LENNOX Furnace/Heater, Gas Manual L0806204

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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LF WVOX)

_ 2006 Lennox Industries Inc.

Dallas, Texas, USA

RETAIN THESE INSTRUCTIONS

FOR FUTURE REFERENCE

INSTALLATION

INSTRUCTIONS

G61MP SERIES UNITS

GAS UNITS _) Technical

505,124M _.LLL. Publications

07/2007

Supersedes 09/2006 Lithe U.S.A.

Unit Dimensions ............................... 2

G61MP Parts Identification ...................... 3

Shipping and Packing List ....................... 4

Safety Information .............................. 4

General ....................................... 6

Combustion, Dilution & Ventilation Air ............. 6

Installation - Setting Equipment .................. 8

Filters ........................................ 17

Duct System .................................. 17

Pipe & Fittings Specifications ................... 18

Vent Piping Guidelines ......................... 20

Joint Cementing Procedure ..................... 21

Venting Practices ............................. 21

Gas Piping ................................... 32

Electrical ..................................... 34

Integrated Control Board ....................... 41

Unit Start-Up ................................. 41

Gas Pressure Adjustment ...................... 43

High Altitude Information ....................... 44

Other Unit Adjustments ........................ 45

Service ...................................... 47

Ignition Control Board Diagnostic Codes ......... 49

Troubleshooting ............................... 50

Repair Parts List .............................. 55

Vent Pipe Sizing Worksheet .................... 56

Start-Up & Performance Check List .............. 56

A WARNING

Do not store or use gasoline or other

flammable vapors and liquids in the

vicinity of this or any other ap-

pliance.

Installation and service must be

performed by a qualified installer,

service agency or the gas 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.

07/07

IIIllllllnlnllllllllllllllllllllllllllll Page 1

505,124M

IIIIIINIIIIIIIIIIIIIIIHIIIIIIIIIIIIIIIIIIIIIIII

*NOTE - 60C and 60D size units installed in upflow ap-

plications that require air volumes over 1800 cfm (850 L/s)

must have one of the following:

1. Single side return air with transition, to accommodate

20 x 25 x 1 in. (508 x 635 x 25 mm) air filter.

Required to maintain proper air velocity.

2. Single side return air with optional RAB Return Air Base

3. Bottom return air.

4. Return air from both sides.

5. Bottom and one side return air.

Refer to Engineering Handbook for additional information.

**Consider sizing requirements for optional IAQ equip-

ment before cutting side return opening.

1 Optional External Side Return Air Filter Kit is not for use

with the optional NAB Return Air Base.

,,_ A-_

B-_ _-9/16(14)

AIR FLOW

SUPPLY AIR

OPENING

_OPTIONAL 23-3/4 (603)

EXTERNAL. I_

SIDE RETURN i_--_ 25 (635)

AIR FILTER KIT TOP VIEW

(Either Side)

t6-1/2

11-5/8 11}5) *-_

(295) Right

28-1/2

J_ (724)

5-112 _I_ 19-7116_

r_ COMBUSTION AIR INTAKE

.... _ _ (Either Side)

( ly \ /EXHAUST AIR OUTLET

9- _/_ Av(Either Side)

_ GASP,P,NG,NLET

_11_ y\ (Either Side)

\.r_ CONDENSATE

L_TRAPCONNECTION

°Oo_ (Either Side)

_ ELECTRICAL INLET

, ,E,, ers, ei

(64) _ ....

I23

1OPTIONAL

EXTERNAL

SIDE RETURN

AIR FILTER KIT

(Either Side)

(1016)

5/8(16)

--J_l- 3/4 (19)

9-3/4 (248) 4-1/8 6-3/4

Left (103) (171)

4-7/8 (124) Right

2-1/4 (57) Left -I_

18-3/4 (476) -I_ {1_2_1_A (584) I

I*OPTIONAL 14"*

I RETURN CUTOUT

I (Either Side)

JL--o --I- +-

3/4 (19) *Bottom Return 4-1/4 *Bottom Return

Air Opening (108) Air Opening

FRONT VIEW SIDE VIEW

9/16

91-(14)

A B C

Model No. in. mm in. mm in. mm

G61MP-36B-045

G61MP-36B-070 17-1/2 446 16-3/8 416 16 406

G61 MP-48C-090

G61MP-60C-090 21 533 19-7/8 454 19-1/2 495

G61MP-48C-110

G61MP-60C-110

G61MP-60D-135 24-1/2 622 23-3/8 546 23 584

Page 2

G61MP PARTS IDENTIFICATION

DuralokPlus TM

HEATEXCHANGER

ASSEMBLY

CABINET

GAS VALVE

AND MANIFOLD

FLUE

COLLAR

COMBUSTION

AIR PRESSURE

PROVE SWITCHES*

COMBUSTION AIR

INDUCER

BURNER

ACCESS

PANEL

BLOWER

ACCESS

DOOR

*G61MP-090 shown.

G61MP-045 and -070

are equipped with

two switches.

SIGHT

GLASS

DOOR

INTERLOCK

SWITCH

CONTROL BOX

FIGURE 1

WARM HEADER

(COLLECTOR)

BOX

CONDENSER COIL

PRIMARY LIMIT

COLD HEADER

(COLLECTOR)

BOX

--.¢ -....SECONDARY

LIMITS (2)

BLOWER

ASSEMBLY

Page 3

TheG61MPgasfurnaceisshippedreadyforinstallationin

theupflow,downflow,horizontalleftairdischargeorhori-

zontalrightairdischargeposition.Thefurnaceisshipped

withthebottompanelinplace.Thebottompanelmustbe

removedif theunitistobeinstalledin upflowapplications

withbottomreturnair.Thebottompanelmustalsobere-

movedanddiscardedinalldownfloworhorizontalapplica-

tions.

