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Page 7

BLOWER DATA Cont.

5 ton units with 1 hp

G40DF−60C−110 PERFORMANCE

External Static

Air Volume / Watts at Different Blower Speeds

External Static

Pressure

High

Medium−High

Medium−Low

Low

in. w.g.

Pa

cfm

L/s

Watts

cfm

L/s

Watts

cfm

L/s

Watts

cfm

L/s

Watts

.00

0

2475

1170

1276

2280

1075

987

1995

940

845

1690

795

698

.10

25

2390

1125

1248

2235

1055

955

1990

940

829

1675

790

690

.20

50

2330

1100

1223

2180

1030

945

1975

930

809

1665

785

675

.30

75

2245

1060

1192

2125

1000

911

1940

915

786

1660

785

657

.40

100

2175

1025

1187

2050

965

880

1895

895

757

1650

780

636

.50

125

2085

985

1145

1970

930

849

1835

870

734

1625

765

619

.60

150

2020

955

1129

1880

885

815

1750

825

695

1580

745

599

.70

175

1920

905

1094

1775

835

785

1660

785

669

1525

720

579

.80

200

1785

840

1052

1685

795

762

1585

745

645

1440

680

556

.90

225

1670

790

1020

1600

755

741

1520

715

633

1370

645

538

G40DF−60D−135 PERFORMANCE

External Static

Air Volume / Watts at Different Blower Speeds

External Static

Pressure

High

Medium−High

Medium−Low

Low

in. w.g.

Pa

cfm

L/s

Watts

cfm

L/s

Watts

cfm

L/s

Watts

cfm

L/s

Watts

.00

0

2660

1255

1379

2325

1095

1059

1960

925

864

1655

780

684

.10

25

2560

1210

1353

2310

1090

1030

1945

915

840

1640

775

667

.20

50

2490

1175

1325

2280

1075

1000

1940

915

824

1630

770

661

.30

75

2415

1140

1293

2225

1050

972

1930

910

801

1625

765

649

.40

100

2345

1105

1264

2170

1025

941

1910

900

779

1620

760

638

.50

125

2265

1070

1235

2115

1000

918

1870

880

754

1615

760

624

.60

150

2165

1020

1199

2020

955

880

1830

865

733

1585

745

604

.70

175

2050

965

1160

1940

915

854

1755

830

705

1570

740

604

.80

200

1955

920

1112

1865

880

828

1680

790

683

1515

715

584

.90

225

1865

880

1096

1760

830

797

1605

755

656

1465

690

567

NOTE − All air data is measured external to unit with 1 in. (25 mm) cleanable filter (not furnished − field provided) in place. Also see Filter Air Resistance table.

FILTER AIR RESISTANCE

cfm

L/s

in. w.g.

Pa

cfm

L/s

in. w.g.

Pa

0

0

0.00

0

1400

660

0.15

35

200

95

0.01

0

1600

755

0.19

45

400

190

0.03

5

1800

850

0.23

55

600

285

0.04

10

2000

945

0.27

65

800

380

0.06

15

2200

1040

0.33

80

1000

470

0.09

20

2400

1130

0.38

95

1200

565

0.12

30

2600

1225

0.44

110

 Data is for 1 inch (25 mm) cleanable filter (field provided).

Summary of Contents for G40DF?24A?045

Page 1: ...dation 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 recommended only an...

Page 2: ...eating P f Model No G40DF 48C 090 G40DF 48C 110 G40DF 60C 110 G40DF 60D 135 eat g Performance Low NOx Model No 48C 090X 60C 110X Input Btuh 88 000 110 000 110 000 132 000 Output Btuh 71 000 89 000 90...

Page 3: ...5M22 56L32 25W20 25W21 135 59M17 49L90 15M22 25W20 25W21 1 Required for proper operation at altitudes from 7501 to 10 000 ft NOTE G40DF X units do NOT require a manifold change due to elevation Manifo...

Page 4: ...to unit with 1 in 25 mm cleanable filter not furnished field provided in place Also see Filter Air Resistance table G40DF 36B 090 PERFORMANCE External Static Air Volume Watts at Different Blower Speed...

Page 5: ...79 1739 820 585 1526 720 503 1329 625 428 0 25 62 1844 870 662 1701 805 568 1502 710 488 1301 615 414 0 30 75 1802 850 645 1663 785 551 1477 695 473 1272 600 399 0 40 100 1693 800 606 1583 745 517 141...

Page 6: ...1515 715 640 1435 675 555 G40DF 60D 135 PERFORMANCE External Static Air Volume Watts at Different Blower Speeds External Static Pressure High Medium High Medium Low Low in w g Pa cfm L s Watts cfm L...

Page 7: ...dium Low Low in w g Pa cfm L s Watts cfm L s Watts cfm L s Watts cfm L s Watts 00 0 2660 1255 1379 2325 1095 1059 1960 925 864 1655 780 684 10 25 2560 1210 1353 2310 1090 1030 1945 915 840 1640 775 66...

Page 8: ...ion Air Inducer Gasket Manifold Burner Gas Valve Flame Rollout Switches Flame Sensor Primary Limit Ignitor Heat Exchanger Ignitor Bracket Combustion Air Pressure Switch Combustion Air Orifice Gas Orif...

Page 9: ...d repairable If control is inoperable sim ply replace entire control Can cause injury or death Unsafe operation will result if repair is attempted 3 SureLight Ignition Control A92 Figure 3 Control 56L...

Page 10: ...mes with an inter purge and warm up time between trials of 35 seconds Af ter a total of five trials for ignition including the initial trial the control goes into Watchguard Flame Failure mode Af ter...

Page 11: ...oard can be used with either electronic or electro mechanical thermostats with out modification The SureLight ignitor is made of durable silicon nitride Ignitor longevity is also enhanced by volt age...

Page 12: ...e SureLight integrated con trol The unit is shipped with a factory fan off setting of 90 seconds Fan off time will affect comfort and is adjustable to satisfy individual applications For customized co...

Page 13: ...n 2 1 2 minutes the control board goes into Watchguard Pressure Switch mode for a 5 min ute re set period After the 15 second pre purge period the ignitor warms up for 20 seconds during which the gas...

Page 14: ...on air inducer ALTERNATING SLOW FLASH ALTERNATING SLOW FLASH Watchguard burners failed to ignite SLOW FLASH OFF Flame sensed without gas valve energized ON SLOW FLASH Rollout switch open OR 24V pin co...

Page 15: ...and are matched with blower wheels with 2 set screws FIGURE 10 B Ignitor Location BURNERS FRONT VIEW MEASUREMENT IS TO I D OF RETENTION RING BRACKET Silicon nitride Mini Nitride A B 625 406 685 306 A...

Page 16: ...well or White Rodgers The valve is internally redundant to assure safety shut off If the gas valve must be replaced the same type valve must be used 24VAC terminals and gas control knob or switch are...

Page 17: ...sing by means of a flexible silicone hose It moni tors negative air pressure in the combustion air inducer housing The switch is a single pole single throw proving switch elec trically connected to th...

Page 18: ...tructions To Turn Off Gas To Unit To Turn Off Gas To Unit 1 Set thermostat to lowest setting 2 Turn off all electrical power to unit if service is to be per formed 3 Remove access panel 4 Switch lever...

Page 19: ...to the manometer The gas valve is factory set and should not require adjust ment All gas valves are factory regulated See specifica tions section of this manual for High Altitude manifold pres sure s...

Page 20: ...sconnect ignition control flame sensor wire from the flame sensor 4 Connect lead of the transducer to flame sensor 5 Connect lead of transducer to the ignition control sen sor wire 6 Turn supply volta...

Page 21: ...Seal around the hole when the check is complete D Blower Speed Taps Blower speed tap changes are made on the SureLight con trol board See figures 3 5 and 6 For controls 56L84 10M93 and 32M88 the heat...

Page 22: ...at exchanger leaks Replace all screws to the collector box and com bustion air inducer Leaving off screws may cause leaks 13 Clean burner by running a vacuum with a soft brush at tachment over face of...

Page 23: ...or control goes into 5 minute Watchguard Pressure Switch delay Once S18 closes a 15 second pre purge follows 4 SureLight control A92 energizes ignitor A 20 second warm up period begins 5 Gas valve ope...

Page 24: ...DS UNTIL ROLLOUT SWITCH CLOSES GAS VALVE OFF COMBUSTION AIR INDUCER ON INDOOR BLOWER ON HEATING SPEED LED 1 SLOW FLASH LED 2 OFF GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF WITH DELAY L...

Page 25: ...HAS CONTROL FAILED TO SENSE FLAME FOR FIVE CONSECUTIVE TRIES DURING A SINGLE HEAT DEMAND WATCHGUARD MODE GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF WITH DELAY LEDs SIGNAL WATCHGUARD FA...

Page 26: ...EMAINS UNCHANGED THROUGHOUT COOLING CYCLE THERMOSTAT CALLS FOR COOLING COMPRESSOR CONTACTOR ENERGIZED AND SYSTEM FAN ENERGIZED Control 69M08 ONLY will have a 2 second delay COOLING SPEED and EAC TERM...

Page 27: ...W THERMOSTAT CALLS FOR COOLING THERMOSTAT OPENS SYSTEM FAN SWITCHED TO COOLING SPEED EAC TERMINAL REMAINS ENERGIZED THERMOSTAT OPENS CONTROL G ENERGIZES SYSTEM FAN AT HEATING SPEED EAC TERMINAL ENERG...

Page 28: ...to 5 minute Watchguard Pressure Switch delay Once S18 closes a 15 second pre purge follows 4 Ignition control A92 energizes ignitor A 20 second warm up period begins 5 Gas valve opens for a 4 second t...

Page 29: ...M OF 1 SECOND GAS VALVE OFF COMBUSTION AIR INDUCER ON INDOOR BLOWER ON HEATING SPEED LED 1 SLOW FLASH LED 2 OFF GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF WITH DELAY LED 1 OFF LED 2 SL...

Page 30: ...DE GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF WITH DELAY LEDs SIGNAL WATCHGUARD FAILURE CODE IS 60 MINUTE RESET PERIOD COMPLETE YES 4 SECONDS YES HAS CONTROL RESET IGNITION SEQUENCE FO...

Page 31: ...OUGHOUT COOLING CYCLE THERMOSTAT CALLS FOR COOLING COMPRESSOR CONTACTOR AND SYSTEM FAN ENERGIZED WITH 2 SECOND DELAY COOLING SPEED EAC TERM ENERGIZED COMPRESSOR OFF THERMOSTAT OPENS SYSTEM FAN AND EAC...

Page 32: ...ED THERMOSTAT CALLS FOR HEAT W THERMOSTAT CALLS FOR COOLING THERMOSTAT OPENS SYSTEM FAN SWITCHED TO COOL SPEED EAC TERM REMAINS ON THERMOSTAT OPENS MANUAL FAN SELECTION MADE AT THERMOSTAT CONTROL G EN...

Page 33: ...the top button ACTION 2 Determine the cause of the roll out switch activation before leaving furnace code LED 1 O 1 2 2 Roll out switch failure ACTION 1 Check continuity across roll out switch Replace...

Page 34: ...BLEM 2 UNIT FAILS TO FIRE IN THE HEATING MODE COMBUSTION AIR BLOWER DOES NOT ENERGIZE Condition Possible Cause Corrective Action Comments 2 1 Unit operates with a cooling or contin uous fan demand Com...

Page 35: ...h a heating demand Diagnostic lights flash the pressure switch failure code 2 5 minutes after heating demand 3 1 2 Prove switch does not close due to obstructions in the pressure lines ACTION 1 Remove...

Page 36: ...switch code LED 1 Off LED 2 Slow Flash 5 1 1 Low pressure differential at the prove switch ACTION 1 Check for restricted exhaust vent Remove all blockage ACTION 2 Check for proper vent sizing See ins...

Page 37: ...the center of the heat exchanger openings Cor rect the location of the burners if necessary 5 4 Combustion air inducer energizes with a heating demand B li ht hl d th it 5 4 1 Poor Venting ACTION 1 Ch...

Page 38: ...Action Comments 7 0 Indoor blower fails to operate in continuous fan cooling or heating mode 7 1 1 Miswiring of furnace or improper connections at control or indoor blower motor ACTION 1 Correct wirin...

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