Lennox G61MPVT-36B-070, G61MPVT-60C-090, G61MPVT-60C-110, G61MPVT-60D-135 Installation Instructions Manual

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Page 1

INSTALLATION

E 2006 Lennox Industries Inc.

Dallas, Texas, USA

RETAIN THESE INSTRUCTIONS

FOR FUTURE REFERENCE

INSTRUCTIONS

G61MPVT SERIES UNITS

GAS UNITS

505,187M 06/2009

Table of Contents

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

G61MPVT Parts Arrangement 3. . . . . . . . . . . . . . . . . . .

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

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

Installation − Setting Equipment 5. . . . . . . . . . . . . . . . . .

Filters 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Duct System 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pipe & Fittings Specifications 10. . . . . . . . . . . . . . . . . . .

Vent Piping Guidelines 11. . . . . . . . . . . . . . . . . . . . . . . . .

Joint Cementing Procedure 12. . . . . . . . . . . . . . . . . . . . .

Venting Practices 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gas Piping 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Integrated Control Board 27. . . . . . . . . . . . . . . . . . . . . . .

Unit Start−Up 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gas Pressure Adjustment 35. . . . . . . . . . . . . . . . . . . . . .

Manifold Pressure & High Altitude Information 35. . . .

Other Unit Adjustments 36. . . . . . . . . . . . . . . . . . . . . . . .

Heating Sequence of Operation 37. . . . . . . . . . . . . . . . .

Service 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Requirements 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Combustion, Dilution & Ventilation Air 41. . . . . . . . . . . .

Ignition Control Board Diagnostic Codes 44. . . . . . . . .

Troubleshooting 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair Parts List 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vent Pipe Sizing Worksheet 51. . . . . . . . . . . . . . . . . . . .

Start−Up & Performance Check List 52. . . . . . . . . . . . . .

Litho U.S.A.

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

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

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

06/09

*2P0609*

WARNING

FIRE OR EXPLOSION HAZARD.

WHAT TO DO IF YOU SMELL GAS:

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

use any phone in your building.

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

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

D If you cannot reach your gas supplier, call

the fire department.

Page 1

505,187M

*P505187M*

Page 2

G61MPVT Unit Dimensions − mm

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

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

2. Single side return

3. Bottom return air.

4. Return air from both sides.

5. Bottom and

Refer to Engineering Handbook for additional information.

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

one side return air.

OPTIONAL

EXTERNAL

SIDE RETURN

AIR FILTER KIT

(Either Side)

SUPPLY AIR

OPENING

603

635

TOP VIEW

OPTIONAL

EXTERNAL

SIDE RETURN

AIR FILTER KIT

(Either Side)

(1016)

295 Right

248 Left

165

103

124 Right

57 Left

140

171

165

724

COMBUSTION AIR INTAKE

(Either Side)

EXHAUST AIR OUTLET

(Either Side)

GAS PIPING INLET

(Either Side)

CONDENSATE

TRAP CONNECTION

(Either Side)

ELECTRICAL INLET

(Either Side)

AIR FLOW

*Bottom Return

Air Opening

375

406

476

RECEPTACLE

102

IEC

108

584

*OPTIONAL

RETURN CUTOUT

(Either Side)

597

*Bottom Return

Air Opening

FRONT VIEW SIDE VIEW

378

356**

Model No.

G61MPVT−36B−070 446 416 406

G61MPVT−60C−090 G61MPVT−60C−110

G61MPVT−60D−135 622 594 584

A B C

mm mm mm

533 454 495

Page 2

Page 3

G61MPVT Parts Arrangement

BURNER BOX

ASSEMBLY

GAS VALVE

AND MANIFOLD

FLUE

COLLAR

TOP CAP

DuralokPlus

HEAT EXCHANGER

ASSEMBLY

CABINET

COMBUSTION

AIR PRESSURE

PROVE SWITCHES

COMBUSTION AIR

INDUCER

BURNER ACCESS

PANEL

BLOWER

ACCESS

PANEL

SIGHT

GLASS

DOOR

INTERLOCK

SWITCH

Two−Stage, Variable Speed

Integrated Control Board

WARM HEADER

(COLLECTOR)

BOX

CONDENSER COIL

PRIMARY LIMIT

COLD HEADER

(COLLECTOR)

BOX

SECONDARY

LIMITS (2)

BLOWER MOTOR

TRANSFORMER

CONTROL BOX

FIGURE 1

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G61MPVT Gas Furnace

The G61MPVT gas furnace is equipped with a two−stage, variable speed integrated control. This control ensures compatibility with a thermostat which provides humidity control. Each G61MPVT is shipped ready for installation in the upflow, downflow, horizontal left air discharge or horizontal right air discharge position. The furnace is shipped with the bottom panel in place. The bottom panel must be removed if the unit is to be installed in upflow applications with bottom return air. The bottom panel must also be removed and discarded in all downflow or horizontal applications.

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

All G61MPVT models can be installed as a Direct Vent gas central furnace. G61MPVT−070, −090 and −110 models can be installed as a Non−Direct Vent gas central furnace.

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

DIRECT VENT INSTALLATION NON−DIRECT VENT

COMBUSTION AIR INTAKE OUTSIDE OF HOUSE

EXHAUST OUTLET

INSTALLATION

EXHAUST OUTLET

Shipping and Packing List

Package 1 of 1 contains

1 − Assembled G61MPVT unit 1 − Bag assembly containing the following:

3 − Screws 3 − Wire nuts 1 − Snap bushing 1 − Snap plug 1 − Wire tie 1 − Condensate trap 1 − Condensate trap cap 2 − 2" diameter vent / intake plugs 1 − 3" diameter cabinet plug (intake) 2 − 2" diameter debris screen

1 − Bag assembly containing the following:

1− 50 hertz power wiring harness

NOTE − G61MPVT−60C−110 and −60D−135 units also include two 50mm to 80mm diameter ABS street elbows and two 80mm to 50mm ABS reducing elbows, which are shipped on the blower deck in the heating compartment.

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

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

Safety Information

CONDENSATE

DRAIN

G61MPVT

FIGURE 2

COMBUSTION

AIR INTAKE INSIDE

OF HOUSE

G61MPVT

CONDENSATE

DRAIN

WARNING

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

CAUTION

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

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Installation − Setting Equipment

WARNING

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

Upflow Applications

The G61MPVT gas furnace can be installed as shipped in the upflow position. Refer to figure 3 for clearances.

Installation Clearances

Top

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

to side.

NOTE − G61MPVT−36B units with 1/2 hp blower motors are equipped with three flexible legs and one rigid leg. The rigid leg is equipped with a shipping bolt and a flat white plastic washer (rather than the rubber mounting grommet used with a flexible mounting leg). The bolt and washer must

be removed before the furnace is placed into operation. After the bolt and washer have been removed, the rig-

id leg will not touch the blower housing.

NOTE − G61MPVT−60D−135 units are equipped with a shipping pad under the blower housing. Remove the shipping pad prior to operation.

Allow for clearances to combustible materials as indicated on the unit nameplate. Minimum clearances for closet or alcove installations are shown in figures 3, 9 and 6.

WARNING

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

WARNING

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

Left Side

Bottom (Floor)

Top/Plenum 25 mm (1 in.)

*Front 0

Back 0

Sides 0†

Vent 0

Floor 0‡

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

Right Side

FIGURE 3

Return Air −− Upflow Units

NOTE − G61MPVT−135 models are not approved for installation in upflow air discharge applications.

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

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

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

1 − Return air from single side with transition which will ac-

commodate508 x 635 x 25 mm (20 x 25 x 1 in.) air filter. (Required to maintain proper air velocity.) See figure 4.

2 − Return air from single side.

3 − Return air from bottom.

4 − Return air from both sides.

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Page 6

5 − Return air from bottom and one side.

Refer to Engineering Handbook for additional information.

G61MPVT applications which include side return air and a condensate trap installed on the same side of the cabinet require either a return air base or field−fabricated transition to accommodate an optional IAQ accessory taller than 368mm (14.5 inches).

Side Return Air

(with transition and filter)

508mm X635mm X 25mm

(20" X 25" X 1")

Air Filter

Return

Air

Plenum

Horizontal Applications

G61MPVT furnaces, with the exception of the G61MPVT−60D−135, can be installed in horizontal applications with either right− or left−hand air discharge. The G61MPVT−60D−135 can only be installed in horizontal applications with right−hand air discharge.

Refer to figure 6 for clearances in horizontal applications.

Horizontal Application

Installation Clearances

Right−Hand Discharge

Top

Left End Right End

Bottom (Floor)**

Left−Hand Discharge

Top

Left End Right End

Transition

FIGURE 4

Removing the Bottom Panel

Remove the two screws that secure the bottom cap to the furnace. Pivot the bottom cap down to release the bottom panel. Once the bottom panel has been removed, reinstall the bottom cap. See figure 5.

Removing the Bottom Panel

Screw

Bottom Cap

Bottom Panel

Bottom (Floor)**

Top 0

Front* 0

Back 0

Ends 0

Vent 0

Floor 0‡

*Front clearance in alcove installation must be 610 mm (24 inches). Maintain a minimum of 610mm (24 inches) for front service access. **A 140mm (5−1/2) service clearance must be maintained below the unit to provide for servicing of the condensate trap. ‡For installations on a combustible floor, do not install the furnace directly on carpeting, tile or other combustible materials other than wood flooring.

FIGURE 6

This furnace may be installed in either a roof space or under floor. Install the furnace on a field−fabricated raised platform, as shown in figure 7. The unit must be supported at both ends and beneath the blower deck to prevent sagging.

NOTE − In horizontal applications, the unit must be level side−to−side. The unit may be tilted back−to−front a maximum of 25mm (1 inch) to ensure proper draining of the heat exchanger. The heat exchanger coil will not

drain properly if the unit is tilted backward.

FIGURE 5

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Page 7

TYPICAL HORIZONTAL ROOF SPACE INSTALLATION (FORCED AIR FURNACE)

INTAKE PIPE

NOTE − Condensate trap and

condensate line must be

protected by self−regulating

heating cable and insulation

when run through unconditioned

spaces.

CONDENSATE LINE

FIGURE 7

Platform Installation of Horizontal Unit in Roof Space

1 − Select location for unit keeping in mind service and

other necessary clearances. See figure 6.

2 − Construct a raised wooden frame and cover frame

with a plywood sheet. Provide a service platform for unit. A drain pan is also recommended.

EXHAUST PIPE

INTAKE

PIPE

GAS

CONNECTOR

RAISED PLATFORM

SERVICE PLATFORM

EXHAUST

PIPE

3 − Route auxiliary drain line so that water draining from

this outlet will be easily noticed by the homeowner.

4 − Set unit in drain pan (if used) as shown in figure 7. Unit

must be level to ensure proper coil drainage. Leave 140mm (5−1/2 inches) for service clearance below unit for condensate trap.

