LENNOX Furnace/Heater, Gas Manual L0806201

User Manual: LENNOX LENNOX Furnace/Heater, Gas Manual LENNOX Furnace/Heater, Gas Owner's Manual, LENNOX Furnace/Heater, Gas installation guides

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INSTALLATION
INSTRUCTIONS

_;_,2006 Lennox Industries Inc.
Dallas, Texas, USA

G60UHV(X)

Series

GAS FURNACE
505,121M
09/2006
Supersedes 06/2006

_-_")
Technical
_--_.L_Publications
Lithe U.S.A.

Unit Dimensions ................................
G60UHV(X) Parts Arrangement ...................
G60UHV(X) Gas Furnace ........................
Shipping and Packing List ........................
Safety Information ...............................
General ........................................
Combustion, Dilution & Ventilation Air ..............
Setting Equipment ...............................
Filters ..........................................
Duct System ....................................
Venting ........................................
Gas Piping .....................................
Electrical .......................................
Integrated Control Board Settings .................
Unit Start-Up ...................................
Gas Pressure Adjustment ........................
High Altitude Information .........................
Other Unit Adjustments ..........................
Heating Sequence of Operation ...................
Service ........................................
Repair Parts List ................................
Ignition Control Board Diagnostic Codes ...........
Troubleshooting .................................
Start-Up & Performance Check List ................

RETAIN THESE INSTRUCTIONS
FOR FUTURE REFERENCE

2
3
4
4
4
5
6
9
13
13
13
21
22
28
37
38
38
38
39
40
42
43
44
50

AWARNING

Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity
of this or any other appliance.
Installation
and service
must be
performed
by a qualified installer,
service agency or the gas supplier.

WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch; do not
use any phone in your building.
• Leave the building immediately.
• Immediately
call your gas supplier from a
neighbor's phone. Follow the gas supplier's
instructions.
• If you cannot reach your gas supplier, call
the fire department.

09/06

iiiHiinlnlllllllllnllllllllllllllllll

505,121M
Page1

IIIlllllllllllllllllllllllllllllllll

*NOTE - 60C and 60D units that require air volumes
over 1800 cfm (850 L/s) must have one of the following:
1. Return air from single side with transition which will
accommodate 20 x 25 x 1 in. (508 x 635 x 25 mm)
cleanable air filter. (Required to maintain proper air
velocity.)
2. Return air from single side with optional RAB Return
Air Base.
3. Return air from bottom.
4. Return air from both sides.
5. Return air from bottom and one side.
Refer to Engineering Handbook for additional information.

3"3/4 (95)-I_1

FLUE OUTLET
(Top)

_OPTIONAL
_---'---'--_----__--_.
EXTERNAL _
_
23-3/4 t603_
SIDE RETURN
- II •
,
AIR FILTER KIT
I_-._
25 (635)
(Either Side)
TOP VIEW

**Flue outlet may be horizontal but furnace must be
vented vertically
_Optional external side return air filter kit cannot be used
with the optional RAB Return Air Base.

I
- uI
=I

TOP VIEW
3-1/4 (83) Right
8-1/8 (206) Left

--I 4
|3-31,

<1-9/16 (14)

t -_
l

28 -1/2
(724)

n._

_._

9/16
'91-(14)

19-7/16._
(494)

(95)

14 (356) Right
13-1/4 (337) Left
_OPTIONAL
EXTERNAL
SIDE RETURN
AIR FILTER KIT
(Either Side)
40
(1016)

4-7/8 (124) Right
2-1/4 (57) Left

14-3/4
(375)
(406)

5/8 (16)
23-1/2
(597)
*Bottom Return
Air Opening
SIDE VIEW

3/4(19)

3/4 (19) -I_

4-1/4
(108)

*Bottom Return
Air Opening
FRONT VIEW
Model No.

in.

G6OUHV-36A-070

14-1/2

368

13-3/8

340

330

4-1/2

114

G6OUHV-36B-090

17-1/2

446

16-3/8

416

406

152

533

19-7/8

454

19-1/2

495

7-3/4

197

24-1/2

622

23-3/8

546

584

9-1/2

241

G6OUHV-6OC-O9O,
G6OUHV-60C-110
G6OUHV-6OD-135

Page 2

Air Deflector
G60UH-60C-110
Units Only

FlueBoxGasket

Gasket

Flue
Collector
Box

Heat Exchanger

Flue
Transition

Combustion Air
Orifice
Combustion Air
Pressure Switch Assembly
(two switches)
Combustion Air Inducer

./
Flame Sensor

Limit Shield

_Flame
_

Air Intake

Rollout Switches
_
Primary

Cover

Limit

Burner

//_ _

Box Tol

Kz'2

NOx Insert
Gas Valve
Gas
Orifices

Gasket

Bracket
Ignitor

Secondary Limit(s)

Sight
Glass
Burner
Box Cover

Burner Box Bottom
Control Transformer
Power Choke
(1 hp Only)

Circuit Breaker

Door Interlock Switch

Two-Stage, Variable Speed
Integrated Control Board

FIGURE 1

Page 3

Variable Speed
Blower Motor

The G60UHV(X)gas furnaceis equippedwith a twostage,variablespeedintegrated
control.Thiscontrolensurescompatibility
withLennox'HarmonyIllzonecontrol
system,aswellas a thermostatwhichprovideshumidity
control.EachG60UHV(X)
unitis shippedreadyforinstallationintheupfloworhorizontal
position(leftorright).The
furnaceisshippedwiththebottompanelinplace.Thebottompanelmustberemovediftheunitistobeinstalledina
horizontal
application.
Thepanelmayalsoberemovedin
upflowapplications.

In the USA, installation of gas furnaces must conform with
local building codes. In the absence of local codes, units
must be installed according to the current National Fuel
Gas Code (ANSI-Z223.1). The National Fuel Gas Code is
available from the following address:
American National Standards Institute, Inc.
11 West 42nd Street
New York, NY 10036
In Canada, installation must conform with current National
Standard of Canada CSA-B149 installation codes for natural gas and propane gas burning appliances and equipment, local plumbing or waste water codes and other applicable local codes.
Adequate clearance must be made around the air openings into the vestibule area. In order to ensure proper unit
operation, combustion and ventilation air supply must be
provided according to the current National Fuel Gas Code
or CSA-B149 standards.

Package1 of 1 contains
1- Assembled
G60UHV(X)
unit
1- Bagassemblycontaining
thefollowing:
2 -Screws
3 -Wirenuts
1-Snapbushing
1-Snapplug
1- Wiretie
1-Vent warning label

Vent installations must be consistent with the venting
tables (in this instruction) and applicable provisions of local
building codes.
This furnace is CSA Intemational certified for installation
clearances to combustible material as listed on the unit

The following items may be ordered separately:
1- Thermostat

nameplate and in the tables in figures 6 and 11. Accessibility
and service clearances must take precedence over fire
protection clearances.

1 - Hanging bracket (for horizontal installations)
1 - Propane/LP changeover kit
1 - Return air base

NOTE- For installation on combustible floors, the furnace
shall not be installed directly on carpeting, tile, or other
combustible material other than wood flooring.

1 - High altitude kit
1 - Side filter kit

For installation in a residential garage, the furnace must
be installed so that the burner(s) and the ignition source
are located no less than 18 inches (457 mm) above the
floor. The furnace must be located or protected to avoid

1 -Owner's

manual and warranty card

Check equipment for shipping damage. If you find any
damage, immediately contact the last carrier.

physical damage by vehicles. When a furnace is installed
in a public garage, hangar, or other building that has a hazardous atmosphere, the furnace must be installed according to recommended good practice requirements and current National Fuel Gas Code or CSA B149 standards.

,&WARNING

NOTE - Furnace must be adjusted to obtain a temperature
rise(high and bw fire) within the range(s) specified on the unit
nameplate. Failure to do so may cause erratic limit operation.
This G60UHV(X) furnace must be installed so that its electrical components are protected from water.

,&,CAUTION

G60UHV(X) units are CSA International certified to ANSI
Z21.47 and CSA 2.3 standard.

When this furnace is used with cooling units, it shall be
installed in parallel with, or on the upstream side of, cooling
units to avoid condensation in the heating compartment.
With a parallel flow arrangement, a damper (or other
means to control the flow of air) must adequately prevent
chilled air from entering the furnace. If the damper is manually operated, it must be equipped to prevent operation of
either the heating or the cooling unit, unless it is in the full
HEAT or COOL setting.

Page 4

Wheninstalled,
thisfurnacemustbeelectrically
grounded
according
tolocalcodes.Inaddition,intheUnitedStates,
installationmustconformwiththecurrentNationalElectricCode,ANSI/NFPA
No.70.TheNationalElectricCode
(ANSI/NFPA
No.70) is availablefromthe followingaddress:
NationalFireProtection
Association
1 BatteryMarchPark
Quincy,MA02269
InCanada,allelectricalwiringandgrounding
fortheunit
mustbeinstalled
according
tothecurrentregulations
ofthe
CanadianElectricalCodePartI (CSAStandardC22.1)
and/orlocalcodes.
NOTE - This furnace is designed for a minimum continuous return air temperature of 60°F (16°C) or an intermit-

• One hundred percent (100%) outdoor air must be provided for combustion air requirements during construction. 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 Air in a
confined space with air from outside.
• The furnace heat exchanger, components, duct system,
air filters and evaporator coils must be thoroughly
cleaned following final construction clean-up.
• All furnace operating conditions (including ignition, input rate, temperature rise and venting) must be verified
according to these installation instructions.
NOTE - The Commonwealth
of Massachusetts
lates these additional requirements:

• Gas furnaces shall be installed by a llcensedplumber or gas fittter only.

tent operation down to 55°F (13°C) dry bulb for cases
where a night setback thermostat is used. Return air tem-

• The gas cock must be "T handle"

perature must not exceed 85°F (29 °C) dry bulb.

Lennox does not recommend the use of G60UHV(X) units
as a construction heater during any phase of construction.
Very low return air temperatures, harmful vapors and operation of the unit with clogged or misplaced filters will damage the unit.

type.

• When a furnace is installed in an attic, the passageway to and service area surrounding the equipment
shall be floored.

The G60UHV(X) furnace may be installed in alcoves, closets, attics, basements, garages, and utility rooms in the upflow or horizontal position.
This furnace design has not been CSA International certified for installation in mobile homes, recreational vehicles,
or outdoors.

stipu-

These instructions are intended as a general guide and do
not supersede local codes in any way. Consult authorities
having jurisdiction before installation.
In addition to the requirements outlined previously, the following general recommendations must be considered
when installing a G60UHV(X) furnace:

G60UHV(X) units may be used for heating of buildings or
structures under construction, if the following conditions
are met:
• The vent system must be permanently installed per
these installation instructions.
• A room thermostat must control the furnace. The use of
fixed jumpers that will provide continuous heating is not
aflowed.
• The return air duct must be provided and sealed to the
furnace.
• Return air temperature range between 60°F (16°C) and
80°F (27°C) must be maintained.
• Air filters must be instafled in the system and must be
maintained during construction.
• Air filters must be replaced upon construction completion.
• The input rate and temperature rise must be set per the
furnace rating plate.

Page 5

• Place the furnace as close to the center of the air distribution system as possible. The furnace should also be
located close to the chimney or vent termination point.
• Do not install the furnace where drafts might blow directly into it. This could cause improper combustion and unsafe operation.
• Do not block the furnace combustion air openings with
clothing, boxes, doors, etc. Air is needed for proper
combustion and safe unit operation.
• When the furnace is installed in an attic or other insulated space, keep insulation away from the furnace.

j WARNING

ACAUTION

In the past, there was no problem in bringing in sufficient outdoor air for combustion. Infiltration provided all the air that
was needed. In today's homes, tight construction practices
make it necessary to bring in air from outside for combustion. Take into account that exhaust fans, appliance vents,
chimneys, and fireplaces force additional air that could be
used for combustion out of the house. Unless outside air is
brought into the house for combustion, negative pressure
(outside pressure is greater than inside pressure) will build
to the point that a downdraft can occur in the furnace vent
pipe or chimney. As a result, combustion gases enter the living space creating a potentially dangerous situation.
In the absence of local codes concerning air for combustion and ventilation, use the guidelines and procedures in
this section to install G60UHV(X) furnaces to ensure efficient and safe operation. You must consider combustion air
needs and requirements for exhaust vents and gas piping.
A portion of this information has been reprinted with permission from the National Fuel Gas Code (ANSI-Z223.1).
This reprinted material is not the complete and official position of the ANSI on the referenced subject, which is represented only by the standard in its entirety.
In Canada, refer to the standard CSA B149 installation
codes.

&CAUTION

All gas-fired appliances require air for the combustion process. If sufficient combustion air is not available, the furnace or other appliances will operate inefficiently and unsafely, 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, exhaust fans, or clothes dryers are used at the same time as
the furnace, much more air is necessary to ensure proper
combustion and to prevent a downdraft. Insufficient air
causes incomplete combustion which can result in carbon
monoxide,
In addition to providing combustion air, fresh outdoor air
dilutes contaminants in the indoor air. These contaminants may include bleaches, adhesives, detergents, solvents and other contaminants which can corrode furnace
components,
The requirements for providing air for combustion and ventilation depend largely on whether the furnace is installed in
an unconfined or a confined space,
Unconfined

Space

An unconfined space is an area such as a basement or
large equipment room with a volume greater than 50 cubic
feet (1,42 m3) per 1,000 Btu (.29 kW) per hour of the combined input rating of all appliances installed in that space,
This space also includes adjacent rooms which are not
separated by a door. Though an area may appear to be unconfined, it might be necessary to bring in outdoor air for
combustion if the structure does not provide enough air by

Page 6

infiltration,If thefurnaceis locatedin a buildingof tight
construction
withweatherstrippingandcaulkingaround
thewindowsanddoors,followthe procedures
in the air
fromoutsidesection,
Confined Space
A confined space is an area with a volume less than 50 cubic feet (1,42 m3) per 1,000 Btu (.29 kW) per hour of the
combined input rating of all appliances installed in that
space. This definition includes furnace closets or small
equipment rooms,
When the furnace is installed so that supply ducts carry air
circulated by the furnace to areas outside the space containing the furnace, the return air must be handled by ducts
which are sealed to the furnace casing and which terminate
outside the space containing the furnace, This is especially
important when the furnace is mounted on a platform in a
confined space such as a closet or small equipment room.
Even a small leak around the base of the unit at the platform
or at the return air duct connection can cause a potentially
dangerous negative pressure condition, Air for combustion
and ventilation can be brought into the confined space either
from inside the building or from outside.
_
CHIMNEY

EQUIPMENT IN CONFINED
SPACE ALL AIR FROM INSIDE

OR GAS

Air from Inside
If the confined space that houses the furnace adjoins a
space categorized as unconfined, air can be brought in by
providing two permanent openings between the two
spaces. Each opening must have a minimum free area of 1
square inch (645 mm 2) 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 ventilation, the confined space must have two permanent openings. 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. These openings must communicate directly or by ducts with the outdoors or spaces (crawl or attic) that freely communicate with the outdoors or indirectly
through vertical ducts. Each opening shall have a minimum
free area of 1 square inch (645 mm 2) per 4,000 Btu (1,17
kW) per hour d total input rating of all equipment in the enclosure, See figures 3 and 4. When communicating with
the outdoors through horizontal ducts, each opening shall
have a minimum free area of 1 square inch (645 mm 2) per
2,000 Btu (.56 kW) per total input rating of all equipment in
the enclosure, See figure 5.

h
HEATER
FURNACE

OPENINGS
(To Adjacent
Room)
_

,,,,j,

I I

WiTER

,, ,, ,, ,, ,,,:

I I

NOTE - Each opening shall have a free area of at least one square
inch (645 mm 2) per 1,000 Btu (.29 kW) per hour of the total input rating of all equipment in the enclosure, but not less than 100 square
inches (64516 ram2).

