Lennox G61MPV Service Manual
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Lennox G61MPV Service Manual

G61mpv series units
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See also: User's Information Manual , Engineering Data
Service Literature
G61MPV series units are high−efficiency multi−position
(upflow, downflow, horizontal right and left) gas furnaces
manufactured with Lennox Duralok Plust heat exchang-
ers formed of an aluminized steel primary with a stainless
steel secondary condensing coil. G61MPV units are avail-
able in heating capacities of 44,000 to 132,000 Btuh
(13.0.0 to 38.6 kW) and cooling applications from 2 to 5
tons (7.0 kW to 17.5 kW). Refer to Engineering Handbook
for proper sizing.
Units are factory equipped for use with natural gas. Kits are
available for conversion to LPG operation. G61MPV model
units are equipped with the two−stage variable speed inte-
grated SureLight® control. All G61MPV units meet the Cali-
fornia Nitrogen Oxides (NO
sonal Efficiency requirements. All units use a redundant gas
valve to assure safety shut−off as required by C.S.A.
All specifications in this manual are subject to change. Pro-
cedures outlined in this manual are presented as a recom-
mendation only and do not supersede or replace local or
state codes. In the absence of local or state codes, the
guidelines and procedures outlined in this manual (except
where noted) are recommendations only and do not consti-
tute code.

TABLE OF CONTENTS

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II Installation
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VIII Field Wiring and Jumper Setting
IX Control Board Troubleshooting
Revised 02−2012
G61MPV SERIES UNITS
) Standards and California Sea-
x
Page 2
Page 4
Page 23
Page 24
Page 50
Page 67
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Page 68
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Page 71
Page 72
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Page 75
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Page 90
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Page 95
Corp. 0310−L7
Improper installation, adjustment, alteration, service
or maintenance can cause property damage, person-
al injury or loss of life. Installation and service must
be performed by a qualified installer, service agency
or the gas supplier.
Electric shock hazard. Can cause injury
or death. Before attempting to perform
any service or maintenance, turn the
electrical power to unit OFF at discon-
nect switch(es). Unit may have multiple
power supplies.
Sharp edges.
Be careful when servicing unit to avoid sharp edges
which may result in personal injury.
Page 1
G61MPV
IMPORTANT
WARNING
WARNING
© 2012 Lennox Industries Inc.

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Summary of Contents for Lennox G61MPV

  • Page 1: Table Of Contents

    Units are factory equipped for use with natural gas. Kits are available for conversion to LPG operation. G61MPV model units are equipped with the two−stage variable speed inte- grated SureLight® control. All G61MPV units meet the Cali- fornia Nitrogen Oxides (NO ) Standards and California Sea- sonal Efficiency requirements.

  • Page 2: Specifications

    SPECIFICATIONS Model No. G61MPV G61MPV G61MPV G61MPV Heating −36B−045 −36B−070 −36B−071 −36C−090 Performance High Fire Input − Btuh 44,000 66,000 66,000 88,000 Output − Btuh 39,000 61,000 62,000 79,000 Temperature rise range − _F 20 − 50 45 − 75 45 −...

  • Page 3: Accessories

    OPTIONAL ACCESSORIES − MUST BE ORDERED EXTRA B" Width Models C" Width Models D" Width Models FILTER KITS Air Filter and Horizontal (end) Size of filter − in. 87L96 − 18 x 25 x 1 87L97 − 20 x 25 x 1 87L98 −...

  • Page 4: Blower Data

    First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 442 cfm. G61MPV−36B−045 BLOWER MOTOR WATTS Motor Watts @ Various External Static Pressures −...
  • Page 5 First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 458 cfm. G61MPV−36B−070 BLOWER MOTOR WATTS Motor Watts @ Various External Static Pressures −...
  • Page 6 First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 458 cfm. G61MPV−36B−071 BLOWER MOTOR WATTS Motor Watts @ Various External Static Pressures −...
  • Page 7 First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 479 cfm. G61MPV−36C−090 BLOWER MOTOR WATTS Motor Watts @ Various External Static Pressures −...
  • Page 8 First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 449 cfm. G61MPV−60C−090 BLOWER MOTOR WATTS Motor Watts @ Various External Static Pressures −...
  • Page 9 First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 449 cfm. G61MPV−60C−090 BLOWER MOTOR WATTS Motor Watts @ Various External Static Pressures −...
  • Page 10 First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 449 cfm. G61MPV−60C−090 BLOWER MOTOR WATTS Motor Watts @ Various External Static Pressures −...
  • Page 11 First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 458 cfm. G61MPV−60C−091 BLOWER MOTOR WATTS Motor Watts @ Various External Static Pressures −...
  • Page 12 First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 458 cfm. G61MPV−60C−091 BLOWER MOTOR WATTS Motor Watts @ Various External Static Pressures −...
  • Page 13 First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 458 cfm. G61MPV−60C−091 BLOWER MOTOR WATTS Motor Watts @ Various External Static Pressures −...
  • Page 14 First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 463 cfm. G61MPV−60C−110 BLOWER MOTOR WATTS Motor Watts @ Various External Static Pressures −...
  • Page 15 First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 463 cfm. G61MPV−60C−110 BLOWER MOTOR WATTS Motor Watts @ Various External Static Pressures −...
  • Page 16 First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 463 cfm. G61MPV−60C−110 BLOWER MOTOR WATTS Motor Watts @ Various External Static Pressures −...
  • Page 17 First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 458 cfm. G61MPV−60C−111 BLOWER MOTOR WATTS Motor Watts @ Various External Static Pressures −...
  • Page 18 First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 458 cfm. G61MPV−60C−111 BLOWER MOTOR WATTS Motor Watts @ Various External Static Pressures −...
  • Page 19 First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 458 cfm. G61MPV−60C−111 BLOWER MOTOR WATTS Motor Watts @ Various External Static Pressures −...
  • Page 20 First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 470 cfm. G61MPV−60D−135 BLOWER MOTOR WATTS Motor Watts @ Various External Static Pressures −...
  • Page 21 First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 470 cfm. G61MPV−60D−135 BLOWER MOTOR WATTS Motor Watts @ Various External Static Pressures −...
  • Page 22 First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 470 cfm. G61MPV−60D−135 BLOWER MOTOR WATTS Motor Watts @ Various External Static Pressures −...

  • Page 23: Parts Identification

    G61MPV PARTS ARRANGEMENT TOP CAP DuralokPlus HEAT EXCHANGER ASSEMBLY CABINET BURNER BOX ASSEMBLY GAS VALVE AND MANIFOLD FLUE COLLAR COMBUSTION AIR PRESSURE PROVE SWITCHES (36B−045 has 2 single switches) WARM HEADER (COLLECTOR) COMBUSTION AIR INDUCER CONDENSER COIL BURNER PRIMARY LIMIT...

  • Page 24: I Unit Components

    3. Circuit Breaker (CB8) A 24V circuit breaker is also located in the control box. G61MPV unit components are shown in figure 1. The gas The switch provides overcurrent protection to the trans- valve, combustion air inducer and burners can be ac- former (T1).
  • Page 25 After the 15−second pre−purge period, the SureLight ignitor warms up for 20 seconds after which the gas valve opens for a 4−second trial for ignition. The ignitor energizes during the trial until flame is sensed. If ignition is not proved during TWO−STAGE, VARIABLE SPEED INTEGRATED the 4−second period, the control will try four more times with CONTROL BOARD...
  • Page 26 TABLE 1 TABLE 3 SureLight Control / Blower Control Terminals SureLight Control 12Pin Terminal Designation LINE Line 120VAC Neutral PIN # Function XFMR Transformer 120VAC Neutral Gas Valve High Fire Electronic Air Cleaner 120VAC Neutral Second Stage Pressure Switch CIRC Indoor Blower 120VAC Neutral Not Used Humidifier 120VAC Neutral...

  • Page 27: Status Codes

    (2) second pauses. One blink equals approximatley 100 CFM. DS7−ON indicaties the DS to R" jumper has not been cut. When the jumper is cut the system will be operating with LENNOX HARMONY IIt (See Harmony Installation Instructions) or YELLOW with the CCB1 Efficiency Plus control.
  • Page 28 S Motor runs at 50% for 30 seconds. S Motor then runs at 82% for approximately 7−1/2 min- Switch 4 −− Not used in G61MPV application. utes. If demand has not been satisfied after 7−1/2 min- Switches 5 and 6 −− Cooling Mode Blower Speed −−...
  • Page 29 60 SEC. DEMAND erate unless the jumper is cut. Refer to table 21 for opera- tion sequence in applications including a G61MPV, CCB1 and single−speed outdoor unit. Table 22 gives the opera- tion sequence in applications with a two−speed outdoor Ramping Option D unit.

  • Page 30: Integrated Control Board(A92)

    SureLight Board 100870 NOTE − Board 100870 provides a regulated 95 volts G61MPV −7 and later units are equipped with the Lennox the ignitor. two−stage, variable speed integrated SureLight control Two Stage Operation / Thermostat Selection Jumper board.
  • Page 31 THERMOSTAT CONNECTIONS (TB1) DIAGNOSTIC LEDs INDOOR HEATING BLOWER DIP SWITCHES SWITCHES H= 24V HUMIDIFIER OUTPUT L= LENNOX SYSTEM OPERATION MONITOR FUTURE USE 1= DO NOT 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 32 FIGURE 6 Page 32...

  • Page 33: Status/Error Description

    TABLE 15 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 34 Dip Switch Settings operation during the cooling mode. The table below pro- vides the cooling mode blower speeds that will result from Heating Operation DIP Switch Settings different switch settings. Refer to blower tables at the front Switch 1 −− Thermostat Selection −− This unit may be used of this manual for corresponding cfm values.
  • Page 35 Refer to tables 21 through 26 the number of blinks between the two−second pauses to for operation sequence in applications including G61MPV determine the CFM. Each blink represents approximately and a thermostat which features humidity control with a 100 CFM.
  • Page 36 TABLE 22 OPERATING SEQUENCE G61MPV, CCB1 and Two−Stage Outdoor Unit OPERATING MODE SYSTEM DEMAND SYSTEM RESPONSE System Thermostat *Relative Humidity ****Compressor Blower CFM Comments Condition Demand (EfficiencyPlus Lights) Speed (COOL) **49% of HIGH Compressor demand and indoor No demand. Acceptable...
  • Page 37 TABLE 23 ® G61MPV, ComfortSense 7000 and SINGLE STAGE OUTDOOR UNIT OPERATING SYSTEM DEMAND SYSTEM RESPONSE SEQUENCE Thermostat Demand Relative Humidity Blower System Compres- Step Comments Condition Status (COOL) NO CALL FOR DEHUMIDIFICATION Compressor and indoor Normal Operation Acceptable High...
  • Page 38 TABLE 24 ® G61MPV, ComfortSense 7000 and TWO STAGE OUTDOOR UNIT OPERATING SYSTEM DEMAND SYSTEM RESPONSE SEQUENCE Thermostat Demand Relative Humidity Blower System Compressor Comments Condition Status (COOL) NO CALL FOR DEHUMIDIFICATION Normal Opera- Acceptable 70%* Compressor and indoor tion − Y1...
  • Page 39 With Heat Pump − Cut W914 (R to DS) & W951 (R to O) on SureLight board Dave Lennox SignatureStat to use for this application − 51M26 1 heat / 1 cool or 51M28 − 2 heat / 2 cool for heat pumps *Dehumidification blower speed is 70% of COOL speed.
  • Page 40 With Heat Pump − Cut W914 (R to DS) & W951 (R to O) on SureLight board Dave Lennox SignatureStat to use for this application − 51M27 2 heat / 2 cool or 51M28 − 2 heat / 2 cool for heat pumps *Normal operation first stage cooling blower speed is 70% of COOL speed.
  • Page 41 G61MPV BLOWER MOTOR COMPONENTS the blower compartment on the back side of the blower hous- STATOR ing. See figure 7. All G61MPV units are equipped with two sec- (WINDINGS) ondary limits. When excess heat is sensed in the blower BEARING compartment, the limit will open.
  • Page 42 Figures 12 and 11 show the two quick-connect jacks (J48 of power lasting less than 1/4 second. This inrush charges a and J49) which connect the motor to the G61MPV. Jack bank of DC filter capacitors inside the controller. If the discon-...
  • Page 43 Power Choke (L13) GenTeq HARNESS CONNECTORS A choke coil is used on G61MPV 5 ton 1 hp units. The POWER CONTROL choke is located on the blower housing and is used to sup- CONNECTOR J48 CONNECTOR J49 press transient current spikes.
  • Page 44 MOTOR SPEED CONTROL WITH D.C. PULSE-WIDTH MODULATION Motor speed is determined by the size of the electrical pulse sent to the motor windings. The longer the pulse, the faster the motor. OUTPUT FROM CONTROLLER TO MOTOR WINDINGS WINDINGS TURNED OFF WINDINGS TURNED ON Ç...
  • Page 45 C−Heating Components NOTE − The G61MPV(X) furnace contains electronic components that are polarity sensitive. Make sure that 6. Ignitor the furnace is wired correctly and is properly grounded. The SureLight ignitor is made of durable silicon nitride. Ig- nitor longevity is enhanced by controlling voltage to the ig- 7.
  • Page 46 5/16" 10. Primary Limit Control (S10) Figure 18 shows the primary limit (S10) used on G61MPV units located in the heating vestibule panel. S10 is provided with a shield on some models (figure 18) and must not be re- moved.
  • Page 47 See figure 19. When measuring the pressure differential, readings should be G61MPV−045 units have two single swithes as shown in fig- taken at the prove switch. Lack of differential usually indicates ure 20. The switches are connected to the cold end header...
  • Page 48 NOTE − Both sides of the cold end header box are negative. 14. Combustion Air Inducer (B6) However the (+) port reads less negative pressure than the All G61MPV units use a two−speed combustion air induc- (−) port. er (CAI) to move air through the burners and heat ex- changer during heating operation.
  • Page 49 TABLE 28 TABLE 32 7501’ to 10,000’ 95% Furnaces G61MPV Unit C.A.I. Orifice Size Set Point Set Point −045 0.719" G61MPV Unit Second Stage First Stage −070 0.938" −071 0.75" 0.70" −071 0.880" −091 1.20" 0.90" −090 1.063" −111 0.85"...
  • Page 50 †† The 44W92 Concentric kit is provided with a 1−1/2" accelerator which must be ***For use only in non−direct vent applications, when snow riser is not required. Re- installed on the exhaust outlet when this kit is used with the G61MPV−36B−045, quires field−provided and installed 2" exhaust accelerator.
  • Page 51 NOTE − Include ALL pipe and ALL fittings, both in NOTE − On G61MPV−071, −091 and −111 units, sweep el- doors and outdoors. bows must be used for all 90° elbows in the venting Regardless of the diameter of pipe used, the standard roof system when 2", 2−1/2"...
  • Page 52 4" diameter pipe †On G61MPV−071, −091 and −111 units, sweep elbows must be used for all 90° elbows in the venting system when 2", 2−1/2" or 3" vent pipe is used. 5 ft. plus 2 elbows of 2−1/2" 3" or 4"...
  • Page 53 24" (610mm) maximum and 3/4" dowflow applications. (19mm) minimum. If a G61MPV furnace replaces a furnace which was commonly vented with another gas appliance, 2. All horizontal runs of exhaust pipe must slope back to- the size of the existing vent pipe for that gas appliance must ward unit.
  • Page 54 FIGURE 24 Intake Piping TYPICAL EXHAUST PIPE CONNECTIONS HORIZONTAL DIRECT OR The G61MPV furnace may be installed in either direct vent NON−DIRECT VENT APPLICATIONS or non−direct vent applications. In non−direct vent applica- (Horizontal Right−Hand Air Discharge Application Shown) tions, when intake air will be drawn into the furnace from the surrounding space, the indoor air quality must be consid- *Limit pipe length to 2"...
  • Page 55 G61MPV−60C−110* G61MPV−60C−111* G61MPV−60C−111* G61MPV−60D−135* *Limit pipe length to4" in G61MPV−110, −111 and −135 applications. FIGURE 26 Follow the next three steps when installing the unit in Non- TYPICAL AIR INTAKE PIPE CONNECTIONS Direct Vent applications where combustion air is taken HORIZONTAL DIRECT VENT APPLICATIONS from indoors and flue gases are discharged outdoors.
  • Page 56 FIGURE 29 1 − Use field−provided materials and the factory−provided After the G61MPV gas furnace has been started, the fol- air intake screen to route the intake piping as shown in lowing test should be conducted to ensure proper venting figures 28 and 29.
  • Page 57 Heating cable installation kit is avail- doors. The G61MPV is then classified as a direct vent, able from Lennox. See Condensate Piping section for part Category IV gas furnace.

  • Page 58: Vent Termination Clearances

    ‡ 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 58...
  • Page 59 ‡ 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 31 Page 59...
  • Page 60 Details of Intake and Exhaust Piping Terminations for FIELD SUPPLIED WALL TERMINATION OR Direct Vent Installations (15F74) WALL RING TERMINATION KIT NOTE − In Direct Vent installations, combustion air is tak- NOTE − FIELD PROVIDED en from outdoors and flue gases are discharged to out- REDUCER MAY BE 1/2"...
  • Page 61 TABLE 38 FIELD SUPPLIED WALL TERMINATION OR EXHAUST PIPE TERMINATION SIZE REDUCTION (15F74) WALL RING TERMINATION KIT G61MPV Termination With INTAKE ELBOW Exhaust Pipe Size MODEL Pipe Size 1−1/2" (38mm) 045, 070, 071 2" (51mm), 2−1/2" (64mm), NOTE − FIELD PROVIDED 090, 091 2"...
  • Page 62 1 1/2" (38mm) accelerator Front View EXHAUST VENT provided on 71M80 & 44W92 kits for SIZE G61MPV−36B−045, TERMINATION 36B−070 & 36B−071 PIPE PER INTAKE TABLE 38. FLASHING 12” (305mm) INTAKE (Not Furnished) Minimum Above Average Snow Accumulation Top View 1/2" (13mm) Foam Insulation...

  • Page 63: Snow Accumulation

    WALL TERMINATION KITS (CLOSE−COUPLE) EXTENDED VENT FOR GRADE CLEARANCE 2 inch (51 mm) 22G44 (US) 3 inch (76 mm) 44J40 (US) If Intake and Exhaust Pipe is less than 12 in. (305 mm) above snow accumulation or other obstructions, FIELD−PROVIDED field fabricated piping must be installed.
  • Page 64 G61MP DIRECT VENT APPLICATION SIZE TERMINATION STRAIGHT−CUT OR USING EXISTING CHIMNEY ANGLE−CUT IN DIRECTION PIPE PER TABLE OF ROOF SLOPE * 12" (305mm) ABOVE AVE. SNOW 1/2" (13mm) FOAM 3" − 8" EXHAUST VENT ACCUMULATION (76mm− INSULATION 8" − 12" 1/2"...
  • Page 65 FIGURE 45 NOTE − In upflow applications where side return air filter is installed on same side as the conden- G61MPV NON−DIRECT VENT APPLICATION sate trap, filter rack must be installed beyond USING EXISTING CHIMNEY condensate trap to avoid interference.
  • Page 66 SCREW cable kit may be used on the condensate trap and line. Heating cable kit is available from Lennox in various NOTE − Use screws to secure condensate trap to cabinet. DO NOT apply glue to this joint. All other joints must be glued.

  • Page 67: Start Up

    5 − Remove the upper access panel. The gas valve on the G61MPV may be equipped with ei- ther a gas control knob or gas control lever. Use only your 6 − Honeywell VR8205 Gas Valve − Turn knob on gas hand to push the lever or turn the gas control knob.

  • Page 68: Heating System Service Checks

    Gas Leak Detector is strongly recommended. It is available all gas valves (both internal and external to unit) to guaran- through Lennox under part number 31B2001. See Corp. tee no gas leak into combustion chamber. Turn off power to 8411−L10, for further details.
  • Page 69 Determine the time in seconds for one revolu- tive burner box must be considered. Use pressure test tions of gas through the meter. A portable LP gas me- adapter kit (available as Lennox part 10L34) to assist in ter (17Y44) is available for LP applications. measurement.
  • Page 70 The maximum carbon monoxide reading should not ex- G61MPV units. The concentration of the acidity of all these ceed 100 ppm. fluids including the condensate is very low and harmless.

  • Page 71: Typical Operating Characteristics

    OFF position. Lennox Repair Parts) is B−Temperature Rise required to measure flame Temperature rise for G61MPV units depends on unit input, signal if meter used will not blower speed, blower horsepower and static pressure as read a low micro amp sig- marked on the unit rating plate.

  • Page 72: Maintenance

    7 − Remove burner box cover and remove four burner box ry or death. screws at the vestibule panel and remove burner box. Set burner box assembly aside. G61MPV−135 only − Filters Remove and discard two additional shipping screws. Filters should be inspected monthly. Clean or replace the See figure 55.
  • Page 73 10 − Disconnect condensate drain line from the conden- 23 − Re-secure the supporting screws along the vestibule sate trap. Remove condensate trap (it may be neces- sides and bottom to the cabinet. sary to cut drain pipe). Remove screws that secure 24 −...
  • Page 74 11 − Replace the blower compartment access panel. which secure burner box assembly to vest panel. Re- move burner box from the unit. G61MPV−135 only − 12 − Refer to instruction on verifying gas and electrical con- Remove and discard two additional shipping screws.

  • Page 75: Wiring And Sequence Of Operation

    VII− Wiring and Sequence of Operation A−SureLight Board 49M59 Page 75...
  • Page 76 E20 set at SINGLE" Sequence depends on type thermostat used. 1− SureLight control energizes combustion air inducer B6 G61MPV units are applicable for single stage or two on low heat speed. Combustion air inducer runs until stage thermostats. Both type thermostats are de- S128 low heat prove switch contacts close (switch scribed below.
  • Page 77 C−Flow Chart SureLight Board 49M59 HEATING SEQUENCE OF OPERATION NORMAL AND ABNORMAL HEATING MODE GAS VALVE OFF. COMBUSTION AIR INDUCER POWER ON OFF. INDOOR BLOWER OFF. CHECK FOR BROKEN IGNITOR OR OPEN IGNITER CIRCUIT. DS 1 AND DS 2 ALTERNATING FAST FLASH. CONTROL SELF−CHECK OKAY? GAS VALVE OFF.
  • Page 78 HEATING SEQUENCE OF OPERATION CONTINUED THERMOSTAT CALLS FOR HEAT DS1 AND DS2 SIMULTANEOUS FAST FLASH (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. INDOOR BLOWER OFF. UNIT WILL RETRY AFTER 5−MINUTE WAIT PERIOD.
  • Page 79 HEATING SEQUENCE OF OPERATION CONTINUED THERMOSTAT CALLS FOR HEAT. DS1 AND DS2 SIMULTANEOUS FAST FLASH. SEE BOX A. FLAME SIGNAL ABOVE (w0.23 microamps) LOW FLAME SIGNAL (Does not affect control operation) DS1 SLOW FLASH, DS2 FAST FLASH. SINGLE−STAGE THERMOSTAT MODE TWO STAGE THERMOSTAT MODE (E20 SET AT SINGLE") (E20 SET AT TWO")
  • Page 80 HEATING SEQUENCE OF OPERATION CONTINUED SEE BOX A NORMAL OPERATION DS1 AND DS2 SIMULTANEOUS SLOW FLASH. SEE BOX B THERMOSTAT CALLS FOR HEAT DS 1 AND DS 2 SIMULTANEOUS FAST FLASH GAS VALVE OFF. COMBUSTION AIR INDUCER OFF. IS PRIMARY, SECONDARY, BACKUP INDOOR BLOWER ON.
  • Page 81 COOLING SEQUENCE OF OPERATION POWER ON IS POLARITY REVERSED? SIGNAL POLARITY REVERSED. DS1 FAST FLASH, DS2 SLOW FLASH. SIGNAL IMPROPER GROUND AT DS. IS THERE IS VOLTAGE SIGNAL HOLDS PROPER GROUND? ABOVE 75 VOLTS? UNTIL UNIT IS PROPERLY GROUNDED. LOW VOLTAGE SIGNAL AT DS HOLDS UNTIL VOLTAGE RISES ABOVE 75 VOLTS.
  • Page 82 D−G61MPV with SureLight Board 100870 Page 82...
  • Page 83 Switch set at SINGLE" Sequence depends on type thermostat used. 1− SureLight control energizes combustion air inducer B6 G61MPV units are applicable for single stage or two on low heat speed. Combustion air inducer runs until stage thermostats. Both type thermostats are de- S128 low heat prove switch contacts close (switch scribed below.
  • Page 84 F−Flow Chart SureLight Board 100870 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 85 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. INDOOR BLOWER OFF. UNIT WILL RETRY AFTER 5−MINUTE WAIT PERIOD.
  • Page 86 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") (DIP SWITCH SET AT TWO") START SECOND−STAGE RECOGNITION...
  • Page 87 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. A FIVE (5) PRESSURE SWITCH CLOSED? MINUTE WAIT PERIOD IS INITIATED BEFORE RETRY.
  • Page 88 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 89 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 90 VIII− Field Wiring Applications and Jumper Settings A−SureLight Board 49M59 TABLE 45 Field Wiring Applications Jumper Settings (See figure 4) Thermostat Wiring Connections W915 W914 W951 1 Heat / 1 Cool SINGLE Intact Intact Intact CONTROL OUTDOOR T’STAT TERM. STRIP UNIT NOTE −...
  • Page 91 TABLE 46 Field Wiring Applications (Continued) Jumper Settings (See figure 4) Thermostat Wiring Connections W915 W914 W951 1 Heat / 2 Cool SINGLE Intact CONTROL OUTDOOR CCB1 with CCB1 T’STAT TERM. STRIP UNIT NOTE − Use dip switch 3 to set second−stage HSXA19 heat ON delay.
  • Page 92 TABLE 47 Field Wiring Applications (Continued) Jumper Settings (See figure 4) Thermostat Wiring Connections W915 W914 W951 2 Heat / 1 Cool Intact Intact Intact CONTROL OUTDOOR T’STAT TERM. STRIP UNIT HSXB15 (LSOM) FM21 Heat Pump / 1 SINGLE Intact Intact CONTROL FM21...
  • Page 93 B−SureLight Board 100870 TABLE 48 Field Wiring Applications (Continued) Dip Switch Settings and On Board Links (See figure 5) W915 W914 Dehu- Two−Stage midification W951 Thermostat Wiring Connections DIP Switch 1 Cooling or Harmony Heat Pumps 1Heat / 1 Cool Intact Intact Intact...
  • Page 94 TABLE 49 Field Wiring Applications (Continued) Dip Switch Settings and On Board Links (See figure 5) 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...
  • Page 95 IX−TROUBLESHOOTING ® A−SureLight Board 49M59 UPON INITIAL POWER UP, REMOVE ALL THERMOSTAT DEMANDS TO THE UNIT PROBLEM: 1 UNIT FAILS TO OPERATE IN THE COOLING, HEATING, OR CONTINUOUS FAN MODE Condition Possible Cause Corrective Action / Comments 1.1.1 ACTION 1 − Check 120V main voltage. −...
  • Page 96 PROBLEM 1: UNIT FAILS TO OPERATE IN THE COOLING, HEATING, OR CONTINUOUS FAN MODE Condition Possible Cause Corrective Action / Comments ACTION 1 − Check that the unit is properly 1.5.1 ground. − Diagnostic lights flash the improper ACTION 2 − Install a proper main ground to the Improper ground to the unit.
  • Page 97 PROBLEM 2: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR INDUCER DOES NOT ENERGIZE (CONT.). Condition Possible Cause Corrective Action/Comments 2.3.1 − Unit operates with a cooling and con- ACTION 1 − Check for correct wiring and loose tinuous fan demand.
  • Page 98 PROBLEM 4: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR BLOWER ENERGIZES, IGNITOR IS ENERGIZED. Condition Possible Cause Corrective Action/Comments ACTION 1 − Check line pressure at the gas valve. 4.1.1 Pressure should not exceed 13" WC for both nat- −...
  • Page 99 ACTION 2 − Seal leakage if possible, replace secondary heat exchanger, and heat exchanger if necessary, tag and return heat exchanger to proper Lennox personnel. combustion air blower. 5.3.4 ACTION 1 − Check for sooting deposits or other restrictions in the heat exchanger assembly.
  • Page 100 PROBLEM 6: CONTROL SIGNALS LOW FLAME SENSE DURING HEATING MODE Condition Possible Cause Corrective Action/Comments 6.1.1 ACTION 1 − Check the sensor rod for proper loca- − Unit operates correctly but the diag- tion on the burner. Properly locate the sensor rod Sensor rod is improperly located on or replace if rod cannot be located correctly.
  • Page 101 ® B−SureLight Board 100870 Two Stage Variable Speed Control Board 100870 UPON INITIAL POWER UP, REMOVE ALL THERMOSTAT DEMANDS TO THE UNIT PROBLEM: 1 UNIT FAILS TO OPERATE IN THE COOLING, HEATING, OR CONTINUOUS FAN MODE Flash Code Possible Cause Corrective Action / Comments LED X + Y 1.1.1...
  • Page 102 PROBLEM 2: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR BLOWER DOES NOT ENERGIZE Flash Code Corrective Action / Comments Possible Cause LED X + Y ACTION 1 − Check continuity across switch(es). 2.1.1 Switches reset automatically upon cool down. Unit operates with a cooling or ACTION 2 −...
  • Page 103 PROBLEM 4: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR INDUCER ENERGIZES, IGNITOR IS NOT ENERGIZED. Flash Code Possible Cause Corrective Action/Comments LED X + Y 4.1.1 ACTION 1 − Check for restricted vent. Remove all blockage. − Unit operates with a cooling and Prove switch does not close due to ACTION 2: Check for proper vent sizing.
  • Page 104 PROBLEM 5: UNIT FIRES ON LOW FIRE, FAILS TO GO TO HIGH FIRE OPERATION Flash Code Possible Cause Corrective Action/Comments LED X + Y 5.1.1 ACTION 1 − Check for restricted vent. Remove all blockage. − Unit light s normally during low fire Prove switch does not close due to ACTION 2: Check for proper vent sizing.
  • Page 105 PROBLEM 6: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR BLOWER ENERGIZES, IGNITOR IS ENERGIZED. Flash Code Possible Cause Corrective Action/Comments LED X + Y ACTION 1 − Check line pressure at the gas valve. 6.1.1 Pressure should not exceed 13" WC for both nat- Unit operates with a cooling and ural and propane.
  • Page 106 PROBLEM 7: BURNERS LIGHT WITH HEATING DEMAND BUT UNIT SHUTS DOWN PREMATURELY (CONT.) Flash Code Possible Cause Corrective Action/Comments LED X + Y ACTION 1 − Check that the manifold pressure matches value listed on nameplate. See installa- Combustion air inducer energizes 7.3.1 tion instructions for proper procedure.
  • Page 107 PROBLEM 7: BURNERS LIGHT WITH HEATING DEMAND BUT UNIT SHUTS DOWN PREMATURELY (CONT.) Flash Code Possible Cause Corrective Action/Comments LED X + Y ACTION 1 − Check that the sensor is properly lo- Combustion air inducer energizes 7.5.1 cated. with a heating demand. ACTION 2 −...
  • Page 108 C−Indoor Blower Motor TWO STAGE VARIABLE SPEED CONTROL WITH GenTeq MOTOR OR EMERSON MOTOR 120V to the motor must not be interrupted. All connections for check out will be from 24VAC to plug J46, after disconnecting from blower control board. REMOVE PLUG FROM BOARD If transformer T1 is used, double check all wiring connections before placing unit back in operation.
  • Page 109 Verify Control / Motor Operation (Emerson Motor Only) 1 Disconnect power to unit. Wait 5 minutes for internal capacitors to fully discharge. 2 Remove three screws (figure 1) securing motor to control. Motor will now separate from control. 3 Disconnect three−wire motor to controller harness. See figure 2. If terminals are damaged replace control.

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