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Lennox International Inc. G61MP User's Manual

1. FIGURE 15 Follow the next three steps when installing the unit in Non Direct Vent applications where combustion air is taken from indoors and flue gases are discharged outdoors TYPICAL AIR INTAKE PIPE CONNECTIONS HORIZONTAL DIRECT VENT APPLICATIONS Horizontal Right Hand Air Discharge Application Shown G61MP 36B 045 G61MP 36B 070 G61MP 48C 090 G61MP 60C 090 G61MP 48C 110 G61MP 60C 110 G61MP 60C 135 TYPICAL AIR INTAKE PIPE CONNECTIONS UPFLOW OR HORIZONTAL NON DIRECT VENT APPLICATIONS Right Hand Exit in Upflow Application Shown 6 in Max DM St OL DEBRIS SCREEN Provided Limit pipe length to 2 in G51MP 110 and 135 applications REDUCER 2 1 2 3 OR 4 UL REDUCER G61MP 36B 045 G61MP 36B 070 G61MP 48C 090 G61MP 60C 090 G61MP 48C 110 G61MP 60C 110 2 G61MP 36B 045 G61MP 36B 070 G61MP 48C 090 G61MP 60C 090 2 NOTE Debris screen and elbow be rotated so that screen may be positioned to face forward backward or downward FIGURE 17 FIGURE 16 Page 21 TYPICAL AIR INTAKE PIPE CONNECTIONS DOWNFLOW NON DIRECT VENT APPLICATIONS Right Hand Ex
2. LENNOX m oRmATION Corp 0308 L6 Revised 10 2004 oi aiuas ssws Service Literature G61MP G61MP SERIES UNITS G61MP series units are high efficiency multi position up flow downflow horizontal right and left gas furnaces manufactured with Lennox Duralok Plus heat exchang ers formed of aluminized steel G61MP units are available in heating capacities of 44 000 to 132 000 Btuh 13 0 0 to 38 6 kW and cooling applications from 2 to 5 tons 7 0 KW to 17 5 kW up to 5 tons Refer to Engineering Handbook for proper sizing Units are factory equipped for use with natural gas Kits are available for conversion to LPG operation G61MP model units are equipped with the Two Stage Integrated SureLight control All G61MP units meet the California Nitrogen Ox ides NO Standards and California Seasonal Efficiency re quirements All units use a redundant gas valve to assure safety shut off as required by C S A All specifications in this manual are subject to change Pro cedures outlined in this manual are presented as a recom mendation only and do not supersede or replace local or state codes In the absence of local or state codes the guidelines and procedures outlined in this manual except where noted are recommendations only and do not consti tute code TABLE OF CONTENTS Introd ctlon 1 Specifications 2 Blower Data
3. Orange Juice pH Range 5 Tomato Juice 6 7 ap Water 8 Increasing 9 Alkalinity 10 1 TABLE 19 Conversion Kit Requirements and Manifold Pressures Manifold Pressure at all altitudes 7501 10 000 Low Fi 2287 3048 m ow mite Required Pressure Required Pressure Required ARE Switch Switch Nat N A No Change N A No Change 59M16 No Change 1 7 0 42 3 5 0 87 Nat N A No Change N A No Change 59M16 56M06 1 7 10 42 3 5 0 87 qM 59 16 56 21 17 10 42 3 5 0 87 No Change 59M13 No Change 59M14 56M06 Nat N A No Change N A 75M22 O s rer Nat N A No Change N A No Change 59M16 No Change 1 7 0 42 3 5 0 87 wom gau Nat N A No Change N A 59M93 59M16 56M93 1 7 10 42 3 5 0 87 No Change 59M13 No Change 59M14 Pressure switch is factory set No adjustment necessary All models use the factory installed pressure switch from 0 4500 feet 0 1370 m 0 4500 ft 0 1372 m 4501 7500 ft 1373 2286 m Pressure Switch Page 33 J Flame Signal DC meter is needed to check the flame signal on the ignition control Flame microamp signal is an electrical current which passes from the furnace control through the sensor during unit opera tion Current passes from the sensor through the flame to ground to complete safety circuit To Measure Flame Signal Ignition Control A transducer Part
4. Diagnostic lights flash watchguard flame failure LED 1 Alternating Slow Flash LED 2 Alternating Slow Flash 5 3 1 Unit is firing above 100 of the nameplate input 5 3 2 Gas orifices leak at the manifold connection 5 3 3 Air leakage at the connections between the primary heat exchanger secondary heat exchanger and combustion air blower 5 3 4 Insufficient flow through the heat exchanger caused by a sooted or restricted heat exchanger 5 3 5 Burners are not properly located in the burner box 5 4 1 Recirculation of flue gases This condition causes rough ignitions and operation Problem is characterized by nuisance flame failures 5 4 2 Improper burner cross overs Page 52 ACTION 1 Check that the manifold pressure matches value listed on nameplate See installa tion instructions for proper procedure ACTION 2 Verify that the installed orifice size match the size listed on the nameplate or installa tion instructions ACTION 3 Check gas valve sensing hose to in sure no leaks are present ACTION 4 Check the input rate to verify rate matches value listed on nameplate ACTION 1 Tighten orifice until leak is sealed NOTE Be careful not to strip orifice threads ACTION 2 Check for gas leakage at the threaded orifice connection Use approved meth od for leak detection see unit instructions ACTION 1 Check for air leakage at all joints in the heat exchanger assembly Condi
5. 4 Parts Identification 7 Unit Components 8 II Installation 16 Ill Start UP he oorr inii RR reet 30 IV Heating System Service Checks 31 V Typical Operating Characteristics 34 VI Maintenance 35 VII Wiring and Sequence of Operation 38 VIII Field Wiring and Jumper Setting 46 IX Control Board Troubleshooting 48 Technical Publications Page 1 A IMPORTANT Improper installation adjustment alteration service or maintenance can cause property damage person al injury or loss of life Installation and service must be performed by a qualified installer service agency or the gas supplier AWARNING Electric shock hazard Can cause injury or death Before attempting to perform any service or maintenance turn the electrical power to unit OFF at discon nect switch es Unit may have multiple power supplies A WARNING Sharp edges Be careful when servicing unit to avoid sharp edges which may result in personal injury 2003 Lennox Industries Inc SPECIFICATIONS Gas Model G61MP 36B 045 G61MP 36B 070 G61MP 48C 090 61 60 090 Heating High Input Btuh KW 44 000 12 9 66 000 19 3 88 000 25 8 88 000 25 8 Performance Fire Output Btuh KW 41 000 12 0 62 000 18 2 83 000 24 3
6. ns ms RAB6OC 12M71 5 Termination Kits Concen 1 1 2 inch 38 mm 60G77 60G77 Direct Vent tric 2 inch 51 mm Se A 33K97 33K97 Applications Only 3 inch 76 mm ER 22 60L46 60L46 Wall Close Couple 2 inch 51 mm 22G44 22G44 3 inch 76 mm 44 40 44 40 44 40 44 40 Close Couple WTK 2 inch 51 mm 30G28 30G28 56 Termination Kits Roof 2 inch 51 mm 15F75 15F75 15F75 15F75 Direct Vent or 3 inch 76 mm 44J41 44J41 44J41 44J41 Non Direct Vent yai Wall Ring Kit 2 inch 51 mm 15F74 15F74 15F74 15F74 NOTE Filters and provisions for mounting are not furnished and must be field provided Cleanable polyurethane frame type filter See Installation Instructions for specific venting information Kits contain enough parts for two non direct vent installations O Q OO N Required for proper operation at altitudes from 7501 to 10 000 ft 2286 to 3048 m Page 2 Annual Fuel Utilization Efficiency based on DOE test procedures and according to FTC labeling regulations Isolated combustion system rating for non weatherized furnaces Determine from venting tables proper exhaust pipe size and termination kit required Gas Model No Heating High Fi 3 Performanc igh Fire Input Btuh kW Output Btuh kW Temperature rise range F C Input Btuh kW Output Btuh kW Temperature rise range F C 1 AFUE California Seasonal Efficiency High static CSA in w g Pa Connections 2 Inta
7. DENOTES OPTIONAL COMPONENTS Page 38 BLOWER SPEED CHART MOTOR FACTORY CONNECTED SPEED TAPS Ec Mun Emu YELLOW RED BROW 2 090 090 60 090 110 60 110 ae SPEED DEUM LO E SPEED BLACK OV RED TAPS BLACK BROWN YELLOW RED Ex U PPB JAG tbe couse RIQ DUER THERMOSTAT HEAT ANTICIPATION SETTING 65 AMP HONEYWELL VALVE A LEAVE 915 CLIPPABLE JUMPER CONNECTED FOR ONE STAGE COOL THERMOSTAT CUT JUMPER 915 AND SEPARATE LEADS FOR TWO STAGE COOL THERMOSTAT FACTORY DEFAULT IS FOR A 2 STAGE THERMOSTAT FIELD SUPPLIED ACC WIRE IMPORTANT TO PREVENT MOTOR BURNOUT NEVER CONNECT MORE THAN ONE MOTOR LEAD TO ANY ONE CONNECTION PARK TERMINAL IS A UNPOWERED TERMINAL ALL UNUSED MOTOR LEADS MUST BE WIRED TO THE PARK TERMINAL USE COPPER CONDUCTORS ONLY 5115 USED ON 090 110 AND 135 UNITS ONLY FOR 090 110 AND 135 UNITS ONLY si FOR 045 070 UNITS ONLY TWO STAGE HEAT COOL P CONTROL 5102 HIGH HEAT PRESSURE RIGHT WARNING ELECTRIC SHOCK HAZARD CAN CAUSE INJURY OR DEATH UNIT MUST BE GRI OUNDED IN ACCORDANCE WITH NATIONAL AND LOCAL CODE OTE 10 ANY WIRE IN THIS APPLIANCE IS REPLACED IT MUST BE REPLACED WITH WIRE OF LIKE 5 RATING INSULATION THICKNESS AND TERMINATION Sequence of Operation Sequence depends on type thermostat used G61MP units are applicable for single stage or two stage ther mostats Both type thermos
8. field provided G61MP 60D 135 PERFORMANCE Less Filter Bottom Return Air Side Return Air with Optional RAB Return Air Base Return Air from Both Sides or Return Air from Bottom and One Side External Static Air Volume Watts at Different Blower Speeds Pressure Medium High Medium Low Low in w g Pa cfm L s Watts cfm L s Watts cfm L s Watts 0 00 0 1560 735 680 0 10 25 1590 750 675 0 20 50 1620 765 665 0 30 75 1615 760 655 0 40 100 1615 760 645 0 50 125 1610 760 635 0 60 150 1600 755 615 0 70 175 1570 740 600 0 80 200 1540 725 580 0 90 225 1540 725 545 NOTES All air data is measured external to unit without filter not furnished field provided Page 6 G61MP PARTS ARRANGEMENT DuralokPlusTM HEAT EXCHANGER ASSEMBLY BURNER BOX ASSEMBLY GAS VALVE AND MANIFOLD FLUE COLLAR COMBUSTION AIR PROVE PROVE SWITCHES grr COMBUSTION AIR INDUCER 3 BURNER ACCESS PANEL Ry f BLOWER ACCESS DOOR 9 G61MP 090 shown G61MP 045 and 070 SIGHT are equipped with GLASS two switches INTERLOCK Z CONTROL BOX FIGURE 1 Page 7 WARM HEADER COLLECTOR BOX CONDENSER COIL PRIMARY LIMIT COLD HEADER COLLECTOR SECONDARY LIMITS 2 BLOWER ASSEMBLY I UNIT COMPONENTS G61MP unit components are shown in figure 1 The gas valve combustion air inducer and burners can be ac cessed by removing the burner acc
9. 3 Air Filter and Rack Kit Horizontal end Size of filter Side Retum Condensate Drain Heat 6 ft 1 8 m Cable 24 ft 7 3 m 50 ft 15 2 m Heat Cable Tape Fiberglass 1 2 in 38 mm x 66 ft 20 m Aluminum foil 2 in 25 mm x 60 ft 8 EZ Filter Base Catalog Number Ship Weight Ibs kg Dimensions H x W x D in mm 26K68 26K69 26K70 39604 39603 73 56 7 3 4 x 17 5 8 28 5 8 102 x 448 x 727 26K68 26K69 26K70 39604 39603 73 56 7 3 4 x 17 5 8 28 5 8 102 x 448 x 727 87197 20 x 25 x 1 in 508 x 635 x 25 mm 26K68 26K69 26K70 39604 39603 73 57 8 4 4 x 21 5 8 28 5 8 102 x 549 x 727 26K68 26K69 26K70 39604 39603 73 57 8 4 4 x 21 5 8 x 28 5 8 102 x 549 x 727 Size of field provided filter in mm 16x25x1 16 x 25 x 1 20x25x1 20x25x1 406 x 635 x 25 406x635x25 508 x 635 x 25 508 x 635 x 25 Down Flow Additive Base 11M60 11M60 11M61 11M61 4 High Altitude Orifice Kit Natural Gas 59M16 59M16 59M16 59M16 High Altitude Pressure Switch Kit Order two each 56 06 7501 10 000ft 2286 3048 Horizontal Support Frame Kit Ship Weight lbs kg 56J18 18 8 56J18 18 8 56J18 18 8 56J18 18 8 LPG Propane Kit 0 7500 ft 0 2286 m 59M13 59M13 59M13 59M13 7501 10 000 ft 2286 3048 m 59M14 59M14 59M14 59M14 Natural to LPG Propane Kit 59M87 59M87 59M87 59M87 RAB Return Air Base
10. 84 000 24 6 Temperature rise range F 25 55 14 31 35 65 21 39 35 65 21 39 25 55 14 31 Low Input Btuh KW 30 000 8 8 45 000 13 2 60 000 17 6 60 000 17 6 Fire Output Btuh KW 28 000 8 2 43 000 12 6 57 000 16 7 58 000 17 0 Temperature rise range F C 10 40 6 24 20 50 12 30 25 55 14 31 15 45 9 27 AFUE 94 196 94 196 94 196 94 196 California Seasonal Efficiency 83 5 86 0 87 3 84 4 High static CSA in w g Pa 0 5 0 5 0 5 0 5 Connections Intake Pipe PVC 2 2 2 2 in 2 Exhaust Pipe PVC 2 2 2 2 Condensate Drain Trap PVC pipe 1 2 1 2 1 2 1 2 with field supplied PVC coupling o d 3 4 3 4 3 4 3 4 hose with hose clamp i d x o d 1 1 4 x 1 1 1 4 x 1 1 1 4 x 1 1 1 4 x 1 Gas pipe size IPS 1 2 1 2 1 2 1 2 Wheel nominal diameter x width in mm Motor output hp W Tons kW of add on cooling Ibs kg 1 package Indoor Blower Shipping Data Electrical characteristics 10 x 8 254 x 203 1 3 249 25 3 8 8 10 5 136 62 10 x 8 254 x 203 1 3 249 2 5 3 5 8 8 12 3 146 66 10 x 10 254 x 254 11 1 2 x 10 292 x 229 1 2 373 3 4 10 5 14 0 168 76 1 746 4 5 14 0 17 5 176 80 120 volts 60 hertz 1 phase less than 12 amps OPTIONAL ACCESSORIES MUST BE ORDERED EXTRA 87L96 18 x 25 x 1 in 457 x 635 x 25 mm Single 44J22 or Ten Pack 66K63 1 16 x 25 x 1 in 406 x 635 x 25 mm
11. NOTE Do not discharge exhaust gases directly into any chimney or vent stack If ver tical discharge through an existing unused chimney or stack is required insert piping inside chimney until the pipe open end is above top of chimney and terminate as illus trated In any exterior portion of chimney the exhaust vent must be insulated FIGURE 32 Condensate Piping This unit is designed for either right or left side exit of con densate piping in either upflow or downflow applications however it must be installed on the same side of the unit as the exhaust piping In horizontal applications the conden sate trap should extend below the unit A 5 1 2 service clearance is required for the condensate trap Refer to fig ure for condensate trap locations CONDENSATE TRAP LOCATIONS Unit shown in upflow position Horizontal Horizontal left and right and optional p gt optional downflow 5 downflow UL Optional upflow Optional upflow FIGURE 33 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 as
12. SPEED BLACK YELLOW RED TAPS BLACK BROWN YELLOW RED VI MAINTENANCE AWARNING 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 opera tion serious injury death or property damage Before servicing disconnect all electrical power to furnace When servicing controls label all wires prior to dis connecting Take care to reconnect wires correctly Verify proper operation after servicing 48C 090 OC 090 48C 110 OC 110 0D 135 At the beginning of each heating season system should be checked as follows by 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 A 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 inju ry or death Page 35 Filters Filters should be inspected monthly Clean or replace the filters when necessary to ensure proper furnace opera tion Replacement filters must be rated for high velocity airflow Table 21 lists recommended filter sizes TABLE 21 Side Return Bottom Return Furnace Cabinet Size 17 1 2 16 X 25 X 1 1
13. Thermostat W915 Wiring Connections Y1 to Y2 1 Heat 1 Cool SINGLE Leave Installed CONTROL OUTDOOR TERM STRIP UNIT NOTE Use dip switch 3 to set second stage heat ON delay HSXB15 ON 10 minutes OFF 15 minutes 1 Heat 2 Cool SINGLE CONTROL OUTDOOR TERM STRIP UNIT NOTE Use dip switch 3 to set second stage heat ON delay ON 10 minutes OFF 15 minutes 2 Heat 2 Cool TWO CONTROL OUTDOOR TERM STRIP UNIT 2 Heat 1 Cool TWO Leave Installed CONTROL OUTDOOR TERM STRIP UNIT HSXB15 Page 46 Field Wiring Applications Continued Jumper Settings See figure 4 Thermostat EO W915 Wiring Connections Y1 to Y2 FM21 Heat Pump 1 SINGLE Leave Installed CONTROL FM21 Cool TERM STRIP Disconnect existing furnace transformer and re 4 place with 75 24 trans former if defrost option to be MENE used D w 75VA 24V C TRANSFORMER lt NOTE Wiring connections to O NOTE outdoor unit and thermostat Cut Y1 Y2 jumper made at FM21 control board for two stage per FM21 instructions cooling Page 47 IX SURELIGHT CONTROL TROUBLESHOOTING CHART UPON INITIAL POWER UP REMOVE ALL THERMOSTAT DEMANDS TO THE UNIT PROBLEM 1 UNIT FAILS TO OPERATE IN THE COOLING HEATING OR CONTINUOUS FAN MODE ACTION 1 Check 120V main voltage Both diagnostic lights fail to light up Main voltage 120V not supplied to unit Determ