Thefurnaceisequippedforinstallationinnaturalgasap-

plications.A conversionkit(orderedseparately)isrequired

foruseinpropane/LPgasapplications.

The G61MP can be installed as either a Direct Vent or a

Non-Direct Vent gas central furnace.

NOTE -In Direct Vent installations, combustion air is taken

from outdoors and flue gases are discharged outdoors. In

Non-Direct Vent installations, combustion air is taken from

indoors and flue gases are discharged outdoors. See fig-

ure 2for appfications involving roof termination.

DIRECT VENT INSTALLATION

COMBUSTION EXHAUST

AIR INTAKE OUTLET

OUTSIDE OF

HOUSE _

CONDENSATE

DRAIN"_I,

NON-DIRECT VENT

INSTALLATION

EXHAUST

OUTLET

COMBUSTION

AIR INTAKE INSIDE

OF HOUSE

FIGURE 2

CONDENSATE

DRAIN

Package 1 of 1 contains

1 - Assembled G61MP unit

1 - Bag assembly containing the following:

3 - Screws

3 -Wire nuts

1 - Snap bushing

1 - Snap plug

1 - Wire tie

1 - Condensate trap

1 - Condensate trap cap

2 -2" diameter vent /intake plugs

1 - 3" diameter cabinet plug (intake)

1 -2" diameter debris screen

1 -Logo sticker (for use in downflow applications)

NOTE -G61MP-48C-110 and G61MP-60C-110 units also

include a 2" diameter ABS street elbow, which is shipped

on the blower deck in the heating compartment.

G61MP-60D-135 units are shipped with a 3" to 2"ABS re-

ducing elbow.

The following items may also be ordered separately:

1- Thermostat

1 - Propane/LP changeover kit

Check equipment for shipping damage. If you find any

damage, immediately contact the last carrier.

-&WARNING

- CAUTION

Use only the type of gas approved for use with this furnace.

Refer to unit nameplate.

G61MP units are CSA International certified to ANSI

Z21.47 and CSA 2.3 standards.

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 (ANSl-Z223.1/NFPA 54). 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 Natural Gas and Propane

Installation Codes, local plumbing or waste water codes

and other applicable local codes.

In order to ensure proper unit operation in non-direct vent

applications, combustion and ventilation air supply must be

provided according to the current National Fuel Gas Code

or CSA-B149 standard.

This furnace is CSA International certified for installation

clearances to combustible material as listed on the unit

nameplate and in the tables in figures 7, 12 and 16. Acces-

sibility and service clearances must take precedence over

fire protection clearances.

NOTE- For installation on combustible floors, the furnace

shall not be installed directly on carpeting, tile, or other

combustible material other than wood flooring.

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 physical

Page 4

damagebyvehicles.Whenafurnaceisinstalledinapublic

garage,hangar,orotherbuildingthathasahazardousat-

mosphere,thefurnacemustbeinstalledaccordingtorec-

ommendedgoodpracticerequirementsandcurrentNa-

tionalFuelGasCodeorCSAB149standard.

NOTE -Furnace must be adjusted to obtain a temperature

rise within the range specified on the unit nameplate. Fail-

ure to do so may cause erratic limit operation.

This G61MP furnace may be used as a high-static unit

heater. The G61MP may also be installed in an aircraft

hangar in accordance with the Standard for Aircraft Han-

gars (ANSI/NFPA No. 408-1990).

Installation in parking structures must be in accordance

with the Standard for Parking Structures (ANSI/NFPA No.

88A-1991 ). Installation in repair garages must be in accor-

dance with the Standard for Repair Garages (ANSI/NFPA

No. 88B-1991).

This G61MP furnace must be installed so that its electrical

components are protected from water.

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 manu-

ally 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.

When installed, this furnace must be electrically grounded

according to local codes. In addition, in the United States,

installation must conform with the current National Electric

Code, ANSI/NFPA No. 70. The National Electric Code

(ANSI/NFPA No. 70) is available from the following ad-

dress:

National Fire Protection Association

1 Battery March Park

Quincy, MA 02269

In Canada, all electrical wiring and grounding for the unit

must be installed according to the current regulations of the

Canadian Electrical Code Part I (CSA Standard C22.1)

and/or local codes.

NOTE -This furnace is designed for a minimum continuous

return air temperature of 60°F (16°C) or an intermittent op-

eration down to 55°F (13°C) dry bulb for cases where a

night setback thermostat is used. Return air temperature

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

The G61MP furnace may be installed in alcoves, closets,

attics, basements, garages, and utility rooms.

This furnace design has not been CSA certified for installa-

tion in mobile homes, recreational vehicles, or outdoors.

Never use an open flame to test for gas leaks. Check all

connections using a commercially available soap solution

made specifically for leak detection.

Lennox does not recommend the use of G61MP 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.

G61MP units may be used for heating dbuildings or struc-

tures 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

allowed.

• 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 installed in the system and must be

maintained during construction.

• Air filters must be replaced upon construction comple-

tion.

• The inputrate and temperature rise mustbe setperthe

furnace rating plate.

•One hundred percent (100%) outdoor air must be pro-

vided for combustion air requirements during construc-

tion. Temporary ducting may supply outdoor air to the

furnace. Do not connect duct directly to the furnace.

