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Lennox G60UH Series User Manual

Lennox G60UH Series
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Page 1
01/10
*2P0110*
506176−01
*P506176-01*
E 2008 Lennox Industries Inc.
Dallas, Texas, USA
RETAIN THESE INSTRUCTIONS
FOR FUTURE REFERENCE
INSTALLATION
INSTRUCTIONS
G60UH(X) Series
GAS FURNACE
506176−01
1/2010
Supersedes 10/2009
Table of Contents
Unit Dimensions 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G60UH(X) Parts Arrangement 3. . . . . . . . . . . . . . . . . . . . .
G60UH(X) Gas Furnace 4. . . . . . . . . . . . . . . . . . . . . . . . . .
Shipping and Packing List 4. . . . . . . . . . . . . . . . . . . . . . . .
Safety Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Use of Furnace as a Construction Heater 5. . . . . . . . . . .
General 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Combustion, Dilution & Ventilation Air 6. . . . . . . . . . . . . .
Setting Equipment 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filters 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Duct System 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Venting 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas Piping 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Integrated Control 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Start−Up 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas Pressure Adjustment 31. . . . . . . . . . . . . . . . . . . . . . .
High Altitude Information 31. . . . . . . . . . . . . . . . . . . . . . . .
Other Unit Adjustments 32. . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Performance 33. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heating Sequence of Operation 35. . . . . . . . . . . . . . . . . .
Service 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Planned Service 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Integrated Control Diagnostic Codes 38. . . . . . . . . . . . . .
Troubleshooting 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Parts List 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start−Up & Performance Check List 46. . . . . . . . . . . . . . .
WHAT TO DO IF YOU SMELL GAS:
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.
D Do not try to light any appliance.
D Do not touch any electrical switch; do not
use any phone in your building.
D Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s
instructions.
D If you cannot reach your gas supplier, call
the fire department.
FIRE OR EXPLOSION HAZARD.
Failure to follow safety warnings exact-
ly could result in serious injury, death,
or property damage.
WARNING
D Leave the building immediately.
Litho U.S.A.
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Lennox G60UH Series Specifications

General IconGeneral
ModelG60UH Series
Blower TypeVariable Speed
WarrantyLimited lifetime warranty on heat exchanger, 5-year parts warranty
Fuel TypeNatural Gas/Propane
Blower MotorECM (Electronically Commutated Motor)

Summary

Unit Dimensions

Parts Arrangement

Furnace Overview

Shipping and Packing List

Lists items included with the furnace and items that may be ordered separately.

Construction Heater Use

General Installation Guidelines

Combustion Air Requirements

Unconfined Space Airflow

Defines an unconfined space and its air requirements for furnace combustion.

Confined Space Airflow

Defines a confined space and its air requirements for furnace combustion.

Air Intake from Adjoining Spaces

Describes bringing air into a confined space from an adjoining unconfined space.

Outdoor Air Intake

Describes bringing outdoor air into a confined space for combustion.

Equipment Setup and Positioning

Upflow Installation Clearances

Details installation clearances for upflow furnace configurations.

Return Air Configuration

Upflow Return Air Options

Explains how to connect return air for upflow installations.

Optional RAB Return Air Base

Describes the optional RAB return air base for upflow applications.

Furnace Panel Removal and Leveling

Bottom Panel Removal

Instructions for removing the furnace bottom panel.

Upflow Unit Leveling

Instructions for installing leveling bolts on an upflow unit.

Horizontal Installation Clearances

Details installation clearances for horizontal furnace configurations.

Horizontal Installation Methods

Suspended Horizontal Application

Illustrates suspending the furnace in an attic or crawlspace.

Platform Horizontal Application

Shows installing the furnace on a platform.

Horizontal Return Air Connection

Explains how to connect return air for horizontal installations.

Air Filters

Duct System Requirements

Supply Air Plenum Installation

Requirements for the supply air plenum when a cooling coil is not used.

Return Air Plenum Guidelines

Guidelines for drawing return air, avoiding negative pressure issues.

Venting System Installation

Masonry Chimney Venting

Tile-Lined Chimney Venting

Additional requirements for venting through a tile-lined masonry chimney.

General Venting Requirements

Common Venting Removal and Testing

Gas Piping Installation

Gas Supply Connection

Details gas supply connection and pipe sizing recommendations.

Gas Line Leak Check

Electrical System

ESD Precautions

Precautions to protect electronic components from static discharge.

Wiring Box Installation

Indoor Blower Speed Control

Thermostat Wiring

Schematic Wiring Diagram

Field Wiring Diagram

Integrated Control Functions

Integrated Control Operation

DIP Switch Settings

Explains the function of DIP switches for thermostat and blower delay settings.

Unit Start-Up Procedures

Initial Furnace Operation

Instructions for starting the furnace for the first time.

Gas Valve Operation

Details how to operate the gas valve for startup and shutdown.

Shutting Off Gas Supply

Steps to safely turn off the gas supply to the furnace.

Gas Pressure and Flow Adjustment

Gas Flow Measurement

How to measure and determine gas flow rate for furnace operation.

Gas Pressure Settings

Checking and adjusting gas line and manifold pressures for optimal performance.

High Altitude Pressure Adjustments

High altitude requirements and manifold pressure settings.

Other Unit Adjustments and Checks

Limit Controls

Location and factory settings of primary and secondary limit controls.

Flame Rollout Switch Check

Location and function of flame rollout switches.

Pressure Switch Function

Location and purpose of pressure switches.

Temperature Rise Adjustment

Adjusting blower speed to achieve the correct temperature rise.

Blower Speed Information

Information on CFM ratings and blower motor performance.

Thermostat Heat Anticipator Setting

Setting the heat anticipator based on amp draw.

Electrical System Checks

Checks for wiring issues and correct voltage.

Electronic Ignition System

Explanation of the SureLight integrated control and Watchguard feature.

Flue and Chimney Integrity

Checks for proper flue and chimney condition and blockages.

Troubleshooting Unit Failure

Troubleshooting steps for when the unit fails to operate.

Blower Performance Data

G60UH-24A-070 Performance

Air volume and wattage data for the 24A-070 model.

G60UH-36A-070 Performance

Air volume and wattage data for the 36A-070 model.

G60UH-36B-090 Performance

Air volume and wattage data for the 36B-090 model.

G60UH-36C-110 Performance

Air volume and wattage data for the 36C-110 model.

G60UH-48B-090 Performance

G60UH-48C-110 Performance

G60UH-60C-100X Performance

G60UH-60D-135 Performance

Heating Sequence of Operation

Two-Stage Thermostat Operation

Heating sequence for two-stage thermostat applications.

Single-Stage Thermostat Operation

Heating sequence for single-stage thermostat applications.

General Service Precautions

General service precautions and recommendations.

Component Maintenance

Blower Maintenance

Maintenance checks for the blower motor and wheel.

Filter Inspection and Replacement

Inspection and replacement guidelines for air filters.

Flue and Chimney Inspection

Checks for flue pipe and chimney integrity and blockages.

Electrical System Checks

Checks for wiring issues and correct voltage.

Planned Annual Service

Integrated Control Diagnostic Codes

Flash Code Descriptions

Explains the meaning of flash codes for system status.

Flame Sensing Codes

Codes indicating flame sensing issues.

Pressure Switch Error Codes

Codes related to pressure switch operation.

Limit Switch Error Code

Code indicating a limit switch has opened.

Watchguard Error Codes

Codes related to the integrated control's watchguard feature.

Hard Lockout Error Codes

Codes indicating a hard lockout condition.

Error Code Storage and Review

How error codes are stored, reviewed, and cleared.

Troubleshooting Heating Operation

Heating Sequence Flowchart

Flowchart detailing normal and abnormal heating operation sequences.

Troubleshooting Cooling Operation

Cooling Sequence Flowchart

Flowchart detailing the cooling operation sequence.

Troubleshooting Continuous Fan Operation

Continuous Fan Sequence Flowchart

Flowchart for continuous fan operation modes.

Replacement Parts List

Cabinet Parts

List of available cabinet replacement parts.

Control Panel Parts

List of available control panel replacement parts.

Blower Assembly Parts

List of available blower replacement parts.

Heating System Parts

List of available heating system replacement parts.

Start-Up and Performance Checklist

Heating Section Checklist

Checklist items for the heating section during start-up.

Thermostat Checks

Checklist items related to thermostat settings.

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