5 − Continue with exhaust, condensate and intake piping

installation according to instructions.

Platform Installation of Horizontal

Unit Installed Under Floor

1 − Select location for unit, keeping in mind service and

other clearances.

EVAPORATOR COIL

FIGURE 8

2 − After positioning cement blocks, mount support frame

on top of blocks and install unit. Unit must be level to ensure proper heat exchanger coil drainage. Leave 140mm (5−1/2 inches) for service clearance) for condensate trap.

3 − Install exhaust and intake piping according to informa-

tion given in following section.

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Return Air −− Horizontal Applications

Return air may be brought in only through the end of a furnace installed in the horizontal position. The furnace is equipped with a removable bottom panel to facilitate installation. See figure 5.

Downflow Applications

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

flow position. Flange damage will result. Refer to figure 9 for clearances in downflow applications.

Downflow Application Installation Clearances

Top

Left Side

Right Side

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

the unit.

4 − Ensure that the seal is adequate.

TABLE 1

NON−COMBUSTIBLE FLOOR OPENING SIZE

Model No.

B Cabinet (445mm) 19 − 3/4 502 16 − 5/8 422

C Cabinet (533mm) 19 − 3/4 502 20−1/8 511

D Cabinet (622mm) 19 − 3/4 502 23 − 5/8 600

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

Front to Rear Side to Side

in. mm in. mm

Installation on Combustible Flooring

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

tive base must be installed between the furnace and the floor. The base must be ordered separately for the following cabinet sizes:

D B cabinet 445mm − # 11M60 D C cabinet 533mm − # 11M61 D D cabinet 622mm − # 11M62

See table 2 for opening size to cut in floor.

Bottom

Top 0

*Front 0

Back 0

Sides 0†

Vent 0

Floor NC‡

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

FIGURE 9

Installation on Non−Combustible Flooring

1 − Cut floor opening keeping in mind clearances listed on

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

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

opening.

CAUTION

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

TABLE 2

ADDITIVE BASE FLOOR OPENING SIZE

Model

B Cabinet (445mm)

C Cabinet (533mm)

D Cabinet (622mm)

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

3 − Check fiberglass strips on additive base to make sure

they are properly glued and positioned.

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

num flanges seal against fiberglass strips.

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

5 − Set the furnace over the plenum.

6 − Ensure that the seal between the furnace and plenum

is adequate.

Front to Rear Side to Side

in. mm in. mm

22 559 18 − 3/4 476

22 559 22 − 3/4 578

22 559 25 − 3/4 654

Page 8

Page 9

G61MPVT UNIT

PLENUM

(Field Provided)

SEALING STRIP

(Field Provided)

SUPPLY AIR PLENUM

PROPERLY

SIZED FLOOR

OPENING

ADDITIVE BASE

FIGURE 10

Installation on Cooling Cabinet

1 − Refer to reverse−flow coil installation instructions for

correctly sized opening in floor and installation of cabinet.

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

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

3 − Seal the cabinet and check for air leaks.

Return Air Opening −− Downflow Units

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

1 − Bottom edge of plenum should be flanged with a

hemmed edge (See figure 11 or 12).

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

between the cabinet and the plenum.

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

nace using sheet metal screws.

4 − Make certain that an adequate seal is made.

PLENUM

(Field Provided)

SEALING STRIP

(Field Provided)

Side View

SECURE FROM

OUTSIDE CABINET

CABINET

SIDE PANEL

FIGURE 11

CABINET

SECURE FROM

INSIDE CABINET

Side View

SIDE PANEL

FIGURE 12

Filters

This unit is not equipped with a filter or rack. A field−provided filter is required for the unit to operate properly. Table 3 lists recommended minimum filter sizes.

A filter must be in place when the unit is operating.

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.

TABLE 3

Furnace

Cabinet Size

445mm 406 X 635 X 25 (1) 406 X 635 X 25 (1)

533mm 406 X 635 X 25 (1) 508 X 635 X 25 (1)

622mm 406 X 635 X 25 (2) 610 X 635 X 25 (1)

Side Return Bottom Return

Filter Size −− mm

Duct System

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

NOTE − Operation of this furnace in heating mode (indoor blower operating at selected heating speed) with an external static pressure which exceeds 200 Pa (0.8 inches w.c.) may result in erratic limit operation.

Supply Air Plenum

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

Return Air Plenum

Return air must not be drawn from a room where this furnace, or any other gas appliance (ie., a water heater), is installed. When return air is drawn from a room, a

negative pressure is created in the room. If a gas appliance is operating in a room with negative pressure, the flue products can be pulled back down the vent pipe and

Page 9

Page 10

into the room. This reverse flow of the flue gas may result in incomplete combustion and the formation of carbon monoxide gas. This toxic gas might then be distributed throughout the house by the furnace duct system.

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

Pipe & Fittings Specifications

All pipe and fittings to be Pressure Pipe, Class E / Class 12 / Schedule 40 or equivalent

All pipe, fittings, primer and solvent cement must conform

OUTDOOR TERMINATION KITS AND CORRESPONDING EQUIVALENCIES

Outdoor Exhaust Accel-

erator

(Dia. X

Length)

40mm X

305mm

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

UNIT

MODEL

−070

−090

−110

−135

VENT

PIPE

DIA.

(in.)

50mm 1.2

80mm 2.4

100mm 4.3

50mm

80mm

100mm

80mm

100mm

80mm

100mm

*Requires field−provided and installed 40mm exhaust accelerator.

Outdoor Ex-

haust Accel-

erator

(Dia. X

Length)

50mm X

305mm

Not

Allowed

Not

Allowed

Not

Allowed

0.3

0.6

1.2

0.6

1.2

1.8

3.0

Concentric

(1−1/2")

71M80 60M29 60L46 22G44 44J40 15F74

Allowed

TABLE 4

Vent Pipe Length Equivalency (meters)

40mm

Kit

3.6

7.3

12.8

Not

with Australian standards. The solvent shall be free flowing and contain no lumps, undissolved particles or any foreign matter that adversely affects the joint strength or chemical resistance of the cement. The cement shall show no gelation, stratification, or separation that cannot be removed by stirring.

CAUTION

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

Table 4 lists the available exhaust termination kits, as well as vent pipe equivalencies which must be used when sizing vent pipe. All Lennox vent terminations are PVC or ABS.

50mm (2")

Concentric

Kit

Not

Allowed

Not

Allowed

Not

Allowed

.9 .9

1.8 1.8

3.7 3.7

1.8 1.8

3.7 3.7

Not

Allowed

Not

Allowed

**Requires field−provided and installed 50mm exhaust accelerator.

80mm (3") Concentric

Kit

Not

Allowed

Not

Allowed

Not

Allowed

4.6

7.6

50mm (2")

Wall Plate

Kit

1.2 1.2* 1.2

2.4 2.4* 2.4

4.3 4.3* 4.3

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

Not

Allowed

80mm (3")

Wall Plate

Kit

0.3 0.3**

0.6 0.6**

1.2 1.2**

0.6 0.6

1.2 1.2

1.8

3.0

50mm (2")

Wall Ring

Kit

Not

Allowed

Not

Allowed

Page 10

Page 11

Vent Piping Guidelines

G61MPVT furnaces, with the exception of the G61MPVT−60D−135, can be installed as either a Non−Direct Vent or a Direct Vent gas central furnace. The G61MPVT−60D−135 can only be installed as a Direct Vent (two pipe) 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 5 and 6. Table 5 lists the minimum equivalent vent pipe lengths permitted. Table 6 lists the maximum equivalent pipe lengths permitted.

Maximum vent length is defined as:

Total length (linear meters) of pipe,

Plus Equivalent length (meters) of fittings, Plus Equivalent length (meters) 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 7.

NOTE − The exhaust pipe should be offset a minimum of 305mm (12 inches) to avoid the possibility of water droplets being released from the exhaust termination. The minimum exhaust vent length is 4.5m (15 feet). Shorter exhaust vent lengths may result in the discharge of water droplets from the exhaust termination, in spite of the 305mm (12−inch) vertical offset.

Each 90° elbow (including those provided with the furnace) of any diameter is equivalent to 1.5m (5 feet ) 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 .76m (2.5 feet) 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 Lennox for assistance in sizing vent pipe in these applications.

NOTE − The flue collar on all models is sized to accommodate 50mm Schedule 40 / Class 12 / Class E pressure pipe. When vent pipe which is larger than 50mm must be used in an upflow application, a 50mm 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 meter value to this elbow according to the larger size pipe being used. Contact Lennox for more information concerning sizing of vent systems which include multiple pipe sizes.

305mm Min.

Upflow and Downflow Application

Rooftop Termination

305mm Min.

Horizontal Application

Rooftop Termination

Exhaust Pipe Offset

305mm Min.

Upflow and Downflow Application

Side Wall Termination

305mm Min.

Horizontal Application

Side Wall Termination

FIGURE 13

Page 11

Page 12

Use the following steps to correctly size vent pipe diameter.

Refer to Vent Pipe Size Determination Worksheet on page 52.

1 − Determine the vent termination and its corresponding

equivalent meter value per table 6.

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

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

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

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

4 − Determine the length of straight pipe required.

5 − Add the total equivalent meters calculated in steps 1

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

TABLE 5

MINIMUM VENT PIPE LENGTHS

G61MPVT

MODEL

070, 090

110***

135***

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

**G61MPVT−60C−110 and G61MPVT−60D−135 must have 90° street ell (supplied) installed directly into unit flue colla and 50mm to 80mm reducer (supplied) must be installed on the 50mm ell. NOTE − All 90° elbows used in configuration of vent, must be sweep el-

bows.

MIN. EQUIV.

VENT LENGTH

4.5m*

EXAMPLE

1.5m plus 2 elbows of 50mm or 80mm diameter pipe

1.5m plus 2 elbows of 80mm diameter pipe

TABLE 6

MAXIMUM VENT PIPE LENGTHS

MAXIMUM EQUIVALENT VENT

ALTITUDE

0 − 610m

611 −1372m

n/a −− Not allowed. *G61MPVT−60C−110 and G61MPVT−60D−135 must have 90° street ell (sup-

plied) installed directly into unit flue colla and 50mm to 80mm reducer (supplied) must be installed on the 50mm ell. NOTE − All 90° elbows used in configuration of vent, must be sweep el-

bows.

G61MPVT

MODEL

070 12.2 16.1 44

090 4.5 12.2 34.5 110* n/a 12.2 30 135* n/a 7.6 20

070 7.6 10 27.5

090 n/a 7.6 21.5 110* n/a 7.6 18.7 135* n/a n/a n/a

LENGTH METERS

50mm

dia.

80mm

dia.

100mm

dia.

IMPORTANT

The G61MPVT unit is not suitable for use at elevations over 610m.

Joint Cementing Procedure

All cementing of joints should be done according to the relevant local authority.

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.

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.

Page 12

Page 13

Venting Practices

1 − Use recommended piping materials for exhaust piping

(Class E / Class 12 / Schedule 40).

