Lennox G60DFV Series Guide

02/02
*2P0202*
504,577M
*P504577M*
G60DFV(X)
SERIES
Litho U.S.A.
504,577M
02/2002
WHAT TO DO IF YOU SMELL GAS:
If the i formatio i this ma ual is ot followed
exactly, a fire or explosio may result causi g
property damage, perso al i jury or loss of
life.
WARNING
DDo ot try to light a y applia ce.
DDo ot touch a y electrical switch; do ot use a y
pho e i your buildi g.
DImmediately call your gas supplier from a eighbor's
pho e. Follow the gas supplier's i structio s.
DIf you ca ot reach your gas supplier, call the fire deĆ
partme t.
DExti guish a y ope flames.
GAS FURNACE
Do ot store or use gasoli e or other flamĆ
mable vapors a d liquids i the vici ity of
this or a y other applia ce.
I stallatio a d service must be performed by
a qualified i staller, service age cy or the gas
supplier.
E 2002 Lennox Industries Inc.
Dallas, Texas, USA

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Pa e 2
G60DFV(X) Parts Ide tificatio
DURALOKTM HEAT
EXCHANGER
ASSEMBLY
BURNERS
VARIABLE
SPEED
BLOWER
MOTOR
GAS
MANIFOLD
CABINET
CONTROL BOX
GAS
VALVE
COMBUSTION AIR
INDUCER
BLOWER ACCESS
PANEL
FLUE
COLLAR
TWO-STAGE,
VARIABLE SPEED
SURELIGHTt
INTEGRATED
CONTROL BOARD
LOWER ACCESS
PANEL
FIGURE 1
WARNING
Product co tai s fiberglass wool.
Disturbi g the i sulatio i this product duri g
i stallatio , mai te a ce, or repair will expose you
to fiberglass wool. Breathi g this may cause lu g
ca cer. (Fiberglass wool is k ow to the State of CalĆ
ifor ia to cause ca cer.)
Fiberglass wool may also cause respiratory, ski ,
a d eye irritatio .
To reduce exposure to this substa ce or for further
i formatio , co sult material safety data sheets
available from address show below, or co tact your
supervisor.
Le ox I dustries I c.
P.O. Box 799900
Dallas, TX 75379-9900
NOTE - This manual must be left with the equipment
user.
WARNING
Do ot set thermostat below 60°F (16°C) i heati g
mode. Setti g thermostat below 60°F (16°C) reduces
the umber of heati g cycles. Damage to the u it
may occur that is ot covered by the warra ty.
WARNING
If overheati g occurs or if gas supply fails to shut off,
shut off the ma ual gas valve to the applia ce before
shutti g off electrical supply.
CAUTION
Before attempti g to perform a y service or mai teĆ
a ce, tur the electrical power to u it OFF at the
disco ect switch.
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Pa e 3
WARNING
Do ot use this fur ace if a y part has bee u der
water. Immediately call a qualified service tech icia
to i spect the fur ace a d to replace a y part of the
co trol system a d a y gas co trol which has bee
u der water.
IMPORTANT
A y additio s, cha ges, or co versio s required i
order for the applia ce to satisfactorily meet the apĆ
plicatio eeds must be made by a Le ox service
tech icia usi g factory specified a d approved
parts.
WARNING
Improper i stallatio , adjustme t, alteratio , service
or mai te a ce ca cause property damage, perso Ć
al i jury or loss of life. I stallatio a d service must
be performed by a qualified i staller, service age cy
or the gas supplier.
Importa t Directio s
1 - Keep the furnace area clear and free of combustible
material, asoline, and other flammable vapors and
liquids. If it is installed in an insulated area, the furnace
must be kept free of insulatin material. Insulatin maĆ
terial may be combustible.
2 - DO NOT obstruct air flow to unit. Unit must receive an
unobstructed flow of combustion and ventilatin air.
3 - DO NOT store chlorine or fluorine products near unit
or introduce these products into the combustion air.
These products can cause furnace corrosion.
4 - DO NOT draw retur air from a room where this furĆ
ace, or a y other gas applia ce (ie., a water heatĆ
er), is i stalled. When return air is drawn from a room,
a ne ative pressure is created in the room. If a as apĆ
pliance is operatin in a room with ne ative pressure,
the flue products can be pulled back down the vent
pipe and into the room. This reverse flow of the flue
as may result in incomplete combustion and the
formation of carbon monoxide as. This toxic as
mi ht then be distributed throu hout the house by the
furnace duct system.
WARNING
The blower door must be securely i place whe the
blower a d bur ers are operati g. Gas fumes, which
could co tai carbo mo oxide, ca be draw i to
the livi g space resulti g i perso al i jury or death.
