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Lennox G61MPV

Lennox G61MPV
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Page 1
© 2012 Lennox Industries Inc.
Corp. 0310−L7
G61MPV
Service Literature
Revised 02−2012
G61MPV SERIES UNITS
G61MPV series units are high−efficiency multi−position
(upflow, downflow, horizontal right and left) gas furnaces
manufactured with Lennox Duralok Plust heat exchang-
ers formed of an aluminized steel primary with a stainless
steel secondary condensing coil. G61MPV units are avail-
able in heating capacities of 44,000 to 132,000 Btuh
(13.0.0 to 38.6 kW) and cooling applications from 2 to 5
tons (7.0 kW to 17.5 kW). Refer to Engineering Handbook
for proper sizing.
Units are factory equipped for use with natural gas. Kits are
available for conversion to LPG operation. G61MPV model
units are equipped with the two−stage variable speed inte-
grated SureLight® control. All G61MPV units meet the Cali-
fornia 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
Specifications Page 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Data Page 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Identification Page 23. . . . . . . . . . . . . . . . . . . . . . . .
I Unit Components Page 24. . . . . . . . . . . . . . . . . . . . . . .
II Installation Page 50. . . . . . . . . . . . . . . . . . . . . . . . . . . .
III Start Up Page 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IV Heating System Service Checks Page 68. . . . . . . . .
V Typical Operating Characteristics Page 71. . . . . . . . .
VI Maintenance Page 72. . . . . . . . . . . . . . . . . . . . . . . . . .
VII Wiring and Sequence of Operation Page 75. . . . . .
VIII Field Wiring and Jumper Setting Page 90. . . . . . . .
IX Control Board Troubleshooting Page 95. . . . . . . . . .
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.

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Lennox G61MPV Specifications

General IconGeneral
Blower TypeVariable speed
Energy Star CertifiedYes
Gas ValveModulating
Fuel TypeNatural gas or propane
Ignition TypeElectronic
Heating Stages2
WarrantyLimited Lifetime warranty on heat exchanger; 10-Year limited warranty on covered components
Heating Capacity44, 000 to 132, 000 BTUH

Summary

G61 MPV SERIES UNITS

Specifications

Detailed technical specifications for G61MPV units, covering performance and electrical data.

Optional Accessories

List of optional accessories available for G61MPV units, including filter kits and cabinet accessories.

Blower Data

Performance data for G61MPV blower motors, including airflow and wattage at various static pressures.

Parts Arrangement

Diagram illustrating the arrangement of major components within the G61MPV unit.

Unit Components

Description and identification of key internal components of the G61MPV unit, including control box and board.

Installation and Venting

Guidelines and requirements for installing G61MPV furnaces, including vent pipe and termination configurations.

Start-Up Procedures

Step-by-step instructions for safely starting up the G61MPV furnace for heating operation.

Heating System Service Checks

Procedures for performing essential service checks on the G61MPV heating system.

Maintenance Procedures

Guidelines for regular maintenance of the G61MPV furnace, including blower, filters, and heat exchanger cleaning.

Wiring and Sequence of Operation

Electrical diagrams and operational sequences for the SureLight control boards.

Field Wiring Applications and Jumper Settings

Guidelines for field wiring and jumper configurations for various thermostat and system setups.

Troubleshooting Guide

Diagnostic codes and corrective actions for common problems encountered with G61MPV furnaces.

General Safety Warnings

SPECIFICATIONS

OPTIONAL ACCESSORIES

BLOWER DATA

G61 MPV PARTS ARRANGEMENT

IUNIT COMPONENTS

Control Box Components

Details on the control box, including transformer, interlock switch, circuit breaker, and integrated control board.

Safety Warnings

Critical safety warnings regarding electronic controls and potential hazards during servicing.

DIP SWITCH SETTINGS

Blower Off Delay Settings

Adjusting the blower-off delay time for comfort using DIP switches 1-4.

Cooling Mode Blower Speed Settings

Selecting cooling mode blower speeds using DIP switches 5-6.

Blower Speed Adjustment Settings

Adjusting blower speed by +/- 10% using DIP switches 7-8.

Cooling Mode Blower Speed Ramping

Selecting cooling mode blower speed ramping options using DIP switches 9-10.