When ducts are used, they shall be of the same cross-sectional area as the free area of the openings to which they
connect. The minimum dimension of rectangular air ducts
shall be no less than 3 inches (75 mm). In calculating free
area, the blocking effect of louvers, grilles, or screens must
be considered. If the design and free area of protective covering is not known for calculating the size opening required,
it may be assumed that wood louvers will have 20 to 25 percent free area and metal louvers and grilles will have 60 to
75 percent free area. Louvers and grilles must be fixed in the
open position or interlocked with the equipment so that they
are opened automatically during equipment operation.

FIGURE 2

Page 7

EQUIPMENT IN CONFINED SPACE
ALL AIR FROM OUTSIDE
(Inlet Air from Crawlspace and Outlet Air to Ventilated

Attic)

CHIMNEY OR
GAS VENT

VENTILATION
LOUVERS
(Each end of altic)
I ......

OUTLET
AIR

FURNACE

WATER
HEATER

VENTILATION
LOUVERS
(For unheated crawl ._

INLET
AIR

_1 _rrrm

rrrm I

NOTE-The inlet and outlet air openings shall each have a free area of at least one square inch (645
mm2) per 4, 000 Btu (1.17 kW) per hour of the total input rating of all equipment in the enclosure.

FIGURE 3
A
TT_.

EQUIPMENT IN CONFINED SPACE
ALL AIR FROM OUTSIDE
CHIMNEY
OR GAS

_
JJ_

I I "b__JY

EQUIPMENT IN
CONFINED SPACE

ALLAIRFROM

(All Air Through Ventilated Attic)

VENT'_
VENTILATION
LOUVERS
(Each end of attic)

FURNACE

!lq!ll

INLET AIR
Ends 12 in.
above bottom

NLET AI

II II l
.
. 1T-T.
II II
II IL_
I
I
I
I
I
I
I
I
I
I
I___J
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
NOTE - Each air duct opening shaft have a free area of at least
one square inch (645 mm 2) per 2,000 Btu (. 59 kW) per hour of
the total input rating of aft equipment in the enclosure. If the
equipment room is located against an outside wall and the air
openings communicate directly with the outdoors, each opening shaft 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 aft
other equipment in the enclosure.

HEATER

NO TE-The inlet and outlet air openings shaft 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 aft equipment in the enclosure.

FIGURE 4

FIGURE 5

Page 8

on the unit nameplate, Minimum clearances for closet or alcove installations are shown in figure 6.

-&WARNING

Upflow Application

Installation Clearances
Top

Left Side

Right Side

The G60UHV(X) gas furnace can be installed as shipped
in either the upflow position or the horizontal position,
with right-hand or left-hand air discharge.
Select a location that allows for the required clearances
that are listed on the unit nameplate. Also consider gas
supply connections, electrical supply, vent connection,
and installation and service clearances [24 inches (610
mm) at unit front]. The unit must be level.
NOTE - Units with 1/2 hp blower motors are equipped with
three flexible legs and one rigid leg. The rigid leg is
equipped with a shipping bolt and a flat white plastic washer (rather than the rubber mounting grommet used with a
flexible mounting leg). The bolt and washer must be removed before the furnace is placed into operation. After the bolt and washer have been removed, the rigid leg
will not touch the blower housing.
NOTE - G60UHV-60D-135

units are equipped with a ship-

ping pad under the blower housing. Remove the shipping
pad prior to operation.
Upflow Applications
Allow for clearances to combustible materials as indicated

Page 9

Bottom
Type of Vent
Connector

Type C

Type B1

Top

1 in. (25 ram)

*Front

3 in. (76 ram)

Back

Sides

01-

Vent

6 in. (152 ram)

1 in. (25 ram)

Floor

*Front clearance in alcove installation
must be 24 in. (610 ram).
Maintain a minimum of 24 in. (610 ram) for front service access.
SFor installation on a combustible floor, do not install the furnace
directly on carpeting, tile or other combustible materials other
than wood flooring.
1-Left side requires 3 inches if a single wall vent is used on 14-1/2
inch cabinets, or 2 inches if a single wall vent is used on 17-1/2
inch cabinets.

FIGURE 6

Return
Return

Air -- Upflow

air can be brought

in through

side of the furnace

installed

furnace

on a platform

is installed

an airtight
platform

seal between
to ensure

Markings
cabinet
NOTE

is equipped

operates

make

and the

properly

with a removable

on both sides of the furnace

that require

at the maximum
- When

If the

with bottom return,

the bottom of the furnace

Side Return Air
(with transition and filter)

or either

and

bottom

20" X 25" X 1"
(508mm X635mm X 25mm)
Cleanable Filter

installation,

are provided

for installations

the bottom

in an upflow application,

that the furnace

safely. The furnace
panel to facilitate

Applications

cabinet

side return air. Cut the furnace

dimensions

air volumes

over

shown

1800 cfm

on page 2.
(850 L/s) are

required
with 60C or 60D models in an upflow application, the following
return air options
are available:

Return Air
Plenum

1 - Return air from single side with transition which will
accommodate
20 x 25 x I in. (508 x 635 x 25 ram) cleanable air filter. (Required to maintain proper air velocity.)
See figure 7.
2 - Return air from single side
Air Base. See figure 8.
3 - Return air from bottom.

with optional

RAB Return

4 - Return air from both sides.
5 - Return air from bottom
Refer to Engineering

FIGURE 7

and one side.

Handbook

for additional information,

(Upflow Applications

Optional Return Air Base
Only -- For use with B, C and D cabinets only)

4
14

"-_

;-.91--

102)1

AIR FLOW

(446) RAB-B

21 (533)

RAB-C

Overall

1 Minimum

11 (279) I
2 Maximun_
1 Unit side return air 1A 1356)_
Opening
___
jl__ _

7-1/4 (184)

24-1/2

(Maximum)

17-1/2

1 23 (584)

(98M60)
(98M58)

(622) RAB-D

(98M59)

OPTIONAL RAB
RETURN AIR BASE

(570)
Overall
'Maximum)

5-5/8

SIDE

(143)

AIR OPENINGS
(Either Side)

_1_

1 22-7-16

_J_

RETURN

23 (584)

3/4
(19)

7/8 .._
(22)

91---

27-5/8 (702)
SIDE VIEW

FRONT VIEW
NOTE- Optional
Side Return Air Filter Kits are not for use with RAB Return Air Base.
1 Both the unit return air opening and the base return air opening must be covered by a single plenum or IAQ cabinet.
Minimum unit side return air opening dimensions for units requiring 1800 cfm or more of air (W x H): 23 x 11 in. (584 x 279 mm).
The opening can be cut as needed to accommodate
plenum or IAQ cabinet while maintaining
dimensions
shown.
Side return air openings must be cut in the field. There are cutting guides stenciled on the cabinet for the side return air
opening. The size of the opening must not extend beyond the markings on the furnace cabinet.
2 To minimize pressure drop, the largest opening height possible (up to 14 inches) is preferred.
NOTE- Optional Side Return Air Filter Kits are not for use with RAB Return Air Base.

FIGURE 8

Page 10

Removingthe

Bottom Panel

Leveling Bolt Installation

Remove the two screws that secure the bottom cap to the
furnace. Pivot the bottom cap down to release the bottom
panel, Once the bottom panel has been removed, reinstall
the bottom cap. See figure 9,

Inches (mm)

3/8

(10)
Furnace Front
3/8

1-3/4
(44)

Removing the Bottom Panel
1-3/4
(44)

Leveling

Leveling Bolt
Locations

Bolt

(3/8)

3/8
(10)

1-3/4
(44)
1-3t4 (44)

FIGURE 10
Screw

Horizontal

Applications

The G60UHV(X) furnace can be installed in horizontal applications,

\/
Bottom Cap

Allow for clearances to combustible materials as indicated
on the unit nameplate. Minimum clearances for closet or alcove installations are shown in figure 11,

Bottom

Horizontal Application
Installation Clearances

FIGURE 9

Top
Leveling an Upflow Unit
When the side return air inlets are used in an upflow application, it may be necessary to install leveling bolts on the

Left End

bottom of the furnace. Use field-supplied corrosion-resistant 5/16 inch machine bolts (4) and nuts (8), See figure 10,

Right End

Bottom
Vent Connector
Type

NOTE - The maximum length of the bolt is 1-1/2 inches.
1 - Lie the furnace on its back and drill a 5/16 inch diame-

Type C

Type

ter hole in each corner of the furnace's bottom, See figure 10 for the correct location of the holes, Drill through
the bottom panel and the bottom flange of the cabinet.

Top

*Front

3 in. (76 ram)

3 in, (76 ram)

Back

2 - Install one bolt and two nuts into each hole. Screw the
first nut onto a bolt and then insert the bolt into a hole. A

Ends

2 in. (51 ram)

Vent

fiat washer may be added between the nut and the bottom of the unit.
3 - Screw another nut onto the bolt on the inside of the furnace base. A fiat washer may be added between the
nut and the bottom of the unit,
4 - Adjust the outside nut to the appropriate height and
tighten the inside nut to secure the arrangement,

Bottom

6 in.

(152 ram)

1 in. (25 ram)

*Front clearance in alcove installation must be 24 in. (610 ram).
Maintain a minimum of 24 in. (610 ram) for front service access.
SFor installations on a combustible floor, do not install the furnace
directly on carpeting, tile or other combustible materials other
than wood flooring.

Page 11

FIGURE 11

Thisfurnacemaybeinstalledineitheranatticora crawlspace.Eithersuspendthe furnacefromroof raftersor
floorjoists,asshowninfigure12,orinstallthefurnaceon
a platform,as shownin figure13.Theunitmustbesupportedat bothendsandbeneaththeblowerdecktopreventsagging.
Typical Horizontal Application
Unit Suspended in Attic or Crawlspace

Horizontal Application
Unit Installed on Platform
NOTE - Line contact is permissible. See the unit nameplate for
clearances.
\

"x,

Leave sufficient clearance between rod and unit to
remove access panel.

FIGURE 13

WARNING
FIGURE 12
NOTE - Heavy-gauge perforated sheet metal straps
(plumbers' straps) may be used to suspend the unit from
roof rafters or ceiling joists. When straps are used to suspend the unit in this way, support must be providedfor both
the ends and the middle of the furnace to prevent sagging.
The straps must not interfere with the plenum or exhaust
piping installation. Securing screws should be 1/2 inch
from the top edge and 1-1/2 inch from the side edge in all
cases. Cooling coils and supply and return air plenums
must be supported separately.
NOTE - When the furnace is installed on a platform in a
crawlspace, it must be elevated enough to avoid water
damage and to allow the evaporator coil to drain.
Return Air -- Horizontal

Applications

Return air can be brought in through the end of a furnace
installed in a horizontal application. The furnace is
equipped with a removable bottom panel to facilitate
installation. See figure 9.

Page 12

_&WARNING

Thisunitis notequippedwitha filteror rack.A field-providedhigh-velocity
filteris requiredfortheunittooperate
properly,Table1 listsrecommended
filtersizes,
A filtermustbein placeanytimetheunitisoperating,
TABLE1
Furnace
Cabinet Size

Filter Size
Side Return

Bottom Return

14-1/2"

16X25X1

(1)

14X25X

1 (1)

17-1/2"

16X25X1

(1)

16X25X

1 (1)

21"

16X25X1

(1)

20 X 25 X 1 (1)

24-1/2"

16X25X1

(2)

24 X 25 X 1 (1)

Use industry-approved standards (such as those published by Air Conditioning Contractors of America or American Society of Heating, Refrigerating and Air Conditioning
Engineers) to size and install the supply and return air duct
system. This will result in a quiet and low-static system that
has uniform air distribution.

A 4-inch diameter flue transition is factory-installed on the
combustion air inducer outlet of all models. Modifying or
removing the flue transition will cause the unit to operate unsafely and will void the unit certification. The
vent connector does not require insulation.
The combustion air inducer may be rotated clockwise or
counterclockwise by 90 ° to allow for top or side vent discharge in all applications. When the unit is installed, the flue
transition must be in the 9 o'clock, 12 o'clock or 3 o'clock
position. The unit will not vent properly with the flue
transition pointed down in the 6 o'clock position. Remove the four mounting screws, rotate the assembly (including the gasket), then reinstall the mounting screws.
See figure 14. Use the provided wire tie to bundle the pressure switch wires with the inducer motor power leads.
Route the wires away from moving parts and the heat
of the inducer motor to prevent damage to the wires.
Combustion
(Upflow

Position)

MOUNTING SCREW%
______

NOTE - Do not operate the furnace with an external static
pressure that exceeds 0.8 inches w.c. Higher external static pressures may cause erratic tim# operation.
Supply Air Plenum

Flue Transition

If the furnace is installed without a cooling coil, a removable
access panel must be installed in the supply air duct. The
access panel should be large enough to permit inspection
(either by smoke or reflected light) of the heat exchanger
for leaks after the furnace is installed. The furnace access

(Do not remove)

panel must always be in place when the furnace is operating and it must not allow leaks into the supply air duct system.

Air Inducer

(Remove)

90 °

Mounting Screws
(Remove)

FIGURE 14

Return Air Plenum
Return air must not be drawn from a room where this
furnace, or any other gas appliance (ie., a water heater), is installed. When return air is drawn from a room, a
negative pressure is created in the room. If a gas appliance is operating in a room with negative pressure, the
flue products can be pulled back down the vent pipe and
into the room. This reverse flow of the flue gas may result
in incomplete combustion and the formation of carbon
monoxide gas. This toxic gas might then be distributed
throughout the house by the furnace duct system.
In upfiow applications, the return air can be brought in
through the bottom or either side of the furnace. If a furnace with bottom return air is installed on a platform, make
an airtight seal between the bottom of the furnace and the
platform to ensure that the unit operates properly and
safely. Use fiberglass sealing strips, caulking, or equivalent sealing method between the plenum and the furnace
cabinet to ensure a tight seal. Ira filter is installed, size the
return air duct to fit the filter frame.

Page 13

Optional Flue Outlet
(Horizontal Installation)
Top View of Furnace
Top Cap -----_.
f_

Flue Outlet
Hole
(Reattach
Cutout Here)

_-J_'J
IIII/! I

Supply Air
Opening

Optional
Flue Outlet

FIGURE 15

Usesheetmetalshearstoremove
thecutoutfromtheside
ofthecabinet.Usethetwoprovided
sheetmetalscrewsto
installthecutoutonthetopcaptocovertheoriginalflue
outletopening.Seefigure15,
TheG60UHV(X)
seriesunitsareclassified
asfan-assisted
CategoryI furnaceswhenverticallyventedaccordingto
thelatesteditionof NationalFuelGasCode(NFPA54 /
ANSI Z223.1) in the USA and the current standards of CSA
B149 Natural Gas and Propane Installation Codes in Canada. 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 exchanger.
NQ TE - Use these instructions as a guide. They do not supersede local codes, This furnace must be vented according to all local codes these installation instructions, and the
provided venting tables in these instructions
The venting tables in this manual were extracted from the
National Fuel Gas Code (NFPA 54 / ANSI Z223,1 ) and are
provided as a guide for proper vent installation, Proper application, termination, construction and location of vents
must conform to local codes having jurisdiction. In the absence of local codes, the NFGC serves as the defining document,
Refer to the tables and the venting information contained in
these instructions to properly size and install the venting
system,

A, IMPORTANT

Use self-drilling sheet metal screws or a mechanical fastener to firmly secure the vent pipe to the round collar of the
flue transition. If self-drilling screws are used to attach the
vent pipe, it is recommended that three be used. Drive one
self-drilling screw through the front and one through each
side of the vent pipe and collar. See figure 16.
Install the first vent connector elbow at a minimum of six
inches (152 mm) from the furnace vent outlet,
Venting Using a Masonry Chimney
The following additional requirements apply when a lined
masonry chimney is used to vent this furnace.
Masonry chimneys used to vent Category I central furnaces must be either tile-lined or lined with a listed metal
lining system or dedicated gas vent, Unlined masonry
chimneys are prohibited, See figures 17 and 18 for common venting.
A chimney with one or more sides exposed to the outside of
the structure is considered to be an exterior chimney.
An exterior masonry chimney that is not tile-lined must be
lined with B1 vent or a listed insulated flexible metal vent.
An exterior tile-lined chimney that is sealed and capped
may be lined with a listed uninsulated flexible metal vent,
If the existing chimney will not accommodate a listed metal
liner, either the chimney must be rebuilt to accommodate
one of these liners or an alternate approved venting method must be found.
G60UHV units installed in upflow applications may be
vented into a tile-lined masonry chimney without using a
listed metal liner, provided that the optional masonry chimney vent adapter kit (18M79) is used. Instructions provided
with the kit must be followed exactly.
Insulation for the flexible vent pipe must be an encapsulated fiberglass sleeve recommended by the flexible vent
pipe manufacturer, See figure 17,
Common Venting Using Metal-Lined Masonry Chimney

AWARNING

MAX. LENGTH
+- SEE NOTE 1
BELOW.

5_!15o,)

MINLENGTH-AS

rnm]rnurn

SHORT AS PRACTICAL

SEALjD

EXTERIOR

___v
VENT CONNECTION

i_-'_-

I',

;

4,n+{,02o,

METAL
LINER

CH_MNEYW_TH

VENT
PIPE

SEALED FIREPLACE
OPENING
NOTE

FURNACE

and
NOTE

FLUE TRANSITIC
COLLAR

used.

1 - Refer
the

venting
2 - Either

Refer

tables
for
CSA-B149

FIGURE 16

to the provided
tables

venting

CSA-B149

single-walled

to the

requirements
in
in

USA
and
Canada.

installations

the

USA

Canada.
vent

shown

FIGURE 17

Page 14

for

installations

or doable-walled

capacity

installations
for installations

tables
for

connector

may

in the provided

venting

tables

venting
in

current

Common

Venting

Using Tile-Lined

Interior

Masonry

Chimney

and Combined

Vent Connector

MINIMUM

LENGTH

FOR MAXIMUM

NOTE- Refer to provided venting tables
for installations
in the USA and the
venting tables in current CSA-B149 for
installations in Canada.

F1
_
H
H

= AS SHORT

LENGTH

I
i=
!
'

SEE NOTE

I
_T L-_--

A p_THAENRcE

FURNACE

_N/

TO LEFT

I
I
I
="
I ]
'l IJ_
_
I _ F_ 4--4

...........

AS PRACTICAL.

_
--_

I A
I _

CONNECTOR
I

SEE

[

NOTE

1 BELOW

INTERIOR

TILE=LINED

MASONRY

CHIMNEY

I ]J
_"_
[/_ ]
_
I

I
]

_
VENT

NOTE-thechimneymustbeproperly
sizedperprovided
venting tables or
lined with llsted

metal llning system.

iiiMANDN_INTLYL

A CE

NOTE - Either single-walled or double-walled
vent connector may be used. Refer to the capacity requirements as shown in the provided venting tables for installations in USA and the venting tables in current CSA-B149 for installations in Canada.

FIGURE 18
DO NOT insulate the space between the liner and the
chimney wall with puffed mica or any other loose granular insulating material

klMPORTANT

Do not install a manual damper, barometric draft regulator,
or flue restrictor between the furnace and the chimney.
Never connect a Category I appliance to a chimney that is
servicing a solid-fuel appliance. If a fireplace chimney flue
is used to vent this appliance, the fireplace opening must
be permanently sealed.
A type B or listed chimney lining system that passes
through an unused masonry chimney flue is not considered
to be exposed to the outdoors.
General Venting Requirements
Vent all G60UHV(X) furnaces according to these instructions:
1 - Vent diameter recommendations and maximum allow-

A fan-assisted furnace may be commonly vented into an
existing lined masonry chimney if the following conditions
are met:
• The chimney is currently serving at least one drafthood
equipped appliance
• The vent connectors and chimney are sized according
to the provided venting tables for the USA, and the appropriate venting tables in the standards of CSA B149
Natural Gas and Propane Installation Codes in Canada.
If type B1 double-wall vent is used inside a chimney, no other appliance can be vented into the chimney. The outer wall
of type B1 vent pipe must not be exposed to flue products.
A type B1 vent or masonry chimney liner shall terminate
above the roof surface with a listed cap or a listed roof assembly according to the terms of their respective listings
and the vent manufacturer's instructions.
When inspection reveals that an existing chimney is not
safe for the intended purpose, it shall be rebuilt to conform
to nationally recognized standards, lined or relined with
suitable materials, or replaced with a gas vent or chimney
suitable for venting G60UHV(X) series units. The chimney
passageway must be checked periodically to ensure that it
is clear and free of obstructions.

able piping runs are found in the provided venting tables
for the USA, and the appropriate venting tables in the
standards of CSA B149 Natural Gas and Propane
Installation Codes for Canada.
2 - In no case should the vent or vent connector diameter
be less than the diameter specified in the provided
venting tables for the USA, and the appropriate venting
tables in the standards of CSA B149 Natural Gas and
Propane Installation Codes for Canada.
3 - The minimum vent capacity determined by the sizing
tables must be less than the low fire input rating and the
maximum vent capacity must be greater than the high
fire input rating.
4 - Single appliance vents - If the vertical vent or tile-lined
chimney has a larger diameter or flow area than the
vent connector, use the vertical vent diameter to determine the minimum vent capacity and the vent
connector diameter to determine the maximum vent
capacity, The flow area of the vertical vent, however,
shall not exceed 7 times the flow area of the listed appliance categorized vent area, drafthood outlet area or
flue collar area unless designed according to approved
engineering methods.

Page 15

Multiple appliance vents - The flow area of the largest
section of vertical vent or chimney shall not exceed 7
times the smallest listed appliance categorized vent
area, drafthood outlet area or flue collar area unless designed according to approved engineering methods.

6 - The entire length of single wall metal vent connector
shall be readily accessible for inspection, cleaning,
and replacement.
7 - Single appliance venting configurations with zero lateral lengths (tables 3 and 4) are assumed to have no
elbows in the vent system. For all other vent configurations, the vent system is assumed to have two 90 ° elbows. For each additional 90 ° elbow or equivalent (for
example two 45 ° elbows equal one 90 ° elbow) beyond
two, the maximum capacity listed in the venting table
should be reduced by 10% (0.90 x maximum listed capacity).
8 - The common venting tables (5, 6, 7, and 8) were generated 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 2
Connector Diameter
inches (mm)

Maximum Horizontal
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 vertical vent is offset, the maximum
common vent capacity listed in the common venting
tables should be reduced by 20%, the equivalent d two
90 ° elbows (0.80 x maximum common vent capacity).
The horizontal length of the offset shall not exceed
1-1/2 feet (.46 m) for each inch (25 mm) of common
vent diameter.
10 - The vent pipe should be as short as possible with the
least number of elbows and angles required to complete the job. Route the vent connector to the vent using the shortest possible route.
11 - A vent connector shall be supported without any dips
or sags and shall slope a minimum of 1/4 inch (6.4 mm)
per linear foot (305 mm) of connector, back toward the
appliance.

12 - Vent connectors shall be firmly attached to the furnace
flue collar by self-drilling screws or other approved
means, except vent connectors of listed type B vent
material which shall be assembled according to the
manufacturer's instructions. Joints between sections
of single wall connector piping shall be fastened by
screws or other approved means.
13-When the vent connector used for Category I appliances must be located in or pass through a crawlspace or other areas which may be cold, that portion of
the vent connector shall be constructed of listed
double-wall type B vent material or material having
equivalent insulation qualities.
14 - All venting pipe passing through floors, walls, and ceilings must be installed with the listed clearance to combustible materials and be fire stopped according to local codes. In absence of local codes, refer to NFGC
(Z223.1).
15 - No portion of the venting system can extend into, or pass
through any circulation air duct or plenum.
16- Vent connectors serving Category I appliances shall
not be connected to any portion of mechanical draft
systems operating under positive pressure such as
Category Ill or IV venting systems.
17 - If vent connectors are combined prior to entering the
common vent, the maximum common vent capacity
listed in the common venting tables must be reduced by
10%, the equivalent of one 90 ° elbow (0.90 x maximum
common vent capacity).
18 - The common vent diameter must always be at least as
large as the largest vent connector diameter.
19 - In no case, shall the vent connector be sized more than
two consecutive table size diameters over the size of
the draft hood outlet or flue collar outlet.
20 - Do not install a manual damper, barometric draft regulator or flue restrictor between the furnace and the
chimney.
21 - When connecting this appliance to an existing dedicated or common venting system, you must inspect the
venting system's general condition and look for signs
of corrosion. The existing vent pipe size must conform
to these instructions and the provided venting tables
for the USA, and the appropriate venting tables in the
standards of CSA B149 Natural Gas and Propane
Installation Codes for Canada. If the existing venting
system does not meet these requirements, it must be
resized.

Page 16

TABLE 3
Capacity

Height
H
(feet)

NOTE

- Single

Lateral
L
(feet)

of Type B Double-Wall Vents with Type B Double-Wall Connectors
Serving a Single Category I Appliance
Vent and Connector
4 Inch

3 Inch

Appliance
MIN

Diameter - D (inches)
5 Inch

Input Rating in Thousands
MAX
MIN

6 Inch

of Btu Per Hour
MAX

MIN

MAX

MIN

MAX

152

251

375

157

232

153

227

149

223

165

276

415

109

178

263

103

171

255

164

247

175

295

447

118

194

289

113

187

280

104

176

267

191

327

502

136

226

339

130

219

330

121

206

315

112

195

301

202

349

540

149

250

377

143

242

367

133

229

351

124

217

337

116

206

322

100

213

374

587

166

283

432

160

275

421

150

262

405

141

249

389

132

237

374

113

214

104

346

appliance

venting

configurations

with zero lateral lengths are assumed

to have no elbows

in the vent system.

For all other

vent configurations,
the vent system is assumed to have two 90 ° elbows. For each additional 90 ° elbow or equivalent (for example two 45 °
elbows equal one 90 ° elbow) beyond two, the maximum capacity listed in the venting table should be reduced by 10 percent (0.90 x maximum listed capacity).

Page 17

TABLE 4
Capacity of Type B Double-Wall Vents with Single-Wall Metal Connectors
Serving a Single Category I Appliance
Vent and Connector
Height
H
(feet)

Lateral
L
(feet)

3 Inch

Diameter - D (inches)

4 Inch
Appliance
MIN

5 Inch

Input Rating in Thousands
MAX
MIN

MIN

MAX

151

6 Inch

of Btu Per Hour
MAX

MIN

MAX

249

126

373

156

123

231

102

152

146

225

114

147

163

220

164

273

123

412

108

176

121

261

102

107

168

151

252

122

161

175

243

174

293

120

444

117

193

119

287

111

105

185

148

277

100

132

171

188

261

190

325

116

499

136

225

115

337

128

102

216

144

326

116

128

201

182

308

158

186

220

290

200

346

114

537

148

248

113

375

140

100

239

141

363

129

125

223

177

344

155

208

216

325

186

192

254

306

211

372

110

584

164

281

109

429

157

271

136

417

144

122

255

171

397

115

131

151

239

208

377

181

223

246

357

NOTE - Single appfiance venting configurations with zero lateral lengths are assumed to have no elbows in the vent system. For all other
vent configurations, the vent system is assumed to have two 90 ° elbows. For each additional 90 ° elbow or equivalent (for example two 45 °
elbows equal one 90 ° elbow) beyond two, the maximum capacity listed in the venting table should be reduced by 10 percent (0.90 x maximum listed capacity).

Page 18

TABLE 5
Vent Connector Capacity
Type B Double-Wall Vents with Type B Double-Wall Connectors
Serving Two or More Category I Appliances
Vent
Height
H
(feet)

Connector
Rise
R
(feet)

Vent and Connector
3 Inch

Diameter - D (inches)

4 Inch
5 Inch
Appliance Input Rating in Thousands of Btu Per Hour
MIN
MAX
MIN
MAX

MIN

MAX

6 Inch
MIN

MAX

106

164

121

183

132

199

114

176

128

195

139

210

123

189

136

206

146

220

142

220

153

235

102

163

248

157

246

105

167

259

110

176

271

113

181

288

118

190

299

123

198

309

TABLE 6
Common Vent Capacity
Type B Double-Wall Vents with Type B Double-Wall Connectors
Serving Two or More Category I Appliances
Common Vent Diameter

Vent
Height
H
(feet)

4 Inch

- D (inches)

5 Inch

6 Inch

FAN + FAN

FAN + NAT

Appliance
FAN + FAN

140

116

204

101

155

129

224

110

169

141

125

112

195

136

123

152

138

7 Inch

Input Rating in Thousands of Btu Per Hour
FAN + NAT
FAN + FAN
FAN + NAT

FAN + FAN

FAN + NAT

161

309

248

178

339

275

243

194

367

299

164

283

228

427

352

215

183

314

255

475

394

244

210

361

297

547

459

Page 19

TABLE 7
Vent Connector Capacity
Type B Double-Wall Vents with Single-Wall Metal Connectors
Serving Two or More Category I Appliances
Vent
Height
H
(feet)

Vent and Connector

Diameter - D (inches)

Connector
Rise
R
(feet)

MIN

MAX

2
3

3 Inch

4 Inch
5 Inch
Appliance Input Rating in Thousands of Btu Per Hour
MIN
MAX
MIN
MAX

6 Inch
MIN

MAX

168

182

121

131

174

198

116

138

177

214

121

150

185

230

100

127

160

193

243

110

113

175

169

278

115

117

185

177

290

119

122

193

185

300

TABLE 8
Common Vent Capacity
Type B Double-Wall Vents with Single-Wall Metal Connectors
Serving Two or More Category I Appliances
Common Vent Diameter

Vent
Height

4 Inch

- D (inches)

5 Inch

6 Inch

7 Inch

H
(feet)

FAN + FAN

FAN + NAT

Appliance
FAN + FAN

Input Rating in Thousands of Btu Per Hour
FAN + NAT
FAN + FAN
FAN + NAT

FAN + FAN

FAN + NAT

136

113

200

158

304

244

151

126

218

173

331

269

106

163

137

237

189

357

292

121

108

189

159

275

221

416

343

131

118

208

177

305

247

463

383

145

132

236

202

350

286

533

446

Removal of the Furnace from Common Vent

and other spaces of the building. Turn on clothes dryers and any appliances not connected to the common
venting system. Turn on any exhaust fans, such as
range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

In the event that an existing furnace is removed from a
venting system commonly run with separate gas appliances, the venting system is likely to be too large to
properly vent the remaining attached appliances,
Conduct the following test while each appliance is operating and the other appliances (which are not operating) remain 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 requirements section.
1 - Seal any unused openings in the common venting system,

4 - Follow the lighting instructions, Turn on the appliance
that is being inspected, Adjust the thermostat so that
the appliance operates continuously,
5 - After the main burner has operated for 5 minutes, test
for leaks of flue gases at the draft hood relief opening,
Use the flame of a match or candle, or smoke from a
cigarette, cigar, or pipe,

leakage, corrosion, or other deficiencies which could
cause an unsafe condition,

6 - After determining that each appliance connected to the
common venting system is venting properly, (step 3)
return all doors, widows, exhaust fans, fireplace dampers, and any other gas-burning appliances to their previous mode of operation,

3 - Close all building doors and windows and all doors between the space in which the appliances remaining
connected to the common venting system are located

7 - If a venting problem is found during any of the preceding tests, the common venting system must be modified to correct the problem,

2 - Inspect the venting system for proper size and horizontal
pitch, Determine that there is no blockage, restriction,

Page 20

Resizethecommonventingsystemto the minimum
ventpipesizedeterminedby usingthe appropriate
tablesinAppendixG. (Thesearein thecurrentstandardsoftheNationalFuelGasCodeANSIZ223.1in
theUSA,andtheappropriate
Category1 NaturalGas
andPropaneappliances
ventingsizingtablesin the
currentstandardsof theCSAB149NaturalGasand
PropaneInstallation
CodesinCanada.)

