Lennox G61MPV−36C−090, G61MPV−36B−045, G61MPV−36B−070, G61MPV−36B−071, G61MPV−60C−090 Service Manual

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Page 1

Corp. 0310−L7

Service Literature

Revised 03−2008

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 sonal Efficiency requirements. All units use a redundant gas valve to assure safety shut−off as required by C.S.A.

) Standards and California Sea-

G61MPV

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 47. . . . . . . . . . . . . . . . . . . . . . . . . . . .

III Start Up Page 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IV Heating System Service Checks Page 62. . . . . . . . .

V Typical Operating Characteristics Page 67. . . . . . . . .

VI Maintenance Page 68. . . . . . . . . . . . . . . . . . . . . . . . . .

VII Wiring and Sequence of Operation Page 71. . . . . .

VIII Field Wiring and Jumper Setting Page 86. . . . . . . .

IX Control Board Troubleshooting Page 91. . . . . . . . . .

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.

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SPECIFICATIONS

Gas Heating Performance

High Fire

ModelNo. G61MPV

−36B−045

Input− Btuh

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

G61MPV

−36B−070

G61MPV

−36B−071

G61MPV

−36C−090

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.)

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

Natural Gas / LPG/Propane

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.)

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

Natural Gas / LPG/Propane

AFUE 94.1% 94.1% 95.0% 94.3%

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

Connections in.

Condensate Drain Trap (PVC pipe) − i.d.

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

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

High Fire

ModelNo. G61MPV

−60C−090

Input− Btuh 88,000

G61MPV

−60C−091

G61MPV

−60C−110

G61MPV

−60C−111

G61MPV

−60D−135

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.)

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

Natural Gas / LPG/Propane

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.)

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

Natural Gas / LPG/Propane

AFUE 94.6% 95.0% 94.3% 95.0% 94.6%

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

Connections in.

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

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

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.

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OPTIONAL ACCESSORIES − MUST BE ORDERED EXTRA

Applications

Kit

B" Width Models C" Width Models D" Width Models

FILTER KITS

Air Filter and

Rack Kit

EZ Filter Base

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

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

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

6 ft. 26K68 26K68 26K68

24 ft. 26K69 26K69 26K69

50 ft. 26K70 26K70 26K70

CONTROLS

SignatureStatt Home Comfort Control 81M27 81M27 81M27

TERMINATION KITS − See Installation Instructions for specific venting information.

Termination

Concentric

Kits

rect Ven

Applications

Wall − Close Couple

Only

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

Termination

s − Direct or

Non−Direct Vent

Roof Termination Flashing Kit − Direct or Non−Direct

Roof 2 in. 15F75 15F75

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

Vent − Contains two flashings.

Cleanable polyurethane frame type filter.

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

Non−direct vent only.

2 in. 71M80 69M29 − − −

3 in. − − − 60L46 60L46

2 in. 22G44 − − − − − −

3 in. 44J40 44J40 44J40

3 in. 81J20 81J20 81J20

− − −

15F74

44J41 44J41 44J41

GAS HEAT ACCESSORIES

High Altitude

Orifice Kit

Input

Natural Gas

Only

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

High Altitude Pressure Switch Kit

ORDER TWO EACH

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LPG/Propane Kit

LPG/Propane to

Natural Gas Kit

7501−10,000 ft.

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BLOWER DATA

ADJUST"

Stc

Positions

BLOWER DATA

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



Switch

Positions

ADJUST"

Switch

Positions

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 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

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

Speed

Tap 1

Tap 2

Tap 3

Tap 4

COOL"

Speed

Tap 1

Tap 2

Tap 3

Tap 4

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

Speed

Tap 1

Tap 2

Tap 3

Tap 4

COOL"

Speed

Tap 1

Tap 2

Tap 3

Tap 4

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

Speed

Tap 1

Tap 2

Tap 3

Tap 4

COOL"

Speed

Tap 1

Tap 2

Tap 3

Tap 4

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

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

HEAT speed position.

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

70 90 11 5 135 155 175 200 220 245 95 120 145 175 190 210 230 255 280

125

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

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

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

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

90 11 0 130 155 175 200 220 240 230 260 295 330 360 390 415 435 460

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

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

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

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

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

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

45 60 75 95 115 130 145 160 175 110 130 155 185 205 230 250 275 295

80 100 11 5 135 155 175 195 215 165 190 215 240 275 305 330 355 380

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

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

50 65 85 100 120 140 155 170 185 55 70 90 110 135 155 170 190 205

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

110

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

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

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

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

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

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

Speed Switch Positions

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BLOWER DATA

ADJUST"

Stc

Positions

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



Switch

Positions

ADJUST"

Switch

Positions

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.

G61MPV−36B−070 BLOWER MOTOR WATTS

Jumper Speed

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

Speed

Tap 1

Tap 2

Tap 3

Tap 4

COOL"

Speed

Tap 1

Tap 2

Tap 3

Tap 4

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

Speed

Tap 1

Tap 2

Tap 3

Tap 4

COOL"

Speed

Tap 1

Tap 2

Tap 3

Tap 4

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

Speed

Tap 1

Tap 2

Tap 3

Tap 4

COOL"

Speed

Tap 1

Tap 2

Tap 3

Tap 4

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

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

HEAT speed position.

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

70 85 105 130 150 170 190 205 225 110 11 5 135 155 175 195 215 240 260

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

100

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

185

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

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

90 11 0 130 150 170 190 205 220 185 215 250 285 315 345 370 395 420

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

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

105

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

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

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

130

145

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

45 60 80 95 115 130 145 160 175 100 120 140 165 190 215 235 255 275

75 95 11 0 130 145 165 180 200 140 165 190 220 245 265 290 315 340

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

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

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

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

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

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

110

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

60 80 95 115 135 145 160 175 95 120 150 175 200 220 240 260 285

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

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

Speed Switch Positions

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BLOWER DATA

ADJUST"

Stc

Positions

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



Switch

Positions

ADJUST"

Switch

Positions

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.

G61MPV−36B−071 BLOWER MOTOR WATTS

Jumper Speed

+" (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

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

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 11 5 140 160 180 200 220 240

Tap 2 8 0

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 11 0 130 155 180 205 225 245 265 285

Tap 2 6 0

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

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

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

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

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 1115 695 770 815 875

 705 795 955 990 645 705 740 790

HEAT speed position.

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

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

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

100 125 150 180 200 220 240 255 11 0 135 165 190 220 240 255 275 290

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

80 100 120 140 165 185 205 225 90 11 0 130 155 175 195 215 235 250

60 80 100 115 135 150 170 185 115 135 160 190 215 235 255 270 295

Speed Switch Positions

Page 6

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BLOWER DATA

ADJUST"

Stc

Positions

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



Switch

Positions

ADJUST"

Switch

Positions

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.

G61MPV−36C−090 BLOWER MOTOR WATTS

Jumper Speed

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

Speed

Tap 1

Tap 2

Tap 3

Tap 4

COOL"

Speed

Tap 1

Tap 2

Tap 3

Tap 4

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

Speed

Tap 1

Tap 2

Tap 3

Tap 4

COOL"

Speed

Tap 1

Tap 2

Tap 3

Tap 4

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

Speed

Tap 1

Tap 2

Tap 3

Tap 4

COOL"

Speed

Tap 1

Tap 2

Tap 3

Tap 4

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

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

HEAT speed position.

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

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

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

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

125

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

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

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

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

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

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

65 90 11 0 135 155 175 200 220 60 80 105 130 155 185 205 220 240

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

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

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

55 70 90 110 130 150 165 185 105 125 145 170 200 225 250 270 295

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

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

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

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

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

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

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

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

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

45 60 75 90 115 135 155 170 190 105 125 150 175 210 240 275 305 335

Speed Switch Positions

Page 7

Page 8

BLOWER DATA

ADJUST"

Stc

Positions

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



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.

HEAT speed position.

G61MPV−60C−090 BLOWER MOTOR WATTS

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

Jumper Speed

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

COOL"

Speed

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

Tap 1

265

Tap 2

Tap 3

Tap 4

Tap 1

Tap 2

Tap 3

Tap 4

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

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

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

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

145

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

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

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

COOL"

Speed

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

Tap 1

200

Tap 2

Tap 3

Tap 4

Tap 1

Tap 2

Tap 3

Tap 4

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

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

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

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

110

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

145

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

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

180

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

Speed

COOL"

Speed

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

Tap 1

155

Tap 2

Tap 3

Tap 4

Tap 1

Tap 2

Tap 3

Tap 4

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

200

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

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

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

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

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

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

Speed Switch Positions

Page 8

Page 9

BLOWER DATA

ADJUST"

Stc

Positions

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



Switch

Positions

ADJUST"

Switch

Positions

Factory default jumper setting.

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

G61MPV−60C−090 BLOWER MOTOR WATTS

Jumper Speed

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

Speed

Tap 1

Tap 2

Tap 3

Tap 4

COOL"

Speed

Tap 1

Tap 2

Tap 3

Tap 4

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

Speed

Tap 1

Tap 2

Tap 3

Tap 4

COOL"

Speed

Tap 1

Tap 2

Tap 3

Tap 4

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

Speed

Tap 1

Tap 2

Tap 3

Tap 4

COOL"

Speed

Tap 1

Tap 2

Tap 3

Tap 4

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

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

HEAT speed position.

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

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

250

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

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

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

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

130

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

160

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

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

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

195

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

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

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

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

100

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

140

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

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

180

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

150

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

210

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

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

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

95 11 5 135 155 175 200 220 245 185 210 235 260 295 325 355 385 415

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

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

Speed Switch Positions

Page 9

Page 10

BLOWER DATA

ADJUST"

Stc

Positions

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



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.

HEAT speed position.

G61MPV−60C−090 BLOWER MOTOR WATTS

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

Jumper Speed

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

COOL"

Speed

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

Tap 1

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

255

Tap 2

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

Tap 3

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

Tap 4

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

Tap 1

125

Tap 2

Tap 3

Tap 4

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

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

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

COOL"

Speed

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

Tap 1

195

Tap 2

Tap 3

Tap 4

Tap 1

Tap 2

Tap 3

Tap 4

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

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

385

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

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

105

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

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

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

COOL"

Speed

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

Tap 1

145

Tap 2

Tap 3

Tap 4

Tap 1

Tap 2

Tap 3

Tap 4

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

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

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

270

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

90 11 0 130 155 180 200 220 245 190 220 250 275 305 335 370 400 430

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

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

Speed Switch Positions

Page 10

Page 11

BLOWER DATA

ADJUST"

Stc

Positions

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



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.

HEAT speed position.

G61MPV−60C−091 BLOWER MOTOR WATTS

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

Jumper Speed

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"

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

Speed

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"

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

Speed

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"

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

Speed

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"

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

Speed

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"

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

Speed

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"

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

Speed

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

Speed Switch Positions

Page 11

Page 12

BLOWER DATA

ADJUST"

Stc

Positions

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



Switch

Positions

ADJUST"

Switch

Positions

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.

G61MPV−60C−091 BLOWER MOTOR WATTS

Jumper Speed

+" (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

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

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

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

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

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

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

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

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

HEAT speed position.

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

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

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

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

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

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

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

Speed Switch Positions

Page 12

Page 13

BLOWER DATA

ADJUST"

Stc

Positions

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



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.

HEAT speed position.

G61MPV−60C−091 BLOWER MOTOR WATTS

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

Jumper Speed

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

Speed Switch Positions

Page 13

Page 14

BLOWER DATA

ADJUST"

Stc

Jumper

Speed

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



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.

HEAT speed position.

G61MPV−60C−110 BLOWER MOTOR WATTS

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

Speed

Positions

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

First Stage

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

Speed

COOL"

Speed

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

Tap 1

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

245

Tap 2

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

365

Tap 3

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

480

Tap 4

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

Tap 1

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

135

Tap 2

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

Tap 3

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

Tap 4

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

Speed

COOL"

Speed

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

Tap 1

195

Tap 2

Tap 3

Tap 4

Tap 1

Tap 2

Tap 3

Tap 4

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

265

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

370

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

100 115 135 150 180 210 235 255 275 205 235 275 310 345 380 415 450 485

110

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

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

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

COOL"

Speed

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

Tap 1

140

Tap 2

Tap 3

Tap 4

Tap 1

Tap 2

Tap 3

Tap 4

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

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

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

70 90 11 0 130 150 175 200 220 240 155 180 210 240 270 295 325 355 385

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

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

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

Speed Switch Positions

Second Stage

Page 14

Page 15

BLOWER DATA

ADJUST"

Stc

Jumpe

Jumper

Speed

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



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.

HEAT speed position.

G61MPV−60C−110 BLOWER MOTOR WATTS

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

First Stage Second Stage

Speed

Positions

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

0 +" (Plus) SETTING (Adjust" Jumper at +" Setting) HEAT"

Speed

COOL"

Speed

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

Tap 1

215

Tap 2

Tap 3

Tap 4

Tap 1

Tap 2

Tap 3

Tap 4

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

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

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

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

125

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

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

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

COOL"

Speed

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

Tap 1

170

Tap 2

Tap 3

Tap 4

Tap 1

Tap 2

Tap 3

Tap 4

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

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

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

360

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

115 140 165 190 220 240 270 295 225 265 315 360 400 440 475 515 555

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

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

COOL"

Speed

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

Tap 1

145

Tap 2

Tap 3

Tap 4

Tap 1

Tap 2

Tap 3

Tap 4

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

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

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

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

95 11 5 140 160 185 210 235 260 170 200 240 275 315 355 390 420 450

105

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

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

Speed Switch Positions

Page 15

Page 16

BLOWER DATA

ADJUST"

Stc

Positions

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



Switch

Positions

ADJUST"

Switch

Positions

Factory default jumper setting.

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

G61MPV−60C−110 BLOWER MOTOR WATTS

Jumper Speed

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

Speed

Tap 1

Tap 2

Tap 3

Tap 4

COOL"

Speed

Tap 1

Tap 2

Tap 3

Tap 4

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

Speed

Tap 1

Tap 2

Tap 3

Tap 4

COOL"

Speed

Tap 1

Tap 2

Tap 3

Tap 4

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

Speed

Tap 1

Tap 2

Tap 3

Tap 4

COOL"

Speed

Tap 1

Tap 2

Tap 3

Tap 4

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

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

HEAT speed position.

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

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

230

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

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

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

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

130

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

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

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

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

185

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

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

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

75 90 11 5 135 160 185 205 225 250 190 220 255 290 325 360 395 430 460

100

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

135

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

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

170

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

145

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

175

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

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

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

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

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

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

Speed Switch Positions

Page 16

Page 17

BLOWER DATA

ADJUST"

Stc

Positions

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



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.

HEAT speed position.

G61MPV−60C−111 BLOWER MOTOR WATTS

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

Jumper Speed

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

Speed Switch Positions

Page 17

Page 18

BLOWER DATA

ADJUST"

Stc

Positions

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



Switch

Positions

ADJUST"

Switch

Positions

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.

G61MPV−60C−111 BLOWER MOTOR WATTS

Jumper Speed

+" (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

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 1 115 130 155 180 205 225 250 270 290 310 335 365 390 415 445 470 500 525

Tap 2 145

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

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

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

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

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

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

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

HEAT speed position.

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

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

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

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

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

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

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

Speed Switch Positions

Page 18

Page 19

BLOWER DATA

ADJUST"

Stc

Positions

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



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 111 0 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.

HEAT speed position.

G61MPV−60C−111 BLOWER MOTOR WATTS

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

Jumper Speed

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 1 115 135 160 185 210 230 250 270 300 145 165 190 215 235 265 290 315 345

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

Speed Switch Positions

Page 19

Page 20

BLOWER DATA

ADJUST"

Stc

Positions

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



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.

HEAT speed position.

G61MPV−60D−135 BLOWER MOTOR WATTS

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

Jumper Speed

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

COOL"

Speed

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

Tap 1

215

Tap 2

Tap 3

Tap 4

Tap 1

Tap 2

Tap 3

Tap 4

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

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

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

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

115

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

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

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

COOL"

Speed

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

Tap 1

165

Tap 2

Tap 3

Tap 4

Tap 1

Tap 2

Tap 3

Tap 4

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

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

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

80 95 11 5 135 160 190 210 230 255 185 215 245 280 310 335 370 400 430

115 140 165 190 215 230 250 265 230 260 295 335 370 405 435 470 500

130

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

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

150

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

Speed

COOL"

Speed

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

Tap 1

130

Tap 2

Tap 3

Tap 4

Tap 1

Tap 2

Tap 3

Tap 4

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

170

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

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

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

90 11 0 130 155 175 200 220 240 160 190 225 255 285 315 345 380 415

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

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

Speed Switch Positions

Page 20

Page 21

BLOWER DATA

ADJUST"

Stc

Positions

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



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.

G61MPV−60D−135 BLOWER MOTOR WATTS

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

Jumper Speed

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

COOL"

Speed

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

Tap 1

205

Tap 2

Tap 3

Tap 4

Tap 1

Tap 2

Tap 3

Tap 4

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

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

315

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

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

105

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

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

150

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

195

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

Speed

COOL"

Speed

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

Tap 1

155

Tap 2

Tap 3

Tap 4

Tap 1

Tap 2

Tap 3

Tap 4

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

235

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

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

70 90 11 5 135 165 190 210 230 245 170 200 235 265 305 345 380 420 455

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

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

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

COOL"

Speed

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 1

125

Tap 2

Tap 3

Tap 4

Tap 1

Tap 2

Tap 3

Tap 4

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

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

205

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

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

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

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

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

Speed Switch Positions

HEAT speed position.

Page 21

Page 22

BLOWER DATA

ADJUST"

Stc

Positions

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



Switch

Positions

ADJUST"

Switch

Positions

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.

G61MPV−60D−135 BLOWER MOTOR WATTS

Jumper Speed

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

Speed

Tap 1

Tap 2

Tap 3

Tap 4

COOL"

Speed

Tap 1

Tap 2

Tap 3

Tap 4

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

Speed

Tap 1

Tap 2

Tap 3

Tap 4

COOL"

Speed

Tap 1

Tap 2

Tap 3

Tap 4

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

Speed

Tap 1

Tap 2

Tap 3

Tap 4

COOL"

Speed

Tap 1

Tap 2

Tap 3

Tap 4

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

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

HEAT speed position.

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

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

205

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

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

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

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

105

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

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

145

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

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

160

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

235

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

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

70 90 11 5 140 165 190 210 230 250 170 200 235 270 305 335 370 400 430

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

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

145

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

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

125

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

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

160

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

200

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

90 11 0 130 150 170 195 215 235 160 185 215 240 275 310 345 375 410

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

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

Speed Switch Positions

Page 22

Page 23

BURNER BOX

ASSEMBLY

GAS VALVE

AND MANIFOLD

FLUE

COLLAR

TOP CAP

G61MPV PARTS ARRANGEMENT

DuralokPlus

HEAT EXCHANGER

ASSEMBLY

CABINET

COMBUSTION

AIR PRESSURE PROVE

SWITCHES

(36B−045 has 2 single switches)

COMBUSTION AIR

INDUCER

BURNER ACCESS

PANEL

BLOWER

ACCESS

PANEL

SIGHT

GLASS

WARM HEADER

(COLLECTOR)

BOX

CONDENSER COIL

PRIMARY LIMIT

COLD HEADER

(COLLECTOR)

BOX

SECONDARY

LIMITS (2)

DOOR

INTERLOCK

SWITCH

CONTROL BOX

FIGURE 1

Page 23

Power Choke

(5 Ton Only)

CIRCUIT BREAKER

Blower Motor

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.

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.

CIRCUIT BREAKER CB8

ELECTROSTATIC DISCHARGE (ESD)

Precautions and Procedures

CAUTION

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

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.

CONTROL BOX G61MPV

PRESS TO RESET

FIGURE 3

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 12). 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.

DOOR INTERLOCK

SURELIGHT®

CONTROL

BOARD

SWITCH

FIGURE 2

CIRCUIT BREAKER

TRANSFORMER

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 24

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

TWO−STAGE, VARIABLE SPEED INTEGRATED

CONTROL BOARD

DIAGNOSTIC

LEDs

DIP

SWITCHES

1 − 3

LEDs

DIP

SWITCHES

5 − 12

LED

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.

ON−BOARD

JUMPER W914

(cut when SignatureStat,

CCB1 or Harmony II are

used)

ON−BOARD

JUMPER W915

(cut when two−stage

cooling is used)

JUMPER W951

(cut when heat pump is

used with FM21)

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

FIGURE 4

ON−BOARD

Page 25

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 26

Page 27

TABLE 5

ONONON

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

STATUS CODES

STATUS LED COLOR FUNCTION

DS3

ON / OFF ’

DS6

CFM"

DS7

HI / LO"

DS8

HEAT"

GREEN

YELLOW

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

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

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−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.

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

FAST FLASH

SLOW FLASH ON

OFF SLOW FLASH

OFF FAST FLASH

ALTERNATING

SLOW FLASH

SLOW FLASH OFF Flame sensed without gas valve energized.

ON ON

OFF ON

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

SIMULTANEOUS

SLOW FLASH

SIMULTANEOUS

FAST FLASH

ALTERNATING

SLOW FLASH

OFF

ALTERNATING

FAST FLASH

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

Normal operation − signaled when heating demand initiated at thermostat.

Primary, secondary, backup secondary or rollout limit switch open. Limits must close within 3 minutes or unit goes into 1 hour Watchguard. Low prove switch open; OR: Blocked inlet/exhaust vent; OR: Low prove switch closed prior to activation of combustion air inducer.

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

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.

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

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 27

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)

S Motor runs at 50% for 30 seconds. S 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.

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

onds then ramps down to stop.

OFF

1/2 MIN 50% CFM

7 1/2 MIN 82% CFM

COOLING DEMAND

Ramping Option B

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

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

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

7 1/2 MIN

OFF

82%CFM

COOLING DEMAND

100% CFM

1/2 MIN 50% CFM

OFF

Page 28

Page 29

Ramping Option C

S Motor runs at 100% until demand is satisfied.

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

onds then ramps down to stop.

OFF

100% CFM

DEMAND

100% CFM

60 SEC.

OFF

Ramping Option D

S Motor runs at 100% until demand is satisfied.

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

100% CFM

COOLING DEMAND

OFFOFF

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

Page 29

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 13). The board and ignitor work in combination to ensure furnace ignition and ignitor durability. The SureLight integrated board controls all major furnace operations. The board features a red LED light, for furnace status and troubleshooting. The LED flashes in X" + Y" codes. For example using table 15 under PRESSURE SWITCH CODES", if the red LED flashes 2 times, then off for 2 seconds then flashes 3 times, the low pressure switch is failed open. Two green LEDs show indoor blower status and CFM. See Page 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 30

Page 31

TWO−STAGE, VARIABLE SPEED INTEGRATED CONTROL BOARD

1/4" QUICK CONNECT TERMINALS

NEUTRALS= 120 VAC NEUTRAL

DIAGNOSTIC

LEDs

HEATING

DIP

SWITCHES

FUTURE USE

INDOOR

BLOWER DIP

SWITCHES

H= 24V HUMIDIFIER OUTPUT

ON−BOARD

JUMPERS

L= LENNOX SYSTEM OPERATION MONITOR 1= FUTURE USE

THERMOSTAT CONNECTIONS (TB1)

DIP SWITCH FUNCTIONS

HTG DIP SWITCH(ES) FUNCTION

1 T’stat Heat Stages (single or two−stage)

W915

W951

W914

INDOOR BLOWER

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

3 and 4 Heating Fan OFF Delay

FUNCTION

DIP SWITCH(ES)

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

FIGURE 5

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 31

Page 32

FIGURE 6

Page 32

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

Pulse Power on − Standby.

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

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

FLAME CODES

1 + 2 Low flame current −− run mode.

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

PRESSURE SWITCH CODES

2 + 3 Low pressure switch failed open.

2 + 4 Low pressure switch failed closed.

2 + 5 High pressure switch failed open.

2 + 6 High pressure switch failed closed.

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

LIMIT CODE

3 + 1 Limit switch open.

WATCHGUARD CODES

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

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

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

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

4 + 6

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

4 + 8 Low line voltage.

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

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.

Page 33

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.

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.

Cooling Mode Blower Speeds

Speed

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.

Blower Speed Adjustment

Adjustment

+10% (approx.) On Off

NORMAL (Factory) Off Off

−10% (approx.) Off On

TABLE 17

Switch 5 Switch 6

TABLE 18

Switch 7 Switch 8

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)

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

Switch 3 Switch 4

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.

Cooling Mode Blower Speed Ramping

Ramping Option

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.

TABLE 19

Switch 9 Switch 10

Page 34

Page 35

TABLE 20

humidity

Dehumidification mode begins when relative hu mand), slide switch is moved down and back up

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 either the Harmony III zone control board or a thermostat which features humidity control. If the jumper is left intact the PWM signal from the HARMONY III control will be blocked and also lead to control damage. Refer to table 21 (CCB1) and table 23 (SignatureStatt) for operation sequence in applications including G60DFV, a thermostat which features humidity control and a single−speed outdoor unit. Table 22 (CCB1) and table 24 (SignatureStat) gives the operation sequence in 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 a thermostat which features dual fuel use. If the jumper is left intact, terminal O" will remain energized eliminating the HEAT MODE in the heat pump.

On−Board Jumper W915

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−Speed Outdoor Unit

OPERATING MODE SYSTEM DEMAND SYSTEM RESPONSE

System Condition

Normal operation Y1

*Call for humidity

removal during

cooling demand

Dehumidification demand satisfied

during cooling demand.

Call for cooling after call for

removal.

Humidity demand

satisfied between

thermostat demands (unit

off cycle).

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

Thermostat

Demand

None

None Over setpoint (1 or more) Off

Y1 Change to acceptable COOL

*Relative Humidity

(EfficiencyPlus Lights)

No demand. Humidity

level is acceptable

Humidity level rises above

setpoint. Demand initiated.

Humidity level falls below set-

point. No demand

Humidity level above setpoint.

Demand initiated.

Humidity level above setpoint.

Demand initiated.

Blower CFM

(COOL)

COOL

70%

of COOL

COOL

Off

70%

of COOL

Comments

Compressor demand and indoor blower speed controlled by thermostat demand.

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

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

Dehumidification mode begins when relative humidity is greater than setpoint.

While unit is not operating (no thermostat de-

Blower operates at COOL CFM.

Page 35

Page 36

TABLE 22

Normal operation

blower speed controlled by

removal during

until after initial thermostat demand is

humidity during

When humidity demand is satisfied

satisfied during

speed compressor operation at begin

compressor) begins with next thermo

satisfied between

OPERATING SEQUENCE

G61MPV, CCB1 and Two−Speed Outdoor Unit

OPERATING MODE SYSTEM DEMAND SYSTEM RESPONSE

System

Condition

Thermostat

Demand

*Relative Humidity

(EfficiencyPlus Lights)

****Compressor

Speed

Blower CFM

(COOL)

Comments

Normal operation

Call for humidity

1st−stage cooling

demand

Significant increase in

thermostat cooling

demand.

Humidity demand

thermostat demand.

Call for humidity

removal during 2nd

stage thermostat

eman

*Call for 1st stage

cooling after call for

humidity removal.

Call for 2nd stage

cooling after call for

humidity removal

Call for cooling after

significant increase in

humidity

Humidity demand satisfied between

thermostat demands

(unit off cycle).

Y1 No demand. Acceptable Low

Y2 No demand. Acceptable High HIGH COOL

Y1 No demand. Acceptable Low

Demand

satisfied

None

Y1 or Y2

None

Y1 or Y2

Humidity level rises slightly

(1) above setpoint. Demand

initiated.

Humidity level remains

slightly (1) above setpoint.

Demand continues.

Humidity level remains

slightly (1) above setpoint.

Demand continues.

No demand. Acceptable

Humidity level rises signifi-

cantly (2 or more) above

setpoint. Demand initiated.

Humidity level

above setpoint.

Humidity level falls below

setpoint. No demand.

No demand. Acceptable

Humidity level rises slightly

(1) above setpoint. Demand

initiated.

No demand. Acceptable

Humidity level is slightly (1)

above setpoint.

Humidity level is slightly (1)

above setpoint.

Humidity level is slightly (1)

above setpoint.

Humidity level is slightly (1)

above setpoint.

Humidity level is significantly

above setpoint (2 or more).

Humidity level is significantly

above setpoint (2 or more).

Humidity level is slightly (1)

above setpoint.

Humidity level falls below

setpoint. No demand.

Low

Off

High

Low

High

Off

Low

High

Off

Low

Off

High

Off

High

Off

High

**49% of HIGH

COOL

**49% of HIGH

COOL

**49% of HIGH

COOL

***70%of

HIGH COOL

**49% of HIGH

COOL

***70% of

HIGH COOL

***70% of

HIGH COOL

**49% of HIGH

COOL

HIGH COOL

***70% of

HIGH COOL

**49% of HIGH

COOL

***70% of

HIGH COOL

***70% of

HIGH COOL

Off

Compressor demand and indoor

blower speed controlled by

thermostat demand

Dehumidification mode does not begin

satisfied and new cooling demand is

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

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-

Blower immediately changes speed in

response to thermostat demand.

Dehumidification mode (high speed

com

ressor) begins with next thermo-

stat demand after initial demand is sat-

Reduced blower speed (dehumidifica-

tion speed) begins immediately with

If humidity increases significantly over

setpoint, or if slide switch is moved,

unit immediately goes into dehumidifi-

cation mode (in presence of thermostat

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

initiated.

thermostat demand).

ning of next cycle.

isfied.

thermostat demand

demand).

next thermostat demand.

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 36

Page 37

TABLE 23

Syst

Blower

begi

idity i

setpoint by allowing the

Jumpers at indoor unit with a single stage outdoor unit

room space to maintain a

With Condensing unit Cut W914 (R to DS) on SureLight board

G61MPV, SignatureStatt and SINGLE STAGE OUTDOOR UNIT

OPERATING

SEQUENCE

Condition

NO CALL FOR DEHUMIDIFICATION

Normal Operation 1 On On On Acceptable

BASIC MODE (only active on a Y1 thermostat demand)

Normal Operation 1 On On On Acceptable

Dehumidification

Call

PRECISION MODE (operates independent of a Y1 thermostat demand)

Normal Operation 1 On On On Acceptable

Dehumidification

call

Dehumidification

call ONLY

Step

2 On On On Demand

1 On On On Demand

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

Thermostat Demand Relative Humidity

Y1 O G

SYSTEM DEMAND SYSTEM RESPONSE

Status D

VAC

ompres-

sor

High 100%

High 70%*

High 100%

High 70%*

Blower

CFM

(COOL)

Comments

Compressor and indoor blower follow thermostat demand

SignatureStat energizes

and de−energizes D on

a call for de−humidification

Dehumidification mode

ns when hum

greater than set point

SignatureStat will try to maintain room humidity

oint by allowing the

set room space to maintain a cooler room thermostat setpoint**

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 37

Page 38

TABLE 24

Syst

Blower

idity i

room space to maintain a

With Condensing unit

Cut W914 (R to DS) on SureLight board

G61MPV, SignatureStatt and TWO STAGE OUTDOOR UNIT

OPERATING

SEQUENCE

Condition

NO CALL FOR DEHUMIDIFICATION

Normal Operation −

ROOM THERMOSTAT CALLS FOR FIRST STAGE COOLING

BASIC MODE (only active on a Y1 thermostat demand)

Normal Operation 1 On On On Acceptable

Dehumidification

Call

PRECISION MODE (operates independent of a Y1 thermostat demand)

Normal Operation 1 On On On Acceptable

Dehumidification

call

Dehumidification

call ONLY

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

Dehumidification

Call

PRECISION MODE (operates independent of a Y1 thermostat demand)

Normal Operation 1 On On On Acceptable

Dehumidification

call

Step

1 On On On Acceptable

2 On On On On Acceptable

2 On On On On Demand

1 On On On On Demand

2 On On On On Demand

Thermostat Demand Relative Humidity

Y1 Y2 O G

SYSTEM DEMAND SYSTEM RESPONSE

W1W

Status D

VAC

Compressor

Low 70%*

High 100%

Low 70%*

High 70%*

Low 70%*

High 70%*

High 100%

High 70%*

Low 70%*

High 70%*

Blower

CFM

(COOL)

Comments

Compressor and indoor

ower follow thermosta

demand

SignatureStat energizes

and de−energizes D on

a call for de−humidification

Dehumidification mode begins when hum greater than set point

SignatureStat will try to maintain room humidity setpoint by allowing the room space to maintain a cooler room thermostat setpoint**

SignatureStat energizes

and de−energizes D on

a call for de−humidification

Dehumidification mode begins when hum greater than set point

Dehumidification

call ONLY

1 On On On On Demand

Jumpers at indoor unit with a two stage outdoor unit Cut factory jumper from Y1 to Y2 or cut W915 (Y1 to Y2) With Condensin With Heat Pump − Cut W914 (R to DS) & W951 (R to O) on SureLight board

unit − Cut W914 (R to DS) on SureLight board

−

VAC

High 70%*

SignatureStat will try to maintain room humidity setpoint by allowing the room s cooler room thermostat setpoint**

ace to maintain a

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 38

Page 39

B−Blower Compartment Figure 7

SECONDARY

LIMITS (2)

Power Choke

(5 Ton Only)

To Remove Blower From Unit: Remove Bolts and

Wiring Jackplugs. Then Slide Out Front of Unit.

Secondary Limt (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 limts. 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)

G61MPV units use a three-phase, electronically controlled D.C. brushless motor (controller converts single phase a.c. to three phase D.C.), with a permanent-magnet-type rotor (figure 8). Because this motor has a permanent magnet rotor it does not need brushes like conventional D.C. motors. Internal components are shown in figure 9. The stator windings are split into three poles which are electrically connected to the controller. This arrangement all o w s mot o r wind i n g s to turn on and off in sequence by the controller.

A solid-state controller is permanently attached to the motor. The controller is primarily an A.C. to D.C. converter. Converted D.C. power is used to drive the motor. The controller contains a microprocessor which monitors varying conditions inside the motor (such as motor workload).

G61MPV BLOWER MOTOR B3

SHAFT

MOTOR

CONTROLLER

Blower Motor

(B3)

FIGURE 7

J48

J49

FIGURE 8

G61MPV BLOWER MOTOR COMPONENTS

STATOR

(WINDINGS)

BEARING

OUTPUT

SHAFT

ROTOR

FIGURE 9

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 9) 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 11), 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 zone control system, Efficiency Plus Humidity Control (CCB1) or a conventional thermostat.

Motor rpm is continually adjusted internally to maintain constant static pressure against the blower wheel. The controller monitors the static work load on the motor and motor ampdraw 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.

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.

Page 39

Page 40

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)

Figure 10 shows 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.

Line voltage must be applied to J48 pin 5 in order for the motor to operate. When using 120VAC pins 1 and 2 must be jumpered. When control voltage is applied to J49 pin 3 and 15, the motor is energized on the continuous fan mode.

When voltage is applied to J49 pin 2 in addition to pin 3 and 15 (first stage heating), the blower is energized on the low speed heating tap. When voltage is applied to J49 pin 13 in addition to pin 3 and 15 (second stage heating), the blower

is energized on the high speed heating tap. 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.

BLOWER B3 HARNESS CONNECTORS

POWER

CONNECTOR J48

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

CONTROL

CONNECTOR J49

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 +

FIGURE 10

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 supress 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 ma ll spec k s or l i ne s 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 rferenc e pers ists, make sure 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 40

Page 41

ЗЗЗЗЗЗЗЗЗЗЗЗЗЗЗЗЗ

MOTOR SPEED CONTROL WITH D.C. PULSE-WIDTH MODULATION

Motor speed is determined by the size of the electrical pulse sent to

the motor windings. The longer the pulse, the faster the motor.

OUTPUT FROM CONTROLLER TO MOTOR WINDINGS

WINDINGS TURNED OFF

The frequency of the pulses to the windings is 20KHz.

DO NOT ATTEMPT TO MEASURE THESE VOLTAGES.

LOW SPEED HEAT/COOL (output from controller to motor windings)

One

Pulse

One revolution

325VDC

O volts

WINDING #1

325VDC

O volts

WINDING #2

325VDC

O volts

WINDING #3

HIGH SPEED HEAT (output from controller to motor windings)

One revolution

325VDC

O volts

WINDING #1

325VDC

O volts

WINDING #2

325VDC

O volts

WINDING #3

WINDINGS TURNED ON

ON PULSE

OFF PULSE

HIGH SPEED COOL (output from controller to motor windings)

One revolution

325VDC

O volts

WINDING #1

325VDC

O volts

WINDING #2

325VDC

O volts

WINDING #3

FIGURE 11

Page 41

Page 42

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 12 and 13 (make note of control board used) for ignitor location.

SureLight Board 49M59 Ignitor Location

MEASUREMENT IS TO

5/8

I.D. OF RETENTION RING

13/32’

NOTE − The G60DFV(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 14 and 15 (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.

5/16"

IGNITOR

7/32’

IGNITOR

BURNERS FRONT VIEW

MEASUREMENT IS TO

5/8

I.D. OF RETENTION RING

BURNERS FRONT VIEW

BRACKET

FIGURE 12

SureLight Board 100870 Ignitor Location

21/64"

BRACKET

FIGURE 13

BURNERS TOP VIEW

Page 42

Page 43

SureLight Board 49M59 Sensor

NORMAL FLAME SIGNAL > 0.23 MICROAMPS LOW FLAME SIGNAL < 0.22 MICROAMPS DROP OUT SIGNAL = 0.16 MICROAMPS

5/16"

FIGURE 14

SureLight Board 100870 Sensor

NORMAL FLAME SIGNAL > 1.50 MICROAMPS LOW FLAME SIGNAL < DROP OUT SIGNAL = 0.20 MICROAMPS

5/16"

1.40 MICROAMPS

FIGURE 15

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 venturi 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 16 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 16) 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 44) or White Rodgers (figure 45). 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 43

Page 44

PRIMARY LIMIT LOCATION

WARNING

The prove switch is a safety shut−down control in the furnace and must not be jumpered for any reason.

DUAL COMBUSTION AIR PROVE SWITCH

(−070, −071, −090, −091, −110, −111 −135 SHOWN)

limit shield

090, −110 and

−135 only

limit faces shield

FIGURE 16

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 17. The G61MPV−045 units have two single swithes as shown in figure 18. 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 26 through 31. 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.

second

stage

first stage

FIGURE 17

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, but may i n d ic a te problems in the heat exchanger, condensing coil, header boxes, combustion inducer or other components.

negative

pressure

positive

pressure

Page 44

Page 45

Measuring pressure differential Figures 18 and 19

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.

CAI & COLD END HEADER BOX ASSEMBLY

(−045 SHOWN)

Install tee’s in the

negative line and positive line then connect hoses to

manometer.

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 26 through 31.

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.

cold end header box

prove switches

orifice size

FIGURE 18

CAI & COLD END HEADER BOX ASSEMBLY

(−070, −071, −090, −091, −110, −111, −135 SHOWN)

Install tee’s in the

negative line and positive line then connect hoses to

manometer.

orifice size

negative and positive taps

(same on other side)

prove switches

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 19. See table 25 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.

FIGURE 19

Page 45

Page 46

TABLE 25

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 26

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 27

0’ to 2000’ 95% Furnaces

G61MPV Unit

Set Point

Second Stage

Set Point

First Stage

−071 1.05" 0.70"

−091 1.50" 0.90"

−111 1.15" 0.65"

TABLE 29

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 30*

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 31*

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.

TABLE 28

2001’ to 7500’ 95% Furnaces

G61MPV Unit

Set Point

Second Stage

−071 0.85" 0.70"

−091 1.30" 0.90"

−111 0.95" 0.55"

Set Point

First Stage

Page 46

Page 47

II−PLACEMENT AND INSTALLATION

36B−045

36B 070

60C 090

60C 111 60D−135

OUTDOOR TERMINATION KITS AND CORRESPONDING EQUIVALENCIES

Outdoor Exhaust

Accelerator

(Dia. X

Length)

UNIT

MODEL

VENT

PIPE

DIA.

(in.)

1−1/2" X 12"

2 4

2−1/2 5

3 7

4 14

2 4

36B−070 36B−071

60C−090 60C−091

60C−110 60C−111

2−1/2 5

3 8

4 14

2−1/2

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

*Requires field−provided and installed 1−1/2" exhaust accelerator. **Requires field−provided and installed 2" exhaust accelerator. ***For use only in non−direct vent applications, when snow riser is

Outdoor

Exhaust

Accelerator

(Dia. X

1−1/2"

Concen-

tric Kit

Length)

2" X 12" 71M80 60M29 60L46 22G44

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

TABLE 32

Vent Pipe Length Equivalency (feet)

2" Con-

Allowed

centric

Kit

Not

3 3

6 6

12 12

6 6

12 12

Not

not required. Requires field−provided and installed 2" exhaust accelerator.

3" Con-

centric

Kit

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

2" Wall

Plate Kit

3" Wall

Plate Kit

Kit with

Vent Ex-

tension

44J40 81J20

4 4* 4 4

5 5* 5 5

7 7* 7 7

14 14* 14 14

4 4* 4 4

5 5* 5 5

8 8* 8 8

14 14* 14 14

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

30G28 15F74

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

2" Wall

Ring Kit

1**

2**

4**

2***

4***

6***

10***

Page 47

Page 48

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 33 and 34. Table 33 lists the minimum equivalent vent pipe lengths permitted. Table 34 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 35.

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

12" Min.

Upflow and Downflow Application

Rooftop Termination

12" Min.

Horizontal Application

Rooftop Termination

Exhaust Pipe Offset

12" Min.

Upflow and Downflow Application

Side Wall Termination

12" Min.

Horizontal Application

Side Wall Termination

FIGURE 20

Page 48

Page 49

Use the following steps to correctly size vent pipe diameter.

ALTITUDE

MODEL

0 − 4500

4501−7500

(1372 2286 m)

)

1 − Determine the vent termination and its corresponding equivalent feet value according to table 32.

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 34 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.

MINIMUM VENT PIPE LENGTHS

G61MPV

MODEL

045, 070, 071, 090,

091

110, 111**

135***

*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.

MIN. EQUIV.

VENT LENGTH

15 ft.*

TABLE 33

EXAMPLE

5 ft. plus 2 elbows of 2", 2−1/2", 3"

or 4" diameter pipe

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

diameter pipe

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

diameter pipe

MAXIMUM VENT PIPE LENGTHS

ALTITUDE

0 − 4500

(0 − 1371 m)

4501−7500

(1372−2286 m)

7501 − 10000

(2287 − 3048

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.

G61MPV

045 59 65 77 234 070 59 65 78 214

†

071

090

†

091

110* n/a 32 72 179

†

111

135**

045 59 65 77 234 070 59 65 78 214

0701

090 26 42 72 204

†

091

110* n/a 32 72 179

†

111

135**

045 59 65 77 234 070 59 65 78 214

†

071

090 26 42 72 204

†

091

110* n/a 32 72 179

†

111

135**

MAXIMUM EQUIVALENT VENT

2" dia. 2−1/2" dia. 3" dia. 4" dia.

59 65 78 214

26 42 72 204

n/a 32 72 179

‡

n/a n/a 61 160

†

59 65 78 214

26 42 72 204

n/a 32 72 179

‡

n/a n/a 46 160

59 65 78 214

26 42 72 204

n/a 32 72 179

‡

n/a n/a 46 160

LENGTH FEET

B−PVC Joint Cementing Procedure

TABLE 34

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 liberal coat of PVC primer for PVC or

ABS cleaner for ABS to inside socket surface of fitting

and male end of pipe to depth of fitting socket.

Page 49

Page 50

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.

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 22 and 23)

NOTE − A 2" diameter street ell is strapped to the blower deck of 60C−110 units. Street ell must be into the unit flue collar. See figure 22. A 3" to 2" reducing ell is strapped to the blower deck of the 60D−135 units. In

upflow or downflow applications, the reducing ell must be

1. Choose the appropriate side for venting in upflow or

glued directly into the unit flue collar.

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.

glued directly

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.

STRAPPING

(metal, plastic

or large wire

ties)

FIGURE 21

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 toward 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.

Page 50

Page 51

PLUG

VENT PLUG

(Must be

glued in

place)

PLUG

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)

2−1/2", 3", OR

2”

TRANSITION (use only if 4"

pipe is required)

G61MPV−045, 070, 071

090 or 091 with 2−1/2",

2”

3", or 4" vent pipe

2”

PLUG

CONDENSATE

TRAP

(Must be installed

on same side as

exhaust piping)

2”

2−1/2", 3", OR

TRANSITION

2"***

2"*

TRANSITION

3"**

*2" diameter street elbow provided.

**3" diameter reducing elbow provided.

***Limit pipe length to 2".

FIGURE 22

TYPICAL EXHAUST PIPE CONNECTIONS

HORIZONTAL DIRECT OR

NON−DIRECT VENT APPLICATIONS

(Horizontal Right−Hand Air Discharge Application Shown)

*Limit pipe length to 2" in G61MPV−110 and

−135 applications.

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

2−1/2", 3", OR

TRANSITION

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

FIGURE 23

G61MPV−110 with

2−1/2", 3", OR 4"

vent pipe

G61MPV−135 with

3" OR 4" vent pipe

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 24 for pipe sizes.

Page 51

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TYPICAL AIR INTAKE PIPE CONNECTIONS

UPFLOW OR DOWNFLOW DIRECT VENT APPLICATIONS

(Right−Hand Exit in Upflow Application Shown)

2

PLUG

(Must be

glued in

place)

2

G61MPV−36B−045 G61MPV−36B−070 G61MPV−36B−071 G61MPV−36C−090 G61MPV−60C−090 G61MPV−60C−091

FIGURE 24

TYPICAL AIR INTAKE PIPE CONNECTIONS

HORIZONTAL DIRECT VENT APPLICATIONS

(Horizontal Right−Hand Air Discharge Application Shown)

G61MPV−36B−045 G61MPV−36B−070 G61MPV−36B−071

*Limit pipe length to 2" in G61MP−110,

−111 and −135 applications.

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

2”

2”*

2”

2−1/2”,

3” OR 4”

TRANSITION

2”*

TRANSITION

2−1/2”,

3” OR 4”

2”

2−1/2",

3" OR

4

TRANSITION

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*

TRANSITION

2

2"*

2−1/2",

3" OR

4

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*

*Limit pipe length to 2" in G61MPV−110, −111 and −135 applications.

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.

TYPICAL AIR INTAKE PIPE CONNECTIONS

UPFLOW OR HORIZONTAL NON−DIRECT

(Right−Hand Exit in Upflow Application Shown)

PLUG

(Must be

glued in

place)

VENT APPLICATIONS

6 in. Max.

INTAKE

DEBRIS

SCREEN

(Provided)

FIGURE 25

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

FIGURE 26

Page 52

Page 53

TYPICAL AIR INTAKE PIPE CONNECTIONS

DOWNFLOW NON−DIRECT VENT APPLICATIONS

(Right−Hand Exit in Downflow Applications Shown)

2" SWEEP

ELL

INTAKE

DEBRIS

SCREEN

(Provided)

PLUG

(Must be

glued in

place)

6 in. Max.

INTAKE DEBRIS

SCREEN

(Provided)

Downflow

Evaporator

Coil

FIGURE 27

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

air intake screen to route the intake piping as shown in figures 26 and 27. 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 27.

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.

PLUG

(Must be

glued in

place)

Downflow Additive Flloor Base

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

2" SWEEP ELL

18 in.

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.

Page 53

Page 54

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.

The venting system should be re-sized to approach

the minimum size as determined by using the ap-

propriate 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 cur-

rent standard of the CSA−B149 Natural Gas and Pro-

pane 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 for Non-Direct Vent Installations.

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 Non-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 end according to location given in figure 28. In addition, position termination end so it is free from any obstructions and above the level of snow accu-

mulation (where applicable). The termination should be at least 12 inches (305mm) from any opening through which flue products could enter the building.

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 54

Page 55

VENT TERMINATION CLEARANCES

FOR INSTALLATIONS IN THE USA AND CANADA*

− G61MPV VENT TERMINATION

− AIR INLET OF OTHER APPLIANCE

less than 10 ft (3.048M)

A − Clearance above grade − 12 in. (305mm) minimum. B − Clearance to window or door that may be opened −

for vent installations in USA − 12 in. (305mm) minimum. for vent installations in Canada − 12 in. (305mm) minimum

for appliances  100,000 Btuh (30 kW); 36 in. (0.9m) minimum for appliances > 100,000 Btuh (30

kW). C − Do not position terminations directly under roof eaves. D − Clearance to electric meters, gas meters, regulators, and

relief equipment −

for vent installations in USA − 48 in (1219mm) minimum.

for vent installations in Canada − see current edition of CSA

B149 Code.

* Note −

(I) Dimensions are from the current edition of The National Fuel Gas Code − ANSI-Z223.1/NFPA 54 for USA installations. In Canada, refer to current edition of CSA B149 installation codes. Local codes or regulations may require different clearances.

(II) In Non-Direct Vent installations, combustion air is taken from indoors and the flue gases are discharged to the outdoors.

E − Clearance to non−mechanical air supply inlet or outlet

for vent installations in USA − 48 in. (1219mm) minimum horizontal and below, 12 in. (305mm) minimum above. for vent installations in Canada − 12 in. (305mm) minimum

for appliances  100,000 Btuh (30 kW); 36 in. (0.9m) minimum for appliances > 100,000 Btuh (30 kW).

F − Clearance to mechanical air supply inlet −−

for vent installations in USA − 36 in. minimum (914mm).

G − Clearance to mechanical air supply inlet −−

for vent installations in Canada − 72 in. (1829mm) minimum.

H − Do not point terminations into recessed areas such as win-

dow wells, stairwells or alcoves.

J − Do not position terminations directly above a walkway.

FIGURE 28

Page 55

Page 56

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 29 through 37 show typical terminations.

1. Exhaust and intake exits must be in same pressure zone. Do not exit one through the roof and one on the side. Also, do not exit the intake on one side and the exhaust on another side of the house or structure.

2. Intake and exhaust pipes should be placed as close together as possible at termination end (refer to illustrations). Maximum separation is 3" (76mm) on roof terminations and 6" (152mm) on side wall terminations.

3. If necessary, install a field−provided reducer to adapt larger vent pipe size to termination pipe size.

4. On roof terminations, the intake piping should terminate straight down using two 90° elbows (See figure

29).

5. Exhaust piping must terminate straight out or up as shown. In rooftop applications, a reducer may be required on the exhaust piping at the point where it exits the structure to improve the velocity of exhaust away from the intake piping. See table 35.

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

6. On field supplied terminations for side wall exits, exhaust piping should extend a maximum of 12 inches (305mm) beyond the outside wall unless supported. Intake piping should be as short as possible. See figure 30.

7. On field supplied terminations, a minimum separation distance between the end of the exhaust pipe and the end of the intake pipe is 8 inches (203mm).

8. If intake and exhaust piping must be run up a side wall to position above snow accumulation or other obstructions, piping must be supported every 3 ft. (.9m) as shown in figure 21. Refer to figure 33 for proper piping method. In addition, WTK wall termination kit must be extended for use in this application. See figure 36. When exhaust and intake piping must be run up an outside wall, the exhaust piping must be terminated with pipe sized per table 35. The intake piping may be equipped with a 90° elbow turndown. Using turndown will add 5 feet (1.5m) to the equivalent length of the pipe.

9. Based on the recommendation of the manufacturer, a multiple furnace installation may use a group of up to four termination kits WTK assembled together horizontally, as shown in figure 35.

TABLE 35

EXHAUST PIPE TERMINATION SIZE REDUCTION

G61MPV

MODEL

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

090, 091 2", 2−1/2", 3" or 4" 2"

110, 111 2−1/2", 3" or 4" 2"*

135 3" or 4" 2"*

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

Inches(mm)

8" (203) MIN

12" (305) ABOVE AVERAGE SNOW ACCUMULATION

3" (76) OR

2" (51) PVC

PROVIDE SUPPORT

FOR INTAKE AND

EXHAUST LINES

Exhaust Pipe Size Termination Pipe Size

3(76) MAX.

DIRECT VENT ROOF TERMINATION KIT

(15F75 or 44J41)

SIZE TERMINATION

PIPE PER TABLE 35.

UNCONDITIONED

ATTIC SPACE

1/2" (13) FOAM

INSULATION IN

UNCONDITIONED

SPACE

FIGURE 29

12" (305) MAX.

1/2" (13) ARMAFLEX

INSULATION IN

UNCONDITIONED SPACE

FIELD−

PROVIDED

REDUCER MAY

BE REQUIRED

TO ADAPT

LARGER VENT

PIPE SIZE TO

TERMINATION

OUTSIDE

WALL

2" (51) PVC COUPLING

TOP VIEW WALL RING KIT

(unless supported)

6" (152)

MAXIMUM

MINIMUM

(15F74)

8" (203)

1/2" (13)

ARMAFLEX

INSULATION

SIZE

TERMINATION

PIPE PER

TABLE 35.

Inches (mm)

FIGURE 30

Page 56

Page 57

EXHAUST

TERMINATION

INTAKE

TERMINATION

12" (305) ABOVE

AVERAGE SNOW

ACCUMULATION

Inches (mm)

INTAKE

VENT

EXHAUST VENT

Front View

FIELD−PROVIDED

REDUCER MAY BE REQUIRED

TO ADAPT LARGER VENT

PIPE SIZE TO TERMINATION

EXHAUST

INTAKE

DIRECT VENT CONCENTRIC ROOFTOP TERMINATION

(71M80, 69M29 or 60L46)

FIGURE 31

Inches (mm)

EXHAUST

INTAKE

FIELD−PROVIDED

REDUCER MAY

BE REQUIRED TO

ADAPT LARGER

VENT PIPE SIZE

TO TERMINATION

DIRECT VENT CONCENTRIC WALL TERMINATION

(71M80, 69M29 or 60L46)

INTAKE

TERMINATION

EXHAUST

TERMINATION

12" (305) Min.

above grade.

FIGURE 32

1/2" (13) Foam Insulation

in Unconditioned Space

FIELD−

PROVIDED

REDUCER MAY

BE REQUIRED

TO ADAPT

LARGER VENT

PIPE SIZE TO

TERMINATION

Inches (mm)

DIRECT VENT WALL TERMINATION KIT

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

EXHAUST

VENT

INTAKE

VENT

Inches (mm)

FIGURE 34

(127)

18" MAX.

(457)

Side View

EXHAUST VENT

INTAKE VENT

OUTSIDE WALL

12"

(305)

5−1/2"

(140)

Front View

EXHAUST VENT

INTAKE

VENT

Side View

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

Inches(mm)

UNCONDITIONED

SPACE

OUTSIDE WALL

PROVIDE SUPPORT

FOR INTAKE AND

EXHAUST LINES EVERY

36" (914)

FIELD−PROVIDED

REDUCER MAY

BE REQUIRED TO

ADAPT LARGER

VENT PIPE SIZE

TO TERMINATION

1/2" (13) FOAM

INSULATION IN

UNCONDITIONED

SPACE

(unless supported)

8 (203)

MIN.

12" (305) ABOVE AVERAGE SNOW ACCUMULATION

1/2" (13) FOAM

INSULATION

SIZE

TERMINATION

PIPE PER

TABLE 35.

SIDE VIEW

DIRECT VENT WALL RING TERMINATION

(15F74)

See venting table 34 for maximum venting lengths with this arrange-

ment.

FIGURE 33

OPTIONAL VENT TERMINATION FOR MULTIPLE UNIT

INSTALLATION OF DIRECT VENT WALL TERMINATION KIT WTK

FIGURE 35

Page 57

Page 58

INTAKE

AIR

GRADE

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

(unless supported)

8" (203)

Minimum

Side View

Inches (mm)

EXHAUST

AIR

12" (305)

Minimum

ABOVE GRADE

INTAKE

AIR

(127)

12"

(305)

5-1/2"

(140)

COVER EXHAUST

VENT WITH

1/2" (13)

FOAM

INSULATION

EXHAUST

AIR

12" MIN.

(305)

Above Grade

GRADE

DIRECT VENT TERMINATION

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

FIGURE 36

Front View

G61MPV DIRECT VENT APPLICATION

USING EXISTING CHIMNEY

3" − 8"

8" − 12"

(203mm − 305mm)

INTAKE PIPE

INSULATION (optional)

SHEET

METAL TOP

PLATE

MINIMUM 12"

(305mm) ABOVE

ROOF

INSULATE

TO FORM

SEAL

*SIZE TERMINATION PIPE PER TABLE 35.

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.

(76mm−

203mm)

STRAIGHT−CUT OR

ANGLE−CUT IN DIRECTION

OF ROOF SLOPE *

EXHAUST VENT

1/2" (13mm)

WEATHERPROOF

INSULATION

SHOULDER OF FITTINGS

PROVIDE SUPPORT

OF PIPE ON TOP PLATE

3" − 8" (76mm− 203mm)

ALTERNATE

INTAKE PIPE

EXTERIOR

PORTION OF

CHIMNEY

FIGURE 37

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 38 through 41 show typical terminations.

1. Exhaust piping must terminate straight out or up as shown. The termination pipe must be sized as listed in table 35.The specified pipe size ensures proper velocity required to move the exhaust gases away from the building.

2. On field supplied terminations for side wall exits, exhaust piping should extend a maximum of 12 inches (305mm) beyond the outside wall, unless support is provided in the horizontal section. See figure 39.

Inches(mm)

12" (305mm)

ABOVE AVE.

SNOW

ACCUMULATION

3" (76) OR

2" (51) PVC

PROVIDE SUPPORT

FOR EXHAUST LINES

SIZE TERMINATION

PIPE PER TABLE

35.

UNCONDITIONED

ATTIC SPACE

NON−DIRECT VENT ROOF TERMINATION KIT

(15F75 or 44J41)

FIGURE 38

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

1/2" (13) ARMAFLEX

INSULATION IN

UNCONDITIONED SPACE

FIELD−PROVIDED

REDUCER MAY

BE REQUIRED TO

ADAPT LARGER

VENT PIPE SIZE

TO TERMINATION

Inches (mm)

Unless Supported

PVC REDUCER

SIZE TERMINATION

PIPE PER TABLE 35.

1/2" (13)

ARMAFLEX

INSULATION

TOP VIEW

NON−DIRECT VENT WALL RING KIT

(15F74)

FIGURE 39

3. If exhaust piping must be run up a side wall to position above snow accumulation or other obstructions, piping must be supported every 3 feet (.9m) as shown in figure 21. Refer to figure 40 for proper piping method. When exhaust piping must be run up an outside wall, any reduction in exhaust pipe size must be done after the final elbow.

Page 58

Page 59

Inches(mm)

UNCONDITIONED

SPACE

OUTSIDE WALL

PROVIDE SUPPORT

FOR EXHAUST LINES

EVERY 36" (914)

FIELD−PROVIDED

REDUCER MAY BE

REQUIRED TO

ADAPT LARGER

VENT PIPE SIZE TO

TERMINATION

1/2" (13) FOAM

INSULATION IN

UNCONDITIONED

SPACE

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

SIZE TERMINATION

PIPE PER

TABLE 35.

12" (305) ABOVE

AVERAGE SNOW

ACCUMULATION

1/2" (13) FOAM

INSULATION

SIDE VIEW

NON−DIRECT VENT WALL RING TERMINATION

(15F74)

FIGURE 40

G61MPV NON−DIRECT VENT APPLICATION

USING EXISTING CHIMNEY

SIZE TERMINATION

PIPE PER TABLE 35.

3" − 8"

(76mm−

MINIMUM 12"

MINIMUM

12" (304mm)

(305mm) ABOVE

ABOVE AVERAGE

AVERAGE SNOW

SNOW ACCUMULATION

ACCUMULATION

METAL TOP

INSULATE

TO FORM

SEAL

203mm)

SHEET

PLATE

STRAIGHT−CUT OR

ANGLE−CUT IN DIRECTION

OF ROOF SLOPE

EXHAUST VENT

1/2" (13mm)

WEATHERPROOF

INSULATION

SHOULDER OF FITTINGS

PROVIDE SUPPORT

OF PIPE ON TOP PLATE

3" − 8" (76mm− 203mm)

EXTERIOR

PORTION OF

CHIMNEY

FIGURE 41

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 42 for condensate trap locations.

CONDENSATE TRAP LOCATIONS

(Unit shown in upflow position)

Horizontal

left and

optional

downflow

Optional

upflow

Horizontal

right and

optional

downflow

Optional

upflow

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.

FIGURE 42

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. See figure 43.

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 59

Page 60

3 − Glue the field−provided coupling or 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.

CONDENSATE ASSEMBLY

HI/LO SCREWS

CAP

O−RINGS

SCREW

(DO NOT use power driver. Hand−tighten

using screw driver.)

NIPPLE

COUPLING

CLEAN−OUT ACCESS

CONDENSATE TRAP

VENT

NIPPLE

TEE

(both sides)

FIGURE 43

Page 60

Page 61

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 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.

ignition

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 44 and 45)

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

44.

White Rodgers 36E Gas Valve − Switch gas valve le-

ver to OFF. See figure 45 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

HIGH FIRE

ADJUSTMENT

SCREW

(under cap)

LOW FIRE

ADJUSTMENT

SCREW

(under cap)

hose barb in place of cap

GAS VALVE SHOWN IN OFF POSITION

to OFF. Do not force. See figure

REFERENCE TO

BURNER BOX

iNLET PRESSURE TAP

FIGURE 44

MANIFOLD

PRESSURE

TAP

Page 61

Page 62

WHITE RODGERS 36E SERIES GAS VALVE

HIGH FIRE

MANIFOLD

PRESSURE

ADJUSTMENT

ON SIDE

(under cap)

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

MANIFOLD

PRESSURE

TAP ON SIDE

INLET PRESSURE

TAP ON SIDE

GAS VALVE SHOWN IN OFF POSITION

8 − Honeywell VR8205 Gas Valve − Turn knob on gas

valve counterclockwise White Rodgers 36E Gas Valve − Switch gas valve lever to ON. See figure 45 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.

LOW FIRE MANIFOLD

PRESSURE ADJUSTMENT

ON SIDE (under cap)

FIGURE 45

to ON. Do not force.

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 46.

GAS PIPING TEST PROCEDURE

MANUAL MAIN SHUT−OFF VALVE

3 − Remove the upper access panel.

4 − Honeywell VR8205 Gas Valve − Turn knob on gas

valve clockwise White Rodgers 36E Gas Valve − Switch gas valve lever to OFF.

5 − Replace the upper access panel.

to OFF. Do not force.

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.

CAP

GAS VALVE

FIGURE 46

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 62

Page 63

D−Testing Gas Supply Pressure

G61MPV

When testing supply gas pressure, connect test gauge to inlet pressure tap on the gas valve. See figures and 44 and

45. Check gas line pressure with unit firing at maximum rate. Low pressure may result in erratic operation or underfire. High pressure can result in permanent damage to gas valve or overfire. See table 36 for operating pressure at unit gas connection (line).

On multiple unit installations, each unit should be checked separately, with and without units operating. Supply pressure must fall within range listed in table 36.

TABLE 36

All G61MPV Units

Line Pressure WC" 4.5 − 10.5 11.0 − 13.0

Natural LP

E−Check Manifold Pressure

After line pressure has been checked and adjusted, check manifold pressure. Move pressure gauge to outlet pressure tap located on unit gas valve (GV1). Checks of manifold pressure are made as verification of proper regulator adjustment. Manifold pressure for the G61MPV can be measured at any time the gas valve is open and is supplying gas to the unit. See table 40 for manifold pressures.

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

NOTE − During this test procedure, the unit will be overfiring:

D Operate unit only long enough to obtain accurate read-

ing to prevent overheating heat exchanger.

D Attempts to clock gas meter during this procedure will

be inaccurate. Measure gas flow rate only during normal unit operation.

7 − When test is complete remove obstruction from hose

and return hose to gas valve barbed fitting.

F− Proper Gas Flow (Approximate)

Furnace should operate at least 5 minutes before checking gas flow. Determine time in seconds for two revolutions of gas through the meter. (Two revolutions assures a more accurate time.) Divide by two and compare to time in table 37 below. If manifold pressure matches table 36 and rate is incorrect, check gas orifices for proper size and restriction.

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

TABLE 37

IMPORTANT

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

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

spheric pressure.

Manifold Pressure Measurement & Adjustment

NOTE − Pressure test adapter kit (10L34) is available from Lennox to facilitate manifold pressure measurement.

1 − Connect test gauge to outlet tap on gas valve. 2 − Disconnect pressure sensing hose from gas valve and

plug hose using tape or equivalent. Leave hose barb on valve open.

3 − Start unit on low heat 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.

GAS METER CLOCKING CHART

Seconds for One Revolution

G61MPV

Unit

−45 82 164 205 410

−70, −071 55 110 136 272

−90, −091 41 82 102 204

−110, −111 33 66 82 164

−135 27 54 68 136

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

Natural LP

1 cu ft

Dial

2 cu ft

Dial

1 cu ft

Dial

2 cu ft

DIAL

IMPORTANT

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

G− Proper Combustion

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

Page 63

Page 64

TABLE 38 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 39

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

pH RANGE

0 1

Increasing

Acidity

Increasing

Alkalinity

2 3 4 5 6 7 8 9 10 11

Vinegar Wine Orange Juice Tomato Juice

Tap Water

G61 Condensate

pH Range

I− 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 tables 40, 41 and 42 for proper manifold pressure settings at varying altitudes and 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.

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.

Page 64

Page 65

TABLE 40

Conversion Kit Requirements and Manifold Pressures for Models

−045, −070, −090, −110 and −135

Model

Input Size

−045

−070

−090

36C−090−9

and later

models

−110

−110−6

and later

−135

Gas

Nat

LPG

Nat

LPG

Nat

LPG

Nat

LPG

Nat

LPG

Nat

LPG

Nat

LPG

0−4500 ft.

(0−1372 m)

Required

Conversion

Kit

N/A

59M13

N/A

59M13

N/A

59M13

N/A

59M13

N/A

59M13

N/A

59M13

N/A

59M13

Pressure

Switch

No Change

4501−7500 ft.

(1373−2286 m)

Required

Conversion

Kit

N/A

59M13

N/A

59M13

N/A

59M13

N/A

59M13

N/A

59M13

N/A

59M13

N/A

59M13

Altitude

Pressure

Switch

No Change

75M22

24W51

56M23

56M93

7501−10,000

(2287−3048 m)

Required

Conversion

Kit

59M17

59M14

59M17

59M14

59M17

59M14

59M17

59M14

59M17

59M14

59M17

59M14

59M17

59M14

Pressure

Switch

No Change

56M23

56M21

24W49

56M23

75M22

56M93

Manifold Pressure at

Low Fire High Fire

in.

w.g.

1.7

4.9

1.7

4.9

1.7

4.9

1.7

4.9

1.7

4.9

1.7

4.9

1.7

4.9

all

altitudes

kPa

0.42

1.22

0.42

1.22

0.42

1.22

0.42

1.22

0.42

1.22

0.42

1.22

0.42

1.22

in.

w.g.

3.5

10.0

3.5

10.0

3.5

10.0

3.5

10.0

3.5

10.0

3.5

10.0

3.5

10.0

kPa

0.87

2.5

0.87

2.5

0.87

2.5

0.87

2.5

0.87

2.5

0.87

2.5

0.87

2.5

Pressure switch is factory set. No adjustment necessary. All models use the factory installed pressure switch from 0−4500 feet (0−1370 m). 1 Oder two pressure switches for conversion

TABLE 41

Conversion Kit Requirements for Models −071, −091 and −111

Altitude

Input

Size

−071

−091

−111

Gas

Nat

LPG

Nat

LPG

Nat

LPG

0 − 2000 ft. (0 − 610 m)

Re-

quired

Con-

ver-

sion

Kit

N/A

59M13

N/A

59M13

N/A

59M13

Pres-

sure

Switch

change

2001 − 4500 ft. (611 − 1372 m)

Re-

quired

Con-

ver-

sion

Kit

N/A

59M13

N/A

59M13

N/A

59M13

Pres-

Switch

75M22

26W85

56M22

sure

4501 − 5500 ft.

(1373 − 1676 m)

Re-

quired

Con-

ver-

sion

Kit

N/A

59M13

N/A

59M13

N/A

59M13

Pres-

sure

Switch

75M22

26W85

56M22

5501 − 6500 ft. (1677−1981 m)

Re-

quired

Con-

ver-

sion

Kit

N/A

59M13

N/A

59M13

N/A

59M13

Pres-

sure

Switch

75M22

26W85

56M22

6501 − 7500 ft.

(1982 − 2286 m)

Re-

quired

Con-

ver-

sion

Kit

N/A

59M13

N/A

59M13

N/A

59M13

Pres-

sure

Switch

75M22

26W85

56M22

7501 − 10,000

(2287 − 3048 m)

Re-

quired

Con-

ver-

sion

Kit

59M17

59M14

47M82

59M14

47M82

59M14

Pres-

sure

Switch

56M21

26W86

56M23

Re-

place-

ment

Orifice

Size

0.086

0.052

0.081

0.052

0.081

0.052

NOTE − Pressure switch is factory set. No adjustment necessary. *Two pressure switch assemblies required per unit.

Page 65

Page 66

Model

Input

Size

−071

−091

−111

Gas

Nat

LPG

Nat

LPG

Nat

LPG

TABLE 42

Manifold Pressures at Different Altitudes for Models −071, −091 and −111

Altitude

0 − 2000 ft.

(0 − 610 m)

Low

Fire

1.7

4.9

1.7

4.9

1.7

4.9

High

Fire

3.5

10.0

3.5

10.0

3.5

10.0

2001 − 4500 ft.

(611 − 1372 m)

Low

Fire

1.7

4.9

1.7

4.9

1.7

4.9

High

Fire

3.5

10.0

3.4

10.0

3.4

10.0

4501 − 5500 ft.

(1373 − 1676 m)

Low

Fire

1.7

4.9

1.7

4.9

1.7

4.9

High

Fire

3.5

10.0

3.3

10.0

3.3

10.0

5501 − 6500 ft.

(1677 − 1981 m)

Low Fire

1.7

4.9

1.7

4.9

1.7

4.9

High

Fire

3.5

10.0

3.2

10.0

3.2

10.0

6501 − 7500 ft.

(1982 − 2286 m)

Low

Fire

1.7

4.9

1.7

4.9

1.7

4.9

High

Fire

3.5

10.0

3.1

10.0

3.1

10.0

7501 − 10,000

(2287 − 3048 m)

Low Fire

1.7

4.9

1.7

4.9

1.7

4.9

High

Fire

3.5

10.0

3.5

10.0

3.5

10.0

Page 66

Page 67

J−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47. The transducer converts microamps to volts on a 1:1 conversion. See figures 14 and 15 for flame signal. A digital readout meter must be u s e d . The transducer plugs into most meters. See figure 48 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.

(−)

FLAME SENSOR

(+) TO

IGNITION

CONTROL

SENSOR

WIRE

FIGURE 48

TRANSDUCER

(PART #78H5401)

FIGURE 47

NOTE−MUST USE DIGITAL METER

SET DIAL TO MEASURE

(+)

(−) TO

VDC

RED COLLAR

INDICATES

POSITIVE

LEAD

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 49. 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.

STATIC PRESSURE TEST

FIGURE 49

Page 67

Page 68

VI−MAINTENANCE

Furnace

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 43 lists recommended filter sizes.

TABLE 43

Furnace

Cabinet Size

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.

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__________

Side Return Bottom Return

Filter Size

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 50.

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

procedures outlined in Burner Cleaning section.

8 − Loosen three clamps and remove flexible exhaust tee.

G61MPV−135 ONLY

Remove and discard two shipping screws.

FIGURE 50

9 − Remove 3/8 inch rubber cap from condensate drain

plug and drain. Replace cap after draining.

Page 68

Page 69

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 69

Page 70

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 50.

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 70

Page 71

VII− Wiring and Sequence of Operation A−SureLight Board 49M59

Page 71

Page 72

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 72

Page 73

C−Flow Chart SureLight Board 49M59

HEATING SEQUENCE OF OPERATION

NORMAL AND ABNORMAL HEATING MODE

POWER ON

CONTROL SELF−CHECK OKAY?

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.

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF. (RESET CONTROL BY

TURNING MAIN POWER OFF.) DS1 ON, DS2 ON

POLARITY OKAY?

YES

IS THERE A

PROPER GROUND?

YES

IS VOLTAGE

ABOVE 75 VOLTS?

YES

(CONTINUOUS FLAME CHECK)

BURNER OFF?

YES

NORMAL OPERATION:

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

PRIMARY, SECONDARY AND BACKUP SECONDARY LIMIT

THERMOSTAT CALLS FOR HEAT:

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

SWITCHES CLOSED?

ROLLOUT SWITCH CLOSED?

FIRST (LOW) STAGE PRESSURE SWITCH

CONTACTS OPEN?

SECOND (HIGH) STAGE PRESSURE SWITCH

CONTACTS OPEN?

YES

SIGNAL HOLDS UNTIL UNIT IS PROPERLY GROUNDED.

DS1 AND DS2 ALTERNATING FAST FLASH.

SIGNAL HOLDS UNTIL VOLTAGE RISES ABOVE 75 VOLTS.

DS1 AND DS2 ALTERNATING FAST FLASH.

GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

INDOOR BLOWER ON HEATING SPEED.

INDOOR BLOWER ON. HAS PRIMARY, SECONDARY

OR BACKUP SECONDARY LIMIT RESET WITHIN 3 MINUTES?

60−MINUTE LIMIT WATCHGUARD MODE.

GAS VALVE OFF, COMBUSTION AIR INDUCER

OFF, INDOOR BLOWER OFF WITH DELAY.

DS1 AND DS2 ALTERNATING SLOW FLASH,

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

HAS MANUAL ROLLOUT SWITCH(ES) BEEN

RESET (CLOSED) WITHIN 3 MINUTES?

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

PRESSURE SWITCH IS DETECTED OPEN.

ON/OFF LED OFF, HEAT LED OFF.

POLARITY REVERSED.

DS 1 −− FAST FLASH

DS 2 −− SLOW FLASH

DS1 SLOW FLASH, DS2 OFF,

ON/OFF LED OFF

COMBUSTION AIR INDUCER OFF.

DS1 SLOW FLASH, DS2 ON,

ON/OFF LED ON, HEAT LED ON.

ON/OFF LED OFF, HEAT LED ON.

DS1 SLOW FLASH, DS2 ON,

ON/OFF LED ON, HEAT LED ON.

DS1 OFF, DS2 SLOW FLASH,

YES

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

COMBUSTION AIR INDUCER OFF.

GAS VALVE OFF.

INDOOR BLOWER OFF.

CONTROL WILL NOT ATTEMPT SECOND−STAGE

OPERATION DURING THIS HEAT DEMAND.

FIRST−STAGE OPERATION WILL BE ATTEMPTED.

DS1 OFF, DS2 FAST FLASH,

ON/OFF LED OFF, HEAT LED ON.

Page 73

Page 74

HEATING SEQUENCE OF OPERATION

CONTINUED

FIRST−STAGE (LOW FIRE) PRESSURE

SWITCH CLOSED WITHIN 2.5 MINUTES?

YES

15−SECOND COMBUSTION AIR INDUCER

PRE−PURGE INITIATED BY CLOSED FIRST−STAGE

PRESSURE SWITCH (or 15 SECOND

INTER−PURGE PERIOD.)

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

IGNITOR WARM−UP (20 SECONDS)

DS1 AND DS2 SIMULTANEOUS FAST FLASH

IS VOLTAGE ABOVE 75 VOLTS?

YES

IS THERE A PROPER GROUND?

IS IGNITOR INTACT AND CONNECTED?

YES

THERMOSTAT CALLS FOR HEAT

DS1 AND DS2 SIMULTANEOUS FAST FLASH

(Refer to box A on previous page)

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.

COMBUSTION AIR INDUCER OFF, IGNITER OFF.

SIGNAL HOLDS UNTIL VOLTAGE RISES ABOVE 75 VOLTS.

DS1 AND DS2 ALTERNATING FAST FLASH.

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.

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)

FLAME PRESENT?

YES

CONTINUED ON NEXT PAGE

GAS VALVE OFF. COMBUSTION AIR

INDUCER ON. INDOOR BLOWER OFF.

HAS CONTROL RESET IGNITION SEQUENCE

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

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?

YES

FOUR (4) TIMES?

DS1 SLOW FLASH, DS2 FAST FLASH,

ON/OFF LED OFF, HEAT LED ON .

YES

Page 74

Page 75

CONTINUED

FLAME SIGNAL ABOVE

(w0.23 microamps)

YES

HEATING SEQUENCE OF OPERATION

THERMOSTAT CALLS FOR HEAT.

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

YES

DS1 SLOW FLASH, DS2 FAST FLASH.

LOW FLAME SIGNAL

(Does not affect control operation)

SEE BOX A.

SINGLE−STAGE THERMOSTAT MODE

(E20 SET AT SINGLE")

YES

START SECOND−STAGE RECOGNITION

ON DELAY (10 OR 15 MINUTES).

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

FIRST−STAGE (LOW FIRE)

PRESSURE SWITCH CLOSED?

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

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 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.

SECOND−STAGE PRESSURE SWITCH CLOSED

IN LESS THAN TEN (10) SECONDS?

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

YES

ON/OFF LED ON.

YES

CONTINUED ON NEXT PAGE

YES

TWO STAGE THERMOSTAT MODE

(E20 SET AT TWO")

YES

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,

HAS PRIMARY, SECONDARY, BACKUP

SWITCH CLOSED WITHIN 3 MINUTES?

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

GAS VALVE OFF, COMBUSTION AIR INDUCER OFF,

DS1 AND DS2 ALTERNATING SLOW FLASH,

IS 60−MINUTE RESET PERIOD COMPLETE?

GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

SECOND−STAGE PRESSURE SWITCH CLOSED

DS1 AND DS2 SIMULTANEOUS SLOW FLASH.

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

DS1 AND DS2 SIMULTANEOUS SLOW FLASH.

YES

ON/OFF LED ON, HEAT LED ON.

SECONDARY OR ROLLOUT

LIMIT SWITCH WATCHGUARD MODE.

INDOOR BLOWER OFF WITH DELAY.

ON/OFF LED OFF, HEAT LED OFF.

INDOOR BLOWER OFF AFTER DELAY.

DS1 OFF, DS 2 SLOW FLASH,

ON/OFF LED OFF, HEAT LED ON.

AT BEGINNING OF HEAT DEMAND?

DS1 OFF, DS2 SLOW FLASH,

ON/OFF LED ON, HEAT LED ON.

SECOND STAGE HEAT DEMAND

MADE FOR SECOND−STAGE HEAT?

YES

NORMAL OPERATION.

YES

Page 75

Page 76

CONTINUED

HEATING SEQUENCE OF OPERATION

SEE BOX A

NORMAL OPERATION

DS1 AND DS2 SIMULTANEOUS SLOW FLASH.

IS PRIMARY, SECONDARY, BACKUP

SECONDARY LIMIT AND ROLLOUT

SWITCH CLOSED?

YES

FIRST−STAGE (LOW FIRE) HEAT

PRESSURE SWITCH CLOSED?

SECOND−STAGE (HIGH FIRE) HEAT

PRESSURE SWITCH CLOSED?

YES

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

HEAT DEMAND SATISFIED?

YES

THERMOSTAT CALLS FOR HEAT

SEE BOX B

DS 1 AND DS 2 SIMULTANEOUS FAST FLASH

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.

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?

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?

SEE BOX C

FIRST−STAGE HEAT DEMAND SATISFIED?

YES

SINGLE−STAGE THERMOSTAT MODE

(E20 SET AT SINGLE")

YES

HEAT DEMAND SATISFIED?

DS1 AND 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

TWO STAGE THERMOSTAT MODE?

(E20 SET AT TWO")

YES

FIRST AND SECOND STAGE HEAT

DEMAND SATISFIED SIMULTANEOUSLY.

DS1 & DS2 SIMULTANEOUS FAST FLASH.

YES

GAS VALVE, COMBUSTION AIR INDUCER

AND INDOOR BLOWER RETURN TO FIRST−

DS1 AND DS2 SIMULTANEOUS FAST FLASH.

FIRST STAGE HEAT DEMAND SATISFIED?

GAS VALVE OFF. COMBUSTION AIR INDUCER

OFF AFTER 5−SECOND LOW SPEED POST−

PURGE PERIOD. INDOOR BLOWER OFF.

DELAY INITIATED ON LOW HEAT SPEED.

DS1 & DS2 SIMULTANEOUS FAST FLASH.

SECOND STAGE HEAT

DEMAND SASTISFIED?

DS1 AND DS2

SIMULTANEOUS FAST FLASH.

YES

STAGE OPERATION.

YES

Page 76

Page 77

COOLING SEQUENCE OF OPERATION

POWER ON

SIGNAL IMPROPER

GROUND AT DS.

SIGNAL HOLDS

UNTIL UNIT IS

PROPERLY

GROUNDED.

THERMOSTAT CALLS FOR FIRST−STAGE COOL.

INDOOR BLOWER ENERGIZED ON FIRST STAGE

FIRST−STAGE DEMAND FOR COOL SATISFIED?

THERMOSTAT CALLS FOR SECOND−STAGE COOL.

IS POLARITY REVERSED?

COMPRESSOR AND CONDENSER FAN

COOL SPEED AFTER 2 SECOND DELAY.

IS THERE

PROPER GROUND?

ENERGIZED.

YES

IS VOLTAGE

ABOVE 75 VOLTS?

YES

SIGNAL POLARITY REVERSED.

DS1 FAST FLASH, DS2 SLOW FLASH.

LOW VOLTAGE SIGNAL AT DS HOLDS

UNTIL VOLTAGE RISES ABOVE 75 VOLTS.

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.

YES YES

YES

INDOOR BLOWER RAMPS TO FIRST STAGE

COOLING SPEED AFTER A 2−SECOND DELAY.

FIRST−STAGE COOL DEMAND SATISFIED?

SECOND STAGE COOL DEMAND

INDOOR BLOWER RAMPS TO SECOND

STAGE COOL SPEED

SECOND STAGE COOL DEMAND SATISFIED?

YES

INDOOR BLOWER RAMPS DOWN TO FIRST STAGE

COOL SPEED.

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.

THERMOSTAT CALLS FOR SECOND−STAGE HEAT.

YES

INDOOR BLOWER SWITCHES TO HIGH HEAT SPEED

AFTER 30−SECOND RECOGNITION PERIOD.

YES

SECOND−STAGE HEAT DEMAND SATISFIED.

YES

INDOOR BLOWER RAMPS DOWN TO LOW

HEAT SPEED.

YES

Page 77

Page 78

D−G61MPV with SureLight Board 100870

Page 78

Page 79

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 79

Page 80

F−Flow Chart SureLight Board 100870

HEATING SEQUENCE OF OPERATION

NORMAL AND ABNORMAL HEATING MODE

POWER ON

CONTROL SELF−CHECK OKAY?

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF. (RESET CONTROL BY

TURNING MAIN POWER OFF.)

POLARITY OKAY?

YES

IS THERE A

PROPER GROUND?

YES

NORMAL OPERATION:

STATUS LED −− PULSE

THERMOSTAT CALLS FOR HEAT:

STATUS LED −− HEARTBEAT

YES

PRIMARY AND SECONDARY LIMIT

SWITCHES CLOSED?

YES

ROLLOUT SWITCH CLOSED?

YES

FIRST (LOW) STAGE PRESSURE SWITCH

CONTACTS OPEN?

YES

SECOND (HIGH) STAGE PRESSURE SWITCH

CONTACTS OPEN?

YES

SIGNAL HOLDS UNTIL UNIT IS PROPERLY GROUNDED.

INDOOR BLOWER ON. HAS PRIMARY OR

SECONDARY LIMIT RESET WITHIN 3 MINUTES?

60−MINUTE LIMIT WATCHGUARD MODE.

GAS VALVE OFF, COMBUSTION AIR INDUCER

OFF, INDOOR BLOWER OFF WITH DELAY.

GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

SEQUENCE HOLDS UNTIL ROLLOUT SWITCH IS RESET AND MAIN POWER IS INTERRUPTED OR

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

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

PRESSURE SWITCH IS DETECTED OPEN.

POLARITY REVERSED.

STATUS ERROR CODE 5 + 4.

STATUS ERROR CODE 5 + 3.

COMBUSTION AIR INDUCER OFF.

STATUS ERROR CODE 3 + 1.

STATUS ERROR CODE 4 + 5.

INDOOR BLOWER ON.

STATUS ERROR CODE 5 + 1.

STATUS ERROR CODE 2 + 4

YES

TWO−STAGE OR SINGLE−STAGE THERMOSTAT

CALL FOR HEAT

COMBUSTION AIR INDUCER ON LOW SPEED.

STATUS LED −− HEARTBEAT

CONTINUED ON NEXT PAGE

COMBUSTION AIR INDUCER OFF.

GAS VALVE OFF.

INDOOR BLOWER OFF.

CONTROL WILL NOT ATTEMPT SECOND−STAGE

OPERATION DURING THIS HEAT DEMAND.

FIRST−STAGE OPERATION WILL BE ATTEMPTED.

STATUS ERROR CODE 2 + 6.

Page 80

Page 81

CONTINUED

HEATING SEQUENCE OF OPERATION

THERMOSTAT CALLS FOR HEAT

STATUS LED − HEARTBEAT

(Refer to box A on previous page)

FIRST−STAGE (LOW FIRE) PRESSURE

SWITCH CLOSED WITHIN 2.5 MINUTES?

YES

15−SECOND COMBUSTION AIR INDUCER

PRE−PURGE INITIATED BY CLOSED FIRST−STAGE

PRESSURE SWITCH (or 15 SECOND

INTER−PURGE PERIOD.)

STATUS LED −− HEARTBEAT.

IGNITOR WARM−UP (20 SECONDS)

STATUS LED −− HEARTBEAT.

YES

IS IGNITOR INTACT AND CONNECTED?

YES

AT END OF IGNITOR 20 SECOND WARM UP

PERIOD, 4−SECOND TRIAL FOR IGNITION.

GAS VALVE OPENS, IGNITOR ENERGIZED DURING

4−SECOND TRIAL UNTIL FLAME SENSED.

YES

4−SECOND FLAME STABILIZATION PERIOD.

GAS VALVE OFF. COMBUSTION AIR INDUCER

OFF. INDOOR BLOWER OFF. UNIT WILL RETRY

AFTER 5−MINUTE WAIT PERIOD.

STATUS ERROR CODE 2 + 3.

COMBUSTION AIR INDUCER OFF, IGNITOR OFF.

SIGNAL HOLDS UNTIL IGNITOR IS REPLACED

OR RECONNECTED.

STATUS ERROR CODE 4 + 7.

IS VOLTAGE ABOVE 90 VOLTS?

COMBUSTION AIR INDUCER OFF, IGNITER OFF.

SIGNAL HOLDS UNTIL VOLTAGE RISES ABOVE 95

VOLTS. STATUS ERROR CODE 4 + 8.

YES

FLAME RECTIFICATION CURRENT CHECK

CAN FLAME BE PROVEN WITHIN 4

SECONDS AFTER GAS VALVE OPENS?

(u0.20 microamps)

FLAME PRESENT?

YES

CONTINUED ON NEXT PAGE

GAS VALVE OFF. COMBUSTION AIR

INDUCER ON. INDOOR BLOWER OFF.

STATUS LED −− HEARTBEAT.

HAS CONTROL FAILED TO SENSE

FLAME FOR FIVE CONSECUTIVE TRIES

DURING A SINGLE HEAT DEMAND?

YES

WATCHGUARD MODE. GAS VALVE OFF,

COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF.

STATUS ERROR CODE 4 + 1.

IS 60−MINUTE RESET PERIOD COMPLETE?

YES

HAS CONTROL RESET IGNITION SEQUENCE

FOUR (4) TIMES?

WATCHGUARD MODE.

STATUS ERROR CODE 4 + 3.

YES

Page 81

Page 82

HEATING SEQUENCE OF OPERATION

CONTINUED

FLAME SIGNAL ABOVE

(u1.40 microamps)

YES

SINGLE−STAGE THERMOSTAT MODE

(DIP SWITCH SET AT SINGLE")

YES

START SECOND−STAGE RECOGNITION

ON DELAY (10 OR 15 MINUTES).

STATUS LED −− HEARTBEAT

ROLLOUT SWITCHES CLOSED?

YES

TWO STAGE THERMOSTAT MODE

(DIP SWITCH SET AT TWO")

YES

45−SECOND INDOOR BLOWER ON DELAY BEGINS.

YES

PRIMARY & SECONDARY LIMIT SWITCHES

THERMOSTAT CALLS FOR HEAT.

STATUS LED −− HEARTBEAT.

SEE BOX A.

LOW FLAME SIGNAL

(Does not affect control operation)

STATUS ERROR CODE 1 + 2.

STATUS LED −− HEARTBEAT.

YES

CLOSED?

YES

FIRST−STAGE (LOW FIRE)

PRESSURE SWITCH CLOSED?

YES

FIRST−STAGE HEAT DEMAND SATISFIED?

YES

GAS VALVE OFF, COMBUSTION AIR INDUCER

OFF FOLLOWING POST PURGE.

INDOOR BLOWER OFF WITH DELAY

STATUS LED −− PULSE

SECOND−STAGE HEAT DEMAND.

SECOND−STAGE HEAT DEMAND REQUIRED?

YES

SECOND STAGE PRESSURE SWITCH CLOSED?

ABNORMAL FLASH CODE.

NOTE − IF SECOND−STAGE PRESSURE SWITCH

WAS ORIGINALLY FOUND CLOSED,

ABNORMAL CODE WILL FLASH.

SECOND−STAGE 30−SECOND DELAY ON BEGINS.

STATUS LED −− HEARTBEAT.

YES

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

CONTINUED ON NEXT PAGE

YES

GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

YES

STATUS ERROR CODE 5 + 1. SEQUENCE HOLDS

UNTIL ROLLOUT SWITCH IS RESET AND MAIN

POWER IS INTERRUPTED OR THERMOSTAT

IS CYCLED OFF/ON FOR 3 SECOND MINIMUM.

GAS VALVE OFF, COMBUSTION AIR INDUCER OFF,

SWITCH CLOSED WITHIN 3 MINUTES?

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

GAS VALVE OFF, COMBUSTION AIR INDUCER OFF,

IS 60−MINUTE RESET PERIOD COMPLETE?

GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

STATUS ERROR CODE 2 + 3. CONTROL RESTARTS

IGNITION SEQUENCE IF PRESSURE SWITCH

SECOND−STAGE PRESSURE SWITCH CLOSED

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

SWITCH CAN BE PROVEN or HEAT DEMAND IS

SATISFIED. FIVE (5) MINUTE WAIT PERIOD

INITIATED BEFORE RETRY. WERE 5 ATTEMPTS

CONTINUES FIRST−STAGE HEATING DEMAND.

WILL NOT REATTEMPT SECOND−STAGE

INDOOR BLOWER ON.

STATUS ERROR CODE 3 + 1.

HAS PRIMARY OR SECONDARY LIMIT

LIMIT SWITCH WATCHGUARD MODE.

INDOOR BLOWER OFF WITH DELAY.

STATUS ERROR CODE 4 + 5

INDOOR BLOWER OFF AFTER DELAY.

CLOSES WITHIN 2−1/2 MINUTES.

AT BEGINNING OF HEAT DEMAND?

STATUS ERROR CODE 2 + 6.

SECOND STAGE HEAT DEMAND

STATUS LED −− HEARTBEAT.

MADE FOR SECOND−STAGE HEAT?

YES

HEATING DEMAND.

STATUS ERROR CODE 2 + 5.

YES

Page 82

Page 83

CONTINUED

HEATING SEQUENCE OF OPERATION

SEE BOX A

NORMAL OPERATION.

SECOND−STAGE (HIGH FIRE) HEAT

PRESSURE SWITCH CLOSED?

YES

HEAT DEMAND SATISFIED?

STATUS LED −− HEARTBEAT.

YES

SINGLE−STAGE THERMOSTAT MODE

(DIP SWITCH SET AT SINGLE")

YES

GAS VALVE OFF, COMBUSTION AIR

INDUCER OFF AFTER 5−SECOND

LOW SPEED POST PURGE PERIOD,

INDOOR BLOWER OFF DELAY

INITIATED ON LOW HEAT SPEED.

STATUS LED −− HEARTBEAT.

FIRST−STAGE CONTINUES UNTIL SECOND−

YES

TWO STAGE THERMOSTAT MODE?

(DIP SWITCH SET AT TWO")

YES

FIRST AND SECOND STAGE HEAT

DEMAND SATISFIED SIMULTANEOUSLY.

STATUS LED −− HEARTBEAT.

STAGE PRESSURE SWITCH CAN BE PROVEN

or HEAT DEMAND IS SATISFIED. A FIVE (5)

MINUTE WAIT PERIOD IS INITIATED BEFORE

YES

THERMOSTAT CALLS FOR HEAT.

RETURN TO FIRST−STAGE HEAT MODE.

RETRY. WERE 5 ATTEMPTS MADE FOR

FIRST−STAGE HEAT DEMAND SATISFIED?

SEE BOX B

SECOND−STAGE HEAT?

SEE BOX C

SECOND STAGE HEAT

GAS VALVE, COMBUSTION AIR INDUCER

AND INDOOR BLOWER RETURN TO FIRST−

STATUS LED −− HEARTBEAT.

DEMAND SASTISFIED?

STATUS LED −− HEARTBEAT.

YES

STAGE OPERATION.

YES

DEMAND FOR HEAT SATISFIED.

POWER ON STAND BY. STATUS LED −− PULSE.

FIRST STAGE HEAT DEMAND SATISFIED?

GAS VALVE OFF. COMBUSTION AIR INDUCER

OFF AFTER 5−SECOND LOW SPEED POST−

PURGE PERIOD. INDOOR BLOWER OFF.

DELAY INITIATED ON LOW HEAT SPEED.

STATUS LED −− PULSE.

YES

Page 83

Page 84

COOLING SEQUENCE OF OPERATION

POWER ON

IS POLARITY REVERSED?

YES

CONTROL WILL CONTINUE TO CALL FOR COOLING

SIGNAL POLARITY REVERSED.

IN THIS CONDITION.

STATUS ERROR CODE 5 + 4.

IS THERE

PROPER GROUND?

YES

THERMOSTAT CALLS FOR FIRST−STAGE COOL.

COMPRESSOR AND CONDENSER FAN

ENERGIZED.

INDOOR BLOWER ENERGIZED ON FIRST STAGE

COOL SPEED AFTER 2 SECOND DELAY.

FIRST−STAGE DEMAND FOR COOL SATISFIED?

THERMOSTAT CALLS FOR SECOND−STAGE COOL.

INDOOR BLOWER RAMPS UP TO SECOND−STAGE COOL SPEED.

YES

SIGNAL IMPROPER GROUND AT LED.

CONTROL WILL CONTINUE TO CALL FOR COOLING

IN THIS CONDITION.

STATUS ERROR CODE 5 + 3.

COMPRESSOR AND CONDENSER FAN DE−ENERGIZED.

INDOOR BLOWER DE−ENEGIZED.

SECOND−STAGE DEMAND FOR COOL SATISFIED?

YES

UNIT RETURNS TO FIRST STAGE COOL

Page 84

Page 85

CONTINUOUS LOW SPEED FAN SEQUENCE OF OPERATION

MANUAL FAN SELECTION MADE AT THERMOSTAT.

AFTER 2 SECOND DELAY, INDOOR BLOWER IS

ENERGIZED ON CONTINUOUS FAN SPEED.

YES YES

YES

INDOOR BLOWER RAMPS TO FIRST STAGE

COOLING SPEED AFTER A 2−SECOND DELAY.

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

YES

AFTER 45−SECOND DELAY, INDOOR BLOWER

SWITCHES TO LOW HEAT SPEED.

YES

FIRST−STAGE COOL DEMAND SATISFIED?

SECOND STAGE COOL DEMAND

INDOOR BLOWER RAMPS TO SECOND

STAGE COOL SPEED

SECOND STAGE COOL DEMAND SATISFIED?

YES

INDOOR BLOWER RAMPS DOWN TO FIRST STAGE

COOL SPEED.

FIRST−STAGE HEAT DEMAND SATISFIED.

THERMOSTAT CALLS FOR SECOND−STAGE HEAT.

YES

INDOOR BLOWER SWITCHES TO HIGH HEAT SPEED

AFTER 30−SECOND RECOGNITION PERIOD.

YES

SECOND−STAGE HEAT DEMAND SATISFIED.

YES

INDOOR BLOWER RAMPS DOWN TO LOW

HEAT SPEED.

YES

Page 85

Page 86

VIII− Field Wiring Applications and Jumper Settings

A−SureLight Board 49M59

TABLE 44

Field Wiring Applications

Thermostat

1 Heat / 1 Cool

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

51M26 SignatureStat

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

Jumper Settings (See figure 4)

E20 W915 W914 W951

SINGLE Intact Intact Intact

SINGLE Intact Cut Intact

Wiring Connections

T’STAT

51M26

T’STAT

CONTROL

TERM. STRIP

CONTROL

TERM. STRIP

OUTDOOR

UNIT

HSXB15

(LSOM)

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.

1 Heat / 2 Cool

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

SINGLE Intact Cut Intact

SINGLE Cut Intact Intact

T’STAT

CCB1

CONTROL

TERM. STRIP

CONTROL

TERM. STRIP

OUTDOOR

UNIT

HSXB15

(LSOM)

OUTDOOR

UNIT

HSXA19

(LSOM)

Page 86

Page 87

TABLE 45

Field Wiring Applications (Continued)

Thermostat

1 Heat / 2 Cool

E20 W915 W914 W951

SINGLE Cut Cut Intact

Jumper Settings (See figure 4)

with CCB1

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

2 Heat / 2 Cool TWO Cut Intact Intact

Wiring Connections

CCB1

CONTROL

TERM. STRIP

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

HSXA19

(LSOM)

OUTDOOR

UNIT

HSXA19

(LSOM)

51M27 SignatureStat TWO Cut Cut Intact

2 Heat / 2 Cool

TWO Cut Cut Intact

with CCB1

51M27

T’STAT

CONTROL

TERM. STRIP

CCB1

CONTROL

TERM. STRIP

OUTDOOR

UNIT

HSXA19

(LSOM)

OUTDOOR

UNIT

HSXA19

(LSOM)

Page 87

Page 88

TABLE 46

Field Wiring Applications (Continued)

Thermostat

E20 W915 W914 W951

Jumper Settings (See figure 4)

2 Heat / 1 Cool TWO Intact Intact Intact

FM21 Heat Pump / 1

SINGLE Intact Intact Cut

Cool

Wiring Connections

T’STAT

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

75VA, 24V

TRANSFORMER*

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

CONTROL

TERM. STRIP

HSXB15 (LSOM)

CONTROL

TERM. STRIP

OUTDOOR

UNIT

FM21

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

Page 88

Page 89

B−SureLight Board 100870

Thermostat

1Heat / 1 Cool

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

DIP Switch 1

ON Intact Intact Intact

TABLE 47

Field Wiring Applications (Continued)

Jumper Settings (See figure 5)

W915

Two−Stage

Cooling

W914 Dehu-

midification or Harmony

III

W951

Heat Pumps

Wiring Connections

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.

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 Intact Intact

ON Cut Cut Intact

T’STAT

CONTROL

TERM. STRIP

CONTROL

TERM. STRIP

OUTDOOR

UNIT

OUTDOOR

UNIT

Page 89

Page 90

TABLE 48

Field Wiring Applications (Continued)

Jumper Settings (See figure 5)

Thermostat

DIP Switch 1

W915

Two−Stage

Cooling

W914 Dehumidification or Harmony

W951

Heat Pumps

III

2 Heat / 2 Cool OFF Cut Intact Intact

Wiring Connections

T’STAT

CONTROL

TERM. STRIP

OUTDOOR

UNIT

2 Heat / 2 Cool

OFF Cut Cut Intact with t’stat with humidity control

2 Heat / 1 Cool OFF Intact Intact Intact

T’STAT

CONTROL

TERM. STRIP

CONTROL

TERM. STRIP

OUTDOOR

UNIT

OUTDOOR

UNIT

Page 90

Page 91

IX− SURELIGHT® CONTROL TROUBLESHOOTING GUIDE

code LED#2 Slow Flash

ACTION 1

ducer does not energize

120V field connection.

on operation

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.

Main voltage 120V not supplied to unit.

1.1.1

ACTION 1 − Check 120V main voltage.

Determine cause of main power failure.

LED#1−Off LED#2−Off

1.2

− Diagnostic lights flash the roll−out

code.

LED#1−On, LED#2−Slow Flash

1.3

− On initial power−up the comb. air in.

− Diagnostic lights flash the reverse

polarity code.

1.1.2

Miswiring of furnace or improper connections.

1.1.3

Blown fuse

1.1.4

Door interlock switch failure.

1.1.5

Transformer Failure.

1.1.6

Failed control board.

1.2.1

Roll−out switch open.

1.2.2

Roll−out switch failure.

1.2.3

Miswiring or improper connections at roll−out switch.

1.2.4

9 pin connector failure

1.3.1

120V main power polarity reversed.

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

ACTION 2 − Check 24V wiring to control board.

ACTION 1 − Replace fuse. ACTION 2 − If fuse still blows, check for short.

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.

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

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

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.

ACTION 1 − Check continuity across roll−out switch. Replace roll−out switch if switch is reset but does not have continuity.

− Check wiring connections to switch.

ACTION 1 − Check 9−pin connector for proper

connection to control board. ACTION 2 − Check continuity of the multi plug pin.

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.

LED#1−Fast Flash, LED#2−Slow Flash.

− On initial power up the combustion

air inducer does not energize.

− Diagnostic lights flash normal power

eration.

on o

LED#1−Slow Flash LED#2−Slow Flash

1.4

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 91

Page 92

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

LED#2 Alternating Fast Flash

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.

1.5.2

6−Pin connector is improperly

attached to the circuit board.

1.5.3

Line voltage is below 75V.

1.5.4

Open ignitor circuit.

1.5.5

Broken or failed ignitor.

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

ACTION 1 − Check 6−pin connector for proper installation. Correctly insert connector into control.

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

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

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.

2.1.2

Miswiring of furnace or improper

connections at limit switch(es).

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.

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.

2.2.2

Prove switch stuck closed.

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

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

Page 92

Page 93

PROBLEM 2: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR INDUCER DOES

switch failure code 2.5 minutes after

LED#1 Off

NOT ENERGIZE (CONT.).

Condition Possible Cause Corrective Action/Comments

2.3

− Unit operates with a cooling and con-

tinuous fan demand.

− Combustion air inducer will not start

with a Heating demand.

− Diagnostic lights flash the pressure

Miswiring of furnace or improper

connections to combustion air induc-

2.3.1

ACTION 1 − Check for correct wiring and loose

connections. Correct wiring and/or replace any loose connections.

er.

switch failure code 2.5 minutes after heating demand.

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

LED#1−Off,

2.3.2

Combustion air inducer failure.

LED#2−Slow Flash

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

Prove switch does not close due to

incorrect routing of the pressure

Prove switch does not close due to

obstructions in the pressure lines.

Prove switch lines damaged

Condensate in prove switch line.

Prove switch does not close due to a

low differential pressure across the

Wrong prove switch installed in the

unit, or prove switch is out of

Miswiring of furnace or improper

connections at prove switch.

Prove switch failure.

3.1.1

switch lines.

3.1.2

3.1.3

3.1.4

3.1.5

prove switch.

3.1.6

calibration.

3.1.7

3.1.8

ACTION 1 − Check that the prove switch lines are

correctly routed. Correctly route pressure switch lines.

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

ACTION 1 − Check prove switch lines for leaks. Replace any broken lines.

ACTION 1 − Check prove switch lines for condensate. Remove condensate from lines.

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.

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

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

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 93

Page 94

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

5.1

LED#1 Off

ignite code.

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.

4.1.2

Miswiring of gas valve or loose-

connections at multi−pin control amp

plugs or valve.

4.1.3

Defective gas valve or ignition

control.

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.

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

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

ACTION 1 − Check for restricted intake and ex-

haust vent. Remove all blockage. ACTION 2: Check for proper vent sizing. See installation instructions.

ACTION 1 − Check vent termination kit installed. See Placement and Installation section.

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.

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

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

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

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

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.

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.

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

5.2

− 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

5.1.1

Low pressure differential at the prove

switch.

5.1.2

Wrong concentric vent kit used for

terminating the unit.

5.1.3

Condensate drain line is not draining

properly.

5.1.4

Low pressure differential at the prove

switch.

5.2.1

Sensor or sense wire is improperly

installed.

5.2.2

Sensor or sense wire is broken.

5.2.3

Sensor or sensor wire is grounded to

the unit.

5.2.4

Control does not sense flame.

Page 94

Page 95

PROBLEM 5: BURNERS LIGHT WITH HEATING DEMAND BUT UNIT SHUTS DOWN

ure.

flame failure.

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 fail-

ure.

LED#1−On LED#2−Slow Flash

PREMATURELY (CONT.)

5.3.1

Unit is firing above 100% of the

nameplate input.

5.3.2

Gas orifices leak at the manifold

connection.

5.3.3

Air leakage at the connections

between the primary heat exchanger,

secondary heat exchanger, and

combustion air blower.

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.

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).

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.

5.4

− 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

5.3.4

Insufficient flow through the heat

exchanger caused by a sooted or

restricted heat exchanger.

5.3.5

Burners are not properly located in

the burner box.

5.4.1

Recirculation of flue gases. This

condition causes rough ignitions and

operation. Problem is characterized

by nuisance flame failures.

5.4.2

Improper burner cross−overs

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.

ACTION 1 − Check that the burners are firing into

the center of the heat exchanger openings. Correct the location of the burners if necessary.

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

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 95

Page 96

PROBLEM 6: CONTROL SIGNALS LOW FLAME SENSE DURING HEATING MODE

code

Condition Possible Cause Corrective Action/Comments

6.0

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

Sensor rod is improperly located on

6.1.1

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.

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.

LED#1−Slow Flash LED#2−Fast Flash

6.1.2

Sensor rod is contaminated.

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.

Miswiring of furnace or improper

connections at control or indoor blow-

120V is not being supplied to the

indoor air blower or blower motor fail-

7.1.1

er motor.

7.1.2

ure.

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

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.

Condition Possible Cause Corrective Action/Comments

8.0

− AM radio interference.

7.1.3

Defective control board

7.1.4

Defective run capacitor

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

ACTION 1 − Replace capacitor

PROBLEM 8: RF STATIC DURING TIME FOR IGNITION

8.1.2

Ignitor operation

ACTION 1 − Call Technical Support, Dallas.

Page 96

Page 97

B−SureLight Board 100870

Diagnostic light flashes the reverse

ACTION 1

120V h

120V main power polarity reversed.

circuit fault

Two Stage Variable Speed Control Board 100870

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

Flash Code

LED X + Y

1.1

− Diagnostic lights fail to light up.

Main voltage 120V not supplied to unit.

Possible Cause Corrective Action / Comments

1.1.1

ACTION 1 − Check 120V main voltage.

Determine cause of main power failure.

LED OFF

1.2

polarity code.

LED 5 + 4

1.3

− Diagnostic light flash the improper

main ground.

1.1.2

Miswiring of furnace or improper connections.

1.1.3

Circuit breaker tripped or fails to close.

1.1.4

Door interlock switch failure.

1.1.5

Transformer Failure.

1.1.6

Failed control board.

1.2.1

120V main power polarity reversed.

1.3.1

Improper ground to the unit.

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

ACTION 2 − Check 24V wiring to control board.

ACTION 1 − Replace circuit breaker if it is reset

but does not have continuity. ACTION 2 − If circuit breaker still trips, check for short.

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.

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

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

−

correctly input into control.

− Check the

ACTION 2 − Reverse the line and neutral at the

120V field connection.

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

as line and neutra

LED 5 + 3

1.4

− Diagnostic light flashes ignitor

circuit fault.

LED 4 + 7

1.5

− Diagnostic light flashes low

line voltage

LED 4 + 8

1.4.1

Open ignitor circuit.

1.4.2

Broken or failed ignitor.

1.5.1

Line voltage is below 90V.

Page 97

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

ACTION 1 − Unplug ignitor and read resistance across ignitor. If resistance does not read between 25 and 47 ohms, replace the ignitor.

ACTION 1 − Check that the line voltage is above 90V. Determine cause of voltage drop and supply correct voltage to the control.

Page 98

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

Diagnostic lights flash the pressure

ENERGIZE

Flash Code

LED X + Y

2.1

Unit operates with a cooling or

continuous fan demand.

Combustion air inducer will not start

with a Heating demand.

Diagnostic lights flash the limit failure

mode.

LED 3 + 1

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 2 +4

2.3

Unit operates with a cooling or

continuous fan demand.

Combustion air inducer will not start

with a Heating demand.

Diagnostic lights flash the open

rollout failure mode.

Possible Cause

2.1.1

Primary Limit or secondary limit

(if equipped ) open.

2.1.2

Miswiring of furnace or improper con-

nections at limit switch(es).

2.2.1

Miswiring of furnace or improper con-

nections to combustion air inducer.

2.2.2

Prove switch stuck closed.

2.3.1

Rollout Switch Open.

Corrective Action / Comments

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.

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

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

ACTION 1 − Check continuity across rollout switches. Rollout switches must be manually reset. ACTION 2 − Look for restrictions in vent pipe or combustion air inlet or heat exchanger. Determine cause before placing unit in operation.

LED 5 + 1

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

NOT ENERGIZE

Condition Possible Cause Corrective Action/Comments

3.3

Unit operates with a cooling and

continuous fan demand.

Combustion air inducer will not start

with a Heating demand.

nostic lights flash the pressure

Dia

switch failure code 2.5 minutes after

heating demand.

LED 2 + 3

Miswiring of furnace or improper con-

nections to combustion air inducer.

Combustion air inducer failure.

3.3.1

3.3.2

ACTION 1 − Check for correct wiring and loose

connections. Correct wiring and/or replace any loose connections.

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

Page 98

Page 99

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

ENERGIZES, IGNITOR IS NOT ENERGIZED.

Flash Code

LED X + Y

4.1

− 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 2 + 3

Prove switch does not close due to

incorrect routing of the prove switch

Prove switch does not close due to

obstructions in the prove switch line.

Condensate in prove switch line.

Prove switch does not close due to a

low differential pressure across the

Wrong prove switch installed in the

unit, or prove switch is out of calibra-

Miswiring of furnace or improper con-

Possible Cause Corrective Action/Comments

4.1.1

obstruction in vent pipe.

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

4.1.2

ACTION 1 − Check that the prove switch line is

correctly routed. Correctly route prove switch line.

line.

4.1.3

4.1.4

Prove switch line damaged

4.1.5

4.1.6

prove switch.

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

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

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

4.1.7

ACTION 1 − Check that the correct prove switch

is installed in the unit. Replace prove switch if necessary.

tion.

4.1.8

nections at prove switch.

4.1.9

Prove switch failure.

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

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 99

Page 100

PROBLEM 5: UNIT FIRES ON LOW FIRE, FAILS TO GO TO HIGH FIRE OPERATION

Flash Code

LED X + Y

5.1

− Unit light s normally during low fire

− Call for high fire inducer switches to

high fire for 10 seconds then back to

low fire.

− Diagnostic lights flash the high pressure switch failure to close.

LED 2 + 5

Possible Cause Corrective Action/Comments

5.1.1

Prove switch does not close due to

obstruction in vent pipe.

5.1.2

Prove switch does not close due to

incorrect routing of the prove switch

line.

5.1.3

Prove switch does not close due to

obstructions in the prove switch line.

5.1.4

Prove switch line damaged

5.1.5

Condensate in prove switch line.

5.1.6

Prove switch does not close due to a

low differential prove across the

prove switch.

5.1.7

Wrong prove switch installed in the

unit, or prove switch is out of calibra-

tion.

5.1.8

Miswiring of furnace or improper con-

nections at prove switch.

5.1.9

Prove switch failure.

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

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

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

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

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

ACTION 1 − Check that the correct prove switch is installed in the unit. Replace prove switch if necessary.

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

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 100

Lennox G61MPV−36C−090, G61MPV−36B−045, G61MPV−36B−070, G61MPV−36B−071, G61MPV−60C−090 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual