Lennox G60DFV Series Installation and operation manual

Page 1 ©2002 Lennox Industries Inc.
Corp. 0211−L3 G60DFV(X)
Service Literature Revised 08−2007
G60DFV(X) SERIES UNITS
G60DFV series units are mid−efficiency gas furnaces used
for downflow applications only, manufactured with Lennox
Duralok Plus heat exchangers formed of aluminized steel.
Units are available in heating capacities of 66,000 to
132,000 Btuh and cooling applications up to 5 tons. Refer
to Engineering Handbook for proper sizing.
Units are factory equipped for use with natural gas. Kits are
available for conversion to LPG operation. G60DFV model
units are equipped with the two−stage variable speed inte-
grated SureLight control. G60DFV model units meet the
California Nitrogen Oxides (NOx) Standards and California
Seasonal 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Altitude Page 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Identification Page 7. . . . . . . . . . . . . . . . . . . . . . . . .
I Unit Components Page 8. . . . . . . . . . . . . . . . . . . . . . . .
II Installation Page 30. . . . . . . . . . . . . . . . . . . . . . . . . . . .
III Start Up Page 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IV Heating System Service Checks Page 31. . . . . . . . .
V Typical Operating Characteristics Page 33. . . . . . . . .
VI Maintenance Page 33. . . . . . . . . . . . . . . . . . . . . . . . . .
VII Wiring and Sequence of Operation Page 37. . . . . .
VIII Field Wiring and Jumper Settings Page 52. . . . . . .
IX Integrated Control Board Troubleshooting Page 57.
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.

Page 2
SPECIFICATIONS
Gas
Hti
ModelNo. G60DFV−36A−070 G60DFV−36B−090 G60DFV−60C−090
Heating
Performance
Low NOxModel No. G60DFV−36A−070X − − − G60DFV−60C−090X
P
er
f
ormance
Input− Btuh (kW) low fire 45,000 (13.2) 60,000 (17.6) 60,000 (17.6)
Output− Btuh (kW) low fire 36,000 (10.5) 48,000 (14.1) 48,000 (14.1)
Input− Btuh (kW) high fire 66,000 (19.3) 88,000 (25.8) 88,000 (25.8)
Output− Btuh (kW) high fire 54,000 (15.8) 72,000 (21.1) 72,000 (21.1)
lAFUE 80.0% 80.0% 80.0%
California Seasonal Efficiency 77.0% 77.1% 77.0%
Highstatic− in.w.g. (Pa) .80 (200) .80 (200) .80 (200)
Temperature rise range − _F (_C) low fire 20 − 50 (11 − 28) 25 − 55 (14 − 31) 20 − 50 (11 − 28)
Temperature rise range − _F (_C) high fire 35 − 65 (19 − 36) 45 − 75 (25 − 42) 30 − 60 (17 − 33)
Connections GaspipesizeIPS− in. (mm) 1/2 (12.7) 1/2 (12.7) 1/2 (12.7)
Flue connection − in. (mm) round 4 (102) 4 (102) 4 (102)
Indoor
Blower
Wheelnominaldiameter xwidth −in. 10 x 8 10 x 8 11−1/2 x 10
Blower
mm 254 x 203 254 x 203 292 x 254
Motoroutput − hp (W) 1/2 (373) 1/2 (373) 1 (746)
Tons(kW) ofadd-oncooling 2 − 3 (7.0 − 10.6) 2 − 3.5 (7.0 − 12.3) 3.5 − 5 (12.3 − 17.6)
Shippingweight − 1 package 132 lbs. (60 kg) 154 lbs. (70 kg) 172 lbs. (78 kg)
Matching Coils CR26−18N−F, CR26−30N−F,
CR26−36N−F
CR26−36W−F,
CR26−48N−F
CR26−48N−F,
CR26−60N−F
Electricalcharacteristics 120 volts − 60 hertz − 1 phase (less than 12 amps)
OPTIONAL ACCESSORIES −MUST BE ORDERED EXTRA
Down−Flow Additive Base − Shipping Weight − lbs. (kg) 11M59 − 9 (4) 11M60 − 10 (5) 11M61 − 11 (5)
High Altitude See Page 6
LPG/Propane Kit See Page 6
Propane/Natural Gas Kit 0 to 7500 ft. (0 to 2286 m) 59M87 59M87 59M87
lAnnual Fuel Utilization Efficiency based on DOE test procedures and according to FTC labeling regulations. Isolated combustion system rating for non-weatherized furnaces.
NOTE − Filters and provisions for mounting are not furnished and must be field provided.

Page 3
SPECIFICATIONS Cont.
Gas
Hti
ModelNo. G60DFV−60C−110 G60DFV−60D−135
Heating
Performance
Low NOxModel No. G60DFV−60C−110X − − − −
P
er
f
ormance
Input− Btuh (kW) low fire 75,000 (22.0) 90,000 (26.4)
Output− Btuh (kW) low fire 61,000 (17.9) 73,000 (21.4)
Input− Btuh (kW) high fire 110,000 (32.2) 132,000 (38.7)
Output− Btuh (kW) high fire 91,000 (26.7) 109,000 (31.9)
lAFUE 80.0% 80.0%
California Seasonal Efficiency 75.8% 76.5%
Highstatic− in.w.g. (Pa) .80 (200) .80 (200)
Temperature rise range − _F (_C) low fire 20 − 50 (11 − 28) 25 − 55 (14 − 31)
Temperature rise range − _F (_C) high fire 30 − 60 (17 − 33) 40 − 70 (22 − 39)
Connections GaspipesizeIPS− in. (mm) 1/2 (12.7) 1/2 (12.7)
Flue connection − in. (mm) round 4 (102) 4 (102)
Indoor
Blower
Wheelnominaldiameter xwidth −in. 11−1/2 x 10 11−1/2 x 10
Blower
mm 292 x 254 292 x 254
Motoroutput − hp (W) 1 (746) 1 (746)
Tons(kW) ofadd-oncooling 3.5 − 5 (12.3 − 17.6) 4 − 5 (14.1 − 17.6)
Shippingweight − 1 package 184 lbs. (83 kg) 198 lbs. (76 kg)
Matching Coils CR26−48N−F,
CR26−60N−F
CR26−48W−F,
CR26−60W−F
Electricalcharacteristics 120 volts − 60 hertz − 1 phase (less than 12 amps)
OPTIONAL ACCESSORIES −MUST BE ORDERED EXTRA
Down−Flow Additive Base − Shipping Weight − lbs. (kg) 11M61 − 11 (5) 11M62 − 13 (6)
High Altitude Page 6
LPG/Propane Kit Page 6
Propane/Natural Gas Kit 0 to 7500 ft. (0 to 2286 m) 59M87 59M87
lAnnual Fuel Utilization Efficiency based on DOE test procedures and according to FTC labeling regulations. Isolated combustion system rating for non-weatherized furnaces.
NOTE − Filters and provisions for mounting are not furnished and must be field provided.

Page 4
BLOWER DATA
G60DFV−36A−070 BLOWER PERFORMANCE
0 through 0.80 in. w.g. (0 Through 200 Pa) External Static Pressure Range
Blower Control Factory Settings ADJUST − NORM
HEAT − 2
COOL − 4
ADJUST"
Speed Switch Positions
ADJUST"
Switch
2nd Stage HEAT" Speed 2nd Stage COOL" Speed
Switch
P
os
i
t
i
o
n
s
1 2 3 4 1 2 3 4
Positions
cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s
+" (Plus) 880 415 1025 485 1135 535 1320 625 1045 495 1210 570 1300 615 1400 660
NORM (Normal) 800 380 930 440 1035 490 1200 565 950 450 1100 520 1180 555 1275 600
" (Minus) 720 340 835 395 930 440 1080 510 855 405 990 465 1060 500 1145 540
ADJUST" 1st Stage HEAT" Speed 1st Stage COOL" Speed
ADJUST
Switch
P iti
1 2 3 4 1 2 3 4
Switch
Positions cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s
+" (Plus) 815 385 945 445 1055 500 1210 570 700 330 785 370 840 395 900 425
NORM (Normal) 740 350 860 405 960 455 1100 520 640 300 715 335 765 360 820 385
" (Minus) 665 315 775 365 865 410 990 465 575 270 645 305 690 325 735 350
NOTES − The effect of static pressure and filter resistance is included in air volumes shown.
1st stage HEAT is approximately 91% of the same 2nd stage HEAT speed position.
1st stage COOL (two speed air conditioning units only) is approximately 70% (65% for units built prior to 09−2002) of the same 2nd stage COOL speed position.