14. units have two combustion air proving switches G61MP 090 110 and 135 units are equipped with two dual prove switch assemblies consist ing of two switches acting as one See figure 9 The switches are connected to the cold end header box by means of a flexible hose that monitors negative air pressure in the cold end header box The switches are a single pole single throw proving switch electrically connected to the furnace control The purpose of the switch is to prevent burner operation if the combustion air inducer is not operating or if the flue becomes obstructed On heat demand first or second stage the switch senses that the combustion air inducer is operating It closes a cir cuit to the furnace control when pressure inside the cold end header box decreases to a certain set point Set points vary depending on unit size See tables 8 9 and 10 The pressure sensed by the switch is negative If the air intake vent pipe or outlet vent pipe becomes obstructed during operation the switch senses change of negative pressure and opens the circuit to the furnace control and gas valve bleed port on the switch allows relatively dry air in the vestibule to purge switch tubing to prevent con densate build up The switch is factory set and is not field adjustable It is safety shut down control in the furnace and must not be by passed for any reason If switch is closed or by passed the control will not initiate ignition a
15. 1410 665 555 1310 620 495 1155 545 440 1000 470 385 0 40 100 1350 640 535 1250 590 465 1120 530 410 980 465 360 0 50 125 1290 610 505 1205 570 450 1080 510 390 950 450 345 0 60 150 1220 575 485 1145 540 420 1020 480 365 905 430 320 0 70 175 1145 540 460 1080 510 400 975 460 345 860 405 300 0 80 200 1050 495 425 985 465 365 870 410 320 785 370 285 0 90 225 945 445 410 900 425 345 825 390 305 730 345 270 NOTES All air data is measured external to unit without filter not furnished field provided Air volume based on bottom air return air Actual air volume may vary on side return air applications G61MP 36B 070 PERFORMANCE Less Filter External Static Air Volume Watts at Different Blower Speeds Pressure High Medium High Medium Low Low in w g Pa cfm L s Watts cfm L s Watts cfm L s Watts cfm L s Watts 0 00 0 1640 775 660 1415 665 575 1160 545 485 1005 475 410 0 10 25 1600 755 635 1395 660 550 1160 545 460 1000 470 385 0 20 50 1540 725 605 1370 650 525 1160 545 445 995 470 375 0 30 75 1495 705 580 1345 635 505 1145 540 425 990 465 365 0 40 100 1420 670 545 1275 605 480 1125 530 395 965 455 345 0 50 125 1360 640 525 1245 590 450 1080 510 375 945 445 325 0 60 150 1275 600 490 1165 550 410 1025 485 350 900 425 305 0 70 175 1170 555 465 1085 515 385 965 430 335 860 405 295 0 80 200 1080 510 440 1010 475 360 865 410 310 775 365 270 0 90 225 945 445 400 840 395 320 765 360 275 710 335 245 NOTES All air data is measured external to unit without filter
16. 16 X 25 X 1 1 16 X 25 X 1 1 20 X 25 X 1 1 24 112 16 25 1 2 24 X 25 X 1 1 Exhaust and air intake pipes Check the exhaust and air intake pipes and all connections for tightness and to make sure there is no blockage Electrical 1 Check all wiring for loose connections 2 Check for the correct voltage at the furnace furnace operating 3 Check amp draw on the blower motor Motor Nameplate Actual Winterizing and Condensate Trap Care 1 Turn off power to the unit 2 Have a shallow pan ready to empty condensate water 3 Remove the drain plug from the condensate trap and empty water Inspect the trap then reinstall the drain plug Cleaning Heat Exchanger If cleaning the heat exchanger becomes necessary follow the below procedures and refer to figure 1 when disassem bling unit Use papers or protective covering in front of fur nace while removing heat exchanger assembly A IMPORTANT Safety glasses and surgical mask should be worn when cleaning heat exchanger and or burner assembly 1 Turn off electrical and gas supplies to the furnace 2 Remove the upper and lower furnace access panels 3 Mark all gas valve wires and disconnect them from valve 4 Remove gas supply line connected to gas valve Re move gas valve manifold assembly 5 Remove sensor wire from sensor Disconnect 2 pin plug from the ignitor 6 Disconnect wires from flame roll out switches 7 Remove burner box cover and
17. 22 Inches mm EXHAUST p INTAKE FIELD PROVIDED REDUCER MAY BE REQUIRED TO ADAPT LARGER VENT PIPE SIZE TO TERMINATION INTAKE TERMINATION 227 EXHAUST xV TERMINATION 12 305 Min above grade DIRECT VENT CONCENTRIC WALL TERMINATION 71M80 69M29 or 60L46 FIGURE 23 Inches mm UNCONDITIONED SPACE OUTSIDE WALL gt PROVIDE SUPPORT FOR INTAKE AND EXHAUST LINES EVERY 36 914 FIELD PROVIDED REDUCER MAY BE REQUIRED TO ADAPT LARGER VENT PIPE SIZE TO TERMINATION 1 2 13 FOAM INSULATION IN UNCONDITIONED SPACE 12 305 MAX for 2 51 unless supported 72777777 f yr 7 4 CY 8 203 i IR m RSS NU SIZE SSSSSSSSSSSSSSN PIPE PER TABLE 14 d SSSSSSSSSI 12 305 ABOVE AVERAGE SNOW ACCUMULATION 1 2 13 FOAM INSULATION SIDE VIEW DIRECT VENT WALL RING TERMINATION 15F74 See venting table 12 for maximum venting lengths with this arrange t FIGURE 24 ment TERMINATION EXHAUST VENT Front View INTAKE K Q VENT 1 2 13 Foam Insulation in Unconditioned Space Side View FIELD VZ ZZ ZZ ZZ ZZ L PROVIDED EXHAUST VENT REDUCER MAY BE REQUIRED TO ADAPT LARGER VENT PIPE SIZE TO TERMINATION INTAKE VENT Inches mm r OUTSIDE WALL DIRECT VENT WALL TERMINATION KIT 22G44 44J40 30G28 or 81J20 FIGURE 25 EXHAUST VENT INTAKE VENT 18 MAX 457 Front View E
18. 78H5401 available from Lennox Repair Parts is amp required to measure flame NG signal if meter used will not b Ne read low micro amp sig NG nal See figure 38 The transducer converts mi FIGURE 38 croamps to volts on a 1 1 conversion Flame signal for the SureLight control should read 0 23 or greater microamps with a lockout signal of 0 16 microamps A digital readout meter must be used The transducer plugs into most meters See figure 39 for proper use of transducer TRANSDUCER PART 78H5401 1 Set the volt meter to the DC voltage scale Insert transducer into the VDC and common inputs Ob serve correct polarities Failure to do so results in negative values 2 Turn off supply voltage to control 3 Disconnect ignition control flame sensor wire from the flame sensor 4 Connect lead of the transducer to flame sensor 5 Connect lead of transducer to the ignition control sen Sor wire 6 Tum supply voltage on and close thermostat contacts to cycle system 7 When main burners are in operation for two minutes take reading Remember 1 DC volt 1 DC microamp NOTE MUST USE DIGITAL METER SET DIAL TO MEASURE VDC RED COLLAR INDICATES POSITIVE IGNITION CONTROL SENSOR WIRE FIGURE 39 V TYPICAL OPERATING CHARACTERISTICS A Blower Operation and Adjustment 1 Blower operation is dependent on thermostat control system 2 Generally blower operation is set at ther
19. COOL SPEED AFTER 2 SECOND DELAY YES COMPRESSOR AND CONDENSER FAN DE ENERGIZED FIRST STAGE DEMAND FOR COOL SATISFIED INDOOR BLOWER DE ENERGIZED NO THERMOSTAT CALLS FOR SECOND STAGE COOL INDOOR BLOWER RAMPS UP TO SECOND STAGE COOL SPEED SECOND STAGE DEMAND FOR COOL SATISFIED YES UNIT RETURNS TO FIRST STAGE COOL Page 44 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 LOW HEAT LOW COOL THERMOSTAT CALLS FOR FIRST STAGE COOL THERMOSTAT CALLS FOR FIRST STAGE HEAT COMPRESSOR IS ENERGIZED AND INDOOR BURNERS IGNITE AND INDOOR BLOWER BLOWER CONTINUES TO OPERATE IN LOW CONTINUES TO OPERATE IN CONTINUOUS COOL SPEED LOW LOW HEAT LOW COOL MODE FIRST STAGE COOL DEMAND SATISFIED FIRST STAGE HEAT DEMAND SATISFIED SECOND STAGE COOL DEMAND THERMOSTAT CALLS FOR SECOND STAGE HEAT YES INDOOR BLOWER RAMPS TO SECOND INDOOR BLOWER SWITCHES TO HIGH HEAT SPEED STAGE COOL SPEED AFTER 30 SECOND RECOGNITION PERIOD YES SECOND STAGE COOL DEMAND SATISFIED SECOND STAGE HEAT DEMAND SATISFIED YES YES INDOOR BLOWER RAMPS DOWN TO FIRST STAGE INDOOR BLOWER RAMPS DOWN TO LOW COOL SPEED HEAT SPEED NOTE Continuous low speed fan and cooling low speed are equal to the low heat fan speed Page 45 VIII Field Wiring Applications and Jumper Settings Field Wiring Applications Jumper Settings See figure 4
20. INDUCER ON INDOOR BLOWER OFF AFTER DELAY DS1 OFF DS 2 SLOW FLASH SECOND STAGE PRESSURE SWITCHES CLOSED AT BEGINNING OF HEAT DEMAND DS1 OFF DS2 SLOW FLASH SECOND STAGE HEAT DEMAND DS1 AND DS2 SIMULTANEOUS SLOW FLASH NO RETURNS TO FIRST STAGE HEAT MODE WHICH CONTINUES UNTIL SECOND STAGE PRESSURE SWITCHES CAN BE PROVEN or HEAT DEMAND IS SATISFIED FIVE 5 MINUTE WAIT PERIOD INITIATED BEFORE RETRY WERE 5 ATTEMPTS MADE FOR SECOND STAGE HEAT YES NORMAL OPERATION DS1 AND DS2 SIMULTANEOUS SLOW FLASH Page 42 HEATING SEQUENCE OF OPERATION CONTINUED SEE BOX A NORMAL OPERATION DS1 AND DS2 SIMULTANEOUS SLOW FLASH SEE BOX B THERMOSTAT CALLS FOR HEAT DS 1 AND DS 2 SIMULTANEOUS FAST FLASH GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER ON ARE PRIMARY SECONDARY ROLLOUT AND DS1 SLOW FLASH DS2 ON BACKUP SECONDARY LIMIT SWITCHES CLOSED HAS PRIMARY SECONDARY ROLLOUT OR BACKUP YES x SECONDARY LIMIT SWITCH CLOSED WITHIN 3 MINUTESP LIMIT SWITCH WATCHGUARD MODE GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF WITH DELAY IS 60 MINUTE RESET PERIOD COMPLETE DS SLOW FLASH DS2 ON GAS VALVE OFF COMBUSTION AIR INDUCER OFF AFTER 15 SECOND POST PURGE INDOOR FIRST STAGE LOW FIRE HEAT BLOWER OFF AFTER DELAY PRESSURE SWITCHES CLOSED DS1 OFF DS2 FAST FLASH RETURN TO HEAT DEMAND RETURN TO FIRST STAGE HEAT MODE FIRST STAGE CONTINUES UNTIL SECOND SECOND STAGE HIGH FIRE HEAT
21. L s Watts cfm L s Watts cfm L s Watts 0 00 0 2720 1285 1385 2410 1135 1090 2055 970 935 1620 765 710 0 10 25 2665 1255 1355 2385 1125 1075 2025 955 885 1730 815 735 0 20 50 2585 1220 1315 2350 1110 1015 2030 955 865 1680 795 690 0 30 75 2505 1180 1275 2290 1080 990 2025 955 840 1695 800 675 0 40 100 2435 1150 1250 2235 1055 940 2030 960 830 1695 800 660 0 50 125 2350 1110 1205 2170 1025 930 1975 930 790 1735 820 665 0 60 150 2255 1065 1185 2100 990 895 1915 905 765 1720 810 650 0 70 175 2160 1020 1150 2005 945 840 1865 880 730 1680 795 635 0 80 200 2020 955 1090 1905 900 825 1810 855 710 1625 765 610 0 90 225 1910 900 1050 1820 860 795 1705 805 675 1540 725 590 NOTES All air data is measured external to unit without filter not furnished field provided G61MP 60D 135 PERFORMANCE Less Filter Single Side Return Air Air volumes in bold require field fabricated transi tion to accommodate 20 x 25 x 1 in 508 x 635 x 25 mm air filter in order to maintain proper air velocity External Static Air Volume Watts at Different Blower Speeds Pressure Medium High Medium Low Low in w g Pa cfm L s Watts cfm L s Watts cfm L s Watts 0 00 0 1410 665 690 0 10 25 1465 690 685 0 20 50 1570 740 675 0 30 75 1590 750 670 0 40 100 1590 750 655 0 50 125 1595 755 645 0 60 150 1580 745 630 0 70 175 1545 730 605 0 80 200 1515 715 590 0 90 225 1440 680 570 NOTES All air data is measured external to unit without filter not furnished
22. The limit is a N C SPST manu al reset limit connected in series with the primary limit S10 When 547 senses rollout the circuit breaks and the ignition control immediately stops ignition and closes the gas valve If unit is running and flame rollout is detected the gas valve will close and ignition control will be disabled Rollout can be caused by a blocked heat exchanger flue or lack of combustion air The switch is factory set to trip open at 250 F and cannot be adjusted The switch can be manually reset To manually reset a tripped switch push the reset but ton located on the control 8 Primary Limit Control 510 Figure 8 shows the primary limit S10 used on G61MP units located in the heating vestibule panel 510 is provided with shield on some models figure 8 and must not be removed Note orientation of shield and limit if limit is replaced When ex cess heat is sensed in the heat exchanger the limit will open Once the limit opens the furnace control energizes the supply air blower and de energizes the gas valve The limit automatically resets when unit temperature returns to nor mal The switch is factory set and cannot be adjusted 9 Backup Secondary Limit Control 5113 G61MP 090 110 135 only Backup secondary limit control 5113 is auto reset switch located on the combustion air inducer 5113 acts as backup to primary limit 510 in the event of an indoor blow er failure 5113 contacts open whe
23. accelerator not required Requires field provided and installed 2 exhaust ac Requires field provided and installed 2 exhaust accelerator celerator For use only in non direct vent applications when snow riser is Page 16 A Vent Piping Guidelines The G61MP can be installed as either a Non Direct Vent or Direct Vent gas central furnace NOTE In Non Direct Vent installations combustion air is taken from indoors and flue gases are discharged outdoors In Direct Vent installations combustion air is taken from out doors 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 12 and 13 Table 12 lists the minimum equivalent vent pipe lengths permitted Table 13 lists the maximum equivalent pipe lengths permitted Maximum vent length is defined as Total length linear feet of pipe Plus Equivalent length feet of fittings Plus Equivalent length feet of termination NOTE Include ALL pipe and ALL fittings both in doors and outdoors Regardless of the diameter of pipe used the standard roof and wall terminations described in section Exhaust Piping Terminations should be used Exhaust vent termination pipe is sized to optimize the velocity of the exhaust gas as it exits the termination Refer to table 14 NOTE The exhaust pipe should be offset a minimum of 12 inches to avoid the
24. collection trap and lines Exhaust Piping NOTE A 2 diameter street ell is strapped to the blower deck of 48C 110 and 60C 110 units Street ell must be glued directly into the unit flue collar See figure 13 A 3 to 2 reducing ell is strapped to the blower deck of the 60D 135 units In upflow or downflow applications the reducing ell must be glued directly into the unit flue collar 1 Choose the appropriate side for venting in upflow or downflow positions Exhaust piping exits from the top of the unit in horizontal air discharge applications Glue the field provided exhaust vent pipe or provided street ell or reducing ell in upflow or downflow applica tions to the flue collar All cement joints should be made according to the specifications outlined in ASTM D 2855 Refer to pipe and fittings specifications and gluing procedures TYPICAL EXHAUST PIPE CONNECTIONS AND CONDENSATE TRAP INSTALLATION UPFLOW DOWNFLOW DIRECT OR NON DIRECT VENT APPLICATIONS Right Hand Exit in Upflow Application Shown 2 1 2 3 OR 4 G61MP 045 070 REDUCER 5 7 or 090 with 2 1 2 3 or 4 vent pipe VENT PLUG Must be glued in place pa PLUG CONDENSATE TRAP Must be installed on same side as exhaust piping 2 diameter stre
25. gas valve GV1 Checks of man ifold pressure are made as verification of proper regulator ad justment Manifold pressure for the G61MP can be measured at any time the gas valve is open and is supplying gas to the unit See table 19 for manifold pressures A IMPORTANT For safety connect a shut off valve between the manometer and the gas tap to permit shut off of gas pressure to the manometer The gas valve is factory set and should not require adjust ment All gas valves are factory regulated sensing atmo spheric pressure Manifold Pressure Measurement amp Adjustment NOTE Pressure test adapter kit 10L34 is available from Lennox to facilitate manifold pressure measurement 1 Connect test gauge to outlet tap on gas valve 2 Disconnect pressure sensing hose from gas valve 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 19 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 overfir ing e Operate unit only long enough to obtain accurate read ing to prev
26. not furnished field provided Air volume based on bottom air return air Actual air volume may vary on side return air applications G61MP 48C 090 PERFORMANCE Less Filter External Static Air Volume Watts at Different Blower Speeds Pressure High Medium High Medium Low Low in w g Pa cfm L s Watts cfm L s Watts cfm L s Watts cfm L s Watts 0 00 0 2180 1030 930 1835 865 790 1520 715 630 1280 605 510 0 10 25 2135 1005 885 1825 860 750 1510 710 610 1275 600 495 0 20 50 2085 985 840 1810 855 720 1505 710 580 1270 600 475 0 30 75 2030 955 800 1775 835 685 1500 705 565 1265 595 460 0 40 100 1940 915 760 1735 820 650 1480 700 535 1250 590 440 0 50 125 1865 880 725 1660 785 600 1430 675 505 1215 575 425 0 60 150 1740 820 670 1590 750 575 1380 650 475 1175 555 410 0 70 175 1645 775 640 1475 695 520 1290 610 450 1105 520 375 0 80 200 1540 725 600 1340 630 465 1175 555 405 1020 480 355 0 90 225 1335 630 540 1170 555 440 1070 505 375 950 450 330 NOTES All air data is measured external to unit without filter not furnished field provided Air volume based on bottom air return air Actual air volume may vary on side return air applications G61MP 48C 110 PERFORMANCE Less Filter External Static Air Volume Watts at Different Blower Speeds Pressure High Medium High Medium Low Low in w g Pa cfm L s Watts cfm L s Watts cfm L s Watts cfm L s Watts 0 00 0 2160 1020 880 1880 890 755 1490 705 602 1235 580 485 0 10 25 2100 990 850 1855 875 730 1480 700 585 123
27. remove four burner box screws at the vestibule panel and remove burner box Set burner box assembly aside G61MP 135 only Remove and discard two additional shipping screws See figure 41 NOTE If necessary clean burners at this time Follow procedures outlined in Burner Cleaning section 8 Loosen three clamps and remove flexible exhaust tee 20 Back wash heat exchanger with soapy water solution or steam If steam is used it must be below 275 F 135 Thoroughly rinse and drain the heat exchanger Soap solutions can be corrosive Take care to rinse entire assembly Reinstall heat exchanger into cabinet making sure that the clamshells of the heat exchanger assembly are resting on the support located at the rear of the cabi net Remove the indoor blower to view this area through the blower opening 23 Re secure the supporting screws along the vestibule sides and bottom to the cabinet 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 FIGURE 41 er deck and reinsert strain relief bushing 27 Reinstall electrical junction box G61MP 135 ONLY Remove and discard two shipping screws 21 22 24 9 Remove 3 8 inch rubber cap from condensate drain 28 Reinstall the combustion air inducer Reconnect the plug and drain Replace cap after draining 3 pin plug to the wire harne
28. 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 VII Wiring and Sequence of Operation 120V OR K43 ECON IF USED SI ROOM THERMOSTAT BOOOOGO I I I I I t DOOR ti INTERLOCK A EQUIPMENT FE COMBUSTION AIR BLOWER MOTOR INTEGRATED J156 LI piss N A Turn GROUND 102 2 COMBUSTION AIR 510 M RRO BR SWITCH LENET SECONDARY J84 LIMIT SI02 fet HIGH HEAT PRESSURE SWITCH FLAME IGNITOR S128 1 SENSOR FLAME ROLLOUT SWITCH INTEGRATED CONTROL DOOR INTERLOCK CIRCUIT BREAKER C4 CAPACITOR TERMINAL BOARD W9I5 A92 INTEGRATED CONTROL HIGH HEAT SEE BLOWER SPEED CHART 5102 2 HIGH HEAT PRESSURE SWITCH PRESSURE SWITCH HUMIDIFIER INDOOR BLOWER MOTOR LENNOX HEATING UNITS GAS 66 1MP 36B 045 Ge IMP 368 045 6 50 090 66 60 110 56 56 070 48 110 66 600 135 New Forn No 534 370W 2005 Lennox Industries Inc Litho U S A LINE VOLTAGE FIELD INSTALLED CLASS II VOLTAGE FIELD WIRING
29. 0 580 475 0 20 50 2035 960 805 1815 860 690 1475 695 560 1225 580 460 0 30 75 1965 925 750 1755 830 650 1475 695 545 1220 575 445 0 40 100 1885 890 725 1715 810 625 1465 690 510 1215 575 430 0 50 125 1780 840 680 1630 770 580 1420 670 490 1150 540 400 0 60 150 1690 800 660 1550 735 550 1360 640 460 1110 525 380 0 70 175 1575 745 620 1410 665 505 1210 570 405 1035 490 350 0 80 200 1375 650 550 1230 580 450 1125 530 380 970 460 325 0 90 225 1225 580 520 1120 530 415 1050 495 365 885 420 310 NOTES All air data is measured external to unit without filter not furnished field provided Air volume based on bottom air return air Actual air volume may vary on side return air applications Page 4 BLOWER DATA G61MP 60C 090 PERFORMANCE Less Filter Single Side Return Air Air volumes in bold require field fabricated transi tion to accommodate 20 x 25 x 1 in 508 x 635 x 25 mm air filter in order to maintain proper air velocity External Static Air Volume Watts at Different Blower Speeds Pressure High Medium High Medium Low Low in w g Pa cfm L s Watts cfm L s Watts cfm L s Watts cfm L s Watts 0 00 0 2835 1335 1495 2340 1105 1155 1800 850 895 1440 680 695 0 10 25 2785 1315 1475 2345 1105 1135 1805 855 865 1515 715 690 0 20 50 2715 1280 1435 2275 1075 1080 1825 860 845 1560 735 685 0 30 75 2620 1235 1380 2260 1065 1035 1840 870 825 1600 755 680 0 40 100 2550 1205 1350 2230 1055 1015 1845 870 815 1620 765 670 0 50 125 2
30. 450 1155 1305 2175 1025 990 1850 870 790 1615 765 655 0 60 150 2365 1115 1270 1830 865 775 1615 760 640 0 70 175 2240 1060 1205 1815 855 760 1595 755 620 0 80 200 2185 1030 1190 1775 840 745 1555 735 605 0 90 225 2015 950 1150 1690 800 715 1440 680 580 NOTES All air data is measured external to unit without filter not furnished field provided G61MP 60C 090 PERFORMANCE Less Filter Bottom Return Air Side Return Air with Optional RAB Return Air Base Return Air from Both Sides or Return Air from Bottom and One Side External Static Pressure in w g Pa 0 00 0 0 10 25 0 20 50 0 30 75 0 40 100 0 50 125 0 60 150 0 70 175 0 80 200 0 90 225 2840 2765 2695 2605 2530 2420 2330 2250 2135 2030 High L s 1340 1305 1270 1230 1195 1140 1100 1060 1010 960 Watts 1450 1415 1385 1335 1300 1260 1220 1190 1140 1090 Air Volume Watts at Different Blower Speeds cfm Medium High L s Watts NOTES All air data is measured external to unit without filter not furnished field provided cfm 1895 1950 1985 1990 1990 1970 1930 1875 1810 1720 Medium Low L s 895 920 935 940 940 930 910 885 855 810 Watts 900 885 870 850 825 800 775 745 715 685 cfm 1515 1580 1620 1645 1665 1675 1665 1645 1620 1560 Low L s 715 745 765 775 785 790 785 775 765 735 Watts 700 700 695 690 675 665 650 630 615 590 G61MP 60C 110 PER
31. 7 4 8 4 8 3 9 3 H High Altitude NOTE In Canada certification for installations at eleva tions over 4500 feet 1372 m is the jurisdiction of local au 6 5 7 5 6 5 7 5 6 9 7 9 6 9 7 9 7 2 8 2 7 2 8 2 TABLE 18 Low Heat G61MP 36B 045 7 4 8 4 7 4 8 4 7 8 8 8 7 8 8 8 8 1 9 1 8 1 9 1 thorities The manifold pressure may require adjustment to ensure proper operation at higher altitudes Refer to table 19 for proper manifold pressure settings at varying altitudes and required pressure switch changes and conversion kits at varying altitudes The combustion air pressure switches are factory set and require no adjustment NOTE A natural to L P propane gas changeover kit is nec essary to convert this unit Refer to the changeover kit installation instruction for the conversion procedure Condensate pH Range 4 8 5 8 5 3 6 3 The condensate is mildly acidic and can be measured with G61MP 36B 070 4 8 5 8 5 3 6 3 pH indicators The pH scale is measurement of acidity G61MP 48C 090 51 641 50 609 and alkalinity The following scale shows the relative pH of G61MP 60C 090 51 61 59 69 some common liquids as compared with condensate of G61MP 486 110 53 63 61 71 G61 MP units The concentration of the acidity of all these fluids including the condensate is very low and harmless G61MP 60C 110 5 3 6 3 6 1 7 1 pH RANGE G61MP 60D 135 5 7 6 7 6 7 7 7 4 0 1 ing 2 Vinegar be 3 Wine G61 Condensate 4
32. Base ED EXTRA 26K68 26K69 26K70 39G04 39G03 73P57 8 lbs 4 kg 4 x 21 5 8 x 28 5 8 102 x 549 x 727 87L97 20 x 25 x 1 in 508 x 635 x 25 mm 5 Single 44J22 or Ten Pack 66K63 1 16 x 25 x 26K68 26K69 26K70 39G04 39G03 73P58 10 Ibs 5 kg 4 x 24 5 8 x 28 5 8 102 x 625 x 727 120 volts 60 hertz 1 phase less than 12 amps 87L98 25 x 25 x 1 in 635 x 635 x 25 mm 1 in 406 x 635 x 25 mm 26K68 26K69 26K70 39G04 39G03 73P58 10 Ibs 5 kg 4 x 24 5 8 x 28 5 8 102 x 625 x 727 Size of field provided filter in mm 20x25x1 24 x 24x 1 24 x 24x 1 508 x 635 x 25 610 x 610 x 25 610 x 610 x 25 Down Flow Additive Base 11M61 11M61 11M62 5 High Altitude Orifice Kit Natural Gas Only 59M16 59M16 59M16 6 High Altitude Pressure Switch Kit Order two each per beg 56M93 4501 10 000 ft 1372 3048 m Horizontal Support Frame Kit Ship Weight Ibs kg 56J18 18 8 56J18 18 8 56J18 18 8 LPG Propane Kit 0 7500 ft 0 2286 m 59M13 59M13 59M13 7501 10 000ft 2286 3048m 59M14 59M14 59M14 Natural to LPG Propane Kit 59M87 59M87 59M87 RAB Return Air Base RAB60C 12M71 RAB60D 12 72 7 Termination Kits Concentric 2 inch 51 mm 33K97 33K97 f Fr RoofWall 3 inch 76 mm 60L46 60L46 60L46 Wall Close Coupled 3 inch 76 mm 44J40 44J40 44J40 78 Termination Kits Roof 2 inch 51 mm 15F75 15F75 nect vent or Non 3 inch 76 mm 44J41 44J41 44J41 Wall Rin
33. C PRESSURE TEST in supply and return air ple nums Insert manometer hose flush with inside edge of hole or insulation Seal around the hose with perma gum Connect the zero end of the manometer to the dis FIGURE 40 charge supply side of the system On ducted sys tems connect the other end of manometer to the return duct as above For systems with non ducted returns leave the other end of the manometer open to the at mosphere 3 With only the blower motor running and the evaporator coil dry observe the manometer reading Adjust blow er motor speed to deliver the air desired according to the job requirements 4 External static pressure drop must not be more than 0 8 W C 5 Seal around the hole when the check is complete Page 34 D Blower Speed Taps Blower speed tap changes are made on the SureLight con trol board See figure 4 The unused tap must be secured on dummy terminals PARK on the SureLight board The high heating tap is connected to the HI HEAT terminal and the low heating continuous blower tap is connected to the LO HEAT terminal The cooling tap is connected to the COOL tap To change existing heat tap turn off power then switch out speed tap on HI HEAT or LO HEAT with tap connected to PARK See table 20 for blower motor tap colors for each speed TABLE 20 BLOWER SPEED CHART FACTORY CONNECTED SPEED TAPS MOTOR SPEEDS AVAIL 1 BLOWER SPEED SELECTION LO
34. Close manual and main gas valves D Extended Period Shutdown Turn off thermostat or set to UNOCCUPIED mode Close all gas valves both internal and external to unit to guaran tee no gas leak into combustion chamber Turn off power to unit All access panels and covers must be in place and se cured Page 31 IV HEATING SYSTEM SERVICE CHECKS A C S A Certification All units are C S A formally A G A and C G A combined design certified without modifications Refer to the G61MP Installation Instruction B Gas Piping A CAUTION If a flexible gas connector is required or allowed by the authority that has jurisdiction black iron pipe shall be installed at the gas valve and extend outside the furnace cabinet A WARNING Do not exceed 600 in Ibs 50 ft lbs torque when attaching the gas piping to the gas valve Gas supply piping should not allow more than 0 5 W C drop in pressure between gas meter and unit Supply gas pipe must not be smaller than unit gas connection Compounds used on gas piping threaded joints should be resistant to action of liquefied petroleum gases C Testing Gas Piping A IMPORTANT In case emergency shutdown is required turn off the main shut off valve and disconnect the main power to unit These controls should be properly labeled by the installer When pressure testing gas lines the gas valve must be dis connected and isolated Gas valves can be damaged if subjected to m
35. E 14 NON DIRECT VENT ROOF TERMINATION KIT 15F75 or 44J41 FIGURE 29 NOTE Do not discharge exhaust gases directly into any chimney or vent stack If ver tical discharge through an existing unused chimney or stack is required insert piping inside chimney until the pipe open end is above top of chimney and terminate as illus trated In any exterior portion of chimney the exhaust vent must be insulated FIGURE 28 Details of Exhaust Piping Terminations for Non Direct Vent Applications 12 305 Max for 2 51 Unless Supported 1 2 13 ARMAFLEX INSULATION IN UNCONDITIONED SPACE 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 pre ferred Figures 29 through 32 show typical terminations 112 13 ARMAFLEX FIELD PROVIDED INSULATION REDUCER MAY ZZZZZZZZzzz z BE REQUIRED TO gt IE ADAPT LARGER 77775577 VENT PIPE SIZE TO TERMINATION 1 Exhaust piping must terminate straight out or up as shown The termination pipe must be sized as listed in table 14 The specified pipe size ensures proper ve locity required to move the exhaust gases away from the building 2 On field supplied terminations for side wall exits ex haust piping should extend a maximum of 12 inches 305mm beyond the outside wall unless support is provided in the horizontal section See figure 30 RS PVC
36. ELAY DS1 AND DS2 SIMULTANEOUS SLOW FLASH SECOND STAGE HEAT DEMAND SECOND STAGE HEAT DEMAND REQUIRED DS1 AND DS2 SIMUTANEOUS SLOW FLASH SECOND STAGE PRESSURE SWITCHES CLOSED ABNORMAL FLASH CODE NOTE IF SECOND STAGE PRESSURE SWITCHES WERE ORIGINALLY FOUND CLOSED ABNORMAL CODE WILL FLASH SECOND STAGE 30 SECOND DELAY ON BEGINS DS1 AND DS2 SIMULTANEOUS FAST FLASH YES SECOND STRAGE COMBUSTION AIR INDUCER ON SECOND STAGE GAS VALVE ON HIGH HEAT INDOOR BLOWER SPEED ON DS1 AND DS2 SIMULTANEOUS FAST FLASH SECOND STAGE PRESSURE SWITCHES CLOSED IN LESS THAN TEN 10 SECONDS DS1 AND DS2 SIMULTANEOUS FAST FLASH CONTINUED ON NEXT PAGE THERMOSTAT CALLS FOR HEAT DS1 AND DS2 SIMULTANEOUS FAST FLASH SEE BOX LOW FLAME SIGNAL Does not affect control operation DS1 SLOW FLASH DS2 FAST FLASH E20 SET AT TWO YES 45 SECOND INDOOR BLOWER ON DELAY BEGINS DS1 AND DS2 SIMULTANEOUS FAST FLASH YES YES PRIMARY SECONDARY ROLLOUT AND BACKUP SECONDARY LIMIT SWITCHES CLOSED NO GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER ON DS1 SLOW FLASH DS2 ON HAS PRIMARY SECONDARY ROLLOUT OR BACKUP SECONDARY LIMIT SWITCH CLOSED WITHIN 3 MINUTES Indoor blower on low speed during 3 minute period LIMIT SWITCH WATCHGUARD MODE GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF WITH DELAY DS1 AND DS2 ALTERNATING SLOW FLASH IS 60 MINUTE RESET PERIOD COMPLETE GAS VALVE OFF COMBUSTION AIR
37. EN or HEAT DEMAND IS SATISFIED A FIVE 5 PRESSURE SWITCHES CLOSED MINUTE WAIT PERIOD IS INITIATED BEFORE RETRY WERE 5 ATTEMPTS MADE FOR SECOND STAGE HEAT HEAT DEMAND SATISFIED NO DS1 AND DS2 SIMULTANEOUS FAST FLASH SEE BOXC FIRST STAGE HEAT DEMAND SATISFIED YES YES r SECOND STAGE HEAT HEAT DEMAND SATISFIED FIRST AND SECOND STAGE HEAT DEMAND SASTISFIED DS1 AND DS2 DEMAND SATISFIED SIMULTANEOUSLY DS1 AND DS2 SIMULTANEOUS FAST FLASH DS1 amp DS2 SIMULTANEOUS FAST FLASH SIMULTANEOUS FAST FLASH GAS VALVE OFF COMBUSTION AIR GAS VALVE COMBUSTION AIR INDUCER INDUCER OFF AFTER POST PURGE AND INDOOR BLOWER RETURN TO FIRST PERIOD INDOOR BLOWER OFF AF STAGE OPERATION TER SELECTED DELAY DS1 AND DS2 SIMULTANEOUS FAST FLASH DS1 AND DS2 SIMULTANEOUS FAST FLASH FIRST STAGE HEAT DEMAND SATISFIED DEMAND FOR HEAT SATISFIED GAS VALVE OFF COMBUSTION AIR INDUCER POWER ON STAND BY OFF AFTER 5 SECOND POST PURGE PERIOD DS1 AND DS2 INDOOR BLOWER OFF DELAY INITIATED SIMULTANEOUS SLOW FLASH 051 amp 052 SIMULTANEOUS FAST FLASH Page 43 COOLING SEQUENCE OF OPERATION POWER ON IS POLARITY REVERSED SIGNAL POLARITY REVERSED DS1 FAST FLASH DS2 SLOW FLASH SIGNAL IMPROPER GROUND AT DS UNTIL UNIT IS PROPER GROUND ABOVE 75 VOLTS UNTIL VOLTAGE RISES ABOVE 75 VOLTS PROPERLY GROUNDED Y THERMOSTAT CALLS FOR FIRST STAGE COOL COMPRESSOR AND CONDENSER FAN ENERGIZED INDOOR BLOWER ENERGIZED ON FIRST STAGE
38. FORMANCE Less Filter Single Side Return Air Air volumes in bold require field fabricated transi tion to accommodate 20 x 25 x 1 in 508 x 635 x 25 mm air filter in order to maintain proper air velocity External Static Pressure in w g Pa 0 00 0 0 10 25 0 20 50 0 30 75 0 40 100 0 50 125 0 60 150 0 70 175 0 80 200 0 90 225 2625 2570 2410 2425 2335 2270 2170 2110 2035 1900 High L s 1240 1215 1135 1145 1100 1070 1025 995 960 895 Watts 1350 1330 1305 1265 1220 1195 1155 1130 1090 1055 Air Volume Watts at Different Blower Speeds cfm Medium High L s Watts NOTES All air data is measured external to unit without filter not furnished field provided Page 5 cfm 1885 1910 1930 1925 1910 1895 1860 1795 1745 1665 Medium Low L s 890 900 910 905 900 895 875 845 825 785 Watts 885 865 845 825 810 785 765 730 705 680 cfm 1515 1575 1620 1635 1640 1640 1630 1590 1540 1470 Low L s 715 745 765 770 775 775 770 750 725 695 Watts 700 700 690 675 660 640 630 610 580 565 BLOWER DATA G61MP 60C 110 PERFORMANCE Less Filter Bottom Return Air Side Return Air with Optional RAB Return Air Base Return Air from Both Sides or Return Air from Bottom and One Side External Static Air Volume Watts at Different Blower Speeds Pressure High Medium High Medium Low Low in w g Pa cfm L s Watts cfm
39. IR INDUCER OFF INDOOR BLOWER OFF UNIT WILL RETRY AFTER 5 MINUTE WAIT PERIOD DS1 OFF DS2 SLOW FLASH COMBUSTION AIR INDUCER OFF IGNITER OFF SIGNAL HOLDS UNTIL VOLTAGE RISES ABOVE 75 VOLTS DS1 AND DS2 ALTERNATING FAST FLASH COMBUSTION AIR INDUCER OFF IGNITER OFF SIGNAL HOLDS UNTIL UNIT IS PROPERLY GROUNDED DS1 AND DS2 ALTERNATING FAST FLASH COMBUSTION AIR INDUCER OFF IGNITOR OFF SIGNAL HOLDS UNTIL IGNITOR IS REPLACED OR RECONNECTED DS1 AND DS2 ALTERNATING FAST FLASH GAS VALVE OFF COMBUSTION AIR INDUCER ON INDOOR BLOWER OFF DS1 SLOW FLASH DS2 FAST FLASHN HAS CONTROL FAILED TO SENSE FLAME FOR FIVE CONSECUTIVE TRIES DURING A SINGLE HEAT DEMAND WATCHGUARD MODE GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF DS1 AND DS2 ALTERNATING SLOW FLASH IS 60 MINUTE RESET PERIOD COMPLETE HAS CONTROL RESET IGNITION SEQUENCE FOUR 4 TIMES DS1 SLOW FLASH DS2 FAST FLASH Page 41 HEATING SEQUENCE OF OPERATION CONTINUED FLAME SIGNAL ABOVE gt 0 22 microamps YES gt E TWO STAGE THERMOSTAT MODE k 4 SINGLE STAGE THERMOSTAT MODE 1 E20 SET AT SINGLE START SECOND STAGE RECOGNITION ON DELAY 10 OR 15 MINUTES DS1 AND DS2 SIMULTANEOUS FAST FLASH FIRST STAGE LOW FIRE PRESSURE SWITCHES CLOSED FIRST STAGE HEAT DEMAND SATISFIED DS1 AND DS2 SIMULTANEOUS SLOW FLASH GAS VALVE OFF COMBUSTION AIR INDUCER OFF FOLLOWING POST PURGE INDOOR BLOWER OFF WITH D
40. NATION CLEARANCES FOR INSTALLATIONS IN THE USA AND CANADA 12222 Clearance above grade 12 in 305mm minimum Clearance to window or door that may be opened for vent installations in USA 12 in 305mm minimum for vent installations in Canada 12 in 305mm minimum for appliances lt 100 000 Btuh 30 KW 36 in 0 9m minimum for appliances gt 100 000 Btuh 30 kW Do not position terminations directly under roof eaves Clearance to electric meters gas meters regulators and relief equipment for vent installations USA 48 in 1219mm minimum for vent installations in Canada see current edition of CSA B149 Code Note E E G H Js G61MP VENT TERMINATION Q AIRINLET OF OTHER APPLIANCE less than 10 ft 3 048M EGG Clearance to non mechanical air supply inlet or outlet for vent installations in USA 48 in 1219mm minimum horizontal and below 12 in 305mm minimum above for vent installations in Canada 12 in 305mm minimum for appliances lt 100 000 Btuh 30 kW 36 in 0 9m minimum for appliances gt 100 000 Btuh 30 kW Clearance to mechanical air supply inlet for vent installations in USA 36 in minimum 914mm Clearance to mechanical air supply inlet for vent installations in Canada 72 in 1829mm mini mum Do not point terminations into recessed areas such as win dow wells stairwells or alcoves Do not position termina
41. NT 2 Iswiring of turnace or Improper connections Correct wiring and or replace any Combustion air inducer will not start connections to combustion air loose connections with a Heating demand inducer Diagnostic lights flash the pressure switch failure code 2 2 2 ACTION 1 Check that the prove switch is open 2 without the combustion air inducer operating Re LED Off Prove switch stuck closed place if defective LED 2 Slow Flash Page 49 PROBLEM 2 UNIT FAILS TO FIRE IN THE HEATING MODE COMBUSTION AIR INDUCER DOES NOT ENERGIZE CONT Possible Cause Corrective Action Comments 2 3 Unit operates with a cooling and con 2 3 1 tinuous fan demand Miswiring of furnace or improper Combustion air inducer will not start connections to combustion air induc with a Heating demand er Diagnostic lights flash the pressure switch failure code 2 5 minutes after heating demand ACTION 1 Check for correct wiring and loose connections Correct wiring and or replace any loose connections 2 3 2 ACTION 1 If there is 120V to combustion air in ducer and it does not operate replace combus LED 1 Off Combustion air inducer failure tion air inducer LED 2 Slow Flash PROBLEM 3 UNIT FAILS TO FIRE IN THE HEATING MODE COMBUSTION AIR INDUCER ENERGIZES IGNITOR IS NOT ENERGIZED 3 1 3 1 1 ACTION 1 Check that the prove switch lines are Unit operates with a cooling and Prove switch does n
42. OFF INDOOR BLOWER OFF CHECK FOR BROKEN IGNITOR OR OPEN IGNITER CIRCUIT DS1 AND DS2 ALTERNATING FAST FLASH GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF RESET CONTROL BY TURNING MAIN POWER OFF DS1 ON DS2 ON CONTROL SELF CHECK OKAY POLARITY REVERSED POLARITY OKAY DS1 FAST FLASH YES DS2 SLOW FLASH IS THERE SIGNAL HOLDS UNTIL UNIT IS PROPERLY GROUNDED PROPER GROUND DS1 AND DS2 ALTERNATING FAST FLASH IS VOLTAGE SIGNAL HOLDS UNTIL VOLTAGE RISES ABOVE 75 VOLTS ABOVE 75 VOLTS DS1 AND DS2 ALTERNATING FAST FLASH YES BURNER OFF GAS VALVE OFF COMBUSTION AIR INDUCER ON CONTINUOUS FLAME CHECK INDOOR BLOWER ON HEATING SPEED DS1 SLOW FLASH DS2 OFF A NORMAL OPERATION DS 1 SIMULTANEOUS SLOW FLASH DS 2 SIMULTANEOUS SLOW FLASH COMBUSTION AIR INDUCER OFF INDOOR BLOWER ON HAS PRIMARY OR SECONDARY LIMIT RESET WITHIN 3 MINUTES B DS1 SLOW FLASH DS2 ON THERMOSTAT CALLS FOR HEAT DS 1 SIMULTANEOUS FAST FLASH DS 2 SIMULTANEOUS FAST FLASH 60 MINUTE LIMIT WATCHGUARD MODE YES GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF WITH DELAY PRIMARY AND SECONDARY LIMIT DS1 AND DS2 ALTERNATING SLOW FLASH SWITCHES CLOSED VES GAS VALVE OFF COMBUSTION AIR INDUCER OFF HAS MANUAL ROLLOUT SWITCH ES BEEN RESET CLOSED WITHIN 3 MINUTES DS1 SLOW FLASH DS2 ON FIRST LOW STAGE PRESSURE SWITCHES OPEN GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF CONTROL
43. OX RENE ce w NS 8 c O THERMOSTAT CONNECTIONS TB1 W2 HEAT DEMAND FROM 2ND STAGE T STAT WI HEAT DEMAND FROM IST STAGE T STAT WHITE R CLASS 2 VOLTAGE TO THERMOSTAT G MANUAL FAN FROM T STAT GREEN C THERMOSTAT SIGNAL GROUND CONNECTED TO TRANSFORMER GROUND TR amp CHASIS GROUND GRD Yl THERMOSTAT Ist STAGE COOL SIGNAL Y2 THERMOSTAT 2nd STAGE COOL SIGNAL 0 THERMOSTAT SIGNAL TO HEAT PUMP REVERSING VALVE DIP SWITCH ES FUNCTION 1 and 2 Blower Off Delay Heating Mode 3 Second Stage ON Delay Single stage t stat 4 Blower Off Delay Cooling Mode FIGURE 4 TABLE 3 LO HEAT Low Heat Low Cool and Continuous Fan Speed TABLE 4 mier c 15 2 Ignitor 2 Combustion ir Inducer High Speed 3 Combustion Ar Inducer Low Spoed 4 Combuston Ar inducer Neutral 38 wWoNeWa TABLE 5 mine Fm Gas Valve 1st stage Low Fire Page 10 TABLE 6 DIAGNOSTIC CODES Diagnostic LEDs labeled DS1 and DS2 See figure 4 for location of diagnostic LEDs 07 052 DESCRIPTION SIMULTANEOUS SIMULTANEOUS Power on Normal operation SLOW FLASH SLOW FLASH Also signaled during cooling and continuous fan SIMULTANEOUS SIMULTANEOUS Normal operation signaled when heating demand initiated at thermostat FAST FLASH FAST FLASH SLOW FLASH Primary secondary backup secondary or rollout limit switch open Limits must clos
44. PREMATURELY Possible Cause Corrective Action Comments 5 1 Burners fire with a heating demand Burners light but unit shuts off prior to satisfying T stat demand Diagnostic lights flash the pressure Switch code LED 1 Off LED 2 Slow Flash 5 2 Combustion air inducer energizes with a heating demand Burners light but fail to stay lit After 5 tries the control diagnostics flash the watchguard burners failed to ignite code LED 1 Alternating Slow Flash LED 2 Alternating Slow Flash 5 1 1 Low pressure differential at the prove switch 5 1 2 Wrong concentric vent kit used for terminating the unit 5 1 3 Condensate drain line is not draining properly 5 1 4 Low pressure differential at the prove switch 5 2 1 Sensor or sense wire is improperly installed 5 2 2 Sensor or sense wire is broken 5 2 3 Sensor or sensor wire is grounded to the unit 5 2 4 Control does not sense flame Page 51 ACTION 1 Check for restricted intake and ex haust vent Remove all blockage ACTION 2 Check for proper vent sizing See installation instructions ACTION 1 Check vent termination kit installed See Placement and Installation section ACTION 1 Check condensate line for proper vent slope and any blockage Condensate should flow freely during operation of furnace Repair or replace any improperly installed con densate lines ACTION 1 Check for restricted intake and ex ha
45. REDUCER SIZE TERMINATION PIPE PER TABLE 14 Inches mm TOP VIEW NON DIRECT VENT WALL RING KIT 15F74 FIGURE 30 Page 27 If exhaust piping must be run up a side wall to position above snow accumulation or other obstructions pip ing must be supported every 3 feet 9m as shown in figure 12 Refer to figure 31 for proper piping method When exhaust piping must be run up an outside wall any reduction in exhaust pipe size must be done after the final elbow 12 305 Max for 2 51 Inches mm Unless Supported UNCONDITIONED SPACE OUTSIDE WALL 3 SIZE TER MINATION PIPE PER PROVIDE SUPPORT TABLE 14 FOR EXHAUST LINES EVERY 36 914 12 305 ABOVE AVERAGE SNOW FIELD PROVIDED ACCUMULATION REDUCER MAY BE REQUIRED TO ADAPT LARGER VENT PIPE SIZE TO TERMINATION 1 2 13 FOAM INSULATION IN USES UNCONDITIONED 1 2 13 FOAM SPACE INSULATION SIDE VIEW NON DIRECT VENT WALL RING TERMINATION 15F74 FIGURE 31 G61MP NON DIRECT VENT APPLICATION USING EXISTING CHIMNEY STRAIGHT CUT OR 1 ANGLE CUT IN DIRECTION OF ROOF SLOPE SIZE TERMINATION PIPE PER TABLE 14 EXHAUST VENT 1 2 13mm WEATHERPROOF INSULATION 3 8 76mm 203mm 12 805mm ABOVE AVERAGE SNOW ACCUMULATION HOULDER OF FITTINGS PROVIDE SUPPORT PIPE ON TOP PLATE SHEET METAL TOP INSULATE TO FORM EXTERIOR 1 SEAL E PORTION OF oa CHIMNEY jue A uM
46. REMAINS UNTIL KD PRESSURE SWITCH IS DETECTED OPEN DS1 OFF DS2 SLOW FLASH GAS VALVE OFF TWO STAGE OR SINGLE STAGE THERMOSTAT COMBUSTION AIR INDUCER OFF CALL FOR HEAT INDOOR BLOWER OFF CONTROL WILL NOT ATTEMPT SECOND STAGE OPERATION DURING THIS HEAT DEMAND FIRST STAGE OPERATION WILL BE ATTEMPTED COMBUSTION AIR INDUCER ON LOW SPEED DS1 OFF DS2 FAST FLASH DS1 AND DS2 SIMULTANEOUS FAST FLASH CONTINUED ON NEXT PAGE Page 40 HEATING SEQUENCE OF OPERATION CONTINUED FIRST STAGE LOW FIRE PRESSURE SWITCH CLOSED WITHIN 2 5 MINUTES YES 15 SECOND COMBUSTION AIR INDUCER PRE PURGE INITIATED BY CLOSED FIRST STAGE PRESSURE SWITCH or 15 SECOND INTER PURGE PERIOD DS1 AND DS2 SIMULTANEOUS FAST FLASH IGNITOR WARM UP 20 SECONDS DS1 AND DS2 SIMULTANEOUS FAST FLASH IS VOLTAGE ABOVE 75 VOLTS IS THERE A PROPER GROUND IS IGNITOR INTACT AND CONNECTED AT END OF IGNITOR 20 SECOND WARM UP PERIOD 4 SECOND TRIAL FOR IGNITION GAS VALVE OPENS IGNITOR ENERGIZED DURING 4 SECOND TRIAL UNTIL FLAME SENSED DS1 AND DS2 SIMULTANEOUS FAST FLASH 4 SECOND FLAME STABILIZATION PERIOD DS1 AND DS2 SIMULTANEOUS FAST FLASH FLAME RECTIFICATION CURRENT CHECK CAN FLAME BE PROVEN WITHIN 4 SECONDS AFTER GAS VALVE OPENS gt 0 16 microamps FLAME PRESENT NO CONTINUED ON NEXT PAGE THERMOSTAT CALLS FOR HEAT DS1 AND DS2 SIMULTANEOUS FAST FLASH Refer to box A on previous page GAS VALVE OFF COMBUSTION A
47. TE TO THE CONTAMINATION PROBLEM PROBLEM 7 INDOOR BLOWER FAILS TO OPERATE IN COOLING HEATING OR CONTINUOUS FAN MODE Possible Cause Corrective Action Comments 7 0 7 1 1 ACTION 1 Correct wiring and or replace Indoor blower fails to operate in Miswiring of furnace or improper loose connections Check for correct wiring and continuous fan cooling or heating connections at control or indoor blow loose connections mode er motor LED 1 Slow Flash LED 2 Fast Flash Sensor rod is contaminated ACTION 1 Check for 120V at the various calls 7 1 2 for indoor blower by energizing Y G and W individually low voltage terminal strip Note 120V is not being supplied to the that when W is energized the blower is delayed indoor air blower or blower motor fail 45 seconds If there is 120V to each motor tap but ure the blower does not operate replace the motor 7 1 3 ACTION 1 If there is not 120V when Y G or Defective control board W is energized replace the control 7 1 4 ACTION 1 Replace capacitor Defective run capacitor PROBLEM 8 RF STATIC DURING TIME FOR IGNITION 8 0 8 1 2 a ACTION 1 Call Technical Support Dallas AM radio interference Ignitor operation Page 53 SERVICE NOTES Page 54
48. XHAUST VENT T INTAKE VENT Side View Inches mm OPTIONAL VENT TERMINATION FOR MULTIPLE UNIT INSTALLATION OF DIRECT VENT WALL TERMINATION KIT WTK FIGURE 26 Page 26 12 305 MAX for 2 51 20 508 MAX for 3 76 unless supported n gt EXHAUST 12 305 Minimum U AIR INTAKE 8 203 AIR Minimum lt ABOVE GRADE 5 EE Side View Y Inches mm INTAKE AIR DIRECT VENT TERMINATION WALL TERMINATION KIT 22644 44J40 30628 81J20 EXTENDED VENT FOR GRADE CLEARANCE FIGURE 27 G61MP DIRECT VENT APPLICATION USING EXISTING CHIMNEY F lt 8 12 203mm 305mm 3 8 avd 203mm INTAKE PIPE SHOULDER OF FITTINGS PROVIDE SUPPORT OF PIPE ON TOP PLATE SHEET METAL TOP 722 ALTERNATE INTAKE PIPE STRAIGHT CUT OR ANGLE CUT IN DIRECTION OF ROOF SLOPE A EXHAUST VENT 1 2 13mm WEATHERPROOF INSULATION INSULATION optional Inches mm 12 305mm ABOVE AVE SNOW ACCUMULATIO 3 76 OR 2 51 PVC COVER EXHAUST VENT WITH 1 2 13 FOAM INSULATION EXHAUST AIR 12 MIN 305 Above Grade Front View SIZE TERMINATION PIPE PER TABLE 14 UNCONDITIONED ATTIC SPACE MINIM 305mm ABOVE 47 PROVIDE SUPPORT FOR EXHAUST LINES ROOF 3 8 203mm INSULATE EXTERIOR TO FORM PORTION OF CHIMNEY SIZE TERMINATION PIPE PER TABL
49. ader box are negative However the port reads less negative pressure than the port CAI amp COLD END HEADER BOX ASSEMBLY 045 amp 070 SHOWN N Install tee s in the negative line and positive line then connect hoses to manometer 9 cold end header box Prove switches FIGURE 10 4 Operate unit and observe manometer reading Read ings will change as heat exchanger warms a Take one reading immediately after start up b Take second reading after unit has reached steady state approximately 5 minutes This will be the pres sure differential The pressure differential should be greater than those listed in table 8 9 or 10 5 Remove thermostat demand and allow to cycle off 6 Remove manometer and tee s Reinstall combustion air sensing hoses to the prove switch 7 Repeat steps 1 through 6 for the other prove switch Page 14 12 Combustion Air Inducer B6 All G61MP units use a combustion air inducer to move air through the burners and heat exchanger during heating operation The blower uses PSC 120 motor The motor operates during all heating operation and is con trolled by the ignition control Blower operates continu ously while there is a call for heat The burner ignition con trol will not proceed with t
50. age 18 C Venting Practices The thickness of construction through which vent pipes may be installed is 24 610mm maximum and 3 76mm minimum If a G61MP furnace replaces a furnace which was commonly vented with another gas appliance the size of the existing vent pipe for that gas appliance must be checked Without the heat of the original furnace flue prod ucts the existing vent pipe is probably oversized for the single water heater or other appliance The vent should be checked for proper draw with the remaining appliance 1 Use recommended piping materials for exhaust pip ing 2 Secure all joints so that they are gas tight using ap proved cement Suspend piping using hangers at a minimum of every 5 feet 1 52m for schedule 40 PVC and every 3 fee 91m for ABS DWV P metal plastic DWV SPR 21 PVC or 27 SDR 26 PVC piping A spit able hanger can be falpri cated by using metal Lo plastic strapping or a large wire tie STRAPPING FIGURE 12 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 conden sate