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

proved cement.

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. Refer to pipe and fittings specifications and gluing procedures.

Suspend piping using hangers at a minimum of every

1.52m (5 feet) for Schedule 40 vent pipe. A suitable hanger can be fabricated by using metal or plastic strapping or a large wire tie.

3 − In areas where piping

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

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

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

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

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

Exhaust Piping (Figures 15 and 16)

NOTE − Two 50mm diameter street ells and two 80mm to 50mm reducers are contained in a bag assembly strapped to the blower deck of 60C−110 and 60D−135 units. The street ells must be flue collar. See figure 15. The 80mm to 50mm reducers must be glued to the street ells in upflow or downflow

applications.

1 − Choose the appropriate side for venting in upflow or

glued directly into the unit

STRAPPING

(metal, plastic

or large wire

ties)

FIGURE 14

IMPORTANT

Exhaust piping and condensate trap must be installed on the same side of the unit in upflow and dowflow applications.

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

ward unit. A minimum of 6mm (1/4") drop for each 305mm (12 inches) of horizontal run is mandatory for drainage. Horizontal runs of exhaust piping must be supported every 1.5m (5 feet) 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

50mm 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 13

Page 14

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)

80mm

PLUG

VENT PLUG

(Must be

glued in

place)

PLUG

*50mm diameter street elbow provided.

**80mm diameter reducing elbow provided.

***Limit pipe length to 50mm.

PLUG

50mm

CONDENSATE

TRAP

(Must be installed

on same side as

exhaust piping)

50mm

FIGURE 15

TYPICAL EXHAUST PIPE CONNECTIONS

HORIZONTAL DIRECT OR

NON−DIRECT VENT APPLICATIONS

(Horizontal Right−Hand Air Discharge Application Shown)

*Limit pipe length to 50mm in G61MPVT−110 and −135 applications.

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

80mm

TRANSITION

50mm

G61MPVT−36B−070 G61MPVT−60C−090 G61MPVT−60C−110* G61MPVT−60D−135*

50mm

G61MPVT−36B−070 G61MPVT−60C−090

FIGURE 16

TRANSITION

50mm

80mm

TRANSITION

50mm***

50mm*

G61MPVT−110

with

80mm vent pipe

G61MPVT−070

or 090 with 80mm

vent pipe

80mm

80mm**

G61MPVT−135

with

80mm vent pipe

Intake Piping

plications, 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 G61MPVT 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.

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 50mm plug into the unused air intake

connector on the opposite side of the cabinet.

4 − Route piping to outside of structure. Continue with

installation following instructions given in general guide lines for piping terminations and in intake and exhaust piping terminations for direct vent sections. Refer to figure 17 for pipe sizes.

Page 14

Page 15

TYPICAL AIR INTAKE PIPE CONNECTIONS

UPFLOW OR DOWNFLOW DIRECT VENT APPLICATIONS

(Right−Hand Exit in Upflow Application Shown)

50mm

PLUG

(Must be

glued in

place)

50mm

G61MPVT−36B−070 G61MPVT−60C−090

FIGURE 17

TYPICAL AIR INTAKE PIPE CONNECTIONS

HORIZONTAL DIRECT VENT APPLICATIONS

(Horizontal Right−Hand Air Discharge Application Shown)

80mm

TRANSITION

80mm

50mm*

TRANSITION

50mm*

50mm

G61MPVT−36B−070 G61MPVT−60C−090 G61MPVT−60C−110*

G61MPVT−36B−070 G61MPVT−60C−090 G61MPVT−60C−110* G61MPVT−60D−135*

*Limit pipe length to 50mm in G61MPVT−110 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.

*Limit pipe length to 50mm in G61MPVT−110 and −135 applications.

G61MPVT−36B−070 G61MPVT−60C−090 G61MPVT−60C−110*

G61MPVT−36B−070 G61MPVT−60C−090 G61MPVT−60C−110* G61MPVT−60D−135*

50mm

G61MPVT−36B−070 G61MPVT−60C−090

50mm*

TRANSITION

50mm*

TRANSITION

50mm

80mm

50mm

TYPICAL AIR INTAKE PIPE CONNECTIONS

UPFLOW OR HORIZONTAL NON−DIRECT

(Right−Hand Exit in Upflow Application Shown)

PLUG

(Must be

glued in

place)

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

VENT APPLICATIONS

156mm Max.

INTAKE

DEBRIS

SCREEN

(Provided)

FIGURE 18

FIGURE 19

Page 15

Page 16

TYPICAL AIR INTAKE PIPE CONNECTIONS

DOWNFLOW NON−DIRECT VENT APPLICATIONS

(Right−Hand Exit in Downflow Applications Shown)

50mm

SWEEP

ELL

INTAKE

DEBRIS

SCREEN

(Provided)

PLUG

(Must be

glued in

place)

150mm Max.

INTAKE DEBRIS

SCREEN

(Provided)

Downflow

Evaporator

Coil

FIGURE 20

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

air intake screen to route the intake piping as shown in figures 19 and 20. Maintain a minimum clearance of 76mm (3 inches) around the air intake opening. The air intake opening (with the protective screen) should always be directed either downward or straight out. Use 50mm pipe and fittings only and make sure that the air intake does not extend more than 156mm (6inches) beyond the G61MPVT 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 20.

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 50mm plug into the unused air intake

connector on the opposite side of the cabinet.

PLUG

(Must be

glued in

place)

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

50mm

50mm SWEEP ELL

Downflow Additive Flloor Base

438mm

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 G61MPVT gas furnace has been started, the following test should be conducted to ensure proper venting and sufficient combustion air has been provided to the G61MPVT, 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.

Page 16

Page 17

If the venting system has been installed improperly, or if provisions have not been made for sufficient amounts of combustion air, corrections must be made as outlined in the previous section.

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

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

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

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

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

nected to the venting system. Turn on any exhaust

fans, such as range hoods and bathroom exhausts, so

they will operate at maximum speed. Do not operate a

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

being inspected into operation. Adjust thermostat so

appliance will operate continuously. 7 − Test for spillage of flue gases at the draft hood relief

opening after 5 minutes of main burner operation. Use

the flame of match or candle, or smoke from a ciga-

rette, cigar. 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. 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 G61MPVT is then classified as a non-direct vent gas furnace. In Non-Direct Vent applications, the vent termination is limited by local building codes.

Position termination end according to location given in figure 21. In addition, position termination end so it is free from any obstructions and above the level of snow accumulation (where applicable). The termination should be at least 305mm (12 inches) 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 1.8m (6 feet) of a condensing unit because the condensate can damage the painted coating.

NOTE − If winter design temperature is below 0°C (32°F), exhaust piping should be insulated with 13mm (1/2 inch), 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 13mm (1/2 inch) Armaflex or equivalent. In extreme cold climate areas, 19mm (3/4 inch) 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 −6.7°C (20°F), 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.

Page 17

Page 18

VENT TERMINATION CLEARANCES

(AS 5601)

− G61MPVT VENT TERMINATION

− AIR INLET OF OTHER APPLIANCE

less than 10 ft (3.048M)

A − Clearance above ground level − 305mm. B − Clearance horizontally to window or door that may be

opened − 305mm minimum for appliances up to 150Mj/h; Clearance vertically below a window that may be opened − 1000mm minimum for appliances up to 150Mj/h.

C − Clearance below eaves, balconies and other projections −

305mm.

D − Clearance to electric meters, gas meters, regulators and re-

lief equipment − 1000mm minimum.

FIGURE 21

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 22 through 25 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 76mm (3 inches) on roof terminations and 152mm (6 inches) on side wall terminations.

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

300mm minimum horizontal and 1000mm minimum vertically for appliances up to 150Mj/h;

F − Clearance to mechanical air supply inlet including a spa

blower −− 1000mm minimum.

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

dow wells, stairwells or alcoves.

H − Do not position terminations directly above a walkway.

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

larger vent pipe size to termination pipe size.

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

nate straight down using two 90° elbows (See figure

22).

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 7.

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

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

haust piping should extend a maximum of 305mm (12 inches) beyond the outside wall unless supported. Intake piping should be as short as possible.

Page 18

Page 19

7 − On field supplied terminations, a minimum separation

distance between the end of the exhaust pipe and the

end of the intake pipe is 203mm (8 inches).

TABLE 7

EXHAUST PIPE TERMINATION SIZE REDUCTION

G61MPVT

MODEL

070 50 or 80mm 40mm 090 50 or 80mm 50mm 110 80mm 50mm* 135 80mm 50mm*

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

203 mm MIN

80mm or

50mm PVC

PROVIDE SUPPORT

FOR INTAKE AND

EXHAUST LINES

Exhaust Pipe Size Termination Pipe Size

76mm MAX.

DIRECT VENT ROOF TERMINATION KIT

SIZE TERMINATION PIPE PER TABLE 7.

UNCONDITIONED

ATTIC SPACE

13mm FOAM

INSULATION IN

UNCONDITIONED

SPACE

FIGURE 22

INTAKE

TERMINATION

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)

above ground level.

EXHAUST

TERMINATION

305mm Min.

FIGURE 24

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. Figure 25 shows a typical terminations.

1 − Exhaust piping must terminate straight out or up as

shown. The termination pipe must be sized as listed in table 7.The specified pipe size ensures proper velocity required to move the exhaust gases away from the building.

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

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

EXHAUST

TERMINATION

INTAKE

TERMINATION

FIELD−PROVIDED

REDUCER MAY BE REQUIRED

TO ADAPT LARGER VENT

PIPE SIZE TO TERMINATION

EXHAUST

DIRECT VENT CONCENTRIC ROOFTOP TERMINATION

(71M80, 69M29 or 60L46)

INTAKE

FIGURE 23

SIZE TERMINATION PIPE PER TABLE 7.

80mm or

50mm PVC

PROVIDE SUPPORT

FOR EXHAUST LINES

NON−DIRECT VENT ROOF TERMINATION KIT

UNCONDITIONED

ATTIC SPACE

FIGURE 25

Page 19

Page 20

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 140mm (5−1/2−inch) service clearance is required for the condensate trap. Refer to figure 26 for condensate trap locations.

CONDENSATE TRAP LOCATIONS

(Unit shown in upflow position)

Horizontal

left and

optional

downflow

Horizontal

right and

optional

downflow

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 19mm (3/4") PVC coupling. The inner diameter of each stub will accept standard 13mm (1/2") diameter PVC pipe.

NOTE − Vinyl tubing may be used for condensate drain. Tubing must be 32mmOD X 25mm ID (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.

Optional

upflow

Optional

upflow

NOTE − In upflow applications where side return air filter is installed on same side as the condensate trap, filter rack must be installed beyond condensate trap to avoid interference.

FIGURE 26

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 27.

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

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

FIGURE 27

VENT

NIPPLE

TEE

(both sides)

Page 20

Page 21

Gas Piping

CAUTION

DO NOT over−tighten when attaching pipe or fittings to gas valve. Damage may occur.

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

the left- or right-hand side. Supply piping enters into

the gas valve from the side of the valve as shown in

figures 29 and 30. 2 − When connecting gas supply, factors such as length of

run, number of fittings and furnace rating must be con-

sidered to avoid excessive pressure drop. Table 8 lists

recommended pipe sizes for typical applications.

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

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

chutes, chimneys or gas vents, dumb waiters or eleva-

tor shafts. Center gas line through piping hole. Gas

line should not touch side of unit. See figures 29 and

30.

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

5.6m) upward toward the gas meter from the furnace.

The piping must be supported at proper intervals, ev-

ery 2.44 to 3.05m (8 to 10 feet), using suitable hangers

or straps. Install a drip leg in vertical pipe runs to serve as

a trap for sediment or condensate. 5 − A 1/8" N.P.T. plugged tap or pressure post is located

on the gas valve to facilitate test gauge connection.

See figure 34. 6 − In some localities, codes may require installation of a

manual main shut-off valve and union (furnished by in-

staller) external to the unit. Union must be of the

ground joint type.

MANUAL MAIN SHUT−OFF

VALVE WILL NOT HOLD

NORMAL TEST PRESSURE

CAP

FURNACE

ISOLATE

GAS VALVE

FIGURE 28

Leak Check

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

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

IMPORTANT

When testing gas lines using pressures in excess of 1/2 psig (3.48 kPa), gas valve must be disconnected and isolated. See figure 28. Gas valves can be damaged if subjected to pressures greater than 1/2 psig (3.48 kPa).

WARNING

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

FIRE OR EXPLOSION HAZARD

IMPORTANT

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

Upflow Application

Left Side Piping

(Standard)

MANUAL

MAIN SHUT−OFF

VALV E

GROUND

JOINT

UNION

DRIP LEG

AUTOMATIC

GAS VALVE

(with manual

shut−off valve)

FIGURE 29

FIELD

PROVIDED

AND INSTALLED

Page 21

Upflow Application

Right Side Piping

(Alternate)

MANUAL

MAIN SHUT−OFF

VALV E

GROUND

JOINT

UNION

DRIP LEG

Page 22

MANUAL

MAIN SHUT−OFF

VALV E

GROUND

JOINT UNION

DRIP LEG

Horizontal Applications

Possible Gas Piping Configerations

MANUAL

MAIN SHUT−OFF

VALV E

GROUND

JOINT

UNION

DRIP LEG

Horizontal Application

Left−Side Air Discharge

Horizontal Application

Right−Side Air Discharge

FIGURE 30

TABLE 8

GAS PIPE CAPACITY − FT3/HR (kL/HR)

Nominal

Iron Pipe Size

−Inches(mm)

1/4

(6.35)

3/8

(9.53)

1/2

(12.7)

3/4

(19.05)

(25.4)

1−1/4

(31.75)

1−1/2

(38.1)

(50.8)

2−1/2

(63.5)

(76.2)

(101.6)

Internal

Diameter

−Inches(mm)

.364

(9.246)

.493

(12.522)

.622

(17.799)

.824

(20.930)

1.049

(26.645)

1.380

(35.052)

1.610

(40.894)

2.067

(52.502)

2.469

(67.713)

3.068

(77.927)

4.026

(102.260)

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

(1.13)

(2.69)

175

(4.96)

360

(10.19)

680

(19.25)

1400

(39.64)

2100

(59.46)

3950

(111.85)

6300

(178.39)

11000

(311.48)

23000

(651.27)

(.82)

(1.84)

120

(3.40)

250

(7.08)

465

(13.17)

950

(26.90)

460

(41.34)

2750

(77.87)

4350

(123.17)

7700

(218.03)

15800

(447.39)

(.68)

(1.47)

(2.75)

200

(5.66)

375

(10.62)

770

(21.80)

1180

(33.41)

2200

(62.30)

3520

(99.67)

6250

(176.98)

12800

(362.44)

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

Length of Pipe−Feet(m)

(.57)

(1.27)

(2.32)

170

(4.81)

320

(9.06)

660

(18.69)

990

(28.03)

1900

(53.80)

3000

(84.95)

5300

(150.07)

10900

(308.64)

(.51)

(1.13)

(2.07)

151

(4.28)

285

(8.07)

580

(16.42)

900

(25.48)

1680

(47.57)

2650

(75.04)

4750

(134.50)

9700

(274.67)

(.45)

(1.02)

(1.87)

138

(3.91)

260

(7.36)

530

(15.01)

810

(22.94)

1520

(43.04)

2400

(67.96)

4300

(121.76)

8800

(249.18)

(.42)

(.73)

(1.73)

125

(3.54)

240

(6.80)

490

(13.87)

750

(21.24)

1400

(39.64)

2250

(63.71)

3900

(110.43)

8100

(229.36)

(.40)

(.88)

(1.61)

118

(3.34)

220

(6.23)

460

(13.03)

690

(19.54)

1300

(36.81)

2050

(58.05)

3700

(104.77)

7500

(212.37)

MANUAL

MAIN SHUT−OFF

VALV E

GROUND

JOINT

UNION

DRIP LEG

(.37)

(.82)

(1.50)

110

(3.11)

205

(5.80)

430

(12.18)

650

(18.41)

1220

(34.55)

1950

(55.22)

3450

(97.69)

7200

(203.88)

100

(30.480)

(.34)

(.76)

(1.42)

103

(2.92)

195

(5.52)

400

(11.33)

620

(17.56)

1150

(32.56)

1850

(52.38)

3250

(92.03)

6700

(189.72)

Page 22

Page 23

Electrical

ELECTROSTATIC DISCHARGE (ESD)

Precautions and Procedures

5 − Electrically ground the unit according to local codes.

NOTE − The G61MPVT furnace contains electronic components that are polarity sensitive. Make sure that the furnace is wired correctly and is properly grounded.

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 power wiring harness is shipped with each G61MPVT furnace. An IEC receptacle is provided on the right side of the unit. Plug the harness into the IEC receptacle and into a properly sized wall plug.

Refer to figure 31 and table 9 for field wiring and figure 32 for schematic wiring diagram and troubleshooting.

1 − Ensure that power connection point is located with 2m

of furnace.

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

tate thermostat wiring.

3 − Before connecting the thermostat wiring, check to

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

4 − Complete the wiring connections to the equipment.

Use the provided unit wiring diagram and the field wiring diagram shown in figure 31 and table 9. Use 18−gauge wire or larger that is suitable for Class II rating for thermostat connections.

6 − One line voltage EAC" spade terminal is provided on

the furnace control board. Any electronic air cleaner rated up to one amp can be connected to this terminal with the neutral leg of the circuit being connected to one of the provided neutral terminals. See figure 33 for control board configuration. This terminal is energized when the indoor blower is operating.

7 − One line voltage HUM" spade terminal is provided on

the furnace control board. Any humidifier rated up to one amp can be connected to this terminal with the neutral leg of the circuit being connected to one of the provided neutral terminals. See figure 33 for control board configuration. This terminal is energized in the heating mode when the combustion air inducer is operating.

8 − Install the room thermostat according to the instruc-

tions provided with the thermostat. See table 9 for thermostat connections. If the furnace is being matched with a heat pump, refer to the instruction packaged with the dual fuel thermostat.

Indoor Blower Speeds

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

blower will run continuously at approximately 38% of the second−stage cooling speed when there is no cooling or heating demand.

2 − When the G61MPVT is running in the heating mode,

the indoor blower will run on the heating speed designated by the positions of DIP switches 7 and 8.

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

run on the cooling speed designated by the positions of DIP switches 3 and 4.

Page 23

Page 24

USE COPPER CONDUCTORS ONLY.

FIELD INSTALLED CLASS II 24V FIELD INSTALLED LINE VOLTAGE

TYPICAL G61MPVT FIELD WIRING DIAGRAM

FIGURE 31

Page 24

Page 25

Thermostat

Heat Staging

Jumper

TABLE 9

Field Wiring Applications

Jumper Settings (See figure 33)

W915

Two−Stage

Cooling

W914 Dehumidification

W951

Heat Pumps

Wiring Connections

1Heat / 1 Cool

NOTE − Use heat staging jumper to set second−stage heat ON delay. No delay (None), 10 minutes, or 15 minutes.

2 Heat / 1 Cool

NOTE − Use heat staging jumper to set second−stage heat ON delay. No delay (None), 10 minutes, or 15 minutes.

15 Minutes Intact Intact Intact

10 Minutes Intact Intact Intact

T’STAT

CONTROL

TERM. STRIP

CONTROL

TERM. STRIP

OUTDOOR

UNIT

OUTDOOR

UNIT

Page 25

Page 26

TYPICAL G61MPVT WIRING DIAGRAM

FIGURE 32

Page 26

Page 27

Integrated Control Board

TWO−STAGE, VARIABLE SPEED INTEGRATED CONTROL BOARD

HEAT

STAGING

DELAY

JUMPER

BLOWER

OFF

DELAY

JUMPER

DIAGNOSTIC

LED

BLOWER

OPERATION

DIP

SWITCHES

OPERATIONAL

LEDS

FIGURE 33

G61MPVT units are equipped with a two−stage, variable speed integrated control. This control manages ignition timing, heating mode fan off delays and indoor blower speeds based on selections made using the control dip switches and jumpers. The control includes an internal watchguard feature which automatically resets the ignition control when it has been locked out. After one hour of continuous thermostat demand for heat, the watchguard will break and remake thermostat demand to the furnace and automatically reset the control to relight the furnace.

Heat Staging Jumper The heat staging jumper is factory−positioned in the

NONE position for use with a two−stage thermostat. If a single−stage thermostat is to be used, the jumper must be repositioned.

When the G61MPVT unit is used with single−stage thermostat −− The heat staging jumper is used to determine the

second stage on delay. The jumper may be positioned to

provide either a 10−minute or a 15−minute delay before second−stage heat is initiated.

Blower−Off Delay Jumper −− The heating mode blower−on delay of 45 seconds is not adjustable. The heating mode blower−off delay (time that the blower operates after the heating demand has been satisfied) can be adjusted by moving blower−off delay jumper 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 32° and 43°C (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. Settings of 60, 90, 120 and 180 seconds are available.

Page 27

Page 28

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 a thermostat which features humidity control.

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

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.

Status LEDs (HI/LO, CFM, ANI)

The green HI/LO 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.

The green CFM LED indicates the blower air flow. Count the number of blinks between the two−second pauses to determine the airf low. Each blink represents approximately 50 L/s (100CFM).

The red ANI LED flashes diagnostic codes, which are detailed on page 43.

Indoor Fan Operation DIP Switch Settings

Switches 1 and 2 −− Blower Speed Adjustment −−

Switches 1 and 2 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 tables 14 through NO TAG for corresponding cfm values.

TABLE 10

Blower Speed Adjustment

Adjustment

Switch 1 Switch 2

+10% (approx.) On Off

NORMAL (Factory) Off Off

−10% (approx.) Off On

Cooling Mode Blower Speeds

TABLE 11

Speed

Switch 3 Switch 4

1 − Low On On

2 − Medium Low Off On

3 − Medium High On Off

4 − High (Factory) Off Off

Switches 5 and 6 −− Cooling Mode Blower Speed Ramping −− Switches 5 and 6 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 12 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 the next page.

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

TABLE 12

Cooling Mode Blower Speed Ramping

Ramping Option

Switch 5 Switch 6

A (Factory) Off Off

B On Off C Off On D On On

Ramping Option A (Factory Selection)

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

tes.

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

motor runs at 100% until demand is satisfied.

D 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

100% CFM

1/2 MIN 50% CFM

OFF

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.

Switches 3 and 4 −− Cooling Mode Blower Speed −−

Switches 3 and 4 are used to select cooling blower motor speed. The unit is shipped from the factory with the DIP switches positioned for high speed (4) indoor blower motor operation during the cooling mode. The table below provides the cooling mode blower speeds that will result from different switch settings. Refer to tables 14 through NO TAG for corresponding cfm values.

OFF

7 1/2 MIN

82%CFM

COOLING DEMAND

100% CFM

Ramping Option C

S Motor runs at 100% until demand is satisfied.

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

onds then ramps down to stop.

Page 28

OFF

Page 29

Switches 7 and 8 −− Heating Mode Blower Speed −−

Switches 7 and 8 are used to select heating mode blower motor speed. The unit is shipped from the factory with the

OFF

100% CFM

DEMAND

100% CFM

45 SEC.

OFF

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 tables 14

Ramping Option D

S Motor runs at 100% until demand is satisfied.

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

through NO TAG for corresponding L/s values.

TABLE 13

Heating Mode Blower Speeds

Speed

Switch 7 Switch 8

1 − Low On On

100% CFM

COOLING DEMAND

2 − Medium Low

(Factory)

OFFOFF

3 − Medium High On Off

4 − High Off Off

Off On

TABLE 14

G61MPVT−36B−070 BLOWER MOTOR PERFORMANCE (LESS FILTER)

0.0" to 0.8" w.g. (0 through 200 Pa) External Static Pressure Range

Factory Settings: Heating Speed − 2; Cooling Speed − 4; Speed Adjust − NORM

Speed Switch Positions

ADJUST"

Switch

Positions

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

895 420 1025 485 1290 610 1340 630 1015 480 1190 560 1280 605 1395 660

NORM 820 385 940 445 1155 545 1210 570 930 440 1065 505 1155 545 1270 600

 N/A

ADJUST"

Switch

Positions

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

820 385 930 440 1160 550 1210 570 730 345 815 385 865 410 935 440

NORM 760 360 865 410 1045 495 1090 515 680 320 755 355 795 375 855 405



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 (235 L/s).

N/A N/A 775 365 930 440 965 455 625 295 695 330 730 345 775 365

Second Stage HEAT" Speed Second Stage COOL" Speed

1 2 3 4 1 2 3 4

N/A 840 395 1020 480 1055 495 830 390 950 450 1010 475 1105 520

First Stage HEAT" Speed First Stage COOL" Speed

1 2 3 4 1 2 3 4

HEAT speed position.

Page 29

Page 30

TABLE 15

G61MPVT−60C−090 BLOWER MOTOR PERFORMANCE (LESS FILTER)

0.0" to 0.8" w.g. (0 through 200 Pa) External Static Pressure Range

Factory Settings: Heating Speed − 2; Cooling Speed − 4; Speed Adjust − NORM.

Return Air Options: Bottom; both sides; or bottom and one side.

Speed Switch Positions

ADJUST"

Switch

Positions

Second Stage HEAT" Speed Second Stage COOL" Speed

1 2 3 4 1 2 3 4

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

1500 710 1675 790 1880 885 2090 985 1605 760 1710 805 1925 910 2165 1020

NORM 1355 640 1545 730 1720 810 1900 895 1440 680 1560 735 1755 825 1960 925

 1194

ADJUST"

Switch

Positions

1360 640 1560 735 1730 815 1910 900 1105 520 1185 560 1355 640 1545 730

565 1365 645 1540 730 1695 800 1275 600 1380 650 1590 750 1755 830

First Stage HEAT" Speed First Stage COOL" Speed

1 2 3 4 1 2 3 4

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

NORM 1220 575 1405 665 1585 750 1740 820 995 470 1080 510 1205 570 1345 635



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

1105 520 1235 585 1410 665 1570 740 890 420 960 455 1090 515 1215 575

HEAT speed position.

TABLE 16

G61MPVT−60C−090 BLOWER MOTOR PERFORMANCE (LESS FILTER)

0.0" to 0.8" w.g. (0 through 200 Pa) External Static Pressure Range

Factory Settings: Heating Speed − 2; Cooling Speed − 4; Speed Adjust − NORM.

Return Air Options: Single side return air − Bold volumes require field−fabricated transition to accommodate

20 x 25 x 1 in. (508 x 635 x 25 mm) cleanable air filter in order to maintain proper air velocity across the filter.

Speed Switch Positions

ADJUST"

Switch

Positions

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

1450 685 1640 775 1820 860 2055 970 1575 745 1690 795 1895 895 2135 1005

NORM 1320 625 1510 710 1700 800 1870 880 1405 665 1530 720 1735 820 1935 910

 1165

ADJUST"

Switch

Positions

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

1315 620 1510 715 1695 800 1875 885 1080 510 1160 545 1315 620 1490 705

NORM 1190 560 1365 645 1545 730 1715 810 985 465 1060 500 1185 560 1330 625



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

1075 510 1205 570 1370 645 1520 715 865 410 930 440 1065 500 1185 560

Second Stage HEAT" Speed Second Stage COOL" Speed

1 2 3 4 1 2 3 4

550 1320 625 1500 705 1665 785 1250 590 1355 640 1560 735 1735 820

First Stage HEAT" Speed First Stage COOL" Speed

1 2 3 4 1 2 3 4

HEAT speed position.

Page 30

Page 31

TABLE 17

G61MPVT−60C−090 BLOWER MOTOR PERFORMANCE (LESS FILTER)

0.0" to 0.8" w.g. (0 through 200 Pa) External Static Pressure Range

Factory Settings: Heating Speed − 2; Cooling Speed − 4; Speed Adjust − NORM.

Return Air Options: Single side return with optional RAB return air base

Speed Switch Positions

ADJUST"

Switch

Positions

Second Stage HEAT" Speed Second Stage COOL" Speed

1 2 3 4 1 2 3 4

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

1440 680 1630 770 1810 855 2015 950 1525 720 1655 780 1860 880 2100 990

NORM 1300 615 1485 700 1655 780 1830 865 1385 655 1500 710 1695 800 1905 900

 1155

ADJUST"

Switch

Positions

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

1320 625 1490 700 1665 785 1840 870 1060 500 1135 535 1285 605 1455 685

545 1310 620 1480 700 1640 775 1240 585 1320 625 1510 710 1695 800

First Stage HEAT" Speed First Stage COOL" Speed

1 2 3 4 1 2 3 4

NORM 1180 555 1345 635 1515 715 1680 795 960 455 1035 490 1165 550 1310 620



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

1055 500 1180 560 1340 630 1490 705 865 405 920 435 1050 495 1165 550

HEAT speed position.

TABLE 18

G61MPVT−60C−110 BLOWER MOTOR PERFORMANCE (LESS FILTER)

0.0" to 0.8" w.g. (0 through 200 Pa) External Static Pressure Range

Factory Settings: Heating Speed − 2; Cooling Speed − 4; Speed Adjust − NORM.

Return Air Options: Bottom; both sides; or bottom and one side.

Speed Switch Positions

ADJUST"

Switch

Positions

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

1505 710 1710 805 1915 905 2130 1005 1625 770 1745 825 1990 940 2210 1045

NORM 1370 645 1565 740 1765 835 1945 920 1465 690 1580 745 1790 845 1995 940

 1205

ADJUST"

Switch

Positions

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

1370 645 1570 740 1760 830 1945 920 945 445 1020 480 1160 545 1300 615

NORM 1235 585 1420 670 1600 755 1780 840 840 395 910 430 1055 500 1180 555



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

1105 525 1250 590 1420 670 1580 745 740 350 800 380 920 435 1045 495

Second Stage HEAT" Speed Second Stage COOL" Speed

1 2 3 4 1 2 3 4

570 1380 650 1565 740 1740 820 1290 610 1405 660 1605 760 1790 845

First Stage HEAT" Speed First Stage COOL" Speed

1 2 3 4 1 2 3 4

HEAT speed position.

Page 31

Page 32

TABLE 19

G61MPVT−60C−110 BLOWER MOTOR PERFORMANCE (LESS FILTER)

0.0" to 0.8" w.g. (0 through 200 Pa) External Static Pressure Range

Factory Settings: Heating Speed − 2; Cooling Speed − 4; Speed Adjust − NORM.

Return Air Options: Single side return air − Bold volumes require field−fabricated transition to accommodate

20 x 25 x 1 in. (508 x 635 x 25 mm) cleanable air filter in order to maintain proper air velocity across the filter.

Speed Switch Positions

ADJUST"

Switch

Positions

Second Stage HEAT" Speed Second Stage COOL" Speed

1 2 3 4 1 2 3 4

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

1485 700 1675 790 1870 885 2080 980 1585 750 1700 800 1905 900 2135 1005

NORM 1350 637 1525 720 1725 815 1895 895 1435 680 1535 725 1740 820 1930 910

 1175

ADJUST"

Switch

Positions

1325 625 1505 710 1695 800 1870 885 935 440 1025 485 1155 545 1285 605

555 1335 630 1505 710 1670 790 1280 605 1385 655 1570 740 1755 830

First Stage HEAT" Speed First Stage COOL" Speed

1 2 3 4 1 2 3 4

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

NORM 1195 565 1365 645 1550 730 1720 810 840 395 915 430 1050 495 1175 555



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

1080 510 1205 570 1365 645 1530 720 750 355 800 380 925 435 1050 495

HEAT speed position.

TABLE 20

G61MPVT−60C−110 BLOWER MOTOR PERFORMANCE (LESS FILTER)

0.0" to 0.8" w.g. (0 through 200 Pa) External Static Pressure Range

Factory Settings: Heating Speed − 2; Cooling Speed − 4; Speed Adjust − NORM.

Return Air Options: Single side return air with optional RAB return base. −

20 x 25 x 1 in. (508 x 635 x 25 mm) cleanable air filter in order to maintain proper air velocity across the filter.

Speed Switch Positions

ADJUST"

Switch

Positions

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

1475 695 1670 790 1865 880 2070 980 1555 735 1685 795 1895 895 2130 1005

NORM 1345 635 1500 710 1695 800 1865 880 1415 670 1540 725 1735 820 1930 910

 1180

ADJUST"

Switch

Positions

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

1330 625 1510 715 1695 800 1875 885 1085 510 1155 545 1310 620 1475 695

NORM 1195 565 1375 650 1550 730 1725 815 955 450 1050 495 1185 560 1335 630



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

1080 510 1210 570 1370 645 1520 715 850 400 920 435 1070 505 1195 565

Second Stage HEAT" Speed Second Stage COOL" Speed

1 2 3 4 1 2 3 4

555 1345 635 1510 710 1685 795 1245 590 1350 635 1545 730 1725 815

First Stage HEAT" Speed First Stage COOL" Speed

1 2 3 4 1 2 3 4

HEAT speed position.

Page 32

Page 33

TABLE 21

G61MPVT−60D−135 BLOWER MOTOR PERFORMANCE (LESS FILTER)

0.0" to 0.8" w.g. (0 through 200 Pa) External Static Pressure Range

Factory Settings: Heating Speed − 2; Cooling Speed − 4; Speed Adjust − NORM.

Return Air Options: Bottom.

Speed Switch Positions

ADJUST"

Switch

Positions

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

1505 710 1705 805 1900 900 2110 995 1615 760 1730 815 1945 920 2190 1035

NORM 1365 645 1550 730 1740 820 1920 905 1455 685 1580 745 1780 840 1985 935

 1225

ADJUST"

Switch

Positions

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

1385 655 1570 740 1760 830 1930 910 1135 535 1205 570 1365 645 1540 725

NORM 1250 590 1425 670 1595 755 1775 835 1025 485 1105 520 1235 580 1390 655



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

1135 535 1265 595 1430 675 1585 750 915 430 985 465 1115 525 1235 585

Second Stage HEAT" Speed Second Stage COOL" Speed

1 2 3 4 1 2 3 4

580 1380 650 1545 730 1720 810 1305 615 1400 660 1600 755 1780 840

First Stage HEAT" Speed First Stage COOL" Speed

1 2 3 4 1 2 3 4

HEAT speed position.

Page 33

Page 34

Unit Start−Up

FOR YOUR SAFETY READ BEFORE OPERATING

WARNING

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

The gas valve on the G61MPVT is equipped with a gas control knob. Use only your hand to turn the gas control knob. Never use tools. If the knob will not push in or turn by hand, do not try to repair it. Call a qualified service technician. Force or attempted repair may result in a fire or explosion.

Placing the furnace into operation:

G61MPVT units are equipped with an automatic ignition system. Do not furnace. Each time the thermostat calls for heat, the burners will automatically light. The ignitor does not get hot when there is no call for heat on units with this ignition system.

attempt to manually light burners on this

WARNING

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

CAUTION

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

Priming Condensate Trap

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

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

eration.

2 − Set the thermostat to initiate a heating demand.

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

4 − Adjust the thermostat to deactivate the heating de-

mand.

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

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

6 − Adjust the thermostat to deactivate the heating de-

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

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

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 (Figure 34)

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

34.

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

ADJUSTING SCREW

(under cap)

LOW FIRE

ADJUSTING SCREW

(under cap)

INLET PRESSURE TAP

GAS VALVE SHOWN IN OFF POSITION

8 − Honeywell VR8205 Gas Valve − Turn knob on gas

valve counterclockwise 9 − Replace the upper access panel.

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

to OFF. Do not force. See figure

MANIFOLD

PRESSURE

TAP

FIGURE 34

to ON. Do not force.

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11− Set the thermostat to desired setting.

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

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

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

Turning Off Gas to Unit

1 − Set the thermostat to the lowest setting. 2 − Turn off all electrical power to the unit if service is to be

performed. 3 − Remove the upper access panel. 4 − Honeywell VR8205 Gas Valve − Turn knob on gas

valve clockwise

to OFF. Do not force.

5 − Replace the upper access panel.

Gas Pressure Adjustment

Gas Flow (Approximate)

1 − Operate unit at least 15 minutes before checking gas

flow. Determine the time in seconds for one revolutions of gas through the meter.

TABLE 22

Gas Flow Rate (Ft.

Seconds for 1

Revolution

1/2 cu ft Dial 1 cu ft Dial

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

2 − Compare the number of seconds and the gas meter

size in table 22 to determine the gas flow rate. Multiply the gas flow rate by the heating value to determine the unit input rate. If manifold pressure is correct and the unit input rate is incorrect, check gas orifices for proper size and restriction.

/Hr.)

Gas Meter Size

3 − Remove temporary gas meter if installed.

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

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 barbed fitting

on gas valve. Use an obstruction to plug the hose.

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

23.

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

NOTE − Shut unit off and remove manometer as soon as an accurate reading has been obtained. Take care to 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 barbed fitting on gas valve.

Manifold Pressure and High Altitude Information

The units are factory−ready for use with natural gas. If LP/ propane fuel use is required, a conversion kit must be installed.

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.

Refer to table 23 for proper gas conversion kits and high altitude pressure switch kits at varying altitudes. Table 24 lists high fire manifold pressure settings at varying altitudes.

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

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TABLE 23

Conversion Kit Requirements

for Models −070, −090, −110 and −135

High Altitude Pressure Switch Kit

Input

−070 56M23 44W48 44W48 44W49 44W49

−090 56M23 44W48 44W48 44W49 44W49

−110 75M22 44W48 44W48 44W49 44W49

−135 Not allowed 44W48 Not allowed 44W49 Not allowed

NOTE − Pressure switch is factory set. No adjustment necessary. All models use the factory installed pressure switch from 0−4500 feet (0−1372 m). *Two pressure switch assemblies required per unit.

ORDER TWO EACH

611 − 1372 m 0 − 610 m 611 − 1372 m 0 − 610 m 611−1372 m

LPG/Propane Kit LPG/Propane to

Natural Gas Kit

TABLE 24

Manifold Pressure (Outlet) at High Fire − kPa

Fuel

Natural 0.87 0.80 0.75 0.70

LPG/Propane 2.49 2.29 2.12 2.02

High Altitude Pressure Switch Kits required for certain models, see Gas Heat Accessories table for order number.

LPG/Propane conversion kit required, see Gas Heat Accessories table for order number.

0−610

611−914

Other Unit Adjustments

Altitude − m

915−1219

Thermostat Heat Anticipation

1220−1372

Set the heat anticipator setting (if adjustable) according to

Primary and Secondary Limits

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

Flame Rollout Switches (Two)

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

Pressure Switches (Two or Four)

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

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

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

Temperature Rise

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

the amp draw listed on the wiring diagram that is attached to the unit.

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__________

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

Electronic Ignition

The integrated control has an added feature of an internal Watchguard control. The feature serves as an automatic reset device for ignition control lockout caused by ignition failure. This type of lockout is usually due to low gas line pressure. After one hour of continuous thermostat demand for heat, the Watchguard will break and remake thermostat demand to the furnace and automatically reset the control to begin the ignition sequence.

Exhaust and Air Intake Pipe

1 − Check exhaust and air intake connections for tightness

and to make sure there is no blockage.

2 − Are pressure switches closed? Obstructed exhaust

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

3 − Reset manual flame rollout switches on burner box

cover.

Failure To Operate

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

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5 − Is the filter dirty or plugged? Dirty or plugged filters will

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

again, call the service technician to inspect the unit for

blockages.

Heating Sequence of Operation

NOTE − The heat staging jumper on the control board is factory−set in the NONE (or no delay) position.

Applications Using a Two−Stage Thermostat

A − Heating Sequence −− Control Board Heat Staging Jumper in NONE Position (Factory Setting)

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

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

2 − Once the control receives a signal that the low pres-

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

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

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

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

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

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

ond−stage heat contacts close and send a signal to the integrated control.

6 − The integrated control energizes the combustion air

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

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

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

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

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

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

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

Applications Using A Single−Stage Thermostat

B − Heating Sequence −− Control Board Heat Staging Jumper in Either 10−Minute or 15−Minute Stage Delay Position

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

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

2 − Once the control receives a signal that the low pres-

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

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

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

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

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

5 − If the heating demand continues beyond the second−

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

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

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

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

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

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Service

WARNING

ELECTRICAL SHOCK, FIRE,

OR EXPLOSION HAZARD.

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

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

Blower

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

WARNING

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

Filters

All G61MPVT filters are installed external to the unit. Filters should be inspected monthly. Clean or replace the filters when necessary to ensure proper furnace operation. Table 3 lists recommended filter sizes.

Exhaust and air intake pipes

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

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__________

Cleaning Heat Exchanger

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

1 − Turn off electrical and gas supplies to the furnace. 2 − Remove the upper and lower furnace access panels.

3 − Mark all gas valve wires and disconnect them from

valve.

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

move gas valve/manifold assembly.

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

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

screws at the vestibule panel and remove burner box.

Set burner box assembly aside.

NOTE − G61MPVT−135 units are secured to the vesti-

bule panel by two additional screws. These screws

must be removed for servicing; however it is not nec-

essary to replace the screws.

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

procedures outlined in Burner Cleaning section.

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

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

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

sary to cut drain pipe). Remove screws that secure

condensate collars to either side of the furnace and re-

move collars. Remove drain tubes from cold end

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

Remove screws that secure both flue collars into

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

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

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

move pressure switches. Keep tubing attached to

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

ducer. Disconnect the two wires to the backup secon-

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

cure combustion air inducer to collector box. Remove

combustion air inducer assembly. Remove ground

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

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

compartment components. Disengage strain relief

bushing and pull wiring and bushing through the hole in

the blower deck. 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.

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20 − Back wash heat exchanger with soapy water solution

or steam. If steam is used it must be below 135°C

(275°F).

21 − Thoroughly rinse and drain the heat exchanger. Soap

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

22 − Reinstall heat exchanger into cabinet making sure that

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

23 − Re-secure the supporting screws along the vestibule

sides and bottom to the cabinet.

24 − Reinstall cabinet screws on front flange at blower

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

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

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

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

switch wiring. 30 − Carefully connect combustion air pressure switch

hosing from pressure switches to proper stubs on

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

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

pipe. Reconnect condensate drain line to the conden-

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

side of the furnace. Reconnect exhaust piping and ex-

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

er and flue collars. Secure using three existing hose

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

ignitor. 38 − Secure burner box assembly to vestibule panel using

four existing screws. Make sure burners line up in

center of burner ports.

39 − Reinstall gas valve manifold assembly. Reconnect

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

nections when re−establishing supplies. 44 − Follow lighting instructions to light and operate fur-

nace for 5 minutes to ensure that heat exchanger is

clean and dry and that furnace is operating properly. 45 − Replace heating compartment access panel.

Cleaning the Burner Assembly

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

Remove upper and lower furnace access panels. 2 − Mark all gas valve wires and disconnect them from the

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

move gas valve/manifold assembly. 4 − Mark and disconnect sensor wire from the sensor. Dis-

connect 2-pin plug from the ignitor at the burner box. 5 − Remove burner box cover and remove four screws

which secure burner box assembly to vest panel. Re-

move burner box from the unit.

NOTE − G61MPVT−135 units are secured to the vesti-

bule panel by two additional screws. These screws

must be removed for servicing; however it is not nec-

essary to replace the screws.

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

gently clean the face of the burners. Visually inspect

the inside of the burners and crossovers for any block-

age 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 burn-

er 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.

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Requirements

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

G61MPVT units are certified for installation clearances to combustible material as listed on the unit nameplate and in the tables in figures 3, 9 and 6. Accessibility and service clearances must take precedence over fire protection clearances.

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

For installation in a residential garage, the furnace must be installed so that the burner(s) and the ignition source are located no less than 457mm (18 inches) above the floor. The furnace must be located or protected to avoid physical damage by vehicles. When a furnace is installed in a public garage, hangar, or other building that has a hazardous atmosphere, the furnace must be installed according to recommended good practice requirements and current National Fuel Gas Code or AS 5601 standard.

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

This G61MPVT furnace must be installed so that its electrical components are protected from water.

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

When installed, this furnace must be electrically grounded according to local codes.

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

The G61MPVT furnace may be installed in alcoves, closets, attics, basements, garages, and utility rooms. This furnace design has not been certified for installation in mobile homes, recreational vehicles, or outdoors.

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

Lennox does not recommend the use of G61MPVT units as a construction heater during any phase of construction. Very low return air temperatures, harmful vapors and operation of the unit with clogged or misplaced filters will damage the unit.

G61MPVT units may be used for heating of buildings or structures under construction, if the following conditions are met:

D The vent system must be permanently installed per

these installation instructions.

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

fixed jumpers that will provide continuous heating is not allowed.

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

furnace.

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

27°C (80°F) must be maintained.

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

maintained during construction.

D Air filters must be replaced upon construction comple-

tion.

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

furnace rating plate.

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

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

D The furnace heat exchanger, components, duct system,

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

D All furnace operating conditions (including ignition, in-

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

General

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

In addition to the requirements outlined previously, the following general recommendations must be considered when installing a G61MPVT furnace:

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

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

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

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

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

CAUTION

G61MPVT unit should not be installed in areas normally subject to freezing temperatures.

WARNING

Product contains fiberglass wool.

Disturbing the insulation in this product during installation, maintenance, or repair will expose you to fiberglass wool.

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

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

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

Combustion, Dilution & Ventilation Air

If the G61MPVT is installed as a Non−Direct Vent Furnace, follow the guidelines in this section.

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

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

In the absence of local codes concerning air for combus− tion and ventilation, use the guidelines and procedures in this section to install G61MPVT furnaces to ensure efficient and safe operation. You must consider combustion air needs and requirements for exhaust vents and gas piping. A portion of this information has been reprinted with permission from the National Fuel Gas Code (ANSI− Z223.1/NFPA 54). This reprinted material is not the complete and official position of the ANSI on the referenced subject, which is represented only by the standard in its entirety.

In Australia, refer to the standard AS 5601−2004 Gas Installation Code.

CAUTION

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

WARNING

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

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

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

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

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

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Unconfined Space

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

Confined Space

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

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

Air from Inside

If the confined space that houses the furnace adjoins a space categorized as unconfined, air can be brought in by providing two permanent openings between the two spaces. Each opening must have a minimum free area of 645 mm

per .29 kW (1 square inch per 1,000Btu) per hour

of total input rating of all gas−fired equipment in the confined space. Each opening must be at least 64516 mm

(100 square inches). One opening shall be within 305 mm (12 inches) of the top of the enclosure and one opening within 305 mm (12 inches) of the bottom.

EQUIPMENT IN CONFINED SPACE − ALL AIR FROM INSIDE

ROOF TERMINATED

EXHAUST PIPE

OPENINGS

SIDE WALL

TERMINATED EX-

HAUST PIPE (ALTER-

NATE LOCATION)

NOTE − Each opening shall have a free area of at least 645mm .29kW (one square inch per 1,000 Btu) per hour of the total input rating of all equipment in the enclosure, but not less than 64516mm. (100 square inches).

G61MPV

(To Adjacent

Unconfined

Space)

FIGURE 35

Air from Outside

If air from outside is brought in for combustion and ventilation, the confined space shall be provided with two permanent openings. One opening shall be within 305mm (12 inches) of the top of the enclosure and one within 305mm (12 inches) of the bottom. These openings must communicate directly or by ducts with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors or indirectly through vertical ducts. Each opening shall

have a minimum free area of 645mm

per 1.17kW (1 square inch per 4,000 Btu) per hour of total input rating of all equipment in the enclosure. When communicating with the outdoors through horizontal ducts, each opening shall

have a minimum free area of 645mm

per .59kW (1 square inch per 2,000 Btu) per total input rating of all equipment in the enclosure.

per

Page 42

Page 43

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

EQUIPMENT IN CONFINED SPACE − ALL AIR FROM OUTSIDE

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

EQUIPMENT IN CONFINED SPACE − ALL AIR FROM OUTSIDE

(All Air Through Ventilated Attic)

ROOF TERMINATED

EXHAUST PIPE

SIDE WALL

TERMINATED

EXHAUST PIPE

(ALTERNATE

LOCATION)

OUTLET

AIR

G61MPVT

VENTILATION LOUVERS

(Each end of attic)

INLET AIR

(Ends 12" above

bottom)

VENTILATION LOUVERS

OUTLET

AIR

(Each end of attic)

VENTILATION

LOUVERS

(For unheated

crawl space)

ROOF TERMINATED

EXHAUST PIPE

SIDE WALL

TERMINATED

EXHAUST PIPE

(ALTERNATE

LOCATION)

NOTE−The inlet and outlet air openings shall each have a free area of at least 645mm

G61MPV

INLET

AIR

per 1.17kW (one square inch per 4,000 Btu) per

hour of the total input rating of all equipment in the enclosure.

FIGURE 36

NOTE−The inlet and outlet air openings shall each have a free area of at least 645mm

per 1.17kW (one square inch per 4,000 Btu) per

hour of the total input rating of all equipment in the enclosure.

FIGURE 37

EQUIPMENT IN CONFINED SPACE −

ALL AIR FROM OUTSIDE

ROOF TERMINATED

EXHAUST PIPE

OUTLET AIR

SIDE WALL

TERMINATED

EXHAUST PIPE

(ALTERNATE

LOCATION)

NOTE−Each air duct opening shall have a free area of at least

645mm

per .59kW (one square inch per 2,000 Btu) per hour of the

G61MPVT

INLET AIR

total input rating of all equipment in the enclosure. If the equipment room is located against an outside wall and the air openings communicate directly with the outdoors, each opening shall have a free area of at least 645mm

per 1.17kW (one square inch per 4,000 Btu) per hour of the total input rating of all other equipment in the enclosure.

FIGURE 38

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Page 44

Ignition Control Board Diagnostic Codes (Red LED)

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 44

Page 45

Troubleshooting: Heating Sequence of Operation

HEATING SEQUENCE OF OPERATION

NORMAL AND ABNORMAL HEATING MODE

POWER ON

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

CONTROL SELF−CHECK OKAY?

INDOOR BLOWER OFF. (RESET CONTROL BY

TURNING MAIN POWER OFF.)

POLARITY OKAY?

YES

IS THERE A

PROPER GROUND?

YES

NORMAL OPERATION:

STATUS LED −− PULSE

THERMOSTAT CALLS FOR HEAT:

STATUS LED −− HEARTBEAT

YES

PRIMARY AND SECONDARY LIMIT

SWITCHES CLOSED?

YES

ROLLOUT SWITCH CLOSED?

YES

FIRST (LOW) STAGE PRESSURE SWITCH

CONTACTS OPEN?

YES

SECOND (HIGH) STAGE PRESSURE SWITCH

CONTACTS OPEN?

YES

SIGNAL HOLDS UNTIL UNIT IS PROPERLY GROUNDED.

INDOOR BLOWER ON. HAS PRIMARY OR

SECONDARY LIMIT RESET WITHIN 3 MINUTES?

60−MINUTE LIMIT WATCHGUARD MODE.

GAS VALVE OFF, COMBUSTION AIR INDUCER

OFF, INDOOR BLOWER OFF WITH DELAY.

GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

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

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

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

PRESSURE SWITCH IS DETECTED OPEN.

POLARITY REVERSED.

STATUS ERROR CODE 5 + 4.

STATUS ERROR CODE 5 + 3.

COMBUSTION AIR INDUCER OFF.

STATUS ERROR CODE 3 + 1.

STATUS ERROR CODE 4 + 5.

INDOOR BLOWER ON.

STATUS ERROR CODE 5 + 1.

STATUS ERROR CODE 2 + 4

YES

TWO−STAGE OR SINGLE−STAGE THERMOSTAT

CALL FOR HEAT

COMBUSTION AIR INDUCER ON LOW SPEED.

STATUS LED −− HEARTBEAT

CONTINUED ON NEXT PAGE

COMBUSTION AIR INDUCER OFF.

GAS VALVE OFF.

INDOOR BLOWER OFF.

CONTROL WILL NOT ATTEMPT SECOND−STAGE

OPERATION DURING THIS HEAT DEMAND.

FIRST−STAGE OPERATION WILL BE ATTEMPTED.

STATUS ERROR CODE 2 + 6.

Page 45

Page 46

Troubleshooting: Heating Sequence of Operation (Continued)

HEATING SEQUENCE OF OPERATION

CONTINUED

THERMOSTAT CALLS FOR HEAT

STATUS LED − HEARTBEAT

(Refer to box A on previous page)

FIRST−STAGE (LOW FIRE) PRESSURE

SWITCH CLOSED WITHIN 2.5 MINUTES?

YES

15−SECOND COMBUSTION AIR INDUCER

PRE−PURGE INITIATED BY CLOSED FIRST−STAGE

PRESSURE SWITCH (or 15 SECOND

INTER−PURGE PERIOD.)

STATUS LED −− HEARTBEAT.

IGNITOR WARM−UP (20 SECONDS)

STATUS LED −− HEARTBEAT.

YES

IS IGNITOR INTACT AND CONNECTED?

YES

AT END OF IGNITOR 20 SECOND WARM UP

PERIOD, 4−SECOND TRIAL FOR IGNITION.

GAS VALVE OPENS, IGNITOR ENERGIZED DURING

4−SECOND TRIAL UNTIL FLAME SENSED.

YES

4−SECOND FLAME STABILIZATION PERIOD.

GAS VALVE OFF. COMBUSTION AIR INDUCER

OFF. INDOOR BLOWER OFF. UNIT WILL RETRY

AFTER 5−MINUTE WAIT PERIOD.

STATUS ERROR CODE 2 + 3.

COMBUSTION AIR INDUCER OFF, IGNITOR OFF.

