Lennox G60UH Series Installation Instructions Manual
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Lennox G60UH Series Installation Instructions Manual

Lennox G60UH Series Installation Instructions Manual

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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.
01/10
*2P0110*
INSTALLATION
INSTRUCTIONS
G60UH(X) Series
GAS FURNACE
506176−01
1/2010
Supersedes 10/2009

Table of Contents

Troubleshooting
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 G60UH Series

  • Page 1: Table Of Contents

    INSTALLATION INSTRUCTIONS E 2008 Lennox Industries Inc. Dallas, Texas, USA G60UH(X) Series GAS FURNACE 506176−01 1/2010 Supersedes 10/2009 Litho U.S.A. Table of Contents Unit Dimensions ....... . .

  • Page 2: Unit Dimensions

    G60UH(X) Unit Dimensions − inches (mm) 3−3/4 (95) *NOTE − 60C and 60D units that require air volumes over 1800 cfm (850 L/s) must have one of the following: 1. Return air from single side with transition which will accommodate 20 x 25 x 1 in. (508 x 635 x 25 mm) cleanable air filter.

  • Page 3: G60Uh(X) Parts Arrangement

    Gas Orifices Ignitor Bracket Ignitor Secondary Limit(s) Burner Bottom Shield Blower Motor Control Transformer Circuit Breaker Capacitor Two−Stage Integrated Control Door Interlock Switch *Flame rollout switches are located on brackets on the inner sides. FIGURE 1 G60UH Series Page 3...

  • Page 4: G60Uh(X) Gas Furnace

    G60UH(X) Gas Furnace CAUTION The G60UH(X) gas furnace is equipped with a two−stage As with any mechanical equipment, personal injury integrated control. Each G60UH(X) unit is shipped ready can result from contact with sharp sheet metal edges. Be careful when you handle this equipment. for installation in the upflow or horizontal position (left or right).

  • Page 5: Use Of Furnace As A Construction Heater

    The furnace should also be located close to the chimney or vent termination point. Lennox does not recommend the use of G60UH(X) units as Do not install the furnace where drafts might blow direct- 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 ) per 1,000 Btu (.29 kW) per hour of the total input rat- open position or interlocked with the equipment so that they ing of all equipment in the enclosure, but not less than 100 square are opened automatically during equipment operation. inches (64516 mm FIGURE 2 G60UH Series Page 7...
  • 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: Setting Equipment

    Allow for clearances to combustible materials as indicated inch cabinets, or 2 inches if a single wall vent is used on 17−1/2 inch cabinets. on the unit nameplate. Minimum clearances for closet or al- FIGURE 6 cove installations are shown in figure 6. G60UH Series Page 9...
  • Page 10 Return Air −− Upflow Applications Side Return Air Return air can be brought in through the bottom or either (with transition and filter) 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.
  • Page 11 4 − Adjust the outside nut to the appropriate height and tighten the inside nut to secure the arrangement. FIGURE 11 G60UH Series Page 11...
  • Page 12 This furnace may be installed in either an attic or a crawl- Horizontal Application space. Either suspend the furnace from roof rafters or Unit Installed on Platform floor joists, as shown in figure 12, or install the furnace on a NOTE −...

  • Page 13: Filters

    6 o’clock position. Re- ing and it must not allow leaks into the supply air duct sys- move the four mounting screws, rotate the assembly (in- tem. cluding the gasket), then reinstall the mounting screws. G60UH Series Page 13...
  • Page 14 See figure 14. Use the provided wire tie to bundle the pres- Codes in Canada. A fan−assisted Category I furnace is an sure switch wires with the inducer motor power leads. appliance equipped with an integral mechanical means to Route the wires away from moving parts and the heat either draw or force combustion products through the com- of the inducer motor to prevent damage to the wires.
  • Page 15 DO NOT insulate the space between the liner and the flexible vent lining system which has been sized ac- chimney wall with puffed mica or any other loose gran- cording to the provided venting tables and the vent pipe manufacturer’s instructions. ular insulating material G60UH Series Page 15...
  • Page 16 A fan−assisted furnace may be commonly vented into an 4 − Single appliance vents − If the vertical vent or tile-lined existing lined masonry chimney if the following conditions chimney has a larger diameter or flow area than the are met: vent connector, use the vertical vent diameter to de- S The chimney is currently serving at least one drafthood termine the minimum vent capacity and the vent...
  • Page 17 15 − No portion of the venting system can extend into, or pass Installation Codes for Canada. If the existing venting through any circulation air duct or plenum. system does not meet these requirements, it must be 16 − Vent connectors serving Category I appliances shall resized. G60UH Series Page 17...
  • Page 18 TABLE 3 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) NOTE −...
  • Page 19 90° elbows. For each additional 90° elbow or equivalent (for example two 45° elbows equal one 90° elbow) beyond two, the maximum capacity listed in the venting table should be reduced by 10 percent (0.90 x maxi- mum listed capacity). G60UH Series Page 19...
  • Page 20 TABLE 5 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 Connector 3 Inch 4 Inch 5 Inch 6 Inch Height Rise Appliance Input Rating in Thousands of Btu Per Hour (feet) (feet)
  • Page 21 3 − Close all building doors and windows and all doors be- ing tests, the common venting system must be modi- tween the space in which the appliances remaining connected to the common venting system are located fied to correct the problem. G60UH Series Page 21...

  • Page 22: 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 23: Electrical

    1/2 psig (3.48 kPa, 14 inches w.c.). MANUAL MAIN ISOLATE Right Side SHUT−OFF VALVE GAS VALVE WILL NOT HOLD FURNACE NORMAL TEST PRESSURE FIGURE 20 FIGURE 21 G60UH Series Page 23...
  • Page 24 6 − Electrically ground the unit according to local codes or, INTERIOR MAKE−UP BOX INSTALLATION in the absence of local codes, according to the current MAKE−UP National Electric Code (ANSI/NFPA No. 70) for the Left side USA and current Canadian Electric Code part 1 (CSA standard C22.1) for Canada.
  • Page 25 ON delay. OFF10 minutes. ON−15 minutes. 1 Heat / 2 Cool Intact CONTROL OUTDOOR T’STAT TERM. STRIP UNIT NOTE − Use DIP switch 2 to set sec- ond−stage heat ON delay. OFF−10 minutes. ON−15 minutes. G60UH Series Page 25...
  • Page 26 TABLE 10 Field Wiring Applications (Continued) DIP Switch Settings and On−Board Links (See figure 25) W915 W951 Two−Stage Thermostat Wiring Connections DIP Switch 1 Cooling Heat Pumps 2 Heat / 2 Cool Intact CONTROL OUTDOOR T’STAT TERM. STRIP UNIT 2 Heat / 1 Cool Intact Intact CONTROL...
  • Page 27 G60UH(X) Schematic Wiring Diagram FIGURE 23 G60UH Series Page 27...
  • Page 28 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 29: Integrated Control

    11 pro- overheating occurs, shut off the gas valve to the furnace before shutting off vides the blower off timings that will result from different the electrical supply. switch settings. G60UH Series Page 29...
  • Page 30 8 − White Rodgers 36E Gas Valve − Move the gas valve CAUTION control switch to ON. See figure 26. 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 27.

  • Page 31: Gas Pressure Adjustment

    Nat. 44W51 18M64 0.42 0.87 −070, −090, −110, −135 44W48 44W50 18M64 1.22 10.0 Pressure switch is factory set. No adjustment necessary. All models use the factory installed pressure switch from 0−7500 feet (0−2285 m). G60UH Series Page 31...

  • Page 32: Other Unit Adjustments

    the amp draw listed on the wiring diagram that is attached Other Unit Adjustments to the unit. Electrical Primary and Secondary Limits 1 − Check all wiring for loose connections. The primary limit is located on the heating compartment 2 − Check for the correct voltage at the furnace (furnace vestibule panel.

  • Page 33: Blower Performance

    0.30 1440 1260 1050 0.40 1345 1170 1000 0.40 1385 1230 1030 0.50 1300 1135 0.50 1320 1190 0.60 1235 1080 0.60 1260 1135 0.70 1165 1020 0.70 1190 1075 0.80 1080 0.80 1090 0.90 0.90 G60UH Series Page 33...
  • Page 34 NOTES − All air data is measured external to unit with 1 in. cleanable filter (not furnished − field provided) in place. Air volume based on bottom air return air. Actual air volume may vary on side return air applications. G60UH−48B−090 PERFORMANCE G60UH−48C−110 PERFORMANCE Air Volume / Watts at Various Blower Speeds...

  • Page 35: Heating Sequence Of Operation

    Wiring errors can cause improper and dan- plete, the inducer and humidifier terminal are de−ener- gerous operation. Verify proper operation after ser- gized. The indoor blower is de−energized at the end of vicing. the off delay. G60UH Series Page 35...
  • Page 36 At the beginning of each heating season, a licensed profes- 3 − Remove the four screws that secure the combustion air sional technician (or equivalent) should check the system inducer. Carefully remove the combustion air inducer to as follows: avoid damaging blower gasket. If gasket is damaged, it must be replaced to prevent leakage.

  • Page 37: Planned Service

    Instruct the homeowners to pay attention to their fur- 20− Turn on power and gas supply to unit. nace. Situations can arise between annual furnace inspec- tions that may result in unsafe operation. 21− Set thermostat and check for proper operation. G60UH Series Page 37...

  • Page 38: 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 39 INDOOR BLOWER OFF. CONTROL WILL NOT ATTEMPT SECOND−STAGE OPERATION DURING THIS HEAT DEMAND. FIRST−STAGE OPERATION WILL BE ATTEMPTED. COMBUSTION AIR INDUCER ON LOW SPEED. STATUS ERROR CODE 2 + 6. STATUS LED −− HEARTBEAT CONTINUED ON NEXT PAGE G60UH Series Page 39...
  • Page 40 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 41 INITIATED BEFORE RETRY. WERE 5 ATTEMPTS MADE FOR SECOND−STAGE HEAT? IN LESS THAN TEN (10) SECONDS? STATUS LED −− HEARTBEAT CONTINUES FIRST−STAGE HEATING DEMAND. WILL NOT REATTEMPT SECOND−STAGE CONTINUED ON NEXT PAGE HEATING DEMAND. STATUS ERROR CODE 2 + 5. G60UH Series Page 41...
  • Page 42 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 43: Troubleshooting: Cooling Sequence Of Operation

    COMPRESSOR AND CONDENSER FAN DE−ENERGIZED. FIRST−STAGE DEMAND FOR COOL SATISFIED? INDOOR BLOWER DE−ENEGIZED. 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 G60UH Series Page 43...
  • Page 44 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 45: 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: G60UH(X)−36A−070−4. All service must be performed by a licensed professional installer (or equivalent), service agency, or gas supplier.
  • Page 46 G60UH(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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G60uhx series

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