Size the temporary duct following these instructions in

section for Combustion, Dilution and Ventilation Air in a

confined space with air from outside.

• The furnace heat exchanger, components, duct sys-

tem, air filters and evaporator coils must be thoroughly

cleaned following final construction clean-up.

• All furnace operating conditions (including ignition, in-

put rate, temperature rise and venting) must be verified

according to these installation instructions.

NOTE -The Commonwealth of Massachusetts stipu-

lates these additional requirements:

•Gas furnaces shall be installed by a licensedplumb-

er or gas fitter only.

•The gas cock must be "T handle" type.

•When a furnace is installed in an attic, the passage-

way to and service area surrounding the equipment

shall be floored.

Page 5

Theseinstructionsareintendedasageneralguideanddo

notsupersedelocalcodesinanyway Consultauthorities

havingjurisdictionbeforeinstallation

Inadditiontotherequirementsoutlinedpreviously,thefol-

lowinggeneralrecommendationsmustbe considered

wheninstallinga G61MPfurnace:

• Placethefurnaceascloseto thecenterof theairdis-

tributionsystemaspossibleThefurnaceshouldalsobe

locatedclosetothechimneyorventterminationpoint

• Whenthefurnaceisinstalledinnon-directventapplica-

tions,donotinstallthefurnacewheredraftsmightblow

directlyintoit Thiscouldcauseimpropercombustion

andunsafeoperation

• Whenthefurnaceisinstalledinnon-directventapplica-

tions,donotblockthefurnacecombustionairopening

withclothing,boxes,doors,etc Airisneededforproper

combustionandsafeunitoperation

• Whenthefurnaceisinstalledinanatticor otherinsu-

latedspace,keepinsulationawayfromthefurnace

• Whenthe furnaceis installedin an unconditioned

space,considerprovisionsrequiredtopreventfreezing

ofcondensatedrainsystem

CAUTION

-&WARNING

If the G61MP is installed as a Non-Direct Vent Furnace,

follow the guidelines in this section.

NOTE- In Non-Direct Vent installations, combustion air is

taken from indoors and flue gases are discharged out-

doors.

WARNING

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 prac-

tices make it necessary to bring in air from outside for com-

bustion, 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 out-

side 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 fur-

nace vent pipe or chimney, As a result, combustion gases

enter the living space creating a potentially dangerous situ-

ation,

In the absence of local codes concerning air for combus-

tion and ventilation, use the guidelines and procedures in

this section to install G61MP 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 per-

mission from the National Fuel Gas Code (ANSI-

Z223 1/NFPA 54) This reprinted material is not the com-

plete and official position of the ANSI on the referenced

subject, which is represented only by the standard in its en-

tirety

In Canada, refer to the standard CSA B149 installation

codes

Page 6

ACAUTION

All gas-fired appliances require air for the combustion pro-

cess. If sufficient combustion air is not available, the fur-

nace or other appliance will operate inefficiently and un-

safely. Enough air must be provided to meet the needs of

all fuel-burning appliances and appliances such as ex-

haust fans which force air out of the house. When fire-

places, exhaust fans, or clothes dryers are used at the

same time as the furnace, much more air is required to en-

sure proper combustion and to prevent a downdraft. Insuf-

ficient air causes incomplete combustion which can result

in carbon monoxide.

In addition to providing combustion air, fresh outdoor air di-

lutes contaminants in the indoor air. These contaminants

may include bleaches, adhesives, detergents, solvents

and other contaminants which can corrode furnace compo-

nents.

The requirements for providing air for combustion and ven-

tilation 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 com-

bined 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 un-

confined, it might be necessary to bring in outdoor air for

combustion if the structure does not provide enough air by

infiltration. If the furnace is located in a building of tight

construction with weather stripping and caulking around

the windows and doors, follow the procedures in the air

from outside section.

Confined Space

A confined space is an area with a volume less than 50 cu-

bic feet (1.42 m3) per 1,000 Btu (.29 kW) per hour of the

com-bined 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 con-

taining 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 ei-

ther from inside the building or from outside.

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 mm2) per 1,000 Btu (.29 kW) per hour of

total input rating of all gas-fired equipment in the confined

space. Each opening must be at least 100 square inches

(64516 mm2). One opening shall be within 12 inches (305

mm) of the top of the enclosure and one opening within 12

inches (305 mm) of the bottom. See figure 3.

EQUIPMENT IN CONFINED SPACE -ALL AIR FROM INSIDE

ROOF TERMINA] ED_lr

EXHAUST PIPE

'-, _ OPENINGS

•-- (To Adjacent

SIDE WALL _1 Unconfined

ERMINATED EX=

UST PIPE (ALTER- -- __pace)

ATE LOCATION) G61MP Y

III

I I I I I I I I I I I I I I I I I I

' h ¢"l ¢'

NOTE -Each opening shall havo a free area of at least ono square

inch per 1,000 Btu (645mm 2per .29kW) per hour of the total input

rating of all equipment in the enclosure, but not less than 100 square

inches (64516mm. 2).

FIGURE 3

Air from Outside

If air from outside is brought in for combustion and ventila-

tion, the confined space shall be provided with two perma-

nent openings. One opening shall be within 12" (305mm) of

the top of the enclosure and one within 12" (305mm) dthe

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 verti-

cal ducts. Each opening shall have a minimum free area of

1 square inch per 4,000 Btu (645mm 2 per 1.17kW) per hour

of total input rating of all equipment in the enclosure. When

communicating with the outdoors through horizontal ducts,

each opening shall have a minimum free area of 1 square

inch per 2,000 Btu (645mm 2 per .59kW) per total input rat-

ing of all equipment in the enclosure (See figure 4).

Page 7

EQUIPMENT IN CONFINED SPACE - ALL AIR FROM OUTSIDE

(Inlet Air from Crawl Space and Outlet Air to Ventilated Attic)

VENTILATION LOU-

ROOF TERMINATED VERS

EXHAUST PIPE (Each end of attic)

\ II I

OUTLET

AIR

IINATED

JST PIPE VENTIL

LOU_.

("IRNATE G61MP INLET (For un

ATION) AIR _.,., crawl .'pace)

I_1 i" rrrm

NOTE-The inlet and outlet air openings shall each have a free area

of at least one square inch per 4,000 Btu (645mm2per 1.17kW) per

hour of the total input rating of all equipment in the enclosure.

FIGURE 4

If air from outside is brought in for combustion and ventila-

tion, the confined space must have two permanent open-

ings, 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 di-

rectly or by ducts with the outdoors or spaces (crawl or at-

tic) 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 of total input rating of all equipment in the en-

closure, See figures 4 and 5. When communicating with

the outdoors through horizontal ducts, each opening shall

have a minimum free area of 1 square inch (645 mm2) per

2,000 Btu (.56 kW) per total input rating of all equipment in

the enclosure, See figure 6,

When ducts are used, they shall be of the same cross-sec-

tional 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 cov-

ering is not known for calculating the size opening required,

it may be assumed that wood louvers will have 20 to 25 per-

cent 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 opera-

tion,

EQUIPMENT IN CONFINED SPACE - ALL AIR FROM OUTSIDE

(All Air Through Ventilated Attic)

ROOF TERMINATED VENTILATION LOUVERS

EXHAUST PIPE (Each end of attic)

TERMINATED

EXHAUSTPtPE

(ALTERNATE

LOCATION)

INLET AIR

(Ends 12"above

bottom)

NOTE-The inlet and outlet air openings shall each have a free area of

at least one square inch per 4,000 Btu (645mm2per 1.17kW) per hour

of the total input rating of all equipment in the enclosure.

FIGURE 5

EQUIPMENT IN CONFINED SPACE -

ALL AIR FROM OUTSIDE

ROOF TERMINATED

EXHAUST PIPE

SIDE WALL

TERMINATED

EXHAUSTPtPE

(ALTERNATE

LOCATION)

NOTE-Each air duct opening shall have a free area of at least one

square inch per 2,000 Btu (645mm2per. 59kW) per hour of the total

input rating of all equipment in the enclosure, ff the equipment room

is located against an outside wall and the air openings communi-

cate directly with the outdoors, each opening shall have a free area

of at least 1 square inch per 4, 000 Btu (645mm 2per 1.17kW) per

hour of the total input rating of all other equipment in the enclosure.

FIGURE 6

I&WARNING I

Page 8

Selecta locationthatallowsfor therequiredclearances

thatarelistedontheunitnameplate.Alsoconsidergas

supplyconnections,electricalsupply,ventconnection,

condensatetrapanddrainconnections,andinstallation

andserviceclearances[24inches(610mm)atunitfront].

The unit must be level from front to back and side to side.

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 wash-

er (rather than the rubber mounting grommet used with a

flexible mounting leg). The bolt and washer must be re-

moved before the furnace is placed into operation. Af-

ter the bolt and washer have been removed, the rigid leg

will not touch the blower housing.

Allow for clearances to combustible materials as indicated

on the unit nameplate. Minimum clearances for closet or al-

cove installations are shown in figures 7, 12 and 16.

WARNING

AWARNING

Upflow Applications

The G61MP gas furnace can be installed as shipped in the

upflow position. Refer to figure 7 for clearances.

Installation Clearances

Top

Left Side Right Side

Bottom (Floor)

............................................... T...............................................

Top/Plenum i1 in. (25 ram)

*Front iO

.-................... ....................T..............................................

..'.....................-.........................f...............................................I

Vent i O

Floor I O:_

*Front clearance in alcove installation must be 24 in. (610 ram).

Maintain a minimum of 24 in. (610 ram) for front service access.

tAllow proper clearances to accommodate condensate trap and

vent pipe installation.

! :_For installations on acombustible floor, do not install the fur-

inace directly on carpeting, tile or other combustible materials oth-

i er than wood flooring.

=================================================================================================

FIGURE 7

Return Air -- Upflow Units

Return air can be brought in through the bottom or either

side of the furnace installed in an upflow application. If the

furnace is installed on a platform with bottom return, make

an airtight seal between the bottom of the furnace and the

platform to ensure that the furnace operates properly and

safely. The furnace is equipped with a removable bottom

panel to facilitate installation.

Markings are provided on both sides of the furnace cabinet

for installations that require side return air. Cut the furnace

cabinet at the maximum dimensions shown on page 2.

NOTE -When air volumes over 1800 cfm (850 L/s) are

required with 60C or 60D models in an upflow applica-

tion, the following return air options are available:

1-Return air from single side with transition which will

accommodate 20 x 25 x I in. (508 x 635 x 25 ram) air filter.

(Required to maintain proper air velocity.) See figure 9.

2-Return air from single side with optional RAB Return

Air Base. See figure 8.

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.

