Lennox G60DFVX Series Installation Instructions Manual Download

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Summary of Contents for G60DFVX Series

Page 1: ...t Adjustments 32 Heating Sequence of Operation 33 Service 34 Repair Parts List 36 Ignition Control Board Diagnostic Codes 37 Troubleshooting 38 Start Up Performance Check List 44 WARNING Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other ap pliance Installation and service must be performed by a qualified installer service agency or the gas supp...

Page 2: ...i _i _i _i _i _i_ _ _i_i _i_i _1 5 8 16 m m 28 1 2 724 9 1 2 495 Jl suoo L 19 C Air m 19 FRONT VIEW 40 1016 4 7 8 124 Right 2 1 4 57 Left I_ t 9 1 4 235 5 8 16 _ _ 19 1 4 Supply 489 Air SIDE VIEW c in mm 13 330 16 406 19 1 2 495 23 584 1 3 4 19 A B D Model No in mm in mm in mm G60DFV X 36A 070 14 1 2 368 13 1 4 337 4 1 2 114 G60DFV X 36 B 090 17 1 2 446 16 1 4 413 6 152 G60DFV X 60C 090 21 533 19 ...

Page 3: ...ernal Flue Pipe Assembly Gasket Circuit Breaker Power 1HP Only Chase Gasket Combustion Air Inducer Transfor _me_r _ Two Stage Integrated Control Board I I Door Interlock Switch Limit Shield Burner Box Cover FIGURE 1 Ignitor Burner Box Bottom Page 3 ...

Page 4: ...sistent with the venting tables in this instruction and applicable provisions of local building codes This furnace is CSA International certified for installation clearances to combustible material as listed on the unit nameplate and in the tables in figure 9 Accessibility and ser vice clearances must take precedence over fire protection clearances For installation in a residential garage the furn...

Page 5: ... comple tion The input rate and temperature rise must be set per the furnace rating plate One hundred percent 100 outdoor air must be pro vided for combustion air requirements during construc tion Temporary ducting may supply outdoor air to the furnace Do not connect duct directly to the furnace Size the temporary duct following these instructions in section for Combustion Dilution and Ventilation...

Page 6: ... standard CSA B149 installation codes CAUTION All gas fired appliances require air for the combustion pro cess If sufficient combustion air is not available the fur nace or other appliances will operate inefficiently and un safely Enough air must be provided to meet the needs of all fuel burning appliances and appliances such as exhaust fans which force air out of the house When fireplaces ex haus...

Page 7: ... 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 inches 64516 mm2 One opening shall be within 12 inches 305 mm of the top of the enclosure and one opening within 12 inches 305 mm of the bottom See figure 2 Air from Outside If air from outside is brought in for combustion and ventila t...

Page 8: ... Each end of attic FURNACE INLET AIR Ends 12 in _ HEATER NO TE The inlet and outlet air openings shall each have a free area of at least one square inch 645 mm 2 per 4 000 Btu 1 17 kW per hour of the total input rating of all equip ment in the enclosure EQUIPMENT IN CONFINED SPACE ALL AIR FROM OUTSIDE FURNACE NOTE Each air duct opening shall have a free area of at least 2 one square inch 645 mm pe...

Page 9: ...NG SIZE Model No A Cabinet 14 5 B Cabinet 17 5 C Cabinet 21 D Cabinet 24 5 NOTE Floor openin Frontto Rear in mm 22 559 22 559 22 559 22 559 Side to Side in 15 3 4 18 3 4 22 3 4 25 3 4 mm 400 476 578 654 dimensions listed are 1 4 inch 6 mm larger than unit opening See unit dimensions on page 2 2 After opening is cut set additive base into opening 3 Check fiberglass strips on additive base to make s...

Page 10: ...d washer must be re moved before the furnace is placed into operation Af ter the bolt and washer have been removed the rigid leg will not touch the blower housing NOTE G60DFV 60D 135 units are equipped with a ship ping pad under the blower housing Remove the shipping pad prior to operation _ WARNING Downflow Application Allow for clearances to combustible materials as indi cated on the unit namepl...

Page 11: ...ory I furnaces when vertically vented according to the latest edition of National Fuel Gas Code NFPA 54 ANSI Z223 1 in the USA and the current standards of CSA B149 Natural Gas and Propane Installation Code in Cana da A fan assisted Category I furnace is an appliance equipped with an integral mechanical means to either draw or force combustion products through the combustion chamber and or heat ex...

Page 12: ...ERIOR CHIMNEY WITH II METAL II LINER 1 I PERMANENTLY SEALED FIREPLACE OPENING NOTE 1 Refer to the provided venting tables for installations in the USA and the venting tables in CSA B149 for installations Canada NOTE 2 Either single walled or double walled vent connector may be used Refer to the capacity requirements shown in the provided venting tables for installations in USA and the venting tabl...

Page 13: ...educed by 10 0 90 x maximum listed ca pacity 8 The common venting tables 7 8 9 and 10 were gen erated using a maximum horizontal vent connector length of 1 1 2 feet 46 m for each inch 25 mm of connector diameter as follows TABLE 4 Connector Diameter Maximum Horizontal inches mm Connector Length feet m 3 76 4 1 2 1 37 4 102 6 1 83 5 127 7 1 2 2 29 6 152 9 2 74 7 178 10 1 2 3 20 9 If the common vert...

Page 14: ...32 6 4 21 49 30 94 39 153 50 227 6 25 46 36 91 47 149 59 223 0 0 84 0 165 0 276 0 415 2 12 57 16 109 25 178 28 263 8 5 23 53 32 103 42 171 53 255 8 28 49 39 98 51 164 64 247 0 0 88 0 175 0 295 0 447 2 12 61 17 118 23 194 26 289 10 5 23 57 32 113 41 187 52 280 10 30 51 41 104 54 176 67 267 0 0 94 0 191 0 327 0 502 2 11 69 15 136 20 226 22 339 15 5 22 65 30 130 39 219 49 330 10 29 59 40 121 51 206 6...

Page 15: ...7 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 5 50 68 73 140 100 239 141 363 20 10 NR NR 93 129 125 223 177 344 15 NR NR NR NR 155 208 216 325 20 NR NR NR NR 186 192 254 306 0 34 99 53 211 76 372 110 584 2 37 80 55 164 76 281 109 429 5 49 74 72 157 98 271 136 417 30 10 NR NR 91 144 122 ...

Page 16: ...3 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 31 113 45 181 60 288 30 2 21 64 33 118 47 190 62 299 3 22 66 34 123 48 198 64 309 TABLE 8 Common Vent Capacity Type B Double Wall Vents with Type B Double Wall Connectors Serving Two or More Category I Appliances Common Vent...

Page 17: ... and the other appliances which are not operating re main connected to the common venting system If the venting system has been installed improperly you must correct the system as indicated in the general venting re quirements section 1 Seal any unused openings in the common venting sys tem _ Inspect the venting system for proper size and horizontal pitch Determine that there is no blockage restri...

Page 18: ...e sizes for typical applications A IMPORTANT NOTE If emergency shutoff is necessary shut off the main manual gas valve and disconnect main power to the fur nace The installer should properly label these devices Nominal Iron Pipe Internal Size Diameter inches inches 10 ram ram 3 048 3 8 493 95 9 53 12 522 2 69 1 2 622 175 12 7 17 799 4 96 3 4 824 360 19 05 20 930 10 19 1 1 049 680 25 4 26 645 919 2...

Page 19: ...ect the main power to the furnace The installer should properly label these devices ELECTROSTATIC DISCHARGE ESD Precautions and Procedures CAUTION CAUTION The furnace 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 pressures less than or equal to 1 2 psig 3 48 kPa 14 inches w c IMPORTANT MANUAL MAIN...

Page 20: ...ctronic air cleaner rated up to one amp can be connected to this terminal with the neutral leg of the circuit being connected to the one of the provided neutral terminals See figure 19 for control board configuration This terminal is energized when the indoor blower is operating 8 One line voltage HUM 1 4 spade terminal is pro vided on the furnace control board Any humidifier rated up to one amp c...

Page 21: ...TE Use DIP switch 2 to set second stage heat ON delay OFF IO minutes 0N 15 minutes DIP Switch 1 ON ON ON TABLE 12 Field Wiring Applications Jumper Settings See figure 19 W915 Two Stage Cooling Intact Cut Cut W914 Dehu midification or Harmony III Intact Intact Cut W951 Heat Pumps Intact Intact Intact Wiring Connections SI CONTROL OUTDOOR T STAT TERM STRIP UNIT SI CONTROL OUTDOOR T STAT TERM STRIP U...

Page 22: ...cations Continued Jumper Settings See figure 19 W915 Two Stage Cooling Cut Cut W914 Dehu midification or Harmony III Intact Cut W951 Heat Pumps Intact Intact OFF Intact Intact Intact 1 T STAT 1 T STAT Wiring Connections CONTROL TERM STRIP 4_ OUTDOOR UNIT CONTROL OUTDOOR TERM STRIP UNIT _ 1 CONTROL OUTDOOR T STAT TERM STRIP UNIT Page 22 ...

Page 23: ... RQOH TNE_ 40_TAT TWO ST_3E 1HERHOSTAT HZkT _ _ PAT ON SL3T_I_ _ AT_0 I _N tEOV ACC G _ _ _ _ GVI _5 ANP _YWELL VALVE _ JB4 _ _ _ 0 VAL_ _FR_t TO R AT A a_ C NTRgLE_AR_ VI EN _ T __ Lm _s I _ 1 L _ _ _ _ _ lrrv_ _ r_rno mR _rn I V_y_Y_ _ _ _ _ _itTCH WHEN U_ _1_ _JAL FUEL APPL_AT QN_ F L_A_ IL F LA_ IGN TI_ _J FI_ _r L_T COOL _TAT CUT A EqFI_R Y TO yE FI_ I I _ _ l e_ kmr _ _al_ _ kmt _ _ F_SSUr_ ...

Page 24: ...CM FIGURE 18 TWO STAGE VARIABLE SPEED INTEGRATED CONTROL BOARD poooq STATUS COW DIAGNOSTIC LEDs HEATING DIP SWITCHES INDOOR BLOWER DIP SWITCHES ON BOARD JUMPERS II4 QUICK CONNECT TERMINALS HUM 120 VAC OUTPUT TO HUMIDIFIER XMFR 12O VAC OUTPUT TO TRANSFORMER LI 120 VAC INPUTTO CONTROL CIRC 120 VAC OUTPUT TO CIRCULATINGBLOWER EAC 120 VAC OUTPUT TO ELECTRONICAIR CLEANER NEUTRALS 120 VAC NEUTRAL THERMO...

Page 25: ...ble to satisfy individual applications Adjust the blower off delay to achieve a supply air temperature between 90 and 110 F at the exact moment that the blower is de energized Longer off delay settings provide lower supply air temperatures shorter settings provide higher supply air temperatu res Table 13 provides the blower off timings that will result from different switch settings TABLE 13 Blowe...

Page 26: ...nals DS and R on the integrated control board must be cut when the fur nace is installed with either the Harmony III zone control board or a thermostat which features humidity control If the jumper is left intact the PMW signal from the HARMO NY Ill control will be blocked and also lead to control dam age Refer to table 23 for operation sequence in applica tions including G60DFV a thermostat which...

Page 27: ...trol Applications Minimum blower speed is 426 cfm 201 L s TABLE 19 ADJUST Switch Positions G60DFV 36B 090 BLOWER MOTOR PERFORMANCE 0 0 to 0 8 w g 0 through 200 Pa External Static Pressure Range Factory Settings Heating Speed 2 Cooling Speed 4 Speed Adjust NORM Speed Switch Positions Second Stage HEAT Speed Second Stage COOL Speed 1 12 3 4 1 2 3 14 cfm L s cfm L s cfm L s cfm L s cfm L s cfm L s cf...

Page 28: ...Control Applications Minimum blower speed is 520 cfm 245 L s TABLE 21 ADJUST Switch Positions G60DFV 60C 110 BLOWER MOTOR PERFORMANCE 0 0 to 0 8 w g 0 through 200 Pa External Static Pressure Range Factory Settings Heating Speed 2 Cooling Speed 4 Speed Adjust NORM Speed Switch Positions econd Stage HEAT Speed Second Stage COOL Speed 1 12 3 4 1 2 3 14 cfm L s cfm L s cfm L s cfm L s cfm L s cfm L s ...

Page 29: ...hermostat with Humidity Control Feature and Single Speed Outdoor Unit OPERATING MODE SYSTEM DEMAND SYSTEM RESPONSE System Condition Thermostat Relative Humidity Blower Demand EfficiencyPlus Lights CFM Comments COOL Normal operation Y1 No demand Humidity COOL Compressor demand and indoor blower level is acceptable speed controlled by thermostat demand Call for humidity Humidity level rises 60 65 Ca...

Page 30: ... HIGH COOL 42 46 of HIGH COOL 65 60 of HIGH COOL 65 60 of HIGH COOL HIGH COOL Off 42 46 of HIGH COOL HIGH COOL 65 60 of HIGH COOL HIGH COOL Off 42 46 of HIGH COOL Off 65 60 of HIGH COOL Off 65 60 of HIGH COOL Off HIGH COOL Compressor demand and indoor blower speed controlled by thermostat demand Dehumidification mode does not begin until after initial thermostat demand is satisfied and new cooling...

Page 31: ...quipped with an ignition device which automatically lights the burners Do not try to light the burners by hand 5 Remove the upper access panel 6 White Rodgers 36E Gas Valve Switch gas valve le ver to OFF See figure 20 Honeywell VR8205 Gas Valve Turn knob on gas valve clockwise _ to OFF Do not force See figure 21 7 Wait five minutes to clear out any gas If you then smell gas STOP Immediately call y...

Page 32: ...ower These limits are factory set and require no adjustment Flame Rollout Switches Two These manually reset switches are located on or inside of the burner box If tripped check for adequate combustion air before resetting Pressure Switches The pressure switch assembly includes two switches is located in the heating compartment adjacent to the com bustion air inducer These switches check for proper...

Page 33: ...r 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 ignition oc curs At the same time the control module sends a sig nal to begin an indoor blower 45 second ON delay When the delay ends the indoor blower motor is ener gized on the low fire heating speed and the 24V hu midifier terminal is energized The f...

Page 34: ...he blower motor Motor Nameplate Actual Cleaning the Heat Exchanger and Burners NOTE Use papers or protective covering in front of the fur nace during cleaning Cleaning the heat exchanger requires a steel spring snake a reversible drill and a vacuum cleaner The steel spring snake may be constructed by purchasing a 4 ft long by 1 4 inch diameter steel wire cable and a 1 4 inch diame ter wire brush T...

Page 35: ...lace all screws may cause leaks 15 To clean the burner run a vacuum cleaner with a soft brush attachment over the face of burners Visually in spect inside the burners and crossovers for any blockage caused by foreign matter Remove any blockage 16 NOx units only Reattach the NOx inserts to the cor bels at the entrance to each heat exchanger opening See figure 23 17 Re install gasket and burner box ...

Page 36: ...mer Two stage variable speed integrated control board Door interlock switch Circuit breaker BlowerParts Blower wheel Blower housing Motor Motor electronics Power choke 1hponly Motor mounting frame Motor capacitor Blower housing cutoffplate HeatingParts FlameSensor Heatexchanger assembly Gasmanifold Two speed combustion airinducer Two stage gasvalve Mainburner cluster Mainburner orifices Pressure s...

Page 37: ... 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 Pulse Power on Standby Heartbeat Normal operation signaled when heating demand initiated at thermostat FLAME CODES 1 2 Low flame current run mode 1 3 Flame sensed out of sequence flame still p...

Page 38: ...E I I GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF RESET CONTROL BY TURNING MAIN POWER OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER ON HAS PRIMARY OR SECONDARY LIMIT RESET WITHIN 3 MINUTES STATUS ERROR CODE 3 1 60 MINUTE LIMIT WATCHGUARD MODE GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF WITH DELAY STATUS ERROR CODE 4 5 GAS VALVE OFF COMBUSTION AIR INDUCER ON INDOOR BLOW...

Page 39: ...UED ON NEXT PAGE I THERMOSTAT CALLS FOR HEAT STATUS LED HEARTBEAT Refer to box A on previous page GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF UNIT WILL RETRY AFTER 5 MINUTE WAIT PERIOD STATUS ERROR CODE 2 3 i COMBUSTION AIR INDUCER OFF IGNITOR OFF SIGNAL HOLDS UNTIL IGNITOR IS REPLACED OR RECONNECTED STATUS ERROR CODE 4 7 1 IS VOLTAGE ABOVE 90 VOLTS COMBUSTION AIR INDUCER OFF IGNITE...

Page 40: ...COND STAGE HEAT DEMAND REQUIRED YES _ __ _ SECOND STAGE PRESSURE SWITCH CLOSED ABNORMAL FLASH CODE NOTE IF SECOND STAGE PRESSURE SWITCH WAS ORIGINALLY FOUND CLOSED ABNORMAL CODE WILL FLASH NO _ I YES _ YES Jt SECOND STAGE PRESSURE SWITCH CLOSED IN LESS THAN TEN 10 SECONDS STATUS LED HEARTBEAT YES _ CONTINUED ON NEXT PAGE I GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER ON STATUS ERROR CODE...

Page 41: ...ODE FIRST STAGE CONTINUES UNTIL SECOND STAGE PRESSURE SWITCH CAN BE PROVEN or HEAT DEMAND IS SATISFIED A FIVE 5 MINUTE WAIT PERIOD IS INITIATED BEFORE RETRY WERE 5 ATTEMPTS MADE FOR SECOND STAGE HEAT NO _ SEE BOX C FIRST STAGE HEAT DEMAND SATISFIED I TWO STAGE THERMOSTAT MODE 1 DIP SWITCH SET AT TWO I I YES f FIRST AND SECOND STAGE HEAT DEMAND SATISFIED SIMULTANEOUSLY STATUS LED HEARTBEAT SECOND S...

Page 42: ...I CONTROL WILL CONTINUE TO CALL FOR COOLING IN THIS CONDITION STATUS ERROR CODE 5 4 l SIGNAL IMPROPER GROUND AT LED CONTROL WILL CONTINUE TO CALL FOR COOLING IN THIS CONDITION STATUS ERROR CODE 5 3 I_ COMPRESSOR AND CONDENSER FAN DE ENERGIZED _1 FIRST STAGE DEMAND FOR COOL SATISFIED NDOOR BLOWER DE ENEG ZED Nol ITHERMOSTAT CALLS FOR SECOND STAGE COOL I I NDOOR BLOWER RAMPS UP TO SECOND STAGE COOL ...

Page 43: ... w _ _ _s_ S_A_ pcoo s_o 1 MANUAL FAN SELECTION MADE AT THERMOSTAT I AFTER 2 SECOND DELAY INDOOR BLOWER IS 19 ENERGIZED ON CONTINUOUS FAN SPEED YES I I II 1 _ _ I I I q THERMOSTAT CALLS FOR FIRST STAGE HEAT I YES AFTER 45 SECOND DELAY INDOOR BLOWER I SWITCHES TO LOW HEAT SPEED FIRST STAGE HEAT DEMAND SATISFIED _YI NO THERMOSTAT CALLS FOR SECOND STAGE HEAT I YES INDOOR BLOWER SWITCHES TO HIGH HEAT ...

Page 44: ...State D Furnace Btu Input High fire Low Fire Manifold Pressure High Fire Manifold Pressure Flue Connections Tight w c Nat w c Nat Line Pressure __ w c LP Propane w c LP Propane Proper Draft Combustion Gas Tested high fire and low fire Blower ON delay confirmed 45 Seconds Fixed On Blower OFF Delay Setting 60 90 120 or 180 Filter Clean Secure Thermostat Heat Anticipator Setting 002 CO External Stati...

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