Lennox G60UH Service Manual
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Lennox G60UH Service Manual

Lennox G60UH Service Manual

G60uh(x) series
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See also: Service Manual , 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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G60UH(X) SERIES UNITS
) Standards and California Sea-
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Corp. 0204−L2
Revised 09−2006
G60UH−1 MODEL SHOWN
Improper installation, adjustment, alteration, service
1
or maintenance can cause property damage, person-
al injury or loss of life. Installation and service must
2
be performed by a qualified installer, service agency
5
or the gas supplier.
10
11
12
Electric shock hazard. Can cause injury
19
or death. Before attempting to perform
any service or maintenance, turn the
19
electrical power to unit OFF at discon-
20
nect switch(es). Unit may have multiple
power supplies.
22
23
25
Sharp edges.
33
Be careful when servicing unit to avoid sharp edges
which may result in personal injury.
35
Page 1
G60UH(X)
IMPORTANT
WARNING
WARNING
© 2002 Lennox Industries Inc.

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Summary of Contents for Lennox G60UH

  • 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

    Integrated Control Board Circuit Breaker *Flame rollout switches are located on brackets on the inner sides. Control Transformer NOTE − G60UH−1, −2 and −3 unit models are equipped with a fully enclosed burner box. See figure 16. 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 onds. After a total of five trials for ignition (including the ini- TABLE 1 tial trial), the control goes into Watchguard−Flame Failure Heating Fan Off Delay 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 TWO−STAGE INTEGRATED CONTROL BOARD 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...
  • Page 15 5. Blower Motors and Capacitors SUPPLY AIR BLOWER AND SECONDARY LIMIT (S) All G60UH(X) units use direct drive blower motors. All mo- tors are 120V permanent split capacitor motors to ensure maximum efficiency. Ratings for capacitors will be on motor nameplate.

  • Page 16: Flame Sensor

    The SureLight control allows should be 10.9 to 19.7. See 7 for ignitor location. the gas valve to remain open as long as flame signal is NOTE − The G60UH(X) furnace contains electronic sensed. components that are polarity sensitive. Make sure that the furnace is wired correctly and is properly grounded.
  • Page 17 FIGURE 9 9. Flame Rollout Switches (S47) The G60UH(X) furnace can be installed in horizontal ap- On all G60UH −1, −2 and −3 units, flame rollout switch is a plications. high temperature limit located on top of the burner box.
  • Page 18 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 19: 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 20: 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 21 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 22: Typical Operating Characteristics

    OFF position. 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. See figure 13. The as marked on the unit rating plate.

  • Page 23: Maintenance

    B−Filters Blower speed tap changes are made on the SureLight con- All G60UH(X) filters are installed external to the unit. Filters trol board. See figure 4. The unused tap must be secured should be inspected monthly. Clean or replace the filters on dummy terminals "PARK "...
  • Page 24 NOx INSERTS G60UH(X) BURNER & HEAT EXCHANGER REMOVAL (X models only) HEAT EXCHANGER GASKET NOx INSERT FIGURE 17 BURNER BOX ASSEMBLY 15− To clean the burner, run a vacuum cleaner with a soft (−1, −2, −3 units only) brush attachment over the face of burners. Visually in-...

  • Page 25: Wiring And Sequence Of Operation

    VII− Wiring and Sequence of Operation G60UH−1, −2, −3 Page 25...
  • Page 26 G60UH−4, −5 Page 26...
  • Page 27 Sequence of Operation 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. Combustion air inducer runs until mostats.
  • Page 28 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. INDOOR BLOWER OFF. CHECK FOR BROKEN IGNITOR OR OPEN IGNITER CIRCUIT.
  • Page 29 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 30 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 31 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 32 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 33: Field Wiring And Jumper Setting

    VIII− Field Wiring Applications and Jumper Settings 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 − Use dip switch 3 to set second−stage heat ON delay.
  • Page 34 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 35: Control Board Troubleshooting

    IX− Integrated Control Board Troubleshooting Guide 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 36 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 37 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 38 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 39 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 40 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.

This manual is also suitable for:

G60uhxG60uh−24a−045G60uh−24a−070G60uh−36a−070G60uh−24a−045xG60uh−36a−070x

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