51. ation ka 12 Min Horizontal Application Rooftop Termination Upflow and Downflow Application Side Wall Termination k 12 Min Horizontal Application Side Wall Termination FIGURE 11 Page 17 Use the following steps to correctly size vent pipe diameter 1 Determine the vent termination and its corresponding equivalent feet value according to table 11 2 Determine the number of 90 elbows required for both indoor and outdoor e g snow riser use Calculate the corresponding equivalent feet of vent pipe 3 Determine the number of 45 elbows required for both indoor and outdoor use Calculate the corresponding equivalent feet of vent pipe 4 Determine the length of straight pipe required 5 Add the total equivalent feet calculated in steps 1 through 4 and compare that length to the maximum values given in table 12 for the proposed vent pipe di ameter If the total equivalent length required exceeds the maximum equivalent length listed in the appropri ate table evaluate the next larger size pipe TABLE 12 MINIMUM VENT PIPE LENGTHS G61MP MIN EQUIV MODEL VENT LENGTH EXAMPLE 045 070 5 ft plus 2 elbows of 2 2 1 2 3 090 or 4 diameter pipe 110 5 ft plus 2 elbows of 2 1 2 3 or 4 diameter pipe 5 ft plus 2 elbows of 3 or 4 135 diameter pipe Any approved termination may be added to the minimum equivalent length listed G61MP 48C 110 and G61MP 60C 110 must ha
52. cable Remove four screws which se 35 Reinstall burner box assembly in vestibule area cure combustion air inducer to collector box Remove 36 R fi Il Out switch wi combustion air inducer assembly Remove ground gt IO OE SUM VE wire from vest panel 37 Reconnect sensor wire and reconnect 2 pin plug from 15 Remove electrical junction box from the side of the fur ignitor 38 Secure burner box assembly to vestibule panel using 16 Mark and disconnect any remaining wiring to heating OSEN Makes ipe Upin center of burner ports Reinstall gas valve manifold assembly Reconnect gas supply line to gas valve 40 Reinstall burner box cover 41 Reconnect wires to gas valve 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 39 the blower deck Spread cabinet sides slightly to allow 42 Replace the blower compartment access panel clearance for removal of heat exchanger 43 Refer to instruction on verifying gas and electrical con 19 Remove screws along vestibule sides and bottom recons when fe establishing supplies which secure vestibule panel and heat exchanger as 44 Follow lighting instructions to light and operate fur sembly to cabinet Remove two screws from blower nace for 5 minutes to ensure
53. creen must not be used in direct vent plications 1 Cement intake piping in slip connector located on the side of the burner box 2 Use a 7 sheet metal screw to secure the intake pipe to the connector if desired pilot indentation is provided the slip connector to assist in locating and starting the fas tener 3 Glue the provided 2 plug into the unused air intake con nector on the opposite side of the cabinet 4 Route piping to outside of structure Continue with instal lation following instructions given in general guide lines for piping terminations and in intake and exhaust piping ter minations for direct vent sections Refer to figure 15 for pipe sizes Page 20 TYPICAL AIR INTAKE PIPE CONNECTIONS UPFLOW OR DOWNFLOW DIRECT VENT APPLICATIONS Right Hand Exit in Upflow Application Shown i A G61MP 36B 045 G61MP 36B 070 G61MP 48C 090 G61MP 60C 090 2 1 2 3 OR 4 REDUCER 5 2 A G61MP 36B 045 G61MP 36B 070 G61MP 48C 090 G61MP 60C 090 G61MP 48C 110 G61MP 60C 110 REDUCER 2 G61MP 36B 045 G61MP 36B 070 G61MP 48C 090 G61MP 60C 090 G61MP 48C 110 G61MP 60C 110 G61MP 60C 135 Limit pipe length to 2 in G61MP 110 and 135 applications
54. d be insulated with 1 2 13mm Ar maflex or equivalent when run through unheated space Do not leave any surface area of exhaust pipe open to out side air exterior exhaust pipe should be insulated with 1 2 13mm Armaflex or equivalent In extreme cold climate areas 3 4 19mm Armaflex or equivalent may be neces sary Insulation on outside runs of exhaust pipe must be painted or wrapped to protect insulation from deterioration Exhaust pipe insulation may not be necessary in some specific applications NOTE During extremely cold temperatures below approximately 20 F 6 7 C units with long runs of vent pipe through unconditioned space even when insulated may form ice in the exhaust termination that prevents the unit from operating properly Longer run times of at least 5 minutes will alleviate most icing problems Also a heating cable may be installed on exhaust piping and termination to prevent freeze ups Heating cable installation kit is avail able from Lennox See Condensate Piping section for part numbers A IMPORTANT Do not use screens or perforated metal in exhaust terminations Doing so will cause freeze ups and may block the terminations A IMPORTANT For Canadian Installations Only In accordance to CSA International B149 installation codes the minimum allowed distance between the combustion air intake inlet and the exhaust outlet of other appliances shall not be less than 12 inches 305mm VENT TERMI
55. der cap iNLET PRESSURE TAP GAS VALVE SHOWN IN OFF POSITION FIGURE 35 Page 30 WHITE RODGERS 36E SERIES GAS VALVE 9 HIGH FIRE MANIFOLD PRESSURE ADJUSTMENT ON SIDE under cap MANIFOLD ka PRESSURE TAP ON SIDE LOW FIRE MANIFOLD PRESSURE ADJUSTMENT ON SIDE under cap GAS VALVE SHOWN IN OFF POSITION FIGURE 36 8 Honeywell VR8205 Gas Valve Turn knob on gas valve counterclockwise amp to ON Do not force White Rodgers 36E Gas Valve Switch gas valve lever to ON See figure 36 for the White Rodgers 36E valve 9 Replace the upper access panel INLET PRESSURE TAP ON SIDE 10 Turn on all electrical power to to the unit 11 Set the thermostat to desired setting NOTE When unit is initially started steps 1 through 11 may need to be repeated to purge air from gas line 12 If the appliance will not operate follow the instructions Turning Off Gas to Unit and call your service techni cian or gas supplier Turning Off Gas to Unit 1 Setthe 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 49 to OFF Do not force White Rodgers 36E Gas Valve Switch gas valve le ver to OFF 5 Replace the upper access panel C Safety or Emergency Shutdown Turn off unit power
56. dges 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 O Promptly apply solvent cement to end of pipe and in side socket surface of fitting Cement should be ap plied lightly but uniformly to inside of socket Take care to keep excess cement out of socket Apply sec ond coat to end of pipe NOTE Time is critical at this stage Do not allow prim er to dry before applying cement N 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 as sembly but not after pipe is fully inserted to distribute cement evenly NOTE Assembly should be completed within 20 sec onds 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 properly made joint will show bead around its entire perimeter Any gaps may indi cate a defective assembly due to insufficient solvent 9 Handle joints carefully until completely set P
57. e burner input and is threaded into the burner manifold All G61MP natural gas units are fitted with 089 sized orifices See SPECIFICATIONS tables for LP kits and high altitude A flame retention ring in the end of each burner maintains cor rect flame length and shape and keeps the flame from lifting off the burner head In addition the burner entrance to each clam shell is fitted with a corbel cup orifice used to direct the flow of combustion products SureLight Ignitor Location MEASUREMENT IS TO 1 0 5 8 OF RETENTION RING IGNITOR BURNERS FRONT VIEW BURNERS TOP VIEW FIGURE 7 Page 12 6 Clamshell Heat Exchanger G61MP units use an aluminized steel primary and stain less steel secondary heat exchanger assembly Heat is transferred to the air stream from all surfaces of the heat exchanger The shape of the heat exchanger ensures maximum efficiency The combustion air inducer pulls fresh air through the air intake box This air is mixed with gas in the burner venturi and at the corbel orifices The gas air mixture is then burned at the entrance of each clamshell Combustion gases are then pulled through the primary and secondary heat exchangers and exhausted out the exhaust vent pipe 7 Flame Rollout Switches 547 Flame rollout switch 847 is a high temperature limit located on each side of the burner box Each furnace is equipped with two identical switches
58. e unused air intake con nector on the opposite side of the cabinet Testing for Proper Venting and Sufficient Combustion Air Non Direct Vent Applications Only WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monox ide poisoning or death The following steps shall be followed for each ap pliance connected to the venting system being placed into operation while all other appliances con nected to the venting system are not in operation After the G61MP gas furnace has been started the follow ing test should be conducted to ensure proper venting and sufficient combustion air has been provided to the G61MP as well as to other gas fired appliances which are separate ly vented The test should be conducted while all ap pliances both in operation and those not in operation are connected to the venting system being tested If the vent ing 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 re striction leakage corrosion or other deficiencies which could cause an unsafe condition Page 22 3 T
59. e within 3 minutes or unit goes into 1 hour Watchguard Low prove switch open OR Blocked inlet exhaust vent OR Low prove switch closed prior to activation of combustion air inducer OFF SLOW FLASH High prove switch open OR Blocked inlet exhaust vent OR High prove switch closed prior to activation of combustion air inducer FAST FLASH Watchguard burners failed to ignite OR limit open more than 3 minutes OR lost flame sense 5 times in one heating cycle OR pressure switch opened 5 times in one heating cycle SLOW FLASH Flame sensed without gas valve energized ON ON ON OFF OFF ON FAST FLASH SLOW FLASH Main power polarity reversed Switch line and neutral SLOW FLASH FAST FLASH Low flame signal Measures below 0 23 microAmps Replace flame sense rod The following conditions are sensed during the ignitor warm up period only 1 Improper main ground 2 Broken ignitor OR Open ignitor circuit 3 Line voltage below 75 volts If voltage lower than 75 volts prior to ignitor warm up control will signal waiting on call from thermostat and will not respond ALTERNATING SLOW FLASH ALTERNATING SLOW FLASH Circuit board failure or control wired incorrectly Check 24 and 115 volts to board ALTERNATING FAST FLASH ALTERNATING FAST FLASH NOTE Slow flash rate equals 1 Hz one flash per second Fast flash rate equals 3 Hz three flashes per second Low flame sense current 0 17 0 22 microAmps B Blo
60. econd stage heat the unit will fire on first stage heat and switch to second stage heat after 30 seconds of operation See Sequence of Operation flow charts in the back of this manual for more detail Dip Switch Settings Dip Switches 1 and 2 Heating Fan off Delay The fan on time of 45 seconds is not adjustable Fan off time time that the blower operates after the heat demand has been satis fied can be adjusted by flipping the dip switches 1 and 2 located on the SureLight integrated control The unit is shipped with a factory fan off setting of 90 seconds Fan off time will affect comfort and is adjustable to satisfy individual applications For customized comfort monitor the supply air temperature once the heat demand is satisfied Note the supply air temperature at the instant the blower is de ener gized Adjust the fan off delay to achieve a supply air tem perature between 90 110 at the instant the blower is de energized Longer delay times allow for lower air tempera ture shorter delay times allow for higher air temperature See table 1 for dip switch settings Page 9 TABLE 1 Heating Fan Off Delay er 9 Switch 3 Second Stage Delay Used with Single Stage Thermostat Only This switch is used to determine the second stage on delay when single stage thermostat is being used The switch is factory set in the ON position which provides 10 minute delay before second stage
61. ensate pump must be used Con densate drain line should be routed within the condi tioned space to avoid freezing of condensate and blockage of drain line If this is not possible heat cable kit may be used on the condensate trap and line Heating cable kit is available from Lennox in various lengths 6 ft 1 8m kit no 18K48 24 ft 7 3m kit no 18K49 50 ft 15 2m kit no 18K50 CAUTION Do not use copper tubing or existing copper condensate lines for drain line Page 29 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 O RINGS DO NOT use power driver Hand tighten using screw driver NIPPLE COUPLING CLEAN OUT ACCESS both sides CONDENSATE TRAP FIGURE 34 lil START UP A Preliminary and Seasonal Checks 1 Inspect electrical wiring both field and factory installed for loose connections Tighten as required 2 Check voltage at disconnect switch Voltage must be within range listed on the nameplate If not consult the power company and have voltage condition corrected before starting unit B Heating Start Up FOR YOUR SAFETY READ BEFORE OPERATING A WARNING Shock and burn hazard G61MP units are equipped with a hot surface igni tion system Do not attempt to ligh
62. ent Pipe Length Equivalency feet Outdoor Outdoor 5 2 Wall VENT Exhaust Exhaust 1 1 2 2 Con 3 Con 2wa Kit with 2 Wall UNIT PIPE Accelerator Accelerator Concen centric centric Plate Kit Plate Kit Vent Ex Rina Kit MODEL DIA Dia X Dia X tric Kit Kit Kit teni 9 in Length Length A g 44J40 1 1 2 X 12 2 X 12 71M80 60M29 60L46 22G44 81J20 30G28 15F74 Not Not Not Allowed Allowed Allowed 2 1 2 Not Not Not Allowed Allowed Allowed 36B 045 3 7 Not Not Not 7 7 7 7 Allowed Allowed Allowed Not Not Not Allowed Allowed Allowed Not Not Not Allowed Allowed Allowed 2 1 2 Not Not Not 36B 070 Allowed Allowed Allowed Not Not Not Allowed Allowed Allowed Not Not Not Allowed Allowed Allowed Not Not Not Not Allowed Allowed Allowed Allowed 2 1 2 Not 2 Not 6 6 Not 2 Not 2 60C 090 Allowed Allowed Allowed Allowed 3 Not 2 Not 6 6 Not 2 Not 2 Allowed Allowed Allowed Allowed 4 Not 4 Not 12 12 Not 4 Not 4 Allowed Allowed Allowed Allowed 2 4 2 Not 2 Not 6 6 Not 2 Not 2 Allowed Allowed Allowed Allowed 60C 110 3 Not 2 Not 6 6 Not 2 Not 2 Allowed Allowed Allowed Allowed 4 Not 4 Not 12 12 Not 4 Not 4 Allowed Allowed Allowed Allowed Not Not Not Not Not 60D 135 Allowed Allowed Allowed Allowed Allowed Ge benet hel Ler Allowed Allowed Allowed Allowed Allowed Requires field provided and installed 1 1 2 exhaust
63. ent overheating heat exchanger e Attempts to clock gas meter during this procedure will be inaccurate Measure gas flow rate only during nor mal unit operation 7 When test is complete remove obstruction from hose and return hose to gas valve barbed fitting F Proper Gas Flow Approximate Furnace should operate at least 5 minutes before check ing gas flow Determine time in seconds for two revolu tions of gas through the meter Two revolutions assures a more accurate time Divide by two and compare to time in table 16 below If manifold pressure matches table 15 and rate is incorrect check gas orifices for proper size and restriction NOTE To obtain accurate reading shut off all other gas appliances connected to meter TABLE 16 GAS METER CLOCKING CHART Seconds for One Revolution Natural 1000 btu cu ft A IMPORTANT For safety shut unit off and remove manometer as soon as an accurate reading has been obtained Take care to replace pressure tap plug LP 2500 btu cu ft G Proper Combustion Furnace should operate minimum 15 minutes with correct manifold pressure and gas flow rate before checking com bustion See sections E and F Take combustion sample beyond the flue outlet and compare to the tables below The maximum carbon monoxide reading should not ex ceed 100 ppm Page 32 TABLE 17 High Heat G61MP 36B 045 G61MP 36B 070 G61MP 48C 090 G61MP 60C 090 G61MP 48C 110 G61MP 60C 110 G61MP 60D 135
64. ess panel Electrical components are in the control box figure 2 found in the blower section G61MP units are factory equipped with a bottom return air panel in place The panel is designed to be field removed as required for bottom air return Markings are provided for side return air and may be cut out in the field ELECTROSTATIC DISCHARGE ESD Precautions and Procedures CAUTION Electrostatic discharge can affect electronic components Take precautions during furnace installation and service to protect the furnace s electronic controls Precautions will help to avoid control exposure to electrostatic dis charge by putting the furnace the control and the technician at the same electrostatic poten tial Neutralize electrostatic charge by touching hand and all tools on an unpainted unit surface such as the gas valve or blower deck before per forming any service procedure A Control Box 1 Control Transformer T1 A transformer located in the control box provides power to the low voltage section of the unit Transformers on all models rated 40VA with 120V primary 24V sec ondary 2 Door Interlock Switch 551 door interlock switch rated 14A at 125VAC is wired in se ries with line voltage When the blower door is removed the unit will shut down CONTROL BOX G61MP CIRCUIT BREAKER DOOR INTERLOCK t SURELIGHT V FIGURE 2 3 Circuit Breaker CB8 A 24V ci
65. et elbow provided 3 diameter reducing elbow provided Limit pipe length to 2 2 1 2 B k REDUCER 3 OR use only if 4 4 pipe is required REDUCER 3 mr f 7 G61MP 135 with 3 OR 4 vent pipe gne G61MP 110 with 2 1 2 3 OR 4 vent pipe FIGURE 13 Page 19 TYPICAL EXHAUST PIPE CONNECTIONS HORIZONTAL DIRECT OR NON DIRECT VENT APPLICATIONS Horizontal Right Hand Air Discharge Application Shown Limit pipe length to 2 in G61MPV 110 and 135 applications 2 1 2 G61MP 36B 045 3 OR G61MP 36B 070 4 G61MP 48C 090 G61MP 60C 090 G61MP 48C 110 REDUCER G61MP 60C 110 G61MP 60C 135 2 2 2 2 522 G61MP 36B 045 G61MP 36B 070 G61MP 48C 090 G61MP 60C 090 DO NOT transition from smaller to larger pipe T size in horizontal runs 2 FIGURE 14 A IMPORTANT Exhaust piping and condensate trap must be installed on the same side of the unit 2 All horizontal runs of exhaust pipe must slope back to ward unit minimum of 1 4 6mm drop for each 12 305mm of horizontal run is mandatory for drainage Horizontal runs of exhaust piping must be supported ev ery 5 feet 1 52m using hangers NOTE Exhaust piping should be checked carefully to make sure there are no sags or low spots 3 On the opposite side of t
66. g Kit 2 inch 51 mm 15F74 15F74 9 45F74 NOTE Filters and provisions for mounting are not furnished and must be field provided 1 Annual Fuel Utilization Efficiency based on DOE test procedures and according to FTC labeling regulations Isolated combustion system rating for non weatherized furnaces Cleanable polyurethane frame type filter ROAN information Required for proper operation at altitudes over 4500 ft 1370 m See Installation Instructions for specific venting information Kits contain enough parts for two non direct vent installations Non direct vent applications only Determine from venting tables exhaust pipe size termination kit required Required for proper operation at altitudes from 7501 to 10 000 ft 2286 to 3048 m Page 3 Not for use with RAB Return Air Base or with 60 and 60D size units with air flow requirements of 1800 850 L s or greater See Blower Performance tables for additional G61MP 36B 045 PERFORMANCE Less Filter BLOWER DATA External Static Air Volume Watts at Different Blower Speeds Pressure High Medium High Medium Low Low in w g Pa cfm L s Watts cfm L s Watts cfm L s Watts cfm L s Watts 0 00 25 1555 735 630 1410 665 585 1190 560 520 1030 485 435 0 10 25 1515 715 605 1385 655 555 1190 560 485 1020 480 415 0 20 50 1470 695 580 1345 635 520 1170 550 455 1010 475 400 0 30 75
67. he cabinet glue the provided 2 vent plug into the unused flue collar 4 Route piping to outside of structure Continue with installation following instructions given in piping ter mination section CAUTION Do not discharge exhaust into an existing stack or stack that also serves another gas appliance If verti cal discharge through an existing unused stack is re quired 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 pres sure and must be completely sealed to prevent leak age of combustion products into the living space Intake Piping The G61MP furnace may be installed in either direct vent ornon direct vent applications In non direct vent applica tions when intake air will be drawn into the furnace from the surrounding space the indoor air quality must be consid ered and guidelines listed in Combustion Dilution and Ven tilation Air section must be followed The G61MP unit is designed for either left side or right side air intake connections in either upflow or downflow applica tions In horizontal applications air intake must be brought in through the top Intake air piping is independent of ex haust piping Follow the next four steps when installing the unit in direct vent applications where combustion air is taken from out doors and flue gases are discharged outdoors The pro vided air intake s
68. he ignition sequence until combus tion air inducer operation is sensed by the proving switches The CAI is installed on the cold end header box The cold end header box is single piece made of hard plastic The box has an internal channel where the combustion air inducer creates negative pressure at unit start up The channel contains an orifice used to regulate flow created by the CAI The box has pressure taps for the CAI prove switch hoses The prove switches measure the pressures across the CAI orifice or difference in the channel and the box window is provided on the bottom right hand side of the box to indicate orifice size See figure 10 See table 7 for orifice size per unit If replacement is necessary the gaskets used to seal the box to the vestbule panel and the CAI to the box must also be replaced TABLE 7 G61MP Unit C A I Orifice Size 090 1 063 Page 15 TABLE 8 0 to 4500 Set Point Set Point Second Stage First Stage 0 95 0 95 s ov 63 TABLE 9 4501 to 7500 Set Point Set Point SOMRE Second Stage First Stage 0 95 0 95 20 ws om Unit may require conversion kit at this altitude See High Altitude table 0 50 TABLE 10 7501 to 10 000 Unit may require conversion kit at this altitude See High Altitude table II PLACEMENT AND INSTALLATION TABLE 11 OUTDOOR TERMINATION KITS AND CORRESPONDING EQUIVALENCIES V
69. heat demand initiated 30 second sec ond stage recognition period begins 7 The combustion air inducer ramps up to high heat speed 8 5102 high heat prove switch closes and the gas valve energizes second stage heat 9 indoor blower energizes on high heat speed Page 39 Single Stage Thermostat Two Stage Heat Jumper E20 set at SINGLE 1 SureLight control energizes combustion air inducer B6 on low heat speed Combustion air inducer runs until 128 low heat prove switch contacts close switch must close within 2 1 2 minutes or control goes into Watchguard Pressure Switch mode High heat prove switch 5102 may also close A 15 second pre purge follows once 5128 closes 2 SureLight control begins 20 second ignitor warm up period 3 Gas valve opens on first stage for a 4 second trial for ignition Ignitor stays energized during the trial or until flame sensed 4 Flame is sensed gas valve remains on first stage heat ignitor de energizes 5 After 45 second delay indoor blower B3 is energized on low heat speed 6 A10 minute factory set or 15 minute field set second stage heat delay period begins 7 After the delay the combustion air inducer ramps up to high heat speed 8 5102 high heat prove switch closes and the gas valve energizes second stage heat 9 indoor blower energizes on high heat speed HEATING SEQUENCE OF OPERATION NORMAL AND ABNORMAL HEATING MODE GAS VALVE OFF COMBUSTION AIR INDUCER
70. heat is initiated If the switch is toggled to the OFF position it will provide 15 minute delay before second stage heat is initiated This switch is only activated when the thermo stat selector jumper is positioned for SINGLE stage ther mostat use Switch 4 Cooling Fan off Delay The fan on delay time of 2 seconds is not adjustable Fan off time time that the blower operates after the cool demand has been satisfied can be adjusted by flipping dip switch 4 The unit is shipped with a factory fan off setting of 45 seconds Fan off time will affect comfort and is adjustable to satisfy individual ap plications See table 2 for cool fan off time settings TABLE 2 Cooling Fan Off Delay Delay Seconds Switch 4 Diagnostic LED s DS1 and DS2 Two diagnostic LED S are located on the two stage inte grated control board See figure 4 These light flashes cor respond with the codes detailed in table 6 Factory Installed Jumper Y1 to Y2 A factory installed jumper from Y1 to Y2 terminals on the integrated control board terminal strip must be clipped for two stage cooling TWO STAGE INTEGRATED CONTROL BOARD F NEUTRAL HOT cc gt LEDs DIP SWITCHES 1 4 WHITE RODGERS 4 W915 FACTORY INSTALLED JUMPER Em MUST CLIP FOR 2 STAGE COOL LENN
71. ine main Power LED 1 Off 1 1 2 ACTION 1 Check for correct wiring of 120V to 5 Miswiring of furnace or improper con Power make up box and transformer LED 2 Off ACTION 2 Check 24V wiring to control board 1 1 3 ACTION 1 Replace fuse Blown fuse ACTION 2 If fuse still blows check for short ACTION 1 Check that door switch is activated when door is closed 1 1 4 ACTION 2 Check wire connections to switch re 1 i place loose connectors Door interlock switch failure ACTION 3 Check continuity of switch in closed position Replace if defective 1 1 5 ACTION 1 Check that transformer output is Transformer Failure 24V Replace if defective 1 1 6 ACTION 1 If all the above items have been Failed control board checked replace Board 1 2 ACTION 1 Manually reset the roll out switch 1 2 1 by pushing the top button Diagnostic lights flash the roll out Roll out switch open ACTION 2 Determine the cause of the roll out code switch activation before leaving furnace 1 2 2 ACTION 1 Check continuity across roll out switch Replace roll out switch if switch is reset Roll out switch failure but does not have continuity LED 1 On LED 2 Slow Flash Miswiring or improper connections at ACTION 1 Check wiring connections to switch roll out switch ACTION 1 Check 9 pin connector for proper 1 2 4 connection to control board 9 pin connector failure ACTION 2 Check conti
72. it in Downflow Applications Shown 6 in Max N INTAKE DEBRIS SCREEN Provided Downflow Evaporator O O 2 SWEEP ELL INTAKE DEBRIS SCREEN Provided 18 in 2 SWEEP ELL Downflow Additive Flloor Base Coil NOTE Debris screen and sweep ell may be rotated so that screen may be positioned to face forward backward or to the side FIGURE 18 1 Use field provided materials and the factory provided air intake screen to route the intake piping as shown in figures 17 and 18 Maintain a minimum clearance of 3 76mm around the air intake opening The air intake opening with the protective screen should always be directed either downward or straight out Use 2 pipe and fittings only and make sure that the air intake does not extend more than 6 beyond the G61MP cabinet The air intake connector must not be located near the floor To avoid this complication in downflow applications which do not include a downflow evaporator coil the intake air routing should be modi fied as shown in figure 18 2 Use a 7 sheet metal screw to secure the intake pipe to the connector if desired A pilot indentation is provided in the slip connector to assist in locating and starting the fas tener Glue the provided 2 plug into th
73. itch is closed by passed Like wise the control will not begin the second stage heating cycle if the second stage prove switch is closed and will al low first stage heat only However if the second stage prove switch closes during the first stage pre purge the control will respond to second stage heat Once the first stage prove switch is determined to be open the combustion air inducer is energized on low first stage heat speed When the differential in the prove switch is great enough the prove switch closes and a 15 second pre purge begins If the switch is not proven within 2 1 2 minutes the control goes into Watchguard Pressure Switch mode for a 5 min ute re set period After the 15 second pre purge period the SureLight ignitor warms up for 20 seconds after which the gas valve opens for a 4 second trial for ignition The ignitor energizes during the trial until flame is sensed If ignition is not proved during the 4 second period the control will try four more times with an inter purge and warm up time between trials of 35 sec Page 8 onds After a total of five trials for ignition including the ini tial trial the control goes into Watchguard Flame Failure mode After a 60 minute reset period the control will begin the ignition sequence again The SureLight control board has an added feature that pro longs the life of the ignitor After a successful ignition the SureLight control utilizes less power to energize the ign
74. itor on successive calls for heat The control continues to ramp down the voltage to the ignitor until it finds the lowest amount of power that will provide successful ignition This amount of power is used for 255 cycles On the 256th call for heat the control will again ramp down until the lowest power is determined and the cycle begins again Two Stage Operation Thermostat Selection Jumper The control can be utilized in two modes SINGLE STAGE thermostat or TWO STAGE thermostat The thermostat selection jumper E20 located just below dip switches 1 through 4 figure 4 must be positioned for the particular application The jumper is factory set on TWO for use with a two stage thermostat with two stage heat Re posi tion jumper to SINGLE for use with single stage thermo stat with two stage heat While in the single stage thermostat mode single jumper setting the burners will always fire on first stage heat The combustion air inducer will operate on low speed and in door blower will operate on low heat speed After a 10 min ute recognition period the unit will switch to second stage heat While in the two stage thermostat mode two jumper setting the burners will fire on first stage heat The com bustion air inducer will operate on low speed and indoor blower will operate on low heat speed The unit will switch to second stage heat on call from the indoor thermostat If there is a simultaneous call for first and s
75. ke Pipe PVC in 2 Exhaust Pipe PVC Condensate Drain Trap PVC pipe i d with field supplied PVC coupling o d hose with hose clamp i d x o d Gas pipe size IPS Wheel nominal diameter x width in mm Motor output hp W Tons kW of add on cooling Low Fire Indoor Blower Shipping Data Ibs kg 1 package SPECIFICATIONS G61MP 48C 110 110 000 32 2 104 000 30 5 45 75 25 42 75 000 22 0 72 000 21 1 30 60 18 36 94 1 88 4 0 5 2 2 1 2 3 4 1 1 4 x 1 1 2 10 x 10 254 x 254 1 2 373 3 4 10 5 14 0 178 81 G61MP 60C 110 110 000 32 2 104 000 30 5 35 65 21 39 75 000 22 0 72 000 21 1 25 55 14 31 94 196 87 096 0 5 2 2 1 2 3 4 1 1 4 x 1 1 2 11 1 2 x 10 292 x 229 1 746 4 5 14 0 17 5 186 84 G61MP 60D 135 132 000 38 7 124 000 36 3 40 70 24 42 90 000 26 4 86 000 25 2 30 60 18 36 94 196 87 7 0 5 3 3 1 2 3 4 1 1 4 x 1 1 2 11 1 2 x 10 292 x 229 1 746 4 5 14 0 17 5 206 93 Electrical characteristics OPTIONAL ACCESSORIES MUST BE ORDER 3 4 Air Filter and Rack Kit Horizontal end Size of filter Side Retum Condensate Drain Heat 6 ft 1 8 m Cable 24 ft 7 3 m 50 ft 15 2 m Heat Cable Tape Fiberglass 1 2 in 38 mm x 66 ft 20 m Aluminum foil 2 in 25 mm x 60 ft 18 m Catalog Number Shipping Weight Dimensions H x W x D in mm EZ Filter
