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Lennox International Inc. G61MP Series Units Gas Heater User Manual

1. Optional upflow Optional upflow FIGURE 44 1 Determine which side condensate piping will exit the unit Remove plugs from the condensate collar at the appropriate location on the side of the unit NOTE The condensate trap is factory shipped with two rubber O rings and two rubber clean out caps installed Check to make sure that these items are in place before installing the trap assembly 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 DO NOT apply glue to secure condensate trap to cabinet All other joints must be glued See figure 45 NOTE In upflow and downflow applications con densate trap must be installed on the same side as exhaust piping A CAUTION DO NOT use a power driver to tighten screws which secure condensate trap to cabinet Screws should be hand tightened using a screw driver to avoid the possibility of damage to the trap assembly 3 The condensate trap provided with the unit is manufactured using ABS material Use ABS to PVC transition solvent cement to glue a field provided PVC coupling or PVC pipe to the trap Installa tee and vent pipe near the trap NOTE The condensate trap drain stu
2. Limit pipe length to 4 in G61MP 110 111 135 applications FIGURE 25 TYPICAL AIR INTAKE PIPE CONNECTIONS Follow the next three steps when installing the unit in Non HORIZONTAL DIRECT VENT APPLICATIONS Direct Vent applications where combustion air is taken Horizontal Right Hand Air Discharge Application Shown from indoors and flue gases are discharged outdoors 36B 045 Fuss Limit pipe 36B 070 length to 4 in 110 111 36B 071 135 applications 48C 090 60C 090 60C 091 48C 110 60C 110 TRANSITION 60C 111 60D 135 o TYPICAL AIR INTAKE PIPE CONNECTIONS UPFLOW OR HORIZONTAL NON DIRECT VENT APPLICATIONS Right Hand Exit in Upflow Application Shown 6 in Max INTAKE DEBRIS SCREEN Provided 2 1 2 36B 045 36B 070 3 OR 4 36B 071 2777 48 090 60 090 TRANSITION 60C 091 48C 110 2 60C 140 60C 111 36B 045 36B 070 eon i 48C 090 60C 090 2 60C 091 NOTE Debris screen and elbow be rotated so that screen may be positioned to fa
3. 57 Repair Parts List 62 Vent Pipe Sizing Worksheet 63 Start Up amp Performance Check List 63 AWARNING FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exact ly could result in serious injury death or property damage Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other ap pliance Installation and service must be performed by a qualified installer service agency or the gas supplier 08 09 WHAT TO DO IF YOU SMELL GAS e Do not try to light any appliance e Do not touch any electrical switch do not use any phone in your building e Leave the building immediately e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e If you cannot reach your gas supplier call the fire department Page 1 506406 01 G61MP Unit Dimensions inches mm NOTE 60C and 60D size units installed in upflow ap plications that require air volumes over 1800 cfm 850 L s must have one of the following 1 Single side return air with transition to accommodate 20 x 25 x 1 in 508 x 635 x 25 mm air filter Required to maintain proper air velocity 2 Single side return air with optional RAB Return Air Base 3 Bottom return air 4 Return air from both sides 5 Bottom and one side return air Refer to E
4. 63 Requirements for Commonwealth of Massachusetts Modifications to NFPA 54 Chapter 10 Revise NFPA 54 section 10 8 3 to add the following re quirements For all side wall horizontally vented gas fueled equipment installed in every dwelling building or structure used in whole or in part for residential purposes including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven 7 feet above the finished grade in the area of the venting in cluding but not limited to decks and porches the following requirements shall be satisfied 1 INSTALLATION OF CARBON MONOXIDE DETEC TORS At the time of installation of the side wall hori zontally vented gas fueled equipment the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery backup is installed on the floor level where the gas equipment is to be installed In addition the installing plumber or gasfitter shall observe that a battery oper ated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwell ing building or structure served by the side wall hori zontally vented gas fueled equipment It shall be the responsibility of the property owner to secure the ser vices of qualified licensed professionals for the instal lation of hard wired carbon monoxide detectors a In the event that the side wa
5. 1 2 13 FOAM G61MP NON DIRECT VENT APPLICATION USING EXISTING CHIMNEY SIZE TERMINATION PIPE PER TABLE 8 STRAIGHT CUT OR 1 ANGLE CUT IN DIRECTION OF ROOF SLOPE puis EXHAUST VENT i 1 2 13mm MINIMUM 12 805mm ABOVE i AVERAGE SNOW ACCUMULATION WEATHERPROOF INSULATION SHOULDER OF FITTINGS PROVIDE SUPPORT OF PIPE ON TOP PLATE SHEET METAL TOP PLATE INSULATE TO FORM PORTION OF CHIMNEY 1 seat 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 43 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 Page 31 sate trap should extend below the unit A 5 1 2 service clearance is required for the condensate trap Refer to fig ure 44 for condensate trap locations CONDENSATE TRAP LOCATIONS Unit shown in upflow position Horizontal right and optional downflow Horizontal left and optional downflow
6. Dc sasay Page 37 TABLE 10 Field Wiring Applications Continued DIP Switch Settings and On Board Links W915 Y1 to Y2 W951 Wiring Connections Two Stage 29019 2 Heat 2 Cool Intact S1 CONTROL OUTDOOR T STAT TERM STRIP UNIT 3 0 Thermostat O to R Heat Pumps 2 Heat 1 Cool Intact Intact S1 CONTROL OUTDOOR T STAT TERM STRIP UNIT EXISTING W915 JUMPER e NOTE Do NOT make a wire connection between the room thermostat L terminal and the L terminal of the G61MP integrated control Page 38 UOOOUJ NEUTRALS STATUS 0 NS DIAGNOSTIC LEDs 00000 Gu DIP SWITCHES lt uy o gt lt TWO STAGE INTEGRATED CONTROL BOARD ON BOARD JUMPERS 1 4 QUICK CONNECT TERMINALS HUM 120 VAC OUTPUT TO HUMIDIFIER EAC 120 VAC OUTPUT TO ELECTRONIC AIR CLEANER XMFR 120 VAC OUTPUT TO TRANSFORMER LI 120 VAC INPUT TO CONTROL SENSE 120 VAC OUTPUT TO FLAME SENSER NEUTRALS 120 VAC NEUTRAL PARK DEAD TERMINAL FOR UNUSED BLOWER LEAD HEAT LOW 120 VAC OUTPUT TO CIRC BLWR LOW HT SPEED AND CONTINUOUS FAN HEAT HIGH COOL LOW 120 VAC OUTPUT TO CIRC BLWR HIGH HEAT AND LOW COOL SPEED COOL HIGH 120 VAC OUTPUT TO CIRC BLWR HIGH COOL SPEED THERMOST
7. NOTE In Non Direct Vent installations combustion air is taken from indoors and flue gases are discharged out doors A WARNING Insufficient combustion air can cause headaches nausea dizziness or asphyxiation It will also cause excess water in the heat exchanger resulting in rust ing and premature heat exchanger failure Excessive exposure to contaminated combustion air will result in safety and performance related problems Avoid exposure to the following substances in the com bustion air supply Permanent wave solutions Chlorinated waxes and cleaners Chlorine base swimming pool chemicals Water softening chemicals De icing salts or chemicals Carbon tetrachloride Halogen type refrigerants Cleaning solvents such as perchloroethylene Printing inks paint removers varnishes etc Hydrochloric acid Cements and glues Antistatic fabric softeners for clothes dryers Masonry acid washing materials In the past there was no problem in bringing in sufficient outdoor air for combustion Infiltration provided all the air that was needed In today s homes tight construction practices make it necessary to bring in air from outside for combustion Take into account that exhaust fans ap pliance vents chimneys and fireplaces force additional air that could be used for combustion out of the house Unless outside air is brought into the house for combus tion negative pressure outside pressure is greater than inside pr
8. Page 43 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 Set the thermostat to the lowest setting 2 Turn off all electrical power to the unit if service is to be performed 3 Remove the upper access panel 4 White Rodgers 36E Gas Valve Move gas valve switch to OFF Honeywell VR8205 Gas Valve Move switch on gas valve clockwise 4 to OFF Do not force 5 Replace the upper access panel Gas Pressure Adjustment Gas Flow Approximate 1 Operate unit at least 15 minutes before checking gas flow Determine the time in seconds for one revolu tions of gas through the meter A portable LP gas me ter 17Y44 is available for LP applications 2 Compare the number of seconds and the gas meter size in table 12 to determine the gas flow rate Multiply the gas flow rate by the heating value to determine the unit input rate If manifold pressure is correct and the unit input rate is incorrect check gas orifices for proper size and restriction 3 Remove temporary gas meter if installed NOTE To obtain accurate reading shut off all other gas appliances connected to meter Supply Pressure Measurement A threaded plug on the inlet side of the gas valve provides access to the supply pressure tap Remove the threaded plug install a field provided barbed fitting and connect a manometer to measure s
9. HEARTBEAT 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 STATUS ERROR CODE 4 1 IS 60 MINUTE RESET PERIOD COMPLETE FLAME PRESENT HAS CONTROL RESET IGNITION SEQUENCE FOUR 4 TIMES WATCHGUARD MODE CONTINUED ON NEXT PAGE STATUS ERROR CODE 4 3 Page 58 Troubleshooting Heating Sequence of Operation Continued HEATING SEQUENCE OF OPERATION CONTINUED THERMOSTAT CALLS FOR HEAT STATUS LED HEARTBEAT SEE BOX A FLAME SIGNAL ABOVE gt 1 40 microamps LOW FLAME SIGNAL Does not affect control operation YES STATUS ERROR CODE 1 2 SINGLE STAGE THERMOSTAT MODE 1 DIP SWITCH SET AT SINGLE START SECOND STAGE RECOGNITION ON DELAY 10 OR 15 MINUTES 45 SECOND INDOOR BLOWER ON DELAY BEGINS STATUS LED HEARTBEAT STATUS LED HEARTBEAT YES ROLLOUT SWITCHES CLOSED GAS VALVE OFF COMBUSTION AIR INDUCER ON INDOOR BLOWER ON STATUS ERROR CODE 5 1 SEQUENCE HOLDS FIRST STAGE LOW FIRE UNTIL ROLLOUT SWITCH IS RESET AND MAIN PRESSURE SWITCH CLOSED POWER IS INTERRUPTED OR THERMOSTAT IS CYCLED OFF ON FOR 3 SECOND MINIMUM GAS VALVE OFF COMBUSTION AIR INDUCER OFF FIRST STAGE HEAT DEMAND SATISFIED INDOOR BLOWER ON STATUS ERROR CODE 3 1 GAS VALVE OFF COMBUSTION AIR INDUCER HAS PRIMARY OR SECONDARY LIMIT OFF FOLLOWING POST PURGE SWITCH CLOSED WITHIN 3
10. 3 8 493 95 65 52 45 40 36 33 31 29 27 9 53 12 522 2 69 1 84 1 0 1 m 13 a 02 Z 73 2 ES 3 4 824 360 250 200 170 151 138 125 118 110 103 19 05 20 930 10 19 7 08 5 66 A 81 4 28 3 91 3 54 3 34 3 11 2 92 1 049 680 465 375 320 285 260 240 220 205 195 26 645 19 25 13 17 10 62 9 06 8 07 7 36 6 80 6 23 5 80 5 52 1 1 4 1 380 1400 950 770 660 580 530 490 460 430 400 31 75 35 052 39 64 26 90 21 80 18 69 16 42 15 01 13 87 13 03 12 18 11 33 1 1 2 1 610 2100 460 1180 990 900 810 750 690 650 620 38 1 40 894 59 46 41 34 33 41 28 03 2548 22 94 2124 19 54 18 41 17 56 2 2 067 3950 2750 2200 1900 1680 1520 1400 1300 1220 1150 50 8 52 502 111 85 77 87 62 30 53 80 47 57 43 04 39 64 36 81 34 55 32 56 2 1 2 2 469 6300 4350 3520 3000 2650 2400 2250 2050 1950 1850 63 5 67 713 178 39 123 17 99 67 84 95 75 04 67 96 63 71 58 05 55 22 52 38 3 3 068 11000 7700 6250 5300 4750 4300 3900 3700 3450 3250 76 2 77 927 311 48 218 03 176 98 150 07 134 50 121 76 110 43 104 77 97 69 92 03 4 4 026 23000 15800 12800 10900 9700 8800 8100 7500 7200 6700 101 6 102 260 651 27 447 39 362 44 308 64 274 67 249 18 229 36 212 37 203 88 189 72 NOTE Capacity given in cubic fee
11. I YT W915 ELECTRIC SHOCK HAZARD CAN CAUSE INJURY OR DEATH UNIT MUST BE GROUNDED IN ACCORDANCE WITH NATIONAL AND LOCAL IFANY WIRE IN THIS APPLIANCE IS REPLACED T MUST BE REPLACED WITH WIRE OF LIKE SIZE RATING INSULATION THICKNESS AND TERMINATION TYPICAL SYSTEM SHOWN FOR 2 HEAT 2 COOL WITH A CONVENTIONAL THERMOSTAT SEE INSTALLATION INSTRUCTIONS FOR CONNECTION TO OTHER EQUIPMENT AND ACCESSORIES Integrated Control Board G61MP units are equipped with a two stage integrated control This control manages ignition timing and fan off delays based on selections made using the control DIP switches and jumpers The control includes an internal watchguard feature which automatically resets the ignition control when it has been locked out After one hour of con tinuous thermostat demand for heat the watchguard will break and remake thermostat demand to the furnace and automatically reset the control to relight the furnace DIP Switch Settings Figure 53 Switch 1 Thermostat Selection This unit may be used with either a single stage or two stage thermostat The thermostat selection is made using a DIP switch which must be properly positioned for the particular application The DIP switch is factory positioned for use with a two stage thermostat If a single stage thermostat is to be used the DIP switch must be repositioned a Select OFF for two stage heating operation
12. Page 59 Troubleshooting Heating Sequence of Operation Continued HEATING SEQUENCE OF OPERATION CONTINUED SEE BOX A NORMAL OPERATION SEE BOX B THERMOSTAT CALLS FOR HEAT RETURN TO FIRST STAGE HEAT MODE FIRST STAGE CONTINUES UNTIL SECOND Er dn PRESSURE SWITCH CLOSED 1 MINUTE WAIT PERIOD IS INITIATED BEFORE RETRY WERE 5 ATTEMPTS MADE FOR SECOND STAGE HEAT HEAT DEMAND SATISFIED NO STATUS LED HEARTBEAT SEE BOX C FIRST STAGE HEAT DEMAND SATISFIED TWO STAGE THERMOSTAT MODE DIP SWITCH SET AT TWO SECOND STAGE HEAT GAS VALVE OFF COMBUSTION AIR FIRST AND SECOND STAGE HEAT DEMAND SASTISFIED INDUCER OFF AFTER 5 SECOND DEMAND SATISFIED SIMULTANEOUSLY STATUS LED HEARTBEAT LOW SPEED POST PURGE PERIOD STATUS LED HEARTBEAT INDOOR BLOWER OFF DELAY INITIATED ON LOW HEAT SPEED STATUS LED HEARTBEAT GAS VALVE COMBUSTION AIR INDUCER AND INDOOR BLOWER RETURN TO FIRST STAGE OPERATION STATUS LED HEARTBEAT FIRST STAGE HEAT DEMAND SATISFIED DEMAND FOR HEAT SATISFIED GAS VALVE OFF COMBUSTION AIR INDUCER POWER ON STAND BY OFF AFTER 5 SECOND LOW SPEED POST PURGE PERIOD INDOOR BLOWER OFF eve LED PULSE DELAY INITIATED ON LOW HEAT SPEED STATUS LED PULSE Page 60 Troubleshooting Cooling Sequence of Operation COOLING SEQUENCE OF OPERATION POWER ON SIGNAL POLARITY REVERSED ISPOLARITY REVERSED CONTROL WILL TA d NON COORING IS POLARITY REVERSED IN THIS CONDI
13. 6 On field supplied terminations for side wall exits ex REGUCER MAY 6 do TERMINA haust piping should extend a minimum of 12 inches MAXI PER TABLE 805mm beyond the outside wall Intake piping EAT d should be as short as possible See figure 32 TERMINATION peus 8 203 Inches mm 7 On field supplied terminations a minimum separation 2 51 MINIMUM distance between the end of the exhaust pipe and the PVC end of the intake pipe is 8 inches 203mm COUREING TOP VIEW WALL RING KIT WITH STRAIGHT INTAKE 8 If intake and exhaust piping must be run up a side wall 15F74 to position above snow accumulation or other obstruc tions piping must be supported every 3 ft 9m as shown in figure 22 Refer to figure 35 for proper piping method In addition WTK wall termination kit must be extended for use in this application See figure 38 When exhaust and intake piping must be run up an outside wall the exhaust piping is reduced to 1 1 2 38mm after the final elbow The intake piping may be equipped with a 90 elbow turndown Using turndown will add 5 feet 1 5m to the equivalent length of the pipe 9 Based on the recommendation of the manufacturer a multiple furnace installation may use a group of up to four termination kits WTK assembled together hori zontally as shown in figure 37 1 2 13 ARMAFLEX INSULATION IN UNCONDITIONED SPACE 12 305 MAX 112 13 ARMAFLEX FIELD PROVIDED R
14. Do not install the furnace on its front or its back Do not connect the return air ducts to the back of the fur nace Doing so will adversely affect the operation of the safety control devices which could result in per sonal injury or death Selectalocation that allows for the required clearances that are listed on the unit nameplate Also consider gas supply connections electrical supply vent connection condensate trap and drain connections and installation and service clearances 24 inches 610 mm at unit front Page 8 SETTING EQUIPMENT UPFLOW APPLICATION DOWNFLOW APPLICATION UNIT MUST BE LEVEL SIDE TO SIDE IN ALL APPLICATIONS HORIZONTAL APPLICATION Em AIR FLOW AIR FLOW AIR FLOW FRONT VIEW FRONT VIEW FRONT VIEW Ih r AIR FLOW END VIEW UNIT SHOULD BE LEVEL FROM LEFT TO RIGHT BUT MAY SIDE VIEW TILTED SLIGHTLY MAX 1 2 FROM BACK TO FRONT SIDE VIEW TO AID IN THE DRAINING OF THE HEAT EXCHANGER FIGURE 7 The unit must be level from side to side The unit may be tilted slightly maximum 1 2 in from back to front to aid in the draining of the heat exchanger See figure 7 NOTE Units with 1 2 hp blower motors are equipped with three flexible legs and one rigid leg The rigid leg is equipped with a shipping bolt and a flat white plastic wash er rather than the rubber mount
15. F 16 C and 80 F 27 C must be maintained e Air filters must be installed in the system and must be maintained during construction e Air filters must be replaced upon construction comple tion e The input rate and temperature rise must be set per the furnace rating plate e One hundred percent 100 outdoor air must be pro vided for combustion air requirements during construc tion Temporary ducting may supply outdoor air to the furnace Do not connect duct directly to the furnace Size the temporary duct following these instructions in section for Combustion Dilution and Ventilation Air in a confined space with air from outside e The furnace heat exchanger components duct system air filters and evaporator coils must be thoroughly cleaned following final construction clean up e All furnace operating conditions including ignition in put rate temperature rise and venting must be verified according to these installation instructions These instructions are intended as a general guide and do not supersede local codes in any way Consult authorities having jurisdiction before installation In addition to the requirements outlined previously the fol lowing general recommendations must be considered when installing a G61MP furnace e Place the furnace as close to the center of the air dis tribution system as possible The furnace should also be located close to the chimney or vent termination point e When the f
16. Total length linear feet of pipe Plus Equivalent length feet of fittings Plus Equivalent length feet of termination NOTE Include ALL pipe and ALL fittings both in doors and outdoors Regardless of the diameter of pipe used the standard roof and wall terminations described in section Exhaust Piping Terminations should be used Exhaust vent termination pipe is sized to optimize the velocity of the exhaust gas as it exits the termination Refer to table 8 NOTE The exhaust pipe should be offset a minimum of 12 inches to avoid the possibility of water droplets being re leased from the exhaust termination The minimum 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 See fig ure 21 Each 90 elbow including those provided with the furnace of any diameter is equivalent to 5 feet 1 52m of vent pipe of the same diameter Two 45 elbows are equivalent to one 90 elbow of the same diameter One 45 elbow is equal to 2 5 feet 76m of vent pipe of the same diameter In some applications which permit the use of several differ ent sizes of vent pipe a combination vent pipe may be used Contact the Application Department for assistance in sizing vent pipe in these applications NOTE The flue collar on all models is sized to accommo date 2 Schedule 40 flue pipe When vent pipe which is lar
17. 40 PVC Cellular Core Pipe Schedule 40 ABS Cellular Core DWV Pipe ABS DWV Drain Waste amp Vent Pipe amp Fittings PVC DWV Drain Waste amp Vent Pipe amp Fittings D2665 ASTM PRIMER amp SOLVENT CEMENT SPECIFICATION PVC CPVC ABS All Purpose Cement For Fit tings amp Pipe of the same material D2564 D2235 ABS to PVC or CPVC Transition Solvent Cement CANADA PIPE amp FITTING amp SOLVENT CEMENT PVC amp CPVC Pipe and Fittings amp CPVC PVC amp CPVC Pipe and Fittings and Fittings PVC amp CPVC Solvent Cement ABS to PVC or CPVC Transition Cement ULCS636 Page 16 Use PVC primer and solvent cement or ABS solvent cement meeting ASTM specifications refer to Table 4 As an alter nate use all purpose cement to bond ABS PVC or CPVC pipe when using fittings and pipe made of the same materi als Use transition solvent cement when bonding ABS to ei ther PVC or CPVC Low temperature solvent cement is recommended Metal or plastic strapping may be used for vent pipe hangers Uni formly apply a liberal coat of PVC primer for PVC or use a clean dry cloth for ABS to clean inside socket surface of fit ting and male end of pipe to depth of fitting socket Canadian Applications Only Pipe fittings primer and solvent cement used to vent exhaust this ap pliance must be certified to ULC S636 and supplied by a single manufacturer as part of an approved vent ex haust system When
18. 56M21 44W48 44W50 44W49 44W49 44W51 091 47M82 26W85 26W85 26W86 44W48 44W50 44W49 44W49 47M82 110 44W51 75M22 44W48 44W50 44W49 44W49 44W51 111 47M82 56M22 56M22 56M23 44W48 44W50 44W49 44W49 47M82 135 44W51 56M93 56M93 44W48 44W50 44W49 44W49 44W51 1 High Altitude Orifice Kit is required and must be ordered separately for applications from 7501 to 10 000 ft Page 45 Testing for Proper Venting and Sufficient Combustion Air for Non Direct Vent Applications A 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 If a G61MP furnace replaces a Category 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 o
19. Base Return Air from Both Sides or Return fabricated transition to accommodate 20 x 25 x 1 in air Static Air from Bottom and One Side filter in order to maintain proper air velocity PTS eure Medium Medium Medium Medium o W g High High Low High Low Low cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts 0 00 2475 1305 2210 1045 1850 860 1435 670 0 10 2395 1260 2170 1010 1850 830 1490 660 0 20 2340 1220 2115 965 1875 810 1525 650 0 30 2255 1205 2075 940 1835 785 1530 640 0 40 2165 1160 2005 905 1800 760 1535 626 0 50 2055 1140 1935 885 1760 740 1555 620 0 60 1995 1120 1835 845 1660 705 1480 595 0 70 1880 1075 1745 810 1620 685 1440 575 0 80 1795 1060 1645 770 1510 655 1370 550 0 90 1680 1020 1545 740 1415 620 1295 530 NOTES All air data is measured external to unit without filter not furnished field provided Page 50 G61MP 60D 135 PERFORMANCE Less Filter Air Volume Watts at Different Blower Speeds Air Volume Watts at Different Blower Speeds Bottom Return Air Side Return Air with Optional RAB Single Side Return Air Air volumes in bold require field External Return Air Base Return Air from Both Sides or Return fabricated transition to accommodate 20 x 25 x 1 in air Static Air from Bottom and One Side filter in order to maintain proper air velocity Pressure Medium Medium Medium In Wg High Low Low High i Low cfm Watts cf
20. Btuh 3kw and lt 100 000 Btuh 30kw 36 inches 9m for appliances gt 100 000 Btuh 30kw 12 4 feet 1 2 m below or to side of opening 1 foot 30 cm above opening 12 Equal to or greater than soffit depth Equal to or greater than soffit depth Equal to or greater than soffit depth Equal to or greater than soffit depth No minimum to outside corner No minimum to outside corner 3 feet 9m 3 feet 9m feet 9m within a height 15 feet 4 5m feet 9m within a height 15 feet 4 5m above the meter regulator assembly above the meter regulator assembly 3 feet 9m 3 feet 9m 6 inches 152mm for appliances lt 10 000 Btuh 3kw 12 inches 305mm for appliances gt 10 000 Btuh 3kw and lt 100 000 Btuh 30kw 36 inches 9m for appliances gt 100 000 Btuh 30kw 6 feet 1 8m 4 feet 1 2 m below or to side of opening 1 foot 30 cm above opening 3 feet 9m above if within 10 feet 3m horizontally 7 feet 2 1m T 7 feet 2 1m T 12 inches 305 12 inches 305mm t deck or balcony 1 In accordance with the current ANSI Z223 1 NFPA 54 Natural Fuel Gas Code 2 In accordance with the current CSA B149 1 Natural Gas and Propane Installation Code T A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings For clearances not specified in ANSI Z223 1 NFPA 54 or CS
21. Left Side Right Side Front clearance in alcove installation must be 24 in 610 mm Maintain a minimum of 24 in 610 mm for front service access TAllow proper clearances to accommodate condensate trap and vent pipe installation The furnace be installed on a combustible wood floor if an op tional additive base is installed between the furnace and the com bustible floor FIGURE 13 Installation on Non Combustible Flooring 1 Cut floor opening keeping mind clearances listed on unit rating plate Also keep in mind gas supply connec tions electrical supply flue and air intake connections and sufficient installation and servicing clearances See table 1 for correct floor opening size 2 Flange warm air plenum and lower the plenum into the opening 3 Set the unit over the plenum and seal the plenum to the unit 4 Ensure that the seal is adequate TABLE 1 NON COMBUSTIBLE FLOOR OPENING SIZE Front to Rear Side to Side Model No B Cabinet 17 5 19 3 4 502 16 5 8 422 C Cabinet 21 19 3 4 502 20 1 8 511 Pemaes Teo soa eo _ NOTE Floor opening dimensions listed are 1 4 inch 6 mm larger than the unit opening See dimension drawing on page 2 Page 12 Installation on Combustible Flooring Using an Additive Base 1 When unit is installed on a combustible floor an addi tive base must be installed bet
22. STAGE OPERATION DURING THIS HEAT DEMAND FIRST STAGE OPERATION WILL BE ATTEMPTED COMBUSTION AIR INDUCER ON LOW SPEED STATUS ERROR CODE 2 6 STATUS LED HEARTBEAT CONTINUED ON NEXT PAGE Page 57 Troubleshooting Heating Sequence of Operation Continued HEATING SEQUENCE OF OPERATION CONTINUED THERMOSTAT CALLS FOR HEAT STATUS LED HEARTBEAT lt Refer to box on previous page GAS VALVE OFF COMBUSTION AIR INDUCER SWITCH CLOSED WITHIN 2 5 MINUTES OFF INDOOR BLOWER OFF UNIT WILL RETRY AFTER 5 MINUTE WAIT PERIOD YES STATUS ERROR CODE 2 3 15 SECOND COMBUSTION AIR INDUCER PRE PURGE INITIATED BY CLOSED FIRST STAGE PRESSURE SWITCH or 15 SECOND INTER PURGE PERIOD STATUS LED HEARTBEAT IGNITOR WARM UP 20 SECONDS STATUS LED HEARTBEAT YES COMBUSTION AIR INDUCER OFF IGNITOR OFF SIGNAL HOLDS UNTIL IGNITOR IS REPLACED OR RECONNECTED STATUS ERROR CODE 4 7 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 IS VOLTAGE ABOVE 90 VOLTS YES COMBUSTION AIR INDUCER OFF IGNITER OFF 4 SECOND FLAME STABILIZATION PERIOD SIGNAL HOLDS UNTIL VOLTAGE RISES ABOVE 95 VOLTS STATUS ERROR CODE 4 8 FLAME RECTIFICATION CURRENT CHECK CAN FLAME BE PROVEN WITHIN 4 GAS VALVE OFF COMBUSTION AIR SECONDS AFTER GAS VALVE OPENS INDUCER ON INDOOR BLOWER OFF gt 0 20 microamps STATUS LED
23. UL Must be installed TRANSITION required on same side as 2 max exhaust piping length 2 74 di i G61MP 110 111 with 2 diameter street elbow provided M G61MP 135 110 111 Street elbow may be used on 045 070 071 090 and 091 2 1 2 3 OR 4 vent with pipe 3 OR 4 vent pipe FIGURE 23 D to 2 REDUCING ELBOW provided Page 21 TYPICAL EXHAUST PIPE CONNECTIONS HORIZONTAL DIRECT OR NON DIRECT VENT APPLICATIONS Horizontal Right Hand Air Discharge Application Shown 48C 090 60C 090 60C 091 48C 110 60C 110 127 60C 111 60D 135 2 maximum length 36B 045 for 110 111 135 only 2 1 2 36B 070 A OR 36B 071 TRANSITION 2 a 36B 045 368 070 36B 071 36C 090 60C 090 60C 091 DO NOT transition from smaller to larger pipe size in horizontal runs of exhaust pipe FIGURE 24 A IMPORTANT Exhaust piping and condensate trap must be installed on the same side of the unit in upflow and dowflow applications or use alternate drain kit 76M20 2 All horizontal runs of exhaust pipe must slope back to ward unit A minimum of 1 4 6mm drop for each 12 305mm of horizontal run is mandatory for drainage Horizontal runs of exhaust piping must be supported ev ery 5 feet 1 52m us
24. burner box screws at the vestibule panel and remove burner box Set burner box assembly aside NOTE G61MP 135 units are secured to the vestibule panel by two additional screws These screws must be removed for servicing however it is not necessary to replace the screws NOTE If necessary clean burners at this time Follow procedures outlined in Burner Cleaning section 8 Loosen three clamps and remove flexible exhaust tee 9 Remove 3 8 inch rubber cap from condensate drain plug and drain Replace cap after draining Disconnect condensate drain line from the conden sate trap Remove condensate trap it may be neces sary to cut drain pipe Remove screws that secure condensate collars to either side of the furnace and re move collars Remove drain tubes from cold end header collector box 10 11 Disconnect condensate drain tubing from flue collar Remove screws that secure both flue collars into place Remove flue collars It may be necessary to cut the exiting exhaust pipe for removal of the fittings 12 Mark and disconnect all combustion air pressure tub ing from cold end header collector box 13 Mark and remove wires from pressure switches Re move pressure switches Keep tubing attached to pressure switches Disconnect the 3 pin plug from the combustion air in ducer Disconnect the two wires to the backup secon dary limit if applicable Remove four screws which se cure combustion air inducer to collector box R
25. cabinet to discharge end of unit heater 3 To ensure proper operation the duct grille cabinet must be at least 18 inches long 4 Use 10 16 x 1 2 inch sheet metal screws to secure duct grille cabinet to unit taking care not to damage in ternal components of unit heater when drilling holes or installing screws See figure 20 5 Use adjustable double deflection grille s to distribute discharge air Adjust static pressure to be in the 0 06 inch to 0 10 inch w c range SHE DRAIN PAN to protect finished space NOTE When installing duct grille cabinet take care not to damage internal unit heater components when drilling holes or installing screws FIGURE 20 Return Air Horizontal Applications Return air may be brought in only through the end of a fur nace installed in the horizontal position The furnace is equipped with a removable bottom panel to facilitate installation See figure 11 Page 15 This unit is not equipped with a filter or rack A field pro vided filter is required for the unit to operate properly Table 3 lists recommended filter sizes A filter must be in place whenever the unit is operating TABLE 3 Furnace Cabinet Width Side Return Bottom Return 17 12 16 X25 X 1 1 16 X25 X 1 1 16 X 25 X 1 1 20 X 25 X 1 1 24 12 16 X 25 X 1 2 24 X 25 X 1 1 Duct System Use industry approved standards to si
26. con trolled by a two stage heating thermostat factory set ting b Select ON for two stage heating operation con trolled by a single stage heating thermostat This set ting provides a timed delay before second stage heat is initiated Switch 2 Second Stage Delay Used with Single Stage Thermostat Only This switch is used to deter mine the second stage on delay when a single stage ther mostat is being used The switch is factory set in the OFF position which provides a 10 minute delay before second stage heat is initiated If the switch is toggled to the ON position it will provide a 15 minute delay before second stage heat is initiated This switch is only activated when the thermostat selector jumper is positioned for SINGLE stage thermostat use Switches 3 and 4 Heating Blower Off Delay The heating blower on delay of 45 seconds is not adjustable The heating blower off delay time that the blower operates after the heating demand has been satisfied can be ad justed by moving switches 3 and 4 on the integrated control board The unit is shipped from the factory with a heating blower off delay of 90 seconds The heating blower off delay affects comfort and is adjustable to satisfy individual applications Adjust the blower off delay to achieve a sup ply air temperature between 90 and 110 F at the exact moment that the blower is de energized Longer off delay settings provide lower supply air temperatures
27. each corner of the furnace s bottom See fig ure 12 for the correct location of the holes Drill through the bottom panel and the bottom flange of the cabinet 2 Install one bolt and two nuts into each hole Screw the first nut onto a bolt and then insert the bolt into a hole A flat washer may be added between the nut and the bot tom of the unit 3 Screw another nut onto the bolt on the inside of the fur nace base A flat washer may be added between the nut and the bottom of the unit 4 Adjust the outside nut to the appropriate height and tighten the inside nut to secure the arrangement NOTE The unit may be tilted back to front a maximum of 1 This will ensure proper draining of the heat exchanger Leveling Bolt Installation Inches mm 3 8 Furnace Front 3 8 Leveling Bolt Furnace Locations Bottom Leveling Bolt Locations 3 8 y 10 1 3 4 44 FIGURE 12 Downflow Applications The unit may be installed three ways in downflow applica tions on non combustible flooring on combustible flooring using an additive base or on a reverse flow cooling cabi net Do not drag the unit across the floor in the down flow position Flange damage will result After unit has been properly set in place position provided logo over existing logo and affix sticker on front panel Refer to figure 13 for clearances in downflow applica tions Downflow Application Installation Clearances
28. in 305mm above average snow accumulation 6 inches 152mm for appliances lt 10 000 6 inches 152mm for appliances lt 10 000 Btuh 3kw 9 inches mm for appliances Btuh 3kw 12 inches 305mm for gt 10 000 Btuh 3kw and lt 50 000 Btuh appliances gt 10 000 Btuh 3kw and 15 kw 12 inches 305mm for ap lt 100 000 Btuh 30kw 36 inches 9m pliances gt 50 000 Btuh 15kw for appliances gt 100 000 Btuh 30kw 42 12 Equal to or greater than soffit depth Equal to or greater than soffit depth Equal to or greater than soffit depth No minimum to outside corner 3 feet 9m 3 feet 9m within a height 15 feet 4 5m above the meter regulator assembly 8 feet 9m Equal to or greater than soffit depth No minimum to outside corner 3 feet 9m 3 feet 9m within a height 15 feet 4 5m above the meter regulator assembly 3 feet 9m 6 inches 152mm for appliances 10 000 6 inches 152mm for appliances 10 000 Btuh 3kw 9 inches mm for appliances Btuh 3kw 12 inches 305mm for gt 10 000 Btuh 3kw and 50 000 Btuh appliances gt 10 000 Btuh 3kw and 15 kw 12 inches 305mm for ap 100 000 Btuh 30kw 36 inches 9m liances 50 000 Btuh 15kw for appliances gt 100 000 Btuh 30kw 3 feet 9m above if within 10 feet 6 feet 1 8m 3m horizontally 7 feet 2 1m 7 feet 2 1m t 12 inches 305mm t 12 inches 305mm t deck or balcony 1 In accordanc
29. least one square inch per 4 000 Btu 645mm2 per 1 17kW per hour of the total input rating of all equipment in the enclosure FIGURE 4 EQUIPMENT IN CONFINED SPACE ALL AIR FROM OUTSIDE All Air Through Ventilated Attic ROOF TERMINATED EXHAUST PIPE VENTILATION LOUVERS Each end of attic w AAE n TERMINATED EXHAUST PIPE ALTERNATE LOCATION INLET AIR Ends 12 above bottom NOTE The inlet and outlet air openings shall each have a free area of at least one square inch per 4 000 Btu 645mm per 1 17kW per hour of the total input rating of all equipment in the enclosure FIGURE 5 If air from outside is brought in for combustion and ventila tion the confined space must have two permanent open ings One opening shall be within 12 inches 305 mm of the top of the enclosure and one opening within 12 inches 305 mm of the bottom These openings must communi cate directly or by ducts with the outdoors or spaces crawl or attic that freely communicate with the outdoors or indi rectly through vertical ducts Each opening shall have a minimum free area of 1 square inch 645 mm per 4 000 Btu 1 17 kW per hour of total input rating of all equipment in the enclosure See figures 4 and 5 When communicat ing with the outdoors through horizontal ducts each open ing shall have a minimum free area of 1 square inch 645 mm per 2 000 Btu 56 kW per total input ratin
30. main disconnect switch closed 4 Is there a blown fuse 5 Is the filter dirty or plugged Dirty or plugged filters will cause the limit control to shut the unit off 6 Is gas turned on at the meter 7 Is the manual main shut off valve open 8 Is the internal manual shut off valve open 9 Is the unit ignition system in lock out If the unit locks out again inspect the unit for blockages Blower Performance Data G61MP 36B 045 PERFORMANCE Less Filter G61MP 48C 090 PERFORMANCE Less Filter External Air Volume Watts at Different Blower Speeds External Air Volume Watts at Different Blower Speeds High DOR Medium Low Meat High Low in W g cfm Watts cfm Watts cfm Watts cfm Watts in W 9 cfm Watts cfm Watts cfm Watts cfm Watts 0 00 1555 630 1410 585 1190 520 1030 435 0 00 2180 930 1280 510 0 10 1515 605 1385 555 1190 485 1020 415 0 10 2135 885 1275 495 0 20 1470 580 1345 520 1170 455 1010 400 0 20 2085 840 1270 475 030 1410 555 1310 495 1155 440 1000 385 0 30 2030 800 1265 460 0 40 1350 535 1250 465 1120 410 980 360 0 40 1940 760 1250 440 0 50 1290 505 1205 450 1080 390 950 345 0 50 1865 725 1215 425 0 60 1220 485 1145 420 1020 365 905 320 0 60 1740 670 1175 410 0 70 1145 460 1080 400 975 345 860 300 0 70 1645 640 1105 375 0 80 1050 425 985 365 870 320 785 285 Ri s 2 Ad a 0 90 945 410 900 345 825 3051730 20_ NOTES
31. neutral leg of the circuit being connected to one of the provided neutral terminals See figure 52 for control board configuration This terminal is energized in the heating mode when the combustion air inducer is oper ating One line voltage EAC 1 4 spade terminal is provided on the furnace control board Any electronic air cleaner rated up to one amp can be connected to this terminal with the neutral leg of the circuit being connected to one of the provided neutral terminals See figure 52 for control board configuration This terminal is energized when the indoor blower is operating 1 N Page 35 9 One 24V H terminal is provided on the furnace control Indoor Blower Speeds board terminal block Any humidifier rated up to 0 5 1 When the thermostat is set to FAN ON the indoor amp can be connected to this terminal with the ground blower will run continuously on the low heat speed leg of the circuit being connected to either ground or when there is no cooling or heating demand the C terminal See figure 52 for control board config 2 When the G61MP is operating in the high fire or low 0 fire heating mode the indoor blower will run on the cor 10 Install the room thermostat according to the instruc responding heating speed provided Wii IE Oq s a TO Tor 3 When there is a cooling demand the indoor blower will field wiring connections in varying applications If the t