Page 9

Optional Return Air Base

(Upflow Applications Only -- For use with B, C and D cabinets only)

f .............. _ f..............

AIR FLOW

--D

FURNACE J,

_- FRONT

7-1/4 (184)

'---. 1

_I ''_ OPTIONAL RAB

17-1/2 (446) RAB-B (98M60) RETURN AIR BASE

21 (533) RAB-C (98M58) 7/8 .__

24-1/2 (622) RAB-D (98M59) (22)

FRONT VIEW

4 I 231584)

(102)1_l-- Overall 1Mihimu"-_

(Maximum) 11 (279) I

2Maximurq

Unit side return airopening14_5.6)/__

5-5/8

(143)

91_ 23 (584)

122-7-16

(570)

Overall

Maximum)

--3/4

(19)

4-- 27-5/8 (702)

SIDE 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

G61MP applications which include side return air and

a condensate trap installed on the same side of the

cabinet require either a return air base or field-fabri-

cated transition to accommodate an optional IAQ ac-

cessory taller than 14.2".

Side Return Air

(with transition and filter)

20" X 25" X 1"

(508mm X635mm X 25mm)

Air Filter

Return

Air

Plenum

Removing the Bottom Panel

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 10.

Removing the Bottom Panel

Screw

Bottom

ottom Cap

FIGURE 9 FIGURE 10

Page 10

Levelingan Upflow Unit

When the side return air inlets are used in an upflow ap-

plication, it may be necessary to install leveling bolts on the

bottom of the furnace. Use field-supplied corrosion-resist-

ant 5/16 inch machine bolts (4) and nuts (8). See figure 11.

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-

ter hole in each corner of the furnace's bottom. See fig-

ure 11 for the correct location of the holes. Drill through

the bottom panel and the bottom flange of the cabinet.

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

flat washer may be added between the nut and the bot-

tom of the unit.

3 - Screw another nut onto the bolt on the inside of the fur-

nace base. A flat 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.

NOTE -The unit may be tilted back-to-front a maximum of

1". This will ensure proper draining of the heat exchanger.

Leveling Bolt Installation

Inches (ram)

3/8

Furnace Front _¢

3/8 1-3/4

(44)

1-3/4

(44)

Leveling Bolt

Furnace

Bottom

Leveling Bolt

Locations

3/8

(10)

3/8 1-3/4

(10) (44)

I-3/4 (44)

FIGURE 11

Downflow Applications

The unit may be installed three ways in downflow applica-

tions: on non-combustible flooring, on combustible flooring

using an additive base, or on a reverse-flow cooling cabi-

net. Do not drag the unit across the floor in the down-

flow position. Flange damage will result.

After unit has been properly set in place, position provided

logo over existing logo and affix sticker on front panel.

Refer to figure 12 for clearances in downflow applica-

tions.

•............................................................................................... q

Downflow Application Installation Clearances

Left Side

Top

Right Side

Bottom

&,1

............................................... T...............................................

Top i O

*Front IO

."................... ....................T..............................................

Sides i 01"

]

Vent i O

............................................... t ................................................

Floor i NC_:

*Front clearance in alcove installation must be 24 in. (616 ram).

Maintain a minimum of 24 in. (610 ram) for front service access.

tAllow proper clearances to accommodate condensate trap and

vent pipe installation.

_:The furnace may be installed on a combustible wood floor if an

i optional additive base is installed between the furnace and the

i combustible floor.

=================================================================================================

FIGURE 12

Installation on Non-Combustible Flooring

1 - Cut floor opening keeping in mind clearances listed on

unit rating plate. Also keep in mind gas supply connec-

tions, electrical supply, flue and air intake connections

and sufficient installation and servicing clearances.

See table 1 for correct floor opening size.

2 - Flange warm air plenum and lower the plenum into the

opening.

3 - Set the unit over the plenum and seal the plenum to

the unit.

4 - Ensure that the seal is adequate.

TABLE 1

NON-COMBUSTIBLE FLOOR OPENING SIZE

i............................[...... ......[...... ........i

iModel No. _................................. _.................................

iii i•

i"i i "i •

I In. I mm I In. I mm l

I, ,I ,I -t., t.

jBCabinet(17.5") i19-3/4, ,i 502 ,i 16-5/8 ,i 422 j

I, ,I ,I -t., t.

jCCabinet(21") ,i 19-3/4 ,i 502 ,i 20-1/8 ,i 511 j

i, ,I ,I -t., t.

' . " -

• DCabmet(245) , 19 3/4 , 502 , 23 5/8 , 600 •

i............................[................L................[................[................i

NOTE -Floor opening dimensions listed are 1/4 inch (6 mm) larger than

the unit opening. See dimension drawing on page 2.

Page 11

Installation on Combustible Flooring

1 - When unit is installed on a combustible floor, an addi-

tive base must be installed between the furnace and

the floor. The base must be ordered separately for the

following cabinet sizes:

• B cabinet 17,5" - # 11M60

• C cabinet21"-# 11M61

• D cabinet 24,5" - # 11M62

See table 2 for opening size to cut in floor.

Ak CAUTION

TABLE 2

ADDITIVE BASE FLOOR OPENING SIZE

Model mm

B Cabinet (17.5") 476

C Cabinet (21") 578

D Cabinet (24.5") 654

Frontto Rear

in. mm

22 559

Side to Side

in.

18 - 3/4

22 - 3/4

25 - 3/4

2 - After opening is cut, set additive base into opening.

3 - Check fiberglass strips on additive base to make sure

they are properly glued and positioned.

4 - Lower supply air plenum into additive base until ple-

num flanges seal against fiberglass strips.

NOTE -Be careful not to damage fiberglass strips.

Check for a tight seal.

5 - Set the furnace over the plenum.

6-Ensure that the seal between the furnace and plenum

is adequate.

G61MP UNIT_ __T

SUPPLY AIR PLENUM

PROPERLY R ,VEBASE

FIGURE 13

Installation on Cooling Cabinet

1 - Refer to reverse-flow coil installation instructions for

correctly sized opening in floor and installation of cabi-

net,

2 - When cooling cabinet is in place, set and secure the

furnace according to the instructions that are provided

with the cooling coil, Secure the furnace to the cabinet,

3 - Seal the cabinet and check for air leaks,

Return Air Opening -- Downflow Units

Return air may be brought in only through the top opening

of a furnace installed in the downflow position.The follow-

ing steps should be taken when installing plenum:

1 - Bottom edge of plenum should be flanged with a

hemmed edge (See figure 14 or 15).

2 - Sealing strips should be used to ensure an airtight seal

between the cabinet and the plenum.

3 - In all cases, plenum should be secured to top of fur-

nace using sheet metal screws,

4 - Make certain that an adequate seal is made,

PLENUM ---,..,._ I_1_ "_

(Field Provided) _ SECURE FROM

•_..............__UTSI DE CABINET

/v II / CABINET

SEAL,NGSTR, IIJ S,DEPANEL

(Field Provided) ...... II

Side View II

FIGURE 14

PLENUM

(Field Provid ed_"_"_---.._

SECUREFROM

INSIDE CABINET Side View

SEALING STRIP

ield Provided)

/CABINET

,SIDE PANEL

FIGURE 15

Page 12

Horizontal Applications

The G61MP furnace can be installed in horizontal applica-

tions with either right- or left-hand air discharge.

Refer to figure 16 for clearances in horizontal applications,

H===================mmmmmmHHHmmmmmmHHHmmmmmmHHHmmmmmmHHHm.

Horizontal Application

Installation Clearances

Right-Hand Discharge

Top

Left End Right End

Left-Hand Discharge

Top

Left End Right End

Top ] O

i................... ron;:...................i.............................................i

Back 1O

".................... ....................i"..............................................

Vent !o

...................." oor"...................T.....................;;.......................

| ............................................... _ ................................................

*Front clearance in alcove installation must be 24 in. (610 ram).

Maintain a minimum of 24 in. (610 ram) for front service access.

**A 5-1/2" service clearance must be maintained below the unit to

provide for servicing of the condensate trap.

_:For installations on a combustible floor, do not install the fur-

nace directly on carpeting, tile or other combustible materials oth-

er than wood flooring.

FIGURE 16

This furnace may be installed in either an attic or a crawl-

space. The G61MP may also be installed as a unit heater.

Either suspend the furnace from roof rafters or floor joists,

as shown in figures 18 or 17, or install the furnace on a field-

fabricated raised platform, as shown in figure 19. The unit

must be supported at both ends and beneath the blower

deck to prevent sagging,

NOTE -The unit must be level front to back and side to

side. If the unit is tilted backward, the heat exchanger coil

will not drain properly,

Installation of Horizontal Furnace

Suspended in Attic

NOTE -If unit is suspended in attic or crawl space, horizon-

tal support kit (Cat No. 56J18 ordered separately) must be

used to ensure proper unit support and coil drainage.

1 - Select location for unit keeping in mind service and

other necessary clearances. See figure 16.

2 - Provide service platform in front of unit,

3 - Fabricate a drain pan fitted with a 1/2 inch or 3/4 inch

N,P,T, fitting.

4- Using 3/8 inch rods and support frame kit (ordered

separately), fabricate suspension hangers for unit

keeping in mind front service access clearances.

5 - Mount unit on support frame as shown in figure 17,

Unit must be level to ensure proper coil drainage,

6- Continue with exhaust, condensate and intake line

piping instructions,

7 - Hang drain pan below support frame as shown in fig-

ure 17. Leave 5-1/2 inches for service clearance be-

low unit for condensate trap,

8 - Route auxiliary drain line so that water draining from

this outlet will be easily noticed by the homeowner,

TYPICAL HORIZONTAL CEILING APPLICATION

BLOWER ACCESS PANEL 3/8 in. RODS

CONNECTION

SUPPORTFRAME

DRAIN PAN /

(to protect finished space)

FIGURE 17

Page 13

TYPICAL HORIZONTAL ATTIC APPLICATION (FORCED AIR FURNACE)

INTAKE \

SAFTERS

BRACED FOR

SUPPORT

WASHER AND 2 NUTS

LAG BOLT

SUPPORT ROD

*Gas connector may be used if acceptable

by the local authority that has jurisdiction.

NOTE - Condensate trap and condensate line

must be protected by self-regulating heating

cable and insulation when run through un-

conditioned spaces.

DRAIN PAN

(to protect

finished

space)

Platform Installation of Horizontal Unit in Attic

j SUPPORT

FRAME

FIGURE 18

1 - Select location for unit keeping in mind service and

other necessary clearances, See figure 16,

2 - Construct a raised wooden frame and cover frame

with a plywood sheet, Provide a service platform and

drain pan for unit,

INTAKE

*Gas connector may be

used for Canadian

installation ff accept-

able by local authority

having jurisdiction.