Continuous Fan Only speed is approximately 38% of the same 2nd stage COOL speed position − minimum 500 cfm (235 L/s).
Lennox Harmony IItzone control applications − Minimum blower heating speed is approximately 75% of the 1st stage HEAT speed position.
Lennox Harmony IItzone control applications − Minimum blower cooling speed is approximately 45% of the 2nd stage COOL speed position.
G60DFV−36B−090 BLOWER PERFORMANCE
0 through 0.80 in. w.g. (0 Through 200 Pa) External Static Pressure Range
Blower Control Factory Settings ADJUST − NORM
HEAT − 2
COOL − 4
ADJUST"
Speed Switch Positions
ADJUST"
Switch
2nd Stage HEAT" Speed 2nd Stage COOL" Speed
Switch
Positions 1 2 3 4 1 2 3 4
Positions
cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s
+" (Plus) N/A N/A 1110 525 1295 610 1350 635 1075 505 1240 585 1345 635 1475 695
NORM (Normal) N/A N/A 1005 475 1180 555 1225 580 975 460 1130 530 1220 575 1345 635
" (Minus) N/A N/A 905 430 1060 500 1105 520 880 415 1015 480 1100 520 1210 570
ADJUST" 1st Stage HEAT" Speed 1st Stage COOL" Speed
ADJUST
Switch
P iti
1 2 3 4 1 2 3 4
Switch
Positions cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s
+" (Plus) N/A N/A 956 450 1175 555 1210 570 800 377 870 410 930 438 1000 471
NORM (Normal) N/A N/A 870 410 1070 505 1110 525 725 3423 800 377 845 398 910 429
" (Minus) N/A N/A 780 370 960 455 995 470 650 306 720 339 770 363 825 389
NOTES − The effect of static pressure and filter resistance is included in air volumes shown.
1st stage HEAT is approximately 91% of the same 2nd stage HEAT speed position.
1st stage COOL (two speed air conditioning units only) is approximately 70% (65% for units built prior to 09−2002) of the same 2nd stage COOL speed position.
Continuous Fan Only speed is approximately 38% of the same 2nd stage COOL speed position − minimum 500 cfm (235 L/s).
Lennox Harmony IItzone control applications − Minimum blower heating speed is approximately 75% of the 1st stage HEAT speed position.
Lennox Harmony IItzone control applications − Minimum blower cooling speed is approximately 45% of the 2nd stage COOL speed position.
N/A − 1st stage and 2nd stage HEAT, speed position 1, cannot be used with this model.

Page 5
BLOWER DATA
G60DFV−60C−090 BLOWER PERFORMANCE
0 through 0.80 in. w.g. (0 Through 200 Pa) External Static Pressure Range
Bottom Return Air, Side Return Air with Optional RAB Return Air Base, Return Air from Both Sides or
Return Air from Bottom and One Side.
Blower Control Factory Settings ADJUST − NORM
HEAT − 2
COOL − 4
ADJUST"
Speed Switch Positions
ADJUST"
Switch
2nd Stage HEAT" Speed 2nd Stage COOL" Speed
Switch
Positions 1 2 3 4 1 2 3 4
Positions
cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s
+" (Plus) 1525 720 1730 815 1850 870 2130 1005 1670 790 1805 850 2035 960 2275 1075
NORM (Normal) 1385 655 1575 745 1770 835 1935 915 1520 715 1640 775 1850 870 2070 975
" (Minus) 1245 590 1415 670 1595 750 1745 825 1365 645 1475 695 1665 785 1860 880
ADJUST" 1st Stage HEAT" Speed 1st Stage COOL" Speed
ADJUST
Switch
P iti
1 2 3 4 1 2 3 4
Switch
Positions cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s
+" (Plus) 1380 650 1580 745 1800 850 1980 935 1070 504 1270 599 1385 653 1545 729
NORM (Normal) 1255 590 1440 680 1635 775 1800 850 955 450 1075 507 1240 585 1370 646
" (Minus) 1130 535 1295 610 1475 695 1620 765 865 408 910 429 1110 523 1220 575
NOTES − The effect of static pressure and filter resistance is included in air volumes shown.
1st stage HEAT is approximately 91% of the same 2nd stage HEAT speed position.
1st stage COOL (two speed air conditioning units only) is approximately 70% (60% for units built prior to 09−2002) of the same 2nd stage COOL speed position.
Continuous Fan Only speed is approximately 38% of the same 2nd stage COOL speed position.
Lennox Harmony IItzone control applications − Minimum blower heating speed is approximately 75% of the 1st stage HEAT speed position.
Lennox Harmony IItzone control applications − Minimum blower cooling speed is approximately 42% of the 2nd stage COOL speed position.
G60DFV−60C−110 BLOWER PERFORMANCE
0 through 0.80 in. w.g. (0 Through 200 Pa) External Static Pressure Range
Bottom Return Air, Side Return Air with Optional RAB Return Air Base, Return Air from Both Sides or
Return Air from Bottom and One Side.
Blower Control Factory Settings ADJUST − NORM
HEAT − 2
COOL − 4
ADJUST"
Speed Switch Positions
ADJUST"
Switch
2nd Stage HEAT" Speed 2nd Stage COOL" Speed
Switch
P
os
i
t
i
o
n
s
1 2 3 4 1 2 3 4
Positions
cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s
+" (Plus) 1530 720 1720 810 1955 925 2145 1010 1665 785 1810 855 2030 960 2300 1085
NORM (Normal) 1390 655 1565 740 1780 840 1950 920 1510 715 1645 775 1845 870 2090 985
" (Minus) 1250 590 1405 665 1600 755 1755 830 1360 640 1480 700 1660 785 1885 890
ADJUST" 1st Stage HEAT" Speed 1st Stage COOL" Speed
ADJUST
Switch
P iti
1 2 3 4 1 2 3 4
Switch
Positions cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s
+" (Plus) 1375 650 1555 735 1795 850 1960 925 1035 488 1035 488 1300 613 1445 681
NORM (Normal) 1250 590 1410 665 1635 770 1785 840 950 448 1030 486 1180 556 1315 620
" (Minus) 1125 530 1270 600 1470 695 1605 755 855 403 925 436 1065 502 1195 563
NOTES − The effect of static pressure and filter resistance is included in air volumes shown.
1st stage HEAT is approximately 91% of the same 2nd stage HEAT speed position.
1st stage COOL (two speed air conditioning units only) is approximately 70% (60% for units built prior to 09−2002) of the same 2nd stage COOL speed position.
Continuous Fan Only speed is approximately 38% of the same 2nd stage COOL speed position.
Lennox Harmony IItzone control applications − Minimum blower heating speed is approximately 75% of the 1st stage HEAT speed position.
Lennox Harmony IItzone control applications − Minimum blower cooling speed is approximately 42% of the 2nd stage COOL speed position.

Page 6
BLOWER DATA
G60DFV−60D−135 BLOWER PERFORMANCE
0 through 0.80 in. w.g. (0 Through 200 Pa) External Static Pressure Range
Bottom Return Air, Side Return Air with Optional RAB Return Air Base, Return Air from Both Sides or
Return Air from Bottom and One Side.
Blower Control Factory Settings ADJUST − NORM
HEAT − 2
COOL − 4
ADJUST"
Speed Switch Positions
ADJUST"
Switch
2nd Stage HEAT" Speed 2nd Stage COOL" Speed
Switch
P
os
i
t
i
o
n
s
1 2 3 4 1 2 3 4
Positions
cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s
+" (Plus) 1545 730 1775 840 1985 935 2175 1025 1710 805 1850 875 2080 980 2300 1085
NORM (Normal) 1405 665 1615 760 1805 850 1980 935 1555 735 1680 795 1890 890 2095 990
" (Minus) N/A N/A 1455 685 1625 765 1780 840 1400 660 1515 715 1700 805 1885 890
ADJUST" 1st Stage HEAT" Speed 1st Stage COOL" Speed
ADJUST
Switch
P iti
1 2 3 4 1 2 3 4
Switch
Positions cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s
+" (Plus) 1400 660 1620 765 1825 860 2020 955 1090 514 1175 554 1350 637 1500 707
NORM (Normal) 1275 600 1475 695 1660 785 1835 865 1000 471 1090 514 1230 580 1375 648
" (Minus) N/A N/A 1325 625 1495 705 1650 780 885 417 975 460 1100 519 1230 580
NOTES − The effect of static pressure and filter resistance is included in air volumes shown.
1st stage HEAT is approximately 91% of the same 2nd stage HEAT speed position.
1st stage COOL (two speed air conditioning units only) is approximately 70% (60% for units built prior to 09−2002) of the same 2nd stage COOL speed position.
Continuous Fan Only speed is approximately 38% of the same 2nd stage COOL speed position.
Lennox Harmony IItzone control applications − Minimum blower heating speed is approximately 75%of the 1st stage HEAT speed position.
Lennox Harmony IItzone control applications − Minimum blower cooling speed is approximately 45% of the 2nd stage COOL speed position.
N/A − 1st stage and 2nd stage HEAT, speed position 1 with " (Minus) adjust, cannot be used with this model.
FILTER AIR RESISTANCE
cfm L/s in. w.g. Pa cfm L/s in. w.g. Pa
0 0 0.00 0 1400 660 0.15 35
200 95 0.01 0 1600 755 0.19 45
400 190 0.03 5 1800 850 0.23 55
600 285 0.04 10 2000 945 0.27 65
800 380 0.06 15 2200 1040 0.33 80
1000 470 0.09 20 2400 1130 0.38 95
1200 565 0.12 30 2600 1225 0.44 110
Data is for 1 inch (25 mm) cleanable filter (field provided).
HIGH ALTITUDE / MANIFOLD PRESSURE INFORMATION
Altitude Manifold Pressure
at all altitudes
Model
In
p
ut Gas
0 − 4500 ft.
(0 − 1372 m)
4,501 − 7500 ft.
(1373 − 2286 m)
7501−10,000 ft.
(2286 − 3048 m)
at all altitudes
Input
Size
Gas
Required
Conversion
Pressure Required
Conversion
Pressure Required
Conversion
Pressure Low Fire High Fire
C
onversion
Kit
Pressure
Switch
C
onversion
Kit
Pressure
Switch
C
onversion
Kit
Pressure
Switch in. w.g. kPa in. w.g. kPa
045/070−1 to −6
Nat. No Change No Change No Change No Change 59M16 18M64 1.7 0.42 3.5 0.87
045/070
−
1
to −
6
LPG 59M13 No Change 59M13 No Change 59M14 18M64 4.9 1.22 10.0 2.5
090−1 to −6
Nat. No Change No Change No Change 18M61 59M16 18M64 1.7 0.42 3.5 0.87
090
−
1
to −
6
LPG 59M13 No Change 59M13 18M61 59M14 18M64 4.9 1.22 10.0 2.5
110/−135−1 to−−6
Nat. No Change No Change No Change 18M63 59M16 18M61 1.7 0.42 3.5 0.87
110/
−
135
−
1
to−−
6
LPG 59M13 No Change 59M13 18M63 59M14 18M61 4.9 1.22 10.0 2.5
045/070−7 and Nat. No Change No Change No Change No Change 59M17 18M64 1.7 0.42 3.5 0.87
045/070 7
and
later LPG 59M13 No Change 59M13 No Change 59M14 18M64 4.9 1.22 10.0 2.5
090−7 and later
Nat. No Change No Change No Change 18M61 59M17 18M64 1.7 0.42 3.5 0.87
090
−
7
an
d
l
ater LPG 59M13 No Change 59M13 18M61 59M14 18M64 4.9 1.22 10.0 2.5
110/135−7 and Nat. No Change No Change No Change 18M63 59M17 18M61 1.7 0.42 3.5 0.87
110/135 7
and
later LPG 59M13 No Change 59M13 18M63 59M14 18M61 4.9 1.22 10.0 2.5
Pressure switch is factory set. No adjustment necessary. All models use the factory installed pressure switch from 0−4500 feet (0−1372 m).

Page 7
FIGURE 1
G60DFV(X) PARTS ARRANGEMENT
Combustion Air Pres-
sure Switch Assembly
(Two switches)
Blower Assembly
Variable Speed
Blower Motor
Internal Flue Pipe
Assembly
Flue Box Gasket
Flue Collector Box
Gasket
Combustion Air Inducer
Gasket
Primary
Limit
Heat Exchanger
Combustion
Air Orifice
Transformer
SureLighttTwo−Stage
Variable Spee Integrated
Control Board
Flue
Chase
Gasket
Door
Interlock Switch
Flame Sensor
Gas
Valve
Burners
Ignitor
Gas
Orifices
Ignitor
Bracket
Burner Box Bottom
Flame Rollout Switches
Air Intake
Cover
Air Baffle
Gasket
Limit
Shield
Burner Box Cover
Power Choke
(1HP Only)
Circuit
Breaker
Sight Glass
Burner Box Top
Secondary Limit
(not shown)

Page 8
I−UNIT COMPONENTS
Unit components are shown in figure 1. The gas valve,
combustion air inducer and burners can be accessed by re-
moving the burner access panel. Electrical components
are in the control box (figure 2) found in the blower section.
