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Lennox G60DF(X) Series Installation Instructions Manual

G60df(x) series
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See also: User's Information Manual
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.
05/09
*2P0509*
INSTALLATION
INSTRUCTIONS
G60DF(X) Series
GAS FURNACE
506178−01
05/2009
Supersedes 10/2008

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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Related Manuals for Lennox G60DF(X) Series

Summary of Contents for Lennox G60DF(X) Series

  • Page 1: Table Of Contents

    INSTALLATION INSTRUCTIONS E 2008 Lennox Industries Inc. Dallas, Texas, USA G60DF(X) Series GAS FURNACE 506178−01 05/2009 Supersedes 10/2008 Litho U.S.A. Table of Contents Unit Dimensions ....... .

  • Page 2: Unit Dimensions

    G60DF(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: G60Df(X) Parts Arrangement

    G60DF(X) Parts Arrangement Blower Motor Blower Assembly Internal Flue Pipe Assembly Gasket Transformer Capacitor Circuit Breaker Flue Chase Door Gasket Interlock Switch Limit Two−Stage Shield Integrated Control Flue Box Gasket Primary Heat Exchanger Limit Flue Collector Box Flame Sensor Gasket Flame Rollout Switches* Flame Rollout Bracket Gas Valve...

  • Page 4: G60Df(X) Gas Furnace

    NOTE − In Non−Direct Vent installations, combustion air is G60DF(X) Gas Furnace taken from indoors and flue gases are discharged out− The G60DF(X) gas furnace is equipped with a two−stage doors. integrated control. Each G60DF(X) unit is shipped ready Use only the type of gas approved for use with this furnace. for installation in the downflow position.

  • Page 5: Use Of Furnace As A Construction Heater

    Use of Furnace as a Construction Heater when installing a G60DF(X) furnace: Lennox does not recommend the use of G60DF(X) units as Place the furnace as close to the center of the air dis- a construction heater during any phase of construction.

  • 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

    4 − In closet installations, it may be impossible to install Downflow Application Installation Clearances sheet metal screws from the outside. In this case, make plenum with a removable front and install screws from the inside (See figure 8). 5 − Make certain that an adequate seal is made. Left Side Right Side PLENUM...

  • Page 11: Filters

    The G60DF(X) series units are classified as fan−assisted WARNING Category I furnaces when vertically vented according to the latest edition of National Fuel Gas Code (ANSI The blower access panel must be securely in place Z223.1/NFPA 54) in the USA and the current standards of when the blower and burners are operating.
  • Page 12 Venting Using a Masonry Chimney A fan−assisted furnace may be commonly vented into an existing lined masonry chimney if the following conditions The following additional requirements apply when a lined are met: masonry chimney is used to vent this furnace. S The chimney is currently serving at least one drafthood Masonry chimneys used to vent Category I central fur- naces must be either tile-lined or lined with a listed metal...
  • Page 13 (tables 5 and 6) are assumed to have no suitable for venting G60DF(X) series units. The chimney elbows in the vent system. For all other vent configura- passageway must be checked periodically to ensure that it tions, the vent system is assumed to have two 90°...
  • Page 14 12 − Vent connectors shall be firmly attached to the furnace 17 − If vent connectors are combined prior to entering the flue collar by self−drilling screws or other approved common vent, the maximum common vent capacity means, except vent connectors of listed type B vent listed in the common venting tables must be reduced material which shall be assembled according to the by 10%, the equivalent of one 90°...
  • Page 15 TABLE 5 Capacity of Type B Double−Wall Vents with Type B Double−Wall 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 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 17 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 18 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 19: 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 20: Electrical

    Left Side Piping AUTOMATIC MANUAL (Standard) GAS VALVE MAIN SHUT−OFF MANUAL (with manual VALVE AUTOMATIC MAIN SHUT−OFF shut−off valve) (With 1/8 in. NPT GAS VALVE VALVE Plugged Tap (with manual (With 1/8 in. NPT Shown) shut−off valve) Plugged Tap Shown) GROUND JOINT UNION...
  • Page 21 National Electric Code (ANSI/NFPA No. 70) for the INTERIOR MAKE−UP BOX INSTALLATION USA and current Canadian Electric Code part 1 (CSA (Right Side) standard C22.1) for Canada. A green ground wire is provided in the field make−up box. NOTE − The G60DF(X) furnace contains electronic components that are polarity sensitive.
  • Page 22 TABLE 12 Field Wiring Applications DIP Switch Settings and On−Board Links (See figure 19) W915 W951 (Y1 to Y2) Thermostat Wiring Connections DIP Switch 1 (O to R) Two−Stage Heat Pumps Cooling 1 Heat / 1 Cool Intact Intact CONTROL OUTDOOR T’STAT TERM.
  • Page 23 TABLE 12 Field Wiring Applications (Continued) DIP Switch Settings and On−Board Links (See figure 19) W915 W951 (Y1 to Y2) Thermostat Wiring Connections DIP Switch 1 (O to R) Two−Stage Heat Pumps Cooling 2 Heat / 2 Cool Intact CONTROL OUTDOOR T’STAT TERM.
  • Page 24 G60DF(X) Schematic Wiring Diagram FIGURE 17 506178−01 05/2009 Page 24...
  • Page 25 DIAGNOSTIC LEDs THERMOSTAT CONNECTIONS (TB1) SWITCHES ON−BOARD LINKS 1= ERROR CODE RECALL H= 24V HUMIDIFIER OUTPUT L= LENNOX SYSTEM OPERATION MONITOR DIP SWITCH FUNCTIONS W915 DIP SWITCH(ES) FUNCTION 1 −− 2 Stage T’stat Selects t/stat type (single or two−stage) W951 2 −−...

  • Page 26: Integrated Control

    TABLE 13 Integrated Control Heating Blower−Off Delay Switch Settings Blower Off Delay G60DF units are equipped with a two−stage integrated con- Switch 3 Switch 4 (Seconds) trol. This control manages ignition timing and fan off delays based on selections made using the control DIP switches. The control includes an internal watchguard feature which automatically resets the ignition control when it has been locked out.
  • Page 27 8 − White Rodgers 36E Gas Valve − Move gas valve con- CAUTION trol switch to ON. See figure 20. Honeywell VR8205 Gas Valve − Turn knob on gas Before attempting to perform any service or mainte- valve counterclockwise to ON. Do not force. See nance, turn the electrical power to unit OFF at dis- figure 21.

  • Page 28: Gas Pressure Adjustment

    2 − Compare the number of seconds and the gas meter Gas Pressure Adjustment size in table 14 to determine the gas flow rate. Multiply Gas Flow (Approximate) the gas flow rate by the heating value to determine the 1 − Operate unit at least 15 minutes before checking gas unit input rate.

  • Page 29: Other Unit Adjustments

    Thermostat Heat Anticipation Other Unit Adjustments Set the heat anticipator setting (if adjustable) according to the amp draw listed on the wiring diagram that is attached to the unit. Primary and Secondary Limits Electrical The primary limit is located on the heating compartment 1 −...

  • Page 30: Blower Performance

    Blower Performance Data G60DF−36A−070X PERFORMANCE G60DF−36B−090 PERFORMANCE Air Volume / Watts at Different Blower Speeds Air Volume / Watts at Different Blower Speeds External External External External Static Static Medium− Medium− Medium− Medium− High High Pressure High High Pressure in. w.g. cfm Watt cfm Watt cfm Watt cfm Watt in.

  • Page 31: Heating Sequence Of Operation

    9 − When the combustion air post−purge period is com- Heating Sequence of Operation plete, the inducer and humidifier terminal are de−ener- NOTE − The thermostat jumper on the integratred control is gized. The indoor blower is de−energized at the end of factory−set in the TWO−STAGE"...

  • Page 32: Service

    spring cable. Crimp the cable around the brush so that the Service brush is secured and will not come off during cleaning. At- tach the other end of the cable to the reversible drill to com- WARNING plete the tool for cleaning the heat exchanger. 1 −...

  • Page 33: Planned Service

    19− Reconnect gas supply piping. G60DF(X) COMBUSTION AIR INDUCER, 20− Turn on power and gas supply to unit. BURNER & HEAT EXCHANGER REMOVAL 21− Set thermostat and check for proper operation. 22− Check all piping connections, factory and field, for gas Heat Exchanger leaks.

  • Page 34: Ignition 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 35: Troubleshooting

    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 36 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 37 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 38 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 39: 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 40 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 41: Repair Parts List

    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 International nameplate −− Example: G60DF(X)−36A−070−4. All service must be performed by a licensed professional installer (or equivalent), service agency, or gas supplier.

  • Page 42: Start−Up & Performance Check List

    G60DF(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 &...

This manual is also suitable for:

G60df(x)−36a−070G60df−36b−090G60df(x)−48c−110

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