Your fur ace is a gas applia ce. It is critical that the as
supplied to the unit be completely burned to avoid the proĆ
duction of carbon monoxide as. Complete combustion of
the as requires, but is not limited to, correct as pressure
and as flow rate, adequate combustion air and proper
ventin .
WARNING
Carbo mo oxide gas is i visible, odorless, a d
toxic.
Exposure to carbon monoxide as can cause personal injuĆ
ry and even death to all occupants, includin pets. Any item
that is powered by, or ives off heat from, a combustion proĆ
cess (includin lawn mowers, automobiles, and fireplaces)
has the potential to produce carbon monoxide as. Because
of this, Le ox recomme ds the use of a carbo mo oxĆ
ide detector i your home, eve if you do ot ow gas
applia ces. Reliable detectors are available at reasonable
retail prices. Contact your Lennox dealer for more details
about this investment in your safety.
Your furnace is desi ned to meet standards set by nationĆ
al a encies. It should operate safely when properly
installed and maintained. However, the unit's perforĆ
mance can be reatly impacted by the individual installaĆ
tion and the operatin environment. It is your responsibilĆ
ity to ensure that this appliance is maintained. Proper
maintenance is critical for your safety and the satisfactory
operation of the product. Le ox stro gly recomme ds
a ual i spectio a d mai te a ce of this applia ce.
Contact your Lennox dealer for an inspection by a qualiĆ
fied service technician.
Lighti g I formatio & Operatio
WARNING
If you do ot follow these i structio s exactly, a fire
or explosio may result causi g property damage,
perso al i jury or death.
BEFORE LIGHTING smell all around the appliance area
for as. Be sure to smell next to the floor because some as
is heavier than air and will settle on the floor.
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Pa e 4
The as valve on the G60DFV(X) is equipped with either a
as control knob or lever. Use only your hand to turn the
as control knob or push the as lever. Never use tools. If
the knob or lever will not 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.
Placi g the G60DFV(X) fur ace i to operatio :
G60DFV(X) units are equipped with a SureLi htt i nition
system. Do ot attempt to manually li ht burners on these
furnaces. Each time the thermostat calls for heat, the burnĆ
ers will automatically li ht. The i nitor does not et hot
when there is no call for heat on units with the SureLi htt
i nition system.
Operati g the Gas Valve (Figures 3 a d 4)
1 - STOP! Read the safety information at the be innin of
this section.
2 - Set the thermostat to the lowest settin . See fi ure 2.
3 - Turn off all electrical power to the unit.
THERMOSTATS
FIGURE 2
4 - This furnace is equipped with an i nition device which
automatically li hts the burners. Do ot try to li ht the
burners by hand.
5 - Remove the upper access panel.
6 - White Rodgers 36E Gas Valve - Switch as valve leĆ
ver to OFF. See fi ure 3.
Honeywell VR8205 Gas Valve - Turn knob on as
valve clockwise to OFF. Do not force. See fi ure
4.
7 - Wait five minutes to clear out any as. If you then smell
as, STOP! Immediately call your as supplier from a
nei hbor's phone. Follow the as supplier's instrucĆ
tions. If you do not smell as o to next step.
8 - White Rodgers 36E Gas Valve - Switch as valve lever to
ON. See fi ure 3.
Honeywell VR8205 Gas Valve - Turn knob on as valve
counterclockwise to ON. Do not force. See fi ure 4.
WHITE RODGERS 36E SERIES GAS VALVE
GAS VALVE SHOWN IN OFF POSITION
FIGURE 3
HONEYWELL VR8205 SERIES GAS VALVE
GAS VALVE SHOWN IN OFF POSITION
FIGURE 4
9 - Replace the upper access panel.
10 - Turn on all electrical power to to the unit.
11 - Set the thermostat to desired settin .
NO E - When unit is initially started, steps 1 through 11
may need to be repeated to purge air from gas line.
12 - If the appliance will not operate, follow the instructions
Turnin Off Gas to the Unit" and call your service techĆ
nician or as supplier.
Tur i g Off Gas to the U it
1 - Set the thermostat to the lowest settin .
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 as valve leĆ
ver to OFF.
Honeywell VR8205 Gas Valve - Turn knob on as
valve clockwise to OFF. Do not force.
5 - Replace the upper access panel.
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Pa e 5
Filters
This unit is not equipped with a filter or rack. A field-proĆ
vided, hi h-velocity filter is required to ensure proper unit
operation.
A filter must be in place any time the unit is operatin .
Seaso al I spectio s
A qualified service technician should inspect the complete
system each season (heatin and coolin ). The followin
maintenance procedures should only be conducted by a
qualified service technician. Do ot attempt to service
the u it i a y way.
Ve ti g System
WARNING
Asphyxiatio Hazard
The exhaust ve t for this fur ace must be securely
co ected to the fur ace flue collar at all times.
For your safety a d to fulfill the terms of the limited
warra ty, a qualified service tech icia must a ualĆ
ly i spect this fur ace a d its ve t system.
Annually (before heatin season) inspect furnace ventin
system, vent cap, heat exchan er and burners for corroĆ
sion, deterioration, or deposits of debris. Remove any obĆ
structions.
Inspect thefurnace ventin system to make sure it is in
place, physically sound and without holes, corrosion, or
blocka e. The vent connector must be correctly posiĆ
tioned and sloped upward. The vent connector must be
physically sound, without holes or excessive corrosion.
Inspect the furnace return air duct connection. The duct
must be sealed to the furnace and it must terminate outside
the space containin the furnace.
Inspect the physical support of the furnace to uarantee
that it is sound. The support must not sa and must not
have cracks or aps around the base of the furnace. There
must be a seal between the furnace base and the support.
Durin a seasonal check, the service technician will inĆ
spect the indoor blower and the burner flames alon with
the ventin system.
Blower
Check blower wheel for any debris and clean it, if necesĆ
sary. The blower motor is pre-lubricated for extended bearĆ
in life. No further lubrication is needed.
Bur er Flame
CAUTION
To e sure proper operatio , a qualified tech icia
should a ually check the bur er flame.
Service Remi der
Call your Lennox service technician if the unit will not operĆ
ate. Before callin , always check the followin to be sure
service is required.
1 - Check that electrical disconnect switches are ON.
2 - Check room thermostat for proper settin .
3 - Replace any blown fuses or reset circuit breakers.
4 - Gas valve should be ON.
5 - Air filter should not be plu ed, which wil limit air flow.
6 - Is as turned on at meter?
7 - Is manual main shut-off valve open?
Record the model and serial number of the furnace. These
numbers are on the unit nameplate, which is located below
the burners.
Serial Number ________________________________
Model Number ________________________________
Safety Precautio s
If you discover a y of the followi g, shut dow your
u it a d co tact a Le ox dealer for a i spectio by a
qualified tech icia .
DIf you repeatedly hear any new or unfamiliar sounds
while your unit is operatin , there may be a problem. For
example, poorly performin burners can produce unfaĆ
miliar noises.
DIf you smell any unusual odors, your unit may be operatĆ
in improperly. For example, units can ive off unfamilĆ
iar odors if components are required to operate in abĆ
normal conditions.
DLook for visible si ns of a malfunctionin unit. Examples
include unusual amounts of condensate on windows inĆ
side your house, visibly burnt components or unusual
dirt or rust accumulations on the vent pipe or in the unit.
DIf you experience headache, nausea, fati ue, or dizziĆ
ness, the cause could be exposure to carbon monoxide
as. This is often misdia nosed as the flu because
symptoms are similar. If you suffer from flu-like sympĆ
toms that are exa erated at home, but seem to subĆ
side while you are away from the house, exposure to
carbon monoxide could be the cause.
Your vi ilance may pay off in early detection of a problem
before either personal injury or property dama e occurs.
Do not hesitate to contact a qualified service technician as
an investment in your well bein .
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Pa e 6
Pla ed Service
You should expect a service technician to check the followĆ
in items durin an annual inspection. Power to the unit
must be shut off for the service technician's safety.
Fresh air grilles a d louvers (on the unit and in the room
where the furnace is installed) - Must be open and unobĆ
structed to provide combustion air.
Bur ers - Must be inspected for rust, dirt, or si ns of water.
Ve t pipe - Must be inspected for si ns of water, dama ed
or sa in pipe, or disconnected joints.
U it appeara ce - Must be inspected for rust, dirt, si ns
of water, burnt or dama ed wires, or components.
Blower access door - Must be properly in place and proĆ
vide a seal between the return air and the room where the
furnace is installed.
Retur air duct - Must be properly attached and provide
an air seal to the unit.
Operati g performa ce - Unit must be observed durin
operation to monitor proper performance of the unit and the
vent system.
Combustio gases - Flue products must be analyzed and
compared to the unit specifications.
Problems detected durin the inspection may make it necĆ
essary to temporarily shut down the furnace until the items
can be repaired or replaced.
Pay atte tio to your fur ace. Situations can arise beĆ
tween annual furnace inspections that may result in unsafe
operation. For instance, items innocently stored next to the
furnace may obstruct the combustion air supply. This could
cause incomplete combustion and the production of carĆ
bon monoxide as.
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