3 - The gas piping must not run in or through air ducts,
clothes chutes, gas vents or chimneys, dumb waiters,
or elevator shafts.
4 - The piping should be sloped 1/4 inch (6,4 mm) per 15
feet (4,57 m) upward toward the meter from the furnace. The piping must be supported at proper intervals
[every 8 to 10 feet (2.44 to 3.01 m)] with suitable hangers or straps, Install a drip leg inside vertical pipe runs
to the unit.
5 - A 1/8" N.RT. plugged tap or pressure post is located
on the gas valve to facilitate test gauge connection.
See figures 26 and 27.

XkCAUTION

6 - In some localities, codes may require the installation of
a manual main shut-off valve and union (furnished by
the installer) external to the unit, The union must be of
the ground joint type.

klMPORTANT

Gas Supply
1 - This unit is shipped standard for left or right side installation of gas piping (or top entry in horizontal applications). Connect the gas supply to the piping assembly.
2 - When connecting the gas supply piping, consider factors such as length of run, number of fittings, and furnace rating to avoid excessive pressure drop. Table 9
lists recommended pipe sizes for typical applications.

NOTE - If emergency shutoff is necessa04 shut off the main
manual gas valve and disconnect main power to the furnace. The installer should properly label these devices.

TABLE 9
Gas Pipe Capacity - ft3/hr (m3/hr)
Nominal
Iron Pipe
Size
inches
(ram)
3/8

Length

of Pipe - feet (m)

Internal
Diameter
inches
(ram)

10
(3.048)

20
(6.096)

30
(9.144)

40
(12.192)

50
(15.240)

60
(18.288)

.493
(12.522)

95
(2.69)

65
(1.84)

52
(1.47)

45
(1.27)

4O
(1.13)

36
(1.02)

33
(.73)

.622
(17.799)

175
(4.96)

120
(3.40)

97
(2.75)

82
(2.32)

73
(2.07)

.824
(20.930)

360
(10.19)

250
(7.08)

2OO
(5.66)

170
(4.81)

151
(4.28)

1.049
(26.645)

680
(919.25)

465
(13.17)

375
(10.62)

32O
(9.06)

1.380
(35.052)

1400
(39.64)

950
(26.90)

77O
(21.80)

66O
(18.69)

(16.42)

53O
(15.01)

490
(13.87)

46O
(13.03)

430
(12.18)

(11.33)

(38.1)

1.610
(40.894)

2100
(59.46)

460
(41.34)

1180
(33.41)

990
(28.03)

9OO
(25.48)

810
(22.94)

75O
(21.24)

69O
(19.54)

65O
(18.41)

62O
(17.56)

2
(50.8)

2.067
(52.502)

3950
(111.85)

2750
(77.87)

2200
(62.30)

1900

(53.80)

1680
(47.57)

1520
(43.04)

1400
(39.64)

1300
(36.81)

1220
(34.55)

1150
(32.56)

2-1/2
(63.5)

2.469
(67.713)

6300
(178.39)

4350
(123.17)

3520
(99.67)

3000
(84.95

2650
(75.04)

2400
(67.96)

2250
(63.71)

2050

(58.05)

1950
(55.22)

1850
(52.38)

3
(76.2)

3.068
(77.927)

11000
(311.48)

7700
(218.03)

6250
(176.98)

5300
(150.07)

4750
(134.50)

4300
(121.76)

3900
(110.43)

3700
(104.77)

3450
(97.69)

3250
(92.03)

(9.53)

1/2
(12.7)

3/4
(19.05)

1
(25.4)

1-1/4
(31.75)

1-1/2

NOTE

- Capacity

given

285

(8.07)
580

80
(24.384)

90
(27.432)

lOO
(30.480)

(.88)

29
(.82)

27
(.76)

61
(1.73)

57
(1.61)

(1.5o)

5O
(1.42)

(3.91)

125
(3.54)

118
(3.34)

110
(3.11)

103
(2.92)

26O
(7.36)

24O

22O
(6.23)

2O5

195

(6.80)

(5.80)

(5.52)
400

(1.87)
138

70
(21.336)

in cubic feet (m3 ) of gas per hour and based on O.60 specific gravity gas.

Page 21

Left Side Piping
(Standard)
MANUAL
MAIN SHUT-OFF

AUTOMATIC
GAS VALVE
(with manual
shuboff valve)

AUTOMATIC
GAS VALVE
(with manual
shut-off valve)

VALVE
(With 1/8 in. NPT
Plugged Tap Shown)

MANUAL
SHUT-OFF
VALVE
(With 1/8 in. NPT
Plugged Tap
Shown)
JOINT
UNION

GROUND
JOINT
UNION

_DRIP

Right Side Piping
(Alternate)

FIELD
PROVIDED
ANDINSTALLED

DRIP LEG

LEG

FIGURE 19
Leak Check
After gas piping is completed, carefully check all piping
connections (factory- and field-installed) for gas leaks, Use
a leak detecting solution or other preferred means.
NOTE - If emergency shutoff is necessa04 shut off the main
manual gas valve and disconnect the main power to the
furnace. The installer should properly label these devices.

ELECTROSTATIC

DISCHARGE

(ESD)

Precautions and Procedures

kCAUTION

,CAUTION

The furnace must be isolated from the gas supply system
by closing #s 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.).

The unit is equipped with a field make-up box, The makeup box may be moved to the right side of the furnace to facilitate installation, If the make-up box is moved to the right
side, the excess wire must be pulled into the blower
compartment, Secure the excess wire to the existing harness to protect it from damage.

,IMPORTANT

INTERIOR MAKE-UP BOX INSTALLATION
MAKE-UP
BOX

ISOLATE
GAS VALVE

SHUT-OFF VALVE
WILL NOT HOLD
NORMAL TEST
PRESSURE
MANUAL MAIN

\
FURNACE

CAP

6
FIGURE 20

FIGURE 21

Page 22

INTERIOR
MAKE-UP

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 G6OUHV(X) furnace contains electron-

BOX INSTALLATION
MAKE-UP

Left side

BOX

ic compon en ts that are polarity sen sitive, Make sure
that the furnace is wired correctly and is properly
grounded,
7 - One line voltage "EAC" 1/4" spade terminal is provided
on the furnace control board. Any electronic air cleaner
rated up to one amp can be connected to this terminal
with the neutral leg d the circuit being connected to the
one of the provided neutral terminals. See figure 25 for
control board configuration, This terminal is energized
when the indoor blower is operating,
8-

FIGURE 22
Refer to figure 23 for schematic wiring diagram and troubleshooting and table 10 and figure 24 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 facilitate wiring,
3 - Install a separate disconnect switch (protected by either 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 wiring diagrams shown in table 10 and figure 24, Use
18-gauge wire or larger that is suitable for Class II rating for thermostat connections,

One line voltage *'HUM" 1/4" spade terminal is provided on the furnace control board. 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 25 for
control board configuration. This terminal is energized
in the heating mode whenever the combustion air inducer is operating.

9 - One 24V "H" terminal is provided on the furnace control
board 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" terminal. See figure 25 for control board configuration.
10-Install the room thermostat according to the instructions provided with the thermostat, See table 10 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 at approximately 38% of
the second-stage cooling speed when there is no cooling or heating demand,

When the G60UHV(X) is running in the heating mode,
the indoor blower will run on the heating speed designated by the positions of DIP switches 11 and 12.

When there is a cooling demand, the indoor blower will
run on the cooling speed designated by the positions
of DIP switches 5 and 6,

6 - Electrically ground the unit according to local codes or,
in the absence of local codes, according to the current

Page 23

TABLE 10
Field Wiring Applications

Thermostat

1 Heat/1

Cool

Jumper Settings
W915
Two-Stage
DIP Switch 1
Cooling
ON

Intact

(See figure 25)
W914 Dehumidification
W951
or Harmony
Heat Pumps
III
Intact

Intact

NOTE - Use DiP
switch 2 to set
second-stage
heat ON delay.
QFF-IO minutes.
ON-15 minutes.

Wiring Connections

Sl
T'STAT

CONTROL
TERM. STRIP

@
®
®
®______
®
_,
®

1 Heat / 2 Cool

OUTDOOR
UNIT

Cut

Intact

NOTE - Use DIP
switch 2 to set
second-stage
heat QN delay.
OFF-IO minutes.
ON-15 minutes.

Sl
T'STAT

®
®

CONTROL
TERM. STRIP

OUTDOOR
UNIT

@
®
®

®
@
@

@
1 Heat / 2 Cool
with t'stat with
humidity control
NOTE - Use DIP
switch 2 to set
second-stage
heat ON delay.
QFF-fO minutes.
ON-15 minutes.

Cut

Intact

$1
T'STAT

CONTROL
TERM. STRIP

OUTDOOR
UNIT

@
@
®
®
®
@

Page 24

®
®
_---_
@---@
®---_

TABLE 10
Field Wiring Applications

(Continued)

Jumper Settings (See figure 25)
W915
W914 DehuThermostat

DIP Switch 1

Two-Stage
Cooling

midification
or Harmony
III

W951
Heat Pumps

2 Heat / 2 Cool

OFF

Cut

Intact

Wiring Connections

$1
T'STAT

CONTROL
TERM. STRIP

OUTDOOR
UNIT

@
®
®

®
@.
@2 Heat / 2 Cool
with t'stat with
humidity control

OFF

Cut

Intact

$1
T'STAT

®
®
@
®
®

®
@
@

CONTROL
TERM. STRIP

@
@

@.
®.
®
®.

®
®

OUTDOOR
UNIT

®
@----@
®----@

@
L
12 Heat / 1 Cool

OFF

Intact

$1
T'STAT

CONTROL
TERM. STRIP

OUTDOOR
UNIT

4_-

Page 25

G60UHV(X)

Schematic

Wiring Diagram

FIGURE 23

Page 26

TYPICAL G60UHV(X) FIELD WIRING DIAGRAM
t20V

ACC

G
PR]HARY

GAS

LI ...,m.ili--

CONDUCTORS

FIELD INSTALLED
FIELD INSTALLED

INDUCE'R HOTOR

P84 _

CQHBUSTIQN

$51

I@@@_)©@@1
f

3t59

RQLLDUT
$VITCH

$_/ITCH

Tt
_i

$21

TRANSFOR_R

SEC_Y
LIMIT

INTEGRATED

CONTROL
=

SVITCH

__P159

PtSS
THERMOSTAT

SENSOR

RDLLOUT
SVITCH

CLASS II 24V
LINE VOLTAGE

VALVE

HIGH HEAT

oQ%o

FLAME

ONLY.

AIR

BURNERS

N ...,,e-i.

USE COPPER

J84

..........

c .....

] _ ...............

L._.

C_8

L_t.U.._HH_-H2L _.H_-i
i. .........................

.........,,

r ...............

, ,

?_1111

.d.-r-J-_..÷_-

t_----

_-e

HDTI_

24V IN_U'T......

FIGURE 24
TWO-STAGE, VARIABLE SPEED INTEGRATED CONTROL BOARD

I OOOq

1/4" QUICK

STATUS=
E-COW-

DIAGNOSTIC
LEDs

HEATING

INDOOR
BLOWER DIP
SWITCHES

SWITCHES

DIP

CONNECT

TERMINALS

HUM : 120 VAC OUTPUT TO HUMIDIFIER
XMFR : 12O VAC OUTPUT TO TRANSFORMER
LI
: 120 VAC INPUT TO CONTROL
CIRC : 120 VAC OUTPUT TO CIRCULATING BLOWER
EAC : 120 VAC OUTPUT TO ELECTRONIC AIR CLEANER
NEUTRALS= 120 VAC NEUTRAL

ON-BOARD
JUMPERS

THERMOSTAT CONNECTIONS (TB1)
DS: DEHUMIDIFICATIONSIGNAL
W2: HEATDEMAND
FROM2ND STAGET'STAT
Wl: HEAT DEMAND FROM IST STAGE T'STAT
R: CLASS 2 VOLTAGE TO THERMOSTAT
G: MANUAL FAN FROM T'STAT
C: THERMOSTAT SIGNAL GROUND CONNECTED TO TRANSFORMER
GROUND (TR) & CHASIS GROUND (GRD)
YI: THERMOSTAT Is_"STAGE COOL SIGNAL
Y2: THERMOSTAT 2nd STAGE COOL SIGNAL
0--THERMOSTAT SIGNAL TO HEAT PUMP REVERSINGVALVE
H= 24V HUMIDIFIER OUTPUT
L= LENNOX SYSTEM OPERATION MONITOR
1= FUTURE USE
DIP SWITCH FUNCTIONS

HTG DIP SWITCH(ES)
1
2
3 and 4
INDOOR BLOWER
DIP SWITCH(ES)
5 and 6
7 and 8
9 and 10
11 and 12

FIGURE 25

Page 27

FUNCTION
T'stat Heat Staqes (sin qle or two-staqe)
Second Staqe ON Delay (sin qle-staqe t'stat)
Heatinq Fan OFF Delay
FUNCTION

Coolinq
Blower
Cooling
Heating

Mode
Speed
Mode
Mode

Blower Speed
Adiustment
Blower Ramping
Blower Speed

Profile

TABLE 11
Blower Off Delay Switch Settings

G60UHVunitsareequippedwitha two-stage,variable
speedintegratedcontrol.This controlmanagesignition
timing,heatingmodefan off delaysandindoorblower
speedsbasedon selectionsmadeusingthe controldip
switchesandjumpers.The controlincludesan internal
watchguard
featurewhichautomatically
resetstheignition
controlwhenithasbeenlockedout.Afteronehourofcontinuousthermostatdemandfor heat,thewatchguard
will
breakandremakethermostat
demandto thefurnaceand
automatically
resetthecontrolto relightthefurnace.
HeatingOperationDIPSwitchSettings
Switch 1 -- ThermostatSelection-- Thisunitmaybe
usedwitheithera single-stage
or two-stagethermostat.
Thethermostat
selection
ismadeusinga DIPswitchwhich
mustbeproperlypositioned
fortheparticular
application.
TheDIPswitchis factory-positioned
for usewitha twostagethermostat.
If a single-stage
thermostat
istobeused,
theDIPswitchmustberepositioned,
a - Select "OFF" for two-stage heating operation conSelect "ON" for two-stage heating operation controlled by a single-stage heating thermostat, This setting provides a timed delay before second-stage heat
is initiated,

Switch 2 -- Second Stage Delay (Used with SingleStage Thermostat Only) -- This switch is used to determine the second stage on delay when a single-stage thermostat is being used. The switch is factory-set in the OFF
position, which provides a 10-minute delay before secondstage heat is initiated, If the switch is toggled to the ON
position, it will provide a 15-minute delay before secondstage heat is initiated, This switch is only activated when
the thermostat selector jumper is positioned for SINGLEstage thermostat use,
Switches 3 and 4 -- Blower-Off Delay -- The blower-on
delay of 45 seconds is not adjustable. The blower-off delay
(time that the blower operates after the heating demand
has been satisfied) can be adjusted by moving switches 3
and 4 on the integrated control board, The unit is shipped
from the factory with a blower-off delay of 90 seconds, The
blower off delay affects comfort and is adjustable 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 temperatures,Table 11 provides the blower off timings that will result
from different switch settings,

Switch 3

Switch 4

Off

90
120
180

Off
On
On

Off
Off
On

Indoor Blower Operation DIP Switch Settings
Switches 5 and 6 -- Cooling Mode Blower Speed -Switches 5 and 6 are used to select cooling blower motor
speed. The unit is shipped from the factory with the dip
switches positioned for high speed (4) indoor blower motor
operation during the cooling mode. The table below provides the cooling mode blower speeds that will result from
different switch settings. Refer to tables 16 through 25 for
corresponding cfm values,
TABLE 12
Cooling Mode Blower Speeds

trolled by a two-stage heating thermostat (factory setting);
b-

Blower Off Delay
(Seconds)
60

Speed
1 - Low
2 - Medium Low

Switch 5
On
Off

Switch 6
On
On

3 - Medium High
4 - High (Factory)

On
Off

Off
Off

Switches 7 and 8 -- Blower Speed Adjustment -Switches 7 and 8 are used to select blower speed adjustment settings. The unit is shipped from the factory with the
dip switches positioned for NORMAL (no) adjustment, The
dip switches may be positioned to adjust the blower speed
by +10% or -10% to better suit the application, The table
below provides blower speed adjustments that will result
from different switch settings. Refer to tables 16 through 25
for corresponding cfm values,
TABLE 13
Blower Speed Adjustment
Adjustment
+10% (approx,)
NORMAL (Factory)

Switch 7
On
Off

Switch 8
Off
Off

-10% (approx,)
Off
On
Switches 9 and 10 -- Cooling Mode Blower Speed
Ramping -- Switches 9 and 10 are used to select cooling
mode blower speed ramping options, Blower speed ramping may be used to enhance dehumidification performance. The switches are factory set at option A which has
the greatest effect on blower motor performance. Table 14
provides the cooling mode blower speed ramping options
that will result from different switch settings, The cooling
mode blower speed ramping options are detailed on the
next page,
NOTE - The off portion of the selected ramp profile also applies during heat pump operation in dual fuel applications,

Page 28

TABLE 14
Cooling Mode Blower Speed Ramping
Ramping Option

Switch 9

Switch 10

A (Factory)
B
C

Off
On
Off

Off
Off
On

•
•
•
•

Switches 11 and 12 -- Heating Mode Blower Speed -Switches 11 and 12 are used to select heating mode blower
motor speed, The unit is shipped from the factory with the
dip switches positioned for medium low (2) speed indoor
blower motor operation during the heating mode. The table

Ramping Option A (Factory Selection)
Motor runs at 50% for 30 seconds.
Motor then runs at 82% for approximately 7-1/2 minutes.
If demand has not been satisfied after 7-1/2 minutes,
motor runs at 100% until demand is satisfied.
Once demand is met, motor runs at 50% for 30 seconds then ramps down to stop.

71/2MIN
82%
CFM

100%
CFM

OFF

COOL,NG
DEMAND

•

Ramping Option B
Motor runs at 82% for approximately 7-1/2 minutes. If
demand has not been satisfied after 7-1/2 minutes,
motor runs at 100% until demand is satisfied.
Once demand is met, motor ramps down to stop.

(
OFF

82%CFM /
--

7 1/2 MIN
_
COOLING

OFF
DEMAND

100% CFM
--'1_"

•

Ramping Option C
Motor runs at 100% until demand is satisfied.

•

Once demand is met, motor runs at 100% for 45 seconds then ramps down to stop.

OFF

OFF
._p--

100% CFM -DEMAND

Ramping Option D
• Motor runs at 100% until demand is satisfied.
•

Once demand is met, motor ramps down to stop.

COOLING
100% CFM
DEMAND

_OFF

below provides the heating mode blower speeds that will
result from different switch settings, Refer to tables 16
through 25 for corresponding cfm values,
TABLE 15
Heating Mode Blower Speeds
Speed
1 - Low

Switch 11
On

Switch 12
On

2 - Medium Low
(Factory)
3 - Medium High

Off

4 - High

Off

On-Board Jumper W914
On-board jumper W914, which connects terminals DS and
R on the integrated control board, must be cut when the furnace 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 HARMONY Ill control will be blocked and also lead to control damage. Refer to table 27 for operation sequence in applications including G60UHV, a thermostat which features
humidity control and a single-speed outdoor unit. Table 28
gives the operation sequence in applications with a twospeed outdoor unit,
On-Board Jumper W951
On-board jumper W951, which connects terminals R and O
on the integrated control board, must be cut when the furnace is installed in applications which include a heat pump
unit and a thermostat which features dual fuel use. If the
jumper is left intact, terminal "O" will remain energized eliminating the HEAT MODE in the heat pump.
On-Board Jumper W915
On-board jumper W915, which connects terminals Y1 and
Y2 on the integrated control board, must be cut if two-stage
cooling will be used. If the jumper is not cut the outdoor unit
will operate in second-stage cooling only.
Status LEDs (SPEED, CFM, STATUS, E-COM)
The green SPEED LED indicates circulating blower speed
in response to the DS signal. The LED is lit during normal
blower operation and is off during a dehumidification demand. In Harmony III applications, the brightness of the
LED indicates the requested blower speed.
The green CFM LED indicates the blower air flow. Count
the number of blinks between the two-second pauses to
determine the CFM. Each blink represents approximately
100 CFM.
The STATUS LED flashes diagnostic codes, which are detailed on page 43.
The green E-COM LED indicates that the control is receiving and processing of commands and inputs. The LED may
flash rapidly or may display a single flash, depending upon
the activity.

Page 29

TABLE 16
G60UHV-36A-070 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
"ADJUST"
Switch
Positions

Second Stage "HEAT" Speed
2
3

Second Stage "COOL" Speed
2
3

cfm

L/s

cfm

L/s

cfm

L/s

cfm

L/s

cfm

L/s

cfm

L/s

cfm

L/s

cfm

L/s

895

420

1015

480

1275

600

1320

625

1000

470

1165

550

1260

595

1380

650

NORM

815

385

925

435

1120

530

1170

555

915

430

1035

490

1115

525

1230

580

740

350

845

400

1000

475

1040

490

830

390

945

445

990

470

1085

510

"ADJUST"
Switch
Positions

cfm

L/s

820

390

930

440

1140

NORM

755

355

855

405

1020

695

325

775

365

920

435

First Stage "HEAT" Speed
2
3
cfm
L/s
cfm
L/s

First Stage "COOL" Speed
2
3
cfm
L/s
cfm
L/s

cfm

L/s

cfm

L/s

540

1195

480

1060

565

730

3455

810

385

865

500

670

315

745

350

785

965

455

630

295

690

325

725

4
cfm

L/s

410

910

430

370

850

400

340

770

365

NOTES - The effect of static pressure is included in air volumes shown.
First stage HEAT is approximately 91% of the same second stage HEAT speed position.
First stage COOL (two-stage air conditioning units only) is approximately 70% of the same second stage COOL speed position.
Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position - minimum 500 cfm (235 L/s).
Lennox Harmony Ill" Zone Control Applications - Minimum blower speed is 426 cfm (200 L!s).

TABLE 17
G60UHV-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
"ADJUST"
Switch
Positions

;econd Stage "HEAT" Speed
2
3

Second Stage "COOL" Speed
2
3

cfm

L/s

cfm

L/s

cfm

L/s

cfm

L/s

cfm

L/s

N/A

1025

485

1265

600

1320

625

1005

NORM

N/A

1125

530

1170

555

905

N/A

1010

475

1045

495

825

i
"ADJUST"
Switch
Positions

1
cfm

L/s

First Stage "HEAT" Speed
2
3
cfm
L/s
cfm
L/s

L/s

cfm

L/s

cfm

L/s

475

1165

550

1260

595

1385

655

425

1035

490

1110

525

1225

580

390

940

445

1000

470

1090

515

cfm

L/s

cfm

L/s

First Stage "COOL" Speed
2
3
cfm
L/s
cfm
L/s

4
cfm

L/s

N/A

940

445

1140

540

1185

560

725

340

810

385

860

405

920

435

NORM

N/A

1030

485

1065

505

670

315

740

350

785

370

840

395

N/A

925

435

950

450

625

295

695

330

725

345

770

365

N/A - First and second stage HEAT positions shown cannot be used on this model.
NOTES - The effect of static pressure is included in air volumes shown.
First stage HEAT is approximately 91% of the same second stage HEAT speed position.
First stage COOL (two-stage air conditioning units only) is approximately 70% of the same second stage COOL speed position.
Continuous Fan Onty speed is approximately 38% of the same second stage COOL speed position - minimum 500 cfm (235 L/s).
Lennox Harmony Ill" Zone Controt Applications - Minimum blower speed is 453 cfm (215 L/s).

Page 30

TABLE 18
G60UHV-60C-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.
Return Air Options: Bottom; both sides; or bottom and one side.
Speed Switch Positions
"ADJUST"
Switch
Positions
+
NORM
-"ADJUST"
Switch
Positions

Second Stage "HEAT" Speed
2
3

Second Stage "COOL" Speed
2
3

cfm

L/s

cfm

L/s

cfm

L/s

cfm

L/s

cfm

L/s

cfm

L/s

cfm

L/s

cfm

L/s

1570
1425
1270

740
675
600

1770
1625
1435

835
765
680

1965
1810
1635

925
855
770

2185
1990
1790

1030
940
845

1680
1520
1355

795
715
640

1795
1635
1460

845
770
690

2015
1855
1670

950
875
785

2255
2065
1845

1065
975
870

First Stage "HEAT" Speed
2
3
cfm
L/s
cfm
L/s

cfm

L/s

1430

675

1625

770

1815

NORM
--

1290
1165

610
550

1470
1300

695
615

1660
1470

First Stage "COOL" Speed
2
3
cfm
L/s
cfm
L/s

cfm

L/s

cfm

L/s

855

1990

940

1170

550

1250

590

1425

780
695

1830
1635

865
770

1060
930

500
440

1140
1015

540
480

1280
1155

4
cfm

L/s

670

1600

755

605
545

1445
1285

680
605

NOTES - The effect of static pressure is included in air volumes shown.
First stage HEAT is approximately 91% of the same second stage HEAT speed position.
First stage COOL (two-stage air conditioning units only) is approximately 70% of the same second stage COOL speed position.
Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position - minimum 500 cfm (235 L/s).
Lennox Harmony Ill ' Zone Control Applications - Minimum blower speed is 478 cfm (225 Us).

TABLE 19
G60UHV-60C-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.
Return Air Options: Single side return air - Bold volumes require field-fabricated
transition to accommodate
20 x 25 x 1 in. (508 x 635 x 25 mm) cleanable air filter in order to maintain proper air velocity across the filter.
Speed Switch Positions
"ADJUST"
Switch
Positions
+
NORM
i

Second Stage "HEAT" Speed
2
3

1
cfm
1520
1380
1230

L/s
715
650
580

"ADJUST"
Switch
Positions

cfm

L/s

+
NORM
i

1385
1255
1135

655
590
535

cfm
1705
1540
1395

L/s
805
730
660

cfm
1910
1750
1570

L/s
900
825
740

First Stage "HEAT" Speed
2
3
cfm
L/s
cfm
L/s
1560
1425
1265

735
670
600

1765
1580
1430

835
745
675

4
cfm
2120
1925
1745

Second Stage "COOL" Speed
2
3

1
L/s
1000
910
825

cfm
1605
1475
1305

L/s
760
695
615
1

cfm

L/s

cfm

L/s

1945
1785
1570

920
840
740

1125
1020
890

530
480
420

cfm
1745
1565
1410

L/s
825
740
665

cfm
1955
1785
1590

First Stage "COOL" Speed
2
3
cfm
L/s
cfm
L/s
1210
1100
980

570
520
465

1370
1235
1115

NOTES - The effect of static pressure is included in air volumes shown.
First stage HEAT is approximately 91% of the same second stage HEAT speed position.
First stage COOL (two-stage air conditioning units only) is approximately 70% of the same second stage COOL speed position.
Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position - minimum 500 cfm (235 L/s).
Lennox Harmony Iit" Zone Control Applications - Minimum blower speed is 478 cfm (225 L/s).

Page 31

L/s
925
840
750

650
580
525

cfm
2195
1985
1795

L/s
1035
935
845
4

cfm

L/s

1525
1385
1235

720
655
580

TABLE 20
G60UHV-60C-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.
Return Air Options: Side return air with optional RAB return air base.
Speed Switch Positions
"ADJUST"
Switch
Positions
+
NORM
-"ADJUST"
Switch
Positions

Second Stage "HEAT" Speed
2
3

Second Stage "COOL" Speed
2
3

cfm

L/s

cfm

L/s

cfm

L/s

cfm

L/s

cfm

L/s

cfm

L/s

cfm

L/s

cfm

L/s

1505
1370
1215

710
645
575

1690
1535
1375

800
725
650

1900
1745
1535

895
825
725

2090
1915
1705

985
905
805

1625
1450
1310

765
685
620

1715
1560
1405

810
735
660

1940
1765
1595

915
835
755

2175
1945
1795

1030
915
850

First Stage "HEAT" Speed
2
3
cfm
L/s
cfm
L/s

cfm

L/s

1370

650

1540

725

1745

NORM
--

1240
1135

585
535

1405
1265

665
600

1565
1420

First Stage "COOL" Speed
2
3
cfm
L/s
cfm
L/s

cfm

L/s

cfm

L/s

825

1925

910

1130

530

1205

570

1360

740
670

1765
1560

830
735

1025
900

485
425

1100
985

520
465

1240
1115

4
cfm

L/s

645

1530

720

585
525

1385
1240

655
585

N/A - First and second stage HEAT positions shown cannot be used on this model.
NOTES - The effect of static pressure is included in air volumes shown.
First stage HEAT is approximately 91% of the same second stage HEAT speed position.
First stage COOL (two-stage air conditioning units only) is approximately 70% of the same second stage COOL speed position.
Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position - minimum 500 cfm (235 Us).
Lennox Harmony Ill ' Zone Control Applications - Minimum blower speed is 478 cfm (225 Us).

TABLE 21
G60UHV-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.
Return Air Options: Bottom; both sides; or bottom and one side.
Speed Switch Positions
"ADJUST"
Switch
Positions
+
NORM
--

Second Stage "HEAT" Speed
2
3

1
cfm
1510
1365
N/A

L/s
715
645
N/A

"ADJUST"
Switch
Positions

cfm

L/s

+
NORM
--

1370
1245
N/A

650
585
N/A

cfm
1700
1545
1375

L/s
805
730
650

cfm
1895
1725
1545

L/s
895
815
730

First Stage "HEAT" Speed
2
3
cfm
L/s
cfm
L/s
1560
1410
1255

735
665
595

1750
1590
1420

825
750
670

4
cfm
2105
1915
1715

Second Stage "COOL" Speed
2
3

1
L/s
995
905
810

cfm
1610
1460
1295

L/s
760
690
610

cfm

L/s

cfm

L/s

1925
1760
1575

910
830
745

1125
1015
900

530
480
425

cfm
1730
1575
1395

L/s
815
745
660

cfm
1955
1780
1600

First Stage "COOL" Speed
2
3
cfm
L/s
cfm
L/s
1190
1090
975

565
515
460

1350
1230
1110

N/A - First and second stage HEAT positions shown cannot be used on this model.
NOTES - The effect of static pressure is included in air volumes shown.
First stage HEAT is approximately 91% of the same second stage HEAT speed position.
First stage COOL (two-stage air conditioning units only) is approximately 70% of the same second stage COOL speed position.
Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position - minimum 500 cfm (235 Us).
Lennox Harmony Ill" Zone Controt Applications - Minimum blower speed is 483 cfm (230 L/s).

Page 32

L/s
920
840
755

640
580
525

4
cfm
2185
1995
1780

L/s
1030
940
840

4
cfm

L/s

1530
1360
1235

720
640
580

TABLE 22
G60UHV-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.
Return Air O _tions: Single side return air - Bold volumes require field-fabricated
transition to accommodate
20 x 25 x 1 in. 508 x 635 x 25 mm) cleanable air filter in order to maintain proper air velocity across the filter.
Speed Switch Positions
"ADJUST"
Switch
Positions

Second Stage "HEAT" Speed
1

Second Stage "COOL"

Speed
4

cfm
1540

L/s
725

cfm
1750

L/s
825

cfm
1945

L/s
915

cfm
2170

L/s
1025

cfm
1635

L/s
770

cfm
1760

L/s
830

cfm
1995

L/s
940

cfm
2225

L/s
1050

NORM
i

1385
1230

655
580

1635
1390

770
655

1785
1585

845
750

1960
1760

925
830

1485
1310

700
620

1610
1415

760
665

1820
1620

860
765

2035
1815

960
855

"ADJUST"
Switch
Positions

cfm

L/s

+
NORM
i

1390
1255
1135

655
590
535

First Stage "HEAT" Speed
2
3
cfm
L/s
cfm
L/s
1595
1425
1265

750
675
600

1785
1615
1435

845
765
675

cfm

L/s

cfm

L/s

1955
1800
1610

925
850
760

1140
1030
925

540
485
435

First Stage "COOL" Speed
2
3
cfm
L/s
cfm
L/s
1215
1105
990

575
520
470

1370
1245
1125

645
585
530

cfm

L/s

1555
1400
1255

735
660
595

NOTES - The effect of static pressure included in air volumes shown.
First stage HEAT is approximately 91% of the same second stage HEAT speed position.
First stage COOL (two-stage air conditioning units only) is approximately 70% of the same second stage COOL speed position.
Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position - minimum 500 cfm (235 L/s).
Lennox Harmony Ill" Zone Control Applications - Minimum blower speed is 483 cfm (230 L/s).

TABLE 23
G60UHV-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.
Return Air Options: Side return air with optional RAB return air base.
Speed Switch Positions
"ADJUST"
Switch
Positions
+
NORM
i
"ADJUST"
Switch
Positions

Second Stage "HEAT" Speed
2
3

1
cfm
1490
1340
N/A

L/s
705
635
N/A
1

cfm
1680
1525
1350

L/s
790
720
635

cfm
1875
1715
1525

L/s
885
810
720

First Stage "HEAT" Speed
2
3
cfm
L/s
cfm
L/s

cfm

L/s

1375

650

1570

740

1765

NORM
--

1255
N/A

590
N/A

1425
1255

870
590

1570
1415

4
cfm
2085
1885
1700

Second Stage "COOL" Speed
2
3

1
L/s
985
890
805

cfm
1620
1470
1305

L/s
765
695
615
1

cfm
1735
1595
1400

L/s
820
750
660

cfm
1950
1780
1605

First Stage "COOL" Speed
2
3
cfm
L/s
cfm
L/s

cfm

L/s

cfm

L/s

830

1935

915

1017

480

1075

510

1375

740
665

1750
1880

825
885

1025
920

485
435

1100
990

520
470

1235
1000

N/A - First and second stage HEAT positions shown cannot be used on this model.
NOTES - The effect of static pressure is included in air volumes shown.
First stage HEAT is approximately 91% of the same second stage HEAT speed position.
First stage COOL (two-stage air conditioning units only) is approximately 70% of the same second stage COOL speed position.
Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position - minimum 500 cfm (235 L/s).
Lennox Harmony Ill ' Zone Control Applications - Minimum blower speed is 483 cfm (230 L!s).

Page 33

L/s
920
840
760

cfm
2185
1975
1785

L/s
1030
935
845
4

cfm

L/s

650

1540

725

585
470

1385
1110

855
525

TABLE 24
G60UHV-60D-135 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.
Return Air Options: Bottom; both sides; or bottom and one side.
Speed Switch Positions
"ADJUST"
Switch
Positions

Second Stage "HEAT" Speed
2
3

Second Stage "COOL" Speed
2
3

cfm

L/s

cfm

L/s

cfm

L/s

cfm

L/s

cfm

L/s

cfm

L/s

cfm

L/s

cfm

L/s

1470

695

1665

785

1855

875

2050

970

1575

745

1695

800

1900

900

2140

1010

NORM

1335

630

1520

715

1695

800

1870

885

1430

675

1540

725

1745

825

1945

920

N/A

1340

630

1510

710

1675

790

1275

600

1370

645

1565

740

1735

820

i
"ADJUST"
Switch
Positions

First Stage "HEAT" Speed
2
3
cfm
L/s
cfm
L/s

cfm

L/s

1345

635

1520

715

1710

NORM

1220

575

1375

650

N/A

1230

580

First Stage "COOL" Speed
2
3
cfm
L/s
cfm
L/s

cfm

L/s

cfm

L/s

805

1880

890

1100

520

1180

560

1330

1545

730

1725

815

1000

475

1075

510

1380

650

1535

725

900

425

670

455

4
cfm

L/s

625

1495

705

1205

570

1350

635

1095

515

1210

570

N/A - First and second stage HEAT positions shown cannot be used on this model.
NOTES - The effect of static pressure is included in air volumes shown.
First stage HEAT is approximately 91% of the same second stage HEAT speed position.
First stage COOL (two-stage air conditioning units only) is approximately 70% of the same second stage COOL speed position.
Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position - minimum 500 cfm (235 Us).
Lennox Harmony Ill ' Zone Control Applications - Minimum blower speed is 495 cfm (235 Us).

TABLE 25
G60UHV-60D-135
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.
Return Air Options: Single side return air - Bold volumes require field-fabricated
transition
to accommodate
20 x 25 x 1 in. 508 x 635 x 25 mm) cleanable air filter in order to maintain proper air velocity across the filter.
Speed Switch Positions
"ADJUST"
Switch
Positions

Second Stage "HEAT" Speed
2
3

Second Stage "COOL" Speed
2
3

cfm
1405

L/s
665

cfm
1600

L/s
755

cfm
1775

L/s
840

cfm
1965

L/s
925

cfm
1500

L/s
705

cfm
1620

L/s
765

cfm
1815

L/s
860

cfm
2040

L/s
965

NORM
i

N/A
N/A

1440
N/A

680
N/A

1635
1445

770
685

1800
1620

850
765

1360
1225

645
580

1470
1310

695
620

1660
1490

785
705

1860
1670

875
785

"ADJUST"
Switch
Positions

cfm

L/s

+
NORM
i

1285
N/A
N/A

605
N/A
N/A

First Stage "HEAT" Speed
2
3
cfm
L/s
cfm
L/s
1450
1325
N/A

685
625
N/A

1635
1485
1325

770
700
625

cfm

L/s

cfm

L/s

1800
1660
1460

850
785
690

1075
955
870

505
450
410

First Stage "COOL" Speed
2
3
cfm
L/s
cfm
L/s
1150
1040
930

545
490
440

1275
1165
1065

N/A - First and second stage HEAT positions shown cannot be used on this model.
NOTES - The effect of static pressure is included in air volumes shown.
First stage HEAT is approximately 91% of the same second stage HEAT speed position.
First stage COOL (two-stage air conditioning units only) is approximately 70% of the same second stage COOL speed position.
Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position - minimum 500 cfm (235 Us).
Lennox Harmony Ill" Zone Control Applications - Minimum blower speed is 495 cfm (235 Us).

Page 34

605
550
500

4
cfm

L/s

1425
1300
1175

675
615
555

TABLE 26
G60UHV-60D-135 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.
Return Air Options: Side return air with optional RAB return air base.
Speed Switch Positions
"ADJUST"
Switch
Positions
+
NORM
-"ADJUST"
Switch
Positions

Second Stage "HEAT" Speed
2
3

Second Stage "COOL" Speed
2
3

cfm

L/s

cfm

L/s

cfm

L/s

cfm

L/s

cfm

L/s

cfm

L/s

cfm

L/s

cfm

L/s

1425
N/A
N/A

675
N/A
N/A

1615
1455
N/A

760
690
N/A

1795
1640
1455

845
775
685

1975
1805
1630

930
850
770

1505
1370
1225

710
650
580

1620
1470
1320

765
695
625

1815
1670
1500

855
790
705

2035
1850
1670

960
875
790

First Stage "HEAT" Speed
2
3
cfm
L/s
cfm
L/s

1
cfm

L/s

1305

615

1470

695

1655

NORM
--

N/A
N/A

1345
N/A

635
N/A

1505
1340

First Stage "COOL" Speed
2
3
cfm
L/s
cfm
L/s

cfm

L/s

cfm

L/s

780

1825

860

1075

510

1155

545

1295

710
635

1670
1475

790
695

980
875

465
415

1050
935

495
440

1175
1070

4
cfm

L/s

610

1445

680

555
505

1305
1180

615
555

N/A - First and second stage HEAT positions shown cannot be used on this model.
NOTES - The effect of static pressure is included in air volumes shown.
First stage HEAT is approximately 91% of the same second stage HEAT speed position.
First stage COOL (two-stage air conditioning units only) is approximately 70% of the same second stage COOL speed position.
Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position - minimum 500 cfm (235 L/s).
Lennox Harmony Ill ' Zone Control Applications - Minimum blower speed is 495 cfm (235 L/s).

G60UHV,
OPERATING
SEQUENCE

Thermostat

with

NO CALL

S¥S tEM DEMAND

•
.
Thermostat

Condition
System

TABLE 27
OPERATING
SEQUENCE
Humidity Control Feature and Single-Speed

Y1
Step

O
I

Demand

III
G

W
1

Relative

Outdoor

Unit

S¥S t EM RESPONSE

Humidity

.......

Compressor

Blower
CFM
(COOL)

Comments

Compressor and indoor
blower follow thermostat
demand

Status

Acceptable

24
VAC

High

lOO%

FOR DEHUMIDIFICATION

Normal Operation

BASIC MODE (only active on a Y1 thermostat demand)
Normal Operation

Dehumidification
Call

PRECISION

MODE

(operates

Acceptable

24
VAC

High

lOO%

Demand

0
VAC

High

70%

ind_ oendent

of a Y1 thermostat

SignatureStat T" thermostat energizes Y1 and deenergizes D on a call for
de-humidification

demand)

Normal Operation

Acceptable

24
VAC

High

100%

Dehumidification
call

Demand

0
VAC

High

70%

Dehumidification
call ONLY

Demand

0
VAC

High

70%

Jumpers at indoor unit with a single stage outdoor unit
With Condensing unit - Cut W914 (R to DS) on SureLight board
With Heat Pump - Cut W914 (R to DS) & W951 (R to O) on SureLight board

Dehumidification mode
begins when humidity is
greater than set point
SignatureStat
T`' thermostat will try to maintain
room humidity setpoint by
allowing the room space
to maintain a temperature
that is cooler than the
room thermostat

setpoint*

Thermostat used: 51M26 -- 1 heat/1 cool or 51M28 -- 2 heat/2 cool for heat pumps
*In Precision mode, SignatureStat "thermostat will allow room temperature up to 2 °F (1.2°C) cooler than room temperature
setting in order to meet humidity control demand.

Page 35

TABLE 28
OPERATING SEQUENCE
G60UHV, Thermostat with Humidity Control Feature and Two-Speed Outdoor Unit
_-I
SYS EM DEMAND

SEQUENCE

OPERATING
Thermostat
System

Ste

Condition

Demand

Relative Humidity

ww
1

T
S¥S EM RESPONSE

Status

Compressor

Blower
CFM

.......

Comments

(COOL)

NO CALL FOR DEHUMIDIFICATION
Normal Operation Y1

Normal Operation Y2

ROOM THERMOSTAT

Acceptable

24
VAC

Low

Acceptable

24
VAC

High

70%
100%

Compressor and indoor
blower follow thermostat
demand

CALLS FOR FIRST STAGE COl)LING

BASIC MODE (only active on a Y1 thermostat demand)
Normal Operation

Dehumidification
Call

Acceptable

24
VAC

Low

70%

Demand

0
VAC

High

70%

PRECISION MODE (operates independent
Normal Operation

Dehumidification
call

Dehumidification
call ONLY

SignatureStat T" thermostat energizes Y2 and deenergizes D on a call for
de-humidification

of a Y1 thermostat demand)

Acceptable

24
VAC

Low

70%

Demand

0
VAC

High

70%

Dehumidification mode
begins when humidity is
greater than set point

70%

SignatureStat
T_ thermostat will try to maintain
room humidity setpoint by
allowing the room space

Demand

0
VAC

High

to maintain a temperature
that is cooler than the
room

ROOM THERMOSTAT

thermostat

setpoint*

CALLS FOR FIRST AND SECOND STAGE COOLING

BASIC MODE (only active on a Y1 thermostat demand)
Normal Operation

Acceptable

Dehumidification
Call

Demand

PRECISION MODE (operates independent
Normal Operation

Dehumidification
call

Dehumidification
call ONLY

24
VAC

High

10o%

0
VAC

High

7o%

SignatureStat T" thermostat energizes Y2 and deenergizes D on a call for
de-humidification

of a Y1 thermostat demand)

Acceptable

24
VAC

Low

70%

Demand

0
VAC

High

70%

Demand

0
VAC

High

70%

Jumpers at indoor unit with a two stage outdoor unit
Cut factory jumper from Y1 to Y2 or cut W915 (Y1 to Y2)
With Condensing unit - Cut W914 (R to DS) on SureLight board
With Heat Pump - Cut W914 (R to DS) & W951 (R to O) on SureLight board

Dehumidification mode
begins when humidity is
greater than set point
SignatureStat
T_ thermostat will try to maintain
room humidity setpoint by
allowing the room space
to maintain a temperature
that is cooler than the
room

thermostat

setpoint*

Thermostat used: 51M27 -- 2 heat/2 cool or 51M28 -- 2 heat/2 cool for heat pumps
*In Precision mode, SignatureStat "thermostat will allow room temperature up to 2 °F (1.2°C) coolerthan room temperature
setting in order to meet humidity control demand.

Page 36

4 - This furnace is equipped with an ignition device which
automatically lights the burners. Do not try to light the
burners by hand.

FOR YOUR SAFETY READ BEFORE LIGHTING

5 - Remove the upper access panel.
6 - White Rodgers 36E Gas Valve - Switch gas valve lever to OFF. See figure 26.
Honeywell VR8205 Gas Valve - Turn knob on gas
valve clockwise _
to OFF. Do not force. See figure
27.

AWARNING

7 - Wait five minutes to clear out any gas. If you then smell
gas, STOP! Immediately call your gas supplier from a
neighbor's phone. Follow the gas supplier's instructions. If you do not smell gas go to next step.

AWARNING

WHITE RODGERS 36E SERIES GAS VALVE
HIGH FIRE
MANIFOLD
PRESSURE
ADJUSTMENT
ON SIDE
(under cap)

ACAUTION
MANIFOLD
TAP ON SIDE

BEFORE LIGHTING smell all around the appliance area for
gas, Be sure to smell next to the floor because some gas is
heavier than air and will settle on the floor.

INLET PRESSURE
TAP ON SIDE

GAS VALVE SHOWN IN OFF POSITION

FIGURE 26

The gas valve on the G60UHV(X) unit may be equipped
with either a gas control knob or gas control lever. Use only
your hand to push the lever or to turn the gas control knob.
Never use tools, If the knob will not tum or if the lever will not

HONEYWELL VR8205 SERIES GAS VALVE
HIGH FIRE
ADJUSTING SCREW
(under cap)

move by hand, do not try to repair it. Call a qualified service
technician. Force or attempted repair may result in a fire or
explosion.
Placing the furnace

LOW FIRE MANIFOLD
PRESSURE ADJUSTMENT
ON SIDE (under cap)

MANIFOLD
PRESSURE
TAP

into operation:

G60UHV(X) units are equipped with an automatic ignition
system. Do not attempt to manually light burners on these
furnaces, Each time the thermostat calls for heat, the
burners will automatically light, The ignitor does not get
hot when there is no call for heat on units with an automatic

LOW FIRE
(under cap)
INLET PRESSI

_E TAP

GAS VALVE SHOWN IN OFF POSITION

ignition system,

FIGURE 27

AWARNING

8 - White Rodgers 36E Gas Valve - Switch gas valve lever
to ON. See figure 26,
Honeywell VR8205 Gas Valve - Turn knob on gas
valve counterclockwise 41_ to ON. Do not force, See
figure 27,

Gas Valve Operation (Figures 26 and 27)

9 - Replace the upper access panel,

1 - STOP! Read the safety information at the beginning of
this section.

10- Turn on all electrical power to to the unit,

2 - Set the thermostat to the lowest setting,

NOTE - When unit is initially started, steps 1 through 11
may need to be repeated to purge air from gas line,

3 - Turn off all electrical power to the unit,

11- Set the thermostat to desired setting,

Page 37

12- Iftheappliance
willnotoperate,
followtheinstructions
"TurningOffGastoUnit"andcallyourservicetechnicianor gas supplier.

NOTE - In Canada, certification for installations at elevations over 4500 feet (1372 m) is the jurisdiction of local authorities.

Turning Off Gas to Unit

NOTE - A natural to L.P. propane gas changeover kit is necessary to convert this unit. Refer to the changeover kit
installation instruction for the conversion procedure.

1 - Set the thermostat to the lowest setting,
2 - Turn off all electrical power to the unit if service is to be
performed,
3 - Remove the upper access panel.
4 - White Rodgers 36E Gas Valve- Switch gas valve leverto OFF.
Honeywell VR8205 Gas Valve - Turn knob on gas
valve clockwise _ll to OFF, Do not force,
5 - Replace the upper access panel,

Primary and Secondary

The primary limit is located on the heating compartment
vestibule panel. The secondary limits (if equipped) are located in the blower compartment, attached to the back side
of the blower, These limits are factory set and require no
adjustment.
Flame Rollout Switches

Gas Flow
To check for proper gas flow to the combustion chamber,
determine the Btu (kW) input from the unit nameplate, Divide this input rating by the Btu (kW) per cubic foot (cubic
meter) of available gas, The result is the required number
of cubic feet (cubic meter) per hour. Determine the flow of
gas through the gas meter for two minutes and multiply by
30 to get the hourly flow of gas,
Gas Pressure
1 - Check the gas line pressure with the unit firing at maximum rate, A minimum of 4,5 in, w,c, for natural gas or
11,0 in, w,c, for LP/propane gas should be maintained,
2-

After the line pressure has been checked and adjusted, check the low fire and high fire manifold pressures, See figures 26 and 27 for the location of the
manifold pressure adjustment screws. Low and high
fire manifold pressures are given in table 29, A natural
gas to LP/propane gas changeover kit is required to
convert the unit,

Limits

(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 combustion air inducer. These switches check for proper combustion air inducer operation before allowing ignition trial,
The switches are factory-set and require no adjustment,
Temperature Rise
Place the unit into operation with a second-stage heating
demand. After supply and return air temperatures have
stabilized, check the temperature rise. If necessary, adjust
the heating blower speed to maintain the temperature rise
within the range shown on the unit nameplate, Increase the
blower speed to decrease the temperature rise, Decrease
the blower speed to increase the temperature rise. Failure
to properly adjust the temperature rise may cause erratic
limit operation,

Thermostat Heat Anticipation
Set the heat anticipator setting (if adjustable) according to
Refer to table 29 for high altitude requirements and manthe amp draw listed on the wiring diagram that is attached
to the unit,
ifold pressure settings at all altitudes.
TABLE 29
High Altitude

Requirements / Manifold Pressure Settings
Altitude

Model
Input
Size

-070

-090

0 - 4500 ft.
(0 - 1372 m)

Gas

Required
Conversion
Kit

Pressure
Switch

Nat.

N/A

LPG

59M13"

Nat,
LPG

4,501 - 7500 ft.
(1373 - 2286 m)
Required
Conversion
Kit

Pressure
Switch

No Change

N/A

No Change

59M13"

N/A

No Change

59M13"

No Change

Manifold Pressure
at all altitudes

7501-10,000 ft.
(2286 - 3048 m)
Required
Conversion
Kit

Pressure
Switch

No Change

59M16

No Change

59M14"

N/A

18M61

59M13"

18M61

Low Fire

High Fire
in. w.g.

kPa

0.42

3.5

0.87

1.22

10.0

2.5

1.7

0.42

3.5

0.87

4.9

1.22

10.0

2.5

in. w.g.

kPa

18M64

1.7

18M64

4.9

59M16

18M64

59M14"

18M64

-110

Nat.

N/A

No Change

N/A

18M63

59M16

18M61

1.7

0.42

3.5

0.87

-135

LPG

59M13"

No Change

59M13"

18M63

59M14"

18M61

4.9

1.22

10.0

2.5

Pressure switch is factory set. No adjustment necessary. All models use the factory installed pressure switch from 0-4500 feet (0-1370 m).
*LPG/Propane conversion kit includes LP regulator.

Page 38

Electrical
1 - Checkallwiringforlooseconnections.
2 - Checkforthecorrectvoltageat thefurnace(furnace
operating).
3 - Checkamp-draw
ontheblowermotor.
MotorNameplate
Actual
NOTE - Do not secure the electrical conduit directly to the
air ducts or structure.
Electronic

Ignition

The two-stage, variable speed integrated control used in
G60UHV units has an added feature of an internal Watchguard control, The feature serves as an automatic reset device for ignition control lockout caused by ignition failure.
This type of lockout is usually due to low gas line pressure,
After one hour of continuous thermostat demand for heat,
the Watchguard will break and remake thermostat demand
to the furnace and automatically reset the control to begin
the ignition sequence,
Flue And Chimney
1 - Check flue pipe, chimney and all connections for tightness and to make sure there is no blockage,
2 - Check unit for proper draft.
3 - Is pressure switch closed? Obstructed flue will cause
unit to shut off at pressure switch. Check flue and outlet
for blockages.
4 - Reset manual flame rollout switches on burner box,
Failure To Operate
If the unit fails to operate, check the following:
1 - Is the thermostat calling for heat?
2 - Are access panels securely in place?
3 - Is the main disconnect switch closed?
4 - Is there a blown fuse or tripped circuit breaker?
5 - Is the filter dirty or plugged? Dirty or plugged filters will
cause the limit control to shut the unit off.
6 - Is gas turned on at the meter?
7 - Is the manual main shut-off valve open?
8 - Is the internal manual shut-off valve open?
9 - Is the unit ignition system in lock out? If the unit locks out
again, call the service technician to inspect the unit for
blockages.

NOTE - The control board thermostat selection DIP switch is
factory-set in the "TWO-STAGE" position.
Applications
Using a Two-Stage Thermostat
A - Heating Sequence -- Control Board 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 integrated 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 energized at low speed and the 120 VAC humidifier terminal is energized.

2 - Once the control receives a signal that the low pressure switch has closed, the combustion air inducer begins a 15-second pre-purge in low speed.
3 - After the pre-purge is complete, a 20-second initial ignitor warm-up period begins. The combustion air inducer 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 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 and the 24V humidifier terminal is energized. The furnace will continue this operation as long as the thermostat has a
first-stage heating demand,
5 - If second-stage heat is required, the thermostat second-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 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.
7 - When the demand for high fire (second stage) heat is
satisfied, thecombustion 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 complete, the inducer and humidifier terminals are de-energized. The indoor blower is de-energized at the end
of the off delay,
Applications
Using A Single-Stage Thermostat
B - Heating Sequence -- Control Board Thermostat
Selection DIP Switch in "Single-Stage"
Position
NOTE - In these applications, two-stage heat will be initiated 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 integrated 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 energized at low speed and the 120 VAC humidifier terminal is energized,
2 - Once the control receives a signal that the low pressure switch has closed, the combustion air inducer begins a 15-second pre-purge in low speed,
3 - After the pre-purge is complete, a 20-second initial ignitor warm-up period begins. The combustion air inducer continues to operate at low speed.

Page 39

4 - Afterthe20-second
warm-up
periodhasended,thegas
valveisenergized
onlowfire(firststage)andignition
occurs.Atthesametime,thecontrolmodulesendsa signalto beginan indoorblower45-secondON-delay.
Whenthedelayends,theindoorblowermotorisenergizedonthelowfire heatingspeedandthe24Vhumidifierterminalis energized.
Theintegrated
control
alsoinitiatesa second-stage
ondelay(factory-set
at
10minutes;adjustable
to 15minutes).
5 - Iftheheatingdemandcontinuesbeyondthesecondstageon delay,the integratedcontrolenergizesthe
combustion
airinducerathighspeed.Thecontrolalso
checksthehighfire(secondstage)pressure
switchto
makesureit isclosed.The
highfire(second
stage)gas
valveis energized
andtheindoorblowermotoris energizedforoperation
atthehighfire heatingspeed.
6 - Whenthethermostat
heatingdemandissatisfied,
thecombustion
airinducerbeginsa 5-second
lowspeed
post-purge.Thefield-selected
indoorbloweroffdelay
begins.The indoorbloweroperatesat the low-fire
heatingspeed.
7 - Whenthecombustion
air post-purge
periodis complete,theinducerandhumidifier
terminalsarede-energized.Theindoorbloweris de-energized
attheend
oftheoffdelay.

Flue And Chimney
Check the flue pipe, chimney and all connections for tightness and to make sure there is no blockage,
Electrical
1 - Check all wiring for loose connections.
2 - Check for the correct voltage at the furnace (furnace
operating),
3 - Check amp-draw on the blower motor.
Motor Nameplate
Actual
Cleaning

the Heat Exchanger

and Burners

NOTE - Use papers or protective covering in front of the furnace 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 diameter wire brush, These items are available at a hardware

store. Insert wire end of brush into the open end of the
spring cable. Crimp the cable around the brush so that the
brush is secured and will not come off during cleaning, Attach the other end of the cable to the reversible drill to com..............................................................................................................................................................................
plete the tool for cleaning the heat exchanger.
1 - Turn off both electrical and gas power supplies to furnace.
2 - Remove flue pipe and top cap from 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 inducer to
avoid damaging blower gasket. If gasket is damaged, it
must be replaced to prevent leakage. See figure 1.
4 - Remove the collector box located behind the combus-

AWARNING
ACAUTION

At the beginning of each heating season, a qualified technician should check the system as follows:
Blower
Check the blower wheel for debris and clean if necessary.
The blower motors are prelubricated for extended bearing
life. No further lubrication is needed.

AWARNING

Filters
All G60UHV(X) filters are installed external to the unit. Filters should be inspected monthly, Clean or replace the filters when necessary to ensure that the furnace operates
properly. Replacement filters must be rated for high velocity airflow, Table 1 lists recommended filter sizes,

tion air inducer. Be careful with the collector box gasket. If the gasket is damaged, it must be replaced to
prevent leakage.
5 - Label the wires from gas valve and rollout switches,
then disconnect them.
6 - Remove the four screws securing the burner box cover
and remove the cover.
7 - Disconnect gas supply piping. Remove six screws securing the burner box / manifold assembly to the vestibule panel and remove the assembly from the unit.
Take care not to damage the gasket.
8 - NOx units only - Remove the three screws that attach
the NOx insert to the corbel at the entrance to each
heat exchanger section. Carefully remove the NOx insert from each section. See figure 29.
9 - Insert the brush end of cable snake into the top of one
of the heat exchanger openings, Do not force the
cable into the heat exchanger. Insert the cable and
operate the drill on slow speed, Move the cable in and
out of the heat exchanger section three or four times or
until sufficient cleaning is accomplished. Reverse drill
and slowly work the cable out of opening,

Page 40

G60UHV(X)

BURNER & HEAT EXCHANGER

12- Remove the cable from the heat exchanger. Use a vacuum cleaner to remove debris knocked loose during
cleaning.
13- Attach the exhaust end (positive pressure) of the vacuum cleaner to the top of the heat exchanger section.
Any loose debris will be forced to the bottom of the heat
exchanger section. Vacuum debris from bottom openings.

REMOVAL

HEATEXCHANGER

14- Replace collector box and combustion air inducer.
Check gaskets for damage. Damaged gaskets must be
replaced to avoid heat exchanger leaks. Replace all
screws to the collector box and combustion air inducer.
Failure to replace all screws may cause leaks.

GASKET

15- To clean the burner, run a vacuum cleaner with a soft
brush attachment over the face of burners. Visually inspect 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 corbels at the entrance to each heat exchanger opening.
See figure 29.

BOX
ASSEMBLY
GAS VALVE
ASSEMBLY

17- Re-install gasket and burner box / manifold assembly
onto the vestibule panel. Replace burner box cover
and re-secure using screws.
NOTE - Gasket must be replaced if it was damaged
during disassembly.

FIGURE 28
NOxlNSERTS
(X modelsonly)

18- Reconnect wires to pressure switch, roll-out switches,
gas valve and combustion air inducer. Refer to unit wiring diagram.
19- Re-install top cap and re-secure vent pipe to combustion air inducer outlet.
20- Reconnect gas supply piping.

21- Turn on power and gas supply to unit.
22- Set thermostat and check for proper operation.
23- Check all piping connections, factory and field, for gas
leaks. Use a leak detecting solution or other preferred
means,

CAUTION

FIGURE 29
10- Repeat procedure for each heat exchanger section.
11- After each of the top heat exchanger sections has been
cleaned, insert the brush end of the cable snake into
the bottom openings of each of the heat exchanger
sections and clean as described in step 8.

24- Ira leak is detected,
repair leak.

shut gas and electricity

offand

25- Repeat steps 23 and 24 until no leaks are detected.
26- Replace front access panel.

Page 41

Thefollowingrepairpartsareavailablethroughindependent
Lennoxdealers.Whenorderingparts,includethecomplete
furnacemodelnumberlistedontheCSAInternational
nameplate
-- Example:
G60UHV(X)-36A-070-7.
CabinetParts
HeatingParts
Upperaccesspanel
FlameSensor
Blowerpanel
Heatexchanger
assembly
Topcap
Gasmanifold
ControlPanelParts
Two-speed
combustion
airinducer
Transformer
Two-stage
gasvalve
Two-stage,
variablespeedintegrated
controlboard
Mainburnercluster
Doorinterlockswitch
Mainburnerorifices
Circuitbreaker
Pressure
switch
BlowerParts
Ignitor
Blowerwheel
Primarylimitcontrol
Flamerolloutswitch
Blowerhousing
Motor
Secondary
limit
Motorelectronics
Powerchoke(1hponly)
Motormountingframe
Motorcapacitor
Blowerhousingcutoffplate

Page42

FLASH

CODE

(x. Y)

STATUS

FLASH

/ ERROR

DESCRIPTION

CODE DESCRIPTIONS

Pulse

A 114 second flash followed by four seconds of off time.

Heartbeat

Constant 1/2 second bright and 1/2 second dim cycles.

X+Y

LED flashes X times at 2Hz, remains off for two seconds, flashes Y times at 2Hz, remains off for four
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 present.

PRESSURE

SWITCH

CODES

2+3

Low pressure switch failed open.

2+4

Low pressure switch failed closed.

2+5

High pressure switch failed open.

2+6

High pressure switch failed closed.

2+7

Low pressure switch opened during ignition trial or heating demand.

LIMIT CODE
3+1

Limit switch open.

WATCHGUARD

CODES

4+1

Watchguard -- Exceeded maximum number of retries.

4+2

Watchguard -- Exceeded maximum number of retries or last retry was due to pressure switch opening.

4+3

Watchguard -- Exceeded maximum number of retries or last retry was due to flame failure.

4+5

Watchguard -- Limit remained open longer than three minutes.

4+6

Watchguard -- Flame sensed out of sequence; flame signal gone.

4+7

Ignitor circuit fault -- Failed ignitor or triggering circuitry.

4+8

Low line voltage.

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 restart if error recovers).

5+4

Reversed line voltage polarity (control will restart if the error recovers).

5+6

Low secondary (24VAC) voltage.

Page 43

HEATING SEQUENCE OF OPERATION
NORMAL AND ABNORMAL HEATING MODE
I

POWER ON

CONTROL SELF-CHECK

POLARITY

OKAY?

STATUS ERROR CODE 5 + 4,
POLARITY REVERSED,

I._

YES
IS THERE A
PROPER GROUND?

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.
INDOOR BLOWER OFF. (RESET CONTROL BY
TURNING MAIN POWER OFF.)

OKAY?

.__.1

STATUS
5 + 3. GROUNDED.
SIGNAL HOLDS
UNTIL ERROR
UNIT ISCODE
PROPERLY

YES

_
A
NORMAL OPERATION:
STATUS LED -- PULSE

COMBUSTION AIR INDUCER OFF.
INDOOR BLOWER ON. HAS PRIMARY OR
SECONDARY LIMIT RESET WITHIN 3 MINUTES?
STATUS ERROR CODE 3 + 1.

I y_:.q

B
THERMOSTAT CALLS FOR HEAT:
STATUS LED -- HEARTBEAT

YES
PRIMARY AND SECONDARY

60-MINUTE LIMIT WATCHGUARD MODE.
GAS VALVE OFF, COMBUSTION AIR INDUCER
OFF, INDOOR BLOWER OFF WITH DELAY.

LIMIT

STATUS ERROR CODE 4 + 5.
SWITCHESyEs
_LOSED?

ROLLOUT SWITCH CLOSED?
YES

YES

I
r
I
L

FIRST (LOW) STAGE PRESSURE
CONTACTS OPEN?

SECOND

SWITCH

(HIGH)coNTACTS
YES
STAGE_ PRESSURE
OPEN?

TWO-STAGE

[.NO

GAS VALVE OFF. COMBUSTION AIR INDUCER OFR
INDOOR BLOWER OFR CONTROL REMAINS UNTIL
PRESSURE SWITCH IS DETECTED OPEN.
STATUS ERROR CODE 2 + 4
SWITCH

OR SINGLE-STAGE
THERMOSTAT
CALL FOR HEAT

I_
I
i._..._
1

STATUS LED -- HEARTBEAT

GAS VALVE OFR 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,

CONTINUED ON NEXT PAGE

GAS VALVE OFR
COMBUSTION AIR INDUCER OFF.
INDOOR BLOWER OFR
CONTROL WILL NOT ATTEMPT SECOND-STAGE
OPERATION DURING THIS HEAT DEMAND.
FIRST-STAGE OPERATION WILL BE ATTEMPTED.
STATUS ERROR CODE 2 + 6.

Page 44

YES

HEATING SEQUENCE OF OPERATION
CONTINUED

THERMOSTAT CALLS FOR HEAT
STATUS LED - HEARTBEAT.
(Refer to box A on previous page)
NO

GAS VALVE OFR COMBUSTION AIR INDUCER
OFF. INDOOR BLOWER OFF. UNIT WILL RETRY
AFTER 5-MINUTE WAIT PERIOD,
STATUS ERROR CODE 2 + 3.

FIRST-STAGE
(LOW
F,RE)PRESSURE
I

SWITCH CLOSED WITHIN 2.5 MINUTES?
YES

_
m

15-SECOND COMBUSTION AIR INDUCER
PRE-PURGE INITIATED BY CLOSED FIRST-STAGE
PRESSURE SWITCH (or 15 SECOND
INTER-PURGE PERIOD.)
STATUS LED -- HEARTBEAT.

[

IGNITOR
STATUS
WARM-UP
LED -- HEARTBEAT.
I_0
SECONDStJ
YES

NO
is IGNITOR INTACT AND CONNECTED?

SIGNAL HOLDS UNTIL IGNITOR IS REPLACED
COMBUSTION OR
AIRRECONNECTED,
INDUCER OFF, IGNITOR OFF.
STATUS ERROR CODE 4 + 7.

YES

PERIOD, 4-SECOND TRIAL FOR IGNITION.
I
GAS VALVE OPENS, IGNITOR ENERGIZED DURING
I
AT END OF IGNITOR 20 SECOND WARM UP
I
4-SECOND TR AL UNT L FLAME SENSED,

---4

IS VOLTAGE ABOVE 90 VOLTS?

.o_

YES
I

4-SECOND

FLAME STABILIZATION

PERIOD.

COMBUSTION AIR INDUCER OFF, IGNITER OFF.
SIGNAL HOLDS UNTIL VOLTAGE RISES ABOVE 95
VOLTS, STATUS ERROR CODE 4 + 8.

CAN FLAME BE PROVEN WITHIN 4
SECONDS AFTER GAS VALVE OPENS?
FLAME RECTIFICATION CURRENT CHECK
( > 0.20 microamps)

GAS VALVE OFF. COMBUSTION AIR
INDUCER ON. INDOOR BLOWER OFF.
STATUS LED -- HEARTBEAT.
HAS CONTROL FAILED TO SENSE
FLAME FOR FIVE CONSECUTIVE TRIES
DURING A SINGLE HEAT DEMAND?

YES lr
WATCHGUARD MODE. GAS VALVE OFF,
COMBUSTION AIR INDUCER OFR
INDOOR BLOWER OFF.
STATUS ERROR CODE 4 + 1.
IS 60-MINUTE RESET PERIOD COMPLETE?

YES

YES _

HAS CONTROL
FLAMEyES
PRESENT?_

[

CONTINUED ON NEXT PAGE

RESET IGNITION SEQUENCE
FOUR (4) TIMES?
WATCHGUARD MODE,
STATUS ERROR CODE 4 + 3.

IN--_-_°
J

Page 45

HEATING SEQUENCE OF OPERATION
CONTINUED

THERMOSTAT CALLS FOR HEAT.
STATUS LED -- HEARTBEAT
SEE BOX A.

FLAME SIGNAL ABOVE
( > 1.40 microamps)

LOW FLAME SIGNAL
(Does not affect control operation)
STATUS ERROR CODE 1 + 2.

YES
I SINGLE-STAGE THERMOSTAT MODE
'L
(DiP SWITCH SET AT 'SINGLE")

I
I'

I TWO STAGE THERMOSTAT MODE
I.
(DIP SWITCH SET AT "TWO")

YES _
I

ROLLOUT

SWITCHES

CLOSED?

PRESSURE
FIRST-STAGE
SWITCH
(LOWCLOSED?
FIRE)

YES _l
FIRST-STAGE

GAS VALVE OFF. COMBUSTION AIR INDUCER ON.
INDOOR BLOWER ON.
STATUS ERROR CODE 5 + 1. SEQUENCE HOLDS
UNTIL
PRIMARY
ROLLOUT
& SECONDARY
SWITCH IS LIMIT
RESET
SWITCHES
AND MAIN
POWER IS INTERRUPTED OR THERMOSTAT
IS CYCLED OFF/ON FOR 3 SECOND MINIMUM.

45-SECOND STATUS
INDOORLED
BLOWER
ON DELAY BEGINS.
-- HEARTBEAT.
YES _

YES
I

I_
j

YES _

START SECOND-STAGE RECOGNITION
ON DELAY (10 OR 15 MINUTES).
STATUS LED -- HEARTBEAT

_ NO

HEAT DEMAND SATISFIED?

INDOOR BLOWER ON.
I GAS VALVE STATUS
OFF, COMBUSTION
AIR3 INDUCER
OFF,
ERROR CODE
+ 1.

YES _

GAS VALVE OFF, COMBUSTION AIR INDUCER
OFF FOLLOWING POST PURGE.
INDOOR BLOWER OFF WITH DELAY
STATUS LED -- PULSE

ABNORMAL FLASH CODE.
NOTE - IF SECOND-STAGE PRESSURE SWITCH
SECOND
WASSTAGE
ORIGINALLY
PRESSURE
FOUND
SWITCH
CLOSED,
CLOSED?
ABNORMAL CODE WILL FLASH.
NO _I

YES _

SECOND-STAGE
30-SECOND
DELAY ON BEGINSJ
STATUS
LED -- HEARTBEAT.
YES _
SECOND-STAGE COMBUSTION AIR INDUCER
ON. SECOND-STAGE GAS VALVE ON. HIGH
HEAT INDOOR BLOWER SPEED ON.
STATUS LED -- HEARTBEAT.

YES
SECOND-STAGE

PRESSURE

SWITCH CLOSED

IN LESS THAN TEN (10) SECONDS?
STATUS LED -- HEARTBEAT
YES _

CONTINUED ON NEXT PAGE

SWITCH CLOSED WITHIN 3 MINUTES?
PRIMARY
SECONDARY
LIMITperiod
(IndoorHAS
blower
on low OR
speed
during 3-minute

NO1,

SECOND-STAGE
HEAT DEMAND
REQUIRED?
SECOND-STAGE
HEAT DEMAND.
YES _

GAS VALVE OFF, COMBUSTION AIR INDUCER OFF,
INDOOR BLOWER OFF WITH DELAY
LY..ES_
LIMITSTATUS
SWITCH ERROR
WATCHGUARD
I
CODE 4 +MODE.
5
IS 60-MINUTE RESET PERIOD COMPLETE?
|
GAS VALVE OFF. COMBUSTION AIR INDUCER ON.
INDOOR BLOWER OFF AFTER DELAY.
STATUS ERROR CODE 2 + 3. CONTROL RESTARTS
IGNITION SEQUENCE IF PRESSURE SWITCH
CLOSES WITHIN 2-1/2 MINUTES.

YES

SECOND-STAGE PRESSURE SWITCH CLOSED
AT BEGINNING OF HEAT DEMAND?
STATUS ERROR CODE 2 + 6.

._.o

SECOND STAGE HEAT DEMAND
STATUS LED -- HEARTBEAT.

No f
RETURNS TO FIRST-STAGE HEAT MODE WHICH
CONTINUES UNTIL SECOND-STAGE PRESSURE
SWITCH CAN BE PROVEN or HEAT DEMAND IS
SATISFIED. FIVE (5) MINUTE WAIT PERIOD
INITIATED BEFORE RETRY. WERE 5 ATTEMPTS
MADE FOR SECOND-STAGE HEAT?
YES _
CONTINUES FIRST-STAGE HEATING DEMAND.
WILL NOT REATTEMPT SECOND-STAGE
HEATING DEMAND,
STATUS ERROR CODE 2 + 5.

Page 46

HEATING SEQUENCE OF OPERATION
CONTINUED

SEE BOX A
NORMAL OPERATION.

SEE BOX B
THERMOSTAT CALLS FOR HEAT.

RETURN TO FIRST-STAGE HEAT MODE.
FIRST-STAGE CONTINUES UNTIL SECONDSTAGE PRESSURE SWITCH CAN BE PROVEN

SECOND-STAGE
(HIGH CLOSED?
FIRE) HEAT
PRESSURE SWITCH

or HEAT DEMAND IS SATISFIED. A FIVE (5)
MINUTE WAIT PERIOD IS INITIATED BEFORE
RETRY. WERE 5 ATTEMPTS MADE FOR

NO
YES _
I

HEAT DEMAND
SATISFIED?
STATUS
LED -- HEARTBEAT.

[

SINGLE-STAGE THERMOSTAT MODE
(DiP SWITCH SET AT "SINGLE")

YES
I

YES

SECOND-STaGE
HEAT?
NO ,_
SEE BOX C
FIRST-STAGE HEAT DEMAND SATISFIED?

YES 1
1
I
1

I '
I
I.

TWO STAGE THERMOSTAT MODE?
(DIP SWITCH SET AT "TWO")

3,
I
J

YES'f

GAS VALVE OFF, COMBUSTION
AIR
INDUCER OFF AFTER 5-SECOND
LOW SPEED POST PURGE PERIOD,
INDOOR BLOWER OFF DELAY
INITIATED ON LOW HEAT SPEED,
STATUS LED - HEARTBEAT.

DEMAND SATISFIED SIMULTANEOUSLY.
STATUS LED -- HEARTBEAT.
FIRST AND SECOND STAGE HEAT

STATUS LED -- HEARTBEAT.
SECOND STAGE HEAT
DEMAND SASTISFIED?
YES _

AND INDOOR BLOWER RETURN TO FIRSTSTAGE OPERATION.
GAS VALVE, COMBUSTION AIR INDUCER
STATUS LED -- HEARTBEAT.

FIRST STAGE HEAT DEMAND SATISFIED?
YES

DEMAND FOR HEAT SATISFIED.
POWER ON STAND BY.
STATUS LED -- PULSE.

OFF AFTER 5-SECOND LOW SPEED POSTPURGE PERIOD. INDOOR BLOWER OFF.
GAS VALVE OFF. COMBUSTION AIR INDUCER
DELAY INITIATED ON LOW HEAT SPEED,
STATUS LED -- PULSE,

Page 47

COOLING
SEQUENCE
OF OPERATION
I

POWER ON

4,
IS POLARITY

SIGNAL POLARITY REVERSED.
CONTROL WILL CONTINUE TO CALL FOR COOLING
IN THIS CONDITION,
STATUS ERROR CODE 5 + 4.

REVERSED?

I PROPER
IS THERE
GROUND?

CONTROL WILL CONTINUE TO CALL FOR COOLING
IN THIS CONDITION,
SIGNAL IMPROPER GROUND AT LED.
STATUS ERROR CODE 5 + 3.

_ YES

THERMOSTAT

CALLS FOR FIRST-STAGE

COOL.

4,
COMPRESSOR AND CONDENSER
ENERGIZED.

FAN

4,
INDOOR BLOWER ENERGIZED ON FIRST STAGE
COOL SPEED AFTER 2 SECOND DELAY.

4,
_1

FIRST-STAGE

I THERMOSTAT

DEMAND FOR COOL SATISFIED?

CALLS FOR SECOND-STAGE

COOL,

COMPRESSOR
AND BLOWER
CONDENSER
FAN DE-ENERGIZED.
NDOOR
DE-ENEG
ZED.

I ,NDOOR
BLOWER
RAMPS
UP
TO
SECOND-STAGE
COOL
SPEED
I

ISECOND-STAGE
DEMAND
FOR
COOL
SAT'SF'ED?
I
YES 4,

Page 48

CONTINUOUS
LOW

SPEED FAN SEQUENCE OF OPERATION

MANUAL FAN SELECTION MADE AT THERMOSTAT
AFTER 2 SECOND DELAY, INDOOR BLOWER IS
ENERGIZED ON CONTINUOUS FAN SPEED.

YES
I

THERMOSTAT

CALLS FOR FIRST STAGE

YES

COOL.

THERMOSTAT

CALLS FOR FIRST-STAGE

YES
I

YES

COOLING
DELAY,
INDOOR SPEED
BLOWERAFTER
RAMPSA 2-SECOND
TO FIRST STAGE

FIRST-STAGE

HEAT.

LOW HEAT
SPEED,
AFTERSWITCHES
45-SECONDTO DELAY,
INDOOR
BLOWER

COOL DEMAND SATISFIED?

FIRST-STAGE

NO_
SECOND
STAGE
COOL
DEMAND

HEAT DEMAND SATISFIED.

_YI

NO
I

THERMOSTAT CALLS FOR SECOND-STAGE

HEAT.

YES
I

INDOOR BLOWER
RAMPS
TO SECOND
STAGE COOL
SPEED

INDOOR
BLOWER
SWITCHES
TO HIGH HEAT
SPEED
AFTER
30-SECOND
RECOGNITION
PERIOD.

YES

SECOND
STAGE
COOL
DEMAND
SAT,SFIED?
I I
YES

INDOOR BLOWER COOL
RAMPSSPEED.
DOWN TO FIRST STAGE

SECOND-STAGE

HEAT DEMAND SATISFIED.

YES
p

Page 49

INDOOR BLOWERHEATRAMPSsPEED.DOWN
TO LOW

JobName

Job No.

JobLocation

City

State

Installer

City

State

UnitModelNo.

Technician

Date

SerialNo.
Heating

Section

[]

Electrical Connections Tight?
Line Voltage

Blower Motor H.P.

Blower Motor Amps

Gas Piping Connections
Tight & Leak-Tested?

[]

Fuel Type: Natural Gas?

LP/Propane Gas?

[]

Line Pressure

Furnace Btu Input (High fire)
Low Fire Manifold Pressure

w.c.- Nat,:

High Fire Manifold Pressure

w.c.- Nat,:

[]

Flue Connections Tight?

Combustion Gas Tested (high fire and low fire)?
Blower ON delay confirmed?
(45 Seconds Fixed On)

[]

w.c. - LP/Propane

w.c. - LP/Propane
Proper Draft?
[]

002

[]
[]

External Static Pressure?
(0.8 maximum)

Blower OFF Delay Setting (60, 90, 120 or 180)?
Filter Clean & Secure?

Temperature Rise

[]

Thermostat
Heat Anticipator Setting?

Thermostat Level? []

Page 50

Source Exif Data:

File Type                       : PDF
File Type Extension             : pdf
MIME Type                       : application/pdf
PDF Version                     : 1.2
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Page Count                      : 50
Page Layout                     : SinglePage
Page Mode                       : UseNone
Producer                        : Goby Monitor Application version 4, 0, 0, 13
Create Date                     : Mon Jun 30 04:42:46 2008
Author                          : 
Title                           : 
Subject                         :

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LENNOX Furnace/Heater, Gas Manual L0806201

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