CAUTION
Electrostatic discharge can affect electronic
components. Take precautions during furnace
installation and service to protect the furnace’s
electronic controls. Precautions will help to avoid
control exposure to electrostatic discharge by
putting the furnace, the control and the techni-
cian at the same electrostatic potential. Neutral-
ize electrostatic charge by touching hand and all
tools on an unpainted unit surface, such as the
gas valve or blower deck, before performing any
service procedure.
ELECTROSTATIC DISCHARGE (ESD)
Precautions and Procedures
1. Control Transformer (T1)
A transformer located in the control box provides power to
the low voltage section of the unit. Transformers on all
models are rated 40VA with a 120V primary and a 24V sec-
ondary.
2. Door Interlock Switch (S51)
A door interlock switch rated 14A at 125VAC is wired in se-
ries with line voltage. When the blower door is removed the
unit will shut down.
FIGURE 2
CONTROL BOX G60DFV
Transformer
SureLighttTwo−Stage
Integrated Control Board
Door
Interlock Switch
Circuit
Breaker
3. Circuit Breaker (CB8)
A 24V circuit breaker is also located in the control box.
The switch provides overcurrent protection to the trans-
former (T1). The breaker is rated 3A at 32V. If the current
exceeds this limit the breaker will trip and all unit opera-
tion will shutdown. The breaker can be manually reset
by pressing the button on the face. See figure 3.
FIGURE 3
CIRCUIT BREAKER CB8
PRESS TO RESET
WARNING
Shock hazard.
Disconnect power before servicing. Integrated
Control Board is not field repairable. If control is
inoperable, simply replace entire control.
Can cause injury or death. Unsafe operation will
result if repair is attempted.
4. Integrated Control Board (A92)
Board 18M99
G60DFV units are equipped with the Lennox two−stage,
variable speed integrated SureLight control board. The
system consists of a ignition / blower control board (figure
4 with control terminal designations in tables 1 through 4)
and ignitor (figure 12). The board and ignitor work in com-
bination to ensure furnace ignition and ignitor durability.
The SureLight integrated board controls all major furnace
operations. The board features two LED lights, DS1 and
DS2 for troubleshooting and four LED lights (DS3, DS6,
DS7 and DS8) to show furnace status. The board also has
two accessory terminals rated at (1) one amp each. See
table 5 for status code and table 6 for troubleshooting
diagnostic codes.
Electronic Ignition
At the beginning of each heating cycle, the SureLight con-
trol monitors the first stage and second stage combustion
air inducer prove switch. The control will not begin the heat-
ing cycle if the first stage prove switch is closed (by−
passed). Likewise the control will not begin the second
stage heating cycle if the second stage prove switch is
closed, and will allow first stage heat only. However if the
second stage prove switch closes during the first stage pre−
purge, the control WILL respond to second stage heat call.
Once the first stage prove switch is determined to be open,
the combustion air inducer is energized on low (first stage)
heat speed. When the differential in the prove switch is
great enough, the prove switch closes and a 15−second
pre−purge begins. If the switch is not proven within 2−1/2
minutes, the control goes into Watchguard−Pressure
Switch mode for a 5−minute re−set period.

Page 9
After the 15−second pre−purge period, the SureLight ignitor
warms up for 20 seconds after which the gas valve opens
for a 4−second trial for ignition. The ignitor energizes during
the trial until flame is sensed. If ignition is not proved during
the 4−second period, the control will try four more times with
an inter purge and warm−up time between trials of 35 sec-
onds. After a total of five trials for ignition (including the ini-
tial trial), the control goes into Watchguard−Flame Failure
mode. After a 60−minute reset period, the control will begin
the ignition sequence again.