EXHAUST PIPE

*GAS

CONNECTOR

RAISED

CONDENSATE

LINE SERVICE PLATFORM

FIGURE 19

3 - Set unit in drain pan as shown in figure 19, Unit must

be level to ensure proper coil drainage, Leave 5-1/2

inches for service clearance below unit for condensate

trap.

4 - Continue with exhaust, condensate and intake piping

installation according to instructions.

SERVICE

PLATFORM

DRAIN

PAN

BLOWER ACCESS

PANEL

Installation of Horizontal Unit

Suspended in Crawl Space

NO TE -If unit is suspended in attic or crawl space, support

frame kit (Cat No 56J18 ordered separately) must be used

to ensure proper unit support and coil drainage.

1 - Select location for unit keeping in mind service and

other clearances, See figure 16,

2 - Using 3/8 inch rods and support frame kit, fabricate

suspension hangers keeping in mind service access

panel clearances,

3 - Install unit on support frame as shown in figure 20. Unit

must be level to ensure proper coil drainage, Leave

5-1/2 inches for service clearance below unit for con-

densate trap.

INTAKE"

PIPE SUPPORT

FRAME

FIGURE 20

4 - Install exhaust and intake piping according to instruc-

tions given in following section. Condensate line

should be run into condensate pump if necessary to

meet drain line slope requirements.

Page 14

Platform Installation of Horizontal

Unit in Crawl Space

1 - Select location for unit, keeping in mind service and

other clearances,

2 - After positioning cement blocks, mount support frame

kit (ordered separately) on top of blocks and install unit

on frame. Unit must be level to ensure proper heat ex-

changer coil drainage. Leave 5-1/2 inches for service

clearance) for condensate trap.

FIGURE 21

DISCHARGE AIR DUCT/GRILLE CABINET

18in, (457 mm) k ql

FIELD-FABRICATE GRILL CABINET

TO DESIRED DIMENSION

FIGURE 22

3- To ensure proper operation, the duct/grille cabinet

must be at least 18 inches long.

4 - Use #10-16 x 1/2 inch sheet metal screws to secure

duct/grille cabinet to unit, taking care not to damage in-

ternal components of unit heater when drilling holes or

installing screws. See figure 23,

5 - Use adjustable, double-deflection grille(s) to distribute

discharge air. Adjust static pressure to be in the 0.06

inch to 0.10 inch w.c. range.

3 - Install exhaust and intake piping according to informa-

tion given in following section, Condensate line should

be run into condensate pump as shown in figure 21.

G61MP Installed in Unit Heater Applications

Horizontal unit heaters may be installed either suspended

from the ceiling using the support frame kit or mounted on a

field-fabricated raised platform. The condensate trap must

be installed where it can be serviced at a later date,

Unit Heater Discharge Duct Guidelines

A field-fabricated and installed discharge air duct and grille

cabinet is suitable for use with the G61MP heater. See fig-

ure 22, Keep the following items in mind when constructing

the cabinet,

1 - Outer dimensions of cabinet should match those of the

unit heater, so the duct/grille cabinet installs flush with

the unit heater cabinet, See figure 22,

2 - Flange both ends of duct/grille cabinet so that screws

can be used to secure cabinet to discharge end of unit

heater.

DRAIN PAN

(to protect

finished

space)

NOTE -When installing duct/grille cabinet, take care not to damage internal unit

heater components when drilling holes or instalhng screws.

FIGURE 23

Installation of Horizontal Unit Heater

Suspended from Ceiling

1 - Select location for unit keeping in mind service and

other clearances.

2 - Fabricate a drain pan fitted with 1/2 inch (13 mm) or

3/4 inch (19 mm) N.P.T. fitting.

3 - Using 3/8 inch (9 mm) rods and support frame kit (or-

dered separately), fabricate suspension hangers,

keeping in mind service access panel clearances.

Page 15

4 - Hangdrainpanbelowsupportframeasshowninfig-

ure23,Routeauxiliarydrainlinesothatwaterdraining

fromthisoutletwillbeeasilynoticedbythehomeown-

er,

5- Mountunitonsupportframeasshowninfigure23.

Unitmustbelevelto ensurepropercoildrainage,

Leave5-1/2inchesforserviceclearancebelowunitfor

condensatetrap,

6- Continuewithexhaust,condensateand intakeline

pipinginstructions,

PlatformInstallationof HorizontalUnitHeater

1- Selectlocationfor unitkeepingin mindserviceand

othernecessaryclearances.

2 - Constructa raisedwoodenframeandcoverframe

witha plywoodsheet.Provideserviceplatformand

drainpanforunit,Routeauxiliarydrainlinesothatwa-

terdrainingfromthisoutletwillbeeasilynoticedbythe

homeowner,

3- Setunitindrainpanasshowninfigure24,Unitmust

beleveltoensurepropercoildrainage,Leave5-1/2

inchesforserviceclearancebelowunitforcondensate

trap.

4 - Continuewithexhaust,condensateandintakepiping

installationaccordingtoinstructionswhichfollow.

*GAS CONNECTOR

INTAKE

PIPE \ *Gas connector may be

used for Canadian instal_

lation if acceptable by lo-

cal authority having juris-

diction.

RAISE

CONDENSATE LINE PLATFORM

FIGURE 24

Return Air -- Horizontal Applications

Return air may be brought in only through the end of a fur-

nace installed in the horizontal position. The furnace is

equipped with a removable bottom panel to facilitate instal-

lation, See figure 10,

This unit is not equipped with a filter or rack, A field-pro-

vided filter is required for the unit to operate properly. Table

3 lists recommended filter sizes,

A filter must be in place whenever the unit is operating,

TABLE 3

Furnace

Cabinet Size

17-1/2"

21"

24-1/2"

Filter Size

Side Return Bottom Return

16X25X 1(1) 16X25X1(1)

16X25X 1(1) 20X25X1(1)

16X25X 1(2) 24X25X1(1)

Use industry-approved standards 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,

NOTE -Operation of this furnace in heating mode (indoor

blower operating at selected heating speed) with an exter-

nal static pressure which exceeds 0.5 inches w.c. may re-

sult in erratic limit operation.

Supply Air Plenum

If the furnace is installed without a cooling coil, a removable

access panel should be installed in the supply air duct. The

access panel should be large enough to permit inspection

(by reflected light) of the heat exchanger for leaks after the

furnace is installed. If present, this access panel must al-

ways be in place when the furnace is operating and it must

not allow leaks into the supply air duct system,

Return Air Plenum

Return air must not be drawn from aroom where this

furnace, or any other gas appliance (ie., a water heat-

er), 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 prod-

ucts can be pulled back down the vent pipe and into the

room, This reverse flow of the flue gas may result in incom-

plete combustion and the formation of carbon monoxide

gas. This toxic gas might then be distributed throughout the

house by the furnace duct system,

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. If a

filter is installed, size the return air duct to fit the filter frame,

Page 16

Allpipe,fittings,primerandsolventcementmustconform

withAmericanNationalStandardInstituteandtheAmeri-

canSocietyforTestingandMaterials(ANSI/ASTM)stan-

dards.Thesolventshallbefreeflowingandcontainno

lumps,undissolvedparticlesoranyforeignmatterthatad-

verselyaffectsthejointstrengthorchemicalresistanceof

thecement,Thecementshallshownogelation,stratifica-

tion,orseparationthatcannotberemovedbystirring,Re-

fertothetable4 belowforapprovedpipingandfittingmate-

rials.

,&, CAUTION

Primers and solvents must meet ASTM specifications.

PVC primer is specified in ASTM F 656. Use PVC solvent

cement as specified in ASTM D 2564 and ABS solvent ce-

ment as specified in ASTM D 2235. Low temperature sol-

vent cement is recommended. Metal or plastic strapping

may be used for vent pipe hangers.

When making ABS joints, pieces can be prepared with a

cleaner. When joining ABS to PVC materials, use PVC sol-

vent cement. Refer to the procedure specified in ASTM

D3138.

TABLE 4

PIPING AND FITTINGS SPECIFICATIONS

ASTM

PIPE & FITTING MATERIAL SPECIFICATION

Schedule 40 PVC (Pipe) D1785

Schedule 40 PVC (Cellular Core Pipe) F891

Schedule 40 PVC (Fittings) D2466

SDR-21PVC (Pipe) D2241

SDR-26 PVC (Pipe) D2241

Schedule 40 ABS Cellular Core DWV (Pipe) F628

Schedule 40 ABS (Pipe) D1527

Schedule 40 ABS (Fittings) D2468

ABS-DWV (Drain Waste & Vent) D2661

(Pipe & Fittings)

PVC-DWV (Drain Waste & Vent) D2665

Pipe & Fittings)

Canadian Applications Only - Pipe, fittings, primer and sol-

vent cement used to vent this appliance must be certified to

ULC $636 and supplied by a single manufacturer as part of

an approved venting system. When bonding the vent sys-

tem to the furnace, use ULC S636 approved One-Step

Transition Cement to bond the pipe to the flue collar, 90o

elbow or reducing 90 °elbow as applicable. In addition, the

first three feet of vent pipe from the furnace flue collar must

be accessible for inspection.

Table 5 lists the available exhaust termination kits, as well

as vent pipe equivalencies which must be used when sizing

vent pipe. All Lennox vent terminations are PVC or ABS.

Page 17

TABLE 5

OUTDOOR TERMINATION KITS AND CORRESPONDING EQUIVALENCIES

Outdoor

VENT Exhaust

UNIT PIPE Accelerator

MODEL DIA. (Dia. X

(in.) Length)

Outdoor

Exhaust

Accelera-

tor

(Dia. X

Length)

Vent Pipe Length Equivalency (feet)

1-1/2"

Concen-

tric Kit

2" Con-

centric

Kit

3" Con-

centric

Kit

2" Wall

Plate Kit

3" Wall

Plate Kit

2" Wall

Kit with

Vent Ex-

tension

2" Wall

Ring Kit

22G44 44J40

1-1/2" X 12" 2" X 12" 71M80 69M29 60L46 30G79 15F74

30G28 81J20

2 4 Not 12 Not Not 4 4* 4 4

Allowed Allowed Allowed

2-1/2 5 Not 15 Not Not 5 5* 5 5

Allowed Allowed Allowed

36B-045

3 7 Not 21 Not Not 7 7* 7 7

Allowed Allowed Allowed

4 14 Not 42 Not Not 14 14" 14 14

Allowed Allowed Allowed

2 4 Not 12 Not Not 4 4* 4 4

Allowed Allowed Allowed

2-1/2 5 Not 15 Not Not 5 5* 5 5

Allowed Allowed Allowed

36B-070

3 8 Not 24 Not Not 8 8* 8 8

Allowed Allowed Allowed

4 14 Not 42 Not Not 14 14" 14 14

Allowed Allowed Allowed

2 Not 1 Not 3 3 Not 1 Not 1"*