Lennox G61MPV Service Manual

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Page 1

Corp. 0310−L7

G61MPV

Service Literature

Revised 02−2012

G61MPV SERIES UNITS

G61MPV series units are high−efficiency multi−position (upflow, downflow, horizontal right and left) gas furnaces manufactured with Lennox Duralok Plust heat exchang- ers formed of an aluminized steel primary with a stainless steel secondary condensing coil. G61MPV units are available in heating capacities of 44,000 to 132,000 Btuh (13.0.0 to 38.6 kW) and cooling applications from 2 to 5 tons (7.0 kW to 17.5 kW). Refer to Engineering Handbook for proper sizing.

Units are factory equipped for use with natural gas. Kits are available for conversion to LPG operation. G61MPV model units are equipped with the two−stage variable speed integrated SureLight® control. All G61MPV units meet the California Nitrogen Oxides (NO

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

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

TABLE OF CONTENTS

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

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

Parts Identification Page 23. . . . . . . . . . . . . . . . . . . . . . . .

I Unit Components Page 24. . . . . . . . . . . . . . . . . . . . . . .

II Installation Page 50. . . . . . . . . . . . . . . . . . . . . . . . . . . .

III Start Up Page 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IV Heating System Service Checks Page 68. . . . . . . . .

V Typical Operating Characteristics Page 71. . . . . . . . .

VI Maintenance Page 72. . . . . . . . . . . . . . . . . . . . . . . . . .

VII Wiring and Sequence of Operation Page 75. . . . . .

VIII Field Wiring and Jumper Setting Page 90. . . . . . . .

IX Control Board Troubleshooting Page 95. . . . . . . . . .

IMPORTANT

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

WARNING

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

WARNING

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

Page 2

SPECIFICATIONS

Gas Heating Performance

ModelNo. G61MPV

−36B−045

G61MPV

−36B−070

G61MPV

−36B−071

G61MPV

−36C−090

High Fire

Input− Btuh

44,000 66,000 66,000 88,000

Output− Btuh 39,000 61,000 62,000 79,000

Temperature rise range − _F 20 − 50 45 − 75 45 − 75 70 − 100

Gas Manifold Pressure (in. w.g.)

Natural Gas / LPG/Propane

3.5 / 10.0 3.5 / 10.0 3.5 / 10.0 3.5 / 10.0

Low Fire

Input − Btuh 30,000 45,000 45,000 60,000

Output − Btuh 29,000 43,000 43,000 56,000

Temperature rise range − _F 10 − 40 25 − 55 20 − 50 35 − 65

Gas Manifold Pressure (in. w.g.)

Natural Gas / LPG/Propane

1.7 / 4.9 1.7 / 4.9 1.7 / 4.9 1.7 / 4.9

AFUE 94.1% 94.1% 95.0% 94.3%

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

Connections in.

Intake / Exhaust Pipe (PVC) 2 / 2 2 / 2 2 / 2 2 / 2

Condensate Drain Trap (PVC pipe) − i.d. 1/2 1/2 1/2 1/2

with field supplied (PVC coupling) − o.d. 3/4 3/4 3/4 3/4

hose with hose clamp − i.d. x o.d. 1−1/4 x 1 1−1/4 x 1 1−1/4 x 1 1−1/4 x 1

GaspipesizeIPS 1/2 1/2 1/2 1/2

Indoor Blower

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

Motoroutput − hp 1/2 1/2 1/2 1/2

Tons(kW) ofadd−oncooling 2 − 3 2 − 3.5 2 − 3.5 2 − 3.5

Air volume range − cfm

610 − 1420 625 − 1395 625 − 1395 600 − 1395

ShippingData lbs. − 1 package 128 151 151 170

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

NOTE − Filters and provisions for mounting are not furnished and must be field provided.

Annual Fuel Utilization Efficiency based on DOE test procedures and according to FTC labeling regulations. Isolated combustion system rating for non−weatherized furnaces.

Gas Heating Performance

ModelNo. G61MPV

−60C−090

G61MPV

−60C−091

G61MPV

−60C−110

G61MPV

−60C−111

G61MPV

−60D−135

High Fire

Input− Btuh 88,000 88,000 110,000 110,000 132,000

Output− Btuh 81,000 84,000 99,000 103,000 122,000

Temperature rise range − _F 40 − 70 40 − 70 50 − 80 50 − 80 65 − 95

Gas Manifold Pressure (in. w.g.)

Natural Gas / LPG/Propane

3.5 / 10.0 3.5 / 10.0 3.5 / 10.0 3.5 / 10.0 3.5 / 10.0

Low Fire

Input− Btuh 60,000 60,000 75,000 75,000 90,000

Output− Btuh 57,000 58,000 72,000 72,000 87,000

Temperature rise range − _F 20 − 50 20 − 50 30 − 60 25 − 55 40 − 70

Gas Manifold Pressure (in. w.g.)

Natural Gas / LPG/Propane

1.7 / 4.9 1.7 / 4.9 1.7 / 4.9 1.7 / 4.9 1.7 / 4.9

AFUE 94.6% 95.0% 94.3% 95.0% 94.6%

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

Connections in.

Intake / Exhaust Pipe (PVC) 2 / 2 2 / 2 2 / 2 2 / 2 3 / 3

Condensate Drain Trap (PVC pipe) − i.d. 1/2 1/2 1/2 1/2 1/2

with field supplied (PVC coupling) − o.d. 3/4 3/4 3/4 3/4 3/4

hose with hose clamp − i.d. x o.d. 1−1/4 x 1 1−1/4 x 1 1−1/4 x 1 1−1/4 x 1 1−1/4 x 1

GaspipesizeIPS 1/2 1/2 1/2 1/2 1/2

Indoor Blower

Wheelnominaldiameter xwidth −in. 11−1/2 x 10 11−1/2 x 10 11−1/2 x 10 11−1/2 x 10 11−1/2 x 10

Motoroutput − hp 1 1 1 1 1

Tons(kW) ofadd−oncooling 3.5 − 5 3.5 − 5 3.5 − 5 3.5 − 5 3.5 − 5

Air volume range − cfm 895 − 2215 895 − 2215 740 − 2210 740 − 2210 915 − 2190

ShippingData lbs. − 1 package 180 180 188 188 207

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

NOTE − Filters and provisions for mounting are not furnished and must be field provided.

Annual Fuel Utilization Efficiency based on DOE test procedures and according to FTC labeling regulations. Isolated combustion system rating for non−weatherized furnaces.

Page 3

OPTIONAL ACCESSORIES − MUST BE ORDERED EXTRA

B" Width Models C" Width Models D" Width Models

FILTER KITS

Air Filter and

Rack Kit

Horizontal (end) Size of filter − in. 87L96 − 18 x 25 x 1 87L97 − 20 x 25 x 1 87L98 − 25 x 25 x 1

Side Return

Single 44J22 44J22 44J22

Ten Pack 66K63 66K63 66K63

Size of filter − in. 16 x 25 x 1 16 x 25 x 1 16 x 25 x 1

EZ Filter Base

Catalog No. − Ship. Wt. − lbs. 73P56 − 7 73P57 − 8 73P58 − 10

Size of field provided filter − in. 16 x 25 x 1 20 x 25 x 1 24 x 24 x 1

CABINET ACCESSORIES

Down−Flow Additive Base 11M60 11M61 11M62

Horizontal Support Frame Kit 56J18 56J18 56J18

Return Air Base 98M60 98M58 98M59

CONDENSATE DRAIN KITS

Condensate Drain Heat Cable

6 ft. 26K68 26K68 26K68

24 ft. 26K69 26K69 26K69

50 ft. 26K70 26K70 26K70

Heat Cable Tape

Fiberglass − 1/2 in. x 66 ft. 39G04 39G04 39G04

Aluminum foil − 2 in. x 60 ft. 39G03 39G03 39G03

Condensate Trap Alternate Location Kit − Up−Flow Only 76M20 76M20 76M20

CONTROLS

SignatureStat Home Comfort Control 81M27 81M27 81M27

TERMINATION KITS − See Installation Instructions for specific venting information.

Termination Kits Direct Vent Applications Only

Concentric

2 in. 71M80 69M29 − − −

3 in. − − − 60L46 60L46

Wall − Close Couple

2 in. 22G44 − − − − − −

3 in. 44J40 44J40 44J40

Close Couple WTK 2 in. 30G28 − − − − − −

3 in. 81J20 81J20 81J20

Termination Kits − Direct or Non−Direct Vent

Roof 2 in. 15F75 15F75

− − −

Wall − Wall Ring Kit 2 in. 15F74 15F74

15F74

Roof Termination Flashing Kit − Direct or Non−Direct

Vent − Contains two flashings.

44J41 44J41 44J41

Cleanable polyurethane frame type filter.

Kits contain enough parts for two, non−direct vent installations.

Non−direct vent only.

GAS HEAT ACCESSORIES

Input

High Altitude

Orifice Kit

Natural Gas

Only

High Altitude Pressure Switch Kit

ORDER TWO EACH

LPG/Propane Kit

LPG/Propane to

Natural Gas Kit

7501−10,000 ft. 2001−4500 ft. 4501−7500 ft. 7501−10,000 ft. 0−7500 ft. 7501−10,000 ft. 0−7500 ft.

7501−10,000 ft.

−045 59M17 − − − − − − − − − 59M13 59M14 59M87 59M87

−070 59M17 − − − − − − 56M23 59M13 59M14 59M87 59M87

−071 59M17 75M22 75M22 56M21 59M13 59M14 59M87 59M87

−090 59M17 − − − 75M22 56M21 59M13 59M14 59M87 59M87

−090

(036C−9 and later models)

59M17 − − − 24W51 24W49 59M13 59M14 59M87 59M87

−091 47M82 26W85 26W85 26W86 59M13 59M14 59M87 59M87

−110 59M17 − − − 56M23 75M22 59M13 59M14 59M87 59M87

−111 47M82 56M22 56M22 56M23 59M13 59M14 59M87 59M87

−135 59M17 − − − 56M93 56M93 59M13 59M14 59M87 59M87

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

Page 4

BLOWER DATA

G61MPV−36B−045 BLOWER PERFORMANCE (less filter) 0 through 0.80 in. w.g. External Static Pressure Range

ADJUST"

Switch

Positions

Speed Switch Positions

Second Stage HEAT" Speed − cfm Second Stage COOL" Speed − cfm

2 3 4 1 2 3

+ 915 1070 1320 1370 1055 1235 1330 1420

NORM 830 965 1205 1255 945 1100 1185 1295

 740 860 1055 1095 840 970 1050 1150

ADJUST"

Switch

Positions

First Stage HEAT" Speed − cfm First Stage COOL" Speed − cfm

2 3 4 1 2 3

+ 830 970 1210 1255 720 820 890 970

NORM 755 880 1080 1120 665 745 795 875

 690 795 950 995 610 685 725 785

Factory default jumper setting. N/A − First and second stage HEAT positions shown cannot be used on this model. NOTES − The effect of static pressure is included in air volumes shown.

First stage HEAT is approximately 91% of the same second stage

HEAT speed position.

First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 442 cfm.

G61MPV−36B−045 BLOWER MOTOR WATTS

Jumper Speed

Positions

Motor Watts @ Various External Static Pressures − in. wg.

First Stage Second Stage

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 +" (Plus) SETTING (Adjust" Jumper at +" Setting) HEAT"

Speed

Tap 1

70 90 115 135 155 175 200 220 245 95 120 145 175 190 210 230 255 280

Tap 2

125

145 165 185 205 225 255 280 305 155 175 200 225 255 290 310 335 360

Tap 3

220 250 280 310 340 365 390 415 440 305 335 370 400 435 465 480 495 510

Tap 4

225 260 300 345 375 410 430 450 470 330 360 395 430 460 485 510 530 550

COOL"

Speed

Tap 1

55 70 90 110 125 140 160 175 195 140 165 200 230 255 280 305 325 350

Tap 2

70 90 110 130 155 175 200 220 240 230 260 295 330 360 390 415 435 460

Tap 3

110 135 160 185 205 225 245 265 280 315 350 390 430 465 485 505 525

Tap 4

115 135 160 185 210 235 255 280 300 370 410 450 490 520 555 560 565 570

NORM" (Normal) SETTING (Adjust" Jumper at NORM" Setting) HEAT"

Speed

Tap 1

65 80 95 110 135 155 170 190 210 80 95 115 135 155 175 200 220 240

Tap 2

105 125 150 175 195 220 245 270 110 135 160 185 210 230 255 275 295

Tap 3

150 175 205 230 265 295 320 345 365 205 230 260 295 330 370 390 415 440

Tap 4

165 195 230 265 290 315 340 370 400 240 270 310 345 370 395 425 455 485

COOL"

Speed

Tap 1

45 60 75 95 11 5 130 145 160 175 110 130 155 185 205 230 250 275 295

Tap 2

60 80 100 115 135 155 175 195 215 165 190 215 240 275 305 330 355 380

Tap 3

85 11 0 130 150 165 190 210 230 195 225 260 290 320 350 375 400 425

Tap 4

85 105 135 160 175 190 215 240 265 265 300 340 380 410 440 460 485 505

−" (Minus) SETTING (Adjust" Jumper at −" Setting) HEAT"

Speed

Tap 1

50 65 85 100 120 140 155 170 185 55 70 90 11 0 135 155 170 190 205

Tap 2

70 90 105 125 145 165 185 205 230 85 100 125 145 175 200 220 235 250

Tap 3

110

130 155 185 205 225 250 270 290 150 170 195 220 240 265 295 320 350

Tap 4

125 145 170 200 220 240 265 295 320 160 185 215 245 265 290 315 335 360

COOL"

Speed

Tap 1

40 55 70 85 100 120 130 145 160 80 95 115 135 160 185 205 230 255

Tap 2

55 65 80 95 11 5 135 150 165 185 115 140 170 195 215 235 260 280 300

Tap 3

70 90 105 125 145 160 180 195 140 165 195 225 250 270 295 320 345

Tap 4

75 90 105 125 140 155 180 200 225 180 205 235 265 295 325 355 380 410

Page 5

BLOWER DATA

G61MPV−36B−070 BLOWER PERFORMANCE (less filter) 0 through 0.80 in. w.g. External Static Pressure Range

ADJUST"

Switch

Positions

Speed Switch Positions

Second Stage HEAT" Speed − cfm Second Stage COOL" Speed − cfm

2 3 4 1 2 3

+ 895 1025 1290 1340 1015 1190 1280 1395

NORM 820 940 1155 1210 930 1065 1155 1270

 N/A 840 1020 1055 830 950 1010 1105

ADJUST"

Switch

Positions

First Stage HEAT" Speed − cfm First Stage COOL" Speed − cfm

2 3 4 1 2 3

+ 820 930 1160 1210 730 815 865 935

NORM 760 865 1045 1090 680 755 795 855

 N/A 775 930 965 625 695 730 775

Factory default jumper setting. N/A − First and second stage HEAT positions shown cannot be used on this model. NOTES − The effect of static pressure is included in air volumes shown.

First stage HEAT is approximately 91% of the same second stage

HEAT speed position.

G61MPV−36B−070 BLOWER MOTOR WATTS

Jumper Speed

Positions

Motor Watts @ Various External Static Pressures − in. wg.

First Stage Second Stage

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

+" (Plus) SETTING (Adjust" Jumper at +" Setting) HEAT"

Speed

Tap 1

70 85 105 130 150 170 190 205 225 110 115 135 155 175 195 215 240 260

Tap 2

100

120 145 165 190 215 235 260 280 130 155 180 205 230 255 280 300 325

Tap 3

185

210 240 270 290 310 345 375 405 250 280 310 340 370 400 425 450 475

Tap 4

200 230 265 295 325 355 385 410 440 285 310 340 365 400 430 455 485 510

COOL"

Speed

Tap 1

55 70 90 110 130 145 160 175 190 135 155 175 200 220 245 270 295 320

Tap 2

75 90 110 130 150 170 190 205 220 185 215 250 285 315 345 370 395 420

Tap 3

85 100 120 145 165 185 205 225 250 235 265 300 335 370 400 425 455 480

Tap 4

105

125 150 170 190 210 235 255 280 315 340 370 395 440 480 510 540 570

NORM" (Normal) SETTING (Adjust" Jumper at NORM" Setting) HEAT"

Speed

Tap 1

65 75 95 110 130 150 170 185 200 75 90 110 125 150 170 190 205 225

Tap 2

85 100 120 140 160 180 200 225 245 100 120 145 165 190 210 230 250 270

Tap 3

130

155 180 205 235 265 285 305 325 195 210 230 250 280 315 340 370 395

Tap 4

145

170 200 230 255 280 305 330 355 200 225 255 280 315 355 375 400 425

COOL"

Speed

Tap 1

45 60 80 95 11 5 130 145 160 175 100 120 140 165 190 215 235 255 275

Tap 2

60 75 95 110 130 145 165 180 200 140 165 190 220 245 265 290 315 340

Tap 3

65 85 105 125 140 155 175 195 215 175 200 230 260 285 310 340 365 390

Tap 4

85 100 120 140 160 180 200 220 240 230 260 295 325 360 390 410 435 455

−" (Minus) SETTING (Adjust" Jumper at −" Setting) HEAT"

Speed

Tap 1

N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

Tap 2

60 75 100 120 140 160 175 195 210 70 90 115 135 160 185 200 220 235

Tap 3

95 120 145 170 190 210 230 245 265 140 160 180 205 225 245 270 295 325

Tap 4

110

130 155 185 205 225 245 270 290 145 165 190 215 235 255 280 305 330

COOL"

Speed

Tap 1

40 55 70 85 100 120 130 145 160 75 90 110 125 150 175 190 210 225

Tap 2

45 60 80 95 11 5 135 145 160 175 95 120 150 175 200 220 240 260 285

Tap 3

50 65 85 105 125 145 160 175 190 125 150 175 195 220 240 265 290 320

Tap 4

60 75 95 115 135 150 170 190 215 165 190 215 245 265 485 315 340 370

Page 6

BLOWER DATA

G61MPV−36B−071 BLOWER PERFORMANCE (less filter) 0 through 0.80 in. w.g. External Static Pressure Range

ADJUST"

Switch

Positions

Speed Switch Positions

Second Stage HEAT" Speed − cfm Second Stage COOL" Speed − cfm

2 3 4 1 2 3

+ 925 1065 1305 1345 1055 1225 1305 1405

NORM 840 970 1185 1230 955 1100 1185 1280

 775 875 1050 1085 855 975 1040 1140

ADJUST"

Switch

Positions

First Stage HEAT" Speed − cfm First Stage COOL" Speed − cfm

2 3 4 1 2 3

+ 840 965 1190 1235 745 835 895 970

NORM 765 880 1070 111 5 695 770 815 875

 705 795 955 990 645 705 740 790

Factory default jumper setting. N/A − First and second stage HEAT positions shown cannot be used on this model. NOTES − The effect of static pressure is included in air volumes shown.

First stage HEAT is approximately 91% of the same second stage

HEAT speed position.

G61MPV−36B−071 BLOWER MOTOR WATTS

Jumper Speed

Positions

Motor Watts @ Various External Static Pressures − in. wg.

First Stage Second Stage

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

+" (Plus) SETTING (Adjust" Jumper at +" Setting)

HEAT"

Speed

Tap 1 70 90 11 0 135 160 180 195 215 240 100 120 140 165 190 210 235 255 275

Tap 2 115 135 160 185 205 230 250 270 295 160 185 210 230 255 275 295 315 330

Tap 3 205 230 265 295 325 355 380 410 425 290 320 350 380 415 440 465 490 480

Tap 4 220 250 290 325 360 390 425 455 455 310 345 375 410 445 475 500 525 515

COOL"

Speed

Tap 1 55 70 90 110 130 145 165 185 200 145 170 195 220 245 270 295 320 345

Tap 2 7 0 90 11 5 135 160 180 200 220 240 225 255 285 315 350 375 400 425 445

Tap 3 9 0 105 130 150 170 195 220 240 260 265 300 340 375 415 440 465 490 505

Tap 4 110 130 155 180 205 230 250 270 295 360 390 425 460 495 515 540 560 535

NORM" (Normal) SETTING (Adjust" Jumper at NORM" Setting)

HEAT"

Speed

Tap 1 60 75 95 115 135 155 175 195 215 75 95 115 140 160 180 200 220 240

Tap 2 8 0 100 125 150 180 200 220 240 255 110 135 165 190 220 240 255 275 290

Tap 3 150 170 200 225 250 275 300 325 350 210 235 260 285 315 345 375 405 425

Tap 4 165 190 220 250 280 310 335 360 385 230 260 290 325 355 380 405 430 435

COOL"

Speed

Tap 1 45 60 80 95 11 5 130 150 165 185 110 130 155 180 205 225 245 265 285

Tap 2 6 0 75 95 115 135 155 170 190 215 160 185 215 245 280 305 330 355 375

Tap 3 7 0 85 105 130 150 170 190 215 235 205 230 260 290 320 350 380 410 420

Tap 4 8 0 100 125 150 170 195 215 240 260 260 290 320 355 390 415 440 470 480

−" (Minus) SETTING (Adjust" Jumper at −" Setting)

HEAT"

Speed

Tap 1 50 65 85 100 120 140 155 175 195 70 90 105 125 145 165 185 205 215

Tap 2 6 5 80 100 120 140 165 185 205 225 90 110 130 155 175 195 215 235 250

Tap 3 105 125 150 180 205 225 245 265 290 145 170 195 225 255 270 290 305 325

Tap 4 115 135 165 190 215 240 260 285 310 160 185 215 240 270 290 310 330 350

COOL"

Speed

Tap 1 40 55 70 85 100 120 135 155 170 75 95 120 140 165 185 205 225 245

Tap 2 4 5 60 80 100 115 135 150 170 185 115 135 160 190 215 235 255 270 295

Tap 3 5 5 70 90 110 130 150 165 185 205 140 165 190 215 245 265 290 315 340

Tap 4 60 75 100 120 140 165 185 205 225 180 205 235 265 295 320 345 365 390

Page 7

BLOWER DATA

G61MPV−36C−090 BLOWER PERFORMANCE (less filter) 0 through 0.80 in. w.g. External Static Pressure Range

ADJUST"

Switch

Positions

Speed Switch Positions

Second Stage HEAT" Speed − cfm Second Stage COOL" Speed − cfm

2 3 4 1 2 3

+ N/A 1040 1285 1340 1020 1185 1275 1395

NORM N/A 915 1150 1200 905 1060 1145 1270

 N/A N/A 1020 1055 800 925 1010 1100

ADJUST"

Switch

Positions

First Stage HEAT" Speed − cfm First Stage COOL" Speed − cfm

2 3 4 1 2 3

+ N/A 940 1160 1210 705 790 845 920

NORM N/A 840 1040 1075 650 730 770 830

 N/A N/A 915 945 600 670 705 750

Factory default jumper setting. N/A − First and second stage HEAT positions shown cannot be used on this model. NOTES − The effect of static pressure is included in air volumes shown.

First stage HEAT is approximately 91% of the same second stage

HEAT speed position.

G61MPV−36C−090 BLOWER MOTOR WATTS

Jumper Speed

Positions

Motor Watts @ Various External Static Pressures − in. wg.

First Stage Second Stage

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

+" (Plus) SETTING (Adjust" Jumper at +" Setting) HEAT"

Speed

Tap 1

N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

Tap 2

90 11 0 130 155 185 205 225 250 90 110 140 165 185 205 235 260 290

Tap 3

125

150 175 200 230 260 290 325 355 170 195 230 265 290 330 360 395 425

Tap 4

130 160 200 235 265 295 325 355 385 185 220 255 290 325 360 395 430 460

COOL"

Speed

Tap 1

35 50 70 90 105 125 140 160 175 85 110 135 160 185 205 235 265 295

Tap 2

45 60 80 100 125 150 170 185 205 125 155 185 220 245 275 305 330 360

Tap 3

60 75 95 110 135 160 180 200 220 165 195 230 265 300 330 355 380 410

Tap 4

85 11 0 135 160 180 205 225 245 210 245 285 325 360 390 425 460 495

NORM" (Normal) SETTING (Adjust" Jumper at NORM" Setting) HEAT"

Speed

Tap 1

N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

Tap 2

50 65 90 110 135 155 175 200 220 60 80 105 130 155 185 205 220 240

Tap 3

110 145 175 200 225 245 270 290 110 135 170 205 230 250 285 320 355

Tap 4

120 155 190 205 225 250 280 305 140 165 190 220 255 290 315 335 360

COOL"

Speed

Tap 1

35 45 60 75 95 115 130 145 160 60 80 110 135 155 175 195 215 235

Tap 2

40 55 70 90 11 0 130 150 165 185 105 125 145 170 200 225 250 270 295

Tap 3

45 60 80 95 11 5 135 155 175 195 115 140 175 205 235 265 290 315 335

Tap 4

50 65 85 105 130 155 180 200 220 155 185 220 255 285 315 345 380 415

−" (Minus) SETTING (Adjust" Jumper at −" Setting) HEAT"

Speed

Tap 1

N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

Tap 2

N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

Tap 3

65 85 105 130 155 180 200 225 250 85 105 135 160 185 205 230 250 270

Tap 4

95 120 140 165 190 210 230 250 90 115 140 170 190 215 245 275 305

COOL"

Speed

Tap 1

30 40 55 75 90 105 120 135 150 55 65 85 105 125 150 170 190 210

Tap 2

40 50 65 80 100 120 130 145 160 65 90 120 145 165 185 205 225 250

Tap 3

40 55 70 90 105 125 140 160 180 85 105 135 165 185 210 235 260 285

Tap 4

45 60 75 90 11 5 135 155 170 190 105 125 150 175 210 240 275 305 335

Page 8

BLOWER DATA

G61MPV−60C−090 BLOWER PERFORMANCE (less filter) Bottom Return Air, Return Air from Both Sides or Return Air from Bottom and One Side. 0 through 0.80 in. w.g. External Static Pressure Range

ADJUST"

Switch

Positions

Speed Switch Positions

Second Stage HEAT" Speed − cfm Second Stage COOL" Speed − cfm

2 3 4 1 2 3

+ 1500 1675 1880 2090 1605 1710 1925 2165

NORM 1355 1545 1720 1900 1440 1560 1755 1960

 1194 1365 1540 1695 1275 1380 1590 1755

ADJUST"

Switch

Positions

First Stage HEAT" Speed − cfm First Stage COOL" Speed − cfm

2 3 4 1 2 3

+ 1360 1560 1730 1910 1105 1185 1355 1545

NORM 1220 1405 1585 1740 995 1080 1205 1345

 1105 1235 1410 1570 890 960 1090 1215

Factory default jumper setting.

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

First stage HEAT is approximately 91% of the same second stage

HEAT speed position.

G61MPV−60C−090 BLOWER MOTOR WATTS

Jumper Speed

Positions

Motor Watts @ Various External Static Pressures − in. wg.

First Stage Second Stage

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 +" (Plus) SETTING (Adjust" Jumper at +" Setting) HEAT"

Speed

Tap 1

190 215 245 275 305 340 365 390 420 245 275 315 350 380 410 440 475 510

Tap 2

265 300 340 380 415 450 480 510 540 350 385 420 455 490 525 555 580 610

Tap 3

380 415 450 485 520 555 595 630 665 485 520 555 595 640 685 720 755 790

Tap 4

495 535 580 625 660 700 735 770 805 650 695 750 800 850 900 925 955 985

COOL"

Speed

Tap 1

115 135 160 185 205 230 255 275 300 305 340 375 410 440 475 505 535 565

Tap 2

145

165 190 215 240 265 285 305 325 355 390 430 470 510 550 580 610 635

Tap 3

170 200 240 275 305 335 370 400 430 510 555 600 645 690 730 765 795 830

Tap 4

265 295 330 365 400 435 465 500 535 725 780 835 895 935 975 1005 1035 1065

NORM" (Normal) SETTING (Adjust" Jumper at NORM" Setting) HEAT"

Speed

Tap 1

150 170 195 220 245 270 295 325 350 180 210 245 280 305 330 365 400 430

Tap 2

200

230 270 305 330 355 385 415 450 265 295 335 375 405 430 465 500 535

Tap 3

270 310 355 395 425 460 490 525 560 370 400 435 470 515 555 585 615 645

Tap 4

390 420 455 490 525 555 595 630 670 495 530 570 605 645 685 720 755 795

COOL"

Speed

Tap 1

90 11 0 130 155 175 195 215 235 255 220 250 285 320 350 385 415 450 485

Tap 2

110 130 155 180 200 220 245 265 285 270 305 345 385 420 455 485 515 545

Tap 3

145

165 190 215 245 270 295 320 340 390 425 465 500 540 580 610 640 670

Tap 4

180

205 240 270 300 330 365 395 430 540 580 625 670 710 755 795 830 870

−" (Minus) SETTING (Adjust" Jumper at −" Setting) HEAT"

Speed

Tap 1

110 135 165 190 215 235 255 280 300 155 175 195 215 245 270 295 315 340

Tap 2

155 175 200 225 255 285 310 335 365 190 215 250 285 310 335 365 395 425

Tap 3

200

230 270 305 335 365 395 420 450 255 290 335 375 400 430 465 495 530

Tap 4

270 305 345 385 415 450 480 515 545 345 385 425 465 495 530 565 605 645

COOL"

Speed

Tap 1

70 85 105 125 145 165 185 205 225 160 190 220 255 275 300 330 360 390

Tap 2

80 100 120 140 165 190 210 225 245 195 225 260 295 325 350 385 415 450

Tap 3

110 130 160 185 205 225 250 275 300 295 330 365 400 430 460 495 535 570

Tap 4

155 175 195 220 245 270 295 315 340 400 435 470 510 545 585 610 640 665

Page 9

BLOWER DATA

G61MPV−60C−090 BLOWER PERFORMANCE (less filter) Side Return Air with Optional RAB Return Air Base 0 through 0.80 in. w.g. External Static Pressure Range

ADJUST"

Switch

Positions

Speed Switch Positions

Second Stage HEAT" Speed − cfm Second Stage COOL" Speed − cfm

2 3 4 1 2 3

+ 1440 1630 1810 2015 1525 1655 1860 2100

NORM 1300 1485 1655 1830 1385 1500 1695 1905

 1155 1310 1480 1640 1240 1320 1510 1695

ADJUST"

Switch

Positions

First Stage HEAT" Speed − cfm First Stage COOL" Speed − cfm

2 3 4 1 2 3

+ 1320 1490 1665 1840 1060 1135 1285 1455

NORM 1180 1345 1515 1680 960 1035 1165 1310

 1055 1180 1340 1490 865 920 1050 1165

Factory default jumper setting.

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

First stage HEAT is approximately 91% of the same second stage

HEAT speed position.

G61MPV−60C−090 BLOWER MOTOR WATTS

Jumper Speed

Positions

Motor Watts @ Various External Static Pressures − in. wg.

First Stage Second Stage

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 +" (Plus) SETTING (Adjust" Jumper at +" Setting) HEAT"

Speed

Tap 1

180 205 235 260 290 320 350 380 410 230 260 290 320 355 390 420 445 475

Tap 2

250

280 315 350 385 425 455 485 515 325 360 400 435 465 495 530 565 595

Tap 3

345 380 415 455 485 515 550 580 615 460 490 520 550 595 640 675 715 750

Tap 4

465 505 545 585 625 660 695 730 760 665 685 710 735 775 820 860 900 940

COOL"

Speed

Tap 1

110 130 150 175 195 215 240 265 290 275 305 340 380 410 440 470 505 540

Tap 2

130 155 175 200 220 245 265 290 315 360 390 420 455 485 515 550 590 625

Tap 3

160

190 220 255 280 305 335 360 390 490 530 570 610 645 680 715 750 785

Tap 4

220 255 295 330 365 400 430 460 490 695 750 805 855 895 935 965 995 1025

NORM" (Normal) SETTING (Adjust" Jumper at NORM" Setting) HEAT"

Speed

Tap 1

145 165 190 210 235 260 285 310 335 170 195 230 260 290 320 350 375 400

Tap 2

195

220 250 275 305 335 365 395 420 255 285 315 345 370 395 430 465 500

Tap 3

280 305 335 360 395 425 455 485 515 340 375 410 450 480 510 545 580 615

Tap 4

370 400 430 460 495 530 565 595 625 465 500 535 575 610 645 685 725 765

COOL"

Speed

Tap 1

80 95 120 140 165 190 210 235 255 190 225 265 305 330 355 390 420 455

Tap 2

100 120 140 165 190 215 235 255 275 265 295 325 355 390 420 455 495 530

Tap 3

140

160 185 205 235 260 285 305 325 375 410 440 475 500 530 570 610 650

Tap 4

180

205 240 270 300 325 350 380 405 520 560 605 645 685 720 760 805 845

−" (Minus) SETTING (Adjust" Jumper at −" Setting) HEAT"

Speed

Tap 1

100 125 150 175 200 220 245 265 290 135 155 180 200 225 250 275 300 330

Tap 2

150 165 185 205 235 265 290 310 335 170 200 235 265 290 320 350 375 405

Tap 3

210

230 255 275 310 345 370 400 425 255 285 315 350 370 390 430 470 510

Tap 4

260 290 320 350 390 430 455 480 505 340 375 410 445 475 510 535 565 590

COOL"

Speed

Tap 1

70 85 105 125 140 160 180 200 220 155 175 200 225 255 290 315 340 365

Tap 2

80 95 115 135 155 175 200 220 245 185 210 235 260 295 325 355 385 415

Tap 3

105 125 150 175 200 220 240 265 290 255 290 330 365 400 430 460 490 520

Tap 4

135 160 185 215 235 260 285 305 330 370 400 440 475 505 530 565 600 635

Page 10

BLOWER DATA

G61MPV−60C−090 BLOWER PERFORMANCE (less filter) Single Side Return Air − Air volumes in bold require field fabricated transition to accommodate 20 x 25 x 1 in. cleanable air filter in

order to maintain proper air velocity across the filter.

0 through 0.80 in. w.g. External Static Pressure Range

ADJUST"

Switch

Positions

Speed Switch Positions

Second Stage HEAT" Speed − cfm Second Stage COOL" Speed − cfm

2 3 4 1 2 3

+ 1450 1640 1820 2055 1575 1690 1895 2135

NORM 1320 1510 1700 1870 1405 1530 1735 1935

 1165 1320 1500 1665 1250 1355 1560 1735

ADJUST"

Switch

Positions

First Stage HEAT" Speed − cfm First Stage COOL" Speed − cfm

2 3 4 1 2 3

+ 1315 1510 1695 1875 1080 1160 1315 1490

NORM 1190 1365 1545 1715 985 1060 1185 1330

 1075 1205 1370 1520 865 930 1065 1185

Factory default jumper setting.

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

First stage HEAT is approximately 91% of the same second stage

HEAT speed position.

G61MPV−60C−090 BLOWER MOTOR WATTS

Jumper Speed

Positions

Motor Watts @ Various External Static Pressures − in. wg.

First Stage Second Stage

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 +" (Plus) SETTING (Adjust" Jumper at +" Setting) HEAT"

Speed

Tap 1

170 200 230 265 295 325 355 385 415 225 255 290 325 360 390 425 455 490

Tap 2

255

285 320 355 390 425 455 490 520 330 370 410 455 485 515 540 560 585

Tap 3

345 385 430 475 515 555 585 610 640 445 480 520 560 610 660 700 735 775

Tap 4

470 515 560 610 650 685 725 765 800 650 695 745 800 840 885 915 950 980

COOL"

Speed

Tap 1

110 130 155 180 205 225 245 270 290 285 320 355 390 430 465 500 535 565

Tap 2

125 150 175 205 225 250 275 300 325 355 390 430 470 500 530 570 605 645

Tap 3

170 195 230 260 290 325 355 385 415 515 550 590 625 670 710 750 795 840

Tap 4

240 275 315 355 380 405 445 485 525 740 785 835 885 920 955 990 1020 1050

NORM" (Normal) SETTING (Adjust" Jumper at NORM" Setting) HEAT"

Speed

Tap 1

145 165 190 215 240 265 290 315 345 175 200 235 265 300 330 360 385 415

Tap 2

195 225 255 290 320 345 375 405 435 260 290 325 355 390 425 455 490 520

Tap 3

265 300 335 370 405 435 470 505 540 360 395 435 470 515 555 585 620 650

Tap 4

385

420 460 495 525 555 590 625 660 475 515 560 600 640 685 720 760 800

COOL"

Speed

Tap 1

85 100 125 145 170 200 215 235 255 200 230 270 310 340 370 400 430 460

Tap 2

105 125 150 170 195 220 240 260 280 260 295 330 365 400 440 470 500 530

Tap 3

135 160 185 215 240 270 290 315 335 410 440 470 500 540 580 610 640 670

Tap 4

170 200 235 265 305 340 365 390 415 550 585 620 655 695 740 780 825 865

−" (Minus) SETTING (Adjust" Jumper at −" Setting) HEAT"

Speed

Tap 1

105 130 155 180 205 225 245 270 290 130 155 180 204 230 260 285 310 335

Tap 2

145 165 195 220 250 280 305 335 360 170 195 230 265 295 325 355 385 420

Tap 3

190 220 250 285 315 345 375 405 440 245 280 315 350 385 420 450 485 520

Tap 4

270

295 325 355 395 430 465 500 530 340 375 415 455 490 525 560 595 625

COOL"

Speed

Tap 1

65 80 100 120 140 160 180 205 225 155 180 215 245 265 290 320 345 375

Tap 2

75 90 110 130 155 180 200 220 245 190 220 250 275 305 335 370 400 430

Tap 3

100 120 150 175 200 220 245 265 290 290 320 355 385 415 445 485 520 560

Tap 4

135 160 185 215 240 265 290 315 335 405 435 465 495 540 585 610 640 665

Page 11

BLOWER DATA

G61MPV−60C−091 BLOWER PERFORMANCE (less filter) Bottom Return Air, Return Air from Both Sides or Return Air from Bottom and One Side. 0 through 1.00 in. w.g. External Static Pressure Range

ADJUST"

Switch

Positions

Speed Switch Positions

Second Stage HEAT" Speed − cfm Second Stage COOL" Speed − cfm

2 3 4 1 2 3

+ 1560 1770 1895 2110 1665 1790 1990 2175

NORM 1400 1575 1745 1930 1515 1625 1815 2020

 1245 1400 1565 1745 1340 1445 1645 1800

ADJUST"

Switch

Positions

First Stage HEAT" Speed − cfm First Stage COOL" Speed − cfm

2 3 4 1 2 3

+ 1420 1625 1780 1965 1240 1245 1410 1585

NORM 1280 1465 1615 1790 1060 1125 1270 1430

 1145 1290 1445 1610 940 1015 1145 1270

Factory default jumper setting. N/A − First and second stage HEAT positions shown cannot be used on this model. NOTES − The effect of static pressure is included in air volumes shown.

First stage HEAT is approximately 91% of the same second stage

HEAT speed position.

G61MPV−60C−091 BLOWER MOTOR WATTS

Jumper Speed

Positions

Motor Watts @ Various External Static Pressures − in. wg.

First Stage Second Stage

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

+" (Plus) SETTING (Adjust" Jumper at +" Setting)

HEAT"

Speed

Tap 1 255 280 305 330 355 390 420 450 475 305 340 375 415 450 475 505 530 560

Tap 2 325 360 390 425 460 500 540 580 615 395 440 490 540 585 620 655 690 730

Tap 3 495 525 555 590 620 650 680 710 710 615 645 675 705 740 755 775 790 765

Tap 4 625 660 700 740 780 815 855 890 890 800 840 880 920 960 985 1005 1030 1000

COOL"

Speed

Tap 1 180 200 225 250 280 300 320 345 370 390 420 455 485 520 550 585 615 640

Tap 2 200 225 250 280 305 330 350 375 395 485 520 555 590 625 655 680 710 735

Tap 3 245 270 300 335 365 390 420 445 470 655 700 740 785 830 860 890 925 930

Tap 4 355 380 405 435 465 495 520 550 585 930 960 990 1020 1050 1060 1070 1045 1005

NORM" (Normal) SETTING (Adjust" Jumper at NORM" Setting)

HEAT"

Speed

Tap 1 185 210 235 265 290 315 340 365 390 230 260 290 320 350 375 405 430 460

Tap 2 240 270 305 340 375 410 445 475 505 300 335 370 410 450 485 520 560 595

Tap 3 385 410 435 455 480 510 540 656 595 465 495 530 565 595 625 650 680 690

Tap 4 480 510 540 570 600 605 670 705 740 585 626 670 710 750 785 820 855 870

COOL"

Speed

Tap 1 110 130 155 180 205 230 250 275 295 285 315 350 380 415 440 465 490 525

Tap 2 140 160 185 205 230 250 265 285 310 345 380 420 460 495 525 550 580 615

Tap 3 185 210 235 265 290 320 350 380 395 485 525 565 610 650 680 715 745 775

Tap 4 245 275 305 335 365 395 420 450 480 680 720 765 810 855 885 910 940 960

−" (Minus) SETTING (Adjust" Jumper at −" Setting)

HEAT"

Speed

Tap 1 145 165 190 210 235 255 280 300 320 175 195 225 250 275 295 320 340 365

Tap 2 175 200 225 255 280 305 335 360 385 220 250 280 315 350 375 400 430 460

Tap 3 275 305 330 360 385 410 435 460 485 365 390 410 435 460 485 510 535 555

Tap 4 340 370 405 440 475 505 535 570 600 460 490 520 550 580 610 640 675 700

COOL"

Speed

Tap 1 90 105 125 145 165 185 205 225 245 215 240 270 300 325 350 375 395 425

Tap 2 105 125 150 170 195 215 235 255 270 255 285 315 345 380 405 430 455 495

Tap 3 145 165 190 215 235 260 280 305 325 385 410 440 470 495 535 570 605 630

Tap 4 190 215 240 265 290 315 345 370 395 485 520 555 590 625 660 700 735 765

Page 12

BLOWER DATA

G61MPV−60C−091 BLOWER PERFORMANCE (less filter) Side Return Air with Optional RAB Return Air Base 0 through 1.00 in. w.g. External Static Pressure Range

ADJUST"

Switch

Positions

Speed Switch Positions

Second Stage HEAT" Speed − cfm Second Stage COOL" Speed − cfm

2 3 4 1 2 3

+ 1490 1690 1850 2050 1590 1695 1905 2035

NORM 1345 1520 1700 1870 1445 1535 1740 1900

 1195 1345 1525 1675 1280 1370 1580 1700

ADJUST"

Switch

Positions

First Stage HEAT" Speed − cfm First Stage COOL" Speed − cfm

2 3 4 1 2 3

+ 1360 1550 1720 1880 1125 1195 1370 1530

NORM 1225 1400 1540 1715 1030 1085 1230 1380

 1100 1225 1385 1540 915 980 1110 1225

Factory default jumper setting. N/A − First and second stage HEAT positions shown cannot be used on this model. NOTES − The effect of static pressure is included in air volumes shown.

First stage HEAT is approximately 91% of the same second stage

HEAT speed position.

G61MPV−60C−091 BLOWER MOTOR WATTS

Jumper Speed

Positions

Motor Watts @ Various External Static Pressures − in. wg.

First Stage Second Stage

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

+" (Plus) SETTING (Adjust" Jumper at +" Setting)

HEAT"

Speed

Tap 1 210 235 265 295 325 350 380 405 435 265 295 330 365 400 425 450 480 500

Tap 2 270 300 340 380 415 450 485 520 555 355 395 445 490 535 570 610 645 675

Tap 3 430 455 490 520 550 580 610 645 675 530 656 600 640 675 700 730 755 775

Tap 4 525 560 600 635 675 710 750 790 825 680 725 775 820 870 905 935 970 995

COOL"

Speed

Tap 1 145 165 185 210 230 255 275 295 315 353 380 410 440 470 500 530 555 580

Tap 2 175 195 220 245 270 290 315 335 360 445 475 510 540 575 600 625 650 675

Tap 3 230 260 285 315 345 370 395 420 450 640 680 725 765 810 840 870 905 890

Tap 4 335 365 390 415 445 470 500 525 560 855 885 915 940 970 970 965 965 935

NORM" (Normal) SETTING (Adjust" Jumper at NORM" Setting)

HEAT"

Speed

Tap 1 160 185 210 235 260 280 305 325 355 195 225 255 285 320 345 365 390 420

Tap 2 205 235 265 295 330 355 385 415 450 250 285 325 365 405 435 465 495 530

Tap 3 325 350 375 400 430 455 475 500 530 415 445 475 505 540 570 605 635 665

Tap 4 410 445 475 510 545 575 605 640 670 505 545 585 625 660 700 740 780 815

COOL"

Speed

Tap 1 105 125 150 170 195 220 240 261 280 260 285 315 345 375 400 420 445 475

Tap 2 135 155 180 200 225 240 260 275 300 320 350 385 420 455 480 505 530 565

Tap 3 175 200 225 250 275 305 330 360 375 475 515 555 595 635 665 695 730 760

Tap 4 235 260 290 320 350 375 405 430 460 625 665 705 750 790 815 840 865 855

−" (Minus) SETTING (Adjust" Jumper at −" Setting)

HEAT"

Speed

Tap 1 120 140 165 190 215 235 260 285 305 150 170 195 220 245 270 295 320 345

Tap 2 145 170 200 225 255 285 315 345 370 185 210 240 270 305 330 360 390 425

Tap 3 230 255 285 315 345 370 395 420 445 310 335 365 390 415 445 470 495 520

Tap 4 280 315 350 385 420 450 480 515 540 385 415 445 480 515 545 580 610 640

COOL"

Speed

Tap 1 85 100 120 140 160 180 195 215 235 195 220 245 270 295 315 335 360 385

Tap 2 100 120 145 165 190 210 230 250 265 235 260 290 320 345 370 395 420 455

Tap 3 140 155 180 200 225 245 265 285 305 375 400 430 455 485 520 555 590 620

Tap 4 180 205 230 255 280 305 330 355 380 450 480 515 545 580 610 645 675 705

Page 13

BLOWER DATA

G61MPV−60C−091 BLOWER PERFORMANCE (less filter) Single Side Return Air − Air volumes in bold require field fabricated transition to accommodate 20 x 25 x 1 in. cleanable air filter in

order to maintain proper air velocity across the filter.

0 through 1.00 in. w.g. External Static Pressure Range

ADJUST"

Switch

Positions

Speed Switch Positions

Second Stage HEAT" Speed − cfm Second Stage COOL" Speed − cfm

2 3 4 1 2 3

+ 1510 1720 1810 2065 1615 1735 1900 2055

NORM 1365 1535 1725 1880 1465 1575 1735 1915

 1210 1360 1520 1700 1300 1400 1575 1715

ADJUST"

Switch

Positions

First Stage HEAT" Speed − cfm First Stage COOL" Speed − cfm

2 3 4 1 2 3

+ 1385 1560 1755 1900 1150 1220 1385 1545

NORM 1240 1400 1570 1750 1050 1105 1245 1395

 1125 1260 1410 1560 930 995 1125 1240

Factory default jumper setting. N/A − First and second stage HEAT positions shown cannot be used on this model. NOTES − The effect of static pressure is included in air volumes shown.

First stage HEAT is approximately 91% of the same second stage

HEAT speed position.

G61MPV−60C−091 BLOWER MOTOR WATTS

Jumper Speed

Positions

Motor Watts @ Various External Static Pressures − in. wg.

First Stage Second Stage

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

+" (Plus) SETTING (Adjust" Jumper at +" Setting)

HEAT"

Speed

Tap 1 230 255 285 315 350 375 400 425 455 285 315 350 385 420 450 485 515 545

Tap 2 290 325 365 405 445 480 510 545 585 370 410 455 500 545 585 625 670 705

Tap 3 475 505 545 580 620 645 670 695 695 560 595 625 660 695 720 745 770 755

Tap 4 570 610 655 700 740 775 805 835 835 750 790 835 880 925 960 995 1025 1010

COOL"

Speed

Tap 1 155 175 200 225 250 275 295 320 345 385 415 450 485 515 545 580 610 635

Tap 2 175 200 225 250 275 300 320 340 370 470 500 535 570 600 630 655 685 710

Tap 3 240 265 295 325 355 385 410 435 465 645 685 730 770 815 845 875 905 890

Tap 4 355 380 410 440 465 495 525 555 590 905 935 965 995 1025 1025 1020 1020 985

NORM" (Normal) SETTING (Adjust" Jumper at NORM" Setting)

HEAT"

Speed

Tap 1 160 190 220 250 280 305 325 350 375 215 240 270 300 330 360 390 415 445

Tap 2 205 235 275 315 350 380 415 445 475 270 305 345 385 420 455 495 530 565

Tap 3 360 385 415 440 465 490 515 540 570 450 480 515 545 580 605 630 660 690

Tap 4 455 485 520 550 585 615 650 680 715 555 590 630 675 715 745 780 810 850

COOL"

Speed

Tap 1 115 135 160 185 210 235 260 280 300 285 315 345 380 410 435 460 485 520

Tap 2 135 160 180 205 230 245 265 280 305 335 365 405 440 480 505 530 560 595

Tap 3 180 205 230 260 285 315 345 370 390 475 515 555 595 640 670 700 730 760

Tap 4 245 275 305 335 370 395 425 450 485 660 705 750 790 835 865 890 915 905

−" (Minus) SETTING (Adjust" Jumper at −" Setting)

HEAT"

Speed

Tap 1 135 155 175 200 225 250 275 300 320 160 185 205 230 255 280 310 335 360

Tap 2 160 185 215 240 270 300 335 365 390 200 225 255 285 310 345 380 415 445

Tap 3 270 295 320 345 375 400 420 445 475 330 355 385 410 435 460 485 510 535

Tap 4 325 355 385 420 450 480 510 535 575 420 450 485 515 550 580 610 640 670

COOL"

Speed

Tap 1 90 11 0 130 150 170 195 215 235 250 215 240 270 295 325 345 370 390 420

Tap 2 105 125 145 170 195 215 235 255 270 245 275 305 335 365 390 415 440 475

Tap 3 145 165 185 210 235 255 275 300 320 375 400 430 460 490 525 560 595 620

Tap 4 190 215 240 265 290 320 345 375 400 475 510 545 575 610 645 680 715 745

Page 14

BLOWER DATA

G61MPV−60C−110 BLOWER PERFORMANCE (less filter) Bottom Return Air, Return Air from Both Sides or Return Air from Bottom and One Side. 0 through 0.80 in. w.g. External Static Pressure Range

ADJUST"

Switch

Positions

Speed Switch Positions

Second Stage HEAT" Speed − cfm Second Stage COOL" Speed − cfm

2 3 4 1 2 3

+ 1505 1710 1915 2130 1625 1745 1990 2210

NORM 1370 1565 1765 1945 1465 1580 1790 1995

 1205 1380 1565 1740 1290 1405 1605 1790

ADJUST"

Switch

Positions

First Stage HEAT" Speed − cfm First Stage COOL" Speed − cfm

2 3 4 1 2 3

+ 1370 1570 1760 1945 1150 1215 1380 1540

NORM 1235 1420 1600 1780 1050 1125 1265 1430

 1105 1250 1420 1580 935 1000 1140 1255

Factory default jumper setting.

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

First stage HEAT is approximately 91% of the same second stage

HEAT speed position.

G61MPV−60C−110 BLOWER MOTOR WATTS

Jumper

Speed

Positions

Motor Watts @ Various External Static Pressures − in. wg.

First Stage Second Stage

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

+" (Plus) SETTING (Adjust" Jumper at +" Setting) HEAT"

Speed

Tap 1

165 195 230 265 300 336 370 400 430 210 245 290 330 365 395 435 470 510

Tap 2

245 285 325 370 400 435 470 505 540 330 365 405 445 480 520 560 600 640

Tap 3

365

395 430 465 510 550 590 630 670 450 490 535 580 625 665 700 735 770

Tap 4

480

520 565 610 645 685 725 770 810 625 670 715 760 805 850 890 930 970

COOL"

Speed

Tap 1

110 130 160 185 210 230 255 280 305 280 315 350 390 430 475 510 550 585

Tap 2

135 155 180 210 230 255 285 315 350 340 380 425 465 505 545 575 610 645

Tap 3

180 210 250 285 310 340 370 400 425 510 545 585 620 675 735 770 805 840

Tap 4

235 270 310 350 380 420 450 480 515 710 755 805 855 905 950 980 1010 1035

NORM" (Normal) SETTING (Adjust" Jumper at NORM" Setting) HEAT"

Speed

Tap 1

150 170 190 205 245 280 305 335 365 170 200 235 270 300 330 365 400 430

Tap 2

195 220 255 285 320 360 390 420 445 240 275 320 365 400 430 465 500 530

Tap 3

265

300 335 370 410 445 480 520 555 360 395 435 475 510 550 585 620 650

Tap 4

370

410 455 495 525 550 590 630 670 460 500 545 590 635 675 720 760 805

COOL"

Speed

Tap 1

100 11 5 135 150 180 210 235 255 275 205 235 275 310 345 380 415 450 485

Tap 2

110 130 150 175 200 235 260 280 300 250 285 325 360 400 440 470 505 540

Tap 3

155 180 200 225 250 280 310 340 370 375 410 445 485 530 575 605 635 670

Tap 4

190

220 255 290 320 350 380 410 440 510 550 595 640 685 725 770 815 860

−" (Minus) SETTING (Adjust" Jumper at −" Setting) HEAT"

Speed

Tap 1

105 130 155 180 210 235 260 285 305 140 160 180 200 235 265 295 320 350

Tap 2

140 165 195 225 250 280 310 345 375 165 195 230 265 300 335 370 405 440

Tap 3

185 220 255 290 325 355 390 420 450 250 285 325 360 395 430 465 500 530

Tap 4

250 290 335 375 410 445 480 520 560 340 375 420 460 495 530 565 605 645

COOL"

Speed

Tap 1

70 90 110 130 150 175 200 220 240 155 180 210 240 270 295 325 355 385

Tap 2

80 100 120 145 170 200 220 240 260 185 215 245 280 315 345 380 415 450

Tap 3

110 130 155 180 205 235 260 280 310 265 300 345 385 425 465 500 535 570

Tap 4

160 180 200 225 250 275 300 330 360 375 415 455 495 535 575 615 650 690

Page 15

BLOWER DATA

G61MPV−60C−110 BLOWER PERFORMANCE (less filter) Single Side Return Air − Air volumes in bold require field fabricated transition to accommodate 20 x 25 x 1 in. cleanable air filter in

order to maintain proper air velocity across the filter.

0 through 0.80 in. w.g. External Static Pressure Range

ADJUST"

Switch

Positions

Speed Switch Positions

Second Stage HEAT" Speed − cfm Second Stage COOL" Speed − cfm

2 3 4 1 2 3

+ 1485 1675 1870 2080 1585 1700 1905 2135

NORM 1350 1525 1725 1895 1435 1535 1740 1930

 1175 1335 1505 1670 1280 1385 1570 1755

ADJUST"

Switch

Positions

First Stage HEAT" Speed − cfm First Stage COOL" Speed − cfm

2 3 4 1 2 3

+ 1325 1505 1695 1870 1140 1215 1345 1490

NORM 1195 1365 1550 1720 1005 1085 1220 1380

 1080 1205 1365 1530 930 1000 1105 1220

Factory default jumper setting. NOTES − The effect of static pressure is included in air volumes shown.

First stage HEAT is approximately 91% of the same second stage

HEAT speed position.

G61MPV−60C−110 BLOWER MOTOR WATTS

Jumper

Speed

Positions

Motor Watts @ Various External Static Pressures − in. wg.

First Stage Second Stage

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 +" (Plus) SETTING (Adjust" Jumper at +" Setting) HEAT"

Speed

Tap 1

155 185 220 255 285 320 350 380 410 205 240 280 320 355 390 420 450 480

Tap 2

215 255 300 345 370 395 430 465 500 320 350 380 410 455 495 530 565 595

Tap 3

335 375 415 455 490 530 570 605 645 445 475 510 545 590 630 670 710 750

Tap 4

450 490 535 580 615 645 690 730 775 580 625 680 735 770 810 850 890 930

COOL"

Speed

Tap 1

105 130 160 190 210 230 260 280 310 255 295 345 390 430 470 510 545 580

Tap 2

125 150 175 200 225 250 280 310 335 340 375 415 455 490 525 570 615 660

Tap 3

170 195 230 265 295 325 355 380 410 455 500 555 610 650 695 750 800 850

Tap 4

215 250 295 340 375 405 440 470 500 650 710 770 835 880 920 960 995 1035

NORM" (Normal) SETTING (Adjust" Jumper at NORM" Setting) HEAT"

Speed

Tap 1

140 160 185 210 235 265 285 310 330 155 185 220 250 285 320 350 380 410

Tap 2

170 200 235 270 305 340 370 400 430 220 260 300 345 370 395 430 465 500

Tap 3

250 290 330 370 400 430 465 505 540 355 385 415 450 485 520 555 595 630

Tap 4

360

395 430 465 510 550 580 605 635 460 490 525 560 605 645 685 730 770

COOL"

Speed

Tap 1

80 100 120 145 170 195 220 245 275 195 230 270 305 345 380 415 455 490

Tap 2

95 11 5 140 165 190 220 240 270 295 225 265 315 360 400 440 475 515 555

Tap 3

140 160 190 215 240 265 295 320 350 365 400 445 485 525 565 610 650 690

Tap 4

175 205 240 270 305 340 370 400 430 495 535 580 625 675 725 770 815 860

−" (Minus) SETTING (Adjust" Jumper at −" Setting) HEAT"

Speed

Tap 1

105 125 150 175 195 215 240 265 290 135 155 180 205 225 245 275 300 330

Tap 2

145 165 190 210 240 265 290 315 340 170 195 225 255 290 325 355 385 410

Tap 3

175 200 235 265 300 335 370 400 430 230 260 295 335 370 405 440 475 510

Tap 4

240 275 320 360 390 420 450 485 515 325 365 410 455 490 520 550 575 600

COOL"

Speed

Tap 1

60 80 100 125 150 170 195 220 245 155 180 205 235 270 305 340 370 400

Tap 2

75 95 115 140 160 185 210 235 260 170 200 240 275 315 355 390 420 450

Tap 3

105

125 150 175 200 225 250 275 295 250 290 330 375 410 445 485 525 570

Tap 4

140 160 190 215 240 265 300 330 360 365 405 450 490 535 575 615 655 690

Page 16

BLOWER DATA

G61MPV−60C−110 BLOWER PERFORMANCE (less filter) Side Return Air with Optional RAB Return Air Base 0 through 0.80 in. w.g. External Static Pressure Range

ADJUST"

Switch

Positions

Speed Switch Positions

Second Stage HEAT" Speed − cfm Second Stage COOL" Speed − cfm

2 3 4 1 2 3

+ 1475 1670 1865 2070 1555 1685 1895 2130

NORM 1345 1500 1695 1865 1415 1540 1735 1930

 1180 1345 1510 1685 1245 1350 1545 1725

ADJUST"

Switch

Positions

First Stage HEAT" Speed − cfm First Stage COOL" Speed − cfm

2 3 4 1 2 3

+ 1330 1510 1695 1875 1085 1155 1310 1475

NORM 1195 1375 1550 1725 955 1050 1185 1335

 1080 1210 1370 1520 850 920 1070 1195

Factory default jumper setting.

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

First stage HEAT is approximately 91% of the same second stage

HEAT speed position.

G61MPV−60C−110 BLOWER MOTOR WATTS

Jumper Speed

Positions

Motor Watts @ Various External Static Pressures − in. wg.

First Stage Second Stage

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 +" (Plus) SETTING (Adjust" Jumper at +" Setting) HEAT"

Speed

Tap 1

170 195 225 255 290 320 350 380 410 215 250 285 320 355 390 425 455 490

Tap 2

230 265 305 345 380 415 445 480 515 315 355 400 445 480 510 540 575 605

Tap 3

350 385 420 460 495 525 560 595 630 460 490 525 555 605 655 690 730 770

Tap 4

450 490 535 580 610 640 680 720 760 590 630 680 725 785 840 880 915 955

COOL"

Speed

Tap 1

105 125 150 175 200 220 245 265 290 250 285 320 360 395 435 470 500 535

Tap 2

130

150 175 200 220 240 270 295 320 335 365 405 445 480 515 550 590 630

Tap 3

165 190 220 250 275 305 335 370 400 470 505 545 585 630 670 710 755 800

Tap 4

205 240 285 330 360 390 420 450 485 655 695 745 790 840 885 925 965 1005

NORM" (Normal) SETTING (Adjust" Jumper at NORM" Setting) HEAT"

Speed

Tap 1

150 170 190 215 240 265 290 315 340 155 190 225 265 295 325 355 385 420

Tap 2

185

215 245 275 310 340 370 400 430 230 265 300 335 370 400 440 475 515

Tap 3

255 285 325 365 400 440 465 495 525 335 370 410 450 490 530 560 595 625

Tap 4

345 385 430 475 510 545 575 605 635 460 490 520 550 595 645 680 715 750

COOL"

Speed

Tap 1

75 90 115 135 160 185 205 225 250 190 220 255 290 325 360 395 430 460

Tap 2

100 120 145 165 185 205 230 255 280 250 285 325 360 390 420 455 485 520

Tap 3

135

155 175 200 230 260 280 305 330 355 395 435 475 510 545 580 620 660

Tap 4

170

195 225 255 290 320 350 375 405 475 515 565 610 655 705 745 785 825

−" (Minus) SETTING (Adjust" Jumper at −" Setting) HEAT"

Speed

Tap 1

110 130 150 175 195 215 240 265 290 135 155 180 210 230 250 275 300 325

Tap 2

145 165 190 210 240 270 295 315 340 170 195 230 265 295 325 355 390 420

Tap 3

175

205 240 280 310 340 370 400 430 220 255 295 335 370 405 440 475 515

Tap 4

245 280 320 355 390 420 455 490 525 325 360 400 440 475 510 540 565 590

COOL"

Speed

Tap 1

55 70 90 110 135 155 175 195 220 150 170 200 225 255 285 315 340 370

Tap 2

65 80 105 130 150 170 195 215 240 165 195 230 265 300 330 360 390 420

Tap 3

100 125 150 180 200 220 240 260 280 240 280 320 360 400 435 470 505 540

Tap 4

140 160 180 200 230 260 285 305 330 350 385 420 455 500 540 575 610 645

Page 17

BLOWER DATA

G61MPV−60C−111 BLOWER PERFORMANCE (less filter) Bottom Return Air, Return Air from Both Sides or Return Air from Bottom and One Side. 0 through 1.00 in. w.g. External Static Pressure Range

ADJUST"

Switch

Positions

Speed Switch Positions

Second Stage HEAT" Speed − cfm Second Stage COOL" Speed − cfm

2 3 4 1 2 3

+ 1585 1810 1950 2170 1635 1750 1965 2195

NORM 1430 1635 1770 1970 1480 1605 1805 2015

 1265 1440 1600 1780 1290 1400 1605 1800

ADJUST"

Switch

Positions

First Stage HEAT" Speed − cfm First Stage COOL" Speed − cfm

2 3 4 1 2 3

+ 1450 1650 1790 1990 1120 1195 1380 1560

NORM 1295 1475 1630 1810 1020 1095 1225 1385

 1165 1330 1470 1635 900 970 1105 1245

Factory default jumper setting. N/A − First and second stage HEAT positions shown cannot be used on this model. NOTES − The effect of static pressure is included in air volumes shown.

First stage HEAT is approximately 91% of the same second stage

HEAT speed position.

G61MPV−60C−111 BLOWER MOTOR WATTS

Jumper Speed

Positions

Motor Watts @ Various External Static Pressures − in. wg.

First Stage Second Stage

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

+" (Plus) SETTING (Adjust" Jumper at +" Setting) HEAT"

Speed

Tap 1 210 235 270 300 335 365 395 425 455 275 305 345 380 415 445 475 505 535

Tap 2 265 305 345 385 425 465 505 545 585 350 395 440 485 530 570 605 645 685

Tap 3 425 460 490 525 560 590 615 645 675 575 605 640 670 700 730 765 795 800

Tap 4 540 580 625 665 710 745 780 815 850 730 770 805 845 885 925 965 1005 1015

COOL"

Speed

Tap 1 120 140 165 190 215 235 260 285 305 325 355 390 425 460 490 520 550 580

Tap 2 145 165 190 215 235 260 290 315 340 390 425 465 500 540 570 600 630 660

Tap 3 190 220 250 285 320 345 375 400 425 545 585 630 670 715 755 790 830 865

Tap 4 275 305 340 375 410 440 470 505 535 775 815 860 900 945 975 1010 1040 1060

NORM" (Normal) SETTING (Adjust" Jumper at NORM" Setting) HEAT"

Speed

Tap 1 160 185 215 245 270 295 320 345 370 200 225 260 290 325 355 385 415 445

Tap 2 205 235 275 310 350 380 410 445 475 255 290 330 375 415 455 490 530 570

Tap 3 325 350 380 410 440 470 500 530 550 425 455 490 520 555 580 610 635 665

Tap 4 410 445 480 520 555 595 630 670 700 540 575 620 660 700 735 770 805 840

COOL"

Speed

Tap 1 90 11 0 135 160 185 200 220 235 260 225 255 290 325 360 390 425 455 485

Tap 2 105 130 155 180 205 230 250 270 290 295 325 360 395 430 465 495 525 560

Tap 3 145 165 195 220 250 275 295 320 350 435 465 505 540 575 605 635 665 700

Tap 4 190 220 250 280 315 345 370 400 430 590 625 665 705 745 790 830 875 905

−" (Minus) SETTING (Adjust" Jumper at −" Setting) HEAT"

Speed

Tap 1 120 140 165 195 220 240 265 290 310 150 175 200 225 250 275 305 330 355

Tap 2 155 180 215 245 280 310 340 370 395 195 220 255 285 315 355 390 425 455

Tap 3 240 265 290 320 345 370 395 420 445 315 340 370 395 425 450 475 500 525

Tap 4 305 335 370 405 440 470 500 535 565 400 430 465 500 535 570 600 630 665

COOL"

Speed

Tap 1 75 90 11 0 130 150 170 190 215 230 165 190 220 245 275 305 330 360 390

Tap 2 85 105 125 145 165 190 210 230 255 200 230 260 295 325 355 385 415 445

Tap 3 115 135 160 185 205 230 250 270 295 305 335 370 405 440 470 505 540 570

Tap 4 155 175 205 230 260 285 310 335 360 425 460 495 530 570 595 625 655 690

Page 18

BLOWER DATA

G61MPV−60C−111 BLOWER PERFORMANCE (less filter) Side Return Air with Optional RAB Return Air Base 0 through 1.00 in. w.g. External Static Pressure Range

ADJUST"

Switch

Positions

Speed Switch Positions

Second Stage HEAT" Speed − cfm Second Stage COOL" Speed − cfm

2 3 4 1 2 3

+ 1490 1695 1875 2080 1565 1655 1890 2060

NORM 1345 1530 1700 1890 1410 1515 1730 1900

 1210 1380 1530 1700 1230 1325 1545 1695

ADJUST"

Switch

Positions

First Stage HEAT" Speed − cfm First Stage COOL" Speed − cfm

2 3 4 1 2 3

+ 1365 1555 1730 1925 1090 1155 1335 1505

NORM 1235 1410 1575 1750 995 1060 1190 1335

 1115 1270 1410 1565 875 935 1070 1200

Factory default jumper setting. N/A − First and second stage HEAT positions shown cannot be used on this model. NOTES − The effect of static pressure is included in air volumes shown.

First stage HEAT is approximately 91% of the same second stage

HEAT speed position.

G61MPV−60C−111 BLOWER MOTOR WATTS

Jumper Speed

Positions

Motor Watts @ Various External Static Pressures − in. wg.

First Stage Second Stage

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

+" (Plus) SETTING (Adjust" Jumper at +" Setting) HEAT"

Speed

Tap 1 165 190 225 255 290 320 355 385 410 210 245 280 320 355 385 410 440 470

Tap 2 210 245 285 330 370 410 450 490 525 270 310 360 405 455 490 525 560 600

Tap 3 385 415 445 475 505 535 570 600 625 490 520 560 595 630 660 690 720 745

Tap 4 490 525 565 600 640 680 720 760 790 620 660 705 750 795 835 870 910 945

COOL"

Speed

Tap 1 11 5 130 155 180 205 225 250 270 290 310 335 365 390 415 445 470 500 525

Tap 2 145 160 185 210 230 255 280 305 330 360 390 425 460 495 525 550 580 605

Tap 3 180 210 240 270 300 330 355 380 405 530 570 615 655 700 735 775 810 845

Tap 4 265 295 325 360 390 420 450 480 510 715 750 795 835 875 900 930 960 960

NORM" (Normal) SETTING (Adjust" Jumper at NORM" Setting) HEAT"

Speed

Tap 1 140 160 185 205 230 255 285 310 340 155 185 215 250 280 310 340 365 395

Tap 2 175 205 235 265 295 330 360 395 435 200 235 275 320 360 395 435 470 505

Tap 3 295 320 350 380 405 430 455 485 505 360 390 425 460 490 520 550 585 610

Tap 4 375 405 445 480 515 545 580 610 640 460 495 540 580 620 660 700 740 770

COOL"

Speed

Tap 1 85 105 130 150 175 190 210 225 250 200 230 260 295 325 355 385 410 440

Tap 2 105 125 150 175 200 220 240 265 285 270 300 330 365 395 425 455 485 515

Tap 3 135 160 185 210 235 260 280 305 330 425 455 490 525 560 590 620 650 685

Tap 4 180 210 240 270 300 330 355 385 415 545 580 615 651 690 730 770 810 835

−" (Minus) SETTING (Adjust" Jumper at −" Setting) HEAT"

Speed

Tap 1 105 125 150 170 195 220 240 265 285 135 155 175 200 225 250 275 300 325

Tap 2 135 160 190 220 250 280 310 340 365 170 195 226 255 285 320 350 385 420

Tap 3 210 230 255 280 305 335 365 395 420 275 300 325 350 375 400 430 455 485

Tap 4 265 295 325 355 390 425 465 500 530 350 380 410 440 475 510 545 580 610

COOL"

Speed

Tap 1 70 85 105 120 140 160 180 205 220 150 170 195 220 250 275 300 325 350

Tap 2 85 100 120 140 160 185 205 225 245 195 220 245 270 300 325 355 380 410

Tap 3 110 130 150 175 195 215 235 255 280 300 330 360 395 430 460 495 530 560

Tap 4 145 170 195 220 245 270 295 320 345 395 425 455 490 525 550 580 605 635

Page 19

BLOWER DATA

G61MPV−60C−111 BLOWER PERFORMANCE (less filter) Single Side Return Air − Air volumes in bold require field fabricated transition to accommodate 20 x 25 x 1 in. cleanable air filter in

order to maintain proper air velocity across the filter.

0 through 1.00 in. w.g. External Static Pressure Range

ADJUST"

Switch

Positions

Speed Switch Positions

Second Stage HEAT" Speed − cfm Second Stage COOL" Speed − cfm

2 3 4 1 2 3

+ 1525 1740 1905 2115 1585 1695 1880 2080

NORM 1370 1560 1720 1915 1430 1555 1725 1915

 1225 1395 1555 1730 1250 1355 1540 1710

ADJUST"

Switch

Positions

First Stage HEAT" Speed − cfm First Stage COOL" Speed − cfm

2 3 4 1 2 3

+ 1395 1590 1730 1920 1110 1175 1355 1520

NORM 1255 1430 1590 1765 1010 1075 1200 1350

 1130 1285 1430 1590 895 955 1085 1215

Factory default jumper setting. N/A − First and second stage HEAT positions shown cannot be used on this model. NOTES − The effect of static pressure is included in air volumes shown.

First stage HEAT is approximately 91% of the same second stage

HEAT speed position.

G61MPV−60C−111 BLOWER MOTOR WATTS

Jumper Speed

Positions

Motor Watts @ Various External Static Pressures − in. wg.

First Stage Second Stage

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

+" (Plus) SETTING (Adjust" Jumper at +" Setting) HEAT"

Speed

Tap 1 190 220 250 280 310 345 375 410 430 260 290 320 350 380 415 445 480 510

Tap 2 245 280 320 360 400 440 480 520 555 335 370 410 445 485 530 570 615 650

Tap 3 390 425 460 495 530 560 590 615 650 540 580 615 655 695 725 755 785 805

Tap 4 490 535 580 630 675 710 745 780 820 685 730 780 830 880 920 960 995 1015

COOL"

Speed

Tap 1 120 145 170 195 220 245 270 295 315 315 350 385 420 455 485 515 545 575

Tap 2 145 165 190 210 235 260 285 310 340 375 410 445 485 520 550 580 610 635

Tap 3 185 215 250 280 315 340 370 395 420 535 575 615 660 700 740 775 815 845

Tap 4 280 310 345 375 410 445 475 505 535 755 795 840 880 925 955 985 1015 1015

NORM" (Normal) SETTING (Adjust" Jumper at NORM" Setting) HEAT"

Speed

Tap 1 155 175 200 230 255 275 300 320 350 180 205 240 270 300 330 360 390 420

Tap 2 200 225 260 290 325 355 385 410 450 230 265 305 345 385 425 460 500 535

Tap 3 315 340 375 405 440 460 485 510 535 390 425 460 495 530 560 590 615 645

Tap 4 395 435 475 515 555 585 615 645 675 495 535 580 625 670 705 745 780 815

COOL"

Speed

Tap 1 95 11 5 140 165 190 205 225 245 270 220 250 285 320 360 390 420 450 480

Tap 2 105 130 155 180 205 225 250 270 290 285 315 350 380 415 445 475 505 540

Tap 3 140 165 190 220 245 270 290 315 345 425 460 495 530 565 595 625 655 690

Tap 4 190 220 250 285 315 345 375 405 435 575 610 650 690 725 770 810 855 885

−" (Minus) SETTING (Adjust" Jumper at −" Setting) HEAT"

Speed

Tap 1 11 5 135 160 185 210 230 250 270 300 145 165 190 215 235 265 290 315 345

Tap 2 150 175 205 235 265 295 320 250 385 185 210 245 275 305 335 370 405 440

Tap 3 235 260 285 310 335 360 380 405 435 295 325 350 380 410 440 470 495 515

Tap 4 300 330 360 390 420 455 485 515 550 375 410 445 485 520 555 590 630 655

COOL"

Speed

Tap 1 75 90 110 130 150 175 195 220 235 165 185 215 245 275 300 330 355 385

Tap 2 85 100 125 145 165 185 210 230 250 195 225 255 285 315 340 370 400 430

Tap 3 115 135 155 180 205 225 245 265 290 300 330 365 395 430 465 495 530 560

Tap 4 155 180 205 235 260 285 310 340 365 415 450 485 520 555 585 610 640 675

Page 20

BLOWER DATA

G61MPV−60D−135 BLOWER PERFORMANCE (less filter) Bottom Return Air, Return Air from Both Sides or Return Air from Bottom and One Side. 0 through 0.80 in. w.g. External Static Pressure Range

ADJUST"

Switch

Positions

Speed Switch Positions

Second Stage HEAT" Speed − cfm Second Stage COOL" Speed − cfm

2 3 4 1 2 3

+ 1505 1705 1900 2110 1615 1730 1945 2190

NORM 1365 1550 1740 1920 1455 1580 1780 1985

 1225 1380 1545 1720 1305 1400 1600 1780

ADJUST"

Switch

Positions

First Stage HEAT" Speed − cfm First Stage COOL" Speed − cfm

2 3 4 1 2 3

+ 1385 1570 1760 1930 1135 1205 1365 1540

NORM 1250 1425 1595 1775 1025 1105 1235 1390

 1135 1265 1430 1585 915 985 1115 1235

Factory default jumper setting.

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

First stage HEAT is approximately 91% of the same second stage

HEAT speed position.

G61MPV−60D−135 BLOWER MOTOR WATTS

Jumper Speed

Positions

Motor Watts @ Various External Static Pressures − in. wg.

First Stage Second Stage

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

+" (Plus) SETTING (Adjust" Jumper at +" Setting) HEAT"

Speed

Tap 1

155 185 220 255 285 315 340 365 390 215 225 265 305 335 365 400 435 465

Tap 2

215 250 285 325 360 390 425 455 490 275 315 360 400 440 475 505 540 575

Tap 3

315 350 390 430 460 490 530 565 605 405 440 475 515 550 585 630 670 715

Tap 4

435 465 500 530 575 615 655 695 735 530 575 620 670 725 780 825 870 915

COOL"

Speed

Tap 1

95 120 145 170 190 215 240 265 290 250 285 320 360 390 420 450 485 515

Tap 2

115

135 160 185 210 235 260 290 315 290 330 375 420 455 490 525 565 605

Tap 3

145 175 215 250 275 300 330 355 385 425 465 505 550 590 635 670 710 750

Tap 4

205 240 280 320 350 380 410 445 480 615 655 700 745 800 855 900 940 980

NORM" (Normal) SETTING (Adjust" Jumper at NORM" Setting) HEAT"

Speed

Tap 1

130 155 180 205 235 260 285 305 330 155 180 210 245 270 300 330 355 385

Tap 2

165

195 230 265 300 330 360 385 415 215 250 295 335 360 385 420 455 490

Tap 3

240 270 310 345 380 415 440 470 500 305 340 380 420 455 490 520 545 575

Tap 4

335 365 405 440 480 515 550 585 620 405 445 485 530 570 610 650 690 735

COOL"

Speed

Tap 1

80 95 115 135 160 190 210 230 255 185 215 245 280 310 335 370 400 430

Tap 2

90 11 5 140 165 190 215 230 250 265 230 260 295 335 370 405 435 470 500

Tap 3

130

150 170 195 225 255 275 300 320 315 355 400 445 480 515 555 590 625

Tap 4

150

180 220 255 285 315 345 375 405 445 485 530 580 625 670 705 740 775

−" (Minus) SETTING (Adjust" Jumper at −" Setting) HEAT"

Speed

Tap 1

100 120 140 165 190 215 240 265 290 125 150 175 200 225 245 270 295 320

Tap 2

130 155 180 210 235 265 285 310 330 155 185 215 250 280 305 335 365 395

Tap 3

170

200 235 270 300 330 360 390 420 220 250 280 315 350 390 425 460 490

Tap 4

225 260 300 335 375 410 435 465 490 295 325 360 395 435 470 505 545 580

COOL"

Speed

Tap 1

65 80 100 120 140 160 180 195 215 145 170 195 225 250 280 305 330 355

Tap 2

70 90 110 130 155 175 200 220 240 160 190 225 255 285 315 345 380 415

Tap 3

95 120 145 170 190 215 235 250 270 245 280 315 355 385 415 445 480 515

Tap 4

135 155 175 200 220 245 270 300 325 325 365 405 445 485 520 550 580 610

Page 21

BLOWER DATA

G61MPV−60D−135 BLOWER PERFORMANCE (less filter) Single Side Return Air − Air volumes in bold require field fabricated transition to accommodate 20 x 25 x 1 in. cleanable air filter in

order to maintain proper air velocity across the filter.

0 through 0.80 in. w.g. External Static Pressure Range

ADJUST"

Switch

Positions

Speed Switch Positions

Second Stage HEAT" Speed − cfm Second Stage COOL" Speed − cfm

2 3 4 1 2 3

+ 1470 1650 1845 2040 1585 1705 1905 2130

NORM 1325 1495 1680 1865 1430 1545 1765 1975

 N/A 1335 1505 1670 1275 1370 1565 1755

ADJUST"

Switch

Positions

First Stage HEAT" Speed − cfm First Stage COOL" Speed − cfm

2 3 4 1 2 3

+ 1335 1510 1695 1870 1105 1180 1330 1500

NORM 1210 1370 1540 1710 990 1075 1210 1355

 N/A 1225 1375 1515 890 950 1085 1210

Factory default jumper setting. N/A − First and second stage HEAT positions shown cannot be used on this model. NOTES − The effect of static pressure is included in air volumes shown.

First stage HEAT is approximately 91% of the same second stage

HEAT speed position.

G61MPV−60D−135 BLOWER MOTOR WATTS

Jumper Speed

Positions

Motor Watts @ Various External Static Pressures − in. wg.

First Stage Second Stage

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 +" (Plus) SETTING (Adjust" Jumper at +" Setting) HEAT"

Speed

Tap 1

150 175 210 240 270 300 330 360 390 180 215 255 295 330 365 400 430 465

Tap 2

205 235 275 310 355 395 430 465 500 275 315 360 400 435 470 510 550 585

Tap 3

315

345 385 420 460 495 535 570 610 415 450 490 525 565 600 640 675 715

Tap 4

430 460 495 530 575 620 665 705 750 535 585 640 695 730 765 810 860 905

COOL"

Speed

Tap 1

90 11 0 140 170 195 220 240 265 290 230 265 310 355 390 425 460 490 525

Tap 2

105 130 165 195 215 235 260 290 315 285 330 380 430 455 485 525 565 605

Tap 3

150

175 205 235 270 300 330 360 385 425 465 515 560 605 645 685 730 770

Tap 4

195

230 270 305 340 375 410 445 480 605 650 695 740 800 855 900 945 985

NORM" (Normal) SETTING (Adjust" Jumper at NORM" Setting) HEAT"

Speed

Tap 1

120 140 170 200 225 255 280 305 330 150 175 210 240 270 300 335 365 400

Tap 2

155 185 220 255 295 335 365 395 425 205 240 275 315 350 385 422 460 495

Tap 3

235

265 300 330 370 405 440 470 500 290 330 380 430 460 485 515 545 575

Tap 4

320 355 390 430 465 505 540 575 610 395 440 485 530 575 620 660 700 740

COOL"

Speed

Tap 1

70 90 115 135 165 190 210 230 245 170 200 235 265 305 345 380 420 455

Tap 2

80 100 130 160 185 210 230 255 275 245 270 305 335 370 410 440 470 505

Tap 3

120 140 170 195 225 255 280 305 330 350 385 420 455 495 530 570 610 645

Tap 4

145

175 215 250 280 315 345 375 410 455 500 555 605 645 680 725 770 810

−" (Minus) SETTING (Adjust" Jumper at −" Setting) HEAT"

Speed

Tap 1

N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

Tap 2

125 150 175 195 230 265 290 310 335 150 175 210 240 255 290 330 370 405

Tap 3

155 185 215 250 285 320 355 385 420 205 235 270 305 345 380 420 455 490

Tap 4

205

240 285 325 355 385 420 460 495 290 325 360 400 440 480 515 545 580

COOL"

Speed

Tap 1

60 75 95 115 135 150 175 195 220 140 160 185 205 240 280 305 335 360

Tap 2

60 75 100 125 150 175 195 215 235 145 180 215 250 290 325 355 385 420

Tap 3

90 11 0 140 165 190 215 235 255 270 230 265 305 345 380 420 450 480 510

Tap 4

120 140 170 195 225 255 275 300 325 330 365 405 445 485 525 560 595 635

Page 22

BLOWER DATA

G61MPV−60D−135 BLOWER PERFORMANCE (less filter) Side Return Air with Optional RAB Return Air Base 0 through 0.80 in. w.g. External Static Pressure Range

ADJUST"

Switch

Positions

Speed Switch Positions

Second Stage HEAT" Speed − cfm Second Stage COOL" Speed − cfm

2 3 4 1 2 3

+ 1445 1635 1825 2025 1550 1660 1875 2105

NORM 1305 1475 1660 1840 1400 1510 1720 1920

 N/A 1315 1480 1650 1250 1345 1530 1715

ADJUST"

Switch

Positions

First Stage HEAT" Speed − cfm First Stage COOL" Speed − cfm

2 3 4 1 2 3

+ 1315 1490 1675 1855 1080 1155 1310 1478

NORM 1195 1365 1530 1695 985 1055 1190 1325

 N/A 1210 1360 1500 875 945 1060 1190

Factory default jumper setting. N/A − First and second stage HEAT positions shown cannot be used on this model. NOTES − The effect of static pressure is included in air volumes shown.

First stage HEAT is approximately 91% of the same second stage

HEAT speed position.

G61MPV−60D−135 BLOWER MOTOR WATTS

Jumper Speed

Positions

Motor Watts @ Various External Static Pressures − in. wg.

First Stage Second Stage

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 +" (Plus) SETTING (Adjust" Jumper at +" Setting) HEAT"

Speed

Tap 1

145 175 205 235 265 295 325 355 385 195 225 260 290 330 370 400 435 470

Tap 2

205

235 270 305 340 375 415 450 485 275 310 355 400 430 460 495 535 570

Tap 3

285 325 370 410 450 490 525 565 600 420 445 470 495 545 590 630 675 715

Tap 4

385 430 480 530 570 610 650 690 725 535 580 625 670 710 755 800 845 890

COOL"

Speed

Tap 1

90 11 0 140 165 190 210 235 260 285 235 265 305 340 380 415 450 480 515

Tap 2

105 130 160 190 210 230 255 285 310 290 325 370 410 450 490 515 545 575

Tap 3

145

170 205 235 265 290 325 355 390 420 460 510 555 595 640 680 715 755

Tap 4

200 230 270 305 345 385 415 445 480 580 630 690 745 800 850 895 935 975

NORM" (Normal) SETTING (Adjust" Jumper at NORM" Setting) HEAT"

Speed

Tap 1

130 150 170 190 225 260 285 305 330 150 175 205 235 265 295 325 355 385

Tap 2

160

190 225 260 290 325 355 390 420 200 230 265 300 345 385 410 440 465

Tap 3

235

265 300 335 370 400 435 470 500 290 330 375 415 450 485 515 540 570

Tap 4

310 350 390 435 470 500 540 575 610 405 440 485 525 560 590 635 680 725

COOL"

Speed

Tap 1

70 90 115 140 165 190 210 230 250 170 200 235 270 305 335 370 400 430

Tap 2

90 105 125 150 175 200 225 250 270 200 230 270 310 355 400 435 465 495

Tap 3

115 140 170 195 225 250 275 300 325 330 365 400 440 485 525 555 585 615

Tap 4

145

175 205 240 270 295 330 365 395 435 480 530 580 625 675 715 750 790

−" (Minus) SETTING (Adjust" Jumper at −" Setting) HEAT"

Speed

Tap 1

N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A

Tap 2

125 145 170 195 225 255 280 300 325 150 175 210 240 265 290 325 365 400

Tap 3

160

190 220 250 285 320 350 380 410 200 230 270 305 350 395 420 445 475

Tap 4

200

235 275 310 355 395 425 460 490 285 320 355 395 435 475 510 545 580

COOL"

Speed

Tap 1

60 75 95 115 135 155 175 195 215 135 155 180 205 240 280 305 330 355

Tap 2

70 90 110 130 150 170 195 215 235 160 185 215 240 275 310 345 375 410

Tap 3

85 105 130 155 180 205 230 250 270 220 255 295 335 370 410 440 475 510

Tap 4

120 140 170 195 220 240 270 295 325 330 365 400 440 480 525 555 585 615

Page 23

G61MPV PARTS ARRANGEMENT

FIGURE 1

TOP CAP

CABINET

BURNER BOX

ASSEMBLY

SIGHT

GLASS

DuralokPlus

HEAT EXCHANGER

ASSEMBLY

CONDENSER COIL

DOOR

INTERLOCK

SWITCH

COLD HEADER

(COLLECTOR)

BOX

COMBUSTION AIR

INDUCER

BLOWER

ACCESS

PANEL

BURNER ACCESS

PANEL

FLUE

COLLAR

COMBUSTION

AIR PRESSURE PROVE

SWITCHES

(36B−045 has 2 single switches)

PRIMARY LIMIT

WARM HEADER

(COLLECTOR)

BOX

GAS VALVE

AND MANIFOLD

SECONDARY

LIMITS (2)

Power Choke

(5 Ton Only)

Blower Motor

CONTROL BOX

CIRCUIT BREAKER

Page 24

I−UNIT COMPONENTS

G61MPV unit components are shown in figure 1. The gas valve, combustion air inducer and burners can be accessed by removing the burner access panel. Electrical components are in the control box (figure 2) found in the blower section. G61MPV units are factory equipped with a bottom return air

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

CAUTION

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

ELECTROSTATIC DISCHARGE (ESD)

Precautions and Procedures

A−Control Box

1. Control Transformer (T1)

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

2. Door Interlock Switch (S51)

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

FIGURE 2

CONTROL BOX G61MPV

SURELIGHT®

CONTROL

BOARD

TRANSFORMER

CIRCUIT BREAKER

DOOR INTERLOCK

SWITCH

3. Circuit Breaker (CB8)

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

FIGURE 3

CIRCUIT BREAKER CB8

PRESS TO RESET

WARNING

Shock hazard. Disconnect power before servicing. Integrated

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

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

4. Integrated Control Board (A92) SureLight Board 49M59

G61MPV units are equipped with the Lennox two−stage, variable speed integrated SureLight® control. The system consists of a ignition / blower control (figure 4 with control terminal designations in tables 1 through 4) and ignitor (figure 14). The control and ignitor work in combination to ensure furnace ignition and ignitor durability. The SureLight integrated board controls all major furnace operations. The control features two LED lights, (DS1 and DS2) for troubleshooting and four LED lights (DS3, DS6, DS7 and DS8) to show furnace status. The control also has two accessory terminals rated at (1) one amp each. See table 5 for status code and table 6 for troubleshooting diagnostic codes.

Electronic Ignition

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

Page 25

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

Two Stage Operation / Thermostat Selection Jumper

The control can be utilized in two modes: SINGLE−STAGE thermostat or TWO−STAGE thermostat. The thermostat selection jumper E20, located just below dip switches 1 through 3 (figure 4), must be positioned for the particular application. The jumper is factory set on TWO" for use with a two−stage thermostat with two stage heat. Re−position jumper to SINGLE" for use with a single stage thermostat with two stage heat. While in the single−stage thermostat mode (single jumper setting), the burners will always fire on first−stage heat. The combustion air inducer will operate on low speed and indoor blower will operate on low heat speed. After a 10 minute recognition period, the unit will switch to second stage heat. While in the two−stage thermostat mode (two jumper setting) the burners will fire on first−stage heat. The combustion air inducer will operate on low speed and indoor blower will operate on low heat speed. The unit will switch to second−stage heat on call from the indoor thermostat. If there is a simultaneous call for first and second stage heat, the unit will fire an first stage heat and switch to second stage heat after 30 seconds of operation. See Sequence of Operation flow charts in the back of this manual for more detail.

TWO−STAGE, VARIABLE SPEED INTEGRATED

CONTROL BOARD

FIGURE 4

DIP

SWITCHES

5 − 12

DIP

SWITCHES

1 − 3

DIAGNOSTIC

LEDs

LED

ON−BOARD

JUMPER W951

(cut when heat pump is

used with FM21)

ON−BOARD

JUMPER W914

(cut when SignatureStat,

CCB1 or Harmony II are

used)

ON−BOARD

JUMPER W915

(cut when two−stage

cooling is used)

LEDs

THERMOSTAT CONNECTIONS (TB1)

DIP SWITCH FUNCTIONS

DIP SWITCH(ES) FUNCTION

1 and 2 Blower Off Delay

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

4 Not used 5 and 6 Cooling Mode Blower Speed 7 and 8 Blower Speed Adjustment

9 and 10 Cooling Mode Blower Ramping Profile

11 and 12 Heating Mode Blower Speed

Page 26

TABLE 1

SureLight Control / Blower Control Terminals

LINE Line 120VAC Neutral

XFMR Transformer 120VAC Neutral

EAC Electronic Air Cleaner 120VAC Neutral

CIRC Indoor Blower 120VAC Neutral

HUM Humidifier 120VAC Neutral

HUM Humidifier 120VAC Hot

XMFR Transformer 120VAC Hot

LINE Line 120VAC Hot

CIRC Indoor Blower 120VAC Hot

EAC Electronic Air Cleaner 120VAC Hot

TABLE 2

SureLight Control 5 Pin Terminal Designation

PIN # Function

1 Ignitor

2 Combustion Air Inducer High Speed

3 Combustion Air Inducer Low Speed

4 Combustion Air Inducer Neutral

5 Ignitor Neutral

TABLE 3

SureLight Control 12Pin Terminal Designation

PIN # Function

1 Gas Valve High Fire

2 Second Stage Pressure Switch

3 Not Used

4 Ground

5 24V Hot

6 Primary Limit In

7 Gas Valve Low Stage

8 Gas Valve Common

9 24V Neutral

10 Ground

11 Primary Limit Out

12 1st Stage Pressure Switch

TABLE 4

SureLight Control 16 Pin Blower Control Terminals

PIN # Function

1 Ground

2 Low Heat Speed

3 Ground

4 DELAY" Dip Switch Selection

5 COOL" Dip Switch Selection

6 Y1" Signal

7 ADJUST" Dip Switch Selection

8 Ground

9 0" From Thermostat

10 DS" Output Signal

11 HEAT" Dip Switch Selection

12 24 VAC

13 HIGH HEAT Speed

14 Y2" Signal

15 G"

16 CFM LED

Page 27

TABLE 5

STATUS CODES

STATUS LED COLOR FUNCTION

DS3

ON / OFF ’

GREEN

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

DS6

CFM"

GREEN

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

DS7

HI / LO"

YELLOW

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

DS8

HEAT"

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

TABLE 6

DIAGNOSTIC CODES

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

DS1 DS2 DESCRIPTION

SIMULTANEOUS

SLOW FLASH

SIMULTANEOUS

SLOW FLASH

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

SIMULTANEOUS

FAST FLASH

SIMULTANEOUS

FAST FLASH

Normal operation − signaled when heating demand initiated at thermostat.

SLOW FLASH ON

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

OFF SLOW FLASH

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

OFF FAST FLASH

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

ALTERNATING

SLOW FLASH

ALTERNATING

SLOW FLASH

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

SLOW FLASH OFF Flame sensed without gas valve energized.

ON ON

OFF

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

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

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

ALTERNATING

FAST FLASH

ALTERNATING

FAST FLASH

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

1) Improper main ground;

2) Broken ignitor; OR: Open ignitor circuit;

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

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

Page 28

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

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

TABLE 7

Blower Off Delay Switch Settings

Blower Off Delay

(Seconds)

Switch 1 Switch 2

60 Off Off

90 Off On 120 On Off 180 On On

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

mine the second stage on delay when a single−stage thermostat is being used. The switch is factory−set in the ON position, which provides a 10−minute delay before second− stage heat is initiated. If the switch is toggled to the OFF position, it will provide a 15−minute delay before second− stage heat is initiated. This switch is only activated when the E20 thermostat selector jumper is positioned for SINGLE−stage thermostat use.

Switch 4 −− Not used in G61MPV application.

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

Switches 5 and 6 are used to select second stage cooling blower motor speed (first stage cooling speed is 70% of second stage). The unit is shipped from the factory with the dip switches positioned for high speed (4) indoor blower motor operation during the cooling mode. The table below provides the cooling mode blower speeds that will result from different switch settings. Refer to blower data tables at the front of this manual for corresponding cfm values.

TABLE 8

Cooling Mode Blower Speeds

Speed

Switch 5 Switch 6

1 − Low On On

2 − Medium Low Off On

3 − Medium High On Off

4 − High (Factory) Off Off

Switches 7 and 8 −− Blower Speed Adjustment −−

Switches 7 and 8 are used to select blower speed adjustment settings. The unit is shipped from the factory with the dip switches positioned for NORMAL (no) adjustment. The

dip switches may be positioned to adjust the blower speed by +10% or −10% to better suit the application. The table below provides blower speed adjustments that will result from different switch settings. Refer to blower data tables at the front of this manual for corresponding cfm values.

TABLE 9

Blower Speed Adjustment

Adjustment

Switch 7 Switch 8

+10% (approx.) On Off

NORMAL (Factory) Off Off

−10% (approx.) Off On

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

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

TABLE 10

Cooling Mode Blower Speed Ramping

Ramping Option

Switch 9 Switch 10

A (Factory) Off Off

B On Off C Off On D On On

COOLING MODE RAMPING OPTIONS

Ramping Option A (Factory Selection)

 Motor runs at 50% for 30 seconds.  Motor then runs at 82% for approximately 7−1/2 min-

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

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

onds then ramps down to stop.

OFF

1/2 MIN 50% CFM

COOLING DEMAND

7 1/2 MIN 82% CFM

100% CFM

1/2 MIN 50% CFM

Ramping Option B

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

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

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

OFF

82%CFM

100% CFM

COOLING DEMAND

7 1/2 MIN

Page 29

Ramping Option C

 Motor runs at 100% until demand is satisfied.

 Once demand is met, motor runs at 100% for 60 sec-

onds then ramps down to stop.

OFF

100% CFM

DEMAND

60 SEC.

Ramping Option D

 Motor runs at 100% until demand is satisfied.

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

OFFOFF

100% CFM

COOLING DEMAND

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

Switches 11 and 12 are used to select second stage heat-

ing mode blower motor speed (first stage heating blower

speed is 91% of second stage). The unit is shipped from the

factory with the dip switches positioned for medium low (2)

speed indoor blower motor operation during the heating

mode. The table below provides the heating mode blower

speeds that will result from different switch settings. Refer

to blower data tables at the front of this manual for corre-

sponding cfm values.

TABLE 11

Heating Mode Blower Speeds

Speed

Switch 11 Switch 12

1 − Low On On

2 − Medium Low

(Factory)

Off On

3 − Medium High On Off

4 − High Off Off

On−Board Jumper W914

On−board jumper W914, which connects terminals DS and R on the integrated control board, must be cut when the furnace is installed with the Harmony II zone control board, the CCB1 EfficiencyPlus humidity control or the Lennox SignatureStat.t If the jumper is left intact the PMW signal from the Harmony II control will be blocked and also lead to control damage. The SignatureStat and CCB1 will not operate unless the jumper is cut. Refer to table 21 for operation sequence in applications including a G61MPV, CCB1 and single−speed outdoor unit. Table 22 gives the operation sequence in applications with a two−speed outdoor unit. See table 23 for applications for a G61MVP, SignatureStat and single−speed outdoor unit and table 24 for applications with a two−speed outdoor unit.

On−Board Jumper W951

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 the FM21 FuelMaster control board. If the jumper is left intact, terminal "O" will remain energized eliminating the HEAT MODE in the heat pump.

On−Board Jumper W915

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.

Diagnostic LEDs (DS1 and DS2)

Two diagnostic LEDs are located on the two−stage, variable speed integrated control just to the left of the first bank of dip switches. These flashing lights correspond with diagnostic codes detailed on page 52.

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

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

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

Page 30

WARNING

Shock hazard. Disconnect power before servicing. Integrated

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

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

5. Integrated Control Board(A92) SureLight Board 100870

G61MPV −7 and later units are equipped with the Lennox two−stage, variable speed integrated SureLight control board. The system consists of a ignition / blower control board (figures 5 and 6) with control pin designations in tables 12, 13 and 14 and ignitor (figure 15). The board and ignitor work in combination to ensure furnace ignition and ignitor durability. The SureLight integrated board controls all major furnace operations. The board features a red LED light, for furnace status and troubleshooting. The LED flashes in X" + Y" codes. For example using table 15 under PRESSURE SWITCH CODES", if the red LED flashes 2 times, then off for 2 seconds then flashes 3 times, the low pressure switch is failed open. Two green LEDs show indoor blower status and CFM. See Page 35 for more detail. The board also has two 120 volt accessory terminals rated at (1) one amp each. In addition there is a 24 volt accessory terminal located on TB1.

Electronic Ignition

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

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

Two Stage Operation / Thermostat Selection Jumper

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

Page 31

TWO−STAGE, VARIABLE SPEED INTEGRATED CONTROL BOARD

FIGURE 5

THERMOSTAT CONNECTIONS (TB1)

1/4" QUICK CONNECT TERMINALS

DIP SWITCH FUNCTIONS

INDOOR

BLOWER DIP

SWITCHES

HEATING

DIP

SWITCHES

DIAGNOSTIC

LEDs

ON−BOARD

LINKS

H= 24V HUMIDIFIER OUTPUT L= LENNOX SYSTEM OPERATION MONITOR 1= DO NOT USE

NEUTRALS= 120 VAC NEUTRAL

W914

W951

W915

HTG DIP SWITCH(ES) FUNCTION

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

9 and 10 Cooling Mode Blower Ramping Profile

11 and 12 Heating Mode Blower Speed

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

3 and 4 Heating Fan OFF Delay

INDOOR BLOWER

DIP SWITCH(ES)

FUNCTION

FUTURE USE

TABLE 12

SureLight Board 5 Pin Terminal Designation

PIN # Function

1 Ignitor

2 Combustion Air Inducer High Speed

3 Combustion Air Inducer Low Speed

4 Combustion Air Inducer Neutral

5 Ignitor Neutral

TABLE 13

SureLight Board 12Pin Terminal Designation

PIN # Function

1 Gas Valve High Fire

2 Second Stage Prove Switch

3 Rollout In

4 Ground

5 24V Hot

6 Primary Limit In

7 Gas Valve Low Stage

8 Gas Valve Common

9 24V Neutral

10 Ground

11 Rollout Switch Out

12 1st Stage Prove Switch

TABLE 14

SureLight Board 16 Pin Blower Control Terminals

PIN # Function

1 Ground

2 Low Heat Speed

3 Ground

4 DELAY" Dip Switch Selection

5 COOL" Dip Switch Selection

6 Y1" Signal

7 ADJUST" Dip Switch Selection

8 Ground

9 0" From Thermostat

10 DS" Output Signal

11 HEAT" Dip Switch Selection

12 24 VAC

13 HIGH HEAT Speed

14 Y2" Signal

15 G"

16 CFM LED

Page 32

FIGURE 6

Page 33

TABLE 15

FLASH CODE

(X + Y)

STATUS / ERROR DESCRIPTION

FLASH CODE DESCRIPTIONS

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

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

X + Y

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

Pulse Power on − Standby.

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

FLAME CODES

1 + 2 Low flame current −− run mode.

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

PRESSURE SWITCH CODES

2 + 3 Low pressure switch failed open.

2 + 4 Low pressure switch failed closed.

2 + 5 High pressure switch failed open.

2 + 6 High pressure switch failed closed.

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

LIMIT CODE

3 + 1 Limit switch open.

WATCHGUARD CODES

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

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

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

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

4 + 6

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

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

4 + 8 Low line voltage.

HARD LOCKOUT CODES

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

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

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

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

5 + 6 Low secondary (24VAC) voltage.

Error Code Storage

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

Error Code Review

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

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

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

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

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

TUS LED turning off. This activates error code review.

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

LED.

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

flash to indicate normal operation.

Clearing Error Codes

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

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

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

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

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

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

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

indicate normal operation.

Page 34

Dip Switch Settings

Heating Operation DIP Switch Settings

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

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

TABLE 16

Blower Off Delay Switch Settings

Blower Off Delay

(Seconds)

Switch 3 Switch 4

60 Off On

90 Off Off 120 On Off 180 On On

Indoor Blower Operation DIP Switch Settings

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

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

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

TABLE 17

Cooling Mode Blower Speeds

Speed

Switch 5 Switch 6

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

4 − High (Factory) Off Off

Switches 7 and 8 −− Blower Speed Adjustment −−

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

TABLE 18

Blower Speed Adjustment

Adjustment

Switch 7 Switch 8

+10% (approx.) On Off

NORMAL (Factory) Off Off

−10% (approx.) Off On

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

mode blower speed ramping options. Blower speed ramping may be used to enhance dehumidification performance. The switches are factory set at option A which has the greatest effect on blower motor performance. Table 19 provides the cooling mode blower speed ramping options that will result from different switch settings. The cooling mode blower speed ramping options are detailed on Page 28.

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

TABLE 19

Cooling Mode Blower Speed Ramping

Ramping Option

Switch 9 Switch 10

A (Factory) Off Off

B On Off C Off On D On On

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

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

Page 35

TABLE 20

Heating Mode Blower Speeds

Speed

Switch 11 Switch 12

1 − Low On On

2 − Medium Low

(Factory)

Off On

3 − Medium High On Off

4 − High Off Off

On−Board Link W914

On−board link W914 is a clippable connection which connects terminals DS and R on the integrated control board. W914 must be cut when the furnace is installed with either the Harmony III zone control board or a thermostat which features humidity control. If the link is left intact the PWM signal from the HARMONY III control will be blocked and also lead to control damage. Refer to tables 21 through 26 for operation sequence in applications including G61MPV and a thermostat which features humidity control with a single−stage or two−stage outdoor unit.,

On−Board Link W951

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

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

On−Board Link W915

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

Status LEDs (SPEED, CFM, E−COM)

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

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

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

TABLE 21

G61MPV, CCB1 and Single−Stage Outdoor Unit

OPERATING MODE SYSTEM DEMAND SYSTEM RESPONSE

System Condition

Thermostat

Demand

*Relative Humidity

(EfficiencyPlus Lights)

Blower CFM

(COOL)

Comments

Normal operation Y1

No demand. Humidity

level is acceptable

COOL

Compressor demand and indoor blower speed controlled by thermostat demand.

*Call for humidity

removal during

cooling demand

Humidity level rises above

setpoint. Demand initiated.

70%

of COOL

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

Dehumidification demand satisfied

during cooling demand.

Humidity level falls below set-

point. No demand

COOL

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

Call for cooling after call for

humidity removal.

None

Humidity level above setpoint.

Demand initiated.

Off

Dehumidification mode begins when relative humidity is greater than setpoint.

Humidity level above setpoint.

Demand initiated.

70%

of COOL

Humidity demand satisfied between

thermostat demands (unit

off cycle).

None Over setpoint (1 or more) Off

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

Y1 Change to acceptable COOL

NOTE − When changing unit mode of operation from cooling to heating, indicating lights that are on will stay on until the first thermostat heating demand. * Reduced blower speed is 70% of COOL

Page 36

TABLE 22

OPERATING SEQUENCE

G61MPV, CCB1 and Two−Stage Outdoor Unit

OPERATING MODE SYSTEM DEMAND SYSTEM RESPONSE

System

Condition

Thermostat

Demand

*Relative Humidity

(EfficiencyPlus Lights)

****Compressor

Speed

Blower CFM

(COOL)

Comments

Normal operation

Y1 No demand. Acceptable Low

**49% of HIGH

COOL

Compressor demand and indoor

blower speed controlled by

thermostat demand

Y2 No demand. Acceptable High HIGH COOL

Call for humidity

removal during

1st−stage cooling

demand

Y1 No demand. Acceptable Low

**49% of HIGH

COOL

Dehumidification mode does not begin

until after initial thermostat demand is

satisfied and new cooling demand is

initiated.

Humidity level rises slightly

(1) above setpoint. Demand

initiated.

Low

**49% of HIGH

COOL

Demand

satisfied

Humidity level remains

slightly (1) above setpoint.

Demand continues.

Off

Humidity level remains

slightly (1) above setpoint.

Demand continues.

High

***70%of

HIGH COOL

Significant increase in

humidity during

thermostat cooling

demand.

No demand. Acceptable

Low

**49% of HIGH

COOL

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

cantly, unit will immediately go into de-

humidification mode (in presence of

thermostat demand).

Humidity level rises signifi-

cantly (2 or more) above

setpoint. Demand initiated.

High

***70% of

HIGH COOL

Humidity demand

satisfied during

thermostat demand.

Humidity level

above setpoint.

High

***70% of

HIGH COOL

When humidity demand is satisfied,

blower immediately shifts to the COOL

CFM in order to hasten the end of the

cycle. Unit can only shift out of high

speed compressor operation at begin-

ning of next cycle.

Humidity level falls below

setpoint. No demand.

High

HIGH COOL

None

No demand. Acceptable

Off

No demand. Acceptable

Low

**49% of HIGH

COOL

Call for humidity

removal during 2nd

stage thermostat

demand

No demand. Acceptable

High

HIGH COOL

Blower immediately changes speed in

response to thermostat demand.

Humidity level rises slightly

(1) above setpoint. Demand

initiated.

High

***70% of

HIGH COOL

No demand. Acceptable

High

HIGH COOL

*Call for 1st stage

cooling after call for

humidity removal.

None

Humidity level is slightly (1)

above setpoint.

Off

Dehumidification mode (high speed

compressor) begins with next thermo-

stat demand after initial demand is sat-

isfied.

Humidity level is slightly (1)

above setpoint.

Low

**49% of HIGH

COOL

Call for 2nd stage

cooling after call for

humidity removal

None

Humidity level is slightly (1)

above setpoint.

Off

Reduced blower speed (dehumidifica-

tion speed) begins immediately with

thermostat demand

Humidity level is slightly (1)

above setpoint.

High

***70% of

HIGH COOL

Call for cooling after

significant increase in

humidity

None

Humidity level is significantly

above setpoint (2 or more).

Off

If humidity increases significantly over

setpoint, or if slide switch is moved,

unit immediately goes into dehumidifi-

cation mode (in presence of thermostat

demand).

Y1 or Y2

Humidity level is significantly

above setpoint (2 or more).

High

***70% of

HIGH COOL

Humidity demand satisfied between

thermostat demands

(unit off cycle).

None

Humidity level is slightly (1)

above setpoint.

Off

While unit is not operating (no thermo-

stat demand), slide switch is moved

down and back up. Blower and com-

pressor operate at high speed until

next thermostat demand.

Y1 or Y2

Humidity level falls below

setpoint. No demand.

High

HIGH COOL

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

*IMPORTANT - If power to unit is turned on with CCB1 calling for humidity removal, outdoor unit may be locked into high speed indefinitely. To reset, move humidity slide switch all the way down then back up to desired setpoint (with unit running) ** Reduced blower speed is 49% HIGH COOL speed. *** Reduced blower speed is 70% HIGH COOL speed. ****If the two−speed control on a two−speed outdoor unit is set for LATCH 2 (15 minutes) or LATCH 3 (30 minutes), the compressor will latch into high speed after a Y1 demand has occurred for that period of time.

Page 37

TABLE 23

G61MPV, ComfortSense 7000

and SINGLE STAGE OUTDOOR UNIT

OPERATING

SEQUENCE

SYSTEM DEMAND SYSTEM RESPONSE

System

Condition

Step

Thermostat Demand Relative Humidity

Compres-

sor

Blower

CFM

(COOL)

Comments

Y1 O G

Status D

NO CALL FOR DEHUMIDIFICATION

Normal Operation 1 On On On Acceptable

VAC

High 100%

Compressor and indoor blower follow thermostat demand

BASIC MODE (only active on a Y1 thermostat demand)

Normal Operation 1 On On On Acceptable

VAC

High 100%

ComfortSense® 7000 thermostat energizes Y1 and de−energizes D on a call for de−humidification

Dehumidification

Call

2 On On On Demand

VAC

High 70%*

PRECISION MODE (operates independent of a Y1 thermostat demand)

Normal Operation 1 On On On Acceptable

VAC

High 100%

Dehumidification mode begins when humidity is greater than set point

Dehumidification

call

2 On On On Demand

VAC

High 70%*

Dehumidification

call ONLY

1 On On On Demand

VAC

High 70%*

ComfortSense

7000

thermostat

will try to

maintain room humidity setpoint by allowing the room space to maintain a cooler room thermostat setpoint**

Jumpers at indoor unit with a single stage outdoor unit With Condensing unit − Cut W914 (R to DS) on SureLight

control

With Heat Pump − Cut W914 (R to DS) & W951 (R to O) on SureLight

control

Dave Lennox ComfortSense® 7000 thermostat to use for this application − Y2081 4 heat / 2 cool *Dehumidification blower speed is 70% of COOL speed for all units . **In Precision mode, ComfortSense

7000 thermostat will maintain room temperature up to 2 °F (1.2°C) cooler than room setting.

Page 38

TABLE 24

G61MPV, ComfortSense 7000

and TWO STAGE OUTDOOR UNIT

OPERATING

SEQUENCE

SYSTEM DEMAND SYSTEM RESPONSE

System

Condition

Ste

Thermostat Demand Relative Humidity

Compressor

Blower

CFM

(COOL)

Comments

Y1 Y2 O G

W1W

Status D

NO CALL FOR DEHUMIDIFICATION

Normal Opera-

tion − Y1

1 On On On Acceptable

VAC

Low 70%*

Compressor and indoor blower follow thermostat demand

Normal Opera-

tion − Y2

2 On On On On Acceptable

VAC

High 100%

ROOM THERMOSTAT CALLS FOR FIRST STAGE COOLING

BASIC MODE (only active on a Y1 thermostat demand)

Normal Opera-

tion

1 On On On Acceptable

VAC

Low 70%*

ComfortSense

7000 thermostat energizes Y2 and de−energizes D on a call for de−humidification

Dehumidification

Call

2 On On On On Demand

VAC

High 70%**

PRECISION MODE (operates independent of a Y1 thermostat demand)

Normal Opera-

tion

1 On On On Acceptable

VAC

Low 70%*

Dehumidification mode begins when humidity is greater than set point

Dehumidification

call

2 On On On On Demand

VAC

High 70%**

Dehumidification

call ONLY

1 On On On On Demand

VAC

High 70%**

ComfortSense® 7000 thermostat will try to maintain room humidity setpoint by allowing the room space to maintain a cooler room thermostat setpoint***

ROOM THERMOSTAT CALLS FOR FIRST AND SECOND STAGE COOLING

BASIC MODE (only active on a Y1 thermostat demand)

Normal Opera-

tion

1 On On On On Acceptable

VAC

High 100%

ComfortSense® 7000 thermostat energizes Y2 and de−energizes D on a call for de−humidification

Dehumidification

Call

2 On On On On Demand

VAC

High 70%**

PRECISION MODE (operates independent of a Y1 thermostat demand)

Normal Opera-

tion

1 On On On Acceptable

VAC

Low 70%*

Dehumidification mode begins when humidity is greater than set point

Dehumidification

call

2 On On On On Demand

VAC

High 70%**

Dehumidification

call ONLY

1 On On On On Demand

VAC

High 70%**

ComfortSense® 7000 thermostat will try to maintain room humidity setpoint by allowing the room space to maintain a cooler room thermostat setpoint***

Jumpers at indoor unit with a two stage outdoor unit Cut factory jumper from Y1 to Y2 or cut W915 (Y1 to Y2) With Condensing unit − Cut W914 (R to DS) on SureLight

control

With Heat Pump − Cut W914 (R to DS) & W951 (R to O) on SureLight

control

Dave Lennox ComfortSense® 7000 thermostat to use for this application − Y2081 4 heat / 2 cool *Normal operation first stage cooling blower speed is 70% COOL speed. **Dehumidification blower speed is, reduced to 70% of COOL. ***In Precision mode, ComfortSense

7000 thermostat will maintain room temperature up to 2 °F (1.2°C) cooler than room setting.

Page 39

TABLE 25

G61MPV, SignatureStat and SINGLE STAGE OUTDOOR UNIT

OPERATING SEQUENCE

SYSTEM DEMAND SYSTEM RESPONSE

System

Condition

Step

Thermostat Demand Relative Humidity

Compres-

sor

Blower

CFM

(COOL)

Comments

Y1 O G

Status D

NO CALL FOR DEHUMIDIFICATION

Normal Operation 1 On On On Acceptable

VAC

High 100%

Compressor and indoor blower follow thermostat demand

BASIC MODE (only active on a Y1 thermostat demand)

Normal Operation 1 On On On Acceptable

VAC

High 100%

SignatureStat energizes Y1 and de−energizes D on a call for de−humidification

Dehumidification

Call

2 On On On Demand

VAC

High 70%*

PRECISION MODE (operates independent of a Y1 thermostat demand)

Normal Operation 1 On On On Acceptable

VAC

High 100%

Dehumidification mode begins when humidity is greater than set point

Dehumidification

call

2 On On On Demand

VAC

High 70%*

Dehumidification

call ONLY

1 On On On Demand

VAC

High 70%*

SignatureStat will try to maintain room humidity setpoint by allowing the room space to maintain a cooler room thermostat setpoint**

Jumpers at indoor unit with a single stage outdoor unit With Condensing unit − Cut W914 (R to DS) on SureLight board With Heat Pump − Cut W914 (R to DS) & W951 (R to O) on SureLight board

Dave Lennox SignatureStat to use for this application − 51M26 1 heat / 1 cool or 51M28 − 2 heat / 2 cool for heat pumps *Dehumidification blower speed is 70% of COOL speed. **In Precision mode, SignatureStats built before 10−2003 will maintain room temperature up to 3°F(1.8°C) cooler than room setting. SignatureStats built 10−2003 and later will maintain room temperature up to 2 °F (1.2°C) cooler than room setting.

Page 40

TABLE 26

G61MPV, SignatureStat and TWO STAGE OUTDOOR UNIT

OPERATING

SEQUENCE

SYSTEM DEMAND SYSTEM RESPONSE

System

Condition

Step

Thermostat Demand Relative Humidity

Compressor

Blower

CFM

(COOL)

Comments

Y1 Y2 O G

W1W

Status D

NO CALL FOR DEHUMIDIFICATION

Normal Operation −

1 On On On Acceptable

VAC

Low 70%*

Compressor and indoor blower follow thermostat demand

Normal Operation −

2 On On On On Acceptable

VAC

High 100%

ROOM THERMOSTAT CALLS FOR FIRST STAGE COOLING

BASIC MODE (only active on a Y1 thermostat demand)

Normal Operation 1 On On On Acceptable

VAC

Low 70%*

SignatureStat energizes Y2 and de−energizes D on a call for de−humidification

Dehumidification

Call

2 On On On On Demand

VAC

High 70%*

PRECISION MODE (operates independent of a Y1 thermostat demand)

Normal Operation 1 On On On Acceptable

VAC

Low 70%*

Dehumidification mode begins when humidity is greater than set point

Dehumidification

call

2 On On On On Demand

VAC

High 70%*

Dehumidification

call ONLY

1 On On On On Demand

VAC

High 70%*

SignatureStat will try to maintain room humidity setpoint by allowing the room space to maintain a cooler room thermostat setpoint**

ROOM THERMOSTAT CALLS FOR FIRST AND SECOND STAGE COOLING

BASIC MODE (only active on a Y1 thermostat demand)

Normal Operation 1 On On On On Acceptable

VAC

High 100%

SignatureStat energizes Y2 and de−energizes D on a call for de−humidification

Dehumidification

Call

2 On On On On Demand

VAC

High 70%*

PRECISION MODE (operates independent of a Y1 thermostat demand)

Normal Operation 1 On On On Acceptable

VAC

Low 70%*

Dehumidification mode begins when humidity is greater than set point

Dehumidification

call

2 On On On On Demand

VAC

High 70%*

Dehumidification

call ONLY

1 On On On On Demand

VAC

High 70%*

SignatureStat will try to maintain room humidity setpoint by allowing the room space to maintain a cooler room thermostat setpoint**

Jumpers at indoor unit with a two stage outdoor unit Cut factory jumper from Y1 to Y2 or cut W915 (Y1 to Y2) With Condensing unit − Cut W914 (R to DS) on SureLight board With Heat Pump − Cut W914 (R to DS) & W951 (R to O) on SureLight board

Dave Lennox SignatureStat to use for this application − 51M27 2 heat / 2 cool or 51M28 − 2 heat / 2 cool for heat pumps *Normal operation first stage cooling blower speed is 70% of COOL speed. **In Precision mode, SignatureStats built before 10−2003 will maintain room temperature up to 3°F(1.8°C) cooler than room setting. SignatureStats built 10−2003 and later will maintain room temperature up to 2 °F (1.2°C) cooler than room setting.

Page 41

B−Blower Compartment Figure 7

FIGURE 7

SECONDARY

LIMITS (2)

Power Choke

(5 Ton Only)

Blower Motor

(B3)

To Remove Blower From Unit: Remove Bolts and

Wiring Jackplugs. Then Slide Out Front of Unit.

Secondary Limit (S21)

The secondary limits (S21) on G61MPV units are located in the blower compartment on the back side of the blower housing. See figure 7. All G61MPV units are equipped with two secondary limits. When excess heat is sensed in the blower compartment, the limit will open. If the limit is open, the furnace control energizes the supply air blower and closes the gas valve. The limit automatically resets when unit temperature returns to normal. The switch is factory set to open at 125°F and cannot be adjusted.

Blower Motor (B3)

Blower motors are manufactured by GenTeq (formally G.E.) and Emerson. See figures 8 and 9. Motors operate the same and are only different in physical appearance. They are both three-phase, electronically controlled DC brushless motors (controller converts single−phase AC to three−phase DC), with a permanent magnet type rotor (figure 8). Because these motors have a permanent magnet rotor it does not need brushes like conventional DC motors. Internal components for both manufactured motors are similar and shown in figure 10. The stator windings are split into three poles which are electrically connected to the controller. This arrangement allows motor windin g s to turn on an d off in sequence by the controller.

A solid-state controller is attached to the motor. The controller is primarily an AC to DC converter. Converted DC power is used to drive the motor. The controller contains a microprocessor which monitors varying conditions inside the motor (such as motor workload). The controller on the Emerson motor includes the 16X4W control with three LED’s PW, RX and TX located on the face for troubleshooting. Figure 9 shows the location of the 16X4W and table 27 the LED codes.

FIGURE 8

GenTeq BLOWER MOTOR B3

MOTOR

CONTROLLER

J49

J48

EMERSON BLOWER MOTOR B3

FIGURE 9

MOTOR

CONTROLLER

16X4W

J48

J49

G61MPV BLOWER MOTOR COMPONENTS

FIGURE 10

STATOR

(WINDINGS)

OUTPUT

SHAFT

BEARING

ROTOR

The controller uses sensing devices to sense what position the rotor is in at any given time. By sensing the position of the rotor and then switching the motor windings on and off in sequence, the rotor shaft turns the blower.

All G61MPV blower motors use single phase power. An external run capacitor is not used. The motor uses permanently lubricated ball-type bearings.

Internal Operation

Each time the controller switches a stator winding (figure 10) on and off, it is called a pulse." The length of time each pulse stays on is called the pulse width." By varying the pulse width (figure 13), the controller varies motor speed (called pulsewidth modulation"). This allows for precise control of motor speed and allows the motor to compensate for varying load conditions as sensed by the controller. In this case, the controller monitors the static workload on the motor and varies motor rpm in order to maintain constant airflow (cfm).

The motor controller is driven by the Two−stage Variable Speed Integrated control board. The board receives its demand (PWM signal or fixed 24 VAC or VDC signal) from optional controls such as the Harmony IIIt zoning system, SignatureStatt, Efficiency Plus Humidity Control (CCB1) or a conventional thermostat.

Page 42

TABLE 27

Emerson Motor Only

LEDRXLEDTXLED

Motor

Blower

Action

Off Blink Blink

Not

Rotating

Normal

Blink Blink Blink Rotating Normal. PW blink is 100cfm/blink

Blink Off Blink

Not

Rotating

Verify 16X4W and motor control hp match. Verify

power to motor control.

Turn off power for 1 minute then restart. If motor still

does not rotate replace the controller. See Page 109 for

further diagnosis.

Off Off Off

Not

Rotating

Verify power to the 16X4W. Turn off power then restart.

If LED’s are still out, replace controller. See Page 109

for further diagnosis.

Motor rpm is continually adjusted internally to maintain constant cfm. The controller monitors the static work load on the motor and motor amp-draw to determine the amount of rpm adjustment. Blower rpm may be adjusted any amount in order to maintain a constant cfm as shown in Blower Ratings Tables. The cfm remains relatively stable over a broad range of static pressure. Since the blower constantly adjusts rpm to maintain a specified cfm, motor rpm is not rated. Hence, the terms cool speed" , heat speed " or speed tap" in this manual, on the unit wiring diagram and on blower B3, refer to blower cfm regardless of motor rpm.

The unit control indicates the desired cfm. The blower will maintain the desired cfm as long as external static pressure does not exceed 0.8". If the system exceeds this amount, the blower may enter a cut back", mode wherein it then slows down to protect itself from electrical damage. During this cut back" mode the unit control will still indicate the same desired cfm regardless of actual motor rpm.

When Harmony is used, speed taps are overridden and a PWM signal generated by the Harmony controller continuously varies motor speed based upon zone demands.

Initial Power Up

When line voltage is applied to B3, there will be a large inrush of power lasting less than 1/4 second. This inrush charges a bank of DC filter capacitors inside the controller. If the disconnect switch is bounced when the disconnect is closed, the disconnect contacts may become welded. Try not to bounce the disconnect switch when applying power to the unit.

Motor Start-Up

When B3 begins start-up, the motor gently vibrates back and forth for a moment. This is normal. During this time the electronic controller is determining the exact position of the rotor. Once the motor begins turning, the controller slowly eases the motor up to speed (this is called soft-start"). The motor may take as long as 10-15 seconds to reach full speed. If the

motor does not reach 200rpm within 13 seconds, the motor shuts down. Then the motor will immediately attempt a restart. The shutdown feature provides protection in case of a frozen bearing or blocked blower wheel. The motor may attempt to start eight times. If the motor does not start after the eighth try, the controller locks out. Reset controller by momentarily turning off power to unit.

The DC filter capacitors inside the controller are connected electrically to the speed tap wires. The capacitors take approximately 5 minutes to discharge when the disconnect is opened. For this reason it is necessary to wait at least 5 minutes after turning off power to the unit before attempting to change speed taps.

DANGER

Disconnect power from unit and wait at least five minutes to allow capacitors to discharge before attempting to adjust motor speed tap settings. Failure to wait may cause personal injury or death.

External Operation (Speed Tap Priority)

Figures 12 and 11 show the two quick-connect jacks (J48 and J49) which connect the motor to the G61MPV. Jack J48 is the power plug and jack J49 connects the unit controls to the motor.

Jack J48 is the power plug. Line voltage must be applied to J48 pins 4 and 5 in order for the motor to operate. When using 120VAC pins 1 and 2 must be jumpered. Jack J49 connects the unit controls to the motor. The motor assigns priority to J49 pin 2 so that if a call for cooling and a call for heating are concurrent, heating call overrides and the blower operates on high speed heating tap. See Page 108 for more detailed speed tap operation.

Page 43

FIGURE 11

POWER

CONNECTOR J48

CONTROL

CONNECTOR J49

GenTeq HARNESS CONNECTORS

J49 PIN 1 - C1 PIN 2 - W / W1 PIN 3 - C2 PIN 4 − Delay PIN 5 - Cool PIN 6 - Y1 PIN 7 - Adjust PIN 8 - 0ut PIN 9 - 0 PIN 10 - DS(PWM) PIN 11 - Heat PIN 12 - R PIN 13 - EM / W2 PIN 14 - Y / Y2 PIN 15 - G PIN 16 - Out +

J48 PIN 1 - Jumper PIN 1 to PIN2 for 120VAC line input only. PIN 2 - Jumper PIN 1 to PIN2 for 120VAC line input only. PIN 3 - Ground PIN 4 - AC Line PIN 5 - AC Line

FIGURE 12

EMERSON MOTOR HARNESS CONNECTORS

POWER

CONNECTOR J48

CONTROL

CONNECTOR J49

J48 PIN 1 - Jumper PIN 1 to PIN2 for 120VAC line input only. PIN 2 - Jumper PIN 1 to PIN2 for 120VAC line input only. PIN 3 - Ground PIN 4 - AC Line PIN 5 - AC Line

Power Choke (L13)

A choke coil is used on G61MPV 5 ton 1 hp units. The ch oke is located on the blower housing and is used to suppress transient current spikes.

Precautions

If the G61MPV or its electronically controlled blower motor is improperly or inadequately grounded, it may cause television interference (commonly known as RFI or radio frequency interference).

This interference is caused by internal switching frequencies of the motor controller. TV interference may show u p as s m al l spec k s or lines which randomly appear on the TV screen accompanied by pops or clicks in the sound. Before attempting any service, make sure the indoor unit is causing the interference. To check, disconnect power to indoor unit then check TV for continued signs of interference.

TV interference may be stopped by making sure the motor is solidly grounded to the cabinet (metal to metal) and by making sure the cabinet is solidly grounded. If TV inte r ference persis ts, m a ke sur e the television (and all affected RF appliances) are moved away from the G61MPV. Also make sure affected appliances are connected to a separate electrical circuit.

Page 44

One revolution

FIGURE 13

HIGH SPEED COOL (output from controller to motor windings)

MOTOR SPEED CONTROL WITH D.C. PULSE-WIDTH MODULATION

WINDING #1

WINDING #2

WINDING #3

LOW SPEED HEAT/COOL (output from controller to motor windings)

HIGH SPEED HEAT (output from controller to motor windings)

O volts

325VDC

One revolution

O volts

325VDC

O volts

325VDC

WINDING #1

WINDING #2

WINDING #3

O volts

325VDC

O volts

325VDC

O volts

325VDC

WINDING #1

WINDING #2

WINDING #3

O volts

325VDC

O volts

325VDC

O volts

325VDC

Motor speed is determined by the size of the electrical pulse sent to

the motor windings. The longer the pulse, the faster the motor.

One

Pulse

ON PULSE

OFF PULSE

WINDINGS TURNED OFF

The frequency of the pulses to the windings is 20KHz.

DO NOT ATTEMPT TO MEASURE THESE VOLTAGES.

WINDINGS TURNED ON

OUTPUT FROM CONTROLLER TO MOTOR WINDINGS

One revolution

Page 45

C−Heating Components

6. Ignitor

The SureLight ignitor is made of durable silicon nitride. Ignitor longevity is enhanced by controlling voltage to the ignitor. Board 49M59 finds the lowest ignitor temperature which will successfully light the burner, thus increasing the life of the ignitor. Due to this feature of the board, voltage cannot be measured so ignitor must be ohmed. Board 100870 provides a regulated 95 volts to the ignitor for consistent ignition and long ignitor life. Ohm value for ignitors with SureLight board 49M59 should be 10.9 to 19.7. Ohm value for ignitors with board 100870 should be 25 to 47. Ignitors not interchangeable between boards. See figure 14 and 15 (make note of control board used) for ignitor location.

NOTE − The G61MPV(X) furnace contains electronic

components that are polarity sensitive. Make sure that

the furnace is wired correctly and is properly grounded.

7. Flame Sensor

A flame sensor is located on the left side of the burner support. See figure 16 and 17 (make note of control board used). The sensor is mounted on the flame rollout plate and the tip protrudes into the flame envelope of the left−most burner. The sensor can be removed for service without removing any part of the burners. During operation, flame is sensed by current passed through the flame and sensing electrode. The SureLight control allows the gas valve to remain open as long as flame signal is sensed.

FIGURE 14

5/16"

13/32’

5/8 "

SureLight Board 49M59 Ignitor Location

BURNERS TOP VIEW

BURNERS FRONT VIEW

MEASUREMENT IS TO I.D. OF RETENTION RING

IGNITOR

BRACKET

FIGURE 15

21/64"

7/32’

5/8 "

SureLight Board 100870 Ignitor Location

BURNERS TOP VIEW

BURNERS FRONT VIEW

MEASUREMENT IS TO I.D. OF RETENTION RING

IGNITOR

BRACKET

Page 46

FIGURE 16

NORMAL FLAME SIGNAL > 0.23 MICROAMPS LOW FLAME SIGNAL < 0.22 MICROAMPS DROP OUT SIGNAL = 0.16 MICROAMPS

5/16"

SureLight Board 49M59 Sensor

FIGURE 17

NORMAL FLAME SIGNAL > 1.50 MICROAMPS LOW FLAME SIGNAL <

1.40 MICROAMPS

DROP OUT SIGNAL = 0.20 MICROAMPS

5/16"

SureLight Board 100870 Sensor

8. Clamshell Heat Exchanger

G61MPV units use an aluminized steel primary and stainless steel secondary heat exchanger assembly. Heat is transferred to the air stream from all surfaces of the heat exchanger. The shape of the heat exchanger ensures maximum efficiency.

The combustion air inducer pulls fresh air through the burner box. This air is mixed with gas in the burner ventur i and at the corbel orifices. The gas / air mixture is then burned at the entrance of each clamshell. Combustion gases are then pulled through the primary and secondary heat exchangers and exhausted out the exhaust vent pipe.

9. Flame Rollout Switches (S47)

Flame rollout switch S47 is a high temperature limit located on each side of the burner box. Each furnace is equipped with two identical switches. The limit is a N.C. SPST manual-reset limit connected in series with the primary limit S10. When S47 senses rollout, the circuit breaks and the ignition control immediately stops ignition and closes the gas valve.

If unit is running and flame rollout is detected, the gas valve will close and ignition control will be disabled. Rollout can be caused by a blocked heat exchanger, flue or lack of combustion air. The switch is factory set to trip (open) at 250°F and cannot be adjusted. The switch can be manually reset. To manually reset a tripped switch, push the reset button located on the control.

10. Primary Limit Control (S10)

Figure 18 shows the primary limit (S10) used on G61MPV units located in the heating vestibule panel. S10 is provided with a shield on some models (figure 18) and must not be removed. Note orientation of shield and limit if limit is replaced. When excess heat is sensed in the heat exchanger, the limit will open. Once the limit opens, the furnace control energizes the supply air blower and de−energizes the gas valve. The limit automatically resets when unit temperature returns to normal. The switch is factory set and cannot be adjusted.

11. Backup Secondary Limit Control (S113) (G61MPV−090, 110, 135 only)

Backup secondary limit control S113 is a N.C. auto−reset switch located on the combustion air inducer. S113 acts as a backup to primary limit S10 in the event of an indoor blower failure. S113 contacts open when temperature on the CAI reaches 142°.

12. Gas Valve (GV1)

The G61MPV uses a two−stage gas valve manufactured by Honeywell (figure 49) or White Rodgers (figure 50). The valves are internally redundant to assure safety shut−off. If the gas valve must be replaced, the same type valve must be used.

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

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

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

The burner box is sealed and operates under a negative pressure. A pressure hose is connected from the burner box to the gas valve. The gas valve senses the pressure in the burner box and changes gas valve outlet (manifold) pressure based on changes in the burner box pressure. The intent is to compensate for different vent configurations which can greatly affect the rate of the unit.

Page 47

FIGURE 18

PRIMARY LIMIT LOCATION

limit faces shield

limit shield

090, −110 and

−135 only

13. Combustion Air Inducer Prove Switch (S18)

All G61MPV units are equipped with combustion air prove switches located on the combustion air inducer housing. G61MPV−070, −071, −090, −091, −110, −111 and −135 model units are equipped with two dual prove switch assemblies" consisting of two switches. See figure 19. The G61MPV−045 units have two single swithes as shown in figure 20. The switches are connected to the cold end header box by means of a flexible hose that monitors negative air pressure in the cold end header box.

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

On heat demand (first or second stage) the switch senses that the combustion air inducer is operating. It closes a circuit to the furnace control when pressure inside the cold end header box decreases to a certain set point. Set points vary depending on unit size. See tables 29 through 34. The pressure sensed by the switch is negative. If the air intake vent pipe or outlet vent pipe becomes obstructed during operation, the switch senses a change of negative pressure and opens the circuit to the furnace control and gas valve. A bleed port on the switch allows relatively dry air in the vestibule to purge switch tubing, to prevent condensate build up.

The switch is factory set and is not field adjustable. If switch is closed or jumpered, the control will not initiate ignition at start up.

WARNING

The prove switch is a safety shut−down control in the furnace and must not be jumpered for any reason.

FIGURE 19

DUAL COMBUSTION AIR PROVE SWITCH

(−070, −071, −090, −091, −110, −111 −135 SHOWN)

second

stage

first stage

positive

pressure

negative

pressure

To troubleshoot the prove switches, temporarily jumper them. The unit will not fire with the switches jumpered. Therefore, the prove switches must be bypassed after the combustion air inducer is activated. This will determine if the prove switches and furnace are operating properly. However, this may not indicate if the sealed combustion system is operating properly.

Checks of pressure differential can aid in troubleshooting. When measuring the pressure differential, readings should be taken at the prove switch. Lack of differential usually indicates problems in the intake or exhaust piping, b u t may indica t e problems in the heat exchanger, condensing coil, header boxes, combustion inducer or other components.

Page 48

Measuring pressure differential Figures 20 and 21

The differential pressure is the difference in pressure measured across the cold end header box orifice.

1 − Remove thermostat demand and allow unit to cycle

off.

2 − Install a tee in the negative (−) line and a tee in the positive

(+) line running from one of the prove switches to the cold end header box.

3 − Install a manometer with hose from the negative (−)

side of the manometer to the tee installed in the negative (−) line and with hose from the positive (+) side of the manometer to the tee in the positive (+) line.

NOTE − Both sides of the cold end header box are negative. However the (+) port reads less negative pressure than the (−) port.

FIGURE 20

Install tee’s in the

negative line and positive line then connect hoses to

manometer.

prove switches

orifice size

CAI & COLD END HEADER BOX ASSEMBLY

(−045 SHOWN)

cold end header box

FIGURE 21

Install tee’s in the

negative line and positive line then connect hoses to

manometer.

prove switches

orifice size

CAI & COLD END HEADER BOX ASSEMBLY

(−070, −071, −090, −091, −110, −111, −135 SHOWN)

negative and positive taps

(same on other side)

4 − Operate unit and observe manometer reading. Read-

ings will change as heat exchanger warms.

a. Take one reading immediately after start-up. b. Take a second reading after unit has reached steady state (approximately 5 minutes). This will be the pressure differential.

The pressure differential should be greater than those listed in tables 29 through 34.

5 − Remove thermostat demand and allow to cycle off.

6 − Remove manometer and tee’s. Reinstall combustion air

sensing hoses to the prove switch.

7 − Repeat steps 1 through 6 for the other prove switch.

14. Combustion Air Inducer (B6)

All G61MPV units use a two−speed combustion air inducer (CAI) to move air through the burners and heat exchanger during heating operation. The inducer uses a PSC 120VAC motor. The motor operates during all heating operation and is controlled by the ignition control A92. Inducer operates continuously while there is a call for heat. The burner ignition control will not proceed with the ignition sequence until combustion air inducer operation is sensed by the proving switches.

The CAI is installed on the cold end header box. The cold end header box is a single piece made of hard plastic. The box has an internal channel where the combustion air inducer creates negative pressure at unit start up. The channel contains an orifice used to regulate flow created by the CAI. The box has pressure taps for the CAI prove switch hoses.

The prove switches measure the pressures across the CAI orifice or difference in the channel and the box. A window is provided on the bottom right hand side of the box to indicate orifice size. See figure 21. See table 28 for orifice size per unit. If replacement is necessary the

gaskets used to seal the box to the vestbule panel and the CAI to the box, must also be replaced.

Page 49

TABLE 28

G61MPV Unit

C.A.I. Orifice Size

−045 0.719"

−070 0.938"

−071 0.880"

−090 1.063"

36C−090 only −9 and later 0.985"

−091 0.985"

−110 1.313"

−111 1.250"

−135 1.688"

TABLE 29

0’ to 4500’

G61MPV Unit

Set Point

Second Stage

Set Point

First Stage

−045 0.95" 0.95"

−070 0.95" 0.55"

−090 0.85" 0.50"

−110 0.95" 0.55"

−135 0.60" 0.35"

TABLE 30

0’ to 2000’ 95% Furnaces

G61MPV Unit

Set Point

Second Stage

Set Point

First Stage

−071 0.95" 0.55"

−091 1.50" 0.90"

−111 1.15" 0.65"

TABLE 31

2001’ to 7500’ 95% Furnaces

G61MPV Unit

Set Point

Second Stage

Set Point

First Stage

−071 0.85" 0.70"

−091 1.30" 0.90"

−111 0.95" 0.55"

TABLE 32

7501’ to 10,000’ 95% Furnaces

G61MPV Unit

Set Point

Second Stage

Set Point

First Stage

−071 0.75" 0.70"

−091 1.20" 0.90"

−111 0.85" 0.50"

TABLE 33*

4501’ to 7500’

G61MPV Unit

Set Point

Second Stage

Set Point

First Stage

−045 0.95" 0.95"

−070 0.95" 0.55"

−090 0.75" 0.50"

−110 0.85" 0.50"

−135 0.55" 0.35"

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

TABLE 34*

7501’ to 10,000’

G61MPV Unit

Set Point

Second Stage

Set Point

First Stage

−045 0.95" 0.95"

−070 0.85" 0.50"

−090 0.60" 0.35"

−110 0.85" 0.50"

−135 0.55" 0.35"

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

Page 50

II−PLACEMENT AND INSTALLATION

TABLE 35

OUTDOOR TERMINATION KITS AND CORRESPONDING EQUIVALENCIES

UNIT

MODEL

VENT

PIPE

DIA.

(in.)

Vent Pipe Length Equivalency (feet)

Outdoor

Exhaust

Accelerator

(Dia. X

Length)

Outdoor

Exhaust

Accelerator

(Dia. X

Length)

1−1/2" Con-

centric Kit

Concentric

Kit

Concen-

tric Kit

2" Wall

Plate Kit

3" Wall

Plate Kit

2" Wall

Ring Kit

1−1/2" X 12"

2" X 12"

71M80

44W92

69M29

44W92

60L46

44W93

22G44

or 30G28

44J40

or 81J20

15F74

36B−045

2 4

Not

Allowed

Not

Allowed

Not

Allowed

4 4* 4

2−1/2 5

Not

Allowed

Not

Allowed

Not

Allowed

5 5* 5

3 7

Not

Allowed

Not

Allowed

Not

Allowed

7 7* 7

4 14

Not

Allowed

Not

Allowed

Not

Allowed

14 14* 14

36B−070 36B−071

2 4

Not

Allowed

Not

Allowed

Not

Allowed

4 4* 4

2−1/2 5

Not

Allowed

Not

Allowed

Not

Allowed

5 5* 5

3 8

Not

Allowed

Not

Allowed

Not

Allowed

8 8* 8

4 14

Not

Allowed

Not

Allowed

Not

Allowed

14 14* 14

36C−090 60C−090 60C−091

Not

Allowed

Not

Allowed

3 3

Not

Allowed

1 1**

2−1/2

Not

Allowed

Not

Allowed

6 6

Not

Allowed

2 2**

Not

Allowed

Not

Allowed

6 6

Not

Allowed

2 2**

Not

Allowed

Not

Allowed

12 12

Not

Allowed

4 4**

60C−110 60C−111

Not

Allowed

Not

Allowed

3 3

Not

Allowed

1 1**

2−1/2

Not

Allowed

Not

Allowed

6 6

Not

Allowed

2 2***

Not

Allowed

Not

Allowed

6 6

Not

Allowed

2 2***

Not

Allowed

Not

Allowed

12 12

Not

Allowed

4 4***

60D−135

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

6 6***

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

10 10***

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

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

***For use only in non−direct vent applications, when snow riser is not required. Requires field−provided and installed 2" exhaust accelerator.

 Termination kits 44W92, 44W93, 30G28 & 81J20 are ULC−636 approved for Canadian Installation.

 The 44W92 Concentric kit is provided with a 1−1/2" accelerator which must be installed on the exhaust outlet when this kit is used with the G61MPV−36B−045, G61MPV−36B−070 & 071 furnaces.

Page 51

A−Vent Piping Guidelines

The G61MPV 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 36 and 37. Table 36 lists the minimum equivalent vent pipe lengths permitted. Table 37 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 38.

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

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 − On G61MPV−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. On G61MPV−135, sweep elbows must be used for all 90° elbows in the venting system when 3" vent pipe is used. Sweep elbows are recommended for use in vent systems of other G61MPV units.

FIGURE 22

Exhaust Pipe Offset

*12" Min.

Upflow and Downflow Application

Rooftop Termination

Upflow and Downflow Application

Side Wall Termination

Horizontal Application

Rooftop Termination

Horizontal Application

Side Wall Termination

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

Page 52

Use the following steps to correctly size vent pipe diameter. 1 − Determine the vent termination and its corresponding equivalent feet value according to table 35.

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 37 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.

IMPORTANT

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

TABLE 36

MINIMUM VENT PIPE LENGTHS

G61MPV

MODEL

MIN. EQUIV.

VENT LENGTH

EXAMPLE

045, 070, 071, 090,

091

15 ft.*

5 ft. plus 2 elbows of 2", 2−1/2", 3"

or 4" diameter pipe

110, 111**

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

diameter pipe

135***

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

diameter pipe

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

**G61MPV−60C−110 must have 90° street ell (supplied) installed directly into unit flue collar.

***G61MPV−60D−135 must have 3" to 2" reducing ell (supplied) installed directly into unit flue collar.

TABLE 37

MAXIMUM VENT PIPE LENGTHS

ALTITUDE

G61MPV

MODEL

MAXIMUM EQUIVALENT VENT

LENGTH FEET

2" dia. 2−1/2" dia. 3" dia. 4" dia.

0 − 4500

(0 − 1371 m)

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

4501−7500

(1372−2286 m)

045 59 65 77 234 070 59 65 78 214

0701

†

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

7501 − 10000

(2287 − 3048

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

n/a −− Not allowed. *G61MPV−60C−110 must have 90° street ell (supplied) installed directly into unit flue collar. **G61MPV−60D−135 must have 3" to 2" reducing ell (supplied) installed directly into unit flue collar. †On G61MPV−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 G61MPV units.

‡ On G61MPV−60D−135 units, sweep elbows must be used for all 90° elbows in the vent system when 3" pipe is used.

B−PVC 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.

Page 53

NOTE − Furnace flue collar and air inlet fitting are both made of ABS material. Usetransition 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 pipe 1/4 turn during assembly (but not after pipe is fully inserted) to distribute cement evenly.

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.

C− Venting Practices

The thickness of construction through which vent pipes may be installed is 24" (610mm) maximum and 3/4" (19mm) minimum. If a G61MPV 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 piping.

2. Secure all joints so that they are gas-tight using approved 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.

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 (Figures 24 and 25)

NOTE − A 2" diameter PVC street ell is located on the blower deck of 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 24. A 3" to 2" PVC reducing ell is located on the blower deck of the 60D−135 units. In upflow 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 cement joints should be made according to the specifications outlined in ASTM D 2855. Refer to pipe and fittings specifications and gluing procedures.

IMPORTANT

Exhaust piping and condensate trap must be installed on the same side of the unit in upflow and dowflow applications.

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" vent plug into the unused flue collar.

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.

FIGURE 23

STRAPPING

(metal, plastic

or large wire

ties)

Page 54

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)

FIGURE 24

VENT PLUG

(Must be

glued in

place)

PLUG

CONDENSATE

TRAP

(Must be installed

on same side as

exhaust piping)

PLUG

G61MPV−110, −111,

−135 with

3" OR 4" vent pipe

G61MPV−070,

−071, −090, −091

with 2−1/2", 3", or

4" vent pipe

TRANSITION (use only if 4"

pipe is

required)

2" max length

2−1/2", 3", OR

TRANSITION

G61MPV−110,

−111 with

2−1/2", 3", OR 4"

vent pipe

*2"

TRANSITION

2−1/2", 3", OR

45°

MAX

45°

MAX

SIDE VIEW

*2" diameter street elbow provided.

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

3" to 2" REDUCING ELBOW

(provided)

2" max

length

FIGURE 25

TYPICAL EXHAUST PIPE CONNECTIONS

HORIZONTAL DIRECT OR

NON−DIRECT VENT APPLICATIONS

(Horizontal Right−Hand Air Discharge Application Shown)

2"*

2−1/2",

3", OR

*Limit pipe length to 2" in G61MPV−110, −111 and −135 applications.

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

TRANSITION

G61MPV−36B−045 G61MPV−36B−070 G61MPV−36B−071 G61MPV−36C−090 G61MPV−60C−090 G61MPV−60C−091 G61MPV−60C−110* G61MPV−60C−111* G61MPV−60D−135*

G61MPV−36B−045 G61MPV−36B−070 G61MPV−36B−071 G61MPV−36C−090 G61MPV−60C−090 G61MPV−60C−091

Intake Piping

The G61MPV 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 G61MPV 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 − Cement intake piping in slip connector located on the

side of the burner box.

2 − Use a 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" plug into the unused air intake con-

nector on the opposite side of the cabinet.

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 26 for pipe sizes.

Page 55

TYPICAL AIR INTAKE PIPE CONNECTIONS

UPFLOW OR DOWNFLOW DIRECT VENT APPLICATIONS

(Right−Hand Exit in Upflow Application Shown)

FIGURE 26

PLUG

(Must be

glued in

place)

*Limit pipe length to4" in G61MPV−110, −111 and −135 applications.

G61MPV−36B−045 G61MPV−36B−070 G61MPV−36B−071 G61MPV−36C−090 G61MPV−60C−090 G61MPV−60C−091

G61MPV−36B−045 G61MPV−36B−070 G61MPV−36B−071 G61MPV−36C−090 G61MPV−60C−090 G61MPV−60C−091 G61MPV−60C−110* G61MPV−60C−111*

G61MPV−36B−045 G61MPV−36B−070 G61MPV−36B−071 G61MPV−36C−090 G61MPV−60C−090 G61MPV−60C−091 G61MPV−60C−110* G61MPV−60C−111* G61MPV−60D−135*

2

2*

2

2*

2−1/2",

3" OR

4

TRANSITION

2"*

TRANSITION

2−1/2",

3" OR

4

FIGURE 27

TYPICAL AIR INTAKE PIPE CONNECTIONS

HORIZONTAL DIRECT VENT APPLICATIONS

(Horizontal Right−Hand Air Discharge Application Shown)

2”*

2”

2”*

2”

TRANSITION

2”*

2−1/2”,

3” OR 4”

2−1/2”,

3” OR 4”

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

−111 and −135 applications.

2”

G61MPV−36B−045 G61MPV−36B−070 G61MPV−36B−071 G61MPV−36C−090 G61MPV−60C−090 G61MPV−60C−091 G61MPV−60C−110* G61MPV−60C−111* G61MPV−60D−135*

G61MPV−36B−045 G61MPV−36B−070 G61MPV−36B−071 G61MPV−36C−090 G61MPV−60C−090 G61MPV−60C−091 G61MPV−60C−110* G61MPV−60C−111*

G61MPV−36B−045 G61MPV−36B−070 G61MPV−36B−071 G61MPV−36C−090 G61MPV−60C−090 G61MPV−60C−091

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.

FIGURE 28

PLUG

(Must be

glued in

place)

TYPICAL AIR INTAKE PIPE CONNECTIONS

UPFLOW OR HORIZONTAL NON−DIRECT

VENT APPLICATIONS

(Right−Hand Exit in Upflow Application Shown)

6 in. Max.

INTAKE

DEBRIS

SCREEN

(Provided)

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

Page 56

TYPICAL AIR INTAKE PIPE CONNECTIONS

DOWNFLOW NON−DIRECT VENT APPLICATIONS

(Right−Hand Exit in Downflow Applications Shown)

FIGURE 29

PLUG

(Must be

glued in

place)

6 in. Max.

PLUG

(Must be

glued in

place)

Downflow Additive Flloor Base

18 in.

Downflow

Evaporator

Coil

2" SWEEP

ELL

2" SWEEP ELL

INTAKE DEBRIS

SCREEN

(Provided)

INTAKE

DEBRIS

SCREEN

(Provided)

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

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

air intake screen to route the intake piping as shown in figures 28 and 29. 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 G61MPV 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 evaporator coil, the intake air routing should be modi-

fied as shown in figure 29.

2 − Use a 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" plug into the unused air intake con-

nector on the opposite side of the cabinet.

Testing for Proper Venting and Sufficient Combustion Air

(Non−Direct Vent Applications Only)

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 G61MPV gas furnace has been started, the following test should be conducted to ensure proper venting and sufficient combustion air has been provided to the G61MPV, as well as to other gas-fired appliances which are separately vented. 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 a match or candle to test for spillage

of flue gases at the draft hood relief opening after 5

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

above tests, the venting system must be corrected or

sufficient combustion/make-up air must be provided.

Page 57

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.

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 G61MPV 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 G61MPV 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 30 or 31. 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 58

FIGURE 30

VENT TERMINATION CLEARANCES

FOR NON−DIRECT VENT INSTALLATIONS IN THE USA AND CANADA

INSIDE CORNER

DETAIL

VENT TERMINAL

AIR SUPPLY INLET

AREA WHERE TERMINAL IS NOT PERMITTED

Fixed

Closed

Operable

Fixed

Closed

Operable

A =

B =

C =

D =

E =

F =

G =

H =

I =

J =

K =

L =

M =

US Installations

Canadian Installations

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

above average snow accumulation.

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

above average snow accumulation.

Clearance above grade, veranda,

porch, deck or balcony

Clearance to window or

door that may be opened

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

1 foot (30 cm) above opening

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)

Clearance to permanently

closed window

Vertical clearance to ventilated soffit

located above the terminal within a

horizontal distance of 2 feet (mm)

from the center line of the terminal

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-

pliance

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

* 12"

* Equal to or greater than soffit depth.

* 3 feet (.9m)

* 12"

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)

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

(3m) horizontally

6 feet (1.8m)

7 feet (2.1m)

12 inches (305mm)

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

 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.

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

1 foot (30 cm) above opening

7 feet (2.1m)

* Equal to or greater than soffit depth.

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

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

above the meter / regulator assembly

*12 inches (305mm)

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

*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 59

FIGURE 31

VENT TERMINATION CLEARANCES

FOR DIRECT VENT INSTALLATIONS IN THE USA AND CANADA

INSIDE CORNER

DETAIL

VENT TERMINAL

AIR SUPPLY INLET

AREA WHERE TERMINAL IS NOT PERMITTED

Fixed

Closed

Operable

Fixed

Closed

Operable

A =

B =

C =

D =

E =

F =

G =

H =

I =

J =

K =

L =

M =

US Installations

Canadian Installations

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

above average snow accumulation.

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

above average snow accumulation.

Clearance above grade, veranda,

porch, deck or balcony

Clearance to window or

door that may be opened

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)

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)

Clearance to permanently

closed window

Vertical clearance to ventilated soffit

located above the terminal within a

horizontal distance of 2 feet (mm)

from the center line of the terminal

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-

pliance

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

* 12"

* 3 feet (.9m)

* 7 feet (2.1m)

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)

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)

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

(3m) horizontally

6 feet (1.8m)

7 feet (2.1m)

12 inches (305mm)

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

 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.

* 12"

* Equal to or greater than soffit depth

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

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

* No minimum to outside corner

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

above the meter / regulator assembly

3 feet (.9m)

* 3 feet (.9m)

*12 inches (305mm)

Page 60

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 32 through 42 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. On roof terminations, the intake piping should terminate straight down using two 90° elbows (See figure

32).

4. Exhaust piping must terminate straight out or up as shown. 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 38.

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

FIGURE 32

UNCONDITIONED

ATTIC SPACE

1/2" (13mm) FOAM

INSULATION IN

UNCONDITIONED

SPACE

SIZE TERMINATION

PIPE PER TABLE 38.

3"(76mm) MAX.

12" (305mm) ABOVE

AVERAGE SNOW

ACCUMULATION

3" (76mm) OR

2" (51mm) PVC

PROVIDE SUPPORT

FOR INTAKE AND

EXHAUST LINES

8" (203mm) MIN

Inches(mm)

DIRECT VENT ROOF TERMINATION KIT

(15F75 or 44J41)

FIGURE 33

FIELD SUPPLIED WALL TERMINATION OR

(15F74) WALL RING TERMINATION KIT

See venting table 37 for maximum venting lengths with this arrangement.

* Use wall support every 24" (610 mm). Use two wall supports if extension is greater than 24" (610 mm) but less than 48" (1219 mm). NOTE − One wall support must be 6" (152 mm) from top of each pipe (intake and exhaust)

2" (51mm)

Vent Pipe

3" (76mm)

Vent Pipe

A−Minimum clearance

above grade or average

snow accumulation

B−Maximum horizontal separation between

intake and exhaust

C−Minimum from

end of exhaust to

inlet of intake

D−Maximum exhaust

pipe length

E−Maximum wall support

distance from top of each

pipe (intake/exhaust)

12" (508MM) 12" (508MM)

6" (152MM) 6" (152MM)

8" (203MM) 8" (203MM)

12" (305MM) 20" (508MM)

6" (152MM) 6" (152MM)

NOTE − FIELD PROVIDED

REDUCER MAY BE

REQUIRED TO ADAPT

LARGER VENT PIPE SIZE

TO TERMINATION

SIZE TERMINATION

PER TABLE 38

1/2" (13mm) ARMAFLEX

INSULATION IN UN-

CONDITIONED SPACE

STRAIGHT

APPPLICATION

* WALL

SUPPORT

1/2" (13mm) ARMAFLEX INSULATION

IN UNCONDITIONED SPACE

EXTENDED

APPLICATION

Page 61

FIGURE 34

FIELD SUPPLIED WALL TERMINATION OR

(15F74) WALL RING TERMINATION KIT

With INTAKE ELBOW

See venting table 37 for maximum venting lengths with this arrangement.

2" (51mm)

Vent Pipe

3" (76mm)

Vent Pipe

12" (508MM) 12" (508MM)

6" (152MM) 6" (152MM)

6" (152MM)

12" (305MM) 20" (508MM)

6" (152MM) 6" (152MM)

6" (152MM)

A−Minimum clearance

above grade or average

snow accumulation

B−Maximum horizontal

separation between

intake and exhaust

C−Minimum from

end of exhaust to

inlet of intake

D−Maximum exhaust

pipe length

E−Maximum wall support

distance from top of each

pipe (intake/exhaust)

NOTE − FIELD PROVIDED

REDUCER MAY BE

REQUIRED TO ADAPT

LARGER VENT PIPE SIZE

TO TERMINATION

SIZE TERMINATION

PER TABLE 38

1/2" (13mm) ARMAFLEX

INSULATION IN UN-

CONDITIONED SPACE

STRAIGHT

APPPLICATION

* WALL

SUPPORT

1/2" (13mm) ARMAFLEX INSULATION

IN UNCONDITIONED SPACE

EXTENDED

APPLICATION

TABLE 38

EXHAUST PIPE TERMINATION SIZE REDUCTION

G61MPV

MODEL

Exhaust Pipe Size

Termination

Pipe Size

045, 070, 071

2" (51mm), 2−1/2" (64mm),

3" (76mm) or 4" (102mm)

1−1/2" (38mm)

090, 091 2" (51mm)

110, 111 2" (51mm)

135

3" (76mm) or 4" (102mm)

2" (51mm)

5. On field supplied terminations for side wall exit, exhaust piping may extend a maximum of 12 inches (305mm) for 2" PVC and 20 inches (508mm) for 3" (76mm) PVC beyond the outside wall. Intake piping should be as short as possible. See figures 33 and 34.

6. On field supplied terminations, a minimum distance between the end of the exhaust pipe and the end of the intake pipe without a termination elbow is 8" and a minimum distance of 6" with a termination elbow. See figures 33 and 34.

7. 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 24" (610mm) as shown in figures 33 and 34. In addition, close coupled wall termination kits must be extended for use in this application. See figures 40 and 41. When exhaust and intake piping must be run up an outside wall, the exhaust piping must be terminated with pipe sized per table 38.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.

8. Based on the recommendation of the manufacturer, a multiple furnace installation may use a group of up to four terminations assembled together horizontally, as shown in figure 37.

Page 62

FIGURE 35

DIRECT VENT CONCENTRIC ROOFTOP TERMINATION

71M80, 69M29 or 60L46 (US)

41W92 or 41W93 (Canada)

Minimum

Above Average

Snow

Accumulation

SHEET METAL STRAP

(Clamp and sheet metal strap must be field installed to support the weight of the termination kit.)

FLASHING

(Not Furnished)

CLAMP

FIELD−PROVIDED

REDUCER MAY BE REQUIRED

TO ADAPT LARGER VENT

PIPE SIZE TO TERMINATION

INTAKE

1 1/2" (38mm) accelerator

provided on 71M80 &

44W92 kits for

G61MPV−36B−045,

36B−070 & 36B−071

12” (305mm)

12" (305mm) Min.

above grade or

average snow ac-

cumulation.

FIGURE 36

DIRECT VENT CONCENTRIC WALL TERMINATION

71M80, 69M29 or 60L46 (US)

41W92 or 41W93 (Canada)

INTAKE

AIR

EXHAUST

AIR

INTAKE

AIR

INTAKE

AIR

EXHAUST

AIR

OUTSIDE

WALL

GRADE

CLAMP

(Not Furnished)

FIELD−PROVIDED

REDUCER MAY BE

REQUIRED TO ADAPT

LARGER VENT PIPE

SIZE TO TERMINATION

1 1/2" (38mm) accelerator

provided on 71M80 &

44W92 kits for

G61MPV−36B−045,

36B−070 & 36B−071

FIGURE 37

EXHAUST

VENT

INTAKE

AIR

5−1/2"

(140mm)

Front View

12"

(305mm)

(127mm)

18" MAX.

(457mm)

EXHAUST VENT

INTAKE

AIR

OPTIONAL VENT TERMINATION FOR MULTIPLE UNIT

INSTALLATION OF DIRECT VENT WALL TERMINATION KIT

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

Inches (mm)

Side View

12" (305mm) Min.

above grade or

average snow ac-

cumulation.

optional intake elbow

FIGURE 38

1/2" (13mm) Foam Insulation

in Unconditioned Space

EXHAUST VENT

INTAKE AIR

OUTSIDE WALL

EXHAUST VENT

INTAKE

AIR

Front View

Top View

DIRECT VENT WALL TERMINATION KIT

(30G28 or 81J20)

6 (152mm) MIN.

SIZE

TERMINATION

PIPE PER

TABLE 38.

FIELD−PROVIDED

REDUCER MAY

BE REQUIRED TO

ADAPT LARGER

VENT PIPE SIZE

TO TERMINATION

FIGURE 39

1/2" (13mm) Foam Insulation

in Unconditioned Space

EXHAUST VENT

INTAKE AIR

OUTSIDE WALL

EXHAUST VENT

INTAKE

AIR

Front View

Top View

DIRECT VENT WALL TERMINATION KIT

(22G44 or 44J40)

8" (206mm) MIN.

SIZE

TERMINATION

PIPE PER

TABLE 38.

FIELD−PROVIDED

REDUCER MAY

BE REQUIRED TO

ADAPT LARGER

VENT PIPE SIZE

TO TERMINATION

Page 63

FIGURE 40

12” (305 mm) Minimum

Above Grade or Average

Snow Accumulation

1/2” (13 mm)

FOAM INSULATION

(Field Furnished)

5” (127 mm)

5−1/2”

(140 mm)

EXHAUST

AIR

INTAKE

AIR

GRADE

12”

(305 mm)

INTAKE

AIR

EXHAUST

AIR

GRADE

12” (305 mm) Max. for 2” (51 mm) Dia. Exhaust 20” (508 mm) Max. for 3” (76 mm) Dia. Exhaust

WALL SUPPORT*

12” (305 mm) Max. for 2” (51 mm) Dia. Exhaust 20” (508 mm) Max. for 3” (76 mm) Dia. Exhaust

12” (305 mm) Minimum

Above Grade or Average

Snow Accumulation

WALL TERMINATION KITS (CLOSE−COUPLE)

EXTENDED VENT FOR GRADE CLEARANCE

2 inch (51 mm) 22G44 (US)

3 inch (76 mm) 44J40 (US)

6” (152 mm)

Maximum

If Intake and Exhaust Pipe is less than 12 in. (305 mm)

above snow accumulation or other obstructions, field fabricated piping must be installed.

8” (203 mm) Min. for 2” (51 mm) & 3” (76 mm) DIA. pipe

between the end of the exhaust pipe and intake pipe

8” (203 mm) Min.

*Use wall support every 24" (610). Use two supports if

extension is greater than 24" but less than 48".

FIELD−PROVIDED

REDUCER MAY BE REQUIRED TO ADAPT

LARGER VENT PIPE SIZE TO TERMINATION

FIGURE 41

12” (305 mm) Minimum

Above Grade or Average

Snow Accumulation

1/2” (13 mm)

FOAM INSULATION

(Field Furnished)

5” (127 mm)

5−1/2”

(140 mm)

EXHAUST

AIR

INTAKE

AIR

GRADE

12”

(305 mm)

INTAKE

AIR

EXHAUST

AIR

GRADE

WALL SUPPORT*

12” (305 mm) Minimum

Above Grade or Average

Snow Accumulation

WALL TERMINATION KITS (CLOSE−COUPLE)

EXTENDED VENT FOR GRADE CLEARANCE

2 inch (51 mm) 30G28 (WTK Canada) 3 inch (76 mm) 81J20 (WTK Canada)

See Installation Instructions for additional information.

6” (152 mm)

Maximum

If Intake and Exhaust Pipe is less than 12 in. (305 mm) above snow accumulation or other obstructions, field fabricated piping must be installed.

12” (305 mm) Max. for 2” (51 mm) Dia. Exhaust 20” (508 mm) Max. for 3” (76 mm) Dia. Exhaust

6” (152 mm)

Minimum

6” (152 mm)

Minimum

*Use wall support every 24" (610). Use two supports if

extension is greater than 24" but less than 48".

FIELD−PROVIDED

REDUCER MAY BE REQUIRED TO ADAPT

LARGER VENT PIPE SIZE TO TERMINATION

Page 64

G61MP DIRECT VENT APPLICATION

USING EXISTING CHIMNEY

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 42

8" − 12"

(203mm − 305mm)

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

ALTERNATE

INTAKE PIPE

INSULATION (optional)

EXTERIOR

PORTION OF

CHIMNEY

INSULATE

TO FORM

SEAL

SHEET

METAL TOP

PLATE

*SIZE TERMINATION

PIPE PER TABLE 38.

Minimum 12" (305MM)

above chimney top

plate or average snow

accumulation

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 43 through 46 show typical terminations.

1. Exhaust piping must terminate straight out or up as shown. The termination pipe must be sized as listed in table 38.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 exit, exhaust piping may extend a maximum of 12 inches (305mm) for 2" PVC and 20 inches (508mm) for 3" (76mm) PVC beyond the outside wall. See figure 44.

FIGURE 43

NON−DIRECT VENT ROOF TERMINATION KIT

(15F75 or 44J41)

UNCONDITIONED

ATTIC SPACE

3" (76mm) OR

2" (51mm) PVC

PROVIDE SUPPORT

FOR EXHAUST LINES

12" (305mm)

ABOVE AVE.

SNOW

ACCUMULATION

SIZE TERMINATION

PIPE PER TABLE

38.

1/2" (13mm) FOAM

INSULATION

FIGURE 44

1/2" (13mm) ARMAFLEX

INSULATION IN

UNCONDITIONED SPACE

PVC REDUCER

1/2" (13mm)

ARMAFLEX

INSULATION

NON−DIRECT VENT FIELD SUPPLIED WALL TERMINATION OR

(15F74) WALL TERMINATION KIT

SIZE TERMINATION

PIPE PER TABLE 38.

FIELD−PROVIDED

REDUCER MAY

BE REQUIRED TO

ADAPT LARGER

VENT PIPE SIZE

TO TERMINATION

12" MIN.

(305mm)

Above Grade or

average snow

accumulation

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

3. If exhaust piping must be run up a side wall to position above snow accumulation or other obstructions, piping must be supported every 24 inches (610mm) as shown in figure 45. When exhaust piping must be run up an outside wall, any reduction in exhaust pipe size must be done after the final elbow.

Page 65

FIGURE 45

12" (305mm)

ABOVE GRADE OR

AVERAGE SNOW

ACCUMULATION

UNCONDITIONED

SPACE

1/2" (13mm) FOAM

INSULATION

1/2" (13mm) FOAM

INSULATION IN

UNCONDITIONED

SPACE

*WALL SUPPORT

OUTSIDE WALL

SIZE TERMINATION PIPE PER

TABLE 38.

FIELD−PROVIDED

REDUCER MAY BE

REQUIRED TO

ADAPT LARGER

VENT PIPE SIZE TO

TERMINATION

*Use wall support every 24" (610). Use two supports if extension is

greater than 24" but less than 48".

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

NON−DIRECT VENT FIELD SUPPLIED WALL TERMINATION

EXTENDED OR (15F74) WALL TERMINATION VENT PIPE

EXTENDED

6" (152mm)

Max

FIGURE 46

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

EXTERIOR

PORTION OF

CHIMNEY

INSULATE

TO FORM

SEAL

SHEET

METAL TOP

PLATE

SIZE TERMINATION

PIPE PER TABLE 38.

G61MPV NON−DIRECT VENT APPLICATION

USING EXISTING CHIMNEY

Minimum 12" (305MM)

above chimney top

plate or average snow

accumulation

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 condensate trap should extend below the unit. A 5−1/2" service clearance is required for the condensate trap. Refer to figure 47 for condensate trap locations.

FIGURE 47

CONDENSATE TRAP LOCATIONS

(Unit shown in upflow position)

Horizontal

left and

optional

downflow

Horizontal

right and

optional

downflow

Optional

upflow

Optional

upflow

NOTE − In upflow applications where side return air filter is installed on same side as the condensate trap, filter rack must be installed beyond condensate trap to avoid interference.

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

48.

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

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.

Page 66

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.

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.

CAUTION

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

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.

FIGURE 48

CONDENSATE ASSEMBLY

COUPLING

CAP

CONDENSATE TRAP

NIPPLE

TEE

VENT

CLEAN−OUT ACCESS

(both sides)

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

using screw driver.)

SCREW

O−RINGS

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

Page 67

III−START-UP A−Preliminary and Seasonal Checks

1 − Inspect electrical wiring, both field and factory installed

for loose connections. Tighten as required.

2 − Check voltage at disconnect switch. Voltage must be

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

B−Heating Start-Up

FOR YOUR SAFETY READ BEFORE OPERATING

WARNING

Shock and burn hazard.

G61MPV units are equipped with a hot surface ignition system. Do not attempt to light manually.

BEFORE LIGHTING the unit, smell all around the fur-

nace 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 G61MPV may be equipped with either a gas control knob or gas control lever. Use only your hand to push the lever or turn the gas control knob. Never use tools. If the the lever will not move or the knob will not push in or turn by hand, do not try to repair it. Force or attempted repair may result in a fire or explosion.

Placing the furnace into operation:

G61MPV units are equipped with a SureLight

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 SureLight

ignition system.

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.

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 49 and 50)

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

this section.

2 − Set the thermostat to the lowest setting.

3 − Turn off all electrical power to the unit.

4 − This furnace is equipped with an ignition device which

automatically lights the burners. Do not try to light the

burners by hand.

5 − Remove the upper access panel.

6 − Honeywell VR8205 Gas Valve − Turn knob on gas

valve clockwise

to OFF. Do not force. See figure

49.

White Rodgers 36E Gas Valve − Switch gas valve le-

ver to OFF. See figure 50 for the White Rodgers 36E

valve.

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.

HONEYWELL VR8205 Series Gas Valve

GAS VALVE SHOWN IN OFF POSITION

MANIFOLD

PRESSURE

TAP

LOW FIRE

ADJUSTMENT

SCREW

(under cap)

iNLET PRESSURE TAP

HIGH FIRE

ADJUSTMENT

SCREW

(under cap)

REFERENCE TO

BURNER BOX

hose barb in place of cap

FIGURE 49

Page 68

WHITE RODGERS 36E SERIES GAS VALVE

GAS VALVE SHOWN IN OFF POSITION

HIGH FIRE MANIFOLD

PRESSURE

ADJUSTMENT

ON SIDE

(under cap)

MANIFOLD

PRESSURE

TAP ON SIDE

INLET PRESSURE

TAP ON SIDE

LOW FIRE MANIFOLD

PRESSURE ADJUSTMENT

ON SIDE (under cap)

FIGURE 50

8 − Honeywell VR8205 Gas Valve − Turn knob on gas

valve counterclockwise

to ON. Do not force.

White Rodgers 36E Gas Valve − Switch gas valve lever to ON. See figure 50 for the White Rodgers 36E valve.

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.

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 − Honeywell VR8205 Gas Valve − Turn knob on gas

valve clockwise

to OFF. Do not force.

White Rodgers 36E Gas Valve − Switch gas valve lever to OFF.

5 − Replace the upper access panel.

C−Safety or Emergency Shutdown

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

D−Extended Period Shutdown

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

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

All units are C.S.A. (formally A.G.A. and C.G.A. combined) design certified without modifications. Refer to the G61MPV Installation Instruction.

B−Gas Piping

CAUTION

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

WARNING

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

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

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

C−Testing Gas Piping

IMPORTANT

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

When pressure testing gas lines, the gas valve must be disconnected and isolated. Gas valves can be damaged if subjected to more than 0.5psig (14" W.C.). See figure 51.

FIGURE 51

MANUAL MAIN SHUT−OFF VALVE

GAS VALVE

CAP

GAS PIPING TEST PROCEDURE

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

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

Page 69

D−Gas Pressure Adjustment

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 39 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.

TABLE 39

Gas Flow Rate (Ft.

/Hr.)

Seconds for 1

Revolution

Gas Meter Size

1/2 cu ft Dial 1 cu ft Dial

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

E−Check Manifold Pressure

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.

3 − Start unit on low heat (40% 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

40.

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.

CAUTION

Do not attempt to make adjustments to the gas valve.

TABLE 40

Manifold Pressure (Outlet)

Manifold Pressure at All Altitudes (in. w.g.)

Low Fire High Fire

Natural Gas LP/Propane Natural Gas LP/Propane

1.7 4.9 3.5 10.0

F− High Altitude

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 40 for manifold pressure and table 41 for required pressure switch changes and conversion kits at varying altitudes.

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.

Page 70

TABLE 41

Conversion Kit Requirements

Input

High Altitude

Orifice Kit

Natural Gas

Only

High Altitude Pressure Switch Kit

ORDER TWO EACH

LPG/Propane Kit LPG/Propane to

Natural Gas Kit

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

7501−10,000 ft.

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

−070 44W51 − − − − − − 56M23 44W48 44W50 44W49 44W49 + 44W51

−071 44W51 75M22 75M22 56M21 44W48 44W50 44W49 44W49 + 44W51

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

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

−110 44W51 − − − 56M23 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.

G− Proper Combustion

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

TABLE 42 High Heat

Unit

CO2%

For Nat

CO2%

For L.P.

G61MPV−36B−045 6.0 − 7.0 6.9 − 7.9

G61MPV−36B−070 6.5 − 7.6 7.4 − 8.4

G61MPV−36B−071 6.9 − 8.2 8.3 − 9.8

G61MPV−36C−090 6.9 − 8.0 7.8 − 8.8

G61MPV−60C−090 6.7 − 7.7 7.8 − 8.8

G61MPV−60C−091 7.6 − 8.9 8.7 − 10.2

G61MPV−60C−110 7.2 − 8.2 8.1 − 9.1

G61MPV−60C−111 7.5 − 8.8 8.7 − 10.2

G61MPV−60D−135 7.4 − 8.5 8.3 − 9.3

TABLE 43

Low Heat

Unit

CO2%

For Nat

CO2%

For L.P.

G61MPV−36B−045 4.3 − 5.3 4.8 − 5.8

G61MPV−36B−070 4.8 − 5.8 5.3 − 6.3

G61MPV−36B−071 5.0 − 6.2 5.7 − 7.0

G61MPV−36C−090 5.1 − 6.5 5.9 − 6.9

G61MPV−60C−090 5.1 − 6.5 5.9 − 6.9

G61MPV−60C−091 5.4 − 6.7 6.2 − 7.4

G61MPV−60C−110 5.3 − 6.5 6.1 − 7.1

G61MPV−60C−111 5.3 − 6.5 6.1 − 7.4

G61MPV−60D−135 6.5 − 7.5 6.7 − 7.7

H− Condensate pH Range

The condensate is mildly acidic and can be measured with pH indicators. The pH scale is a measurement of acidity and alkalinity. The following scale shows the relative pH of some common liquids as compared with condensate of G61MPV units. The concentration of the acidity of all these fluids including the condensate is very low and harmless.

pH RANGE

0 1 2 3 4 5 6 7 8 9 10 11

Vinegar Wine Orange Juice Tomato Juice

Tap Water

G61 Condensate

pH Range

Increasing

Acidity

Increasing

Alkalinity

Page 71

I−Flame Signal

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

To Measure Flame Signal − Ignition Control:

A transducer (Part #78H5401 available from Lennox Repair Parts) is required to measure flame signal if meter used will not read a low micro amp signal. Seefigure52. The transducer converts microamps to volts on a 1:1 conversion. See figures 16 and 17 for flame signal. A digital readout meter must be u se d . The transducer plugs into most meters. See figure 53 for proper use of transducer.

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

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

2 − Turn off supply voltage to control.

3 − Disconnect ignition control flame sensor wire from the

flame sensor.

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

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

sor wire.

6 − Turn supply voltage on and close thermostat contacts to

cycle system.

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

reading. Remember 1 DC volt = 1 DC microamp.

SET DIAL TO MEASURE

VDC

(+)

(−) TO

FLAME SENSOR

NOTE−MUST USE DIGITAL METER

RED COLLAR

INDICATES

POSITIVE

LEAD

(+) TO

IGNITION

CONTROL

SENSOR

WIRE

FIGURE 53

(−)

V−TYPICAL OPERATING CHARACTERISTICS A−Blower Operation and Adjustment

1 − Blower operation is dependent on thermostat control

system.

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

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

3 − Depending on the type of indoor thermostat, blower

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

B−Temperature Rise

Temperature rise for G61MPV units depends on unit input, blower speed, blower horsepower and static pressure as marked on the unit rating plate. The blower speed must be set for unit operation within the range of TEMP. RISE °F" listed on the unit rating plate.

To Measure Temperature Rise:

1 − Place plenum thermometers in the supply and return air

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

2 − Set thermostat for heat call. Unit must operate on sec-

ond−stage heat. If using a single−stage thermostat fur-

nace must fire at least 10 minutes before switching to second−stage heat.

3 − After plenum thermometers have reached their high-

est and steadiest readings, subtract the two readings. The difference should be in the range listed on the unit rating plate. If the temperature is too low, decrease blower speed. If temperature is too high, first check the firing rate. Provided the firing rate is acceptable, increase blower speed to reduce temperature. To change blower speed taps see tables 9 and 11.

C−External Static Pressure

1 − Tap locations shown in figure 54. 2 − Punch a 1/4" diameter hole

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

3 − With only the blower motor running and the evaporator

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

4 − External static pressure drop must not be more than

0.8" W.C.

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

FIGURE 52

TRANSDUCER

(PART #78H5401)

FIGURE 54

STATIC PRESSURE TEST

Page 72

VI−MAINTENANCE

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

Filters should be inspected monthly. Clean or replace the filters when necessary to ensure proper furnace operation. Replacement filters must be rated for high velocity airflow. Table 44 lists recommended filter sizes.

TABLE 44

Furnace

Cabinet Size

Filter Size

Side Return Bottom Return

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)

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.

IMPORTANT

Safety glasses and surgical mask should be worn when cleaning heat exchanger and or burner 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. G61MPV−135 only − Remove and discard two additional shipping screws. See figure 55.

NOTE − If necessary, clean burners at this time. Follow procedures outlined in Burner Cleaning section.

8 − Loosen three clamps and remove flexible exhaust tee.

FIGURE 55

Remove and discard two shipping screws.

G61MPV−135 ONLY

9 − Remove 3/8 inch rubber cap from condensate drain

plug and drain. Replace cap after draining.

Page 73

10 − Disconnect condensate drain line from the conden-

sate trap. Remove condensate trap (it may be necessary to cut drain pipe). Remove screws that secure condensate collars to either side of the furnace and remove 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 secondary limit, if applicable. Remove four screws which secure 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. 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 as-

sembly to cabinet. Remove two screws from blower

rail which secure bottom heat exchanger flange. Re-

move 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 cabi-

net. 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.

Page 74

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. G61MPV−135 only − Remove and discard two additional shipping screws. See figure 55.

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 75

VII− Wiring and Sequence of Operation A−SureLight Board 49M59

Page 76

B−SureLight Board 49M59

Sequence depends on type thermostat used. G61MPV units are applicable for single stage or two stage thermostats. Both type thermostats are described below. Thermostat jumper E20 dictates which mode unit will operate in. See flow chart for more sequence detail.

SureLight Control Self Check

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

Two−Stage Thermostat, Two−Stage Heat. Jumper E20

set at TWO".

1− SureLight control energizes combustion air inducer B6

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

2− SureLight control begins 20 second ignitor warm up

period.

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

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

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

heat, ignitor de−energizes.

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

on low heat speed.

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

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

second−stage recognition period begins.

7− The combustion air inducer ramps up to high heat

speed.

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

energizes second stage heat.

9− B3 indoor blower ramps up to high heat speed.

Single−Stage Thermostat, Two−Stage Heat. Jumper

E20 set at SINGLE"

1− SureLight control energizes combustion air inducer B6

2− SureLight control begins 20 second ignitor warm up

period.

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

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

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

heat, ignitor de−energizes.

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

on low heat speed.

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

ond−stage heat delay period begins.

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

high heat speed.

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

energizes second−stage heat.

9− B3 indoor blower ramps up to high heat speed.

Page 77

C−Flow Chart SureLight Board 49M59

HEATING SEQUENCE OF OPERATION

NORMAL AND ABNORMAL HEATING MODE

CONTROL SELF−CHECK OKAY?

YES

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF. (RESET CONTROL BY

TURNING MAIN POWER OFF.) DS1 ON, DS2 ON

POLARITY REVERSED.

DS 1 −− FAST FLASH

DS 2 −− SLOW FLASH

POWER ON

POLARITY OKAY?

SIGNAL HOLDS UNTIL UNIT IS PROPERLY GROUNDED.

DS1 AND DS2 ALTERNATING FAST FLASH.

IS THERE A

PROPER GROUND?

IS VOLTAGE

ABOVE 75 VOLTS?

SIGNAL HOLDS UNTIL VOLTAGE RISES ABOVE 75 VOLTS.

DS1 AND DS2 ALTERNATING FAST FLASH.

YES

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF. INDOOR BLOWER OFF. CHECK FOR BROKEN IGNITOR OR OPEN IGNITER CIRCUIT. DS 1 AND DS 2 ALTERNATING FAST FLASH.

BURNER OFF?

(CONTINUOUS FLAME CHECK)

YES

GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

INDOOR BLOWER ON HEATING SPEED.

DS1 SLOW FLASH, DS2 OFF,

ON/OFF LED OFF

NORMAL OPERATION:

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

THERMOSTAT CALLS FOR HEAT:

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

YES

PRIMARY, SECONDARY AND BACKUP SECONDARY LIMIT

SWITCHES CLOSED?

YES

COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER ON. HAS PRIMARY, SECONDARY

OR BACKUP SECONDARY LIMIT RESET WITHIN 3 MINUTES?

DS1 SLOW FLASH, DS2 ON,

ON/OFF LED ON, HEAT LED ON.

ROLLOUT SWITCH CLOSED?

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

HAS MANUAL ROLLOUT SWITCH(ES) BEEN

RESET (CLOSED) WITHIN 3 MINUTES?

DS1 SLOW FLASH, DS2 ON,

ON/OFF LED ON, HEAT LED ON.

YES

FIRST (LOW) STAGE PRESSURE SWITCH

CONTACTS OPEN?

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

PRESSURE SWITCH IS DETECTED OPEN.

DS1 OFF, DS2 SLOW FLASH,

ON/OFF LED OFF, HEAT LED OFF.

YES

GAS VALVE OFF.

COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF.

CONTROL WILL NOT ATTEMPT SECOND−STAGE

OPERATION DURING THIS HEAT DEMAND.

FIRST−STAGE OPERATION WILL BE ATTEMPTED.

DS1 OFF, DS2 FAST FLASH,

ON/OFF LED OFF, HEAT LED ON.

TWO−STAGE OR SINGLE−STAGE THERMOSTAT

CALL FOR HEAT

COMBUSTION AIR INDUCER ON LOW SPEED.

DS1 AND DS2 SIMULTANEOUS FAST FLASH

CONTINUED ON NEXT PAGE

60−MINUTE LIMIT WATCHGUARD MODE.

GAS VALVE OFF, COMBUSTION AIR INDUCER

OFF, INDOOR BLOWER OFF WITH DELAY.

DS1 AND DS2 ALTERNATING SLOW FLASH,

ON/OFF LED OFF, HEAT LED ON.

YES

SECOND (HIGH) STAGE PRESSURE SWITCH

CONTACTS OPEN?

Page 78

HEATING SEQUENCE OF OPERATION

FIRST−STAGE (LOW FIRE) PRESSURE

SWITCH CLOSED WITHIN 2.5 MINUTES?

GAS VALVE OFF. COMBUSTION AIR INDUCER

OFF. INDOOR BLOWER OFF. UNIT WILL RETRY

AFTER 5−MINUTE WAIT PERIOD.

DS1 OFF, DS2 SLOW FLASH,

ON/OFF LED OFF, HEAT LED OFF.

YES

15−SECOND COMBUSTION AIR INDUCER

PRE−PURGE INITIATED BY CLOSED FIRST−STAGE

PRESSURE SWITCH (or 15 SECOND

INTER−PURGE PERIOD.)

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

IGNITOR WARM−UP (20 SECONDS)

DS1 AND DS2 SIMULTANEOUS FAST FLASH

IS VOLTAGE ABOVE 75 VOLTS?

COMBUSTION AIR INDUCER OFF, IGNITER OFF.

SIGNAL HOLDS UNTIL VOLTAGE RISES ABOVE 75 VOLTS.

DS1 AND DS2 ALTERNATING FAST FLASH.

YES

IS THERE A PROPER GROUND?

COMBUSTION AIR INDUCER OFF, IGNITER OFF.

SIGNAL HOLDS UNTIL UNIT IS PROPERLY GROUNDED.

DS1 AND DS2 ALTERNATING FAST FLASH.

COMBUSTION AIR INDUCER OFF, IGNITOR OFF.

SIGNAL HOLDS UNTIL IGNITOR IS REPLACED

OR RECONNECTED.

DS1 AND DS2 ALTERNATING FAST FLASH.

YES

AT END OF IGNITOR 20 SECOND WARM UP

PERIOD, 4−SECOND TRIAL FOR IGNITION.

GAS VALVE OPENS, IGNITOR ENERGIZED DURING

4−SECOND TRIAL UNTIL FLAME SENSED.

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

YES

4−SECOND FLAME STABILIZATION PERIOD.

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

FLAME RECTIFICATION CURRENT CHECK

CAN FLAME BE PROVEN WITHIN 4

SECONDS AFTER GAS VALVE OPENS?

(u0.16 microamps)

GAS VALVE OFF. COMBUSTION AIR

INDUCER ON. INDOOR BLOWER OFF.

DS1 SLOW FLASH, DS2 FAST FLASH,

ON/OFF LED OFF, HEAT LED 0N.

HAS CONTROL FAILED TO SENSE

FLAME FOR FIVE CONSECUTIVE TRIES

DURING A SINGLE HEAT DEMAND?

YES

THERMOSTAT CALLS FOR HEAT

DS1 AND DS2 SIMULTANEOUS FAST FLASH

(Refer to box A on previous page)

YES

FLAME PRESENT?

HAS CONTROL RESET IGNITION SEQUENCE

FOUR (4) TIMES?

DS1 SLOW FLASH, DS2 FAST FLASH,

ON/OFF LED OFF, HEAT LED ON .

YES

CONTINUED ON NEXT PAGE

YES

CONTINUED

IS IGNITOR INTACT AND CONNECTED?

WATCHGUARD MODE. GAS VALVE OFF,

COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF.

DS1 AND DS2 ALTERNATING SLOW FLASH.

ON/OFF LED 0FF, HEAT LED OFF.

IS 60−MINUTE RESET PERIOD COMPLETE?

Page 79

HEATING SEQUENCE OF OPERATION

LOW FLAME SIGNAL

(Does not affect control operation)

DS1 SLOW FLASH, DS2 FAST FLASH.

FLAME SIGNAL ABOVE

(w0.23 microamps)

YES

CONTINUED ON NEXT PAGE

YES

SINGLE−STAGE THERMOSTAT MODE

(E20 SET AT SINGLE")

TWO STAGE THERMOSTAT MODE

(E20 SET AT TWO")

YES

START SECOND−STAGE RECOGNITION

ON DELAY (10 OR 15 MINUTES).

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

45−SECOND INDOOR BLOWER ON DELAY BEGINS.

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

YES

PRIMARY, SECONDARY AND BACKUP SECONDARY

LIMITS AND ROLLOUT SWITCHES CLOSED?

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

ON/OFF LED ON, HEAT LED ON.

HAS PRIMARY, SECONDARY, BACKUP

SECONDARY OR ROLLOUT

SWITCH CLOSED WITHIN 3 MINUTES?

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

YES

FIRST−STAGE (LOW FIRE)

PRESSURE SWITCH CLOSED?

LIMIT SWITCH WATCHGUARD MODE.

GAS VALVE OFF, COMBUSTION AIR INDUCER OFF,

INDOOR BLOWER OFF WITH DELAY.

DS1 AND DS2 ALTERNATING SLOW FLASH,

ON/OFF LED OFF, HEAT LED OFF.

IS 60−MINUTE RESET PERIOD COMPLETE?

THERMOSTAT CALLS FOR HEAT.

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

SEE BOX A.

YES

GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

INDOOR BLOWER OFF AFTER DELAY.

DS1 OFF, DS 2 SLOW FLASH,

ON/OFF LED OFF, HEAT LED ON.

YES

FIRST−STAGE HEAT DEMAND SATISFIED?

DS1 AND DS2 SIMULTANEOUS SLOW FLASH.

GAS VALVE OFF, COMBUSTION AIR INDUCER

OFF FOLLOWING POST PURGE.

INDOOR BLOWER OFF WITH DELAY

DS1 AND DS2 SIMULTANEOUS SLOW FLASH

YES

SECOND−STAGE HEAT DEMAND.

SECOND−STAGE HEAT DEMAND REQUIRED?

DS1 AND DS2 SIMUTANEOUS SLOW FLASH.

SECOND STAGE PRESSURE SWITCH CLOSED?

ABNORMAL FLASH CODE.

NOTE − IF SECOND−STAGE PRESSURE SWITCH

WAS ORIGINALLY FOUND CLOSED,

ABNORMAL CODE WILL FLASH.

SECOND−STAGE PRESSURE SWITCH CLOSED

AT BEGINNING OF HEAT DEMAND?

DS1 OFF, DS2 SLOW FLASH,

ON/OFF LED ON, HEAT LED ON.

YES

SECOND−STAGE 30−SECOND DELAY ON BEGINS.

DS1 AND DS2 SIMULTANEOUS FAST FLASH

SECOND−STRAGE COMBUSTION AIR INDUCER

ON. SECOND−STAGE GAS VALVE ON. HIGH

HEAT INDOOR BLOWER SPEED ON.

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

ON/OFF LED ON.

YES

SECOND−STAGE PRESSURE SWITCH CLOSED

IN LESS THAN TEN (10) SECONDS?

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

YES

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

SWITCH CAN BE PROVEN or HEAT DEMAND IS

SATISFIED. FIVE (5) MINUTE WAIT PERIOD

INITIATED BEFORE RETRY. WERE 5 ATTEMPTS

MADE FOR SECOND−STAGE HEAT?

YES

NORMAL OPERATION.

DS1 AND DS2 SIMULTANEOUS SLOW FLASH.

SECOND STAGE HEAT DEMAND

DS1 AND DS2 SIMULTANEOUS SLOW FLASH.

YES

CONTINUED

Page 80

HEATING SEQUENCE OF OPERATION

IS PRIMARY, SECONDARY, BACKUP

SECONDARY LIMIT AND ROLLOUT

SWITCH CLOSED?

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER ON.

DS1 SLOW FLASH, DS2 ON,

ON/OFF LED ON, HEAT LED 0N.

HAS PRIMARY, SECONDARY, BACKUP SECONDARY

OR ROLLOUT SWITCH CLOSED WITHIN 3 MINUTES?

LIMIT SWITCH WATCHGUARD MODE. GAS VALVE

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

ON/OFF LED OFF, HEAT LED OFF.

SEE BOX B

THERMOSTAT CALLS FOR HEAT

DS 1 AND DS 2 SIMULTANEOUS FAST FLASH

YES

FIRST−STAGE (LOW FIRE) HEAT

PRESSURE SWITCH CLOSED?

SEE BOX A

NORMAL OPERATION

DS1 AND DS2 SIMULTANEOUS SLOW FLASH.

YES

GAS VALVE OFF, COMBUSTION AIR INDUCER OFF

AFTER 15 SECOND POST PURGE, INDOOR

BLOWER OFF AFTER DELAY.

DS1 OFF, DS2 FAST FLASH,

ON/OFF LED ON, HEAT LED ON.

RETURN TO HEAT DEMAND?

YES

RETURN TO FIRST−STAGE HEAT MODE.

FIRST−STAGE CONTINUES UNTIL SECOND−

STAGE PRESSURE SWITCH CAN BE PROVEN

or HEAT DEMAND IS SATISFIED. A FIVE (5)

MINUTE WAIT PERIOD IS INITIATED BEFORE

RETRY. WERE 5 ATTEMPTS MADE FOR

SECOND−STAGE HEAT?

YES

SEE BOX C

FIRST−STAGE HEAT DEMAND SATISFIED?

HEAT DEMAND SATISFIED?

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

YES

TWO STAGE THERMOSTAT MODE?

(E20 SET AT TWO")

SINGLE−STAGE THERMOSTAT MODE

(E20 SET AT SINGLE")

YES

HEAT DEMAND SATISFIED?

DS1 AND DS2

SIMULTANEOUS FAST FLASH.

FIRST AND SECOND STAGE HEAT

DEMAND SATISFIED SIMULTANEOUSLY.

DS1 & DS2 SIMULTANEOUS FAST FLASH.

YES

GAS VALVE OFF, COMBUSTION AIR

INDUCER OFF AFTER 5−SECOND

LOW SPEED POST PURGE PERIOD,

INDOOR BLOWER OFF DELAY

INITIATED ON LOW HEAT SPEED.

DS1 AND DS2

SIMULTANEOUS FAST FLASH

DEMAND FOR HEAT SATISFIED.

POWER ON STAND BY.

DS1 AND DS2

SIMULTANEOUS SLOW FLASH

YES

SECOND STAGE HEAT

DEMAND SASTISFIED?

DS1 AND DS2

SIMULTANEOUS FAST FLASH.

GAS VALVE, COMBUSTION AIR INDUCER

AND INDOOR BLOWER RETURN TO FIRST−

STAGE OPERATION.

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

YES

FIRST STAGE HEAT DEMAND SATISFIED?

YES

GAS VALVE OFF. COMBUSTION AIR INDUCER

OFF AFTER 5−SECOND LOW SPEED POST−

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

DS1 & DS2 SIMULTANEOUS FAST FLASH.

CONTINUED

SECOND−STAGE (HIGH FIRE) HEAT

PRESSURE SWITCH CLOSED?

Page 81

COOLING SEQUENCE OF OPERATION

SIGNAL POLARITY REVERSED.

DS1 FAST FLASH, DS2 SLOW FLASH.

POWER ON

YES

IS POLARITY REVERSED?

THERMOSTAT CALLS FOR FIRST−STAGE COOL.

COMPRESSOR AND CONDENSER FAN

ENERGIZED.

IS THERE

PROPER GROUND?

IS VOLTAGE

ABOVE 75 VOLTS?

LOW VOLTAGE SIGNAL AT DS HOLDS

UNTIL VOLTAGE RISES ABOVE 75 VOLTS.

YES

SIGNAL IMPROPER

GROUND AT DS.

SIGNAL HOLDS

UNTIL UNIT IS

PROPERLY

GROUNDED.

INDOOR BLOWER ENERGIZED ON FIRST STAGE

COOL SPEED AFTER 2 SECOND DELAY.

FIRST−STAGE DEMAND FOR COOL SATISFIED?

THERMOSTAT CALLS FOR SECOND−STAGE COOL.

YES

COMPRESSOR AND CONDENSER FAN DE−ENERGIZED.

INDOOR BLOWER DE−ENEGIZED.

YES

INDOOR BLOWER RAMPS UP TO SECOND−STAGE COOL SPEED.

SECOND−STAGE DEMAND FOR COOL SATISFIED?

YES

UNIT RETURNS TO FIRST STAGE COOL

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.

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

YES

AFTER 45−SECOND DELAY, INDOOR BLOWER

SWITCHES TO LOW HEAT SPEED.

FIRST−STAGE HEAT DEMAND SATISFIED.

YES

THERMOSTAT CALLS FOR SECOND−STAGE HEAT.

YES

INDOOR BLOWER SWITCHES TO HIGH HEAT SPEED

AFTER 30−SECOND RECOGNITION PERIOD.

SECOND−STAGE HEAT DEMAND SATISFIED.

YES

INDOOR BLOWER RAMPS DOWN TO LOW

HEAT SPEED.

INDOOR BLOWER RAMPS TO FIRST STAGE

COOLING SPEED AFTER A 2−SECOND DELAY.

FIRST−STAGE COOL DEMAND SATISFIED?

YES

SECOND STAGE COOL DEMAND SATISFIED?

INDOOR BLOWER RAMPS TO SECOND

STAGE COOL SPEED

YES

SECOND STAGE COOL DEMAND

INDOOR BLOWER RAMPS DOWN TO FIRST STAGE

COOL SPEED.

YES YES

Page 82

D−G61MPV with SureLight Board 100870

Page 83

E−SureLight Board 100870

Sequence depends on type thermostat used. G61MPV units are applicable for single stage or two stage thermostats. Both type thermostats are described below. Thermostat dip switch selection dictates which mode unit will operate in. See flow chart for more sequence detail.

SureLight Control Self Check

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

Two−Stage Thermostat, Two Stage Heat. Dip Switch

set at TWO".

10− SureLight control energizes combustion air inducer B6

11− SureLight control begins 20 second ignitor warm up

period.

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

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

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

ignitor de−energizes.

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

on low heat speed.

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

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

ond stage recognition period begins.

16− The combustion air inducer ramps up to high heat

speed.

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

energizes second stage heat.

18− B3 indoor blower ramps up to high heat speed.

Single−Stage Thermostat, Two Stage Heat. Dip

Switch set at SINGLE"

1− SureLight control energizes combustion air inducer B6

2− SureLight control begins 20 second ignitor warm up

period.

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

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

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

ignitor de−energizes.

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

on low heat speed.

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

stage heat delay period begins.

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

high heat speed.

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

energizes second stage heat.

9− B3 indoor blower ramps up to high heat speed.

Page 84

F−Flow Chart SureLight Board 100870

HEATING SEQUENCE OF OPERATION

NORMAL AND ABNORMAL HEATING MODE

CONTROL SELF−CHECK OKAY?

YES

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF. (RESET CONTROL BY

TURNING MAIN POWER OFF.)

POLARITY REVERSED.

STATUS ERROR CODE 5 + 4.

POWER ON

POLARITY OKAY?

SIGNAL HOLDS UNTIL UNIT IS PROPERLY GROUNDED.

STATUS ERROR CODE 5 + 3.

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

COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER ON. HAS PRIMARY OR

SECONDARY LIMIT RESET WITHIN 3 MINUTES?

STATUS ERROR CODE 3 + 1.

ROLLOUT SWITCH CLOSED?

GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

INDOOR BLOWER ON.

STATUS ERROR CODE 5 + 1. SEQUENCE HOLDS UNTIL ROLLOUT SWITCH IS RESET AND MAIN POWER IS INTERRUPTED OR

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

YES

FIRST (LOW) STAGE PRESSURE SWITCH

CONTACTS OPEN?

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

PRESSURE SWITCH IS DETECTED OPEN.

STATUS ERROR CODE 2 + 4

YES

GAS VALVE OFF.

COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF.

CONTROL WILL NOT ATTEMPT SECOND−STAGE

OPERATION DURING THIS HEAT DEMAND.

FIRST−STAGE OPERATION WILL BE ATTEMPTED.

STATUS ERROR CODE 2 + 6.

TWO−STAGE OR SINGLE−STAGE THERMOSTAT

CALL FOR HEAT

COMBUSTION AIR INDUCER ON LOW SPEED.

STATUS LED −− HEARTBEAT

CONTINUED ON NEXT PAGE

60−MINUTE LIMIT WATCHGUARD MODE.

GAS VALVE OFF, COMBUSTION AIR INDUCER

OFF, INDOOR BLOWER OFF WITH DELAY.

STATUS ERROR CODE 4 + 5.

YES

SECOND (HIGH) STAGE PRESSURE SWITCH

CONTACTS OPEN?

YES

Page 85

HEATING SEQUENCE OF OPERATION

FIRST−STAGE (LOW FIRE) PRESSURE

SWITCH CLOSED WITHIN 2.5 MINUTES?

GAS VALVE OFF. COMBUSTION AIR INDUCER

OFF. INDOOR BLOWER OFF. UNIT WILL RETRY

AFTER 5−MINUTE WAIT PERIOD.

STATUS ERROR CODE 2 + 3.

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.

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

COMBUSTION AIR INDUCER OFF, IGNITOR OFF.

SIGNAL HOLDS UNTIL IGNITOR IS REPLACED

OR RECONNECTED.

STATUS ERROR CODE 4 + 7.

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.

FLAME RECTIFICATION CURRENT CHECK

CAN FLAME BE PROVEN WITHIN 4

SECONDS AFTER GAS VALVE OPENS?

(u0.20 microamps)

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

THERMOSTAT CALLS FOR HEAT

STATUS LED − HEARTBEAT

(Refer to box A on previous page)

YES

FLAME PRESENT?

HAS CONTROL RESET IGNITION SEQUENCE

FOUR (4) TIMES?

WATCHGUARD MODE.

STATUS ERROR CODE 4 + 3.

YES

CONTINUED ON NEXT PAGE

YES

CONTINUED

IS IGNITOR INTACT AND CONNECTED?

WATCHGUARD MODE. GAS VALVE OFF,

COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF.

STATUS ERROR CODE 4 + 1.

IS 60−MINUTE RESET PERIOD COMPLETE?

YES

Page 86

HEATING SEQUENCE OF OPERATION

LOW FLAME SIGNAL

(Does not affect control operation)

STATUS ERROR CODE 1 + 2.

FLAME SIGNAL ABOVE

(u1.40 microamps)

YES

CONTINUED ON NEXT PAGE

YES

SINGLE−STAGE THERMOSTAT MODE

(DIP SWITCH SET AT SINGLE")

TWO STAGE THERMOSTAT MODE

(DIP SWITCH SET AT TWO")

YES

START SECOND−STAGE RECOGNITION

ON DELAY (10 OR 15 MINUTES).

STATUS LED −− HEARTBEAT

45−SECOND INDOOR BLOWER ON DELAY BEGINS.

STATUS LED −− HEARTBEAT.

YES

PRIMARY & SECONDARY LIMIT SWITCHES

CLOSED?

GAS VALVE OFF, COMBUSTION AIR INDUCER OFF,

INDOOR BLOWER ON.

STATUS ERROR CODE 3 + 1.

HAS PRIMARY OR SECONDARY LIMIT SWITCH CLOSED WITHIN 3 MINUTES?

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

FIRST−STAGE (LOW FIRE)

PRESSURE SWITCH CLOSED?

LIMIT SWITCH WATCHGUARD MODE.

GAS VALVE OFF, COMBUSTION AIR INDUCER OFF,

INDOOR BLOWER OFF WITH DELAY.

STATUS ERROR CODE 4 + 5

IS 60−MINUTE RESET PERIOD COMPLETE?

THERMOSTAT CALLS FOR HEAT.

STATUS LED −− HEARTBEAT.

SEE BOX A.

YES

GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

INDOOR BLOWER OFF AFTER DELAY.

STATUS ERROR CODE 2 + 3. CONTROL RESTARTS

IGNITION SEQUENCE IF PRESSURE SWITCH

CLOSES WITHIN 2−1/2 MINUTES.

YES

FIRST−STAGE HEAT DEMAND SATISFIED?

GAS VALVE OFF, COMBUSTION AIR INDUCER

OFF FOLLOWING POST PURGE.

INDOOR BLOWER OFF WITH DELAY

STATUS LED −− PULSE

YES

SECOND−STAGE HEAT DEMAND.

SECOND−STAGE HEAT DEMAND REQUIRED?

SECOND STAGE PRESSURE SWITCH CLOSED?

ABNORMAL FLASH CODE.

NOTE − IF SECOND−STAGE PRESSURE SWITCH

WAS ORIGINALLY FOUND CLOSED,

ABNORMAL CODE WILL FLASH.

SECOND−STAGE PRESSURE SWITCH CLOSED

AT BEGINNING OF HEAT DEMAND?

STATUS ERROR CODE 2 + 6.

YES

SECOND−STAGE 30−SECOND DELAY ON BEGINS.

STATUS LED −− HEARTBEAT.

SECOND−STAGE COMBUSTION AIR INDUCER

ON. SECOND−STAGE GAS VALVE ON. HIGH

HEAT INDOOR BLOWER SPEED ON.

STATUS LED −− HEARTBEAT.

YES

SECOND−STAGE PRESSURE SWITCH CLOSED

IN LESS THAN TEN (10) SECONDS?

STATUS LED −− HEARTBEAT

YES

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

SWITCH CAN BE PROVEN or HEAT DEMAND IS

SATISFIED. FIVE (5) MINUTE WAIT PERIOD

INITIATED BEFORE RETRY. WERE 5 ATTEMPTS

MADE FOR SECOND−STAGE HEAT?

YES

CONTINUES FIRST−STAGE HEATING DEMAND.

WILL NOT REATTEMPT SECOND−STAGE

HEATING DEMAND.

STATUS ERROR CODE 2 + 5.

SECOND STAGE HEAT DEMAND

STATUS LED −− HEARTBEAT.

YES

CONTINUED

GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

INDOOR BLOWER ON.

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.

ROLLOUT SWITCHES CLOSED?

YES

Page 87

HEATING SEQUENCE OF OPERATION

SEE BOX B

THERMOSTAT CALLS FOR HEAT.

SEE BOX A

NORMAL OPERATION.

YES

RETURN TO FIRST−STAGE HEAT MODE.

FIRST−STAGE CONTINUES UNTIL SECOND−

STAGE PRESSURE SWITCH CAN BE PROVEN

or HEAT DEMAND IS SATISFIED. A FIVE (5)

MINUTE WAIT PERIOD IS INITIATED BEFORE

RETRY. WERE 5 ATTEMPTS MADE FOR

SECOND−STAGE HEAT?

YES

SEE BOX C

FIRST−STAGE HEAT DEMAND SATISFIED?

HEAT DEMAND SATISFIED?

STATUS LED −− HEARTBEAT.

YES

TWO STAGE THERMOSTAT MODE?

(DIP SWITCH SET AT TWO")

SINGLE−STAGE THERMOSTAT MODE

(DIP SWITCH SET AT SINGLE")

YES

FIRST AND SECOND STAGE HEAT

DEMAND SATISFIED SIMULTANEOUSLY.

STATUS LED −− HEARTBEAT.

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.

DEMAND FOR HEAT SATISFIED.

POWER ON STAND BY. STATUS LED −− PULSE.

YES

SECOND STAGE HEAT

DEMAND SASTISFIED?

STATUS LED −− HEARTBEAT.

GAS VALVE, COMBUSTION AIR INDUCER

AND INDOOR BLOWER RETURN TO FIRST−

STAGE OPERATION.

STATUS LED −− HEARTBEAT.

YES

FIRST STAGE HEAT DEMAND SATISFIED?

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 −− PULSE.

CONTINUED

SECOND−STAGE (HIGH FIRE) HEAT

PRESSURE SWITCH CLOSED?

Page 88

COOLING SEQUENCE OF OPERATION

SIGNAL POLARITY REVERSED.

CONTROL WILL CONTINUE TO CALL FOR COOLING

IN THIS CONDITION.

STATUS ERROR CODE 5 + 4.

POWER ON

YES

IS POLARITY REVERSED?

THERMOSTAT CALLS FOR FIRST−STAGE COOL.

COMPRESSOR AND CONDENSER FAN

ENERGIZED.

IS THERE

PROPER GROUND?

YES

INDOOR BLOWER ENERGIZED ON FIRST STAGE

COOL SPEED AFTER 2 SECOND DELAY.

FIRST−STAGE DEMAND FOR COOL SATISFIED?

THERMOSTAT CALLS FOR SECOND−STAGE COOL.

COMPRESSOR AND CONDENSER FAN DE−ENERGIZED.

INDOOR BLOWER DE−ENEGIZED.

YES

INDOOR BLOWER RAMPS UP TO SECOND−STAGE COOL SPEED.

SECOND−STAGE DEMAND FOR COOL SATISFIED?

YES

UNIT RETURNS TO FIRST STAGE COOL

SIGNAL IMPROPER GROUND AT LED.

CONTROL WILL CONTINUE TO CALL FOR COOLING

IN THIS CONDITION.

STATUS ERROR CODE 5 + 3.

Page 89

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.

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

YES

AFTER 45−SECOND DELAY, INDOOR BLOWER

SWITCHES TO LOW HEAT SPEED.

FIRST−STAGE HEAT DEMAND SATISFIED.

YES

THERMOSTAT CALLS FOR SECOND−STAGE HEAT.

YES

INDOOR BLOWER SWITCHES TO HIGH HEAT SPEED

AFTER 30−SECOND RECOGNITION PERIOD.

SECOND−STAGE HEAT DEMAND SATISFIED.

YES

INDOOR BLOWER RAMPS DOWN TO LOW

HEAT SPEED.

INDOOR BLOWER RAMPS TO FIRST STAGE

COOLING SPEED AFTER A 2−SECOND DELAY.

FIRST−STAGE COOL DEMAND SATISFIED?

YES

SECOND STAGE COOL DEMAND SATISFIED?

INDOOR BLOWER RAMPS TO SECOND

STAGE COOL SPEED

YES

SECOND STAGE COOL DEMAND

INDOOR BLOWER RAMPS DOWN TO FIRST STAGE

COOL SPEED.

YES YES

Page 90

VIII− Field Wiring Applications and Jumper Settings

A−SureLight Board 49M59

TABLE 45

Field Wiring Applications

Thermostat

Jumper Settings (See figure 4)

Wiring Connections

E20 W915 W914 W951

1 Heat / 1 Cool

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

SINGLE Intact Intact Intact

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

HSXB15

(LSOM)

51M26 SignatureStat

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

SINGLE Intact Cut Intact

51M26

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

HSXB15

(LSOM)

1 Heat / 1 Cool with CCB1

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

SINGLE Intact Cut Intact

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

CCB1

HSXB15

(LSOM)

1 Heat / 2 Cool

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

SINGLE Cut Intact Intact

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

HSXA19

(LSOM)

Page 91

TABLE 46

Field Wiring Applications (Continued)

Thermostat

Jumper Settings (See figure 4)

Wiring Connections

E20 W915 W914 W951

1 Heat / 2 Cool with CCB1

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

SINGLE Cut Cut Intact

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

CCB1

HSXA19 (LSOM)

2 Heat / 2 Cool TWO Cut Intact Intact

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

HSXA19

(LSOM)

51M27 SignatureStat TWO Cut Cut Intact

CONTROL

TERM. STRIP

OUTDOOR

UNIT

51M27

HSXA19

(LSOM)

2 Heat / 2 Cool with CCB1

TWO Cut Cut Intact

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

CCB1

HSXA19

(LSOM)

Page 92

TABLE 47

Field Wiring Applications (Continued)

Thermostat

Jumper Settings (See figure 4)

Wiring Connections

E20 W915 W914 W951

2 Heat / 1 Cool TWO Intact Intact Intact

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

HSXB15

(LSOM)

FM21 Heat Pump / 1 Cool

SINGLE Intact Intact Cut

CONTROL

TERM. STRIP

FM21

75VA, 24V

TRANSFORMER*

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

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

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

Page 93

B−SureLight Board 100870

TABLE 48

Field Wiring Applications (Continued)

Thermostat

Dip Switch Settings and On Board Links (See figure 5)

Wiring Connections

DIP Switch 1

W915

Two−Stage

Cooling

W914 Dehu-

midification or Harmony

III

W951

Heat Pumps

1Heat / 1 Cool

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

ON Intact Intact Intact

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

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 Intact

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

1 Heat / 2 Cool with t’stat with humidity control

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

ON Cut Cut Intact

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

Page 94

TABLE 49

Field Wiring Applications (Continued)

Thermostat

Dip Switch Settings and On Board Links (See figure 5)

Wiring Connections

DIP Switch 1

W915

Two−Stage

Cooling

W914 Dehu-

midification or Harmony

III

W951

Heat Pumps

2 Heat / 2 Cool OFF Cut Intact Intact

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

2 Heat / 2 Cool with t’stat with humidity control

OFF Cut Cut Intact

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

2 Heat / 1 Cool OFF Intact Intact Intact

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

Page 95

IX−TROUBLESHOOTING

A−SureLight

Board 49M59

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

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

Condition Possible Cause Corrective Action / Comments

1.1

− Both diagnostic lights fail to light up.

LED#1−Off LED#2−Off

1.1.1

Main voltage 120V not supplied to unit.

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

1.1.2

Miswiring of furnace or improper connections.

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

ACTION 2 − Check 24V wiring to control board.

1.1.3

Blown fuse

ACTION 1 − Replace fuse. ACTION 2 − If fuse still blows, check for short.

1.1.4

Door interlock switch failure.

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

1.1.5

Transformer Failure.

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

1.1.6

Failed control board.

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

1.2

− Diagnostic lights flash the roll−out

code.

LED#1−On, LED#2−Slow Flash

1.2.1

Roll−out switch open.

ACTION 1 − Manually reset the roll−out switch by pushing the top button. ACTION 2 − Determine the cause of the roll−out switch activation before leaving furnace.

1.2.2

Roll−out switch failure.

ACTION 1 − Check continuity across roll−out switch. Replace roll−out switch if switch is reset but does not have continuity.

1.2.3

Miswiring or improper connections at roll−out switch.

ACTION 1 − Check wiring connections to switch.

1.2.4

9 pin connector failure

ACTION 1 − Check 9−pin connector for proper connection to control board. ACTION 2 − Check continuity of the multi plug pin.

1.3

− On initial power−up the comb. air inducer does not energize.

− Diagnostic lights flash the reverse polarity code.

LED#1−Fast Flash, LED#2−Slow Flash.

1.3.1

120V main power polarity reversed.

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

1.4

− On initial power up the combustion air inducer does not energize.

− Diagnostic lights flash normal power on operation.

LED#1−Slow Flash LED#2−Slow Flash

1.4.1

Open combustion air inducer motor circuit.

ACTION 1 − Check for 120V to combustion air inducer. If no power, check wire and connections.

1.4.2

Failed combustion air inducer motor.

ACTION 1 − If power is present at blower, replace blower.

Page 96

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

Condition Possible Cause Corrective Action / Comments

1.5

− Diagnostic lights flash the improper

main ground.

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

1.5.1

Improper ground to the unit.

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

1.5.2

6−Pin connector is improperly

attached to the circuit board.

ACTION 1 − Check 6−pin connector for proper installation. Correctly insert connector into control.

1.5.3

Line voltage is below 75V.

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

1.5.4

Open ignitor circuit.

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

1.5.5

Broken or failed ignitor.

ACTION 1 − Unplug ignitor and read resistance across ignitor. If resistance does not read between 10.9 and 19.7 ohms, replace the ignitor.

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

ENERGIZE

Condition Possible Cause Corrective Action / Comments

2.1

− Unit operates with a cooling or contin-

uous fan demand.

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

− Diagnostic lights flash the limit failure mode.

LED#1−Slow Flash, LED#2−On

2.1.1

Primary, secondary or backup secon-

dary (if equipped ) limit open.

ACTION 1 − Check continuity across switch(es). Switches reset automatically upon cool down. ACTION 2 − Check for restrictions on blower inlet air (including filter) and outlet air. Determine cause for limit activation before placing unit back in operation.

2.1.2

Miswiring of furnace or improper

connections at limit switch(es).

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

2.2

− Unit operates with a cooling and continuous fan demand.

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

− Diagnostic lights flash the pressure switch failure code.

LED#1−Off, LED#2−Slow Flash

2.2.1

Miswiring of furnace or improper

connections to combustion air

inducer.

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

2.2.2

Prove switch stuck closed.

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

Page 97

PROBLEM 2: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR INDUCER DOES

NOT ENERGIZE (CONT.).

Condition Possible Cause Corrective Action/Comments

2.3

− Unit operates with a cooling and continuous fan demand.

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

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

LED#1−Off, LED#2−Slow Flash

2.3.1

Miswiring of furnace or improper

connections to combustion air induc-

er.

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

2.3.2

Combustion air inducer failure.

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

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

ENERGIZES, IGNITOR IS NOT ENERGIZED.

Condition Possible Cause Corrective Action/Comments

3.1

− Unit operates with a cooling and

continuous fan demand.

− Combustion air inducer energizes with a heating demand.

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

LED#1−Off LED#2−Slow Flash

3.1.1

Prove switch does not close due to

incorrect routing of the pressure

switch lines.

ACTION 1 − Check that the prove switch lines are correctly routed. Correctly route pressure switch lines.

3.1.2

Prove switch does not close due to

obstructions in the pressure lines.

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

3.1.3

Prove switch lines damaged

ACTION 1 − Check prove switch lines for leaks. Replace any broken lines.

3.1.4

Condensate in prove switch line.

ACTION 1 − Check prove switch lines for condensate. Remove condensate from lines.

3.1.5

Prove switch does not close due to a

low differential pressure across the

prove switch.

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

3.1.6

Wrong prove switch installed in the

unit, or prove switch is out of

calibration.

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

3.1.7

Miswiring of furnace or improper

connections at prove switch.

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

3.1.8

Prove switch failure.

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

Page 98

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

ENERGIZES, IGNITOR IS ENERGIZED.

Condition Possible Cause Corrective Action/Comments

4.1

− Unit operates with a cooling and continuous fan demand.

− Combustion air inducer energizes with Heating demand.

− Ignitor is energized but unit fails to light.

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

4.1.1

Check that gas is being supplied to

the unit.

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

4.1.2

Miswiring of gas valve or loose-

connections at multi−pin control amp

plugs or valve.

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

4.1.3

Defective gas valve or ignition

control.

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

PROBLEM 5: BURNERS LIGHT WITH A HEATING DEMAND BUT UNIT SHUTS DOWN

PREMATURELY

Condition Possible Cause Corrective Action/Comments

5.1

− Burners fire with a heating demand.

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

− Diagnostic lights flash the pressure switch code.

LED#1−Off LED#2−Slow Flash

5.1.1

Low pressure differential at the prove

switch.

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

5.1.2

Wrong concentric vent kit used for

terminating the unit.

ACTION 1 − Check vent termination kit installed. See Placement and Installation section.

5.1.3

Condensate drain line is not draining

properly.

ACTION 1 − Check condensate line for proper vent slope, and any blockage. Condensate should flow freely during operation of furnace. Repair or replace any improperly installed condensate lines.

5.1.4

Low pressure differential at the prove

switch.

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

5.2

− Combustion air inducer energizes with a heating demand.

− Burners light but fail to stay lit.

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

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

5.2.1

Sensor or sense wire is improperly

installed.

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

5.2.2

Sensor or sense wire is broken.

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

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

5.2.3

Sensor or sensor wire is grounded to

the unit.

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

ACTION 3 − Correct any shorts found in circuit.

5.2.4

Control does not sense flame.

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

Page 99

PROBLEM 5: BURNERS LIGHT WITH HEATING DEMAND BUT UNIT SHUTS DOWN

PREMATURELY (CONT.)

Condition Possible Cause Corrective Action/Comments

5.3

− Combustion air inducer energizes with a heating demand.

− Burners light.

− Roll−out switch trips during the heating demand.

− Diagnostic lights flash roll−out failure.

LED#1−On LED#2−Slow Flash

5.3.1

Unit is firing above 100% of the

nameplate input.

ACTION 1 − Check that the manifold pressure matches value listed on nameplate. See installation instructions for proper procedure. ACTION 2 − Verify that the installed orifice size match the size listed on the nameplate or installation instructions. ACTION 3 − Check gas valve sensing hose to insure no leaks are present. ACTION 4 − Check the input rate to verify rate matches value listed on nameplate.

5.3.2

Gas orifices leak at the manifold

connection.

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

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

5.3.3

Air leakage at the connections

between the primary heat exchanger,

secondary heat exchanger, and

combustion air blower.

ACTION 1 − Check for air leakage at all joints in the heat exchanger assembly. Condition will cause high CO2 with high CO. ACTION 2 − Seal leakage if possible, replace heat exchanger if necessary, tag and return heat exchanger to proper Lennox personnel.

5.3.4

Insufficient flow through the heat

exchanger caused by a sooted or

restricted heat exchanger.

ACTION 1 − Check for sooting deposits or other restrictions in the heat exchanger assembly. Clean assembly as outlined in instruction manual.

ACTION 2 − Check for proper combustion.

5.3.5

Burners are not properly located in

the burner box.

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

5.4

− Combustion air inducer energizes

with a heating demand.

− Burners light roughly and the unit fails to stay lit.

− Diagnostic lights flash watchguard flame failure.

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

5.4.1

Recirculation of flue gases. This

condition causes rough ignitions and

operation. Problem is characterized

by nuisance flame failures.

ACTION 1 − Check for proper flow of exhaust gases away from intake vent. Remove any obstacles in front of the intake and exhaust vent which would cause recirculation. ACTION 2 − Check for correct intake and exhaust vent installation. See instructions

5.4.2

Improper burner cross−overs

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

Page 100

PROBLEM 6: CONTROL SIGNALS LOW FLAME SENSE DURING HEATING MODE

Condition Possible Cause Corrective Action/Comments

6.0

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

LED#1−Slow Flash LED#2−Fast Flash

6.1.1

Sensor rod is improperly located on

the burner.

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

6.1.2

Sensor rod is contaminated.

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

PROBLEM 7: INDOOR BLOWER FAILS TO OPERATE IN COOLING, HEATING, OR CONTINUOUS

FAN MODE

Condition Possible Cause Corrective Action/Comments

7.0

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

7.1.1

Miswiring of furnace or improper

connections at control or indoor blow-

er motor.

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

7.1.2

120V is not being supplied to the

indoor air blower or blower motor fail-

ure.

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

7.1.3

Defective control board

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

7.1.4

Defective run capacitor

ACTION 1 − Replace capacitor

PROBLEM 8: RF STATIC DURING TIME FOR IGNITION

Condition Possible Cause Corrective Action/Comments

8.0

− AM radio interference.

8.1.2

Ignitor operation

ACTION 1 − Call Technical Support, Dallas.

Lennox G61MPV Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual