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Lennox G60DFV Series Installation Instructions Manual

G60dfv(x) series
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E 2008 Lennox Industries Inc.
Dallas, Texas, USA
RETAIN THESE INSTRUCTIONS
FOR FUTURE REFERENCE
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.
10/08
*2P1008*
INSTALLATION
INSTRUCTIONS
G60DFV(X) Series
GAS FURNACE
506179−01
10/2008
Supersedes 505,126M

Table of Contents

Start−Up & Performance Check List
WARNING
FIRE OR EXPLOSION HAZARD.
Failure to follow safety warnings exact-
ly could result in serious injury, death,
or property damage.
WHAT TO DO IF YOU SMELL GAS:
D Do not try to light any appliance.
D Do not touch any electrical switch; do not
use any phone in your building.
D Leave the building immediately.
D Immediately call your gas supplier from a
neighbor's phone. Follow the gas supplier's
instructions.
D If you cannot reach your gas supplier, call
the fire department.
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Summary of Contents for Lennox G60DFV Series

  • Page 1: Table Of Contents

    INSTALLATION INSTRUCTIONS E 2008 Lennox Industries Inc. Dallas, Texas, USA G60DFV(X) Series GAS FURNACE 506179−01 10/2008 Supersedes 505,126M Litho U.S.A. Table of Contents Unit Dimensions ....... .

  • Page 2: Unit Dimensions

    G60DFV(X) Unit Dimensions − inches (mm) 3−3/4 (95) 5/8 (16) RETURN AIR OPENING FLUE OUTLET 19−1/2 (Top) (16) (495) 5/8 (16) TOP VIEW 28−1/2 (724) 19−1/2 (16) (16) (495) AIR FLOW (1016) ELECTRICAL INLET (Either Side) 4−7/8 (124) Right GAS PIPING INLET 2−1/4 (57) Left (Either Side) 9−1/4...

  • Page 3: G60Dfv(X) Parts Arrangement

    G60DFV(X) Parts Arrangement Variable Speed Blower Motor Blower Assembly Internal Flue Pipe Assembly Gasket Circuit Power Choke Breaker (1HP Only) Flue Door Chase Interlock Switch Transformer Gasket Limit Two−Stage Shield Integrated Control Flue Box Gasket Primary Heat Exchanger Limit Flue Collector Box Flame Rollout Switches Flame Sensor Gasket...

  • Page 4: G60Dfv(X) Gas Furnace

    Gas Code (ANSI-Z223.1). The National Fuel Gas Code is variable speed integrated control. This control ensures available from the following address: compatibility with Lennox’ Harmony III zone control sys- American National Standards Institute, Inc. tem, as well as a thermostat which provides humidity con- 11 West 42nd Street trol.

  • Page 5: General

    Lennox does not recommend the use of G60DFV(X) units as a construction heater during any phase of construction. General Very low return air temperatures, harmful vapors and op- eration of the unit with clogged or misplaced filters will dam- age the unit.

  • Page 6: Combustion, Dilution & Ventilation Air

    Water softening chemicals available from address shown below, or contact your De-icing salts or chemicals supervisor. Carbon tetrachloride Lennox Industries Inc. Halogen type refrigerants P.O. Box 799900 Cleaning solvents (such as perchloroethylene) Dallas, TX 75379−9900 Printing inks, paint removers, varnishes, etc.
  • Page 7 infiltration. If the furnace is located in a building of tight Air from Inside construction with weather stripping and caulking around If the confined space that houses the furnace adjoins a the windows and doors, follow the procedures in the air space categorized as unconfined, air can be brought in by from outside section.
  • Page 8 EQUIPMENT IN CONFINED SPACE ALL AIR FROM OUTSIDE (Inlet Air from Crawlspace and Outlet Air to Ventilated Attic) CHIMNEY OR GAS VENT VENTILATION LOUVERS (Each end of attic) OUTLET WATER FURNACE HEATER INLET VENTILATION LOUVERS (For unheated crawl space) NOTE−The inlet and outlet air openings shall each have a free area of at least one square inch (645 ) per 4,000 Btu (1.17 kW) per hour of the total input rating of all equipment in the enclosure.

  • Page 9: Downflow Installation

    2 − After opening is cut, set additive base into opening. Downflow Installation 3 − Check fiberglass strips on additive base to make sure Downflow unit installs in three ways: on non−combustible they are properly glued and positioned. flooring, on combustible flooring using an additive base, or 4 −...

  • Page 10: Setting Equipment

    Downflow Application PLENUM Allow for clearances to combustible materials as indi- Side View SECURE FROM IN- SIDE CABINET cated on the unit nameplate. Minimum clearances for HEMMED EDGE closet or alcove installations are shown in figure 9. Downflow Application Installation Clearances FIBERGLASS SEALING STRIP CABINET SIDE...

  • Page 11: Filters

    NOTE − Use these instructions as a guide. They do not su- Filters persede local codes. This furnace must be vented accord- This unit is not equipped with a filter or rack. A field−pro- ing to all local codes, these installation instructions, and the vided high−velocity filter is required for the unit to operate provided venting tables in these instructions properly.
  • Page 12 Common Venting Using Tile−Lined Interior Masonry Chimney and Combined Vent Connector MINIMUM LENGTH = AS SHORT AS PRACTICAL. INTERIOR TILE−LINED FOR MAXIMUM LENGTH SEE NOTE TO LEFT MASONRY CHIMNEY NOTE− Refer to provided venting tables for installations in the USA and the venting tables in current CSA−B149 for installations in Canada.
  • Page 13 Never connect a Category I appliance to a chimney that is 8 − The common venting tables (7, 8, 9, and 10) were gen- servicing a solid−fuel appliance. If a fireplace chimney flue erated using a maximum horizontal vent connector is used to vent this appliance, the fireplace opening must length of 1−1/2 feet (.46 m) for each inch (25 mm) of be permanently sealed.
  • Page 14 17 − If vent connectors are combined prior to entering the chimney. common vent, the maximum common vent capacity 21 − When connecting this appliance to an existing dedi- listed in the common venting tables must be reduced cated or common venting system, you must inspect the by 10%, the equivalent of one 90°...
  • Page 15 TABLE 6 Capacity of Type B Double−Wall Vents with Single−Wall Metal Connectors Serving a Single Category I Appliance Vent and Connector Diameter − D (inches) Height Lateral 3 Inch 4 Inch 5 Inch 6 Inch Appliance Input Rating in Thousands of Btu Per Hour (feet) (feet) (feet)
  • Page 16 TABLE 7 Vent Connector Capacity Type B Double−Wall Vents with Type B Double−Wall Connectors Serving Two or More Category I Appliances Vent and Connector Diameter − D (inches) Vent Vent Connector Connector 3 Inch 4 Inch 5 Inch 6 Inch Height Height Rise...
  • Page 17 TABLE 9 Vent Connector Capacity Type B Double−Wall Vents with Single−Wall Metal Connectors Serving Two or More Category I Appliances Vent and Connector Diameter − D (inches) Vent Vent Connector Connector 3 Inch 4 Inch 5 Inch 6 Inch Height Height Rise Rise...

  • Page 18: Gas Piping

    Resize the common venting system to the minimum 3 − The gas piping must not run in or through air ducts, clothes chutes, gas vents or chimneys, dumb waiters, vent pipe size determined by using the appropriate or elevator shafts. tables in Appendix G.

  • Page 19: Electrical

    MANUAL Left Side Piping MAIN SHUT−OFF AUTOMATIC (Standard) VALVE GAS VALVE (with manual AUTOMATIC MANUAL shut−off valve) GAS VALVE MAIN SHUT−OFF (with manual VALVE shut−off valve) GROUND JOINT UNION GROUND JOINT UNION DRIP LEG Right Side Piping FIELD (Alternate) PROVIDED AND INSTALLED DRIP LEG FIGURE 13...
  • Page 20 USA and current Canadian Electric Code part 1 (CSA INTERIOR MAKE−UP BOX INSTALLATION standard C22.1) for Canada. A green ground wire is (Right Side) provided in the field make−up box. NOTE − The G60DFV(X) furnace contains electronic components that are polarity sensitive. Make sure that the furnace is wired correctly and is properly grounded.
  • Page 21 TABLE 12 Field Wiring Applications DIP Switch Setting and On−Board Links (See figure 19) W915 W914 Dehu- Two−Stage midification W951 Thermostat Wiring Connections DIP Switch 1 Cooling or Harmony Heat Pumps 1 Heat / 1 Cool Intact Intact Intact CONTROL OUTDOOR T’STAT TERM.
  • Page 22 TABLE 12 Field Wiring Applications (Continued) DIP Switch Setting and On−Board Links (See figure 19) W915 W914 Dehu- Two−Stage midification W951 Thermostat Wiring Connections DIP Switch 1 Cooling or Harmony Heat Pumps 2 Heat / 2 Cool Intact Intact CONTROL OUTDOOR T’STAT TERM.
  • Page 23 G60DFV(X) Schematic Wiring Diagram FIGURE 17 Page 23...
  • Page 24 DIAGNOSTIC LEDs INDOOR BLOWER DIP HEATING SWITCHES H= 24V HUMIDIFIER OUTPUT SWITCHES L= LENNOX SYSTEM OPERATION MONITOR 1= FUTURE USE ON−BOARD LINKS DIP SWITCH FUNCTIONS HTG DIP SWITCH(ES) FUNCTION T’stat Heat Stages (single or two−stage) Second Stage ON Delay (single−stage t’stat)

  • Page 25: Integrated Control

    TABLE 13 Integrated Control Blower Off Delay Switch Settings Blower Off Delay Switch 3 Switch 4 G60DFV units are equipped with a two−stage, variable (Seconds) speed integrated control. This control manages ignition timing, heating mode fan off delays and indoor blower speeds based on selections made using the control DIP switches.
  • Page 26 TABLE 16 Switches 11 and 12 −− Heating Mode Blower Speed −− Cooling Mode Blower Speed Ramping Switches 11 and 12 are used to select heating mode blower Ramping Option Switch 9 Switch 10 motor speed. The unit is shipped from the factory with the A (Factory) dip switches positioned for medium low (2) speed indoor blower motor operation during the heating mode.
  • Page 27 NOTES − The effect of static pressure is included in air volumes shown. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 426 cfm (201 L/s). TABLE 19 G60DFV−36B−090 BLOWER MOTOR PERFORMANCE...
  • Page 28 NOTES − The effect of static pressure is included in air volumes shown. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 520 cfm (245 L/s). TABLE 21 G60DFV−60C−110 BLOWER MOTOR PERFORMANCE...
  • Page 29 NOTES − The effect of static pressure is included in air volumes shown. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 477 cfm (225 L/s). TABLE 23 OPERATING SEQUENCE G60DFV, Thermostat with Humidity Control Feature and Single−Speed Outdoor Unit...
  • Page 30 TABLE 24 OPERATING SEQUENCE G60DFV, Thermostat with Humidity Control Feature and Two−Speed Outdoor Unit OPERATING MODE SYSTEM DEMAND SYSTEM RESPONSE System Thermostat *Relative Humidity ****Compressor Blower CFM Comments Condition Demand (EfficiencyPlus Lights) Speed (COOL) **42%/46% of Compressor demand and indoor No demand.

  • Page 31: Unit Start−Up

    Gas Valve Operation (Figures 20 and 21) Unit Start−Up 1 − STOP! Read the safety information at the beginning of FOR YOUR SAFETY READ BEFORE LIGHTING this section. 2 − Set the thermostat to the lowest setting. 3 − Turn off all electrical power to the unit. WARNING 4 −...

  • Page 32: Gas Pressure Adjustment

    11 − Set the thermostat to desired setting. NOTE − In Canada, certification for installations at eleva- tions over 4500 feet (1372 m) is the jurisdiction of local au- NOTE − When unit is initially started, steps 1 through 11 thorities.

  • Page 33: Heating Sequence Of Operation

    Electrical 3 − After the pre−purge is complete, a 20−second initial ig- nitor warm−up period begins. The combustion air in- 1 − Check all wiring for loose connections. ducer continues to operate at low speed. 2 − Check for the correct voltage at the furnace (furnace 4 −...

  • Page 34: Service

    4 − After the 20−second warm−up period has ended, the Flue And Chimney gas valve is energized on low fire (first stage) and igni- Check the flue pipe, chimney and all connections for tight- tion occurs. At the same time, the control module ness and to make sure there is no blockage.
  • Page 35 12 −Remove the cable from the heat exchanger. Use a vac- G60DFV(X) COMBUSTION AIR INDUCER, uum cleaner to remove debris knocked loose during BURNER BOX & HEAT EXCHANGER REMOVAL cleaning. 13 −Attach the exhaust end (positive pressure) of the vacu- Heat Exchanger um cleaner to the top of the heat exchanger section.

  • Page 36: Planned Service

    Repair Parts List The following repair parts are available through independent Lennox dealers. When ordering parts, include the complete furnace model number listed on the CSA International nameplate −− Example: G60DFV(X)−36A−070−7. Cabinet Parts Heating Parts...

  • Page 37: Integrated Control Diagnostic Codes

    Integrated Control Diagnostic Codes FLASH CODE STATUS / ERROR DESCRIPTION (X + Y) 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. LED flashes X times at 2Hz, remains off for two seconds, flashes Y times at 2Hz, remains off for four X + Y seconds, then repeats.
  • Page 38 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.

  • Page 39: Troubleshooting

    Troubleshooting: Heating Sequence of Operation (Continued) HEATING SEQUENCE OF OPERATION CONTINUED THERMOSTAT CALLS FOR HEAT STATUS LED − HEARTBEAT. (Refer to box A on previous page) FIRST−STAGE (LOW FIRE) PRESSURE GAS VALVE OFF. COMBUSTION AIR INDUCER SWITCH CLOSED WITHIN 2.5 MINUTES? OFF.
  • Page 40 Troubleshooting: Heating Sequence of Operation (Continued) HEATING SEQUENCE OF OPERATION CONTINUED THERMOSTAT CALLS FOR HEAT. STATUS LED −− HEARTBEAT. SEE BOX A. FLAME SIGNAL ABOVE (u1.40 microamps) LOW FLAME SIGNAL (Does not affect control operation) STATUS ERROR CODE 1 + 2. SINGLE−STAGE THERMOSTAT MODE TWO STAGE THERMOSTAT MODE (DIP SWITCH SET AT SINGLE")
  • Page 41 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− STAGE PRESSURE SWITCH CAN BE PROVEN SECOND−STAGE (HIGH FIRE) HEAT or HEAT DEMAND IS SATISFIED.

  • Page 42: Troubleshooting: Cooling Sequence Of Operation

    Troubleshooting: Cooling Sequence of Operation COOLING SEQUENCE OF OPERATION POWER ON SIGNAL POLARITY REVERSED. CONTROL WILL CONTINUE TO CALL FOR COOLING IS POLARITY REVERSED? IN THIS CONDITION. STATUS ERROR CODE 5 + 4. SIGNAL IMPROPER GROUND AT LED. CONTROL WILL CONTINUE TO CALL FOR COOLING IS THERE IN THIS CONDITION.
  • Page 43 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. THERMOSTAT CALLS FOR FIRST STAGE COOL. THERMOSTAT CALLS FOR FIRST−STAGE HEAT. INDOOR BLOWER RAMPS TO FIRST STAGE AFTER 45−SECOND DELAY, INDOOR BLOWER COOLING SPEED AFTER A 2−SECOND DELAY.
  • Page 44 G60DFV(X) Start−Up & Performance Check List Job Name Job No. Date Job Location City State Installer City State Technician Unit Model No. Serial No. Heating Section Electrical Connections Tight? Blower Motor H.P. Line Voltage Gas Piping Connections Blower Motor Amps Tight &...

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G60dfvx seriesG60dfv-36a-070G60dfvx-36a-070G60dfv-36b-090G60dfvx-36b-090G60dfv-60c-090 ... Show all

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