Heating Mode Blower Speed Settings

Selecting heating mode blower speeds using DIP switches 11-12.

ON-BOARD LINKS AND STATUS LEDs

Integrated Control Board (SureLight Board 100870)

WARNING

ERROR CODE MANAGEMENT

CHeating Components

Ignitor Details

Information on the SureLight ignitor, its voltage control, and resistance values.

Flame Sensor Function

Description of the flame sensor's location, function, and how it ensures continuous burner operation.

WARNING

WARNING

IIPLACEMENT AND INSTALLATION

AVent Piping Guidelines

IMPORTANT Venting Notes

BPVC Joint Cementing Procedure

WARNING

CVenting Practices

Exhaust Piping

Instructions for routing, supporting, and terminating exhaust piping in upflow, downflow, and horizontal applications.

Important Venting Precautions

Intake Piping

Testing for Proper Venting and Sufficient Combustion Air

WARNING

IMPORTANT Venting Notes

VENT TERMINATION CLEARANCES

VENT TERMINATION CLEARANCES FOR DIRECT VENT INSTALLATIONS

Details of Intake and Exhaust Piping Terminations

G61 MP DIRECT VENT APPLICATION USING EXISTING CHIMNEY

Details of Exhaust Piping Terminations

Guidelines for terminating exhaust pipes in non-direct vent applications, including routing and support.

Condensate Piping

CAUTION Regarding Condensate Trap

CAUTION

IIISTART-UP

Preliminary and Seasonal Checks

Steps for inspecting electrical wiring and voltage before starting the unit.

Heating Start-Up

Procedures for initiating heating operation, including gas valve and ignitor sequence.

Gas Valve Operation

Instructions for operating the gas valve, including safety precautions and normal/off positions.

WARNING: Safety Before Operation

IVHEATING SYSTEM SERVICE CHECKS

C.S.A. Certification

Information regarding CSA design certification for G61MPV units.

Gas Piping

Guidelines and precautions for gas piping installation, including connector types and pressure drop.

Testing Gas Piping

Procedures for safely testing gas piping connections for leaks.

Gas Piping Safety Warnings

IMPORTANT Emergency Shutdown

Gas Piping Test Procedure

DGas Pressure Adjustment

Manifold Pressure Measurement

Detailed steps for measuring manifold pressure at low and high fire settings.

High Altitude Considerations

Notes on potential manifold pressure adjustments required for installations at higher altitudes.

CAUTION Regarding Gas Valve Adjustments

G Proper Combustion

H Condensate pH Range

IFlame Signal

VTYPICAL OPERATING CHARACTERISTICS

Blower Operation and Adjustment

How the blower operates based on thermostat settings and how to adjust blower speed.

Temperature Rise Measurement

Instructions for measuring temperature rise and adjusting blower speed for optimal performance.

External Static Pressure Measurement

Procedures for measuring external static pressure and ensuring it meets system requirements.

VIMAINTENANCE

Blower Maintenance

Instructions for checking and cleaning the blower wheel for debris.

Filter Inspection and Replacement

Guidelines for inspecting and replacing furnace filters based on cabinet size.

Exhaust and Air Intake Pipes Check

Instructions for inspecting vent pipes for blockages and ensuring proper connections.

WARNING: Electrical and Servicing Hazards

WARNING: Blower Access Panel Safety

Winterizing and Condensate Trap Care

Cleaning Heat Exchanger

IMPORTANT Safety Gear for Cleaning

VII Wiring and Sequence of Operation

SureLight Board 49 M59 Wiring

Detailed wiring diagram for the SureLight Board 49M59, showing connections to various components.

HEATING SEQUENCE OF OPERATION

COOLING SEQUENCE OF OPERATION

Continuous Low Speed Fan Sequence of Operation

Flowchart describing the operation of the indoor blower in continuous low speed fan mode.

DG61 MPV with SureLight Board 100870

ESureLight Board 100870 Operation

Explanation of the SureLight Board 100870's operation based on thermostat type and dip switch settings.

SureLight Control Self Check

Description of the SureLight control's self-check process upon a call for heat.

Two-Stage Thermostat Operation

Furnace operation with a two-stage thermostat and relevant dip switch settings for the SureLight Board 100870.

Single-Stage Thermostat Operation

Furnace operation with a single-stage thermostat and relevant dip switch settings for the SureLight Board 100870.

HEATING SEQUENCE OF OPERATION

COOLING SEQUENCE OF OPERATION

CONTINUOUS LOW SPEED FAN SEQUENCE OF OPERATION

VIII Field Wiring Applications and Jumper Settings

SureLight Board 49 M59 Wiring Applications

Wiring diagrams and jumper settings for G61MPV units with SureLight Board 49M59 and different thermostats.

IXTROUBLESHOOTING

SureLight Board 49 M59 Troubleshooting

Troubleshooting guide for issues related to the SureLight Board 49M59, including flash codes and possible causes.

PROBLEM 1: UNIT FAILS TO OPERATE

Troubleshooting steps for when the unit fails to operate in cooling, heating, or continuous fan modes.

PROBLEM 2: UNIT FAILS TO FIRE IN HEATING MODE

Troubleshooting steps for when the combustion air inducer does not energize during heating.

PROBLEM 3: UNIT FAILS TO FIRE IN HEATING MODE, COMBUSTION AIR INDUCER DOES NOT ENERGIZE

Troubleshooting steps for heating mode failures where the combustion air inducer is not energized.

PROBLEM 4: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR BLOWER ENERGIZES, IGNITOR IS NOT ENERGIZED.

Troubleshooting steps when the ignitor is energized but the unit fails to fire in heating mode.

PROBLEM 5: BURNERS LIGHT WITH A HEATING DEMAND BUT UNIT SHUTS DOWN PREMATURELY

Troubleshooting steps when burners light but the unit shuts down before satisfying the thermostat.

PROBLEM 6: CONTROL SIGNALS LOW FLAME SENSE DURING HEATING MODE

Troubleshooting steps when the control signals a low flame sense during heating.

PROBLEM 7: INDOOR BLOWER FAILS TO OPERATE IN COOLING, HEATING, OR CONTINUOUS FAN MODE

Troubleshooting steps for indoor blower failure in any operating mode.

PROBLEM 1: UNIT FAILS TO OPERATE IN THE COOLING, HEATING, OR CONTINUOUS FAN MODE

Troubleshooting steps for when the unit fails to operate in cooling, heating, or continuous fan modes.

PROBLEM 2: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR BLOWER DOES NOT ENERGIZE

Troubleshooting steps for heating mode failures where the combustion air inducer does not energize.

PROBLEM 3: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR INDUCER DOES NOT ENERGIZE

Troubleshooting steps for heating mode failures where the combustion air inducer does not energize.

PROBLEM 4: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR BLOWER ENERGIZES, IGNITOR IS NOT ENERGIZED.

Troubleshooting steps when the ignitor is energized but the unit fails to fire in heating mode.

PROBLEM 5: UNIT FIRES ON LOW FIRE, FAILS TO GO TO HIGH FIRE OPERATION

Troubleshooting steps when the unit fires on low fire but fails to transition to high fire operation.

PROBLEM 6: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR BLOWER ENERGIZES, IGNITOR IS ENERGIZED.

Troubleshooting steps when the ignitor is energized but the unit fails to fire in heating mode.

PROBLEM 7: BURNERS LIGHT WITH A HEATING DEMAND BUT UNIT SHUTS DOWN PREMATURELY

Troubleshooting steps when burners light but the unit shuts down before satisfying the thermostat.

PROBLEM 8: CONTROL SIGNALS LOW FLAME SENSE DURING HEATING MODE

Troubleshooting steps when the control signals a low flame sense during heating.

PROBLEM 9: INDOOR BLOWER FAILS TO OPERATE IN COOLING, HEATING, OR CONTINUOUS FAN MODE

Troubleshooting steps for indoor blower failure in any operating mode.

CIndoor Blower Motor

Emerson Motor Control Wiring

Wiring instructions for the Emerson motor with the two-stage variable speed control.

GenTeqEmerson Motor Control Wiring

Wiring instructions for GenTeq/Emerson motors with the two-stage variable speed control.

Verify Control Motor Operation (Emerson Motor Only)

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