32. normally open contacts The combustion air inducer is ener gized at low speed and the humidifier terminal is ener gized 2 Once the control receives a signal that the low fire pressure switch has closed the combustion air induc er begins a 15 second pre purge in low speed 3 After the pre purge is complete a 20 second initial ig nitor warm up period begins The combustion air in ducer continues to operate at low speed 4 After the 20 second warm up period has ended the gas valve is energized on low fire first stage and ignition oc curs At the same time the control module sends a sig nal to begin an indoor blower 45 second ON delay When the delay ends the indoor blower motor is ener gized on the low fire heating speed The integrated control also initiates a second stage on delay factory set at 10 minutes adjustable to 15 minutes 5 If the heating demand continues beyond the second stage on delay the integrated control energizes the combustion air inducer at high speed The control also checks the high fire second stage pressure switch to make sure it is closed Once the control receives a sig nal the high fire pressure switch is closed the high fire second stage gas valve is energized and the indoor blower motor is energized for operation at the high fire heating speed 6 When the thermostat heating demand is satisfied the combustion air inducer begins a 5 second post purge The field selected indoor blowe
33. ordered separately 1 Thermostat 1 Propane LP changeover kit A DANGER Danger of explosion There are circumstances in which odorant used with LP propane gas can lose its scent In case of a leak LP propane gas will settle close to the floor and may be difficult to smell An LP propane leak detector should be installed in all LP applications Safety Information AWARNING 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 licensed professional installer or equivalent service agency or the gas supplier ACAUTION As with any mechanical equipment personal injury can result from contact with sharp sheet metal edges Be careful when you handle this equipment Use only the type of gas approved for use with this furnace Refer to unit nameplate G61MP units are CSA International certified to ANSI Z21 47 and CSA 2 3 standards In the USA installation of gas furnaces must conform with lo cal building codes In the absence of local codes units must be installed according to the current National Fuel Gas Code ANSI Z223 1 NFPA 54 The National Fuel Gas Code is available from the following address American National Standards Institute Inc 11 West 42nd Street New York NY 10036 Page 4 In Canada installation must conform with current National Standard of Canada CSA B149 Natural Gas
34. retum air applications Air volume based on bottom air return air Actual air volume may vary on side return air applications G61MP 36B 071 PERFORMANCE Less Filter Air Volume Watts at Different Blower Speeds External Static Medium Medium Pressure High High Low Low in W 9 cfm Watts cfm Watts cfm Watts cfm Watts 0 00 1460 620 1215 570 965 445 785 375 0 10 1420 590 1215 545 990 425 815 365 0 20 1365 550 1195 505 980 410 810 350 0 30 1325 525 1170 490 980 390 820 335 0 40 1255 495 1155 455 945 365 795 320 0 50 1190 465 1080 425 915 345 785 305 0 60 1120 440 1050 395 865 320 755 285 0 70 1035 410 975 365 790 295 695 255 0 80 900 375 865 330 715 275 615 235 0 90 795 350 745 300 600 245 510 215 NOTES 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 48 G61MP 60C 090 PERFORMANCE Less Filter Air Volume Watts at Different Blower Speeds Bottom Return Air Side Return Air with Optional RAB Single Side Return Air Air volumes in bold require field Return Air Base Return Air from Both Sides or Return Air from Bottom and One Side External Static Pressure in w g 0 00 0 10 0 20 0 30 0 40 0 50 0 60 0 70 0 80 0 90 High Medium High Medium Low cfm 2840 2765 269
35. shorter set tings provide higher supply air temperatures Table 11 pro vides the blower off timings that will result from different switch settings TABLE 11 Heating Blower Off Delay Switch Settings Blower Off Delay Switch 3 P a NN _ y 5 s 120 O Of 6 0 E SO OR Switch 5 Cooling Blower Off Delay The cooling blower off delay time that the blower operates after the cooling demand has been satisfied can be adjusted by moving switch 5 on the integrated control board The switch is factory set in the OFF position which provides a cooling blower off delay of 45 seconds If the switch is toggled to the ON position it will provide a 2 second cool ing blower off delay On Board Jumper W951 Figure 53 On board jumper W951 which connects terminals R and O on the integrated control board must be cut when the fur nace is installed in applications which include a heat pump unit and a thermostat which features dual fuel use If the jumper is left intact terminal O will remain energized elim inating the HEAT MODE in the heat pump On Board Jumper W915 Figure 53 On board jumper W915 which connects terminals Y1 and Y2 on the integrated control board must be cut if two stage cooling will be used If the jumper is not cut the outdoor unit will operate in first stage cooling only Unit Start Up FOR YOUR SAFETY READ BEFORE OPERATING AWARNING Do not use this furnace if any pa
36. to gas valve 42 Replace the blower compartment access panel 43 Refer to instruction on verifying gas and electrical con nections when re establishing supplies 44 Follow lighting instructions to light and operate fur nace for 5 minutes to ensure that heat exchanger is clean and dry and that furnace is operating properly 45 Replace heating compartment access panel Cleaning the Burner Assembly 1 Turn off electrical and gas power supplies to furnace Remove upper and lower furnace access panels 2 Mark all gas valve wires and disconnect them from the valve 3 Disconnect the gas supply line from the gas valve Re move gas valve manifold assembly 4 Mark and disconnect sensor wire from the sensor Dis connect 2 pin plug from the ignitor at the burner box 5 Remove burner box cover and remove four screws which secure burner box assembly to vest panel Re move burner box from the unit NOTE G61MP 135 units are secured to the vestibule panel by two additional screws These screws must be removed for servicing however it is not necessary to replace the screws 6 Use the soft brush attachment on a vacuum cleaner to gently clean the face of the burners Visually inspect the inside of the burners and crossovers for any block age caused by foreign matter Remove any blockage 7 Reconnect the sensor wire and reconnect the 2 pin plug to the ignitor wiring harness 8 Reinstall the burner box assembly usin
37. which will accommodate 20 x 25 x 1 in 508 x 635 x 25 mm air filter Required to maintain proper air velocity See figure 10 2 Return air from single side with optional RAB Return Air Base See figure 9 3 Return air from bottom 4 Return air from both sides 5 Return air from bottom and one side Refer to Engineering Handbook for additional information Page 10 Optional Return Air Base Upflow Applications Only For use with B C and D cabinets only 123 584 Overall 1 Minimum Maximum 11 279 4 2 Maximum 1 22 7 16 Unit side return air 4 356 570 AIR FLOW Opening Overall FURNACE y Maximum FRONT 5 5 8 SIDE RETURN 7 114 184 143 AIR OPENINGS Y Either Side OPTIONAL RAB sss 23 584 peni A 3 4 17 1 2 446 RAB B 98M60 RETURN AIR BASE 19 21 533 RAB C 98M58 718 27 5 8 702 24 1 2 622 RAB D 98M59 22 SIDE VIEW FRONT VIEW NOTE Optional Side Return Air Filter Kits are not for use with RAB Return Air Base 1 Both the unit return air opening and the base return air opening must be covered by a single plenum or IAQ cabinet Minimum unit side return air opening dimensions for units requiring 1800 cfm or more of air W x H 23 x 11 in 584 x 279 mm The opening can be cut as needed to accommodate plenum or IAQ cabinet while maintaining dimensions shown Side return air openings must be cut in the field There are cutting guides stenciled
38. 0 Air from Bottom and One Side High Medium Low Medium High Medium Low Low cfm 2320 2250 2185 2060 1995 1920 1800 1710 1600 Watts 1230 1195 1165 1120 1095 1060 1025 1000 975 1475 940 1750 755 1625 735 1545 700 1405 670 cfm 1605 1500 1455 1305 All air data is measured external to unit without filter not turnishe Watts 640 605 585 555 field provided 1485 560 1380 535 1335 515 1105 450 Page 49 1825 1705 1605 1050 1025 1515 995 1460 950 cfm 2195 2125 2060 1945 1875 1820 1720 1605 Watts 960 930 905 830 815 780 760 725 700 1370 665 cfm Watts 1920 1910 1875 1830 1750 1715 1635 1485 1440 1285 830 800 775 725 705 670 645 615 585 555 cfm 1535 1580 1570 1545 1495 1510 1450 1360 1320 Watts 680 665 655 625 605 585 555 535 510 1175 480 Blower Performance Data G61MP 60C 110 PERFORMANCE Less Filter External Static Pressure in w g 0 00 High 2720 Medium High cfm Watts 1090 2055 Medium Low cfm Watts 935 Air Volume Watts at Different Blower Speeds 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 1620 Medium High 2625 1350 2310 1080 Air Volume Watts at Different Bl
39. 0 mm Maintain a minimum of 24 in 610 mm for front service access A 5 1 2 service clearance must be maintained below the unit to provide for servicing of the condensate trap For installations on a combustible floor do not install the furnace directly on carpeting tile or other combustible materials other than wood flooring FIGURE 17 Suspended Installation of Horizontal Unit NOTE If unit is suspended in attic or crawl space horizon tal support kit Cat No 56 18 ordered separately must be used to ensure proper unit support and coil drainage 1 Select location for unit keeping in mind service and other necessary clearances See figure 17 2 Provide service platform in front of unit Page 14 If unit is installed above finished space fabricate a drain pan fitted with a 1 2 inch 3 4 inch N P T fitting Using 3 8 inch rods and support frame kit or field fabri cated supports fabricate suspension hangers keep ing in mind front service access clearances 5 Mount unit on support frame as shown in figure 18 6 Continue with exhaust condensate and intake line piping instructions f unit is suspended above finished space hang the field provided drain pan below the support frame as shown in figure 18 Leave 5 1 2 inches for service clearance below unit for condensate trap Route auxiliary drain line so that water draining from this outlet will be easily noticed by the homeowner If neces
40. 5 2605 2530 2420 2330 2250 2135 2030 Watts 1450 1415 1385 1335 1300 1260 1220 1190 1140 1090 cfm 2145 2050 2000 1885 Watts 925 885 865 830 cfm 1930 1875 1810 1720 Watts 775 745 715 685 Low cfm Watts fabricated transition to accommodate 20 x 25 x 1 in air filter in order to maintain proper air velocity High Medium High 1665 1645 1620 1560 650 630 615 590 cfm 2365 2240 2185 2015 Watts 1270 1205 1190 1150 cfm 2340 2345 2275 2260 2230 2175 2130 2070 1965 1820 Watts 1155 1135 1080 1035 1015 990 940 915 865 820 Medium Low cfm Watts 1800 1805 1825 1840 1845 1850 1830 1815 1775 1690 895 865 845 825 815 790 775 760 745 715 Low cfm Watts 1440 695 1515 690 1560 685 1600 680 1620 670 1615 655 1615 640 1595 620 1555 605 1440 580 NOTES All air data is measured external to unit without filter not furnished field provided G61MP 60C 091 PERFORMANCE Less Filter Air Volume Watts at Different Blower Speeds Bottom Return Air Side Return Air with Optional RAB Single Side Return Air Air volumes in bold require field Return Air Base Return Air from Both Sides or Return fabricated transition to accommodate 20 x 25 x 1 in air filter in order to maintain proper air velocity External Static Pressure in w g 0 00 0 10 0 20 0 30 0 40 0 50 0 60 0 70 0 80 0 9
41. A B149 1 clear ance will be in accordance with local installation codes and the requirements of the gas supplier and these installation instructions Permitted only if veranda porch deck or balcony is fully open on a minimum of two sides beneath the floor Lennox recommends avoiding this location if possible FIGURE 29 Page 26 VENT TERMINATION CLEARANCES FOR DIRECT VENT INSTALLATIONS IN THE USA AND CANADA VENT TERMINAL Clearance above grade veranda porch deck or balcony Clearance to window or door that may be opened Clearance to permanently closed window Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet mm from the center line of the terminal Clearance to unventilated soffit Clearance to outside corner Clearance to inside corner Clearance to each side of center line ex tended above meter regulator assembly Clearance to service regulator vent outlet Clearance to non mechanical air supply inlet to building or the com bustion air inlet to any other ap pliance Clearance to mechanical air sup ply inlet Clearance above paved sidewalk or paved driveway located on public property Clearance under veranda porch INSIDE CORNER DETAIL lt AREA WHERE TERMINAL Q air SUPPLY INLET 15 NOT PERMITTED US Installations1 12 inches 305mm or 12 in 305mm above average snow accumulation Canadian Installations2 12 inches 305mm or 12
42. AT CONNECTIONS TB1 HEAT DEMAND FROM IST STAGE T STAT HEAT DEMAND FROM 2ND STAGE T STAT MANUAL FAN FROM T STAT THERMOSTAT 2nd STAGE COOL SIGNAL THERMOSTAT Ist STAGE COOL SIGNAL THERMOSTAT SIGNAL GROUND CONNECTED TO TRANSFORMER GROUND TR amp CHASIS GROUND GRD R CLASS 2 VOLTAGE TO THERMOSTAT 1 ERROR CODE RECALL H 24V HUMIDIFIER OUTPUT L DO NOT USE 0 THERMOSTAT SIGNAL TO HEAT PUMP REVERSING VALVE DIP SWITCH FUNCTIONS DIP SWITCH ES FUNCTION 1 2 Stage T stat Selects t stat type single or two stage 2 2nd Stage Dela Second stage ON delay single stage t stat 3 amp 4 Heat Off Dela Heating fan OFF dela 5 Cool Off Dela Cooling fan OFF dela FIGURE 52 Page 39 INTEGRATED CONTROL BOARD DIP SWITCH SETTINGS AND JUMPERS 2ND STAGE DELAY COOL OFF DELAY BLOWER SINGLE STAGE THERMOSTAT TIMED STAGING TSTAT HEAT STAGES TSTAT HEAT STAGES end STAGE DELAY I TSTAT HEAT STAGES 2nd STAGE DELAY H HEAT OFF DELAY 10 MIN rcm 45 SECOND DELAY CLG BLOWER OFF DELAY 2 SECOND CLG BLOWER OFF DELAY J TSTAT HEAT STAGES 2nd STAGE DELAY 2 8TAGE THERMOSTAT SINGLE STAGE THERMOSTAT UNUSED MOTOR SPEED LOW STAGE HEAT amp CONTINUOUS FAN MOTOR SPEED IIGH STAGE HEAT LOW STAGE COOLING SPEED HIGH STAGE COOLING MOTOR SPEED HEATING OFF DELAY BLOWER FUTURE USE e lt x J Tu lt ae 60 SEC
43. All air data is measured external to unit without filter not fumished field provided Rebel Nini ee IE Based Gri boliar are ii aif Acha Gl yolar Tiy en side Teim alr applicalione G61MP 36B 070 PERFORMANCE Less Filter G61MP 48C 110 PERFORMANCE Less Filter External Air Volume Watts at Different Blower Speeds External Air Volume Watts at Blower Speeds in w 9 cfm Watts cfm Watts cfm Watts cfm Watts in W 9 cfm Watts cfm Watts cfm Watts cfm Watts 0 00 1640 660 1415 575 1160 485 1005 410 0 00 2160 880 1235 485 0 10 1600 635 1395 550 1160 460 1000 385 0 10 2100 850 1230 475 0 20 1540 605 1370 525 1160 445 995 375 0 20 2035 805 1225 460 0 30 1965 750 0 40 1885 725 0 50 1780 680 0 60 1690 660 0 70 1575 620 1220 445 1215 430 1150 400 1110 380 1035 350 970 325 0 30 11495 580 1345 505 1145 425 990 365 0 40 1420 545 1275 480 1125 395 965 345 0 50 1360 525 1245 450 1080 375 945 325 0 60 11275 490 1165 410 1025 350 900 305 0 70 1170 465 1085 385 965 335 860 295 0 80 4375 550 0 80 1080 440 1010 360 865 310 775 270 0 90 1225 520 885 310 0 90 945 400 840 320 765 275 710 245 NOTES All air data is measured external to unit without filter not furnished field provided NOTES All air data is measured external to unit without filter not fumished field provided Air volume based on bottom air return air Actual air volume may vary on side
44. E 8 12 305mm ABOVE AVE SNOW ACCUMULATIO Memri 1 2 13mm 3 8 EXHAUST VENT 203mm 8 12 203mm 305mm INTAKE PIPE SHOULDER OF FITTINGS INSULATION optional PROVIDE SUPPORT OF PIPE ON TOP PLATE SHEET ALTERNATE METAL TOP PLATE INTAKE PIPE WEATHERPROOF INSULATION 3 76 OR 2 51 PVC UNCONDITIONED ATTIC SPACE PROVIDE SUPPORT FOR EXHAUST LINES Minimum 12 305 above roof or average snow accumulation 203i INSULATE 77 EXTERIOR TO FORM PORTION OF SEAL CHIMNEY SIZE TERMINATION PIPE PER TABLE 8 NON DIRECT VENT ROOF TERMINATION KIT 15F75 or 44J41 NOTE Do not discharge exhaust gases directly into any chimney or vent stack If ver FIGURE 40 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 39 Details of Exhaust Piping Terminations for Non Direct CES 12 305 Max for 2 51 Vent Applications Unless Supported 1 2 13 ARMAFLEX Exhaust pipes may be routed either horizontally through an INSULATION IN 10 13 outside wall or vertically through the roof In attic or closet GUN DEUS ea SPACE ARMAFLEX installations vertical termination through the roof is pre PROVIDED INSULATION ferred Figures 40 through 43 show typical t
45. EDUCER MAY BE REQUIRED TO ADAPT LARGER VENT PIPE SIZE TO TERMINATION 6 152 MAXIMUM Li TERMINATION PIPE PER TABLE 8 4 102 MINIMUM Inches nm OUTSIDE WALL TOP VIEW WALL RING KIT WITH 90 ELBOW ON INTAKE 15F74 FIGURE 32 Page 28 EXHAUST TERMINATION 12 305 ABOVE AVERAGE SNOW ACCUMULATION Inches mm INTAKE FIELD PROVIDED REDUCER MAY BE REQUIRED TO ADAPT LARGER VENT PIPE SIZE TO TERMINATION EXHAUST INTAKE DIRECT VENT CONCENTRIC ROOFTOP TERMINATION 71M80 69M29 or 60L46 FIGURE 33 INTAKE TERMINATION gt EXHAUST z TERMINATION INTAKE 12 305 above grade or average snow accumulation Inches mm EXHAUST e FIELD PROVIDED REDUCER MAY BE REQUIRED TO ADAPT LARGER VENT PIPE SIZE TO TERMINATION DIRECT VENT CONCENTRIC WALL TERMINATION 71M80 69M29 or 60L46 FIGURE 34 12 305 MAX for 2 51 Inches mm unless supported UNCONDITIONED SPACE 72 LH 2227777 i 8 203 MIN OUTSIDE WALL gt SSSSSSSSSSS SIZE TERMINATION PIPE PER TABLE 8 PROVIDE SUPPORT FOR INTAKE AND EXHAUST LINES EVERY 36 914 SSSSSSSSSSSSSSS SSSSSSSSSSS NS 12 305 ABOVE AVERAGE SNOW ACCUMULATION FIELD PROVIDED REDUCER MAY BE REQUIRED TO Zzzzzzzzzzz 2 ADAPT LARGER VENT PIPE SIZE TO TERMINATION 1 2 13 FOAM INSULATION IN UNCONDITIONED N N NSSSSSSSS 1 2 13 FOAM SPACE INSULATIO
46. ES YES INDOOR BLOWER RAMPS DOWN TO FIRST STAGE INDOOR BLOWER RAMPS DOWN TO LOW COOL SPEED HEAT SPEED Repair Parts List The following repair parts are available through Lennox dealers When ordering parts include the complete furnace model number listed on the CSA nameplate Example G61MP 36B 045 1 All service must be performed by a licensed pro fessional installer or equivalent service agency or gas supplier Cabinet Parts Heating Parts Upper access panel Flame Sensor Blower access panel Heat exchanger assembly Top Cap Gas manifold Control Panel Parts Combustion air inducer Transformer Gas valve Two stage integrated control board Main burner cluster Door interlock switch Main burner orifices Circuit Breaker Pressure switches Blower Parts Ignitor Blower wheel Primary limit control Motor Secondary limit control Motor mounting frame Flame rollout switches Motor capacitor Combustion air inducer auxiliary limit Blower housing cutoff plate Page 62 Vent Pipe Sizing Worksheet Proposed vent pipe size Equivalent Feet Termination kit catalog number Vent pipe equivalency value from table 5 Total number of 90 elbows required indoors and outdoors X5 equivalent feet of pipe Total number of 45 elbows required indoors and outdoors i 2 5 equivalent feet of pipe Linear feet of straight pipe required Add equivalent feet of vent pipe listed in steps 2 through 5 If the total is equal to or l
47. IER DURING HEAT DEMAND J P5B 4 84 J P135 J P156 J P159 THERMOSTAT HEAT ANTICIPATION SETTING 85AMP HONEYWELL VALVE 50AMP WHITE RODGERS VALVE A JUMPER W915 FROM Y1 TO Y2 IS FACTORY INSTALLED AT 92 CONTROL BOARD LEAVE IN FOR ONE STAGE COOL THERMOSTAT CUT JUMPER Y1 TO Y2 FOR TWO STAGE COOL THERMOSTAT FACTORY DEFAULT IS FOR A 2 STAGE THERMOSTAT A 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 S113 USED ON 090 091 110 111 AND 135 UNITS ONLY FOR 045 AND 070 UNITS ONLY FOR 071 090 091 110 111 AND 135 UNITS ONLY CUT W951 JUMPER FROM O TO R LABELED HEAT PUMP AT A92 CONTROL BOARD WHEN USED FOR DUAL FUEL APPLICATIONS TERMINAL 1 IS USED FOR ERROR CODE RECALL ONLY SEE INSTALLATION INSTRUCTIONS FOR TWO STAGE DETAILS HEAT COOL RY 7 ef Ne LINE VOLTAGE FIELD INSTALLED CLASS II VOLTAGE FIELD WIRING DENOTES OPTIONAL COMPONENTS FIGURE 54 Page 41 e roo 9 3
48. 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 TERMINATION CLEARANCES FOR NON DIRECT VENT INSTALLATIONS IN THE USA AND CANADA VENT TERMINAL Clearance above grade veranda porch deck or balcony Clearance to window or door that may be opened Clearance to permanently closed window Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet mm from the center line of the terminal Clearance to unventilated soffit Clearance to outside corner Clearance to inside corner Clearance to each side of center line ex tended above meter regulator assembly Clearance to service regulator vent outlet Clearance to non mechanical air supply inlet to building or the com bustion air inlet to any other ap pliance Clearance to mechanical air sup ply inlet Clearance above paved sidewalk or paved driveway located on public property Clearance under veranda porch INSIDE CORNER DETAIL AREA WHERE TERMINAL IS NOT PERMITTED AIR SUPPLY INLET Canadian Installations2 12 inches 305mm or 12 in 305mm above average snow accumulation US Installations 12 inches 305mm or 12 in 305mm above average snow accumulation 6 inches 152mm for appliances lt 10 000 Btuh 3kw 12 inches 305mm for appliances gt 10 000
49. LENNOX 2009 Lennox Industries Inc Dallas Texas USA THIS MANUAL MUST BE LEFT WITH THE HOMEOWNER FOR FUTURE REFERENCE INSTALLATION INSTRUCTIONS G61MP SERIES UNITS GAS UNITS Technical 506406 01 Publications 08 2009 Supersedes 505 124M Litho U S A Table of Contents Unit Dimensions 2 G61MP Parts Identification 3 Shipping and Packing List 4 Safety Information 4 Use of Furnace as Construction Heater 5 General 6 Combustion Dilution amp Ventilation Air 6 Installation Setting Equipment 8 Filters entschied 16 Duct System sob Due eere rex e See 16 Pipe amp Fittings Specifications 16 Vent Piping Guidelines 18 Joint Cementing Procedure 20 Venting Practices 21 Gas PIPING aw dete dp RR RE EE ate 33 Electrical uuu rene vei ee 35 Integrated Control Board 42 Unit Start UDe u giclee a a clans ea bi vates 42 Gas Pressure Adjustment 44 High Altitude Information 45 Other Unit Adjustments 46 ecstatic ete E 53 Ignition Control Board Diagnostic Codes 56 Troubleshooting
50. MBLY BURNER BOX ASSEMBLY GAS VALVE AND MANIFOLD FLUE COLLAR COMBUSTION AIR PRESSURE BoM gt gt s WARM HEADER PROVE SWITCHES 4 COLLECTOR aN y BOX COMBUSTION AIR wr YA V INDUCERS D i i CONDENSER COIL BURNER ACCESS ic PRIMARY LIMIT PANEL 5 COLD HEADER COLLECTOR BLOWER ACCESS DOOR INTERLOCK 2 Z ZEN SECONDARY 017 LIMITS 2 G61MP 090 shown G61MP 045 and 070 SIGHT J d Z BLOWER S ASSEMBLY are equipped with GLASS two switches CONTROL BOX FIGURE 1 Page 3 G61MP Gas Furnace The G61MP category IV gas furnace is shipped ready for installation in the upflow downflow horizontal left air dis charge or horizontal right air discharge position The fur nace is shipped with the bottom panel in place The bot tom panel must be removed if the unit is to be installed in upflow applications with bottom return air The bottom panel must also be removed and discarded in all downflow or horizontal applications The furnace is equipped for installation in natural gas ap plications A conversion kit ordered separately is re quired for use in propane LP gas applications The G61MP can be installed as either a Direct Vent or a Non Direct Vent gas central furnace NOTE In Direct Vent installations combustion air is taken from outdoors and flue gases are discharged outdoors In Non Direct
51. MINUTES INDOOR BLOWER OFF WITH DELAY Indoor blower on low speed during 3 minute period STATUS LED PULSE SECOND STAGE HEAT DEMAND LIMIT SWITCH WATCHGUARD MODE SECOND STAGE HEAT DEMAND REQUIRED GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF WITH DELAY YES STATUS ERROR CODE 4 5 IS 60 MINUTE RESET PERIOD COMPLETE SECOND STAGE PRESSURE SWITCH CLOSED ABNORMAL FLASH CODE GAS VALVE OFF COMBUSTION AIR INDUCER ON NOTE IF SECOND STAGE PRESSURE SWITCH INDOOR BLOWER OFF AFTER DELAY WAS ORIGINALLY FOUND CLOSED STATUS ERROR CODE 2 3 CONTROL RESTARTS ABNORMAL CODE WILL FLASH IGNITION SEQUENCE IF PRESSURE SWITCH CLOSES WITHIN 2 1 2 MINUTES SECOND STAGE PRESSURE SWITCH CLOSED SECOND STAGE 30 SECOND DELAY ON BEGINS STATUS LED HEARTBEAT AT BEGINNING OF HEAT DEMAND STATUS ERROR CODE 2 6 SECOND STAGE HEAT DEMAND SECOND STAGE COMBUSTION AIR INDUCER STATUS LED HEARTBEAT ON SECOND STAGE GAS VALVE ON HIGH HEAT INDOOR BLOWER SPEED ON STATUS LED HEARTBEAT RETURNS TO FIRST STAGE HEAT MODE WHICH CONTINUES UNTIL SECOND STAGE PRESSURE SWITCH CAN BE PROVEN or HEAT DEMAND IS SATISFIED FIVE 5 MINUTE WAIT PERIOD SECOND STAGE PRESSURE SWITCH CLOSED INITIATED BEFORE RETRY WERE 5 ATTEMPTS IN LESS THAN TEN 10 SECONDS MADE FOR SECOND STAGE HEAT STATUS LED HEARTBEAT YES CONTINUES FIRST STAGE HEATING DEMAND WILL NOT REATTEMPT SECOND STAGE CONTINUED ON NEXT PAGE HEATING DEMAND STATUS ERROR CODE 2 5
52. N SIDE VIEW DIRECT VENT WALL RING TERMINATION 15F74 See venting table 6 for maximum venting lengths with this arrangement FIGURE 35 Page 29 EXHAUST VENT Front View INTAKE VENT 1 2 13 Foam Insulation in Unconditioned Space Side View PROVIDED EXHAUST VENT TO ADAPT LARGER VENT PIPE SIZE TO TERMINATION INTAKE VENT Inches mm OUTSIDE WALL DIRECT VENT WALL TERMINATION KIT 22G44 44J40 30G28 or 81J20 FIGURE 36 EXHAUST VENT INTAKE VENT Front View EXHAUST VENT Inches mm ee INTAKE s VENT Side View OPTIONAL VENT TERMINATION FOR MULTIPLE UNIT INSTALLATION OF DIRECT VENT WALL TERMINATION KIT WTK FIGURE 37 20 508 MAX for 3 76 for 3 unless supported Inches mm COVER EXHAUST VENT WITH a n EXHAUST 1 2 13 mp AIR INTAKE 8 203 INTAKE INSULATION AIR Minimum Minimum 12 lt q 305 k EXHAUST above grade or AIR average snow 5 Minimum 12 accumulation 305 7 above grade or average snow accumulation Side View GRADE ZZEZZZZZZZZZZZZZZZz7 DIRECT VENT TERMINATION WALL TERMINATION KIT 22G44 44J40 30G28 or 81J20 EXTENDED VENT FOR GRADE CLEARANCE FIGURE 38 Front View G61MP DIRECT VENT APPLICATION USING EXISTING CHIMNEY ANGLECUT IN DIRECTION Inches mm SIZE TERMINATION OF ROOF SLOPE PIPE PER TABL
53. OND HTG BLOWER OFF DELAY 90 SECOND HTG BLOWER OFF DELAY 120 SECOND ON BOARD JUMPER HTG BLOWER OPTION SELECTION OFF DELAY 1 STG COMPRESSOR NOTES at w915 x FACTORY DEFAULT SETTING 180 SECOND 2 STAGE HTG BLOWER COMPR SEE INTEGRATED CONTROL DETAILED SETUP OFF DELAY D NOT CUT INFORMATION FOR COMPLETE SETUP amp CONFIGURATION DETAILS DO NOT CUT PROTECTIVE PLASTIC FILM ON DIP SWITCHES MAY BE REMOVED FOR EASE OF SETTING DIP SV 2 STG COMPRESSOR HEAT PUMP UNIT CUT ON BOARD JUMPER SOLDER TRACE COMPLETELY THROUGH BOTH LAYERS ON THE CONTROL BOARD JUMPERS CUT IN ERROR CAN BE RESOLVED BY FIELD INSTALLING A JUMPER UN THE APPROPRIATE TERMINALS ON THE TERMINAL STRIP J W915 JUMPERZZ W951 JUMPER 2 STAGE HEAT PUMP JUMPER COMPRESSOR JUMPER JUMPERS R to D JUMPERS to Y2 FIGURE 53 Page 40 TYPICAL G61MP WIRING DIAGRAM HIGH HEAT PRESSURE SWITCH Bi LOW HEAT 600 135 5 SPEED TAPS ae T STAT HEAT STG Sas ES 2 e ae sS a AA eae SBHSHOOOS TERMINAL BOARD Ad 24v POWER PROVIDED FOR OPTIONAL HUMIDIF
54. TION STATUS ERROR CODE 5 4 SIGNAL IMPROPER GROUND AT LED IS THERE CONTROL WILL CONTINUE TO CALL FOR COOLING PROPER GROUND IN THIS CONDITION STATUS ERROR CODE 5 3 THERMOSTAT CALLS FOR FIRST STAGE COOL COMPRESSOR AND CONDENSER FAN ENERGIZED INDOOR BLOWER ENERGIZED ON FIRST STAGE COOL SPEED AFTER 2 SECOND DELAY COMPRESSOR AND CONDENSER FAN DE ENERGIZED FIRST STAGE DEMAND FOR COOL SATISFIED INDOOR BLOWER DE ENEGIZED NO THERMOSTAT CALLS FOR SECOND STAGE COOL INDOOR BLOWER RAMPS UP TO SECOND STAGE COOL SPEED SECOND STAGE DEMAND FOR COOL SATISFIED UNIT RETURNS TO FIRST STAGE COOL Page 61 Troubleshooting Continuous Fan Sequence of Operation CONTINUOUS LOW SPEED FAN SEQUENCE OF OPERATION MANUAL FAN SELECTION MADE AT THERMOSTAT AFTER 2 SECOND DELAY INDOOR BLOWER IS ENERGIZED ON CONTINUOUS FAN SPEED YES YES THERMOSTAT CALLS FOR FIRST STAGE COOL THERMOSTAT CALLS FOR FIRST STAGE HEAT YES YES INDOOR BLOWER RAMPS TO FIRST STAGE AFTER 45 SECOND DELAY INDOOR BLOWER COOLING SPEED AFTER A 2 SECOND DELAY SWITCHES TO LOW HEAT SPEED lt FIRST STAGE COOL DEMAND SATISFIED FIRST STAGE HEAT DEMAND SATISFIED YES YES NO 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 Y
55. Vent installations combustion air is taken from indoors and flue gases are discharged outdoors See figure 2 for applications involving roof termination DIRECT VENT INSTALLATION COMBUSTION AIR INTAKE are OUTSIDE OF NON DIRECT VENT INSTALLATION EXHAUST HOUSE OUTLET COMBUSTION AIR INTAKE INSIDE OF HOUSE CONDENSATE DRAIN amp CONDENSATE DRAIN FIGURE 2 Package 1 of 1 contains 1 Assembled G61MP unit 1 Bag assembly containing the following 3 Screws 3 Wire nuts 1 Snap bushing 1 Snap plug 1 Wire tie 1 Condensate trap 1 Condensate trap cap 2 2 diameter vent intake plugs 1 3 diameter cabinet plug intake 1 2 diameter debris screen 1 Logo sticker for use in downflow applications NOTE G61MP 48C 110 G61MP 60C 110 G61MP 60C 111 units also include a 2 diameter PVC street elbow which is shipped on the blower deck in the heating compartment G61MP 60D 135 units are shipped with a 3 to 2 PVC reducing elbow Canadian Installations Only Replace the provided 2 street elbow shipped with the G61MP 48C 110 G61MP 60C 110 and G61MP 60C 111 units with 2 street elbow Y0162 Replace the provided 3 X 2 reducing elbow shipped with the G61MP 60D 135 units with 3 X 2 reduc ing elbow 40W22 0162 and 40W22 meet B149 vent re quirements Check equipment for shipping damage If you find any damage immediately contact the last carrier The following items may also be
56. air inlet fitting are both made of ABS material Use transition solvent cement when bonding ABS to either PVC or CPVC refer to the procedure specified in ASTM D3138 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 Immediately after applying last coat of cement to pipe and while both inside socket surface and end of pipe are wet with cement forcefully insert end of pipe into socket until it bottoms out Turn PVC pipe 1 4 turn dur ing assembly but not after pipe is fully inserted to dis tribute cement evenly DO NOT turn ABS or cellular core pipe NOTE Assembly should be completed within 20 sec onds after last application of cement Hammer blows should not be used when inserting pipe After assembly wipe excess cement from pipe at end of fitting socket A properly made joint will show a bead around its entire perimeter Any gaps may indi cate a defective assembly due to insufficient solvent 9 Handle joints carefully until completely set 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 an
57. and Propane Installation Codes local plumbing or waste water codes and other applicable local codes In order to ensure proper unit operation in non direct vent applications combustion and ventilation air supply must be provided according to the current National Fuel Gas Code or CSA B149 standard This furnace is CSA International certified for installation clearances to combustible material as listed on the unit nameplate and in the tables in figures 8 13 and 17 Accessi bility and service clearances must take precedence over fire protection clearances NOTE For installation on combustible floors the furnace shall not be installed directly on carpeting tile or other combustible material other than wood flooring For installation in a residential garage the furnace must be installed so that the burner s and the ignition source are located no less than 18 inches 457 mm above the floor The furnace must be located or protected to avoid physical damage by vehicles When a furnace is installed in apublic garage hangar or other building that has a haz ardous atmosphere the furnace must be installed accord ing to recommended good practice requirements and cur rent National Fuel Gas Code or CSA B149 standard NOTE Furnace must be adjusted to obtain a temperature rise within the range specified on the unit nameplate Failure to do so may cause erratic limit operation This G61MP furnace may be used as a high static unit hea
58. b CONDENSATE ASSEMBLY HI LO SCREWS DO NOT use power driver Hand tighten using screw driver O RINGS NIPPLE COUPLING Q CLEAN OUT ACCESS both sides CONDENSATE TRAP NOTE Use screws to secure condensate trap to cabinet DO NOT apply glue to this joint All other joints must be glued FIGURE 45 ACAUTION 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 AWARNING Compounds used on threaded joints of gas piping must be resistant to the actions of liquified petro leum gases MANUAL MAIN SHUT OFF VALVE WILL NOT HOLD FURNACE NORMAL TEST PRESSURE ISOLATE GAS VALVE Do not exceed 600 in Ibs 50 ft lbs torque when at taching the gas piping to the gas valve 1 Gas piping may be routed into the unit through either the left or right hand side Supply piping enters into the gas valve from the side of the valve as shown in FIGURE 46 figure 48 Leak Check 2 When connecting gas supply factors such as length of After gas piping is completed carefully check all piping run number of fittings and furnace rating must be con connections factory and field installed for gas leaks Use sidered to avoid excessive pressure drop Table 9 lists a leak detecting solution or other preferred means recommended pipe sizes for typical applications The furnace
59. bonding the vent system to the fur nace use ULC S636 approved One Step Transition Ce ment to bond the pipe to the flue collar or to bond the 90 elbow or reducing 90 elbow to the flue collar In addi tion the first three feet of vent pipe from the furnace flue collar must be accessible for inspection Table 5 lists the available exhaust termination kits as well as vent pipe equivalencies which must be used when siz ing vent pipe All Lennox vent terminations are PVC TABLE 5 OUTDOOR TERMINATION KITS AND CORRESPONDING EQUIVALENCIES Vent Pipe Length Equivalency feet Outdoor Ex Outdoor Ex VENT haust Accel haust Accel 1 1 2 UNIT erator erator Concentric MODEL Dia X Dia X Kit Length Length 71M80 69M29 60L46 22G44 44940 2 X 12 or44W92 44W92 or44W93t or 30G28t 81 20 15F74 Not Not 4 Allowed Allowed Not Not 5 Allowed Allowed Not Not 7 Allowed Allowed Not Not 14 Allowed Allowed 4 Not Allowed 12 15 21 42 Not 12 Allowed Not 15 Allowed Not 24 Allowed 2 Not Allowed Not Allowed Not 8 090 Allowed 3 3 60C 090 owe 60C 091 3 Not 2 Not Allowed Allowed Not 4 Not Allowed Allowed 48C 110 Allowed Allowed WX 0 Not Allowed Not Allowed Not Allowed 60 111 4 Allowed 4 2 Con centric Kit MEC 36B 045 Allowed 7 Not Allowed 4 14 Not Allowed 2 4 Not Not Allowed Allowed 2 4 2 5 Not Not 36B 071 Not Not All
60. bs 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 Glue the field provided drain line to the tee Route the drain line to an open drain As an alternate clear vinyl tubing may be used to drain condensate away from the trap Secure the vinyl tubing to the drain stubs on the trap using a hose clamp Do not overtighten the hose clamp Condensate line must be sloped downward away from condensate trap to drain If drain level is above con densate trap condensate 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 a heat cable kit may be used on the condensate trap and line Heating cable kit is available from Lennox in various lengths 6 ft 1 8m kit no 26K68 24 ft 7 3m kit no 26K69 and 50 ft 15 2m kit no 26K70 A CAUTION Do not use copper tubing or existing copper condensate lines for drain line Page 32 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 stu
61. ce forward backward or downward FIGURE 27 FIGURE 26 Page 23 TYPICAL AIR INTAKE PIPE CONNECTIONS DOWNFLOW NON DIRECT VENT APPLICATIONS Right Hand Exit in Downflow Applications Shown 2 SWEEP ora INTAKE DEBRIS SCREEN Provided 6 in Max A 18 in INTAKE DEBRIS 2 SWEEP ELL SCREEN Provided Downflow Additive Flloor Base Downflow Rs E NOTE Debris screen and sweep ell may be rotated so that zu 325 02 H screen may be positioned to face forward backward or to the side FIGURE 28 1 Use field provided materials and the factory provided evaporator coil the intake air routing should be modi air intake screen to route the intake piping as shown in fied as shown in figure 28 figures 27 and 28 Maintain a minimum clearance of 3 2 Use a 7 sheet metal screw to secure the intake pipe to 76mm around the air intake opening The air intake the connector if desired A pilot indentation is provided in opening with the protective screen should always be the slip connector to assist in locating and starting the fas directed either downward or straight out Use 2 pipe tener and fittings only and make sure that the air intake does 3 Glue the provided 2 ABS plug into the
62. combustion air inducer to stop At this point the trap should be primed with suffi cient water to ensure proper condensate drain opera tion 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 will be be equipped with a gas control switch lever Use only your hand to move the switch Never use tools If the the switch will not move by hand do not try to repair it Force or attempted repair may result in a fire or explosion Placing the furnace into operation G61MP units are equipped with an automatic ignition system Do not attempt to manually light burners on this furnace Each time the thermostat calls for heat the burners will automatically light The ignitor does not get hot when there is no call for heat on units with this ignition system 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 55 and 56 1 STOP Read the safety information at the beginning of this section 2 Set the thermostat to the lowest setting 3 Turn off all electrical power to the unit 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 Whi
63. d checks high temperature limit switches for normally closed contacts and pressure switches for normally open contacts The combustion air inducer is ener gized at low speed and the humidifier terminal is ener gized 2 Once the control receives a signal that the low fire pressure switch has closed the combustion air induc er begins a 15 second pre purge in low speed 3 After the pre purge is complete a 20 second initial ig nitor warm up period begins The combustion air in ducer continues to operate at low speed After the 20 second warm up period has ended the gas valve is energized on low fire first stage and ignition oc curs At the same time the control module sends a sig nal to begin an indoor blower 45 second ON delay When the delay ends the indoor blower motor is ener gized on the low fire heating speed The furnace will continue this operation as long as the thermostat has a first stage heating demand If second stage heat is required the thermostat sec ond stage heat contacts close and send a signal to the integrated control The integrated control initiates a 30 second second stage recognition delay At the end of the recognition delay the integrated con trol energizes the combustion air inducer at high speed The control also checks the high fire second stage pressure switch to make sure it is closed Once the the control receives a signal that the high fire pres sure switch is close the high fire second stag
64. densate discharge line from the pump to the outside to avoid freezing 4 Setunit in drain pan as shown in figure 19 Leave 5 1 2 inches for service clearance below unit for condensate trap 5 Continue with exhaust condensate and intake piping installation according to instructions EXHAUST PIPE INTAKE PIPE GAS CONNECTOR Gas connector may be used for Canadian installation if accept able by local authority having jurisdiction lt Zum CONDENSATE LINE SERVICE PLATFORM FIGURE 19 G61MP Installed in Unit Heater Applications The G61MP may also be installed as a unit heater Either suspend the furnace from roof rafters or floor joists as shown in figure 18 or install the furnace on a field fabri cated raised platform as shown in figure 19 The unit must be supported at both ends and beneath the blower deck to prevent sagging The condensate trap must be installed where it can be serviced at a later date Unit Heater Discharge Duct Guidelines A field fabricated and installed discharge air duct and grille cabinet is suitable for use with the G61MP heater Keep the following items in mind when constructing the cabinet 1 Outer dimensions of cabinet should match those of the unit heater so the duct grille cabinet installs flush with the unit heater cabinet See figure 20 2 Flange both ends of duct grille cabinet so that screws can be used to secure
65. e gas valve is energized and the indoor blower motor is en ergized for operation at the high fire heating speed 7 When the demand for high fire second stage heat is satisfied the combustion air inducer is switched to the low fire heating speed and the high fire second stage gas valve is de energized The low fire first stage gas valve continues operation The indoor blower motor is switched to the low fire heating speed 8 When the thermostat demand for low fire first stage heat is satisfied the gas valve is de energized and the field selected indoor blower off delay begins The combustion air inducer begins a 5 second post purge period 9 When the combustion air post purge period is com plete the inducer and humidifier terminal are de ener gized The indoor blower is de energized at the end of the off delay 1 Applications Using A Single Stage Thermostat B Heating Sequence Control Board Thermostat Selection DIP switch in Single Stage Position NOTE In these applications two stage heat will be initi ated by the integrated control if heating demand has not been satisfied after the field adjustable period 10 or 15 minutes 1 Ona all for heat thermostat first stage contacts close sending a signal to the integrated control The inte grated control runs a self diagnostic program and checks high temperature limit switches for normally closed contacts and pressure switches for
66. e located within 6 feet 1 8m of a condensing unit because the condensate can damage the painted coating NOTE If winter design temperature is below 32 F 0 C exhaust piping should be insulated with 1 2 13mm 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 Page 25 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 IMPORTANT Do not use screens or perforated metal in exhaust terminations Doing so will cause freeze ups and may block the terminations IMPORTANT For Canadian Installations Only In accordance to CSA
67. e normal operation Page 56 Troubleshooting Heating Sequence of Operation HEATING SEQUENCE OF OPERATION NORMAL AND ABNORMAL HEATING MODE POWER ON GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF RESET CONTROL BY CONTROL SELF CHECK OKAY TURNING MAIN POWER OFF POLARITY REVERSED POLARITY OKAY STATUS ERROR CODE 5 4 YES IS THERE A SIGNAL HOLDS UNTIL UNIT IS PROPERLY GROUNDED PROPER GROUND STATUS ERROR CODE 5 3 YES A NORMAL OPERATION STATUS LED PULSE COMBUSTION AIR INDUCER OFF INDOOR BLOWER ON HAS PRIMARY OR SECONDARY LIMIT RESET WITHIN 3 MINUTES B STATUS ERROR CODE 3 1 THERMOSTAT CALLS FOR HEAT STATUS LED HEARTBEAT 60 MINUTE LIMIT WATCHGUARD MODE YES GAS VALVE OFF COMBUSTION AIR INDUCER PRIMARY AND SECONDARY LIMIT OFF UE es t s SWITCHES CLOSED TEs GAS VALVE OFF COMBUSTION AIR INDUCER ON ROLLOUT SWITCH CLOSED INDOOR BLOWER ON STATUS ERROR CODE 5 1 SEQUENCE HOLDS UNTIL ROLLOUT SWITCH IS RESET AND MAIN POWER IS INTERRUPTED OR PST STA SE FRESSURE T STAT IS CYCLED OFF ON FOR 3 SEC MINIMUM CONTACTS OPEN 8 GAS VALVE OFF COMBUSTION AIR INDUCER OFF SECOND HIGH STAGE PRESSURE SWITCH INDOOR BLOWER OFF CONTROL REMAINS UNTIL CONTACTS OPEN PRESSURE SWITCH IS DETECTED OPEN STATUS ERROR CODE 2 4 r A GAS VALVE OFF TWO STAGE OR SINGLE STAGE THERMOSTAT COMBUSTION AIR INDUCER OFF CALL FOR HEAT INDOOR BLOWER OFF CONTROL WILL NOT ATTEMPT SECOND
68. e unit Operating performance Unit must be observed during operation to monitor proper performance of the unit and the vent system Combustion gases Flue products must be analyzed and compared to the unit specifications Problems detected during the inspection may make it nec essary to temporarily shut down the furnace until the items can be repaired or replaced Instruct the homeowners to pay attention to their furnace Situations can arise between annual furnace in spections that may result in unsafe operation For instance items innocently stored next to the furnace may obstruct the combustion air supply This could cause incomplete combustion and the production of carbon monoxide gas Page 55 Ignition Control Board Diagnostic Codes F eda STATUS ERROR DESCRIPTION FLASH CODE DESCRIPTIONS Pulse A 1 4 second flash followed by four seconds of off time Heartbeat Constant 1 2 second bright and 1 2 second dim cycles X Y LED flashes X times at 2Hz remains off for two seconds flashes Y times at 2Hz remains off for four seconds then repeats Pulse Power on Standby Heartbeat Normal operation signaled when heating demand initiated at thermostat EE EE TE 2 4 2 5 2 6 2 7 RE Watchguard Exceeded maximum number of retries Watchguard Exceeded maximum number of retries or last retry was due to flame failure Watchguard Limit remained open longer than three minutes Ignitor circuit fault Fa
69. e with the current ANSI Z223 1 NFPA 54 Natural Fuel Gas Code 2 n accordance with the current CSA B149 1 Natural Gas and Propane Installation Code T A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings For clearances not specified in ANSI Z223 1 NFPA 54 or CSA B149 1 clear ance will be in accordance with local installation codes and the requirements of the gas supplier and these installation instructions t Permitted only if veranda porch deck or balcony is fully open on a minimum of two sides beneath the floor Lennox recommends avoiding this location if possible FIGURE 30 Page 27 Details of Intake and Exhaust Piping Terminations for Direct Vent Installations NOTE In Direct Vent installations combustion air is taken TABLE 8 EXHAUST PIPE TERMINATION SIZE REDUCTION G61MP MODEL Exhaust Pipe Size Termination Pipe Size from outdoors and flue gases are discharged to outdoors 045 070 071 2 2 1 2 3 or 4 1 1 2 090 091 2 2 2 sora 110 111 2 1 2 3 or 4 135 Approved 3 concentric termination kit terminates with 2 5 8 ID pipe 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 31 through 39 show typical ter minat
70. eet ell must be glued using transition solvent cement directly into the unit flue collar See figure 23 A 3 to 2 PVC reducing ell is located on the blower deck of the 60D 135 units In up flow or downflow applications the reducing ell must be glued using transition solvent cement directly into the unit flue collar 1 Choose the appropriate side for venting in upflow or downflow positions Exhaust piping exits from the top of the unit in horizontal air discharge applications Glue the field provided exhaust vent pipe or provided street ell or reducing ell in upflow or downflow applica tions to the flue collar All PVC cement joints should be made according to the specifications outlined in ASTM D 2855 Refer to pipe and fittings specifications and gluing procedures TYPICAL EXHAUST PIPE CONNECTIONS AND CONDENSATE TRAP INSTALLATION IN UPFLOW OR DOWNFLOW DIRECT OR NON DIRECT VENT APPLICATIONS Right Hand Exit in Upflow Application Shown VENT PLUG Must be glued in place 45 2 1 2 3 OR 4 TRANSITION G61MP 045 070 071 or 7 090 091 with SIDE VIEW mo 2 1 2 3 or 4 vent pipe PLUG 2 1 2 DUET 3 OR JB 4 TRANSITION j CONDENSATE i use only if 4 TRAP
71. emove combustion air inducer assembly Remove ground wire from vest panel 15 Remove electrical junction box from the side of the fur nace Mark and disconnect any remaining wiring to heating compartment components Disengage strain relief bushing and pull wiring and bushing through the hole in the blower deck 14 16 Page 53 17 Remove the primary limit from the vestibule panel 18 Remove two screws from the front cabinet flange at the blower deck Spread cabinet sides slightly to allow clearance for removal of heat exchanger 19 Remove screws along vestibule sides and bottom which secure vestibule panel and heat exchanger as sembly to cabinet Remove two screws from blower rail which secure bottom heat exchanger flange Re move heat exchanger from furnace cabinet 20 Back wash heat exchanger with soapy water solution or steam If steam is used it must be below 275 F 135 C 21 Thoroughly rinse and drain the heat exchanger Soap solutions can be corrosive Take care to rinse entire assembly 22 Reinstall heat exchanger into cabinet making sure that the clamshells of the heat exchanger assembly are resting on the support located at the rear of the cabi net Remove the indoor blower to view this area through the blower opening 23 Re secure the supporting screws along the vestibule sides and bottom to the cabinet 24 Reinstall cabinet screws on front flange at blower deck 25 Reinstall the primary l
72. equipment rooms When the furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space con taining the furnace the return air must be handled by ducts Page 7 which are sealed to the furnace casing and which terminate outside the space containing the furnace This is especially important when the furnace is mounted on a platform in a confined space such as a closet or small equipment room Even a small leak around the base of the unit at the platform or at the return air duct connection can cause a potentially dangerous negative pressure condition Air for combustion and ventilation can be brought into the confined space ei ther from inside the building or from outside Air from Inside If the confined space that houses the furnace adjoins a space categorized as unconfined air can be brought in by providing two permanent openings between the two spaces Each opening must have a minimum free area of 1 square inch 645 mm per 1 000 Btu 29 kW per hour of total input rating of all gas fired equipment in the confined space Each opening must be at least 100 square inches 64516 mm One opening shall be within 12 inches 305 mm of the top of the enclosure and one opening within 12 inches 305 mm of the bottom See figure 3 EQUIPMENT IN CONFINED SPACE ALL AIR FROM INSIDE ROOF TERMINATED EXHAUST PIPE OPENINGS SIDE WALL TERMINATED EX HAUST PIPE ALTER NATE LOCATION Unconf
73. er combustion air inducer operation before allow ing ignition trial The switches are factory set and require no adjustment Back Up Secondary Limit 090 110 amp 135 Models The back up secondary limit is located on the combustion air inducer This switch protects the plastic components from overheating due to indoor blower motor failure If tripped check for proper blower operation before resetting Temperature Rise After the furnace has been started and supply and return air temperatures have been allowed to stabilize check the temperature rise If necessary adjust the blower speed to maintain the temperature rise within the range shown on the unit nameplate Increase the blower speed to decrease the temperature Decrease the blower speed to increase the temperature rise Failure to do adjust the temperature rise may cause erratic limit operation Thermostat Heat Anticipation Set the heat anticipator setting if adjustable according to the amp draw listed on the wiring diagram that is attached to the unit Electrical 1 Check all wiring for loose connections Page 46 2 Check for the correct voltage at the furnace furnace operating Check amp draw the blower motor Motor Nameplate Actual NOTE Do not secure the electrical conduit directly to the air ducts or structure Blower Speeds NOTE CFM readings are taken external to unit with a dry evaporator coil and without accessories 1 Turn off electrical
74. erminations BE REQUIRED TO 1 Exhaust piping must terminate straight out or up as MENS GEES EE sie REDUCER shown The termination pipe must be sized as listed in TO TERMINATION table 8 The specified pipe size ensures proper veloc QUE SERINNATISN ity required to move the exhaust gases away from the PIPE PER TABLE 8 building SB VIEW 2 On field supplied terminations for side wall exits ex NON DIRECT VENT WALL RING KIT haust piping should extend a maximum of 12 inches 15F74 305mm beyond the outside wall unless support is FIGURE 41 provided in the horizontal section See figure 41 Page 30 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 22 Refer to figure 42 for proper piping method When exhaust piping must be run up an outside wall any reduction in exhaust pipe size must be done after the final elbow 12 305 Max for 2 51 Unless Supported Inches mm UNCONDITIONED SPACE OUTSIDE WALL 3 SIZE TER MINATION PIPE PER PROVIDE SUPPORT TABLE 8 FOR EXHAUST LINES EVERY 36 914 12 305 ABOVE AVERAGE SNOW ACCUMULATION INSULATION IN X UNCONDITIONED 1 2 13 FOAM SPACE INSULATION SIDE VIEW NON DIRECT VENT WALL RING TERMINATION 15F74 FIGURE 42 FIELD PROVIDED REDUCER MAY BE REQUIRED TO ADAPT LARGER VENT PIPE SIZE TO TERMINATION ia
75. ess than the allowable maximum given in table 6 the proposed pipe size is acceptable If the total exceeds the maximum allowed vent pipe length repeat the process above using the next larger diameter pipe until an acceptable total is achieved NOTE In Direct Vent systems total the equivalent length of either the exhaust OR intake piping run depending upon which will be LONGER Intake and exhaust pipe diameter must be the same size and must be terminated in the same pressure zone Intake and exhaust pipe should be roughly the same length G61MP Start Up amp Performance Check List Job Name Job No Job Location City Installer ____ City Unit Model No a Technician Serial No Heating Section Electrical Connections Tight Line Voltage Blower Motor H P Blower Motor Amps Gas Piping Connections Tight amp Leak Tested Fuel Type Natural Gas LP Propane Gas Furnace Btu Input High fire _ _ __ Line Pressure Low Fire Manifold Pressure w c Nat w c LP Propane High Fire Manifold Pressure w c Nat w c LP Propane Flue Connections Tight O Proper Draft Combustion Gas Tested high fire and low fire co co Blower ON delay confirmed External Static Pressure 45 Seconds Fixed On 0 5 maximum Blower OFF Delay Setting 60 90 120 or 180 M Temperature Rise Filter Clean amp Secure Thermostat Heat Anticipator Setting ___ Thermostat Level
76. essure will build to the point that a downdraft can occur in the furnace vent pipe or chimney As a result combustion gases enter the living space creating a po tentially dangerous situation In the absence of local codes concerning air for combus tion and ventilation use the guidelines and procedures in this section to install G61MP furnaces to ensure efficient and safe operation You must consider combustion air needs and requirements for exhaust vents and gas pip ing A portion of this information has been reprinted with permission from the National Fuel Gas Code ANSI Page 6 Z223 1 NFPA 54 This reprinted material is not the com plete and official position of the ANSI on the referenced subject which is represented only by the standard in its entirety In Canada refer to the standard CSA B149 installation codes ACAUTION Do not install the furnace in a corrosive or contami nated atmosphere Meet all combustion and ventila tion air requirements as well as all local codes All gas fired appliances require air for the combustion pro cess If sufficient combustion air is not available the fur nace or other appliance will operate inefficiently and un safely Enough air must be provided to meet the needs of all fuel burning appliances and appliances such as exhaust fans which force air out of the house When fireplaces ex haust fans or clothes dryers are used at the same time as the furnace much more air is req
77. g of all equipment in the enclosure See figure 6 When ducts are used they shall be of the same cross sec tional area as the free area of the openings to which they connect The minimum dimension of rectangular air ducts shall be no less than 3 inches 75 mm In calculating free area the blocking effect of louvers grilles or screens must be considered If the design and free area of protec tive covering is not known for calculating the size opening required it may be assumed that wood louvers will have 20 to 25 percent free area and metal louvers and grilles will have 60 to 75 percent free area Louvers and grilles must be fixed in the open position or interlocked with the equipment so that they are opened automatically during equipment operation EQUIPMENT IN CONFINED SPACE ALL AIR FROM OUTSIDE ROOF TERMINATED EXHAUST PIPE E 7 rs G SIDE WALL TERMINATED EXHAUST PIPE ALTERNATE LOCATION L L L L IL L S L l CL V NOTE Each air duct opening shall have a free area of at least one square inch per 2 000 Btu 645mm2per 59kW per hour of the total input rating of all equipment in the enclosure If the equipment room is located against an outside wall and the air openings communi cate directly with the outdoors each opening shall have a free area of at least 1 square inch per 4 000 Btu 645mm per 1 17kW per hour of the total input rating of all other equipment in the enclosure FIGURE 6 AWARNING
78. g the existing four screws Make sure that the burners line up in the center of the burner ports 9 Reinstall the gas valve manifold assembly Reconnect the gas supply line to the gas valve Reinstall the burn er box cover 10 Reconnect the gas valve wires to the gas valve 11 Replace the blower compartment access panel 12 Refer to instruction on verifying gas and electrical con nections when re establishing supplies 13 Follow lighting instructions to light and operate fur nace for 5 minutes to ensure that heat exchanger is clean and dry and that furnace is operating properly 14 Replace heating compartment access panel Page 54 Planned Service A service technician should check the following items dur ing an annual inspection Power to the unit must be shut off for safety Fresh air grilles and louvers on the unit and in the room where the furnace is installed Must be open and unob structed to provide combustion air Burners Must be inspected for rust dirt or signs of water Vent pipe Must be inspected for signs of water damaged cracked or sagging pipe or disconnected joints Unit appearance Must be inspected for rust dirt signs of water burnt or damaged wires or components Blower access door Must be properly in place and pro vide a seal between the return air and the room where the furnace is installed Return air duct Must be properly attached and provide an air seal to th
79. ger 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 Lennox Application Department for more infor mation concerning sizing of vent systems which include multiple pipe sizes Exhaust Pipe Offset a 12 Min 9 Upflow and Downflow Application Rooftop Termination k 12 Min Horizontal Application Rooftop Termination 12 Min 3 Upflow and Downflow Application Side Wall Termination let 712 Min Horizontal Application Side Wall Termination A minimum of 1 4 6mm drop for each 12 305mm of horizontal run is mandatory for drainage FIGURE 21 Page 18 Use the following steps to correctly size vent pipe diameter Refer to Vent Pipe Size Determination Worksheet on page 53 1 Determine the vent termination and its corresponding equivalent feet value according to table 5 2 Determine the number of 90 elbows required for both indoor and outdoor e g snow riser use Calculate the corresponding equivalent feet of vent pipe 3 Determine the number of 45 elbows required for both indoor and outdoor use Calculate the corresponding equivalent feet of vent pipe 4 Determine the length of s
80. gulations of the Canadian Electrical Code Part CSA Standard C22 1 and or local codes NOTE This furnace is designed for a minimum continu ous return air temperature of 60 F 16 C or an intermit tent operation down to 55 F 13 C dry bulb for cases where a night setback thermostat is used Return air tem perature must not exceed 85 F 29 C dry bulb The G61MP furnace may be installed in alcoves closets attics basements garages and utility rooms This furnace design has not been CSA certified for installa tion in mobile homes recreational vehicles or outdoors Never use an open flame to test for gas leaks Check all connections using a commercially available soap solution made specifically for leak detection Use of Furnace as Construction Heater Lennox does not recommend the use of G61MP units as a construction heater during any phase of construction Very low return air temperatures harmful vapors and operation of the unit with clogged or misplaced filters will damage the unit G61MP units may be used for heating of buildings or struc tures under construction if the following conditions are met e The vent system must be permanently installed per these installation instructions e A room thermostat must control the furnace The use of fixed jumpers that will provide continuous heating is not allowed e The return air duct must be provided and sealed to the furnace e Return air temperature range between 60
81. h di li d furnace is being matched with a heat pump refer to the SEO E PO CODING instruction packaged with the dual fuel thermostat TYPICAL G61MP FIELD WIRING DIAGRAM 1022 COMBUSTION AIR HIGH HEAT MAR y INDUCER MOTOR GAS HIGH HEAT ay ace PRESSURE C PRESSURE e oh DM SWITCH 6D 6 BURNERS HEAT Siege A O O O O PRESSURE LOW HEAT SWITCH PRESSURE FLAME SWITCH SENSOR FLAME 51280 ROLLOUT SWITCH Sei SECONDARY LIMIT age sel INTEGRATED SECONDARY CONTROL 1 CIRCUIT BREAKER CAPACITOR n TRANSF RMER HEAT DFF 51 ROOM THERMOSTAT G9 69 000 2 T STAT HEAT STG ro eND STG DELAY COOL OFF DELAY DOOR INTERLOCK c c c LINE VOLTAGE FIELD INSTALLED CLASS II VOLTAGE FIELD WIRING DENOTES OPTIONAL COMPONENTS FIGURE 51 Page 36 TABLE 10 Field Wiring Applications DIP Switch Settings and On Board Links Figure 52 W915 M Thermostat Y1 to Y2 W951 Wiring Connections Two Stage Cooling DIP Switch 1 O to R Heat Pumps 1 Heat 1 Cool Intact Intact CONTROL OUTDOOR NOTE Use DIP TERM STRIP UNIT switch 2 to set sec ond stage heat ON delay OFF10 minutes ON 15 minutes EXISTING W915 JUMPER Nav asa ZERO Intact CONTROL OUTDOOR NOTE Use DIP UNIT switch 2 to set sec ond stage heat ON delay M OFF 10 minutes R ON 15 minutes
82. h the bottom or either side of the furnace If a furnace with bottom return air is installed on a platform make an airtight seal between the bottom of the furnace and the platform to ensure that the unit operates properly and safely Use fiberglass sealing strips caulking or equivalent sealing method between the plenum and the furnace cabinet to ensure a tight seal If a filter is installed size the return air duct to fit the filter frame Pipe amp Fittings Specifications All pipe fittings primer and solvent cement must conform with American National Standard Institute and the Ameri can Society for Testing and Materials ANSI ASTM stan dards The solvent shall be free flowing and contain no lumps undissolved particles or any foreign matter that ad versely affects the joint strength or chemical resistance of the cement The cement shall show no gelation stratifica tion or separation that cannot be removed by stirring Re fer to the table 4 for approved piping and fitting materials A CAUTION Solvent cements for plastic pipe are flammable liq uids and should be kept away from all sources of ignition Do not use excessive amounts of solvent cement when making joints Good ventilation should be maintained to reduce fire hazard and to minimize breathing of solvent vapors Avoid contact of cement with skin and eyes TABLE 4 PIPING AND FITTINGS SPECIFICATIONS ASTM PIPE amp FITTING MATERIAL SPECIFICATION Schedule
83. have 90 street ell supplied or field replacment Canadian ki installed directly into unit flue collar G61MP 60D 135 must have 3 to 2 reducing ell supplied or field replacment Canadian ki installed directly into unit flue collar 90 elbows used in configuration of G61MP 60D 135 vent must be lim ited to 3 sweep elbows TOn G61MP 071 091 and 111 units sweep elbows must be used for all 90 elbows in the venting system when 2 2 1 2 or 3 vent pipe is used Sweep elbows are recommended for use in vent systems of other G61MP units 0 4500 0 1371 m Joint Cementing Procedure All cementing of joints should be done according to the specifications outlined in ASTM D 2855 A 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 2 3 4 5 Measure and cut vent pipe to desired length Debur and chamfer end of pipe removing any ridges or rough edges If end is not chamfered edge of pipe may remove cement from fitting socket and result in a leaking joint Clean and dry surfaces to be joined Test fit joint and mark depth of fitting on outside of pipe Uniformly apply a liberal coat of PVC primer for PVC or use a clean dry cloth for ABS to clean inside socket surface of fitting and male end of pipe to depth of fitting socket Page 20 NOTE Furnace flue collar and
84. iled ignitor or triggering circuitry Low line voltage Control failed self check internal error control will restart if error recovers F Reversed line voltage polarity control will restart if the error recovers Low secondary 24VAC voltage Error Code Storage 5 After final error code is indicated STATUS LED will The ignition control stores the last ten error codes in flash to indicate normal operation memory The codes are retained in case of power loss Clearing Error Codes Error Code Review 1 Short R 2 to 1 Within 1 2 second the STATUS LED 1 Short R 2 to 1 Within 1 2 second the STATUS LED will stay lit continuously to indicate that the short was will stay lit continuously to indicate that the short was sensed sensed 2 Continue to hold the short between R 2 to 1 After 5 2 Continue to hold the short between R 2 to 1 After 5 seconds STATUS LED will go from being continuously seconds STATUS LED will go from being continuously lit to off lit to off This indicates that error code review is pend 3 Continue to hold the short between R 2 to 1 beyond ing ten seconds after STATUS LED has turned off STA 3 Remove R 2 to 1 short within ten seconds of STA TUS LED will turn on indicating that error codes have TUS LED turning off This activates error code review been cleared 4 Last ten error codes will be flashed on the STATUS 4 Remove R 2 to 1 short STATUS LED will flash to in LED dicat
85. imit on the vestibule panel 26 Route heating component wiring through hole in blow er deck and reinsert strain relief bushing 27 Reinstall electrical junction box 28 Reinstall the combustion air inducer Reconnect the 3 pin plug to the wire harness Reconnect the two wires to the backup secondary limit if applicable 29 Reinstall pressure switches and reconnect pressure switch wiring 30 Carefully connect combustion air pressure switch hosing from pressure switches to proper stubs on cold end header collector box 31 Reinstall condensate collars on each side of the fur nace Reconnect drain tubing to collector box 32 Reinstall condensate trap on same side as exhaust pipe Reconnect condensate drain line to the conden sate trap 33 Use securing screws to reinstall flue collars to either side of the furnace Reconnect exhaust piping and ex haust drain tubing 34 Replace flexible exhaust tee on combustion air induc er and flue collars Secure using three existing hose clamps 35 Reinstall burner box assembly in vestibule area 36 Reconnect flame roll out switch wires 37 Reconnect sensor wire and reconnect 2 pin plug from ignitor 38 Secure burner box assembly to vestibule panel using four existing screws Make sure burners line up in center of burner ports 39 Reinstall gas valve manifold assembly Reconnect gas supply line to gas valve 40 Reinstall burner box cover 41 Reconnect wires
86. ined Ia m NOTE Each opening shall have a free area of at least one square inch per 1 000 Btu 645mm2 per 29kW per hour of the total input rating of all equipment in the enclosure but not less than 100 square inches 64516mm 2 FIGURE 3 Air from Outside If air from outside is brought in for combustion and ventila tion the confined space shall be provided with two perma nent openings One opening shall be within 12 305mm of the top of the enclosure and one within 12 305mm of the bottom These openings must communicate directly or by ducts with the outdoors or spaces crawl or attic that freely communicate with the outdoors or indirectly through vertical ducts Each opening shall have a mini mum free area of 1 square inch per 4 000 Btu 645mm2 per 1 17kW per hour of total input rating of all equipment in the enclosure When communicating with the outdoors through horizontal ducts each opening shall have a mini mum free area of 1 square inch per 2 000 Btu 645mm2 per 59kW per total input rating of all equipment in the en closure See figure 4 EQUIPMENT IN CONFINED SPACE ALL AIR FROM OUTSIDE Inlet Air from Crawl Space and Outlet Air to Ventilated Attic VENTILATION LOUVERS ROOF TERMINATED Each end of attic EXHAUST PIPE SIDE WALL TERMINATED EXHAUST PIPE ALTERNATE LOCATION VENTILATION LOUVERS For unheated crawl space NOTE The inlet and outlet air openings shall each have a free area of at
87. ing grommet used with a flexible mounting leg The bolt and washer must be re moved before the furnace is placed into operation Af ter the bolt and washer have been removed the rigid leg will not touch the blower housing A WARNING Blower access panel must be securely in place when blower and burners are operating Gas fumes which could contain carbon monoxide can be drawn into living space resulting in personal injury or death Page 9 Allow for clearances to combustible materials as indicated on the unit nameplate Minimum clearances for closet or al cove installations are shown in figures 8 13 and 17 A WARNING Improper installation of the furnace can result in per sonal injury or death Combustion and flue products must never be allowed to enter the return air system or air in the living space Use sheet metal screws and joint tape to seal return air system to furnace In platform installations with furnace return the fur nace should be sealed airtight to the return air ple num A door must never be used as a portion of the return air duct system The base must provide a stable support and an airtight seal to the furnace Al low absolutely no sagging cracks gaps etc For no reason should return and supply air duct sys tems ever be connected to or from other heating de vices such as a fireplace or stove etc Fire explo sion carbon monoxide poisoning personal injury and or property damage could resul
88. ing hangers NOTE Exhaust piping should be checked carefully to make sure there are no sags or low spots 3 On the opposite side of the cabinet glue the provided 2 ABS vent plug into the unused ABS flue collar with ABS or all purpose solvent cement 4 Route piping to outside of structure Continue with installation following instructions given in piping ter mination section A 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 A 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 or non direct vent applications In non direct vent applica tions when intake air will be drawn into the furnace from the surrounding space the indoor air quality must be 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 Foll
89. ions 1 Exhaust intake exits must be in same pressure zone Do not exit one through the roof and one on the side Also do not exit the intake on one side and the exhaust on another side of the house or structure 3 76 MAX SIZE TERMINATION PIPE PER TABLE 8 Inches mm UNCONDITIONED 8 203 MIN ATTIC SPACE 1 2 13 FOAM ss INSULATION IN UNCONDITIONED SPACE 2 Intake and exhaust pipes should be placed as close together as possible at termination end refer to il lustrations Maximum separation is 3 76mm on roof terminations and 6 152mm on side wall termina tions 12 305 ABOVE AVERAGE SNOW ACCUMULATION 3 76 OR 2 51 PVC 99 1 If necessary install a field provided reducer to adapt larger vent pipe size to termination pipe size oe f x PROVIDE SUPPORT 4 On roof terminations the intake piping should termi FOR INTAKE AND nate straight down using two 90 elbows See figure EXHAUST EINES 31 DIRECT VENT ROOF TERMINATION KIT 15F75 or 44J41 5 Exhaust piping must terminate straight out or up as FIGURE 31 shown In rooftop applications a reducer may be re quired on the exhaust piping at the point where it exits fines ay atd the structure to improve the velocity of exhaust away from the intake piping See table 8 UNCONDITIONED SPACE gue eke NOTE Care must be taken to avoid recirculation of INSULATION exhaust back into intake pipe
90. ipes Check the exhaust and air intake pipes and all connections for tightness and to make sure there is no blockage NOTE After any heavy snow ice or frozen fog event the furnace vent pipes may become restricted Always check the vent system and remove any snow or ice that may be obstructing the plastic intake or exhaust pipes Electrical 1 Check all wiring for loose connections 2 Check for the correct voltage at the furnace furnace operating 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 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 1 Turn off electrical and gas supplies to the furnace 2 Remove the upper and lower furnace access panels 3 Mark all gas valve wires and disconnect them from valve 4 Remove gas supply line connected to gas valve Re move gas valve manifold assembly 5 Remove sensor wire from sensor Disconnect 2 pin plug from the ignitor 6 Disconnect wires from flame roll out switches 7 Remove burner box cover and remove four
91. ith the appliance or equipment installation instructions and 2 special venting systems shall be Product Ap proved by the Board and the instructions for that sys tem shall include a parts list and detailed installation instructions A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment all venting instructions all parts lists for venting instructions and or all venting design instruc tions shall remain with the appliance or equipment at the completion of the installation Page 64
92. ll horizontally vented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide detec tor with alarm and battery back up may be installed on the next adjacent floor level b In the event that the requirements of this subdivi sion cannot be met at the time of completion of installation the owner shall have a period of thirty 30 days to comply with the above requirements provided however that during said thirty 30 day period a battery operated carbon monoxide detec tor with an alarm shall be installed 2 APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accor dance with the above provisions shall comply with NFPA 720 and be ANSI UL 2034 listed and IAS certi fied 3 SIGNAGE A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight 8 feet above grade di rectly in line with the exhaust vent terminal for the hori zontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECT LY BELOW KEEP CLEAR OF ALL OBSTRUC TIONS 4 INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless upon inspec tion the inspector observes carbon monoxide detec tors and signage installed in accordance with the pro vi
93. m Watts cfm Watts cfm Watts cfm Watts cfm Watts 0 00 2730 1465 2425 2325 1100 1865 890 1410 690 0 10 2670 1440 2400 2310 1065 1915 865 1465 685 0 20 2600 1400 2365 2280 1055 1925 850 1570 675 0 30 2525 1360 2315 1045 2035 845 1615 655 2470 1330 2235 1015 1920 825 1590 670 0 40 2445 1325 2260 1015 2020 820 1615 645 2380 1290 2175 985 1910 805 1590 655 0 50 2360 1280 2195 985 1960 790 1610 635 2310 1265 2120 965 1890 790 1595 645 0 60 2290 1255 2130 965 1900 755 1600 615 2200 1230 2055 935 1835 765 1580 630 0 70 2205 1220 2035 910 1825 730 1570 600 2120 1190 1970 900 1790 740 1545 605 0 80 2110 1195 1945 880 1765 710 1540 580 2025 1160 1890 875 1720 710 1515 590 0 90 1970 1120 1835 830 1680 690 1540 545 1930 1110 1800 835 1655 685 1440 570 NOTES All air data is measured external to unit without filter not furnished field provided Page 51 Heating Sequence of Operation NOTE The thermostat selection DIP switch on the control board is factory set in the TWO STAGE position Applications Using a Two Stage Thermostat A Heating Sequence Control Board Thermostat Selection DIP switch in Two Stage Position Factory Setting 1 Ona call for heat thermostat first stage contacts close sending a signal to the integrated control The inte grated control runs a self diagnostic program an
94. must be isolated from the gas supply system by closing its individual manual shut off valve during any pressure testing of the gas supply system at pressures less than or equal to 1 2 psig 3 48 kPa 14 inches w c NOTE Use two wrenches when connecting gas pip ing to avoid transferring torque to the manifold 3 Gas piping must not run in or through air ducts clothes chutes chimneys or gas vents dumb waiters or eleva tor shafts Center gas line through piping hole Gas AIM PORTANT line should not touch side of unit See figure 48 When testing pressure of gas lines gas valve must 4 Piping should be sloped 1 4 inch per 15 feet 6mm per be disconnected and isolated See figure 46 Gas 5 6m upward toward the gas meter from the furnace valves can be damaged if subjected to pressures The piping must be supported at proper intervals ev greater than 1 2 psig 3 48 kPa ery 8 to 10 feet 2 44 to 3 05m using suitable hangers or straps Install a drip leg in vertical pipe runs to serve as AWARN G a trap for sediment or condensate i FIRE OR EXPLOSION HAZARD 5 A 1 8 N P T plugged tap or pressure post is located the gas vae facilite deaf nice connection Failure to follow the Safety warnings exactly could eg gaug I result in serious injury death or property damage See figures 55 and 56 Never use an open flame to test for gas leaks Check 6 In some localities codes may require installation of a aH COURSES
95. ngineering Handbook for additional information Consider sizing requirements for optional IAQ equip ment before cutting side return opening 1 Optional External Side Return Air Filter Kit is not for use with the optional RAB Return Air Base A O AIR FLOW 5 8 16 Pa e 3 4 19 3 4 19 9 16 14 Right 1 OPTIONAL EXTERNAL SIDE RETURN AIR FILTER KIT Either Side Left Bottom Return Air Opening FRONT VIEW G61MP 36B 045 G61MP 36B 070 G61MP 36B 071 G61MP 48C 090 G61MP 60C 090 17 1 2 446 G61MP 60C 091 G61MP 48C 110 G61MP 60C 110 G61MP 60C 111 G61MP 60D 135 533 24 1 2 11 5 8 295 165 9 3 4 248 4 1 8 4 7 8 124 Right 2 1 4 57 Left SUPPLY AIR OPENING 1OPTIONAL EXTERNAL SIDE RETURN 25 635 AIR FILTER KIT TOP VIEW Either Side 28 1 2 724 19 7 16 a 612 378 M 165 COMBUSTION AIR INTAKE 6 1 2 Either Side EXHAUST AIR OUTLET Either Side GAS PIPING INLET Either Side 6 3 4 103 171 CONDENSATE TRAP CONNECTION Either Side ELECTRICAL INLET Either Side 14 356 OPTIONAL RETURN CUTOUT Either Side 1 15 16 49 vl a 597 4 1 4 108 Bottom Return Air Opening SIDE VIEW 19 7 8 505 19 1 2 495 54 584 G61MP Parts Arrangement G61MP PARTS IDENTIFICATION TOP CAP DuralokPlus HEAT EXCHANGER ASSE
96. on the cabinet for the side return air opening The size of the opening must not extend beyond the markings on the furnace cabinet 2 To minimize pressure drop the largest opening height possible up to 14 inches is preferred NOTE Optional Side Return Air Filter Kits are not for use with RAB Return Air Base FIGURE 9 G61MP applications which include side return air and Removing the Bottom Panel a condensate trap installed on the same side of the Remove the two screws that secure the bottom cap to the cabinet require either a return air base or field fabri furnace Pivot the bottom cap down to release the bottom cated transition to accommodate an optional IAQ ac panel Once the bottom panel has been removed reinstall cessory taller than 14 2 the bottom cap See figure 11 Side Return Air Removing the Bottom Panel with transition and filter 20 X 25 X 1 508mm X635mm X 25mm Air Filter Return Air Plenum SS s lt Bottom Cap Bottom Tbe Aeon FIGURE 11 Transition Page 11 Setting an Upflow Unit When the side return air inlets are used in an upflow ap plication it may be necessary to install leveling bolts on the bottom of the furnace Use field supplied corrosion resist ant 5 16 inch machine bolts 4 and nuts 8 See figure 12 NOTE The maximum length of the bolt is 1 1 2 inches 1 Lie the furnace on its back and drill a 5 16 inch diame ter hole in
97. other 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 feet 91m for ABS DWV PVC DWV SPR 21 PVC and SDR 26 PVC piping A suit able hanger can be fabri cated by using metal or plastic strapping or a large wire tie STRAPPING metal plastic or large wire ties FIGURE 22 O 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 solate 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 collection trap and lines Exhaust Piping NOTE A 2 diameter PVC street ell is located on the blower deck of 48C 110 60C 110 and 60C 111 units In upflow or downflow applications the str
98. ow 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 screen must not be used in direct vent ap plications 1 Use transition solvent cement to connect PVC pipe to the ABS slip connector located on the side of the burn er box 2 Use a 7 sheet metal screw to secure the intake pipe to the connector if desired A pilot indentation is provided in the slip connector to assist in locating and starting the fas tener 3 Glue the provided 2 ABS plug into the unused ABS air intake connector on the opposite side of the cabinet with ABS all pupose cement 4 Route piping to outside of structure Continue with instal lation following instructions given in general guide lines for piping terminations and in intake and exhaust piping ter minations for direct vent sections Refer to figure 25 for pipe sizes Page 22 TYPICAL AIR INTAKE PIPE CONNECTIONS UPFLOW OR DOWNFLOW DIRECT VENT APPLICATIONS Right Hand Exit in Upflow Application Shown 36B 045 36B 070 36B 071 36B 045 36B 045 48C 090 36B 070 36B 070 60C 090 36B 071 36B 071 60C 091 48C 090 48C 090 60C 090 60C 090 60C 091 60C 091 48C 110 48C 110 60C 110 60C 110 60C 111 60C 111 60D 135
99. owed Allowed 4 14 Not 4 Not Not 1 Allowed Allowed Allowed 12 Not 12 Allowed Not Not Allowed Allowed 3 Con centric Kit 2 Wall Plate 3 Wall Plate 2 Wall Ring Kit 4 1 4 1 3 Not Allowed Not Allowed Not Allowed Not Allowed 1 1 1 2 2 4 4 5 7 4 4 5 4 2 2 4 Not Allowed Not Allowed Not Allowed Not Allowed Not Allowed 5 7 4 5 8 4 1 2 2 4 2 2 4 10 3 12 12 15 5 4 Not 1 Not Not 2 Not Not Allowed Allowed Allowed Allowed Allowed Requires field provided and installed 1 1 2 exhaust accelerator Requires field provided and installed 2 exhaust accelerator Page 17 T Termination kits 44W92 includes 1 1 2 reducer 44W93 30G28 and 81J20 approved for use in Canadian installations Vent Piping Guidelines The G61MP can be installed as either a Non Direct Vent or a Direct Vent gas central furnace NOTE In Non Direct Vent installations combustion air is taken from indoors and flue gases are discharged outdoors In Direct Vent installations combustion air is taken from 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 6 and 7 Table 6 lists the mini mum equivalent vent pipe lengths permitted Table 7 lists the maximum equivalent pipe lengths permitted Maximum vent length is defined as
100. ower Speeds Single Side Return Air Air volumes in bold require field fabricated transition to accommodate 20 x 25 x 1 in air filter in order to maintain proper air velocity Medium Low cfm Watts 1885 885 Low cfm Watts 1515 700 0 10 2665 1355 1075 2025 885 1730 2570 1330 2325 1060 1910 865 1575 700 0 20 2585 1315 1015 2030 865 1680 2410 1305 2285 1035 1930 845 1620 690 0 30 2505 1275 990 2025 840 1695 2425 1265 2230 990 1925 825 1635 675 0 40 2435 1250 940 2030 830 1695 2335 1220 2175 950 1910 810 1640 660 0 50 2350 1205 930 1975 790 1735 2270 1195 2120 935 1895 785 1640 640 0 60 2255 1185 2100 895 1915 765 1720 650 2170 1155 2045 885 1860 765 1630 630 0 70 2160 1150 2005 840 1865 730 1680 635 2110 1130 1950 855 1795 730 1590 610 0 80 2020 1090 1905 825 1810 710 1625 610 2035 1090 1885 820 1745 705 1540 580 0 90 1910 1050 1820 795 1705 675 1540 590 1900 1055 1760 780 1665 680 1470 565 NOTES All air data is measured external to unit without filter not furnished field provided G61MP 60C 111 PERFORMANCE Less Filter Air Volume Watts at Different Blower Speeds Bottom Return Air Side Return Air with Optional RAB Air Volume Watts at Different Blower Speeds Single Side Return Air Air volumes in bold require field External Return Air
101. ownflow position The follow ing steps should be taken when installing plenum 1 Bottom edge of plenum should be flanged with a hemmed edge See figure 15 or 16 2 Sealing strips should be used to ensure an airtight seal between the cabinet and the plenum 3 In all cases plenum should be secured to top of fur nace using sheet metal screws 4 Make certain that an adequate seal is made PLENUM Field Provided SECURE FROM OUTSIDE CABINET CABINET SEALING STRI SIDE PANEL Field Provided Side View FIGURE 15 PLENUM Field Provided SEALING STRIP ield Provided CABINET SECURE FROM SIDE PANEL INSIDE CABINET Side View FIGURE 16 Horizontal Applications The G61MP furnace can be installed in horizontal applica tions with either right or left hand air discharge The G61MP may also be installed as a unit heater Either suspend the furnace as shown in figure 18 or install the furnace on a field fabricated raised platform The unit must be supported at both ends and beneath the blower deck to prevent sagging Refer to figure 17 for clearances in horizontal applications Horizontal Application Installation Clearances Right Hand Discharge Top Left End Right End Bottom Floor B Left Hand Discharge Top Left End Right End Front clearance in alcove installation must be 24 in 61
102. power to furnace 2 Remove blower access panel 3 Disconnect existing speed tap at control board speed terminal NOTE Termination of any unused motor leads must be insulated 4 Refer to blower speed selection chart on unit wiring dia gram for desired heating or cooling speed See blower performance data beginning on Page 48 5 Connect selected speed tap at control board speed terminal 6 Resecure blower access panel 7 Turn on electrical power to furnace Electronic Ignition The integrated control has an added feature of an internal Watchguard control The feature serves as an automatic re set device for ignition control lockout caused by ignition fail ure This type of lockout is usually due to low gas line pres Page 47 sure After one hour of continuous thermostat demand for heat the Watchguard will break and remake thermostat de mand to the furnace and automatically reset the control to begin the ignition sequence Exhaust and Air Intake Pipe 1 Check exhaust and air intake connections for tightness and to make sure there is no blockage 2 Are pressure switches closed Obstructed exhaust pipe will cause unit to shut off at pressure switches Check termination for blockages 3 Reset manual flame rollout switches on burner box cover Failure To Operate If the unit fails to operate check the following 1 Is the thermostat calling for heat 2 Are access panels securely in place 3 Is the
103. r 5 min utes of main burner operation 8 If improper venting is observed during any of the above tests the venting system must be corrected or sufficient combustion make up air must be provided The venting system should be re sized to approach the minimum size as determined by using the ap propriate tables in appendix G in the current standards of the National Fuel Gas Code ANSI Z223 1 NPFA 54 in the U S A and the appropriate Natural Gas and Propane appliances venting sizing tables in the cur rent standard of the CSA B149 Natural Gas and Pro pane Installation Codes in Canada 9 After determining that each appliance remaining connected to the common venting system properly vents when tested as indicated in step 3 return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous condition of use Other Unit Adjustments Primary and Secondary Limits The primary limit is located on the heating compartment vestibule panel The secondary limits are located in the blower compartment attached to the back side of the blow er These limits are factory set and require no adjustment Flame Rollout Switches Two These manually reset switches are located on the burner box If tripped check for adequate combustion air before resetting Pressure Switches Two or Four The pressure switches are located in the heating compart ment on the combustion air inducer These switches check for prop
104. r off delay begins 7 When the combustion air post purge period is com plete the inducer and humidifier terminal are de ener gized The indoor blower is de energized at the end of the off delay Page 52 A WARNING ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in dangerous operation serious injury death or property damage Improper servicing could result in dangerous 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 At the beginning of each heating season system should be checked as follows by a qualified service technician Blower Check the blower wheel for debris and clean if necessary The blower motors are prelubricated for extended bearing life No further lubrication is needed AWARNING 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 Filters All G61MP filters are installed external to the unit Filters should be inspected monthly Clean or replace the filters when necessary to ensure proper furnace operation Table 3 lists recommended filter sizes Exhaust and air intake p
105. rt has been under water A flood damaged furnace is extremely dan gerous Attempts to use the furnace can result in fire or explosion Immediately call a qualified ser vice technician to inspect the furnace and to replace all gas controls control system parts and electrical parts that have been wet or to replace the furnace if deemed necessary AWARNING Danger of explosion Can cause injury or product or property damage Should the gas supply fail to shut off or if overheating occurs shut off the gas valve to the furnace before shutting off the electrical supply W Page 42 ACAUTION Before attempting to perform any service or mainte nance turn the electrical power to unit OFF at dis connect switch Priming Condensate Trap The condensate trap should be primed with water prior to start up to ensure proper condensate drainage Either pour 10 fl oz 300 ml of water into the trap or follow these steps to prime the trap 1 Follow the lighting instructions to place the unit into op eration 2 Set the thermostat to initiate a heating demand Allow the burners to fire for approximately 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 low the burners to fire for approximately 3 minutes Adjust the thermostat to deactivate the heating de mand and again wait for the
106. sary run the condensate line into a condensate pump to meet drain line slope requirements The pump must be rated for use with condensing furnaces Protect the condensate discharge line from the pump to the outside to avoid freezing TYPICAL HORIZONTAL CEILING APPLICATION BLOWER ACCESS PANEL 3 8 in RODS INTAKE EXHAU ST CONNECTION s DRAIN PAN ve to protect finished space FIGURE 18 SUPPORT FRAME Platform Installation of Horizontal Unit Select location for unit keeping in mind service and other necessary clearances See figure 17 Construct a raised wooden frame and cover frame with a plywood sheet Provide a service platform in front of unit If unit is installed above finished space fabricate a drain pan to be installed under unit When installing the unit in a crawl space a proper sup port platform may be created using cement blocks and the horizontal support frame kit ordered separately Lennox part number 56J18 Position the support frame on top of the blocks and install the unit on the frame Leave 5 1 2 inches for service clearance for condensate trap 99 1 Route auxiliary drain line so that water draining from this outlet will be easily noticed by the homeowner If necessary run the condensate line into a condensate pump to meet drain line slope requirements The pump must be rated for use with condensing furnaces Protect the con
107. sions of 248 CMR 5 08 2 a 1 through 4 EXEMPTIONS The following equipment is exempt from 24 CMR 5 08 2 a 1 through 4 1 The equipment listed in Chapter 10 entitled Equip ment Not Required to Be Vented in the most current edition of NFPA 54 as adopted by the Board and 2 Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure sepa rate from the dwelling building or structure used in whole or in part for residential purposes MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturer of Product Approved side wall horizontally vented gas fueled equipment provides a vent ing system design or venting system components with the equipment the instructions provided by the manufacturer for installation of the equipment and the venting system shall include 1 Detailed instructions for the installation of the venting System design or the venting system components and 2 A complete parts list for the venting system design or venting system MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufacturer of Product Approved side wall horizontally vented gas fueled equipment does not pro vide the parts for venting the flue gases but identifies spe cial venting systems the following requirements shall be satisfied by the manufacturer 1 The referenced special venting system instructions shall be included w
108. t Upflow Applications The G61MP gas furnace can be installed as shipped in the upflow position Refer to figure 8 for clearances Installation Clearances Top Left Side Right Side x w 3 m s GN Front clearance in alcove installation must be 24 in 610 mm Maintain a minimum of 24 in 610 mm for front service access TAllow proper clearances to accommodate condensate trap and vent pipe installation For installations on a combustible floor do not install the furnace directly on carpeting tile or other combustible materials other than wood flooring FIGURE 8 Return Air Upflow Units Return air can be brought in through the bottom or either side of the furnace installed in an upflow application If the furnace is installed on a platform with bottom return make an airtight seal between the bottom of the furnace and the platform to ensure that the furnace operates properly and safely The furnace is equipped with a removable bottom panel to facilitate installation Markings are provided on both sides of the furnace cabinet for installations that require side return air Cut the furnace cabinet at the maximum dimensions shown on page 2 NOTE When air volumes over 1800 cfm 850 L s are required with 60C or 60D models in an upflow applica tion the following return air options are available 1 Return air from single side with transition
109. t of gas per hour kilo liters of gas per hour and based on 0 60 specific gravity gas Page 34 ELECTROSTATIC DISCHARGE ESD Precautions and Procedures ACAUTION Electrostatic discharge can affect electronic com ponents Take precautions during furnace installa tion and service to protect the furnace s electronic controls Precautions will help to avoid control ex posure to electrostatic discharge by putting the fur nace the control and the technician at the same electrostatic potential Neutralize electrostatic charge by touching hand and all tools on an un painted unit surface such as the gas valve or blower deck before performing any service procedure INTERIOR MAKE UP BOX INSTALLATION MAKE UP BOX E 9 Right Side s Pe FIGURE 49 INTERIOR MAKE UP BOX INSTALLATION Left side FIGURE 50 The unit is equipped with a field make up box The make up box may be moved to the right side of the furnace to fa cilitate installation If the make up box is moved to the right side the excess wire must be pulled into the blower compartment Secure the excess wire to the existing har ness to protect it from damage Refer to figure 51 and table 10 for field wiring and figure 54 for schematic wiring diagram and troubleshooting 1 Select circuit protection and wire size according to the unit nameplate The power supply wiring m
110. te Rodgers 36E Gas Valve Move gas valve switch to OFF See figure 55 for the White Rodgers 36E valve Honeywell VR8205 Gas Valve Move switch on gas valve clockwise 49 to OFF Do not force See figure 56 7 Wait five minutes to clear out any gas If you then smell gas STOP Immediately call your gas supplier from a neighbor s phone Follow the gas suppliers instruc tions If you do not smell gas go to next step WHITE RODGERS 36E SERIES GAS VALVE HIGH FIRE MANIFOLD PRESSURE ADJUSTMENT ON SIDE under cap MANIFOLD ke PRESSURE TAP ON SIDE LOW FIRE MANIFOLD PRESSURE ADJUSTMENT ON SIDE under cap GAS VALVE SHOWN IN OFF POSITION FIGURE 55 HONEYWELL VR8205 SERIES GAS VALVE HIGH FIRE ADJUSTING SCREW under cap INLET PRESSURE TAP ON SIDE MANIFOLD PRESSURE TAP LOW FIRE ADJUSTING SCRE under cap INLET PRESSURE TAP GAS VALVE SHOWN IN OFF POSITION FIGURE 56 8 White Rodgers 36E Gas Valve Move gas valve switch to ON See figure 55 for the White Rodgers 36E valve Honeywell VR8205 Gas Valve Move switch on gas valve counterclockwise amp to ON Do not force 9 Replace the upper access panel 10 Turn on all electrical power to to the unit 11 Set the thermostat to desired setting NOTE When unit is initially started steps 1 through 11 may need to be repeated to purge air from gas line
111. ter The G61MP may also be installed in an aircraft han gar in accordance with the Standard for Aircraft Hangars ANSI NFPA No 408 1990 Installation in parking structures must be in accordance with the Standard for Parking Structures ANSI NFPA No 88A 1991 Installation in repair garages must be in accor dance with the Standard for Repair Garages ANSI NFPA No 88B 1991 This G61MP furnace must be installed so that its electrical components are protected from water When this furnace is used with cooling units it shall be installed in parallel with or on the upstream side of cooling units to avoid condensation in the heating compartment With a parallel flow arrangement a damper or other means to control the flow of air must adequately prevent chilled air from entering the furnace If the damper is manually oper ated it must be equipped to prevent operation of either the heating or the cooling unit unless it is in the full HEAT or COOL setting Page 5 When installed this furnace must be electrically grounded according to local codes In addition in the United States installation must conform with the current National Electric Code ANSI NFPA No 70 The National Electric Code ANSI NFPA No 70 is available from the following ad dress National Fire Protection Association 1 Battery March Park Quincy MA 02269 In Canada all electrical wiring and grounding for the unit must be installed according to the current re
112. to the gas valve Page 44 TABLE 13 Manifold Pressure Outlet inches w c Altitude feet 0 2000 2001 4500 4501 5500 5501 6500 6501 7500 7501 10000 Model Number Low High Low High Low High Low High Low High Low High Fire Fire Fire Fiire Fire Fiire Fire Fiire Fire Fiire Fire Fiire High Altitude Information NOTE In Canada certification for installations at eleva The combustion air pressure switches are factory set and tions over 4500 feet 1372 m is the jurisdiction of local au require no adjustment thorities NOTE A natural to L P propane gas changeover kit is nec The manifold pressure may require adjustment to ensure essary to convert this unit Refer to the changeover kit proper operation at higher altitudes Refer to table 13 for installation instruction for the conversion procedure proper manifold pressure settings at varying altitudes Refer to table 14 for required pressure switch changes and conversion kits at varying altitudes TABLE 14 Conversion Kit Requirements Orifice Kit ORDER TWO EACH Natural Gas Kit Input Natural Gas Only 7501 10 000 ft 2000 4500 ft 4501 7500 ft 7501 10 000 ft 0 7500 ft 7501 10 000 ft 0 7500 ft 1 7501 10 000 ft 045 44W51 44W48 44W50 44W49 44W49 44W51 070 44w51 56M06 44W48 44W50 44W49 44W49 44W51 071 47M82 24W49 24W49 26W83 44W48 44W50 44W49 44W49 47M82 090 44W51 75M22
113. traight pipe required 5 Add the total equivalent feet calculated in steps 1 through 4 and compare that length to the maximum values given in table 6 for the proposed vent pipe 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 6 MINIMUM VENT PIPE LENGTHS G61MP MIN EQUIV MODEL VENT LENGTH EXAMPLE 045 070 071 090 091 5 ft plus 2 elbows of 2 2 1 2 3 or 4 diameter pipe 410 111 15 ft 5 ft plus 2 elbows of 2 1 2 3 or 4 diameter pipe T 5 ft plus 2 elbows of 3 or 4 135 diameter pipe Any approved termination may be added to the minimum equivalent length listed 661 48 110 G61MP 60C 110 and G61MP 60C 111 must have 90 street ell supplied or field replacment Canadian kit installed directly into unit flue collar G61MP 60D 135 must have 3 to 2 reducing ell supplied or field replac ment Canadian ki installed directly into unit flue collar Page 19 TABLE 7 MAXIMUM VENT PIPE LENGTHS MAXIMUM VENT FEET G61MP ALTITUDE MODEL 2 24 T PIPE PIPE PIPE PIPE 045 5 6 77 234 00 26 42 72 204 4501 7500 090 26 42 72 204 1372 2286 m 7501 10000 090 26 42 72 204 2287 3048 m 135 t na na 46 160 n a Not allowed G61MP 48C 110 G61MP 60C 110 and G61MP 60C 111must
114. uired to ensure proper combustion and to prevent a downdraft Insufficient air causes incomplete combustion which can result in carbon monoxide In addition to providing combustion air fresh outdoor air di lutes contaminants in the indoor air These contaminants may include bleaches adhesives detergents solvents and other contaminants which can corrode furnace compo nents The requirements for providing air for combustion and ven tilation depend largely on whether the furnace is installed in an unconfined or a confined space Unconfined Space An unconfined space is an area such as a basement or large equipment room with a volume greater than 50 cubic feet 1 42 m3 per 1 000 Btu 29 kW per hour of the com bined input rating of all appliances installed in that space This space also includes adjacent rooms which are not separated by a door Though an area may appear to be un confined it might be necessary to bring in outdoor air for combustion if the structure does not provide enough air by infiltration If the furnace is located in a building of tight construction with weather stripping and caulking around the windows and doors follow the procedures in the air from outside section Confined Space A confined space is an area with a volume less than 50 cubic feet 1 42 m3 per 1 000 Btu 29 kW per hour of the com bined input rating of all appliances installed in that space This definition includes furnace closets or small
115. unused ABS air not extend more than 6 beyond the G61MP cabinet intake connector on the opposite side of the cabinet with The air intake connector must not be located near ABS or all purpose solvent cement the floor To avoid this complication in downflow applications which do not include a downflow Page 24 General Guidelines for Vent Terminations 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 Direct Vent applications combustion air is taken from outdoors and the flue gases are discharged to the out doors The G61MP is then classified as a direct vent Category IV gas furnace In both Non Direct Vent and Direct Vent applications the vent termination is limited by local building codes In the absence of local codes refer to the current National Fuel Gas Code ANSI Z223 1 NFPA 54 in U S A and current CSA B149 Natural Gas and Propane Installation Codes in Canada for details Position termination according to location given in figure 29 or 30 In addition position termination so it is free from any obstructions and 12 above the average snow accumula tion 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 b
116. upply pressure Replace the threaded plug after measurements have been taken Manifold Pressure Measurement To correctly measure manifold pressure the differential pressure between the positive gas manifold and the nega tive burner box must be considered Use pressure test adapter kit available as Lennox part 10L34 to assist in measurement 1 Remove the threaded plug from the outlet side of the gas valve and install a field provided barbed fitting Connect test gauge connection to barbed fitting to measure manifold pressure 2 Tee into the gas valve regulator vent hose and connect test gauge connection TABLE 12 Gas Flow Rate Ft Hr Seconds for 1 Gas Meter Size Revolution TZcuRDis TcufDi _ 18 257 38 10 3 j 180 771 25 138 remi reu 113 106 3 Start unit on low heat 68 rate and allow 5 minutes for unit to reach steady state 4 While waiting for the unit to stabilize notice the flame Flame should be stable and should not lift from burner Natural gas should burn blue 5 After allowing unit to stabilize for 5 minutes record manifold pressure and compare to value given in table 13 6 Repeat steps 3 4 and 5 on high heat NOTE Shut unit off and remove manometer as soon as an accurate reading has been obtained Take care to remove barbed fitting and replace threaded plug A CAUTION Do not attempt to make adjustments
117. urnace is installed in non direct vent applica tions do not install the furnace where drafts might blow directly into it This could cause improper combustion and unsafe operation e When the furnace is installed in non direct vent applica tions do not block the furnace combustion air opening with clothing boxes doors etc Air is needed for proper combustion and safe unit operation e When the furnace is installed in an attic or other insu lated space keep insulation away from the furnace e When the furnace is installed in an unconditioned space consider provisions required to prevent freezing of condensate drain system AWARNING Product contains fiberglass wool Disturbing the insulation in this product during installation maintenance or repair will expose you to fiberglass wool Breathing this may cause lung cancer Fiberglass wool is known to the State of Cal ifornia to cause cancer Fiberglass wool may also cause respiratory skin and eye irritation To reduce exposure to this substance or for further information consult material safety data sheets available from address shown below or contact your supervisor Lennox Industries Inc P O Box 799900 Dallas TX 75379 9900 G61MP unit should not be installed in areas normally subject to freezing temperatures Combustion Dilution amp Ventilation Air If the G61MP is installed as a Non Direct Vent Fur nace follow the guidelines in this section
118. using a commercially i 7 0 solution made specifically for detection Some manual main shut off valve and unon furnished by in soaps used for leak detection are corrosive to certain staller external to the unit Union must be of the metals Carefully rinse piping thoroughly after leak ground joint type test has been completed Upflow Application AUTOMATIC Upflow Application Left Side Piping GAS VALVE Right Side Piping Standard with manual Alternate shut off valve MANUAL MAIN SHUT OFF B MAIN SHUT OFF VALVE GROUND Hi E GROUND JOINT JOINT UNION NS DRIP LEG PROVIDED DRIP LEG AND INSTALLED FIGURE 47 Page 33 Horizontal Applications Possible Gas Piping Configerations MANUAL MAIN SHUT OFF VALVE Horizontal Application Left Side Air Discharge K MANUAL MAIN SHUT OFF VALVE GROUND JOINT UNION GROUND JOINT DRIP LEG 7 UNION DRIP LEG 7 MANUAL gt MAIN SHUT OFF Horizontal Application J VALVE Right Side Air Discharge With 1 8 in NPT Plugged Tap Shown GROUND JOINT UNION DRIP LEG FIGURE 48 TABLE 9 GAS PIPE CAPACITY FT3 HR kL HR Nominal Internal Length of Pipe Feet m Iron Pipe Size Diameter Inches mm Inches mm 14 29 24 20 18 16 15 14 13 12 6 35 9 246 1 13 82 68 57 51 45 42 40 37 34
119. ust meet Class restrictions 2 Holes are on both sides of the furnace cabinet to facili tate wiring 3 Install a separate disconnect switch protected by ei ther fuse or circuit breaker near the furnace so that power can be turned off for servicing 4 Before connecting the thermostat or the power wiring check to make sure the wires will be long enough for servicing at a later date Remove the blower access panel to check the length of the wire 5 Complete the wiring connections to the equipment Use the provided unit wiring diagram and the field wir ing diagram shown in figure 51 and table 10 Use 18 gauge wire or larger that is suitable for Class ll rat ing for thermostat connections NOTE Do NOT make a wire connection between the room thermostat L terminal and the L terminal of the G61MP integrated control Electrically ground the unit according to local codes or in the absence of local codes according to the current National Electric Code ANSI NFPA No 70 for the USA and current Canadian Electric Code part 1 CSA standard C22 1 for Canada A green ground wire is provided in the field make up box NOTE The G61MP furnace contains electronic com ponents that are polarity sensitive Make sure that the furnace is wired correctly and is properly grounded One line voltage HUM 1 4 spade terminal is provided on the furnace control board Any humidifier rated up to one amp can be connected to this terminal with the
120. versized for the single water heater or other appliance The vent should be checked for proper draw with the remaining appliance The test should be conducted while all appliances both in operation and those not in operation are connected to the venting system being tested If the venting system has been installed improperly or if provisions have not been made for sufficient amounts of combustion air corrections must be made as outlined in the previous section 1 Seal any unused openings in the venting system 2 Visually inspect the venting system for proper size and horizontal pitch Determine there is no blockage or re striction leakage corrosion or other deficiencies which could cause an unsafe condition 3 To the extent that it is practical close all building doors and windows and all doors between the space in which the appliances connected to the venting system are lo cated and other spaces of the building 4 Close fireplace dampers 5 Turn on clothes dryers and any appliances not con nected to the venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan 6 Follow the lighting instruction to place the appliance being inspected into operation Adjust thermostat so appliance will operate continuously 7 Use the flame of match or candle to test for spillage of flue gases at the draft hood relief opening afte
121. ween the furnace and the floor The base must be ordered separately See table 2 for opening size to cut in floor A CAUTION The furnace and additive base shall not be installed directly on carpeting tile or other combustible ma terial other than wood flooring TABLE 2 ADDITIVE BASE FLOOR OPENING SIZE Cabinet Catalog Front to Rear Side to Side B Cabinet D Cabinet 2 After opening is cut set additive base into opening 3 Check fiberglass strips on additive base to make sure they are properly glued and positioned 4 Lower supply air plenum into additive base until ple num flanges seal against fiberglass strips NOTE Be careful not to damage fiberglass strips Check for a tight seal 5 Set the furnace over the plenum 6 Ensure that the seal between the furnace and plenum is adequate G61MP UNIT SUPPLY AIR PLENUM PROPERLY SIZED FLOOR OPENING WS ADDITIVE BASE FIGURE 14 Page 13 Installation on Cooling Coil Cabinet 1 Refer to reverse flow coil installation instructions for correctly sized opening in floor and installation of cabi net 2 When cooling cabinet is in place set and secure the furnace according to the instructions that are provided with the cooling coil Secure the furnace to the cabinet 3 Seal the cabinet and check for air leaks Return Air Opening Downflow Units Return air may be brought in only through the top opening of a furnace installed in the d
122. ze and install the supply and return air duct system This will result in a quiet and low static system that has uniform air distribution NOTE Operation of this furnace in heating mode indoor blower operating at selected heating speed with an exter nal static pressure which exceeds 0 5 inches w c may re sult in erratic limit operation Supply Air Plenum If the furnace is installed without a cooling coil a removable access panel should be installed in the supply air duct The access panel should be large enough to permit inspection by reflected light of the heat exchanger for leaks after the furnace is installed If present this access panel must al ways be in place when the furnace is operating and it must not allow leaks into the supply air duct system Return Air Plenum NOTE Return air must not be drawn from a room where this furnace or any other gas fueled ap pliance i e water heater or carbon monoxide producing device i e wood fireplace is installed When return air is drawn from a room a negative pres sure is created in the room If a gas appliance is operating in a room with negative pressure the flue products can be pulled back down the vent pipe and into the room This reverse flow of the flue gas may result in incomplete com bustion and the formation of carbon monoxide gas This toxic gas might then be distributed throughout the house by the furnace duct system Return air can be brought in throug

Lennox International Inc. G61MP Series Units Gas Heater User Manual

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