76. mostat sub base fan switch With fan switch in ON position blower operates continuously With fan switch in AUTO position blower cycles with demand or runs continuously while heating or cooling circuit cycles 3 Depending on the type of indoor thermostat blower and entire unit will be off when the system switch is in OFF position B Temperature Rise Temperature rise for G61MP units depends on unit input blower speed blower horsepower and static pressure as marked on the unit rating plate The blower speed must be set for unit operation within the range of TEMP RISE F listed on the unit rating plate To Measure Temperature Rise 1 Place plenum thermometers in the supply and return air plenums Locate supply air thermometer in the first hori zontal run of the plenum where it will not pick up radiant heat from the heat exchanger 2 Setthermostat to highest setting 3 After plenum thermometers have reached their high est and steadiest readings subtract the two readings The difference should be in the range listed on the unit rating plate If the temperature is too low decrease blower speed If temperature is too high first check the firing rate Provided the firing rate is acceptable in crease blower speed to reduce temperature To change blower speed taps see the Blower Speed Taps section in this manual C External Static Pressure 1 locations shown in figure 40 2 Punch a 1 4 diameter hole STATI
77. n temperature on the CAI reaches 142 10 Gas Valve GV1 The G61MP uses a two stage gas valve manufactured by Honeywell figure 35 or White Rodgers figure 36 The valves are internally redundant to assure safety shut off If the gas valve must be replaced the same type valve must be used Page 13 24VAC terminals and gas control knob or switch are located on the valve All terminals on the gas valve are connected to wires from the electronic ignition control 24V applied to the ter minals energizes the valve Inlet and outlet pressure taps are located on the valve regu lator adjustment screw is located on the valve LPG change over kit s are available from Lennox Kits include burner orifices and gas valve regulator conversion kit The burner box is sealed and operates under negative pressure pressure hose is connected from the burner box to the gas valve The gas valve senses the pressure in the burner box and changes gas valve outlet manifold pressure based on changes in the burner box pressure The intent is to compensate for different vent configura tions which can greatly affect the rate of the unit PRIMARY LIMIT LOCATION f III limit shield 090 110 and 4 135 Fa limit faces shield FIGURE 8 11 Combustion Air Inducer Prove Switch 518 All G61MP units are equipped with combustion air prove switches located on the combustion air inducer housing G61MP 045 and 070 figure 10
78. nd supply Line voltage is below 75V correct voltage to the control 1 5 4 ACTION 1 Check for correct wiring and loose 1427 connections the ignitor circuit Check mult plug Open ignitor circuit connections for correct installation 1 5 5 ACTION 1 Unplug ignitor and read resistance across ignitor If resistance does not read be Broken or failed ignitor tween 10 9 and 19 7 ohms replace the ignitor PROBLEM 2 UNIT FAILS TO FIRE IN THE HEATING MODE COMBUSTION AIR BLOWER DOES NOT ENERGIZE Possible Cause Corrective Action Comments 2 1 ACTION 1 Check continuity across switch es Unit operates with cooling or contin 2 1 1 Switches reset automatically upon cool down uous fan demand ACTION 2 Check for restrictions on blower inlet Combustion air inducer will not start Primary secondary or backup secon air including filter and outlet air Determine da if equipped limit open cause for limit activation before placing unit back with a Heating demand DUE eaulpped P in operation OH Diagnostic lights flash the limit failure mode 2 1 2 ACTION 1 Check for correct wiring and loose Miswiring of furnace or improper connections Correct wiring and or replace any LED 1 Slow Flash connections at limit switch es loose connections LED 2 On 2 2 Unit operates with a cooling and con 2 2 1 nous ia demand 9 Miswiri ff ACTION 1 Check for correct wiring and loose A E
79. ntric termination kit terminates with 2 5 8 ID pipe exhaust on another side of the house or structure 2 Intake and exhaust pipes should be placed as close Inches mm 3 76 MAX SIZE TERMINATION together as possible at termination end refer to il PIPE PER TABLE 14 lustrations Maximum separation is 3 76mm on roof re 4 UNCONDITIONED terminations and 6 152mm on side wall termina 20 ATTIC SPACE tions Y 1 2 13 FOAM 3 If necessary install a field provided reducer to adapt INSULATION IN VEA 12 305 UNCONDITIONED larger vent pipe size to termination pipe size AVERAGE SNOW SPACE 4 On roof terminations the intake piping should termi ACCUMULATION S nate straight down using two 90 elbows See figure 20 bal 3 76 OR 5 Exhaust piping must terminate straight out or up as 2 51 PVC shown In rooftop applications a reducer may be re quired on the exhaust piping at the point where it exits PROVIDE SUPPORT f FOR INTAKE AND the structure to improve the velocity of exhaust away EXHAUST LINES from the intake piping See table 14 NOTE Care must be taken to avoid recirculation of DIRECT VENT ROOF TERMINATION KIT exhaust back into intake pipe 15F75 or 44J41 6 On field supplied terminations for side wall exits FIGURE 20 haust piping should extend minimum of 12 inches 305mm beyond the outside wall Intake piping 12 305 MAX should be as short a
80. nuity of the multi plug pin 1 3 On initial power up the comb air in ducer dees not gnerglze ACTION 1 Check the 120V has li d neutral g ecl e as line and neutra Diagnostic lights flash the reverse 1 3 1 correctly input into control polarity code 120V main power polarity reversed ACTION 2 Reverse the line and neutral at the p P y 120V field connection LED 1 Fast Flash LED 2 Slow Flash 1 4 On initial power up the combustion 1 4 1 ACTION 1 Check for 120V to combustion air air inducer does not energize Open combustion air inducer motor inducer If no power check wire and connec u tions Diagnostic lights flash normal power circuit 242 on operation 1 4 2 ACTION 1 If power is present at blower replace LED 1 Slow Flash Failed combustion air inducer motor 019 LED 2 Slow Flash Page 48 PROBLEM 1 UNIT FAILS TO OPERATE IN THE COOLING HEATING OR CONTINUOUS FAN MODE 1 5 ACTION 1 Check that the unit is properly 1 5 1 ground Improper ground to the unit ACTION 2 Install proper main ground to the unit Diagnostic lights flash the improper main ground 1 5 2 ACTION 1 Check 6 pin connector for proper installation Correctly insert connector into con LED 1 Alternating Fast Flash 6 Pin connector is improperly LED 2 Alternating Fast Flash attached to the circuit board 1 5 3 ACTION 1 Check that the line voltage is above 75V Determine cause of voltage drop a
81. o 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 The venting system should be re sized to approach the minimum size as determined by using the ap propriate tables in appendix G in the current standards of the National Fuel Gas Code ANSI Z223 1 NPFA 54 in the U S A and the appropriate Natural Gas and Propane appliances venting sizing tables in the cur rent standard of the CSA B149 Natural Gas and Pro pane Installation Codes in Canada 9 After determining that each appliance remaining connected to the common venting system properly vents when tes
82. onnections at prove switch ACTION 1 If all the above modes of failure have 3 1 8 been checked the prove switch may have failed Prove switch failure Replace prove switch and determine if unit will operate Page 50 PROBLEM 4 UNIT FAILS TO FIRE IN THE HEATING MODE COMBUSTION AIR BLOWER ENERGIZES IGNITOR IS ENERGIZED Possible Cause Corrective Action Comments 4 1 Unit operates with cooling and continuous fan demand Combustion air inducer energizes with Heating demand Ignitor is energized but unit fails to light LED 1 Alternating Slow Flash LED 2 Alternating Slow Flash 4 1 1 Check that gas is being supplied to the unit 4 1 2 Miswiring of gas valve or loose connections at multi pin control amp plugs or valve 4 1 3 Defective gas valve or ignition control ACTION 1 Check line pressure at the gas valve Pressure should not exceed 13 WC for both nat ural and propane Line pressure should read a minimum 4 5 WC for natural and 8 0 WC for pro pane ACTION 1 Check for correct wiring and loose connections Correct wiring and or replace any loose connections ACTION 1 Check that 24V is supplied to the gas valve approximately 35 seconds after heat de mand is initiated ACTION 2 Replace the valve if 24V is supplied but valve does not open ACTION 3 Replace the control board if 24V is not supplied to valve PROBLEM 5 BURNERS LIGHT WITH A HEATING DEMAND BUT UNIT SHUTS DOWN
83. ore than 0 5psig 14 W C See figure 37 GAS PIPING TEST PROCEDURE MANUAL MAIN SHUT OFF VALVE rn uu GAS VALVE When checking piping connections for gas leaks use pre ferred means Kitchen detergents can cause harmful corro sion on various metals used in gas piping Use of a specialty Gas Leak Detector is strongly recommended It is available through Lennox under part number 31B2001 See Corp 8411 110 for further details Do not use matches candles flame or any other source of ignition to check for gas leaks D Testing Gas Supply Pressure When testing supply gas pressure connect test gauge to inlet pressure tap on the gas valve See figures and 35 and 36 Check gas line pressure with unit firing at maximum rate Low pressure may result in erratic operation or under fire High pressure can result in permanent damage to gas valve or overfire See table 15 for operating pressure at unit gas connection line On multiple unit installations each unit should be checked separately with and without units operating Supply pres sure must fall within range listed in table 15 TABLE 15 G61MP Units LP Line Pressure WC 4 5 10 5 11 0 13 0 E Check Manifold Pressure After line pressure has been checked and adjusted check manifold pressure Move pressure gauge to outlet pres sure tap located on unit
84. ot close due to correctly routed Correctly route pressure switch continuous fan demand incorrect routing of the pressure lines Combustion air inducer energizes switch lines with a heating demand Diagnostic lights flash th 3 152 the pressure ACTION 1 Remove any obstructions from the switch failure code 2 5 minutes after Prove switch does not close due to the pressure lines and or taps heating demand obstructions in the pressure lines 3 1 3 ACTION 1 Check prove switch lines for leaks LED 1 Off Prove switch lines damaged Replace ariy broken lines LED 2 Slow Flash 3 1 4 ACTION 1 Check prove switch lines for conden Condensate in prove switch line sate Remove condensate from lines ACTION 1 Check the differential pressure 3 1 5 across the prove switch This pressure should exceed the set point listed on the switch ACTION 2 Check for restricted inlet vent Re move all blockage ACTION 3 Check for proper vent sizing and run length Prove switch does not close due toa low differential pressure across the prove switch 3 1 6 A ACTION 1 Check that the proper prove switch Wrong prove switch installed in the is installed in the unit Replace prove switch if unit or prove switch is out of necessary calibration 3 1 7 ACTION 1 Check for correct wiring and loose Miswiring of furnace or improper connections Correct wiring and or replace any loose connections c
85. ow 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 suffi cient water to ensure proper condensate drain opera tion AWARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or death Gas Valve Operation Figures 35 and 36 1 STOP Read the safety information at the beginning of this section 2 Setthe 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 P to OFF Do not force See figure 35 White Rodgers 36E Gas Valve Switch gas valve le ver to OFF See figure 36 for the White Rodgers 36E valve 7 Wait five minutes to clear out any gas If you then smell gas STOP Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instruc tions If you do not smell gas go to next step HONEYWELL VR8205 Series Gas Valve REFERENCE TO BURNER BOX hose barb in place of cap MANIFOLD PRESSURE HIGH FIRE ADJUSTMENT SCREW a TAP under cap N IOW FIRE ADJUSTMENT SCREW un
86. possibility of water droplets being re leased from the exhaust termination The minimum ex haust vent length is 15 ft Shorter exhaust vent lengths may result in the discharge of water droplets from the exhaust termination in spite of the 12 inch vertical offset Each 90 elbow including those provided with the furnace of any diameter is equivalent to 5 feet 1 52m of vent pipe of the same diameter Two 45 elbows are equivalent to one 90 elbow of the same diameter One 45 elbow is equal to 2 5 feet 76m of vent pipe of the same diameter In some applications which permit the use of several differ ent sizes of vent pipe combination vent pipe may be used Contact the Application Department for assistance in sizing vent pipe in these applications NOTE The flue collar on all models is sized to date 2 Schedule 40 flue pipe When vent pipe which is larger than 2 must be used in an upflow application a 2 elbow must be applied at the flue collar in order to proper ly transition to the larger diameter flue pipe This elbow must be added to the elbow count used to determine ac ceptable vent lengths Assign an equivalent feet value to this elbow according to the larger size pipe being used Contact the Application Department for more information concerning sizing of vent systems which include multiple pipe sizes Exhaust Pipe Offset lat 12 Min gt l Upflow and Downflow Application Rooftop Termin
87. rcuit breaker is also located in the control box The switch provides overcurrent protection to the trans former T1 The breaker is rated 3A at 32V If the current exceeds this limit the breaker will trip and all unit opera tion will shutdown The breaker can be manually reset by pressing the button on the face See figure 3 CIRCUIT BREAKER ee PRESS TO RESET kK 2 FIGURE 3 A WARNING Shock hazard Disconnect power before servicing Integrated Control Board is not field repairable If control is inoperable simply replace entire control Can cause injury or death Unsafe operation will result if repair is attempted 4 Integrated Control Board A92 All G61MP units are equipped with the Lennox Two Stage Integrated control board The system consists of a igni tion control board figure 4 with control terminal designa tions in tables 3 4 and 5 and ignitor figure 7 The board and ignitor work in combination to ensure furnace ignition and ignitor durability The board controls all major furnace operations The board features two LED lights DS1 and DS2 for troubleshooting The board also has two accesso ry terminals rated at 1 one amp See table 6 for trouble shooting diagnostic codes Electronic Ignition At the beginning of the heat cycle SureLight control moni tors the first stage and second stage combustion air induc er prove switch The control will not begin the heating cycle if the first stage prove sw
88. s possible See figure 21 112 13 ARMAFLEX unless supported 7 On field supplied terminations a minimum separation NGENDITONED SPACE 1 2 13 distance between the end of the exhaust pipe and the fe end of the intake pipe is 8 inches 203mm 8 If intake and exhaust piping must be run up a side wall PROVIBED 10 E ES SIZE to position above snow accumulation or other obstruc tions piping must be supported every 3 ft 9m as shown in figure 12 Refer to figure 24 for proper piping method In addition WTK wall termination kit must be extended for use in this application See figure 27 When exhaust and intake piping must be run up an outside wall the exhaust piping is reduced to 1 1 2 88mm after the final elbow The intake piping may be equipped with a 90 elbow turndown Using turndown will add 5 feet 1 5m to the equivalent length of the pipe Page 25 TERMINATION 7ZZZZZZZZ REDUCER MAY BE REQUIRED TO ADAPT LARGER VENT PIPE SIZE TO TERMINATION PIPE PER 6 152 TABLE 14 OUTSIDE WALL 2 51 PVC COUPLING 8 203 MINIMUM Inches mm TOP VIEW WALL RING KIT 15F74 FIGURE 21 EXHAUST TERMINATION INTAKE TERMINATION EXHAUST 12 305 ABOVE AVERAGE SNOW ACCUMULATION Inches mm FIELD PROVIDED REDUCER MAY BE REQUIRED TO ADAPT LARGER VENT PIPE SIZE TO TERMINATION INTAKE DIRECT VENT CONCENTRIC ROOFTOP TERMINATION 71M80 69M29 or 60L46 FIGURE
