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Page 21

G60DF Series

INTERIOR MAKE−UP BOX INSTALLATION

(Right Side)

FIGURE 16

MAKE−UP

BOX

Refer to figure 17 for schematic wiring diagram and trou-
bleshooting and table 12 and figure 18 for field wiring.

 1 − Select circuit protection and wire size according to the

unit nameplate. The power supply wiring must meet
Class I restrictions.

 2 − Holes are on both sides of the furnace cabinet to facili-

tate wiring.

 3 − Install a separate disconnect switch (protected by ei-

ther fuse or circuit breaker) near the furnace so that
power can be turned off for servicing.

 4 − Before connecting the thermostat or the power wiring,

check to make sure the wires will be long enough for
servicing at a later date. Remove the blower access
panel to check the length of the wire.

 5 − Complete the wiring connections to the equipment.

Use the provided unit wiring diagram and the field wir-
ing diagrams shown in table 12 and figure 18. Use
18−gauge wire or larger that is suitable for Class II rat-
ing for thermostat connections.

 6 − Electrically ground the unit according to local codes or,

in the absence of local codes, according to the current

National Electric Code (ANSI/NFPA No. 70) for the
USA and current Canadian Electric Code part 1 (CSA
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. Make sure 
that the furnace is wired correctly and is properly
grounded.

 7 − One line voltage HUM" 1/4" spade terminal is pro-

vided on the furnace integrated control. Any humidifier
rated up to one amp can be connected to this terminal
with the neutral leg of the circuit being connected to
one of the provided neutral terminals. See figure 19 for
control configuration. This terminal is energized in the
heating mode when the combustion air inducer is oper-
ating.

 8 − One line voltage EAC" 1/4" spade terminal is provided

on the furnace integrated control. Any electronic air
cleaner rated up to one amp can be connected to this
terminal with the neutral leg of the circuit being con-
nected to one of the provided neutral terminals. See
figure 19 for control configuration. This terminal is en-
ergized when the indoor blower is operating.

 9 − One 24V H" terminal is provided on the furnace control

terminal block. Any humidifier rated up to 0.5 amp can
be connected to this terminal with the ground leg of the
circuit being connected to either ground or the C" ter-
minal. See figure 19 for control configuration.

 10 −Install the room thermostat according to the instruc-

tions provided with the thermostat. See table 12 for
field wiring connections in varying applications. If the
furnace is being matched with a heat pump, refer to the
instruction packaged with the dual fuel thermostat.

Indoor Blower Speeds

1 − When the thermostat is set to FAN ON," the indoor

blower will run continuously on the low speed when
there is no cooling or heating demand.

2 − When the G60DF(X) is operating in the high−fire or low−

fire heating mode, the indoor blower will run on the cor-
responding heating speed.

3 − When there is a cooling demand, the indoor blower will

run on the cooling speed.

Summary of Contents for G60DF(X) Series

Page 1: ...erformance 30 Heating Sequence of Operation 31 Service 32 Planned Service 33 Ignition Control Diagnostic Codes 34 Troubleshooting 35 Repair Parts List 41 Start Up Performance Check List 42 WHAT TO DO...

Page 2: ...19 3 4 19 28 1 2 724 19 1 2 495 19 1 4 489 9 1 4 235 4 7 8 124 Right 2 1 4 57 Left 40 1016 3 3 4 95 5 8 16 AIR FLOW 5 8 16 3 4 19 19 1 2 495 5 8 16 B 5 8 16 5 8 16 Supply Air Supply Air Model No A B C...

Page 3: ...mit Heat Exchanger Combustion Air Pressure Switch Assembly Two Switches Combustion Air Orifice Transformer Two Stage Integrated Control Flue Chase Gasket Door Interlock Switch Limit Shield Circuit Bre...

Page 4: ...lding codes In the absence of local codes units must be installed according to the current National Fuel Gas Code ANSI Z223 1 NFPA 54 The National Fuel Gas Code is available from the following address...

Page 5: ...hese installation instructions D A room thermostat must control the furnace The use of fixed jumpers that will provide continuous heating is not allowed D The return air duct must be provided and seal...

Page 6: ...nts as well as all local codes CAUTION Insufficient combustion air can cause headaches nausea dizziness or asphyxiation It will also cause excess water in the heat exchanger resulting in rust ing and...

Page 7: ...g must have a minimum free area of 1 square inch 645 mm2 per 1 000 Btu 29 kW per hour of total input rating of all gas fired equipment in the confined space Each opening must be at least 100 square in...

Page 8: ...least one square inch 645 mm2 per 4 000 Btu 1 17 kW per hour of the total input rating of all equip ment in the enclosure CHIMNEY OR GAS VENT WATER HEATER OUTLET AIR VENTILATION LOUVERS Each end of a...

Page 9: ...her combustible ma terial other than wood flooring TABLE 2 ADDITIVE BASE FLOOR OPENING SIZE Model No Front to Rear Side to Side Model No in mm in mm A Cabinet 14 5 22 559 15 3 4 400 B Cabinet 17 5 22...

Page 10: ...housing Downflow Application Allow for clearances to combustible materials as indi cated on the unit nameplate Minimum clearances for closet or alcove installations are shown in figure 9 Downflow Appl...

Page 11: ...ansition will cause the unit to operate unsafely and will void the unit certification The vent connector does not require insula tion The G60DF X series units are classified as fan assisted Category I...

Page 12: ...nto an existing lined masonry chimney if the following conditions are met S The chimney is currently serving at least one drafthood equipped appliance S The vent connectors and chimney are sized accor...

Page 13: ...chimney has a larger diameter or flow area than the vent connector use the vertical vent diameter to de termine the minimum vent capacity and the vent connector diameter to determine the maximum vent...

Page 14: ...ory I appliances shall not be connected to any portion of mechanical draft systems operating under positive pressure such as Category III or IV venting systems 17 If vent connectors are combined prior...

Page 15: ...5 136 20 226 22 339 15 5 22 65 30 130 39 219 49 330 10 29 59 40 121 51 206 64 315 15 35 53 48 112 61 195 76 301 0 0 97 0 202 0 349 0 540 2 10 75 14 149 18 250 20 377 20 5 21 71 29 143 38 242 47 367 20...

Page 16: ...8 69 57 136 80 225 115 337 15 5 51 63 75 128 102 216 144 326 10 NR NR 95 116 128 201 182 308 15 NR NR NR NR 158 186 220 290 0 35 96 54 200 78 346 114 537 2 37 74 56 148 78 248 113 375 20 5 50 68 73 14...

Page 17: ...2 52 146 69 220 1 21 50 33 89 47 142 64 220 15 2 22 53 35 96 49 153 66 235 3 24 55 36 102 51 163 68 248 1 21 54 33 99 46 157 62 246 20 2 22 57 34 105 48 167 64 259 3 23 60 35 110 50 176 66 271 1 20 62...

Page 18: ...ing test while each appliance is operat ing and the other appliances which are not operating re main connected to the common venting system If the vent ing system has been installed improperly you mus...

Page 19: ...iping must be resistant to the actions of liquified petro leum gases NOTE Install a 1 8 inch NPT plugged tap in the field piping upstream of the gas supply connection to the unit The tap must be acces...

Page 20: ...urnace must be isolated from the gas supply system by closing its individual manual shut off valve during any pressure testing of the gas supply system at pressuresless than or equal to 1 2 psig 3 48...

Page 21: ...tage HUM 1 4 spade terminal is pro vided on the furnace integrated control Any humidifier rated up to one amp can be connected to this terminal with the neutral leg of the circuit being connected to o...

Page 22: ...ooling W951 O to R Heat Pumps Wiring Connections 1 Heat 1 Cool NOTE Use DIP switch 2 to set sec ond stage heat ON delay OFF10 minutes ON 15 minutes ON Intact Intact S1 T STAT CONTROL TERM STRIP OUTDOO...

Page 23: ...ings and On Board Links See figure 19 Thermostat DIP Switch 1 W915 Y1 to Y2 Two Stage Cooling W951 O to R Heat Pumps Wiring Connections 2 Heat 2 Cool OFF Cut Intact S1 T STAT CONTROL TERM STRIP OUTDOO...

Page 24: ...Page 24 506178 01 05 2009 G60DF X Schematic Wiring Diagram FIGURE 17...

Page 25: ...UT TO FLAME SENSER NEUTRALS 120 VAC NEUTRAL PARK DEAD TERMINAL FOR UNUSED BLOWER LEAD HEAT LOW 120 VAC OUTPUT TO CIRC BLWR LOW HT SPEED HEAT HIGH COOL LOW 120 VAC OUTPUT TO CIRC BLWR HIGH HEAT AND LOW...

Page 26: ...s The heating blower off delay affects comfort and is adjustable to satisfy individual applications Adjust the blower off delay to achieve a sup ply air temperature between 90 and 110 F at the exact m...

Page 27: ...e upper access panel 6 White Rodgers 36E Gas Valve Move gas valve con trol switch to OFF See figure 20 Honeywell VR8205 Gas Valve Turn knob on gas valve clockwise to OFF Do not force See figure 21 7 W...

Page 28: ...c for LP propane gas should be maintained 2 After the line pressure has been checked and ad justed check the low fire and high fire manifold pres sures See figures 20 and 21 for the location of the ma...

Page 29: ...at Heat Anticipation Set the heat anticipator setting if adjustable according to the amp draw listed on the wiring diagram that is attached to the unit Electrical 1 Check all wiring for loose connecti...

Page 30: ...1495 556 1350 485 1150 406 965 335 0 25 1465 544 1325 473 1135 398 955 329 0 30 1430 532 1300 460 1125 389 945 323 0 40 1370 509 1250 438 1095 373 935 313 0 50 1295 482 1200 420 1055 355 900 302 0 60...

Page 31: ...first stage heat is satisfied the gas valve is de energized and the field selected indoor blower off delay begins The combustion air inducer begins a 5 second post purge period 9 When the combustion...

Page 32: ...m the unit Label the pressure switch wires then disconnect them 3 Remove the four screws that secure the combustion air inducer Carefully remove the combustion air induc er to avoid damaging blower ga...

Page 33: ...3 and 24 until no leaks are detected 25 Replace front access panel Planned Service The service technician should check the following during an annual inspection Power to the unit must be shut off for...

Page 34: ...ltage HARD LOCKOUT CODES 5 1 Hard lockout Rollout circuit open or previously opened 5 2 Control failed self check internal error control will restart if error recovers 5 3 No Earth ground control will...

Page 35: ...VE OFF COMBUSTION AIR INDUCER ON INDOOR BLOWER ON STATUS ERROR CODE 5 1 SEQUENCE HOLDS UNTIL ROLLOUT SWITCH IS RESET AND MAIN POWER IS INTERRUPTED OR T STAT IS CYCLED OFF ON FOR 3 SEC MINIMUM NO YES F...

Page 36: ...CED OR RECONNECTED STATUS ERROR CODE 4 7 YES AT END OF IGNITOR 20 SECOND WARM UP PERIOD 4 SECOND TRIAL FOR IGNITION GAS VALVE OPENS IGNITOR ENERGIZED DURING 4 SECOND TRIAL UNTIL FLAME SENSED YES 4 SEC...

Page 37: ...O YES FIRST STAGE HEAT DEMAND SATISFIED GAS VALVE OFF COMBUSTION AIR INDUCER OFF FOLLOWING POST PURGE INDOOR BLOWER OFF WITH DELAY STATUS LED PULSE YES SECOND STAGE HEAT DEMAND SECOND STAGE HEAT DEMAN...

Page 38: ...RMOSTAT MODE DIP SWITCH SET AT SINGLE YES YES FIRST AND SECOND STAGE HEAT DEMAND SATISFIED SIMULTANEOUSLY STATUS LED HEARTBEAT YES GAS VALVE OFF COMBUSTION AIR INDUCER OFF AFTER 5 SECOND LOW SPEED POS...

Page 39: ...ENERGIZED NO IS THERE PROPER GROUND YES NO INDOOR BLOWER ENERGIZED ON FIRST STAGE COOL SPEED AFTER 2 SECOND DELAY FIRST STAGE DEMAND FOR COOL SATISFIED NO THERMOSTAT CALLS FOR SECOND STAGE COOL COMPR...

Page 40: ...SWITCHES TO LOW HEAT SPEED FIRST STAGE HEAT DEMAND SATISFIED YES NO THERMOSTAT CALLS FOR SECOND STAGE HEAT YES INDOOR BLOWER SWITCHES TO HIGH HEAT SPEED AFTER 30 SECOND RECOGNITION PERIOD SECOND STAG...

Page 41: ...agency or gas supplier Cabinet Parts Upper access panel Blower panel Top cap Control Panel Parts Transformer Two stage integrated control Door interlock switch Circuit breaker Blower Parts Blower whee...

Page 42: ...ions Tight Heating Section Thermostat Heat Anticipator Setting Thermostat Level Fuel Type Natural Gas Blower Motor Amps Blower Motor H P Gas Piping Connections Tight Leak Tested Proper Draft State Blo...

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