Lennox G60UH Service Manual
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Lennox G60UH Service Manual

Lennox G60UH Service Manual

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See also: Instruction and Installation Manual
Service Literature
G60UH(X) series units are mid−efficiency gas furnaces
used for upflow or horizontal applications only, manufac-
tured with Lennox Duralok Plus heat exchangers formed of
aluminized steel. G60UH(X) units are available in heating
capacities of 44,000 to 132,000 Btuh and cooling applica-
tions up to 5 tons. Refer to Engineering Handbook for prop-
er sizing.
Units are factory equipped for use with natural gas. Kits are
available for conversion to LPG operation. G60UH(X) model
units are equipped with the Two−Stage / Variable Speed Inte-
grated SureLight control. G60UH(X) unit meets the Califor-
nia Nitrogen Oxides (NO
x
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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VIII Field Wiring and Jumper Setting
IX Control Board Troubleshooting
G60UH(X) SERIES UNITS
) Standards and California Sea-
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Corp. 0204−L2
Revised 11−2006
G60UH−1 MODEL SHOWN
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
G60UH(X)
IMPORTANT
WARNING
WARNING
© 2002 Lennox Industries Inc.

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  • Page 1: Table Of Contents

    G60UH(X) series units are mid−efficiency gas furnaces used for upflow or horizontal applications only, manufac- tured with Lennox Duralok Plus heat exchangers formed of aluminized steel. G60UH(X) units are available in heating capacities of 44,000 to 132,000 Btuh and cooling applica- tions up to 5 tons.

  • Page 2: Specifications

    SPECIFICATIONS Heating Model No. G60UH−24A−045 G60UH−24A−070 G60UH−36A−070 Performance Low NOx Model No. G60UH−24A−045X − − − G60UH−36A−070X Input − Btuh (kW) low fire 30,000 (8.8) 45,000 (13.2) 45,000 (13.2) Output − Btuh (kW) low fire 24,000 (7.0) 36,000 (10.6) 36,000 (10.6) Input −...
  • Page 3 SPECIFICATIONS Cont. Model No. G60UH−36B−090 G60UH−48B−070 G60UH−48B−090 G60UH−36C−110 Heating Performance Low NOx Model No. − − − − − − G60UH−48B−090X − − − Input − Btuh (kW) low fire 60,000 (17.6) 45,000 (13.2) 60,000 (17.6) 75,000 (22.0) Output − Btuh (kW) low fire 48,000 (14.1)
  • Page 4 SPECIFICATIONS Cont. Model No. G60UH−48C−110 G60UH−60C−110 G60UH−60D−135 Heating Heating Low NOx Model No. − − − G60UH−60C−110X − − − Performance Input − Btuh (kW) low fire 75,000 (22.0) 75,000 (22.0) 90,000 (26.4) Output − Btuh (kW) low fire 60,000 (17.6) 61,000 (17.9)

  • Page 5: Blower Data

    BLOWER DATA G60UH−24A−045 PERFORMANCE Air Volume / Watts at Various Blower Speeds External Static External Static Pressure High Medium in. w.g. Watts Watts Watts 0.00 1090 0.05 1080 0.10 1065 0.15 1050 0.20 1030 0.25 1015 0.30 0.40 0.50 0.60 0.70...
  • Page 6 BLOWER DATA Cont. G60UH−36B−090 PERFORMANCE Air Volume / Watts at Various Blower Speeds External Static External Static Pressure High Medium−High Medium−Low in. w.g. Watts Watts Watts Watts 0.00 1500 1255 1040 0.05 1485 1250 1040 0.10 1465 1240 1035 0.15...
  • Page 7 NOTE − Air volumes based on bottom return air. Actual air volume may vary on side return air applications. G60UH−60C−110 with 3/4 hp PERFORMANCE − Bottom Return Air, Side Return Air with Optional RAB Return Air Base, Re- turn Air from Both Sides or Return Air from Bottom and One Side.
  • Page 8 BLOWER DATA Cont. G60UH−60C−110 with 3/4 hp PERFORMANCE − Single Side Return Air − Air volumes in bold require field fabricated transi- tion to accommodate 20 x 25 x 1 in. (508 x 635 x25 mm) cleanable air filter in order to maintain proper air velocity across the filter.
  • Page 9 BLOWER DATA Cont. G60UH−60C−110 with 1 hp PERFORMANCE − Bottom Return Air, Side Return Air with Optional RAB Return Air Base, Re- turn Air from Both Sides or Return Air from Bottom and One Side. Air Volume / Watts at Different Blower Speeds...

  • Page 10: High Altitude

    BLOWER DATA Cont. G60UH−60D−135 with 1 hp PERFORMANCE − Single Side Return Air − Air volumes in bold require field fabricated transition to accommodate 20 x 25 x 1 in. (508 x 635 x25 mm) cleanable air filter in order to maintain proper air velocity.

  • Page 11: Parts Identification

    Two−Stage Integrated Control Board Door Interlock Switch *Flame rollout switches are located on brackets on the inner sides. NOTE − G60UH−1, −2 and −3 unit models are equipped with a fully enclosed burner box. See figure 19. FIGURE 1 Page 11...

  • Page 12: I Unit Components

    3. Circuit Breaker (CB8) A 24V circuit breaker is also located in the control box. G60UH(X) 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 13 seconds. After a total of five trials for ignition (including the TABLE 1 initial trial), the control goes into Watchguard−Flame Fail- Heating Fan Off Delay ure mode. After a 60−minute reset period, the control will begin the ignition sequence again. Delay (Seconds) Switch 1 Switch 2...
  • Page 14 TABLE 3 CONTROL BOARD 18M34 Integrated Control Board Terminals 120VAC Neutral LINE Line XFMR Transformer LEDs Electronic Air Cleaner CIRC Indoor Blower SWITCHES 1 − 4 Humidifier 120VAC Line Humidifier XMFR Transformer LINE Line PARK For Unused Leads COOL Cooling Speed Electronic Air Cleaner HI HEAT HIigh Heat Speed...
  • Page 15 TABLE 6 DIAGNOSTIC CODES Diagnostic LEDs are labeled DS1 and DS2. See figure 4 for location of diagnostic LEDs. DESCRIPTION Power on − Normal operation. SIMULTANEOUS SIMULTANEOUS Also signaled during cooling and continuous fan. SLOW FLASH SLOW FLASH SIMULTANEOUS SIMULTANEOUS Normal operation −...
  • Page 16 After a 60−minute reset period, the control will begin SureLight Board 100869 the ignition sequence again. G6OUH units are equipped with the Lennox two−stage in- NOTE − Board 100869 DOES NOT ramp down voltage tegrated SureLight control board. The system consists of to the ignitor.
  • Page 17 DIP Switch Settings ply air temperature between 90° and 110°F at the exact Switch 1 −− Thermostat Selection −− This unit may be used moment that the blower is de−energized. Longer off delay with either a single−stage or two−stage thermostat. The settings provide lower supply air temperatures;...
  • Page 18 THERMOSTAT CONNECTIONS (TB1) SWITCHES ON−BOARD FUTURE USE JUMPERS 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 19 TABLE 10 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 20 7. Ignitor The SureLight ignitor is made of durable silicon nitride. Ig- All G60UH(X) units use direct drive blower motors. All mo- nitor longevity is enhanced by controlling voltage to the ig- tors are 120V permanent split capacitor motors to ensure nitor.
  • Page 21 SureLight Board 18M34 Ignitor Location MEASUREMENT IS TO I.D. OF RETENTION RING " 13/32’ 5/16" BRACKET IGNITOR BURNERS TOP VIEW BURNERS FRONT VIEW FIGURE 7 SureLight Board 100869 Ignitor Location MEASUREMENT IS TO I.D. OF RETENTION RING " 7/32’ 21/64" BURNERS TOP VIEW BRACKET IGNITOR...
  • Page 22 FIGURE 12 10. Flame Rollout Switches (S47) plications. On all G60UH −1, −2 and −3 units, flame rollout switch is a The combustion air inducer may be rotated clockwise or high temperature limit located on top of the burner box.
  • Page 23 On heat demand (first or second stage) the switch senses that the combustion air inducer is operating. It closes a cir- The primary limit (S10) on G60UH(X) units is located in the cuit to the furnace control when pressure inside the com- heating vestibule panel.

  • Page 24: Installation

    Shock and burn hazard. Turning Off Gas To Unit G60UH(X) units are equipped with a hot surface igni- 1 − Set thermostat to lowest setting. tion system. Do not attempt to light manually.

  • Page 25: Heating System Service Checks

    IMPORTANT justment. Manifold pressure for the G60UH(X) can be mea- sured at any time the gas valve is open and is supplying gas In case emergency shutdown is required, turn off to the unit.
  • Page 26 3 − After allowing unit to stabilize for 5 minutes, record Unit manifold pressure. For Nat For L.P. NOTE−Shut unit off and remove manometer as soon as G60UH−24A−045(X) 6.5 − 7.5 7.3 − 8.3 an accurate reading has been obtained. Take care to re- G60UH−24A−070 6.8 − 7.8 8.3 −...

  • Page 27: Typical Operating Characteristics

    Lennox Repair Parts) is required to measure flame B−Temperature Rise signal if meter used will not Temperature rise for G60UH(X) units depends on unit in- read a low micro amp sig- put, blower speed, blower horsepower and static pressure nal.

  • Page 28: Maintenance

    If the gasket is damaged, it must be replaced to B−Filters prevent leakage. All G60UH(X) filters are installed external to the unit. Filters 5 − Label the wires from gas valve and rollout switches, should be inspected monthly. Clean or replace the filters then disconnect them.
  • Page 29 NOx INSERTS G60UH(X) BURNER & HEAT EXCHANGER REMOVAL (X models only) HEAT EXCHANGER GASKET NOx INSERT FIGURE 20 BURNER BOX ASSEMBLY (−1, −2, −3 units only) 15− To clean the burner, run a vacuum cleaner with a soft brush attachment over the face of burners. Visually in-...

  • Page 30: Wiring And Sequence Of Operation

    VII− Wiring and Sequence of Operation G60UH−1, −2, −3 Page 30...
  • Page 31 G60UH−4, −5 Page 31...
  • Page 32 Sequence of Operation G60UH−1 through −5 Single−Stage Thermostat, Two Stage Heat. Jumper E20 set at SINGLE" Sequence depends on type thermostat used. G60UH 1− SureLight control energizes combustion air inducer B6 units are applicable for single stage or two stage ther- on low heat speed.
  • Page 33 FLOW CHART G60UH−1 through −5 units with SureLight Board 18M49 HEATING SEQUENCE OF OPERATION NORMAL AND ABNORMAL HEATING MODE Slow flash rate equals 1Hz (one flash per second). Fast flash rate equals 3 Hz (three flashes per second). GAS VALVE OFF. COMBUSTION AIR INDUCER POWER ON OFF.
  • Page 34 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 35 HEATING SEQUENCE OF OPERATION CONTINUED THERMOSTAT CALLS FOR HEAT. DS1 AND DS2 SIMULTANEOUS FAST FLASH. SEE BOX A. FLAME SIGNAL ABOVE (u0.23 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 36 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. INDOOR BLOWER ON. IS PRIMARY AND SECONDARY LIMIT DS1 SLOW FLASH, DS2 ON.
  • Page 37 COOLING SEQUENCE OF OPERATION POWER ON IS POLARITY REVERSED? SIGNAL POLARITY REVERSED. DS1 FAST FLASH, DS2 SLOW FLASH. SIGNAL IMPROPER GROUND AT DS. SIGNAL HOLDS IS THERE IS LINE VOLTAGE LOW VOLTAGE SIGNAL AT DS HOLDS UNTIL UNIT IS PROPER GROUND? ABOVE 75 VOLTS? UNTIL LINE VOLTAGE RISES ABOVE 75 VOLTS.
  • Page 38 G60UH−7 and later Page 38...
  • Page 39 SureLight Board 100869 G60UH−7 and later Single−Stage Thermostat, Two Stage Heat. Dip Switch set at SINGLE" Sequence depends on type thermostat used. G0UH 1− SureLight control energizes combustion air inducer B6 units are applicable for single stage or two stage ther- on low heat speed.
  • Page 40 Flow Chart G60UH−7 Units and later with SureLight Board 100869 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.
  • Page 41 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 42 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 43 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 44 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 45 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. AFTER 45−SECOND DELAY, INDOOR BLOWER INDOOR BLOWER SWITCHES TO FIRST STAGE SWITCHES TO LOW HEAT SPEED.
  • Page 46 VIII− Field Wiring Applications and Jumper Settings A−SureLight Board 18M49 Field Wiring Applications Jumper Settings (See figure 4) Thermostat Wiring Connections Term. Strip Y1 to Y2 1 Heat / 1 Cool SINGLE Leave Installed CONTROL OUTDOOR T’STAT TERM. STRIP UNIT NOTE −...
  • Page 47 Field Wiring Applications (Continued) Jumper Settings (See figure 4) Thermostat Wiring Connections Term. Strip Y1 to Y2 FM21 Heat Pump / 1 SINGLE Leave Installed CONTROL FM21 TERM. STRIP Cool *Disconnect existing furnace transformer and re- place with 75VA, 24V trans- former if defrost option to be used.
  • Page 48 B−SureLight Board 100869 TABLE 19 Field Wiring Applications (Continued) Jumper Settings (See figure 5) W915 Two−Stage W951 Thermostat Wiring Connections DIP Switch 1 Cooling Heat Pumps 1Heat / 1 Cool Intact Intact CONTROL OUTDOOR T’STAT TERM. STRIP UNIT NOTE − Use DIP switch 2 to set sec- ond−stage heat ON delay.
  • Page 49 TABLE 20 Field Wiring Applications (Continued) Jumper Settings (See figure 5) W915 Two−Stage W951 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 50 IX− Integrated Control Board Troubleshooting Guide A−SureLight Board 18M34 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 −...
  • Page 51 PROBLEM 2: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR BLOWER DOES NOT ENERGIZE Condition Possible Cause Corrective Action / Comments ACTION 1 − Check continuity across switch(es). Switches reset automatically upon cool down. − Unit operates with a cooling or contin- 2.1.1 Rollout switch must be reset manually.
  • Page 52 PROBLEM 4: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR BLOWER ENERGIZES, IGNITOR IS NOT ENERGIZED. Condition Possible Cause Corrective Action/Comments 4.1.1 ACTION 1 − Check that the pressure switch line − Unit operates with a cooling and Pressure switch does not close due is correctly routed.
  • Page 53 PROBLEM 5: 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. 5.1.1 Pressure should not exceed 13" WC for both nat- −...
  • Page 54 PROBLEM 6: BURNERS LIGHT WITH HEATING DEMAND BUT UNIT SHUTS DOWN PREMATURELY (CONT.) Condition Possible Cause Corrective Action/Comments ACTION 1 − Check that the manifold pressure matches value listed on nameplate. See installa- − Combustion air inducer energizes 6.3.1 tion instructions for proper procedure. with a heating demand.
  • Page 55 PROBLEM 6: BURNERS LIGHT WITH HEATING DEMAND BUT UNIT SHUTS DOWN PREMATURELY (CONT.) ACTION 1 − Check that the sensor is properly lo- 6.5.1 cated. − Combustion air inducer energizes ACTION 2 − Check that the sense wire is properly Loose sensor wire connection causes with a heating demand.
  • Page 56 B−SureLight Board 100869 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 ACTION 1 −...
  • Page 57 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 58 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 59 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 60 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 61 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 62 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 −...

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