The SureLight control board has an added feature that pro-
longs the life of the ignitor. After a successful ignition, the
SureLight control utilizes less power to energize the ignitor
on successive calls for heat. The control continues to ramp
down the voltage to the ignitor until it finds the lowest
amount of power that will provide a successful ignition. This
amount of power is used for 255 cycles. On the 256th call
for heat, the control will again ramp down until the lowest
power is determined and the cycle begins again.
Two Stage Operation / Thermostat Selection Jumper
The control can be utilized in two modes: SINGLE−STAGE
thermostat or TWO−STAGE thermostat. The thermostat
selection jumper E20, located just below dip switches 1
through 3 (figure 4), must be positioned for the particular
application. The jumper is factory set on TWO" for use
with a two−stage thermostat with two stage heat. Re−posi-
tion jumper to SINGLE" for use with a single stage thermo-
stat with two stage heat.
While in the single−stage thermostat mode (single jumper
setting), the burners will always fire on first−stage heat. The
combustion air inducer will operate on low speed and in-
door blower will operate on low heat speed. After a field se-
lectable 10 or 15 minute delay (dip switch 3), the unit will
switch to second stage heat. While in the two−stage ther-
mostat mode (two jumper setting) the burners will fire on
first−stage heat. The combustion air inducer will operate on
low speed and indoor blower will operate on low heat
speed. The unit will switch to second−stage heat on call
from the indoor thermostat. If there is a simultaneous call
for W1 and W2 (first and second stage heat) the unit will fire
on first stage heat and switch to second stage heat after 30
seconds of operation. See Sequence of Operation flow
charts in the back of this manual for more detail.
TW0−STAGE, VARIABLE SPEED INTEGRATED
CONTROL BOARD
FIGURE 4
DIP
SWITCHES
1 − 3
DIP
SWITCHES
5 − 12
DIAGNOSTIC
LEDs
ON−BOARD
JUMPER W951
(cut when heat pump
is used with FM21)
ON−BOARD
JUMPER W914
(cut when CCB1,
Harmony II or
SignatureStat are used)
LEDs
LED
FACTORY−
INSTALLED
JUMPER
THERMOSTAT CONNECTIONS (TB1)
DIP SWITCH FUNCTIONS
DIP SWITCH(ES) FUNCTION
1 and 2 Blower Off Delay
3 Second Stage ON Delay (Single−stage t’stat)
4 Not used
5 and 6 Cooling Mode Blower Speed
7 and 8 Blower Speed Adjustment
9 and 10 Cooling Mode Blower Ramping Profile
11 and 12 Heating Mode Blower Speed
E20
JUMPER
16 PIN BLOWER
CONTROL TERMINALS
DS8
DS7 DS3
DS6

Page 10
TABLE 1
Two Stage Ignition / Blower Control Terminals
120VAC Neutral
LINE Line 120VAC Neutral
XFMR Transformer 120VAC Neutral
EAC Electronic Air Cleaner 120VAC Neutral
CIRC Indoor Blower 120VAC Neutral
HUM Humidifier 120VAC Neutral
120VAC Line
HUM Humidifier 120VAC Hot
XMFR Transformer 120VAC Hot
LINE Line 120VAC Hot
CIRC Indoor Blower 120VAC Hot
EAC Electronic Air Cleaner 120VAC Hot
TABLE 2
SureLight Board 12Pin Terminal Designation
PIN # Function
1Gas Valve 2nd. Stage (High Fire)
2Second Stage Pressure Switch
3Not Used
4 Ground
524V Hot
6Primary Limit In
7Gas Valve 1st. Stage (Low Fire)
8Gas Valve Common
924V Neutral
10 Ground
11 Primary Limit Out
12 1st Stage Pressure Switch
TABLE 3
SureLight Board 5 Pin Terminal Designation
PIN # Function
1 Ignitor
2Combustion Air Inducer High Speed
3Combustion Air Inducer Low Speed
4Combustion Air Inducer Neutral
5Ignitor Neutral
TABLE 4
SureLight Board 16 Pin Blower Control Terminals
PIN # Function
1 Ground
2Low Heat Speed
3 Ground
4DELAY" Dip Switch Selection
5COOL" Dip Switch Selection
6Y1" Signal
7ADJUST" Dip Switch Selection
8 Ground
9o" From Thermostat
10 DS" Output Signal
11 HEAT" Dip Switch Selection
12 24 VAC
13 HIGH HEAT Speed
14 Y2" Signal
15 G"
16 CFM LED