SIGNAL HOLDS UNTIL IGNITOR IS REPLACED

OR RECONNECTED.

STATUS ERROR CODE 4 + 7.

IS VOLTAGE ABOVE 90 VOLTS?

COMBUSTION AIR INDUCER OFF, IGNITER OFF.

SIGNAL HOLDS UNTIL VOLTAGE RISES ABOVE 95

VOLTS. STATUS ERROR CODE 4 + 8.

YES

FLAME RECTIFICATION CURRENT CHECK

CAN FLAME BE PROVEN WITHIN 4

SECONDS AFTER GAS VALVE OPENS?

(u0.20 microamps)

FLAME PRESENT?

YES

CONTINUED ON NEXT PAGE

GAS VALVE OFF. COMBUSTION AIR

INDUCER ON. INDOOR BLOWER OFF.

STATUS LED −− HEARTBEAT.

HAS CONTROL FAILED TO SENSE

FLAME FOR FIVE CONSECUTIVE TRIES

DURING A SINGLE HEAT DEMAND?

YES

WATCHGUARD MODE. GAS VALVE OFF,

COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER OFF.

STATUS ERROR CODE 4 + 1.

IS 60−MINUTE RESET PERIOD COMPLETE?

YES

HAS CONTROL RESET IGNITION SEQUENCE

FOUR (4) TIMES?

WATCHGUARD MODE.

STATUS ERROR CODE 4 + 3.

YES

Page 46

Page 47

Troubleshooting: Heating Sequence of Operation (Continued)

HEATING SEQUENCE OF OPERATION

CONTINUED

FLAME SIGNAL ABOVE

(u1.40 microamps)

YES

SINGLE−STAGE THERMOSTAT MODE

(Heat staging jumper on 10 or 15 minutes)

YES

START SECOND−STAGE ON DELAY

(10 OR 15 MINUTES).

STATUS LED −− HEARTBEAT

ROLLOUT SWITCHES CLOSED?

YES

TWO STAGE THERMOSTAT MODE

(Heat staging jumper on NONE)

45−SECOND INDOOR BLOWER ON DELAY BEGINS.

YES

THERMOSTAT CALLS FOR HEAT.

STATUS LED −− HEARTBEAT.

SEE BOX A.

LOW FLAME SIGNAL

(Does not affect control operation)

STATUS ERROR CODE 1 + 2.

YES

STATUS LED −− HEARTBEAT.

YES

PRIMARY & SECONDARY LIMIT SWITCHES

CLOSED?

YES

FIRST−STAGE (LOW FIRE)

PRESSURE SWITCH CLOSED?

YES

FIRST−STAGE HEAT DEMAND SATISFIED?

YES

GAS VALVE OFF, COMBUSTION AIR INDUCER

OFF FOLLOWING POST PURGE.

INDOOR BLOWER OFF WITH DELAY

STATUS LED −− PULSE

SECOND−STAGE HEAT DEMAND.

SECOND−STAGE HEAT DEMAND REQUIRED?

YES

SECOND STAGE PRESSURE SWITCH CLOSED?

ABNORMAL FLASH CODE.

NOTE − IF SECOND−STAGE PRESSURE SWITCH

WAS ORIGINALLY FOUND CLOSED,

ABNORMAL CODE WILL FLASH.

SECOND−STAGE 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,

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

GAS VALVE OFF, COMBUSTION AIR INDUCER OFF,

IS 60−MINUTE RESET PERIOD COMPLETE?

GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

INDOOR BLOWER OFF AFTER DELAY.

STATUS ERROR CODE 2 + 3. CONTROL RESTARTS

IGNITION SEQUENCE IF PRESSURE SWITCH

SECOND−STAGE PRESSURE SWITCH CLOSED

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

SWITCH CAN BE PROVEN or HEAT DEMAND IS

SATISFIED. FIVE (5) MINUTE WAIT PERIOD

INITIATED BEFORE RETRY. WERE 5 ATTEMPTS

CONTINUES FIRST−STAGE HEATING DEMAND.

WILL NOT REATTEMPT SECOND−STAGE

INDOOR BLOWER ON.

STATUS ERROR CODE 3 + 1.

HAS PRIMARY OR SECONDARY LIMIT

SWITCH CLOSED WITHIN 3 MINUTES?

LIMIT SWITCH WATCHGUARD MODE.

INDOOR BLOWER OFF WITH DELAY.

STATUS ERROR CODE 4 + 5

CLOSES WITHIN 2−1/2 MINUTES.

AT BEGINNING OF HEAT DEMAND?

STATUS ERROR CODE 2 + 6.

SECOND STAGE HEAT DEMAND

STATUS LED −− HEARTBEAT.

MADE FOR SECOND−STAGE HEAT?

YES

HEATING DEMAND.

STATUS ERROR CODE 2 + 5.

YES

Page 47

Page 48

Troubleshooting: Heating Sequence of Operation (Continued)

HEATING SEQUENCE OF OPERATION

CONTINUED

NORMAL OPERATION.

SEE BOX A

SECOND−STAGE (HIGH FIRE) HEAT

PRESSURE SWITCH CLOSED?

YES

HEAT DEMAND SATISFIED? STATUS LED −− HEARTBEAT.

YES

SINGLE−STAGE THERMOSTAT MODE

(Heat staging jumper on 10− or 15−minutes)

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?

(Heat staging jumper on NONE)

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

GAS VALVE, COMBUSTION AIR INDUCER

AND INDOOR BLOWER RETURN TO FIRST−

STATUS LED −− HEARTBEAT.

SECOND STAGE HEAT

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 48

Page 49

Troubleshooting: Cooling Sequence of Operation

COOLING SEQUENCE OF OPERATION

POWER ON

YES

IS POLARITY REVERSED?

CONTROL WILL CONTINUE TO CALL FOR COOLING

SIGNAL POLARITY REVERSED.

IN THIS CONDITION.

STATUS ERROR CODE 5 + 4.

IS THERE

PROPER GROUND?

YES

THERMOSTAT CALLS FOR FIRST−STAGE COOL.

COMPRESSOR AND CONDENSER FAN

ENERGIZED.

INDOOR BLOWER ENERGIZED ON FIRST STAGE

COOL SPEED AFTER 2 SECOND DELAY.

FIRST−STAGE DEMAND FOR COOL SATISFIED?

THERMOSTAT CALLS FOR SECOND−STAGE COOL.

INDOOR BLOWER RAMPS UP TO SECOND−STAGE COOL SPEED.

YES

SIGNAL IMPROPER GROUND AT LED.

CONTROL WILL CONTINUE TO CALL FOR COOLING

IN THIS CONDITION.

STATUS ERROR CODE 5 + 3.

COMPRESSOR AND CONDENSER FAN DE−ENERGIZED.

INDOOR BLOWER DE−ENERGIZED AFTER 45−SECOND

DELAY.

SECOND−STAGE DEMAND FOR COOL SATISFIED?

YES

UNIT RETURNS TO FIRST STAGE COOL .

Page 49

Page 50

Troubleshooting: Continuous Fan Sequence of Operation

CONTINUOUS LOW SPEED FAN SEQUENCE OF OPERATION

MANUAL FAN SELECTION MADE AT THERMOSTAT.

AFTER 2 SECOND DELAY, INDOOR BLOWER IS

ENERGIZED ON CONTINUOUS FAN SPEED.

YES YES

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

YES

INDOOR BLOWER RAMPS TO FIRST STAGE

COOLING SPEED AFTER A 2−SECOND DELAY.

AFTER 45−SECOND DELAY, INDOOR BLOWER

YES

SWITCHES TO LOW HEAT SPEED.

YES

FIRST−STAGE COOL DEMAND SATISFIED?

SECOND STAGE COOL DEMAND

INDOOR BLOWER RAMPS TO SECOND

STAGE COOL SPEED

SECOND STAGE COOL DEMAND SATISFIED?

YES

INDOOR BLOWER RAMPS DOWN TO FIRST STAGE

COOL SPEED.

FIRST−STAGE HEAT DEMAND SATISFIED.

THERMOSTAT CALLS FOR SECOND−STAGE HEAT.

YES

INDOOR BLOWER SWITCHES TO HIGH HEAT SPEED

AFTER 30−SECONDS.

YES

SECOND−STAGE HEAT DEMAND SATISFIED.

YES

INDOOR BLOWER RAMPS DOWN TO LOW

HEAT SPEED.

YES

Page 50

Page 51

Repair Parts List

The following repair parts are available through Lennox dealers. When ordering parts, include the complete furnace model number listed on the nameplate −− Example: G61MPVT−36B−070−01.

Cabinet Parts

Upper access panel Blower access panel Top Cap

Control Panel Parts

Transformer Integrated control board Door interlock switch Circuit Breaker

Blower Parts

Blower wheel Motor Motor mounting frame Blower housing cutoff plate

Vent Pipe Sizing Worksheet

Step 1

Step 2

Step 3

Step 4

Step 5

Step 6

Proposed vent pipe size : ______

Termination kit catalog number : _____________ Vent pipe equivalency value from table 6 : ______

Total number of 90° elbows required (indoors and outdoors) ______ X 1.5 = ______ equivalent meters of pipe

Total number of 45° elbows required (indoors and outdoors) ______ X .76 = ______ equivalent meters of pipe

Linear feet of straight pipe required : ______

Add equivalent meters of vent pipe listed in steps 2 through 5.

Heating Parts

Flame Sensor

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

Equivalent Meters

TOTAL

If the total is equal to, or less than, the allowable maximum given in table 6, the proposed pipe size is acceptable. If the total exceeds the maximum allowed vent pipe length, repeat the process above using the next larger diameter pipe until an acceptable total is achieved.

NOTE − In Direct Vent systems, total the equivalent length of either the exhaust OR intake piping run, depending upon which will be LONGER. Intake and exhaust pipe diameter must be the same size and must be terminated in the same pressure zone. Intake and exhaust pipe should be roughly the same length.

Page 51

Page 52

G61MPVT Start−Up & Performance Check List

Job Name

Job Location

Installer Unit Model No. Serial No.

Job No.

City

City Technician

Date

State

Heating Section

Electrical Connections Tight? Supply Voltage

Blower Motor Amps

Fuel Type: Natural Gas?

Furnace Btu Input

Line Pressure

Regulator Pressure Flue Connections Tight? Condensate Connections Tight? Combustion Gas Tested? Fan Control Setting

(45 Seconds Fixed On)

Fan Control Off Setting Filter Clean & Secure?

w.c. − Nat.:

LP/Propane Gas?

Blower Motor H.P.

Gas Piping Connections Tight & Leak−Tested?

w.c. − LP/Propane

Proper Draft?

Temperature Rise

Vent Clear?

Thermostat

Calibrated? Heat Anticipator Properly Set? Level?

Page 52

Lennox G61MPVT-36B-070, G61MPVT-60C-090, G61MPVT-60C-110, G61MPVT-60D-135 Installation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual