fixed

Closed

AREA WHERE TERMINAL IS NOT PERMITTED

Canadian Installations

12 inches (305mm) or 12 in. 305mm)

above average snow accumulation.

6 inches (152mm) for appliances <10,000

Btuh (3kw), 12 inches (305mm) for

appliances > 10,000 Btuh (3kw) and

<100,000 Btuh (30kw), 36 inches (.9m)

for appliances > 100,000 Btuh (30kw)

* 12"

* Equal to or greater than soffit depth.

3 feet (.9m) within a height 15 feet (4.5m)

above the meter / regulator assembly

3 feet (.9m)

6 inches (152mm) for appliances <10,000

Btuh (3kw), 12 inches (305mm) for

appliances > 10,000 Btuh (3kw) and

<100,000 Btuh (30kw), 36 inches (.9m)

for appliances > 100,000 Btuh (30kw)

6 feet (1.8m)

7 feet (2.1m)

12 inches (305mm)

*For clearances not specified in ANSI Z223.1/NFPA 54 or CSA B149.1, clearance will be in accordance with local installation codes and the requirements of the gas supplier and these installation instructions."

Page 26

Page 27

VENT TERMINATION CLEARANCES

FOR DIRECT VENT INSTALLATIONS IN THE USA AND CANADA

INSIDE CORNER

DETAIL

Fixed

Closed

Operable

VENT TERMINAL

AIR SUPPLY INLET

US Installations

A =

B =

Clearance above grade, veranda,

porch, deck or balcony

Clearance to window or

door that may be opened

12 inches (305mm) or 12 in. 305mm)

above average snow accumulation.

6 inches (152mm) for appliances <10,000

Btuh (3kw), 9 inches (mm) for appliances

> 10,000 Btuh (3kw) and <50,000 Btuh

(15 kw), 12 inches (305mm) for ap-

pliances > 50,000 Btuh (15kw)

C =

Clearance to permanently

closed window

D =

Vertical clearance to ventilated soffit

located above the terminal within a

* Equal to or greater than soffit depth

horizontal distance of 2 feet (mm)

from the center line of the terminal

E =

F =

G =

H =

Clearance to unventilated soffit

Clearance to outside corner

Clearance to inside corner

Clearance to each side of center line ex-

tended above meter / regulator assembly

I =

Clearance to service regulator

vent outlet

J =

Clearance to non−mechanical air

supply inlet to building or the com-

bustion air inlet to any other ap-

pliance

* Equal to or greater than soffit depth * Equal to or greater than soffit depth

* No minimum to outside corner

* 3 feet (.9m)

3 feet (.9m) within a height 15 feet (4.5m)

above the meter / regulator assembly

3 feet (.9m)

6 inches (152mm) for appliances <10,000

Btuh (3kw), 9 inches (mm) for appliances

> 10,000 Btuh (3kw) and <50,000 Btuh

(15 kw), 12 inches (305mm) for ap-

pliances > 50,000 Btuh (15kw)

K =

L =

M =

 A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings.

 Permitted only if veranda, porch, deck or balcony is fully open on a minimum of two sides beneath the floor. Lennox recommends avoiding this location if possible.

Clearance to mechanical air sup-

ply inlet

Clearance above paved sidewalk or

paved driveway located on public property

Clearance under veranda, porch,

deck or balcony

In accordance with the current ANSI Z223.1/NFPA 54 Natural Fuel Gas Code

In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code

3 feet (.9m) above if within 10 feet

(3m) horizontally

* 7 feet (2.1m)

*12 inches (305mm)

FIGURE 30

Operable

Fixed

Closed

AREA WHERE TERMINAL IS NOT PERMITTED

Canadian Installations

12 inches (305mm) or 12 in. 305mm)

above average snow accumulation.

6 inches (152mm) for appliances <10,000

Btuh (3kw), 12 inches (305mm) for

appliances > 10,000 Btuh (3kw) and

<100,000 Btuh (30kw), 36 inches (.9m)

for appliances > 100,000 Btuh (30kw)

* 12"

* Equal to or greater than soffit depth* Equal to or greater than soffit depth

* No minimum to outside corner

* 3 feet (.9m)

3 feet (.9m) within a height 15 feet (4.5m)

above the meter / regulator assembly

3 feet (.9m)

6 inches (152mm) for appliances <10,000

Btuh (3kw), 12 inches (305mm) for

appliances > 10,000 Btuh (3kw) and

<100,000 Btuh (30kw), 36 inches (.9m)

for appliances > 100,000 Btuh (30kw)

6 feet (1.8m)

7 feet (2.1m)

12 inches (305mm)

Page 27

Page 28

Details of Intake and Exhaust Piping Terminations for Direct Vent Installations

NOTE − In Direct Vent installations, combustion air is taken from outdoors and flue gases are discharged to outdoors.

Intake and exhaust pipes may be routed either horizontally through an outside wall or vertically through the roof. In attic or closet installations, vertical termination through the roof is preferred. Figures 31 through 39 show typical terminations.

1 − Exhaust and intake exits must be in same pressure

zone. Do not exit one through the roof and one on the side. Also, do not exit the intake on one side and the exhaust on another side of the house or structure.

2 − Intake and exhaust pipes should be placed as close

together as possible at termination end (refer to illustrations). Maximum separation is 3" (76mm) on roof terminations and 6" (152mm) on side wall terminations.

3 − If necessary, install a field−provided reducer to adapt

larger vent pipe size to termination pipe size.

4 − On roof terminations, the intake piping should termi-

nate straight down using two 90° elbows (See figure

31).

5 − Exhaust piping must terminate straight out or up as

shown. In rooftop applications, a reducer may be required on the exhaust piping at the point where it exits the structure to improve the velocity of exhaust away from the intake piping. See table 8.

NOTE − Care must be taken to avoid recirculation of exhaust back into intake pipe.

6 − On field supplied terminations for side wall exits, ex-

haust piping should extend a minimum of 12 inches (305mm) beyond the outside wall. Intake piping should be as short as possible. See figure 32.

7 − On field supplied terminations, a minimum separation

distance between the end of the exhaust pipe and the end of the intake pipe is 8 inches (203mm).

8 − If intake and exhaust piping must be run up a side wall

to position above snow accumulation or other obstructions, piping must be supported every 3 ft. (.9m) as shown in figure 22. Refer to figure 35 for proper piping method. In addition, WTK wall termination kit must be extended for use in this application. See figure 38. When exhaust and intake piping must be run up an outside wall, the exhaust piping is reduced to 1−1/2" (38mm) after the final elbow. The intake piping may be equipped with a 90° elbow turndown. Using turndown will add 5 feet (1.5m) to the equivalent length of the pipe.

9 − Based on the recommendation of the manufacturer, a

multiple furnace installation may use a group of up to four termination kits WTK assembled together horizontally, as shown in figure 37.

EXHAUST PIPE TERMINATION SIZE REDUCTION

TABLE 8

G61MP

MODEL

045, 070, −071 2", 2−1/2", 3" or 4" 1−1/2"

090, −091 2", 2−1/2", 3" or 4" 2"

110, −111 2−1/2", 3" or 4" *2"

135 3" or 4" *2"

*Approved 3" concentric termination kit terminates with 2−5/8" ID pipe.

Inches(mm)

8" (203) MIN

12" (305) ABOVE

AVERAGE SNOW

ACCUMULATION

3" (76) OR

2" (51) PVC

PROVIDE SUPPORT

FOR INTAKE AND

EXHAUST LINES

Exhaust Pipe Size Termination Pipe Size

3(76) MAX.

DIRECT VENT ROOF TERMINATION KIT

(15F75 or 44J41)

SIZE TERMINATION PIPE PER TABLE 8.

UNCONDITIONED

ATTIC SPACE

1/2" (13) FOAM INSULATION IN

UNCONDITIONED

SPACE

FIGURE 31

12" (305) MAX.

1/2" (13) ARMAFLEX

INSULATION IN

UNCONDITIONED SPACE

FIELD−

PROVIDED

REDUCER MAY

BE REQUIRED

TO ADAPT

LARGER VENT

PIPE SIZE TO

TERMINATION

TOP VIEW WALL RING KIT WITH STRAIGHT INTAKE

1/2 (13) ARMAFLEX

INSULATION IN

UNCONDITIONED

FIELD−

PROVIDED

REDUCER MAY

BE REQUIRED

TO ADAPT

LARGER VENT

PIPE SIZE TO

TERMINATION

Inches (mm)

TOP VIEW WALL RING KIT WITH 90° ELBOW ON INTAKE

OUTSIDE

SPACE

OUTSIDE

WALL

2" (51)

PVC

COUPLING

(unless supported)

6" (152)

8" (203)

MINIMUM

(15F74)

12 (305) MAX.

6 (152)

MAXIMUM

4 (102)

MINIMUM

(15F74)

1/2" (13)

ARMAFLEX

INSULATION

TERMINA-

MAXI-

MUM

TION PIPE

PER TABLE

Inches (mm)

1/2" (13)

ARMAFLEX

INSULATION

TERMINATION PIPE

PER TABLE 8.

SIZE

FIGURE 32

Page 28

Page 29

EXHAUST

TERMINATION

INTAKE

TERMINATION

12" (305) ABOVE

AVERAGE SNOW

ACCUMULATION

Inches (mm)

INTAKE

VENT

EXHAUST VENT

Front View

FIELD−PROVIDED

REDUCER MAY BE REQUIRED

TO ADAPT LARGER VENT

PIPE SIZE TO TERMINATION

EXHAUST

INTAKE

DIRECT VENT CONCENTRIC ROOFTOP TERMINATION

(71M80, 69M29 or 60L46)

FIGURE 33

Inches (mm)

EXHAUST

INTAKE

FIELD−PROVIDED

REDUCER MAY

BE REQUIRED TO

ADAPT LARGER

VENT PIPE SIZE

TO TERMINATION

DIRECT VENT CONCENTRIC WALL TERMINATION

(71M80, 69M29 or 60L46)

INTAKE

TERMINATION

12" (305) Min.

above grade or average

snow accumulation.

EXHAUST

TERMINATION

FIGURE 34

12" (305) MAX. for 2" (51)

(15F74)

(unless supported)

8 (203)

MIN.

12" (305) ABOVE

AVERAGE SNOW

ACCUMULATION

1/2" (13) FOAM

INSULATION

SIZE

TERMINATION

PIPE PER

TABLE 8.

Inches(mm)

UNCONDITIONED

SPACE

OUTSIDE WALL

PROVIDE SUPPORT

FOR INTAKE AND

EXHAUST LINES EVERY

36" (914)

FIELD−PROVIDED

REDUCER MAY

BE REQUIRED TO

ADAPT LARGER

VENT PIPE SIZE

TO TERMINATION

1/2" (13) FOAM INSULATION IN

UNCONDITIONED

SPACE

SIDE VIEW

DIRECT VENT WALL RING TERMINATION

See venting table 6 for maximum venting lengths with this arrangement.

1/2" (13) Foam Insulation

in Unconditioned Space

FIELD−

PROVIDED

REDUCER MAY

BE REQUIRED

TO ADAPT

LARGER VENT

PIPE SIZE TO

TERMINATION

Side View

EXHAUST VENT

INTAKE VENT

Inches (mm)

OUTSIDE WALL

DIRECT VENT WALL TERMINATION KIT

(22G44, 44J40, 30G28 or 81J20)

FIGURE 36

EXHAUST

VENT

INTAKE

VENT

Inches (mm)

(127)

18" MAX.

(457)

12"

(305)

5−1/2"

(140)

Front View

EXHAUST VENT

INTAKE

VENT

Side View

OPTIONAL VENT TERMINATION FOR MULTIPLE UNIT

INSTALLATION OF DIRECT VENT WALL TERMINATION KIT WTK

FIGURE 37

FIGURE 35

Page 29

Page 30

INTAKE

AIR

GRADE

12" (305) MAX. for 2" (51) 20" (508) MAX. for 3" (76)

(unless supported)

8" (203)

Minimum

Side View

Inches (mm)

EXHAUST

AIR

Minimum 12"

(305)

above grade or

average snow accumulation.

INTAKE

AIR

(127)

12"

(305)

5-1/2"

(140)

COVER EXHAUST

VENT WITH

1/2" (13)

FOAM

INSULATION

EXHAUST

AIR

Minimum 12"

(305)

above grade or

average snow accumulation.

GRADE

DIRECT VENT TERMINATION

WALL TERMINATION KIT (22G44, 44J40, 30G28 or 81J20) EXTENDED VENT FOR GRADE CLEARANCE

FIGURE 38

Front View

G61MP DIRECT VENT APPLICATION

USING EXISTING CHIMNEY

3" − 8"

8" − 12"

(203mm − 305mm)

INTAKE PIPE

INSULATION (optional)

SHEET

METAL TOP

PLATE

Minimum 12" (305)

MINIMUM 12"

above roof or average

(305mm) ABOVE

snow accumulation.

ROOF

INSULATE TO FORM

SEAL

*SIZE TERMINATION

PIPE PER TABLE 8.

NOTE − Do not discharge exhaust gases directly into any chimney or vent stack. If ver-

tical discharge through an existing unused chimney or stack is required, insert piping inside chimney until the pipe open end is above top of chimney and terminate as illustrated. In any exterior portion of chimney, the exhaust vent must be insulated.

(76mm− 203mm)

STRAIGHT−CUT OR

ANGLE−CUT IN DIRECTION

OF ROOF SLOPE *

EXHAUST VENT

1/2" (13mm)

WEATHERPROOF

INSULATION

SHOULDER OF FITTINGS

PROVIDE SUPPORT

OF PIPE ON TOP PLATE

3" − 8" (76mm− 203mm)

ALTERNATE

INTAKE PIPE

EXTERIOR

PORTION OF

CHIMNEY

FIGURE 39 Details of Exhaust Piping Terminations for Non-Direct Vent Applications

Exhaust pipes may be routed either horizontally through an outside wall or vertically through the roof. In attic or closet installations, vertical termination through the roof is preferred. Figures 40 through 43 show typical terminations.

1 − Exhaust piping must terminate straight out or up as

shown. The termination pipe must be sized as listed in table 8.The specified pipe size ensures proper velocity required to move the exhaust gases away from the building.

2 − On field supplied terminations for side wall exits, ex-

haust piping should extend a maximum of 12 inches (305mm) beyond the outside wall, unless support is provided in the horizontal section. See figure 41.

Inches(mm)

12" (305mm) ABOVE AVE.

SNOW

ACCUMULATION

3" (76) OR

2" (51) PVC

PROVIDE SUPPORT

FOR EXHAUST LINES

NON−DIRECT VENT ROOF TERMINATION KIT

(15F75 or 44J41)

FIGURE 40

12" (305) Max. for 2" (51)

1/2" (13) ARMAFLEX

INSULATION IN

UNCONDITIONED SPACE

FIELD−PROVIDED

REDUCER MAY

BE REQUIRED TO

ADAPT LARGER VENT PIPE SIZE

TO TERMINATION

Unless Supported

Inches (mm)

TOP VIEW

NON−DIRECT VENT WALL RING KIT

(15F74)

FIGURE 41

SIZE TERMINATION

PIPE PER TABLE 8.

UNCONDITIONED

ATTIC SPACE

1/2" (13)

ARMAFLEX

INSULATION

PVC REDUCER

SIZE TERMINATION PIPE PER TABLE 8.

Page 30

Page 31

3 − If exhaust piping must be run up a side wall to position

above snow accumulation or other obstructions, piping must be supported every 3 feet (.9m) as shown in figure 22. Refer to figure 42 for proper piping method. When exhaust piping must be run up an outside wall, any reduction in exhaust pipe size must be done after the final elbow.

Inches(mm)

UNCONDITIONED

SPACE

OUTSIDE WALL

PROVIDE SUPPORT

FOR EXHAUST LINES

EVERY 36" (914)

FIELD−PROVIDED

REDUCER MAY BE

REQUIRED TO

ADAPT LARGER

VENT PIPE SIZE TO

TERMINATION

1/2" (13) FOAM

INSULATION IN

UNCONDITIONED

SPACE

SIDE VIEW

NON−DIRECT VENT WALL RING TERMINATION

(15F74)

12" (305) Max. for 2" (51) Unless Supported

SIZE TERMINATION

PIPE PER

TABLE 8.

12" (305) ABOVE

AVERAGE SNOW

ACCUMULATION

1/2" (13) FOAM

INSULATION

FIGURE 42

G61MP NON−DIRECT VENT APPLICATION

USING EXISTING CHIMNEY

SIZE TERMINATION PIPE PER TABLE 8.

MINIMUM 12"

MINIMUM

12" (304mm)

(305mm) ABOVE

ABOVE AVERAGE

AVERAGE SNOW

SNOW ACCUMULATION

ACCUMULATION

INSULATE TO FORM

SEAL

SHEET

METAL TOP

PLATE

3" − 8" (76mm− 203mm)

STRAIGHT−CUT OR

ANGLE−CUT IN DIRECTION

OF ROOF SLOPE

EXHAUST VENT

1/2" (13mm)

WEATHERPROOF

INSULATION

SHOULDER OF FITTINGS

PROVIDE SUPPORT

OF PIPE ON TOP PLATE

3" − 8" (76mm− 203mm)

EXTERIOR

PORTION OF

CHIMNEY

sate trap should extend below the unit. A 5−1/2" service clearance is required for the condensate trap. Refer to figure 44 for condensate trap locations.

CONDENSATE TRAP LOCATIONS

(Unit shown in upflow position)

Horizontal

left and optional

downflow

Optional

upflow

Horizontal

right and

optional

downflow

Optional

upflow

FIGURE 44

1 − Determine which side condensate piping will exit the

unit. Remove plugs from the condensate collar at the appropriate location on the side of the unit.

NOTE − The condensate trap is factory−shipped with two rubber O−rings and two rubber clean−out caps installed. Check to make sure that these items are in place before installing the trap assembly.

2 − Install condensate trap onto the condensate collar.

Use provided HI/LO screws to secure two upper flanges of the trap to the collar. Use provided sheet metal screw to secure bottom trap flange to side of unit. DO NOT apply glue to secure condensate trap to cabinet. All other joints must be glued. See figure

45.

NOTE − In upflow and downflow applications, condensate trap must be installed on the same side as exhaust piping.

NOTE − Do not discharge exhaust gases directly into any chimney or vent stack. If vertical discharge through an existing unused chimney or stack is required, insert piping inside chimney until the pipe open end is above top of chimney and terminate as illustrated. In any exterior portion of chimney, the exhaust vent must be insulated.

FIGURE 43

Condensate Piping

This unit is designed for either right- or left-side exit of condensate piping in either upflow or downflow applications; however, it must be installed on the same side of the unit as the exhaust piping. In horizontal applications, the conden-

CAUTION

DO NOT use a power driver to tighten screws which secure condensate trap to cabinet. Screws should be hand−tightened using a screw driver to avoid the possibility of damage to the trap assembly.

3 − The condensate trap provided with the unit is

manufactured using ABS material. Use ABS to PVC transition solvent cement to glue a field−provided PVC coupling or PVC pipe to the trap. Install a tee and vent pipe near the trap.

Page 31

Page 32

NOTE − The condensate trap drain stubs (both sides) have an outer diameter which will accept a standard 3/4" PVC coupling. The inner diameter of each stub will accept standard 1/2" diameter PVC pipe.

NOTE − Vinyl tubing may be used for condensate drain. Tubing must be 1−1/4" OD X 1" ID and should be attached to the drain stubs on the trap using a hose clamp.

4 − Glue the field−provided drain line to the tee. Route the

drain line to an open drain. As an alternate, clear vinyl tubing may be used to drain condensate away from the trap. Secure the vinyl tubing to the drain stubs on the trap using a hose clamp. Do not overtighten the hose clamp. Condensate line must be sloped downward away from condensate trap to drain. If drain level is above condensate trap, condensate pump must be used. Condensate drain line should be routed within the conditioned space to avoid freezing of condensate and blockage of drain line. If this is not possible, a heat cable kit may be used on the condensate trap and line. Heating cable kit is available from Lennox in various lengths; 6 ft. (1.8m) − kit no. 26K68; 24 ft. (7.3m) − kit no. 26K69; and 50 ft. (15.2m) − kit no. 26K70.

5 − If unit will be started immediately upon completion of

installation, prime trap per procedure outlined in Unit Start−Up section.

6 − Glue the provided cap onto the unused condensate

drain line stub.

CONDENSATE ASSEMBLY

CAP

O−RINGS

SCREW

HI/LO SCREWS (DO NOT use power driver. Hand−tighten using screw driver.)

NIPPLE

COUPLING

CLEAN−OUT ACCESS

CONDENSATE TRAP

VENT

NIPPLE

TEE

(both sides)

CAUTION

Do not use copper tubing or existing copper condensate lines for drain line.

NOTE − Use screws to secure condensate trap to cabinet. DO NOT apply glue to this joint. All other joints must be glued.

FIGURE 45

Page 32

Page 33

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.

IMPORTANT

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

MANUAL MAIN SHUT−OFF

VALVE WILL NOT HOLD

NORMAL TEST PRESSURE

FURNACE

WARNING

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

1 − Gas piping may be routed into the unit through either

the left- or right-hand side. Supply piping enters into the gas valve from the side of the valve as shown in figure 48.

2 − When connecting gas supply, factors such as length of

run, number of fittings and furnace rating must be considered to avoid excessive pressure drop. Table 9 lists recommended pipe sizes for typical applications.

NOTE − Use two wrenches when connecting gas piping to avoid transferring torque to the manifold.

3 − Gas piping must not run in or through air ducts, clothes

chutes, chimneys or gas vents, dumb waiters or elevator shafts. Center gas line through piping hole. Gas line should not touch side of unit. See figure 48.

4 − Piping should be sloped 1/4 inch per 15 feet (6mm per

5.6m) upward toward the gas meter from the furnace. The piping must be supported at proper intervals, every 8 to 10 feet (2.44 to 3.05m), using suitable hangers or straps. Install a drip leg in vertical pipe runs to serve as a trap for sediment or condensate.

5 − A 1/8" N.P.T. plugged tap or pressure post is located

on the gas valve to facilitate test gauge connection. See figures 55 and 56.

6 − In some localities, codes may require installation of a

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

ISOLATE

GAS VALVE

CAP

FIGURE 46

Leak Check

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

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

IMPORTANT

When testing pressure of gas lines, gas valve must be disconnected and isolated. See figure 46. Gas valves can be damaged if subjected to pressures greater than 1/2 psig (3.48 kPa).

WARNING

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

FIRE OR EXPLOSION HAZARD

Upflow Application

Left Side Piping

(Standard)

MANUAL

MAIN SHUT−OFF

VALV E

GROUND

JOINT UNION

DRIP LEG

AUTOMATIC

GAS VALVE

(with manual

shut−off valve)

FIELD

PROVIDED

AND INSTALLED

FIGURE 47

Page 33

Upflow Application

Right Side Piping

(Alternate)

MANUAL

MAIN SHUT−OFF

VALV E

GROUND

JOINT

UNION

DRIP LEG

Page 34

MANUAL

MAIN SHUT−OFF

VALV E

GROUND

JOINT

UNION

DRIP LEG

Horizontal Application

Right−Side Air Discharge

Horizontal Applications

Possible Gas Piping Configerations

MANUAL

MAIN SHUT−OFF

VALV E

GROUND

JOINT

UNION

DRIP LEG

Horizontal Application

Left−Side Air Discharge

MANUAL

MAIN SHUT−OFF

VALV E

(With 1/8 in. NPT

Plugged Tap

Shown)

GROUND

JOINT

UNION

DRIP LEG

FIGURE 48

TABLE 9

GAS PIPE CAPACITY − FT3/HR (kL/HR)

Nominal

Iron Pipe Size

−Inches(mm)

1/4

(6.35)

3/8

(9.53)

1/2

(12.7)

3/4

(19.05)

(25.4)

1−1/4

(31.75)

1−1/2

(38.1)

(50.8)

2−1/2

(63.5)

(76.2)

(101.6)

Internal

Diameter

−Inches(mm)

.364

(9.246)

.493

(12.522)

.622

(17.799)

.824

(20.930)

1.049

(26.645)

1.380

(35.052)

1.610

(40.894)

2.067

(52.502)

2.469

(67.713)

3.068

(77.927)

4.026

(102.260)

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

(1.13)

(2.69)

175

(4.96)

360

(10.19)

680

(19.25)

1400

(39.64)

2100

(59.46)

3950

(111.85)

6300

(178.39)

11000

(311.48)

23000

(651.27)

(.82)

(1.84)

120

(3.40)

250

(7.08)

465

(13.17)

950

(26.90)

460

(41.34)

2750

(77.87)

4350

(123.17)

7700

(218.03)

15800

(447.39)

(.68)

(1.47)

(2.75)

200

(5.66)

375

(10.62)

770

(21.80)

1180

(33.41)

2200

(62.30)

3520

(99.67)

6250

(176.98)

12800

(362.44)

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

Length of Pipe−Feet(m)

(.57)

(1.27)

(2.32)

170

(4.81)

320

(9.06)

660

(18.69)

990

(28.03)

1900

(53.80)

3000

(84.95)

5300

(150.07)

10900

(308.64)

(.51)

(1.13)

(2.07)

151

(4.28)

285

(8.07)

580

(16.42)

900

(25.48)

1680

(47.57)

2650

(75.04)

4750

(134.50)

9700

(274.67)

(.45)

(1.02)

(1.87)

138

(3.91)

260

(7.36)

530

(15.01)

810

(22.94)

1520

(43.04)

2400

(67.96)

4300

(121.76)

8800

(249.18)

(.42)

(.73)

(1.73)

125

(3.54)

240

(6.80)

490

(13.87)

750

(21.24)

1400

(39.64)

2250

(63.71)

3900

(110.43)

8100

(229.36)

(.40)

(.88)

(1.61)

118

(3.34)

220

(6.23)

460

(13.03)

690

(19.54)

1300

(36.81)

2050

(58.05)

3700

(104.77)

7500

(212.37)

(.37)

(.82)

(1.50)

110

(3.11)

205

(5.80)

430

(12.18)

650

(18.41)

1220

(34.55)

1950

(55.22)

3450

(97.69)

7200

(203.88)

100

(30.480)

(.34)

(.76)

(1.42)

103

(2.92)

195

(5.52)

400

(11.33)

620

(17.56)

1150

(32.56)

1850

(52.38)

3250

(92.03)

6700

(189.72)

Page 34

Page 35

Electrical

ELECTROSTATIC DISCHARGE (ESD)

Precautions and Procedures

CAUTION

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

INTERIOR MAKE−UP BOX INSTALLATION

MAKE−UP

BOX

Right Side

FIGURE 49

INTERIOR MAKE−UP BOX INSTALLATION

Left side

MAKE−UP

BOX

FIGURE 50

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

Refer to figure 51 and table 10 for field wiring and figure 54 for schematic wiring diagram and troubleshooting.

1 − Select circuit protection and wire size according to the

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

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

tate wiring.

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

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

4 − Before connecting the thermostat or the power wiring,

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

5 − Complete the wiring connections to the equipment.

Use the provided unit wiring diagram and the field wiring diagram shown in figure 51 and table 10. Use 18−gauge wire or larger that is suitable for Class II rating for thermostat connections.

NOTE − Do NOT make a wire connection between the room thermostat L terminal and the L terminal of the G61MP integrated control.

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

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

NOTE − The G61MP furnace contains electronic components that are polarity sensitive. Make sure that the furnace is wired correctly and is properly grounded.

7 − One line voltage HUM" 1/4" spade terminal is provided

on the furnace control board. Any humidifier rated up to one amp can be connected to this terminal with the neutral leg of the circuit being connected to one of the provided neutral terminals. See figure 52 for control board configuration. This terminal is energized in the heating mode when the combustion air inducer is operating.

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

on the furnace control board. Any electronic air cleaner rated up to one amp can be connected to this terminal with the neutral leg of the circuit being connected to one of the provided neutral terminals. See figure 52 for control board configuration. This terminal is energized when the indoor blower is operating.

Page 35

Page 36

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

board terminal block. Any humidifier rated up to 0.5 amp can be connected to this terminal with the ground leg of the circuit being connected to either ground or the C" terminal. See figure 52 for control board configuration.

10 −Install the room thermostat according to the instruc-

tions provided with the thermostat. See table 10 for field wiring connections in varying applications. If the furnace is being matched with a heat pump, refer to the instruction packaged with the dual fuel thermostat.

TYPICAL G61MP FIELD WIRING DIAGRAM

Indoor Blower Speeds

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

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

2 − When the G61MP is operating in the high−fire or low−

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

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

run on the corresponding cooling speed.

FIGURE 51

Page 36

Page 37

Thermostat

1 Heat / 1 Cool

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

TABLE 10

Field Wiring Applications

DIP Switch Settings and On−Board Links

(Figure 52)

W915

DIP Switch 1

(Y1 to Y2)

Two−Stage

Cooling

ON Intact Intact

W951

(O to R)

Heat Pumps

T’STAT

Wiring Connections

CONTROL

TERM. STRIP

W915 JUMPER

OUTDOOR

UNIT

EXISTING

1 Heat / 2 Cool

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

ON Cut Intact

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

Page 37

Page 38

TABLE 10

Field Wiring Applications (Continued)

DIP Switch Settings and On−Board Links

(Figure 52)

Thermostat

DIP Switch 1

W915

(Y1 to Y2)

Two−Stage

Cooling

W951

(O to R)

Heat Pumps

2 Heat / 2 Cool OFF Cut Intact

T’STAT

Wiring Connections

CONTROL

TERM. STRIP

OUTDOOR

UNIT

2 Heat / 1 Cool OFF Intact Intact

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

EXISTING

W915 JUMPER

NOTE − Do NOT make a wire connection between the room thermostat L terminal and the L terminal of the G61MP integrated control.

Page 38

Page 39

DIAGNOSTIC

LEDs

DIP

SWITCHES

TWO−STAGE INTEGRATED CONTROL BOARD

1/4" QUICK CONNECT TERMINALS

SENSE = 120 VAC OUTPUT TO FLAME SENSER

NEUTRALS= 120 VAC NEUTRAL

PARK = DEAD TERMINAL FOR UNUSED BLOWER LEAD

W915

W951

HEAT LOW = 120 VAC OUTPUT TO CIRC BLWR −− LOW HT SPEED

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

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

ON−BOARD

JUMPERS

1= ERROR CODE RECALL H= 24V HUMIDIFIER OUTPUT L= DO NOT USE

DIP SWITCH(ES) FUNCTION

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

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

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

5 −− Cool Off Delay Cooling fan OFF delay

AND CONTINUOUS FAN

HIGH HEAT AND LOW COOL SPEED

THERMOSTAT CONNECTIONS (TB1)

DIP SWITCH FUNCTIONS

FIGURE 52

Page 39

Page 40

INTEGRATED CONTROL BOARD DIP SWITCH SETTINGS AND JUMPERS

FIGURE 53

Page 40

Page 41

TYPICAL G61MP WIRING DIAGRAM

FIGURE 54

Page 41

Page 42

Integrated Control Board

G61MP units are equipped with a two−stage integrated control. This control manages ignition timing and fan off delays based on selections made using the control DIP switches and jumpers. The control includes an internal watchguard feature which automatically resets the ignition control when it has been locked out. After one hour of continuous thermostat demand for heat, the watchguard will break and remake thermostat demand to the furnace and automatically reset the control to relight the furnace.

DIP Switch Settings −− Figure 53 Switch 1 −− Thermostat Selection −− This unit may be used

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

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

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

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

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

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

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

Switches 3 and 4 −− Heating Blower−Off Delay −− The heating blower−on delay of 45 seconds is not adjustable. The heating blower−off delay (time that the blower operates after the heating demand has been satisfied) can be adjusted by moving switches 3 and 4 on the integrated control board. The unit is shipped from the factory with a heating blower−off delay of 90 seconds. The heating blower off delay affects comfort and is adjustable to satisfy individual applications. Adjust the blower off delay to achieve a supply air temperature between 90° and 110°F at the exact moment that the blower is de−energized. Longer off delay settings provide lower supply air temperatures; shorter settings provide higher supply air temperatures.Table 11 provides the blower off timings that will result from different switch settings.

Heating Blower−Off Delay Switch Settings

Blower Off Delay

(Seconds)

60 Off On

90 Off Off 120 On Off 180 On On

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

On−Board Jumper W951 −− Figure 53

On−board jumper W951, which connects terminals R and O on the integrated control board, 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 jumper is left intact, terminal O" will remain energized eliminating the HEAT MODE in the heat pump.

On−Board Jumper W915 −− Figure 53

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

TABLE 11

Switch 3 Switch 4

Unit Start−Up

FOR YOUR SAFETY READ BEFORE OPERATING

WARNING

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

WARNING

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

Page 42

Page 43

CAUTION

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

Priming Condensate Trap

The condensate trap should be primed with water prior to start−up to ensure proper condensate drainage. Either pour 10 fl. oz. (300 ml) of water into the trap, or follow these steps to prime the trap:

1 − Follow the lighting instructions to place the unit into op-

eration.

2 − Set the thermostat to initiate a heating demand.

3 − Allow the burners to fire for approximately 3 minutes.

4 − Adjust the thermostat to deactivate the heating de-

mand.

5 − Wait for the combustion air inducer to stop. Set the

thermostat to initiate a heating demand and again allow the burners to fire for approximately 3 minutes.

6 − Adjust the thermostat to deactivate the heating de-

mand and again wait for the combustion air inducer to stop. At this point, the trap should be primed with sufficient water to ensure proper condensate drain operation.

BEFORE LIGHTING the unit, smell all around the furnace area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

The gas valve on the G61MP will be be equipped with a gas control switch (lever). Use only your hand to move the switch. Never use tools. If the the switch will not move by hand, do not try to repair it. Force or attempted repair may result in a fire or explosion.

Placing the furnace into operation:

G61MP units are equipped with an automatic ignition system. Do not attempt to manually light burners on this furnace. Each time the thermostat calls for heat, the burners will automatically light. The ignitor does not get hot when there is no call for heat on units with this ignition system.

4 − This furnace is equipped with an ignition device which

automatically lights the burners. Do not try to light the

burners by hand. 5 − Remove the upper access panel. 6 − White Rodgers 36E Gas Valve − Move gas valve

switch to OFF. See figure 55 for the White Rodgers

36E valve.

Honeywell VR8205 Gas Valve − Move switch on gas

valve clockwise to OFF. Do not force. See figure

56.

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.

WHITE RODGERS 36E SERIES GAS VALVE

HIGH FIRE

MANIFOLD

PRESSURE

ADJUSTMENT

ON SIDE

(under cap)

MANIFOLD

PRESSURE

TAP ON SIDE

INLET PRESSURE

TAP ON SIDE

GAS VALVE SHOWN IN OFF POSITION

LOW FIRE MANIFOLD

PRESSURE ADJUSTMENT

ON SIDE (under cap)

FIGURE 55

HONEYWELL VR8205 SERIES GAS VALVE

HIGH FIRE

ADJUSTING SCREW

(under cap)

MANIFOLD

PRESSURE

TAP

LOW FIRE

ADJUSTING SCREW

(under cap)

INLET PRESSURE TAP

GAS VALVE SHOWN IN OFF POSITION

WARNING

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

Gas Valve Operation (Figures 55 and 56)

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.

FIGURE 56

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

to ON. See figure 55 for the White Rodgers 36E

valve.

Honeywell VR8205 Gas Valve − Move switch on gas

valve counterclockwise to ON. Do not force. 9 − Replace the upper access panel.

10− Turn on all electrical power to to the unit.

11− Set the thermostat to desired setting.

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

Page 43

Page 44

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

Turning Off Gas to Unit" and call your service technician or gas supplier.

Turning Off Gas to Unit

1 − Set the thermostat to the lowest setting.

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

performed.

3 − Remove the upper access panel.

4 − White Rodgers 36E Gas Valve − Move gas valve

switch to OFF. Honeywell VR8205 Gas Valve − Move switch on gas

valve clockwise to OFF. Do not force.

5 − Replace the upper access panel.

Gas Pressure Adjustment

Gas Flow (Approximate)

1 − Operate unit at least 15 minutes before checking gas

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

2 − Compare the number of seconds and the gas meter

size in table 12 to determine the gas flow rate. Multiply the gas flow rate by the heating value to determine the unit input rate. If manifold pressure is correct and the unit input rate is incorrect, check gas orifices for proper size and restriction.

3 − Remove temporary gas meter if installed.

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

Supply Pressure Measurement

A threaded plug on the inlet side of the gas valve provides access to the supply pressure tap. Remove the threaded plug, install a field−provided barbed fitting and connect a manometer to measure supply pressure. Replace the threaded plug after measurements have been taken.

Manifold Pressure Measurement

To correctly measure manifold pressure, the differential pressure between the positive gas manifold and the negative burner box must be considered. Use pressure test

adapter kit (available as Lennox part 10L34) to assist in measurement.

1 − Remove the threaded plug from the outlet side of the

gas valve and install a field−provided barbed fitting. Connect test gauge +" connection to barbed fitting to measure manifold pressure.

2 − Tee into the gas valve regulator vent hose and connect

test gauge −" connection.

TABLE 12

Gas Flow Rate (Ft.3/Hr.)

Seconds for 1

Revolution

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

3 − Start unit on low heat (68% rate) and allow 5 minutes

for unit to reach steady state.

4 − 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.

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

manifold pressure and compare to value given in table

13.

6 − Repeat steps 3, 4 and 5 on high heat.

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

1/2 cu ft Dial 1 cu ft Dial

Gas Meter Size

CAUTION

Do not attempt to make adjustments to the gas valve.

Page 44

Page 45

TABLE 13

Manifold Pressure (Outlet) inches w.c.

Model Number Fuel

045, 070, 090, 110, 135

Natural 1.7 3.5 1.7 3.5 1.7 3.5 1.7 3.5 1.7 3.5 1.7 3.5

Propane 4.9 10.0 4.9 10.0 4.9 10.0 4.9 10.0 4.9 10.0 4.9 10.0

0−2000 2001−4500 4501−5500 5501−6500 6501−7500 7501−10000

Low Fire

High Fire

Low Fire

Natural 1.7 3.5 1.7 3.4 1.7 3.3 1.7 3.2 1.7 3.1 1.7 3.5

071, 091, 111

Propane 4.9 10.0 4.9 10.0 4.9 10.0 4.9 10.0 4.9 10.0 4.9 10.0

High Altitude Information

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

The manifold pressure may require adjustment to ensure proper operation at higher altitudes. Refer to table 13 for proper manifold pressure settings at varying altitudes. Refer to table 14 for required pressure switch changes and conversion kits at varying altitudes.

Altitude (feet)

High Fiire

Low Fire

High Fiire

Low Fire

High Fiire

Low Fire

High Fiire

The combustion air pressure switches are factory−set and require no adjustment.

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

Low Fire

High Fiire

TABLE 14

Conversion Kit Requirements

High Altitude

Orifice Kit

Input

−045 44W51 − − − − − − − − − 44W48 44W50 44W49 44W49 + 44W51

−070 44W51 − − − − − − 56M06 44W48 44W50 44W49 44W49 + 44W51

−071 47M82 24W49 24W49 26W83 44W48 44W50 44W49 44W49 + 47M82

−090 44W51 − − − 75M22 56M21 44W48 44W50 44W49 44W49 + 44W51

−091 47M82 26W85 26W85 26W86 44W48 44W50 44W49 44W49 + 47M82

−110 44W51 − − − − − − 75M22 44W48 44W50 44W49 44W49 + 44W51

−111 47M82 56M22 56M22 56M23 44W48 44W50 44W49 44W49 + 47M82

−135 44W51 − − − 56M93 56M93 44W48 44W50 44W49 44W49 + 44W51

High Altitude Orifice Kit is required and must be ordered separately for applications from 7501 to 10,000 ft.

Natural Gas

Only

7501−10,000 ft. 2000−4500 ft. 4501−7500 ft. 7501−10,000 ft. 0−7500 ft. 7501−10,000 ft. 0−7500 ft.

High Altitude Pressure Switch Kit

ORDER TWO EACH

LPG/Propane Kit LPG/Propane to

Natural Gas Kit

7501−10,000 ft.

Page 45

Page 46

Testing for Proper Venting and Sufficient Combustion Air for Non−Direct Vent Applications

sufficient combustion/make-up air must be provided.

WARNING

CARBON MONOXIDE POISONING HAZARD!

Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monoxide poisoning or death. The following steps shall be followed for each appliance connected to the venting system being placed into operation, while all other appliances connected to the venting system are not in operation.

After the G61MP gas furnace has been started, the following test should be conducted to ensure proper venting and sufficient combustion air has been provided to the G61MP, as well as to other gas-fired appliances which are separately vented.

If a G61MP furnace replaces a Category I furnace which was commonly vented with another gas appliance, the size of the existing vent pipe for that gas appliance must be checked. Without the heat of the original furnace flue products, the existing vent pipe is probably oversized for the single water heater or other appliance. The vent should be checked for proper draw with the remaining appliance.

The test should be conducted while all appliances (both in operation and those not in operation) are connected to the venting system being tested. If the venting system has been installed improperly, or if provisions have not been made for sufficient amounts of combustion air, corrections must be made as outlined in the previous section.

1 − Seal any unused openings in the venting system. 2 − Visually inspect the venting system for proper size and

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

3 − To the extent that it is practical, close all building doors

and windows and all doors between the space in which the appliances connected to the venting system are lo-

cated and other spaces of the building. 4 − Close fireplace dampers. 5 − Turn on clothes dryers and any appliances not con-

nected to the venting system. Turn on any exhaust

fans, such as range hoods and bathroom exhausts, so

they will operate at maximum speed. Do not operate a

summer exhaust fan. 6 − Follow the lighting instruction to place the appliance

being inspected into operation. Adjust thermostat so

appliance will operate continuously. 7 − Use the flame of match or candle to test for spillage of

flue gases at the draft hood relief opening after 5 min-

utes of main burner operation. 8 − If improper venting is observed during any of the

above tests, the venting system must be corrected or

The venting system should be re-sized to approach the minimum size as determined by using the appropriate tables in appendix G in the current standards of the National Fuel Gas Code ANSI−Z223.1/NPFA 54 in the U.S.A., and the appropriate Natural Gas and Propane appliances venting sizing tables in the current standard of the CSA−B149 Natural Gas and Propane Installation Codes in Canada.

9 − After determining that each appliance remaining

connected to the common venting system properly vents when tested as indicated in step 3, return doors, windows, exhaust fans, fireplace dampers and any other gas-burning appliance to their previous condition of use.

Other Unit Adjustments

Primary and Secondary Limits

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

Flame Rollout Switches (Two)

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

Pressure Switches (Two or Four)

The pressure switches are located in the heating compartment on the combustion air inducer. These switches check for proper combustion air inducer operation before allowing ignition trial. The switches are factory−set and require no adjustment.

Back−Up Secondary Limit (090, 110 & 135 Models)

The back−up secondary limit is located on the combustion air inducer. This switch protects the plastic components from overheating due to indoor blower motor failure. If tripped, check for proper blower operation before resetting.

Temperature Rise

After the furnace has been started and supply and return air temperatures have been allowed to stabilize, check the temperature rise. If necessary, adjust the blower speed to maintain the temperature rise within the range shown on the unit nameplate. Increase the blower speed to decrease the temperature. Decrease the blower speed to increase the temperature rise. Failure to do adjust the temperature rise may cause erratic limit operation.

Thermostat Heat Anticipation

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

Electrical

1 − Check all wiring for loose connections.

Page 46

Page 47

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

operating).

3 − Check amp-draw on the blower motor.

Motor Nameplate__________Actual__________

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

Blower Speeds

NOTE − CFM readings are taken external to unit with a dry evaporator coil and without accessories.

1 − Turn off electrical power to furnace. 2 − Remove blower access panel. 3 − Disconnect existing speed tap at control board speed

terminal.

NOTE − Termination of any unused motor leads must be insulated.

4 − Refer to blower speed selection chart on unit wiring dia-

gram for desired heating or cooling speed. See blower performance data beginning on Page 48.

5 − Connect selected speed tap at control board speed

terminal. 6 − Resecure blower access panel. 7 − Turn on electrical power to furnace.

Electronic Ignition

The integrated control has an added feature of an internal Watchguard control. The feature serves as an automatic reset device for ignition control lockout caused by ignition failure. This type of lockout is usually due to low gas line pres-

sure. After one hour of continuous thermostat demand for heat, the Watchguard will break and remake thermostat demand to the furnace and automatically reset the control to begin the ignition sequence.

Exhaust and Air Intake Pipe

1 − Check exhaust and air intake connections for tightness

and to make sure there is no blockage.

2 − Are pressure switches closed? Obstructed exhaust

pipe will cause unit to shut off at pressure switches. Check termination for blockages.

3 − Reset manual flame rollout switches on burner box

cover.

Failure To Operate

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

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

again, inspect the unit for blockages.

Page 47

Page 48

Blower Performance Data

G61MP−36B−045 PERFORMANCE (Less Filter)

External

Static

Pressure

in. w.g.

0.00

0.10 1515 605 1385 555 1190 485 1020 415

0.20 1470

0.30

0.40 1350 535 1250 465 1120 410 980 360

0.50 1290

0.60

0.70 1145 460 1080 400 975 345 860 300

0.80 1050

0.90

NOTES − All air data is measured external to unit without filter (not furnished − field provided). Air volume based on bottom air return air. Actual air volume may vary on side return air applications.

G61MP−36B−070 PERFORMANCE (Less Filter)

External

Static

Pressure

in. w.g.

0.00

0.10 1600 635 1395 550 1160 460 1000 385

0.20 1540

0.30

0.40 1420 545 1275 480 1125 395 965 345

0.50 1360

0.60

0.70 1170 465 1085 385 965 335 860 295

0.80 1080

0.90

G61MP−36B−071 PERFORMANCE (Less Filter)

External

Static

Pressure

in. w.g.

0.00

0.10 1420 590 1215 545 990 425 815 365

0.20 1365

0.30

0.40 1255 495 1155 455 945 365 795 320

0.50 1190

0.60

0.70 1035 410 975 365 790 295 695 255

0.80 900

0.90

Air Volume / Watts at Different Blower Speeds

High

Medium−

High

Medium−

Low

cfm Watts cfm Watts cfm Watts cfm Watts

1555 630 1410 585 1190 520 1030 435

580 1345 520 1170 455 1010 400

1410 555 1310 495 1155 440 1000 385

505 1205 450 1080 390 950 345

1220 485 1145 420 1020 365 905 320

425 985 365 870 320 785 285

945 410 900 345 825 305 730 270

Air Volume / Watts at Different Blower Speeds

High

Medium−

High

Medium−

Low

cfm Watts cfm Watts cfm Watts cfm Watts

1640 660 1415 575 1160 485 1005 410

605 1370 525 1160 445 995 375

1495 580 1345 505 1145 425 990 365

525 1245 450 1080 375 945 325

1275 490 1165 410 1025 350 900 305

440 1010 360 865 310 775 270

945 400 840 320 765 275 710 245

Air Volume / Watts at Different Blower Speeds

High

Medium−

High

Medium−

Low

cfm Watts cfm Watts cfm Watts cfm Watts

1460 620 1215 570 965 445 785 375

550 1195 505 980 410 810 350

1325 525 1170 490 980 390 820 335

465 1080 425 915 345 785 305

1120 440 1050 395 865 320 755 285

375 865 330 715 275 615 235

795 350 745 300 600 245 510 215

G61MP−48C−090 PERFORMANCE (Less Filter)

External

Static

Pressure

in. w.g.

0.00

Air Volume / Watts at Different Blower Speeds

High

Medium−

High

Medium−

Low

cfm Watts cfm Watts cfm Watts cfm Watts

2180 930 1835 790 1520 630 1280 510

0.10 2135 885 1825 750 1510 610 1275 495

0.20 2085 840 1810 720 1505 580 1270 475

0.30 2030 800 1775 685 1500 565 1265 460

0.40 1940 760 1735 650 1480 535 1250 440

0.50 1865 725 1660 600 1430 505 1215 425

0.60 1740 670 1590 575 1380 475 1175 410

0.70 1645 640 1475 520 1290 450 1105 375

0.80 1540

600 1340 465 1175 405 1020 355

0.90 1335 540 1170 440 1070 375 950 330

G61MP−48C−110 PERFORMANCE (Less Filter)

External

Static

Pressure

in. w.g.

0.00

Air Volume / Watts at Different Blower Speeds

High

Medium−

High

Medium−

Low

cfm Watts cfm Watts cfm Watts cfm Watts

2160 880 1880 755 1490 602 1235 485

0.10 2100 850 1855 730 1480 585 1230 475

0.20 2035 805 1815 690 1475 560 1225 460

0.30 1965 750 1755 650 1475 545 1220 445

0.40 1885 725 1715 625 1465 510 1215 430

0.50 1780 680 1630 580 1420 490 1150 400

0.60 1690 660 1550 550 1360 460 111 0 380

0.70 1575 620 1410 505 1210 405 1035 350

0.80 1375 550 1230 450 1125 380 970 325

0.90 1225 520 1120 415 1050 365 885 310

Page 48

Page 49

G61MP−60C−090 PERFORMANCE (Less Filter)

Air Volume / Watts at Different Blower Speeds

External

Static

Pressure

in. w.g.

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

High

Medium−

High

Medium−

Low

Low High

Single Side Return Air − Air volumes in bold require field

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

Medium−

High

Medium−

Low

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

0.00 2840 1450 2345 1105 1895 900 1515 700 2835 1495 2340 1155 1800 895 1440 695

0.10 2765 1415 2365 1080 1950 885 1580 700 2785 1475 2345 1135 1805 865 1515 690

0.20 2695

0.30

1385 2345 1050 1985 870 1620 695 2715 1435 2275 1080 1825 845 1560 685

2605 1335 2315 1030 1990 850 1645 690 2620 1380 2260 1035 1840 825 1600 680

0.40 2530 1300 2265 990 1990 825 1665 675 2550 1350 2230 1015 1845 815 1620 670

0.50 2420

0.60

1260 2210 955 1970 800 1675 665 2450 1305 2175 990 1850 790 1615 655

2330 1220 2145 925 1930 775 1665 650 2365 1270 2130 940 1830 775 1615 640

0.70 2250 1190 2050 885 1875 745 1645 630 2240 1205 2070 915 1815 760 1595 620

0.80 2135

0.90

NOTES − All air data is measured external to unit without filter (not furnished − field provided).

2030 1090 1885 830 1720 685 1560 590 2015 1150 1820 820 1690 715 1440 580

1140 2000 865 1810 715 1620 615 2185 1190 1965 865 1775 745 1555 605

G61MP−60C−091 PERFORMANCE (Less Filter)

Air Volume / Watts at Different Blower Speeds

External

Static

Pressure

in. w.g.

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

High

Medium−

High

Medium−

Low

Low High

Single Side Return Air − Air volumes in bold require field

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

Medium−

High

Medium−

Low

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

0.00 2320 1230 2240 960 1970 810 1505 690 2350 1275 2195 960 1920 830 1535 680

0.10 2250 1195 2155 910 1950 805 1610 665 2270 1240 2125 930 1910 800 1580 665

0.20 2185

0.30

2060 1120 1965 835 1795 710 1590 620 2070 1135 1945 830 1830 725 1545 625

1165 2080 890 1915 775 1630 660 2200 1190 2060 905 1875 775 1570 655

0.40 1995 1095 1890 805 1720 690 1535 600 1935 1095 1875 815 1750 705 1495 605

0.50 1920

0.60

1060 1860 790 1705 665 1540 580 1910 1070 1820 780 1715 670 1510 585

1800 1025 1750 755 1605 640 1485 560 1825 1050 1720 760 1635 645 1450 555

0.70 1710 1000 1625 735 1500 605 1380 535 1705 1025 1605 725 1485 615 1360 535

0.80 1600

0.90

NOTES − All air data is measured external to unit without filter (not furnished − field provided).

1475 940 1405 670 1305 555 1105 450 1460 950 1370 665 1285 555 1175 480

975 1545 700 1455 585 1335 515 1605 995 1515 700 1440 585 1320 510

Low

Page 49

Page 50

Blower Performance Data

G61MP−60C−110 PERFORMANCE (Less Filter)

Air Volume / Watts at Different Blower Speeds Air Volume / Watts at Different Blower Speeds

External

Static

Pressure

in. w.g.

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

High

Medium−

High

Medium−

Low

Low High

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

0.00 2720 1385 2410 1090 2055 935 1620 710 2625 1350 2310 1080 1885 885 1515 700

0.10 2665 1355 2385 1075 2025 885 1730 735 2570 1330 2325 1060 1910 865 1575 700

0.20 2585

1315 2350 1015 2030 865 1680 690 2410 1305 2285 1035 1930 845 1620 690

0.30 2505 1275 2290 990 2025 840 1695 675 2425 1265 2230 990 1925 825 1635 675

0.40 2435 1250 2235 940 2030 830 1695 660 2335 1220 2175 950 1910 810 1640 660

0.50 2350 1205 2170 930 1975 790 1735 665 2270 1195 2120 935 1895 785 1640 640

0.60 2255 1185 2100 895 1915 765 1720 650 2170 1155 2045 885 1860 765 1630 630

0.70 2160 1150 2005 840 1865 730 1680 635 2110 1130 1950 855 1795 730 1590 610

0.80 2020 1090 1905 825 1810 710 1625 610 2035 1090 1885 820 1745 705 1540 580

0.90 1910 1050 1820 795 1705 675 1540 590 1900 1055 1760 780 1665 680 1470 565

NOTES − All air data is measured external to unit without filter (not furnished − field provided).

G61MP−60C−111 PERFORMANCE (Less Filter)

Air Volume / Watts at Different Blower Speeds Air Volume / Watts at Different Blower Speeds

External

Static

Pressure

in. w.g.

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

High

Medium−

High

Medium−

Low

Low High

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

0.00 2475 1305 2275 1010 1800 870 1425 680 2460 1355 2210 1045 1850 860 1435 670

0.10 2395 1260 2215 980 1850 850 1495 675 2395 1320 2170 1010 1850 830 1490 660

0.20 2340 1220 2165 945 1860 830 1535 665 2280 1270 2115 965 1875 810 1525 650

0.30 2255 1205 2085 915 1855 805 1545 655 2225 1250 2075 940 1835 785 1530 640

0.40 2165 1160 2000 880 1820 780 1540 645 2150 1210 2005 905 1800 760 1535 626

0.50 2055 1140 1920 845 1780 755 1535 625 2050 1155 1935 885 1760 740 1555 620

0.60

1995 1120 1845 825 1720 725 1485 605 1975 1140 1835 845 1660 705 1480 595

0.70 1880 1075 1760 800 1680 710 1470 595 1870 1110 1745 810 1620 685 1440 575

0.80 1795 1060 1640 755 1595 680 1415 570 1760 1065 1645 770 1510 655 1370 550

0.90 1680 1020 1530 725 1505 645 1345 550 1635 1025 1545 740 1415 620 1295 530

NOTES − All air data is measured external to unit without filter (not furnished − field provided).

Single Side Return Air − Air volumes in bold require field

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

Medium−

High

Medium−

Low

Single Side Return Air − Air volumes in bold require field

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

Medium−

High

Medium−

Low

Page 50

Page 51

G61MP−60D−135 PERFORMANCE (Less Filter)

Air Volume / Watts at Different Blower Speeds Air Volume / Watts at Different Blower Speeds

External

Static

Pressure

in. w.g.

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

High

Medium−

High

Medium−

Low

Low High

Single Side Return Air − Air volumes in bold require field

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

Medium−

High

Medium−

Low

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

0.00 2730 1465 2425 1125 2055 915 1560 680 2665 1440 2325 1100 1865 890 1410 690

0.10 2670 1440 2400 1100 2065 890 1590 675 2615 1405 2310 1065 1915 865 1465 685

0.20 2600 1400 2365 1070 2045 865 1620 665 2530 1370 2280 1055 1925 850 1570 675

0.30 2525 1360 2315 1045 2035 845 1615 655 2470 1330 2235 1015 1920 825 1590 670

0.40 2445 1325 2260 1015 2020 820 1615 645 2380 1290 2175 985 1910 805 1590 655

0.50 2360 1280 2195 985 1960 790 1610 635 2310 1265 2120 965 1890 790 1595 645

0.60 2290 1255 2130 965 1900 755 1600 615 2200 1230 2055 935 1835 765 1580 630

0.70 2205 1220 2035 910 1825 730 1570 600 2120 1190 1970 900 1790 740 1545 605

0.80 2110 1195 1945 880 1765 710 1540 580 2025 1160 1890 875 1720 710 1515 590

0.90 1970 1120 1835 830 1680 690 1540 545 1930 1110 1800 835 1655 685 1440 570

NOTES − All air data is measured external to unit without filter (not furnished − field provided).

Low

Page 51

Page 52

Heating Sequence of Operation

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

Applications Using a Two−Stage Thermostat A − Heating Sequence −− Control Board Thermostat Selection DIP switch in Two−Stage" Position (Factory Setting)

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

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

2 − Once the control receives a signal that the low−fire

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Applications Using A Single−Stage Thermostat

B − Heating Sequence −− Control Board Thermostat Selection DIP switch in Single−Stage" Position

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

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

2 − Once the control receives a signal that the low−fire

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

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

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

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

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

5 − If the heating demand continues beyond the second−

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

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

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

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

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

Page 52

Page 53

Service

WARNING

ELECTRICAL SHOCK, FIRE,

OR EXPLOSION HAZARD.

Failure to follow safety warnings exactly could result in dangerous operation, serious injury, death or property damage. Improper servicing could result in dangerous operation, serious injury, death, or property damage. Before servicing, disconnect all electrical power to furnace. When servicing controls, label all wires prior to disconnecting. Take care to reconnect wires correctly. Verify proper operation after servicing.

At the beginning of each heating season, system should be checked as follows by a qualified service technician:

Blower

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

WARNING

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

Filters

All G61MP filters are installed external to the unit. Filters should be inspected monthly. Clean or replace the filters when necessary to ensure proper furnace operation. Table 3 lists recommended filter sizes.

Exhaust and air intake pipes

Check the exhaust and air intake pipes and all connections for tightness and to make sure there is no blockage.

NOTE − After any heavy snow, ice or frozen fog event the furnace vent pipes may become restricted. Always check the vent system and remove any snow or ice that may be obstructing the plastic intake or exhaust pipes.

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__________

Winterizing and Condensate Trap Care

1 − Turn off power to the unit.

2 − Have a shallow pan ready to empty condensate water.

3 − Remove the drain plug from the condensate trap and

empty water. Inspect the trap then reinstall the drain plug.

Cleaning Heat Exchanger

If cleaning the heat exchanger becomes necessary, follow the below procedures and refer to figure 1 when disassembling unit. Use papers or protective covering in front of furnace while removing heat exchanger assembly.

1 − Turn off electrical and gas supplies to the furnace. 2 − Remove the upper and lower furnace access panels. 3 − Mark all gas valve wires and disconnect them from

valve.

4 − Remove gas supply line connected to gas valve. Re-

move gas valve/manifold assembly.

5 − Remove sensor wire from sensor. Disconnect 2-pin

plug from the ignitor. 6 − Disconnect wires from flame roll−out switches. 7 − Remove burner box cover and remove four burner box

screws at the vestibule panel and remove burner box.

Set burner box assembly aside.

NOTE − G61MP−135 units are secured to the vestibule

panel by two additional screws. These screws must be

removed for servicing; however it is not necessary to

replace the screws.

NOTE − If necessary, clean burners at this time. Follow

procedures outlined in Burner Cleaning section.

8 − Loosen three clamps and remove flexible exhaust tee. 9 − Remove 3/8 inch rubber cap from condensate drain

plug and drain. Replace cap after draining. 10 − Disconnect condensate drain line from the conden-

sate trap. Remove condensate trap (it may be neces-

sary to cut drain pipe). Remove screws that secure

condensate collars to either side of the furnace and re-

move collars. Remove drain tubes from cold end

header collector box. 11 − Disconnect condensate drain tubing from flue collar.

Remove screws that secure both flue collars into

place. Remove flue collars. It may be necessary to cut

the exiting exhaust pipe for removal of the fittings. 12 − Mark and disconnect all combustion air pressure tub-

ing from cold end header collector box. 13 − Mark and remove wires from pressure switches. Re-

move pressure switches. Keep tubing attached to

pressure switches. 14 − Disconnect the 3-pin plug from the combustion air in-

ducer. Disconnect the two wires to the backup secon-

dary limit, if applicable. Remove four screws which se-

cure combustion air inducer to collector box. Remove

combustion air inducer assembly. Remove ground

wire from vest panel. 15 − Remove electrical junction box from the side of the fur-

nace. 16 − Mark and disconnect any remaining wiring to heating

compartment components. Disengage strain relief

bushing and pull wiring and bushing through the hole in

the blower deck.

Page 53

Page 54

17 − Remove the primary limit from the vestibule panel. 18 − Remove two screws from the front cabinet flange at

the blower deck. Spread cabinet sides slightly to allow clearance for removal of heat exchanger.

19 − Remove screws along vestibule sides and bottom

which secure vestibule panel and heat exchanger assembly to cabinet. Remove two screws from blower rail which secure bottom heat exchanger flange. Remove heat exchanger from furnace cabinet.

20 − Back wash heat exchanger with soapy water solution

or steam. If steam is used it must be below 275°F

(135°C) .

21 − Thoroughly rinse and drain the heat exchanger. Soap

solutions can be corrosive. Take care to rinse entire assembly.

22 − Reinstall heat exchanger into cabinet making sure that

the clamshells of the heat exchanger assembly are resting on the support located at the rear of the cabinet. Remove the indoor blower to view this area through the blower opening.

23 − Re-secure the supporting screws along the vestibule

sides and bottom to the cabinet.

24 − Reinstall cabinet screws on front flange at blower

deck. 25 − Reinstall the primary limit on the vestibule panel. 26 − Route heating component wiring through hole in blow-

er deck and reinsert strain relief bushing. 27 − Reinstall electrical junction box. 28 − Reinstall the combustion air inducer. Reconnect the

3−pin plug to the wire harness. Reconnect the two

wires to the backup secondary limit, if applicable. 29 − Reinstall pressure switches and reconnect pressure

switch wiring. 30 − Carefully connect combustion air pressure switch

hosing from pressure switches to proper stubs on

cold end header collector box. 31 − Reinstall condensate collars on each side of the fur-

nace. Reconnect drain tubing to collector box. 32 − Reinstall condensate trap on same side as exhaust

pipe. Reconnect condensate drain line to the conden-

sate trap. 33 − Use securing screws to reinstall flue collars to either

side of the furnace. Reconnect exhaust piping and ex-

haust drain tubing. 34 − Replace flexible exhaust tee on combustion air induc-

er and flue collars. Secure using three existing hose

clamps. 35 − Reinstall burner box assembly in vestibule area. 36 − Reconnect flame roll−out switch wires. 37 − Reconnect sensor wire and reconnect 2−pin plug from

ignitor.

38 − Secure burner box assembly to vestibule panel using

four existing screws. Make sure burners line up in

center of burner ports.

39 − Reinstall gas valve manifold assembly. Reconnect

gas supply line to gas valve.

40 − Reinstall burner box cover. 41 − Reconnect wires to gas valve. 42 − Replace the blower compartment access panel. 43 − Refer to instruction on verifying gas and electrical con-

nections when re−establishing supplies.

44 − Follow lighting instructions to light and operate fur-

nace for 5 minutes to ensure that heat exchanger is clean and dry and that furnace is operating properly.

45 − Replace heating compartment access panel.

Cleaning the Burner Assembly

1 − Turn off electrical and gas power supplies to furnace.

Remove upper and lower furnace access panels.

2 − Mark all gas valve wires and disconnect them from the

valve.

3 − Disconnect the gas supply line from the gas valve. Re-

move gas valve/manifold assembly.

4 − Mark and disconnect sensor wire from the sensor. Dis-

connect 2-pin plug from the ignitor at the burner box.

5 − Remove burner box cover and remove four screws

which secure burner box assembly to vest panel. Remove burner box from the unit.

NOTE − G61MP−135 units are secured to the vestibule panel by two additional screws. These screws must be removed for servicing; however it is not necessary to replace the screws.

6 − Use the soft brush attachment on a vacuum cleaner to

gently clean the face of the burners. Visually inspect the inside of the burners and crossovers for any blockage caused by foreign matter. Remove any blockage.

7 − Reconnect the sensor wire and reconnect the 2−pin

plug to the ignitor wiring harness.

8 − Reinstall the burner box assembly using the existing

four screws. Make sure that the burners line up in the center of the burner ports.

9 − Reinstall the gas valve manifold assembly. Reconnect

the gas supply line to the gas valve. Reinstall the burner box cover.

10 − Reconnect the gas valve wires to the gas valve. 11 − Replace the blower compartment access panel. 12 − Refer to instruction on verifying gas and electrical con-

nections when re−establishing supplies.

13 − Follow lighting instructions to light and operate fur-

nace for 5 minutes to ensure that heat exchanger is clean and dry and that furnace is operating properly.

14 − Replace heating compartment access panel.

Page 54

Page 55

Planned Service

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

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

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

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

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

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

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

cracked or sagging pipe, or disconnected joints.

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

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

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

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

spections that may result in unsafe operation. For instance, items innocently stored next to the furnace may obstruct the combustion air supply. This could cause incomplete combustion and the production of carbon monoxide gas.

Page 55

Page 56

Ignition Control Board Diagnostic Codes

FLASH CODE

(X + Y)

STATUS / ERROR DESCRIPTION

FLASH CODE DESCRIPTIONS

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

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

X + Y

Pulse Power on − Standby.

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

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

FLAME CODES

1 + 2 Low flame current −− run mode.

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

PRESSURE SWITCH CODES

2 + 3 Low pressure switch failed open.

2 + 4 Low pressure switch failed closed.

2 + 5 High pressure switch failed open.

2 + 6 High pressure switch failed closed.

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

LIMIT CODE

3 + 1 Limit switch open.

WATCHGUARD CODES

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

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

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

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

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

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

4 + 8 Low line voltage.

HARD LOCKOUT CODES

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

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

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

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

5 + 6 Low secondary (24VAC) voltage.

Error Code Storage

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

Error Code Review

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

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

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

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

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

TUS LED turning off. This activates error code review.

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

LED.

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

flash to indicate normal operation.

Clearing Error Codes

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

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

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

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

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

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

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

dicate normal operation.

Page 56

Page 57

Troubleshooting: Heating Sequence of Operation

HEATING SEQUENCE OF OPERATION

NORMAL AND ABNORMAL HEATING MODE

POWER ON

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

CONTROL SELF−CHECK OKAY?

INDOOR BLOWER OFF. (RESET CONTROL BY

TURNING MAIN POWER OFF.)

POLARITY OKAY?

YES

IS THERE A

PROPER GROUND?

YES

NORMAL OPERATION:

STATUS LED −− PULSE

THERMOSTAT CALLS FOR HEAT:

STATUS LED −− HEARTBEAT

YES

PRIMARY AND SECONDARY LIMIT

SWITCHES CLOSED?

YES

ROLLOUT SWITCH CLOSED?

YES

FIRST (LOW) STAGE PRESSURE SWITCH

CONTACTS OPEN?

YES

SECOND (HIGH) STAGE PRESSURE SWITCH

CONTACTS OPEN?

YES

SIGNAL HOLDS UNTIL UNIT IS PROPERLY GROUNDED.

INDOOR BLOWER ON. HAS PRIMARY OR

SECONDARY LIMIT RESET WITHIN 3 MINUTES?

60−MINUTE LIMIT WATCHGUARD MODE.

GAS VALVE OFF, COMBUSTION AIR INDUCER

OFF, INDOOR BLOWER OFF WITH DELAY.

GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

SEQUENCE HOLDS UNTIL ROLLOUT SWITCH IS

RESET AND MAIN POWER IS INTERRUPTED OR

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

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF. CONTROL REMAINS UNTIL

PRESSURE SWITCH IS DETECTED OPEN.

POLARITY REVERSED.

STATUS ERROR CODE 5 + 4.

STATUS ERROR CODE 5 + 3.

COMBUSTION AIR INDUCER OFF.

STATUS ERROR CODE 3 + 1.

STATUS ERROR CODE 4 + 5.

INDOOR BLOWER ON.

STATUS ERROR CODE 5 + 1.

STATUS ERROR CODE 2 + 4

YES

TWO−STAGE OR SINGLE−STAGE THERMOSTAT

CALL FOR HEAT

COMBUSTION AIR INDUCER ON LOW SPEED.

STATUS LED −− HEARTBEAT

CONTINUED ON NEXT PAGE

COMBUSTION AIR INDUCER OFF.

GAS VALVE OFF.

INDOOR BLOWER OFF.

CONTROL WILL NOT ATTEMPT SECOND−STAGE

OPERATION DURING THIS HEAT DEMAND.

FIRST−STAGE OPERATION WILL BE ATTEMPTED.

STATUS ERROR CODE 2 + 6.

Page 57

Page 58

Troubleshooting: Heating Sequence of Operation (Continued)

HEATING SEQUENCE OF OPERATION

CONTINUED

THERMOSTAT CALLS FOR HEAT

STATUS LED − HEARTBEAT.

(Refer to box A on previous page)

FIRST−STAGE (LOW FIRE) PRESSURE

SWITCH CLOSED WITHIN 2.5 MINUTES?

YES

15−SECOND COMBUSTION AIR INDUCER

PRE−PURGE INITIATED BY CLOSED FIRST−STAGE

PRESSURE SWITCH (or 15 SECOND

INTER−PURGE PERIOD.)

STATUS LED −− HEARTBEAT.

IGNITOR WARM−UP (20 SECONDS)

STATUS LED −− HEARTBEAT.

YES

IS IGNITOR INTACT AND CONNECTED?

YES

AT END OF IGNITOR 20 SECOND WARM UP

PERIOD, 4−SECOND TRIAL FOR IGNITION.

GAS VALVE OPENS, IGNITOR ENERGIZED DURING

4−SECOND TRIAL UNTIL FLAME SENSED.

YES

4−SECOND FLAME STABILIZATION PERIOD.

GAS VALVE OFF. COMBUSTION AIR INDUCER

OFF. INDOOR BLOWER OFF. UNIT WILL RETRY

AFTER 5−MINUTE WAIT PERIOD.

STATUS ERROR CODE 2 + 3.

COMBUSTION AIR INDUCER OFF, IGNITOR OFF.

SIGNAL HOLDS UNTIL IGNITOR IS REPLACED OR

RECONNECTED.

STATUS ERROR CODE 4 + 7.

IS VOLTAGE ABOVE 90 VOLTS?

COMBUSTION AIR INDUCER OFF, IGNITER OFF.

SIGNAL HOLDS UNTIL VOLTAGE RISES ABOVE 95

VOLTS. STATUS ERROR CODE 4 + 8.

YES

FLAME RECTIFICATION CURRENT CHECK

CAN FLAME BE PROVEN WITHIN 4

SECONDS AFTER GAS VALVE OPENS?

(u0.20 microamps)

FLAME PRESENT?

YES

CONTINUED ON NEXT PAGE

GAS VALVE OFF. COMBUSTION AIR

INDUCER ON. INDOOR BLOWER OFF.

STATUS LED −− HEARTBEAT.

HAS CONTROL FAILED TO SENSE

FLAME FOR FIVE CONSECUTIVE TRIES

DURING A SINGLE HEAT DEMAND?

YES

WATCHGUARD MODE. GAS VALVE OFF,

COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF.

STATUS ERROR CODE 4 + 1.

IS 60−MINUTE RESET PERIOD COMPLETE?

YES

HAS CONTROL RESET IGNITION SEQUENCE

FOUR (4) TIMES?

WATCHGUARD MODE.

STATUS ERROR CODE 4 + 3.

YES

Page 58

Page 59

Troubleshooting: Heating Sequence of Operation (Continued)

HEATING SEQUENCE OF OPERATION

CONTINUED

FLAME SIGNAL ABOVE

(u1.40 microamps)

YES

SINGLE−STAGE THERMOSTAT MODE

(DIP SWITCH SET AT SINGLE")

YES

START SECOND−STAGE RECOGNITION

ON DELAY (10 OR 15 MINUTES).

STATUS LED −− HEARTBEAT

ROLLOUT SWITCHES CLOSED?

YES

TWO STAGE THERMOSTAT MODE

(DIP SWITCH SET AT TWO")

45−SECOND INDOOR BLOWER ON DELAY BEGINS.

YES

THERMOSTAT CALLS FOR HEAT.

STATUS LED −− HEARTBEAT.

SEE BOX A.

LOW FLAME SIGNAL

(Does not affect control operation)

STATUS ERROR CODE 1 + 2.

YES

STATUS LED −− HEARTBEAT.

YES

PRIMARY & SECONDARY LIMIT SWITCHES

CLOSED?

YES

FIRST−STAGE (LOW FIRE)

PRESSURE SWITCH CLOSED?

YES

FIRST−STAGE HEAT DEMAND SATISFIED?

YES

GAS VALVE OFF, COMBUSTION AIR INDUCER

OFF FOLLOWING POST PURGE.

INDOOR BLOWER OFF WITH DELAY

STATUS LED −− PULSE

SECOND−STAGE HEAT DEMAND.

SECOND−STAGE HEAT DEMAND REQUIRED?

YES

SECOND STAGE PRESSURE SWITCH CLOSED?

NOTE − IF SECOND−STAGE PRESSURE SWITCH

SECOND−STAGE 30−SECOND DELAY ON BEGINS.

SECOND−STAGE COMBUSTION AIR INDUCER

ON. SECOND−STAGE GAS VALVE ON. HIGH

SECOND−STAGE PRESSURE SWITCH CLOSED

ABNORMAL FLASH CODE.

WAS ORIGINALLY FOUND CLOSED,

ABNORMAL CODE WILL FLASH.

STATUS LED −− HEARTBEAT.

YES

HEAT INDOOR BLOWER SPEED ON.

STATUS LED −− HEARTBEAT.

YES

IN LESS THAN TEN (10) SECONDS?

STATUS LED −− HEARTBEAT

YES

CONTINUED ON NEXT PAGE

GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

YES

STATUS ERROR CODE 5 + 1. SEQUENCE HOLDS

UNTIL ROLLOUT SWITCH IS RESET AND MAIN

POWER IS INTERRUPTED OR THERMOSTAT

IS CYCLED OFF/ON FOR 3 SECOND MINIMUM.

GAS VALVE OFF, COMBUSTION AIR INDUCER OFF,

SWITCH CLOSED WITHIN 3 MINUTES?

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

GAS VALVE OFF, COMBUSTION AIR INDUCER OFF,

IS 60−MINUTE RESET PERIOD COMPLETE?

GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

INDOOR BLOWER OFF AFTER DELAY.

STATUS ERROR CODE 2 + 3. CONTROL RESTARTS

IGNITION SEQUENCE IF PRESSURE SWITCH

SECOND−STAGE PRESSURE SWITCH CLOSED

RETURNS TO FIRST−STAGE HEAT MODE WHICH

CONTINUES UNTIL SECOND−STAGE PRESSURE

SWITCH CAN BE PROVEN or HEAT DEMAND IS

SATISFIED. FIVE (5) MINUTE WAIT PERIOD

INITIATED BEFORE RETRY. WERE 5 ATTEMPTS

CONTINUES FIRST−STAGE HEATING DEMAND.

WILL NOT REATTEMPT SECOND−STAGE

INDOOR BLOWER ON.

STATUS ERROR CODE 3 + 1.

HAS PRIMARY OR SECONDARY LIMIT

LIMIT SWITCH WATCHGUARD MODE.

INDOOR BLOWER OFF WITH DELAY.

STATUS ERROR CODE 4 + 5

CLOSES WITHIN 2−1/2 MINUTES.

AT BEGINNING OF HEAT DEMAND?

STATUS ERROR CODE 2 + 6.

SECOND STAGE HEAT DEMAND

STATUS LED −− HEARTBEAT.

MADE FOR SECOND−STAGE HEAT?

YES

HEATING DEMAND.

STATUS ERROR CODE 2 + 5.

YES

Page 59

Page 60

Troubleshooting: Heating Sequence of Operation (Continued)

HEATING SEQUENCE OF OPERATION

CONTINUED

NORMAL OPERATION.

SEE BOX A

SECOND−STAGE (HIGH FIRE) HEAT

PRESSURE SWITCH CLOSED?

YES

HEAT DEMAND SATISFIED? STATUS LED −− HEARTBEAT.

YES

SINGLE−STAGE THERMOSTAT MODE

(DIP SWITCH SET AT SINGLE")

YES

GAS VALVE OFF, COMBUSTION AIR

INDUCER OFF AFTER 5−SECOND

LOW SPEED POST PURGE PERIOD,

INDOOR BLOWER OFF DELAY

INITIATED ON LOW HEAT SPEED.

STATUS LED −− HEARTBEAT.

RETURN TO FIRST−STAGE HEAT MODE.

FIRST−STAGE CONTINUES UNTIL SECOND−

YES

TWO STAGE THERMOSTAT MODE?

(DIP SWITCH SET AT TWO")

YES

FIRST AND SECOND STAGE HEAT

DEMAND SATISFIED SIMULTANEOUSLY.

STATUS LED −− HEARTBEAT.

STAGE PRESSURE SWITCH CAN BE PROVEN

or HEAT DEMAND IS SATISFIED. A FIVE (5)

MINUTE WAIT PERIOD IS INITIATED BEFORE

YES

THERMOSTAT CALLS FOR HEAT.

RETRY. WERE 5 ATTEMPTS MADE FOR

FIRST−STAGE HEAT DEMAND SATISFIED?

SEE BOX B

SECOND−STAGE HEAT?

SEE BOX C

SECOND STAGE HEAT

GAS VALVE, COMBUSTION AIR INDUCER

AND INDOOR BLOWER RETURN TO FIRST−

STATUS LED −− HEARTBEAT.

DEMAND SASTISFIED?

STATUS LED −− HEARTBEAT.

YES

STAGE OPERATION.

YES

DEMAND FOR HEAT SATISFIED.

POWER ON STAND BY.

STATUS LED −− PULSE.

FIRST STAGE HEAT DEMAND SATISFIED?

GAS VALVE OFF. COMBUSTION AIR INDUCER

OFF AFTER 5−SECOND LOW SPEED POST−

PURGE PERIOD. INDOOR BLOWER OFF. DELAY INITIATED ON LOW HEAT SPEED.

STATUS LED −− PULSE.

YES

Page 60

Page 61

Troubleshooting: Cooling Sequence of Operation

COOLING SEQUENCE OF OPERATION

POWER ON

YES

IS POLARITY REVERSED?

CONTROL WILL CONTINUE TO CALL FOR COOLING

SIGNAL POLARITY REVERSED.

IN THIS CONDITION.

STATUS ERROR CODE 5 + 4.

IS THERE

PROPER GROUND?

YES

THERMOSTAT CALLS FOR FIRST−STAGE COOL.

COMPRESSOR AND CONDENSER FAN

ENERGIZED.

INDOOR BLOWER ENERGIZED ON FIRST STAGE

COOL SPEED AFTER 2 SECOND DELAY.

FIRST−STAGE DEMAND FOR COOL SATISFIED?

THERMOSTAT CALLS FOR SECOND−STAGE COOL.

INDOOR BLOWER RAMPS UP TO SECOND−STAGE COOL SPEED.

YES

SIGNAL IMPROPER GROUND AT LED.

CONTROL WILL CONTINUE TO CALL FOR COOLING

IN THIS CONDITION.

STATUS ERROR CODE 5 + 3.

COMPRESSOR AND CONDENSER FAN DE−ENERGIZED.

INDOOR BLOWER DE−ENEGIZED.

SECOND−STAGE DEMAND FOR COOL SATISFIED?

YES

UNIT RETURNS TO FIRST STAGE COOL

Page 61

Page 62

Troubleshooting: Continuous Fan Sequence of Operation

CONTINUOUS LOW SPEED FAN SEQUENCE OF OPERATION

MANUAL FAN SELECTION MADE AT THERMOSTAT.

AFTER 2 SECOND DELAY, INDOOR BLOWER IS

ENERGIZED ON CONTINUOUS FAN SPEED.

YES YES

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

YES

INDOOR BLOWER RAMPS TO FIRST STAGE

COOLING SPEED AFTER A 2−SECOND DELAY.

AFTER 45−SECOND DELAY, INDOOR BLOWER

YES

SWITCHES TO LOW HEAT SPEED.

YES

FIRST−STAGE COOL DEMAND SATISFIED?

SECOND STAGE COOL DEMAND

INDOOR BLOWER RAMPS TO SECOND

STAGE COOL SPEED

SECOND STAGE COOL DEMAND SATISFIED?

YES

INDOOR BLOWER RAMPS DOWN TO FIRST STAGE

COOL SPEED.

FIRST−STAGE HEAT DEMAND SATISFIED.

THERMOSTAT CALLS FOR SECOND−STAGE HEAT.

YES

INDOOR BLOWER SWITCHES TO HIGH HEAT SPEED

AFTER 30−SECOND RECOGNITION PERIOD.

YES

SECOND−STAGE HEAT DEMAND SATISFIED.

YES

INDOOR BLOWER RAMPS DOWN TO LOW

HEAT SPEED.

YES

Repair Parts List

The following repair parts are available through Lennox dealers. When ordering parts, include the complete furnace model number listed on the CSA nameplate −− Example: G61MP−36B−045−1. All service must be performed by a licensed pro-

fessional installer (or equivalent), service agency, or gas supplier.

Cabinet Parts

Upper access panel

Blower access panel

Top Cap

Control Panel Parts

Transformer

Two−stage integrated control board

Door interlock switch

Circuit Breaker

Blower Parts

Blower wheel

Motor

Motor mounting frame

Motor capacitor

Blower housing cutoff plate

Heating Parts

Flame Sensor

Heat exchanger assembly Gas manifold Combustion air inducer Gas valve Main burner cluster Main burner orifices Pressure switches Ignitor Primary limit control Secondary limit control Flame rollout switches Combustion air inducer auxiliary limit

Page 62

Page 63

Vent Pipe Sizing Worksheet

Step 1 Step 2

Proposed vent pipe size : ______ Termination kit catalog number : _____________

Equivalent Feet

Vent pipe equivalency value from table 5 : ______

Step 3

Total number of 90° elbows required (indoors and outdoors) ______ X 5 = ______ equivalent feet of pipe

Step 4

Total number of 45° elbows required (indoors and outdoors) ______ X 2.5 = ______ equivalent feet of pipe

Step 5

Step 6

Linear feet of straight pipe required : ______

Add equivalent feet of vent pipe listed in

TOTAL

steps 2 through 5.

If the total is equal to, or less than, the allowable maximum given in table 6, the proposed pipe size is acceptable. If the total exceeds the maximum allowed vent pipe length, repeat the process above using the next larger diameter pipe until an acceptable total is achieved.

NOTE − In Direct Vent systems, total the equivalent length of either the exhaust OR intake piping run, depending upon which will be LONGER. Intake and exhaust pipe diameter must be the same size and must be terminated in the same pressure zone. Intake and exhaust pipe should be roughly the same length.

G61MP Start−Up & Performance Check List

Job Name

Job No.

Date

Job Location

Installer

Unit Model No.

Serial No.

City

Technician

Heating Section

Electrical Connections Tight?

Line Voltage

Blower Motor Amps

Fuel Type: Natural Gas?

Furnace Btu Input (High fire) Line Pressure

Low Fire Manifold Pressure

High Fire Manifold Pressure

Flue Connections Tight?

Combustion Gas Tested (high fire and low fire)?

Blower ON delay confirmed?

(45 Seconds Fixed On)

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

LP/Propane Gas?

w.c. − Nat.:

Blower Motor H.P.

Gas Piping Connections Tight & Leak−Tested?

w.c. − LP/Propane

Proper Draft?

External Static Pressure? (0.5 maximum)

Temperature Rise

State

Filter Clean & Secure?

Thermostat

Heat Anticipator Setting? Thermostat Level?

Page 63

Page 64

Requirements for Commonwealth of Massachusetts

Modifications to NFPA−54, Chapter 10

Revise NFPA−54 section 10.8.3 to add the following requirements:

For all side wall, horizontally vented, gas−fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above the finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:

1 − INSTALLATION OF CARBON MONOXIDE DETEC-

TORS. At the time of installation of the side wall, hori-

zontally vented, gas−fueled equipment, the installing

plumber or gasfitter shall observe that a hard−wired

carbon monoxide detector with an alarm and battery

backup is installed on the floor level where the gas

equipment is to be installed. In addition, the installing

plumber or gasfitter shall observe that a battery−oper-

ated or hard−wired carbon monoxide detector with an

alarm is installed on each additional level of the dwell-

ing, building or structure served by the side wall, hori-

zontally vented, gas−fueled equipment. It shall be the

responsibility of the property owner to secure the ser-

vices of qualified licensed professionals for the instal-

lation of hard−wired carbon monoxide detectors.

a − In the event that the side wall, horizontally vented,

gas−fueled equipment is installed in a crawl space or an attic, the hard−wired carbon monoxide detector with alarm and battery back−up may be installed on the next adjacent floor level.

b − In the event that the requirements of this subdivi-

sion cannot be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery−operated carbon monoxide detector with an alarm shall be installed.

2 − APPROVED CARBON MONOXIDE DETECTORS.

Each carbon monoxide detector as required in accor-

dance with the above provisions shall comply with

NFPA 720 and be ANSI/UL 2034 listed and IAS certi-

fied.

3 − SIGNAGE. A metal or plastic identification plate shall

be permanently mounted to the exterior of the building

at a minimum height of eight (8) feet above grade di-

rectly in line with the exhaust vent terminal for the hori-

zontally vented, gas−fueled heating appliance or

equipment. The sign shall read, in print size no less

than one−half (1/2) inch in size, GAS VENT DIRECT-

LY BELOW. KEEP CLEAR OF ALL OBSTRUC-

TIONS."

4 − INSPECTION. The state or local gas inspector of the

side wall, horizontally vented, gas−fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a) 1 through 4.

EXEMPTIONS: The following equipment is exempt from 24 CMR 5.08(2)(a) 1 through 4:

1 − The equipment listed in Chapter 10 entitled Equip-

ment Not Required to Be Vented" in the most current edition of NFPA 54 as adopted by the Board; and

2 − Product Approved side wall, horizontally vented, gas−

fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.

MANUFACTURER REQUIREMENTS − GAS EQUIPMENT VENTING SYSTEM PROVIDED.

When the manufacturer of Product Approved side wall, horizontally vented, gas−fueled equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include:

1 − Detailed instructions for the installation of the venting

system design or the venting system components: and

2 − A complete parts list for the venting system design or

venting system.

MANUFACTURER REQUIREMENTS − GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED.

When the manufacturer of Product Approved side wall, horizontally vented, gas−fueled equipment does not provide the parts for venting the flue gases, but identifies special venting systems," the following requirements shall be satisfied by the manufacturer:

1 − The referenced special venting system" instructions

shall be included with the appliance or equipment installation instructions; and

2 The special venting systems" shall be Product Ap-

proved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions.

A copy of all installation instructions for all Product Approved side wall, horizontally vented, gas−fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.

Page 64

Lennox G61MP-60C-090, G61MP-36B-070, G61MP-60C-091, G61MP-48C-110, G61MP-60C-110 Installation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual