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Page 31

G60DF Series

Heating Sequence of Operation

NOTE − The thermostat  jumper on the integratred control is
factory−set in the TWO−STAGE" position.

Applications Using a Two−Stage Thermostat

A − Heating Sequence −− Control Thermostat Selection
DIP switch in Two−Stage" Position (Factory Setting)

 1 − On a call for heat, thermostat first−stage contacts close

sending a signal to the integrated control. The inte-
grated control runs a self-diagnostic program and
checks high temperature limit switches for normally
closed contacts and pressure switches for normally
open contacts.The combustion air inducer is ener-
gized at low speed and the humidifier terminal is ener-
gized.

 2 − Once the control receives a signal that the low pres-

sure switch has closed, the combustion air inducer be-
gins a 15−second pre−purge in low speed.

 3 − After the pre−purge is complete, a 20−second initial ig-

nitor warm−up period begins. The combustion air in-
ducer continues to operate at low speed.

 4 − After the 20−second warm−up period has ended, the

gas valve is energized on low fire (first stage) and igni-
tion occurs. At the same time, the control module
sends a signal to begin an indoor blower 45−second
ON−delay. When the delay ends, the indoor blower
motor is energized on the low fire heating speed. The
furnace will continue this operation as long as the ther-
mostat has a first−stage heating demand.

 5 − If second−stage heat is required, the thermostat sec-

ond−stage heat contacts close and send a signal to the
integrated control. The integrated control initiates a
30−second second−stage recognition delay.

 6 − At the end of the recognition delay, the integrated con-

trol energizes the combustion air inducer at high
speed. The control also checks the high−fire (second
stage) pressure switch to make sure it is closed.The
high−fire (second stage) gas valve is energized and
the indoor blower motor is energized for operation at
the high−fire heating speed.

 7 − When the demand for high−fire (second stage) heat is

satisfied, the combustion air inducer is switched to the
low−fire heating speed and the high−fire (second
stage) gas valve is de−energized. The low−fire (first
stage) gas valve continues operation. The indoor
blower motor is switched to the low−fire heating speed.

 8 − When the thermostat demand for low−fire (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 air post−purge period is com-

plete, the inducer and humidifier terminal are de−ener-
gized. The indoor blower is de−energized at the end of
the off delay.

 Applications Using A Single−Stage Thermostat

B − Heating Sequence −− Integrated Control Thermostat
Selection DIP switch in Single−Stage"  Position

NOTE − In these applications, two−stage heat will be initi-
ated by the integrated control if heating demand has not
been satisfied after the field adjustable period (10 or 15
minutes).

 1 − On a call for heat, thermostat first−stage contacts close

sending a signal to the integrated control. The inte-
grated control runs a self-diagnostic program and
checks high temperature limit switches for normally
closed contacts and pressure switches for normally
open contacts.The combustion air inducer is ener-
gized at low speed and the humidifier terminal is ener-
gized.

 2 − Once the control receives a signal that the low pres-

sure switch has closed, the combustion air inducer be-
gins a 15−second pre−purge in low speed.

 3 − After the pre−purge is complete, a 20−second initial ig-

nitor warm−up period begins. The combustion air in-
ducer continues to operate at low speed.

 4 − After the 20−second warm−up period has ended, the

gas valve is energized on low fire (first stage) and igni-
tion occurs. At the same time, the control module
sends a signal to begin an indoor blower 45−second
ON−delay. When the delay ends, the indoor blower
motor is energized on the low−fire heating speed. The
integrated control also initiates a second−stage on
delay (factory−set at 10 minutes; adjustable to 15 min-
utes).

 5 − If the heating demand continues beyond the second−

stage on delay, the integrated control energizes the
combustion air inducer at high speed. The control also
checks the high−fire (second stage) pressure switch to
make sure it is closed.The high−fire (second stage)
gas valve is energized and the indoor blower motor is
energized for operation at the high−fire heating speed.

 6 − When the thermostat heating demand is satisfied, the-

combustion air inducer begins a 5−second post−purge.
The field−selected indoor blower off delay begins.

 7 − When the combustion air post−purge period is com-

plete, the inducer and humidifier terminal are de−ener-
gized. The indoor blower is de−energized at the end of
the off delay.

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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