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Lennox G60UHV User Manual

Lennox G60UHV
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Page 1
© 2003 Lennox Industries Inc.
Corp. 0124−L11
G60UHV(X)
Service Literature
Revised 1−2009
G60UHV(X) SERIES UNITS
G60UHV(X) series units are mid−efficiency gas furnaces
used for upflow or horizontal applications only, manufac-
tured with Lennox Duralok Plus heat exchangers formed of
aluminized steel. G60UH(X) units are available in heating
capacities of 66,000 to 132,000 Btuh and cooling applica-
tions up to 5 tons. Refer to Engineering Handbook for prop-
er sizing.
Units are factory equipped for use with natural gas. Kits are
available for conversion to LPG operation. G60UH(X) model
units are equipped with the Two−Stage / Variable Speed Inte-
grated SureLight control. G60UH(X) unit meets the Califor-
nia Nitrogen Oxides (NO
x
) Standards and California Sea-
sonal Efficiency requirements. All units use a redundant gas
valve to assure safety shut−off as required by C.S.A.
All specifications in this manual are subject to change. Pro-
cedures outlined in this manual are presented as a recom-
mendation only and do not supersede or replace local or
state codes. In the absence of local or state codes, the
guidelines and procedures outlined in this manual (except
where noted) are recommendations only and do not consti-
tute code.
TABLE OF CONTENTS
Introduction Page 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications Page 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Data Page 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Altitude Page 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I Unit Components Page 9. . . . . . . . . . . . . . . . . . . . . . . .
II Installation Page 32. . . . . . . . . . . . . . . . . . . . . . . . . . . .
III Start Up Page 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IV Heating System Service Checks Page 33. . . . . . . . .
V Typical Operating Characteristics Page 35. . . . . . . . .
VI Maintenance Page 36. . . . . . . . . . . . . . . . . . . . . . . . . .
VII Wiring and Sequence of Operation Page 38. . . . . .
VIII Field Wiring and Jumper Settings Page 53. . . . . . .
IX Troubleshooting Page 58. . . . . . . . . . . . . . . . . . . . . . .
IMPORTANT
Improper installation, adjustment, alteration, service
or maintenance can cause property damage, person-
al injury or loss of life. Installation and service must
be performed by a qualified installer, service agency
or the gas supplier.
WARNING
Electric shock hazard. Can cause injury
or death. Before attempting to perform
any service or maintenance, turn the
electrical power to unit OFF at discon-
nect switch(es). Unit may have multiple
power supplies.
WARNING
Sharp edges.
Be careful when servicing unit to avoid sharp edges
which may result in personal injury.

Table of Contents

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Lennox G60UHV Specifications

General IconGeneral
Heating StagesTwo-Stage
Blower MotorVariable Speed
Fuel TypeNatural Gas
Ignition SystemHot Surface Ignition
ConfigurationUpflow/Horizontal
Heating Capacity44, 000 to 132, 000 BTU/h
WarrantyLimited Lifetime Heat Exchanger Warranty, 5-Year Limited Warranty on covered components

Summary

Unit Information

Safety Warning: Installation and Service

Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life.

Warning: Electric Shock Hazard

Can cause injury or death. Turn electrical power OFF before service.

Warning: Sharp Edges

Be careful when servicing unit to avoid sharp edges.

Specifications

Optional Accessories

List of optional accessories like Air Filter, EZ Filter Base, CCB1, etc.

Blower Data

Blower Data Notes

Explains static pressure, filter resistance, and zone control application effects on blower performance.

High Altitude Considerations

Parts Arrangement Diagram

Unit Components

Electrostatic Discharge (ESD) Precautions

Precautions to protect electronic components from electrostatic discharge during installation and service.

Control Box Components (Transformer, Switches, Board)

Includes transformer, door interlock, circuit breaker, and integrated control board.

Warning: Control Board Repair

Integrated Control Board is not field repairable; replace entire control if inoperable.

Two-Stage Operation and Thermostat Selection

Control Board Terminal Designations

Status and Diagnostic Codes

Dip Switch Settings

Blower Off Delay Settings

Adjusts the time the blower operates after heating demand is satisfied.

Second Stage Heat Delay

Sets the delay for second-stage heat initiation with a single-stage thermostat.

Cooling Mode Blower Speed and Adjustment

Configures cooling speed, speed adjustment (+/-10%), and ramping options.

Cooling Mode Blower Ramping Options

Heating Mode Blower Speed Selection

On-Board Jumper Configuration

Status LED Indicators

Control Board Terminal Designations

Control Board DIP Switch and Jumper Settings

Status and Error Codes

Error Code Review and Clearing

Explains how to review stored error codes and how to clear them.

Dip Switch Settings and Operation

Heating Operation Settings (Switches 1, 2, 11, 12)

Sets thermostat mode, second stage delay, and heating blower speed.

Blower Speed and Ramping Settings (Switches 5-10)

Configures cooling speed, adjustment (+/-10%), and ramping options.

Heating Mode Blower Speed Settings

On-Board Link Configuration

Status LED Indicators

System Response Table (CCB1, Single-Speed Outdoor)

System Response Table (CCB1, Two-Speed Outdoor)

System Response Table (SignatureStat, Single-Stage Outdoor)

System Response Table (SignatureStat, Two-Stage Outdoor)

Blower Motor Components and Operation

Warning: ECM Motor Interference

ECM motor energy may interfere with pacemakers; distance and shielding reduce interference.

Initial Power Up and Motor Start-Up

Danger: Capacitor Discharge Wait Time

Wait at least five minutes after power off for capacitors to discharge before adjusting speed taps.

External Operation and Speed Tap Priority

Power Choke (L13)

Motor Speed Control via Pulse-Width Modulation

SureLight Ignitor Operation and Specifications

Flame Sensor Operation and Location

Combustion Air Inducer Operation

Horizontal Installation Considerations

Flame Rollout Switches (S47)

Primary Limit Control (S10)

Secondary Limit Controls (S21)

Gas Valve Operation and Replacement

Combustion Air Inducer Prove Switch (S18)

Combustion Air Inducer Prove Switch Set Points

Installation and Placement

Start-Up Procedures

Preliminary Checks and Safety Warnings

Covers preliminary checks, hot surface ignition warning, gas shutdown, and emergency procedures.

Heating System Service Checks

CSA Certification

Units are CSA certified without modifications.

Gas Piping Procedures and Safety

Guidelines for gas piping installation, connections, material, and leak testing.

Gas Pressure Testing (Supply and Manifold)

Procedures for testing gas supply and manifold pressures.

Gas Pressure and Combustion Data

Important: Manometer Safety

Shut off unit and remove manometer when finished; replace tap plug.

Proper Combustion Analysis

Flame Signal Measurement

Typical Operating Characteristics

Blower, Temperature Rise, and Static Pressure

Details blower operation, temperature rise measurement, and static pressure checks.

Maintenance Procedures

Blower, Filter, Flue, and Electrical Checks

Covers maintenance for blower, filters, flue, chimney, and electrical connections.

Warning: Blower Access Panel Safety

Ensure blower access panel is secure when unit is operating to prevent gas fume entry.

Heat Exchanger and Burner Cleaning

Procedure for cleaning the heat exchanger and burners using specific tools.

NOx Insert Reattachment

Caution: Leak Detection Fluid

Wiring and Sequence of Operation

Wiring Diagram (G60UHV-1, -2, -3 Units)

Electrical wiring diagram for specific G60UHV unit models.

Warning: Unit Grounding

Unit must be grounded in accordance with national and local codes to prevent electric shock.

Sequence of Operation

SureLight Control Self-Check

Control performs a self-check of limits and prove switches before heat call.

Two-Stage Thermostat Operation

Describes the heating sequence for two-stage thermostat operation.

Single-Stage Thermostat Operation

Describes the heating sequence for single-stage thermostat operation.

Heating Sequence Flow Chart (18M99 & 49M59)

Cooling Sequence of Operation

Continuous Fan Operation

Wiring Diagram (G60UHV-7 and Later)

Warning: Unit Grounding (Later Models)

Emphasizes the importance of proper unit grounding for safety.

Sequence of Operation (SureLight Board 100870)

SureLight Control Self-Check (Board 100870)

Control performs a self-check of limits and prove switches before heat call.

Two-Stage Thermostat Operation (Board 100870)

Describes the heating sequence for two-stage thermostat operation.

Single-Stage Thermostat Operation (Board 100870)

Describes the heating sequence for single-stage thermostat operation.

Heating Sequence Flow Chart (Board 100870)

Cooling Sequence of Operation (Board 100870)

Continuous Fan Operation (Board 100870)

Field Wiring and Jumper Settings

SureLight Boards 18M99 & 49M59 Settings

Jumper settings and wiring connections for various thermostat and accessory combinations.

SureLight Board 100870 Settings

Troubleshooting Guide

Unit Fails to Operate (All Modes)

Identifies causes and corrective actions for unit failure to operate in any mode.

Reverse Polarity Diagnostic Code

Explains the reverse polarity code and how to correct it.

Improper Ground Diagnostic Code

Explains the improper ground code and how to correct it.

Combustion Air Blower Fails to Energize (Heating Mode)

Combustion Air Inducer Fails to Energize (Heating Mode)

Ignitor Not Energized (Heating Mode)

Unit Fails to Fire (Heating Mode)

Burners Shut Down Prematurely (Heating Demand)

Low Flame Sense Signal (Heating Mode)

Indoor Blower Fails to Operate

Troubleshooting (Control Board 100870)

Unit Fails to Operate (Board 100870)

Identifies causes and corrective actions for unit failure to operate in any mode.

Diagnostic Codes (Polarity, Ground, Ignitor, Voltage)

Explains common diagnostic codes and their corrective actions.

Combustion Air Blower Fails to Energize (Heating Mode - Board 100870)

Combustion Air Inducer Fails to Energize (Heating Mode - Board 100870)

Ignitor Not Energized (Heating Mode - Board 100870)

Fails to Go to High Fire Operation

Unit Fails to Fire (Heating Mode - Board 100870)

Burners Shut Down Prematurely (Heating Demand - Board 100870)

Low Flame Sense Signal (Heating Mode - Board 100870)

Indoor Blower Fails to Operate (Board 100870)

ICM-2 Control Board Checkout Procedure

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