89. sembly N 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 34 NOTE In upflow and downflow applications con densate trap must be installed on the same side as exhaust piping CAUTION DO NOT use a power driver to tighten screws which secure condensate trap to cabinet Screws should be hand tightened using screw driver to avoid the possibility of damage to the trap assembly 3 Glue the field provided coupling or pipe to the trap Install a tee and vent pipe near the trap NOTE The condensate trap drain stubs both sides have an outer diameter which will accept a standard 3 4 PVC coupling The inner diameter of each stub will accept standard 1 2 diameter PVC pipe NOTE Vinyl tubing may be used for condensate drain Tubing must be 1 1 4 OD X 1 ID and should be attached to the drain stubs on the trap using a hose clamp 4 Glue the field provided drain line to the tee Route the drain line to an open drain As an alternate clear vinyl tubing may be used to drain condensate away from the trap Secure the vinyl tubing to the drain stubs on the trap using a hose clamp Do not overtighten the Page 28 hose clamp Condensate line must be sloped downward away from condensate trap to drain If drain level is above con densate trap cond
90. ss Reconnect the two 10 Disconnect condensate drain line from the conden wires to the backup secondary limit if applicable sate trap Remove condensate trap it may be neces 29 Reinstall pressure switches and reconnect pressure sary to cut drain pipe Remove screws that secure switch wiring condensate collars to either side of the furnace and re 30 move collars Remove drain tubes from cold end header collector box Carefully connect combustion air pressure switch hosing from pressure switches to proper stubs on cold end header collector box Te a a pi d sen 31 Reinstall condensate collars on each side of the fur nace Reconnect drain tubing to collector box place Remove flue collars It may be necessary to cut 9 the exiting exhaust pipe for removal of the fittings 32 Reinstall condensate trap on same side as exhaust ipe Reconnect condensate drain line to the conden 12 Mark and disconnect all combustion air pressure tub p trap ing from cold end header collector box i 33 Use securing screws to reinstall flue collars to either 13 Mark and remove wires from pressure switches Re side of the furnace Reconnect exhaust piping and ex move HR switches Keep tubing attached to haust drain tubing EN eng ap m 34 Replace flexible exhaust tee on combustion air induc 14 2 POPSET er and flue collars Secure using three existing hose 22198 gt 7 clamps dary limit if appli
91. t manually BEFORE LIGHTING the unit smell all around the fur nace area for gas Be sure to smell next to the floor be cause some gas is heavier than air and will settle on the floor The gas valve on the G61MP may be equipped with ei ther a gas control knob or gas control lever Use only your hand to push the lever or turn the gas control knob Never use tools If the the lever will not move or the knob will not push in or turn by hand do not try to repair it Force or at tempted repair may result in a fire or explosion Placing the furnace into operation G61MP units are equipped with a SureLight ignition system Do not attempt to manually light burners on this furnace Each time the thermostat calls for heat the burners will automatically light The ignitor does not get hot when there is no call for heat on units with SureLight ignition system Priming Condensate Trap The condensate trap should be primed with water prior to start up to ensure proper condensate drainage Either pour 10 fl oz 300 ml of water into the trap or follow these steps to prime the trap 1 Follow the lighting instructions to place the unit into op eration 2 Setthe 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 al l
92. t start up DUAL COMBUSTION AIR PROVE SWITCH G61MP 090 110 amp 135 negative pressure N positive pressure FIGURE 9 To troubleshoot the prove switches temporarily jumper them The unit will not fire with the switches jumpered Therefore the prove switches must be bypassed after the combustion air in ducer is activated This will determine if the prove switches and furnace are operating properly However this may not in dicate if the sealed combustion system is operating properly Checks of pressure differential can aid in troubleshooting When measuring the pressure differential readings should be taken at the prove switch Lack of differential usually indicates problems in the intake or exhaust piping but may indicate problems in the heat exchanger condensing coil head er boxes combustion inducer or other components Measuring pressure differential The differential pressure is the difference in pressure mea sured across the cold end header box orifice 1 Remove thermostat demand and allow unit to cycle off 2 Install a tee in the negative line and a tee in the positive line running from one of the prove switches to the cold end header box 3 Install a manometer with hose from the negative side of the manometer to the tee installed in the nega tive line and with hose from the positive side of the manometer to the tee in the positive line NOTE Both sides of the cold end he
93. tats are described below Thermostat jumper E20 dictates which mode unit will operate in See flow chart for more sequence detail SureLight Control Self Check When there is a call for heat the SureLight integrated con trol runs self check The control checks for 610 primary limit 521 secondary limit and 547 rollout switch nor mally closed contacts The control also checks for 5102 high heat and 5128 low heat prove switch normally open contacts Once self check is complete and all safety switches are operational heat call can continue Two Stage Thermostat Two Stage Heat Jumper E20 set at 1 SureLight control energizes combustion air inducer on low heat speed Combustion air inducer runs until 128 low heat prove switch contacts close switch must close within 2 1 2 minutes or control goes into Watchguard Pressure Switch mode High heat prove switch 5102 may also close A 15 second pre purge follows once 5128 closes 2 SureLight control begins 20 second ignitor warm up period 3 Gas valve opens on first stage for a 4 second trial for ignition Ignitor stays energized during the trial or until flame sensed 4 Flame is sensed gas valve remains on first stage heat ignitor de energizes 5 After 45 second delay indoor blower B3 is energized on low heat speed The furnace will stay in this mode until first stage de mand is satified OR a second stage heat demand is initiated 6 Second stage
94. ted 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 out doors The G61MP is then classified as a non direct vent Category IV gas furnace In Non Direct Vent applications the vent termination is limited by local building codes In the absence of local codes refer to the current National Fuel Gas Code ANSI Z223 1 NFPA 54 in U S A and cur rent CSA B149 Natural Gas and Propane Installation Codes in Canada for details Position termination end according to location given in fig ure 19 In addition position termination end so itis free Page 23 from any obstructions and above the level of snow accu mulation where applicable The termination should be at least 12 inches 305mm from any opening through which flue products could enter the building At vent termination care must be taken to maintain protective coatings over building materials prolonged exposure to exhaust condensate can destroy protective coatings It is recommended that the exhaust outlet not be located within 6 feet 1 8m of a condensing unit because the condensate can damage the painted coating NOTE If winter design temperature is below 32 F 0 C exhaust piping shoul
95. that heat exchanger is rail which secure bottom heat exchanger flange Re clean and dry and that furnace is operating properly move heat exchanger from furnace cabinet 45 Replace heating compartment access panel Page 36 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 G61MP 135 only Re move and discard two additional shipping screws See figure 41 6 Use the soft brush attachment on 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 Page 37 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
96. the left most burner The sensor can be re moved for service without removing any part of the burn ers During operation flame is sensed by current passed through the flame and sensing electrode The SureLight control allows the gas valve to remain open as long as flame signal is sensed NORMAL FLAME SIGNAL gt 0 23 MICROAMPS lt 0 22 MICROAMPS 7 0 16 MICROAMPS LOW FLAME SIGNAL DROP OUT SIGNAL FIGURE 6 4 Ignitor The SureLight ignitor is made of durable silicon nitride 10 nitor longevity is enhanced by controlling voltage to the ig nitor The board finds the lowest ignitor temperature which will successfully light the burner thus increasing the life of the ignitor Due to this feature of the board voltage cannot be measured so ignitor must be ohmed Ohme value should be 10 9 to 19 7 See 7 for ignitor location NOTE The G61MP furnace contains electronic com ponents that are polarity sensitive Make sure that the furnace is wired correctly and is properly grounded 5 Burners Figure 7 All units use inshot burners Burners are factory set and do not require adjustment The manifold brackets are slotted so burn ers can be removed as an assembly for service Burner main tenance and service is detailed in the MAINTENANCE sec tion of this manual Each burner uses an orifice which is pre cisely matched to th
97. tion will cause high CO2 with high CO ACTION 2 Seal leakage if possible replace heat exchanger if necessary tag and return heat exchanger to proper Lennox personnel ACTION 1 Check for sooting deposits or other restrictions in the heat exchanger assembly Clean assembly as outlined in instruction manu al ACTION 2 Check for proper combustion ACTION 1 Check that the burners are firing into the center of the heat exchanger openings Cor rect the location of the burners if necessary ACTION 1 Check for proper flow of exhaust gases away from intake vent Remove any ob stacles in front of the intake and exhaust vent which would cause recirculation ACTION 2 Check for correct intake and exhaust vent installation See instructions ACTION 1 Remove burner and inspect the cross overs for burrs or any restriction or if crossover is warped Remove restriction or re place burners PROBLEM 6 CONTROL SIGNALS LOW FLAME SENSE DURING HEATING MODE 6 0 6 1 1 ACTION 1 Check the sensor rod for proper loca Unit operates correctly but the diag Sensor rod is improperly located tion on the burner Properly locate the sensor rod nostic lights flash low flame sense the burner or replace if rod cannot be located correctly code ACTION 1 Check sensor rod for contamination or coated surface Clean the sensor rod with steel 6 1 2 wool or replace sensor DO NOT USE SAND PA PER TO CLEAN ROD SAND PAPER WILL CONTRIBU
98. tions directly above a walkway I Dimensions are from the current edition of The National Fuel Gas Code ANSI Z223 1 NFPA 54 for USA installa tions In Canada refer to current edition of CSA B149 installation codes Local codes or regulations may require dif ferent clearances II In Non Direct Vent installations combustion air is taken from indoors and the flue gases are discharged to the outdoors FIGURE 19 Page 24 9 Based on the recommendation of the manufacturer multiple furnace installation may use group of up to four termination kits WTK assembled together hori Zontally as shown in figure 26 TABLE 14 EXHAUST PIPE TERMINATION SIZE REDUCTION G61MP MODEL 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 at tic or closet installations vertical termination through the roof is preferred Figures 20 through 28 show typical ter minations 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 Pipe Size Termination Pipe Size 0 070 2 2 1 2 3 or 4 1 1 2 or zur Gor Approved 3 conce
99. ust Remove all blockage ACTION 2 Check for proper vent sizing See installation instructions ACTION 1 Check that sensor is properly lo cated and that the sense wire is properly at tached to both the sensor and the control ACTION 1 Check for a broken sensor ACTION 2 Test continuity across the sense wire If wire or sensor are damaged replace the component ACTION 1 Check for resistance between the sensor rod and the unit ground ACTION 2 Check for resistance between the sensor wire and the unit ground ACTION 3 Correct any shorts found in circuit ACTION 1 Check the microamp signal from the burner flame If the microamp signal is be low normal check the sense rod for proper location or contamination ACTION 2 Replace clean or relocate flame sense rod If rod is to be cleaned use steel wool or replace sensor DO NOT CLEAN ROD WITH SAND PAPER SAND PAPER WILL CONTRIBUTE TO THE CONTAMINATION PROBLEM NOTE Do not attempt to bend sense rod PROBLEM 5 BURNERS LIGHT WITH HEATING DEMAND BUT UNIT SHUTS DOWN PREMATURELY CONT Possible Cause Corrective Action Comments 5 3 Combustion air inducer energizes with heating demand Burners light Roll out switch trips during the heating demand Diagnostic lights flash roll out fail ure LED 1 On LED 2 Slow Flash 5 4 Combustion air inducer energizes with a heating demand Burners light roughly and the unit fails to stay lit
100. ve 90 street ell supplied installed directly into unit flue collar G61MP 60D 135 must have 3 to 2 reducing ell supplied installed directly into unit flue collar TABLE 13 MAXIMUM VENT PIPE LENGTHS MAXIMUM EQUIVALENT VENT amuoe 070 s 6 78 214 E Us wa 32 72 11 ow 5 6 77 2m voss aT 8 EV ysi sm E m ma 4 5 77 5 78 72 72 65 0 4500 22 32 65 65 42 32 65 65 42 32 n a 0 1371 6 ma 746 6 6 77 6 214 42 72 32 72 9 9 9 9 59 070 59 2287 Sun Tj 090 26 135 ma na 46 160 n a Not allowed G61MP 48C 110 and G61MP 60C 110 must have 90 street ell supplied installed directly into unit flue collar G61MP 60D 135 must have 3 to 2 reducing ell supplied installed directly into unit flue collar 90 elbows used in configuration of G61MP 60D 135 vent must be lim ited to 3 sweep elbows B PVC Joint Cementing Procedure All cementing of joints should be done according to the specifications outlined in ASTM D 2855 WARNING DANGER OF EXPLOSION Fumes from PVC glue may ignite during system check Allow fumes to dissipate for at least 5 minutes before placing unit into operation Measure and cut vent pipe to desired length 2 Debur and chamfer end of pipe removing any ri
101. wer Compartment 1 Blower Motor B3 and Capacitor C4 All G61MP units use direct drive blower motors All motors are 120V permanent split capacitor motors to ensure maxi mum efficiency Ratings for capacitors will be on motor nameplate See SPECIFICATIONS section for motor speci fications NOTE Shafts on 1 HP motors have 2 flat sides and are matched with blower wheels with 2 set screws SUPPLY AIR BLOWER AND SECONDARY LIMITS SECONDARY LIMIT S 2 Secondary Limit Controls S21 The secondary limits S21 on G61MP units are located in the blower compartment on the back side of the blower housing MOTOR BLOWER ASSEMBLY CAPACITOR To Remove Blower From Unit Disconnect Power Remove Control See figure 5 All G61MP units are equipped with two secon dary limts When excess heat is sensed in the blower compart ment the limit will open If the limit is open the furnace control energizes the supply air blower and closes the gas valve The limit automatically resets when unit temperature returns to nor mal The switch is factory set to open at 125 F and cannot be adjusted Page 11 Box Remove Bolts and Unplug Motor Wires From Control Board Then Slide Out Front of Unit FIGURE 5 C Heating Components 3 Flame Sensor A flame sensor is located on the left side of the burner sup port See figure 6 The sensor is mounted through the bot tom of the burner box and the tip protrudes into the flame envelope of

Lennox International Inc. G61MP User's Manual

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