Lennox G60DFVX Series User manual

,1,_2006 Lennox Industries tnc+
Dallas, Texas, USA
INSTALLATION
INSTRUCTIONS
G60DFV(X) Series
GAS FURNACE _ Technical
505,126M _i E_--'.LLLLPublications
06/2006
Supersedes 504,576M Lithe U.S.A.
RETAIN THESE INSTRUCTIONS
FOR FUTURE REFERENCE
Unit Dimensions ................................. 2
G60DFV(X) Parts Arrangement .................... 3
G60DFV(X) Gas Furnace ......................... 4
Shipping and Packing List ........................ 4
Safety Information ............................... 4
General ........................................ 5
Combustion, Dilution & Ventilation Air .............. 6
Downflow Installation ............................. 9
Setting Equipment .............................. 10
Filters ......................................... 11
Duct System ................................... 11
Venting ....................................... 11
Gas Piping .................................... 18
Electrical ...................................... 19
Integrated Control Board ........................ 25
Unit Start-Up ................................... 31
Gas Pressure Adjustment ....................... 32
High Altitude Information ........................ 32
Other Unit Adjustments .......................... 32
Heating Sequence of Operation .................. 33
Service ....................................... 34
Repair Parts List ............................... 36
Ignition Control Board Diagnostic Codes ........... 37
Troubleshooting ................................ 38
Start-Up & Performance Check List ............... 44
.,WARNING
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.
WHAT TO DO IF YOU SMELL GAS:
•Do not try to light any appliance.
•Do not touch any electrical switch; do not
use any phone in your building.
•Leave the building immediately.
•Immediately call your gas supplier from a
neighbor's phone. Follow the gas supplier's
instructions.
•If you cannot reach your gas supplier, call
the fire department.
06/06
IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII
Page 1 505,126M
IIIlllllllllllllllllllllllllllllllllllllllll

5/8 (16)
FLUE OUTLET 5/8
(Top) (16)
5/8 (16)
TOP VIEW
!_!_i_i_i!ii_i_ii!i_i_i_i_i_ii_!i_i_i_i_i_iiiiii!:_ii_'!_!_i_i_iiiiiii_ii_ii_ii_ii_ii_ii_i_ii_ii!iiii_!i_iiiiiiiii!!!i_i_i_i_i_i_ii_!i_i_i_i_i_iil;ii!i!i!:il_i;i_i_i_ii_!i_!_!i_iiiii_i_i!;i!;i!;i!;i!;i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i!_i_!_!_i_i_i_i
_1- 5/8
(16)
m m
28-1/2
(724)
-- 9-1/2 --
(495)
,,,Jl.- suoo,L,,,
(19) C Air m (19)
FRONT VIEW
40
(1016)
4-7/8 (124) Right
2-1/4 (57) Left-I_
t
9 -1/4
(235)
5/8
(16)
_,_ 19-1/4 Supply
(489) Air
SIDE VIEW
c
in mm
13 330
16 406
19-1/2 495
23 584
1- 3/4
(19)
A B D
Model No. in. mm in. mm in. mm
G60DFV(X)-36A-070 14-1/2 368 13-1/4 337 4-1/2 114
G60DFV(X)-36 B-090 17-1/2 446 16-1/4 413 6 152
G60DFV(X)-60C-090, 21 533 19-1/4 502 7-3/4 197
G50DFV(X)-60C-110
G60DFV(X)-60D-135 24-1/2 622 23-1/4 591 9-1/2 241
Page 2

Variable Speed
Blower Motor Blower Assembly
Internal Flue Pipe
Assembly
Gasket
Circuit
Breaker
\. Power
(1HP Only)
Chase
Gasket
Combustion Air Inducer
Transfor'_me_r/_
Two-Stage
Integrated Control Board //I I
/
Door /
Interlock Switch//
/
/
//Limit
/Shield
/
/
/
/
/
/
Burner Box Cover
FIGURE 1
Ignitor
Burner Box Bottom
Page 3

TheG60DFV(X)gasfurnaceis equippedwitha two-
stage,variablespeedintegratedcontrol.Thiscontrolen-
surescompatibilitywithLennox'HarmonyItlzonecontrol
system,aswellasathermostatwhichprovideshumidity
control.EachG60DFV(X)unitisshippedreadyforinstal-
lationinthedownfiowposition.
Package 1 of 1 contains
1 - Assembled G60DFV(X) unit
1 - Bag assembly containing the following:
2 - Screws
3-Wire nuts
1-Snap bushing
1 -Snap plug
1 - Wire tie
1 -Vent warning label
1 -Owner's manual and warranty card
The following items may be ordered separately:
1- Thermostat
1 - Propane/LP changeover kit
1 - Additive base
1 - High altitude kit
Check equipment for shipping damage. If you find any
damage, immediately contact the last carrier.
A,WARNING
,CAUTION
G60DFV(X) units are CSA International certified to ANSI
Z21.47 and CSA 2.3 standard.
In the USA, installation of gas furnaces must conform with
local building codes. In the absence of local codes, units
must be installed according to the current National Fuel
Gas Code (ANSI-Z223.1). The National Fuel Gas Code is
available from the following address:
American National Standards Institute, Inc.
11 West 42nd Street
New York, NY 10036
In Canada, installation must conform with current National
Standard of Canada CSA-B149 installation codes for natu-
ral gas burning appliances and equipment, local plumbing
or waste water codes and other applicable local codes.
Adequate clearance must be made around the air open-
ings into the vestibule area. In order to ensure proper unit
operation, combustion and ventilation air supply must be
provided according to the current National Fuel Gas Code
or CSA-B149 standards.
Vent installations must be consistent with the venting
tables (in this instruction) and applicable provisions of local
building codes.
This furnace is CSA International certified for installation
clearances to combustible material as listed on the unit
nameplate and in the tables in figure 9. Accessibility and ser-
vice clearances must take precedence over fire protection
clearances.
For installation in a residential garage, the furnace must
be installed so that the burner(s) and the ignition source
are located no less than 18 inches (457 mm) above the
floor. The furnace must be located or protected to avoid
physical damage by vehicles. When a furnace is installed
in a public garage, hangar, or other building that has a haz-
ardous atmosphere, the furnace must be installed accord-
ing to recommended good practice requirements and cur-
rent National Fuel Gas Code or CSA B149 standards.
NOTE -Furnace must be adjusted to obtain a temperature
rise(high and low fire) within the range(s) specified on the unit
nameplate. Failure to do so may cause erratic limit operation
and may also result in premature heat exchanger failure.
This G60DFV(X) furnace must be installed so that its elec-
trical components are protected from water.
When this furnace is used with cooling units, it shall be
installed in parallel with, or on the upstream side of, cooling
units to avoid condensation in the heating compartment.
With a parallel flow arrangement, a damper (or other
means to control the flow of air) must adequately prevent
chilled air from entering the furnace. If the damper is manu-
ally operated, it must be equipped to prevent operation of
either the heating or the cooling unit, unless it is in the full
HEAT or COOL setting.
When installed, this furnace must be electrically grounded
according to local codes. In addition, in the United States,
installation must conform with the current National Elec-
Page 4

tricCode,ANSl/NFPANo.70.TheNationalElectricCode
(ANSI/NFPANo.70)isavailablefromthefollowingad-
dress:
NationalFireProtectionAssociation
1BatteryMarchPark
Quincy,MA02269
InCanada,allelectricalwiringandgroundingfortheunit
mustbeinstalledaccordingtothecurrentregulationsofthe
CanadianElectricalCodePartI (CSAStandardC22.1)
and/orlocalcodes.
NOTE -This furnace is designed for a minimum continu-
ous return air temperature of 60°F (16°C) or an intermit-
tent operation down to 55°F (13°C) dry bulb for cases
where a night setback thermostat is used. Return air tem-
perature must not exceed 85°F (29 °C) dry bulb.
The G60DFV(X) furnace may be installed in alcoves, clos-
ets, attics, basements, garages, and utility rooms in the
downflow position.
This furnace design has not been CSA International certi-
fied for installation in mobile homes, recreational vehicles,
or outdoors.
Lennox does not recommend the use of G60DFV(X) units
as a construction heater during any phase of construction.
Very low return air temperatures, harmful vapors and op-
eration dthe unit with clogged or misplaced filters will dam-
age the unit.
G60DFV(X) units may be used for heating of buildings or
structures under construction, if the following conditions
are met:
•The vent system must be permanently installed per
these installation instructions.
• A room thermostat must control the furnace. The use of
fixed jumpers that will provide continuous heating is not
allowed.
• The return air duct must be provided and sealed to the
furnace.
• Return air temperature range between 60°F (16°C) and
80 °F (27°C) must be maintained.
• Air filters must be installed in the system and must be
maintained during construction.
• Air filters must be replaced upon construction comple-
tion.
• The input rate and temperature rise must be set per the
furnace rating plate.
One hundred percent (100%) outdoor air must be pro-
vided for combustion air requirements during construc-
tion. Temporary ducting may supply outdoor air to the
furnace. Do not connect duct directly to the furnace.
Size the temporary duct following these instructions in
section for Combustion, Dilution and Ventilation Air in a
confined space with air from outside.
• The furnace heat exchanger, components, duct system,
air filters and evaporator coils must be thoroughly
cleaned following final construction clean-up.
• All furnace operating conditions (including ignition, in-
put rate, temperature rise and venting) must be verified
according to these installation instructions.
NOTE -The Commonwealth of Massachusetts stipu-
lates these additional requirements:
• Gas furnaces shall be installed by alicensed plumb-
er or gas fittter only.
•The gas cock must be "T handle" type.
• When a furnace is installed in an attic, the passage-
way to and service area surrounding the equipment
shall be floored.
These instructions are intended as a general guide and do
not supersede local codes in any way. Consult authorities
having jurisdiction before installation.
In addition to the requirements outlined previously, the fol-
lowing general recommendations must be considered
when installing a G60DFV(X) furnace:
•Place the furnace as close to the center of the air dis-
tribution system as possible. The furnace should also be
located close to the chimney or vent termination point,
•Do not install the furnace where drafts might blow direct-
ly into it. This could cause improper combustion and un-
safe operation.
•Do not block the furnace combustion air openings with
clothing, boxes, doors, etc. Air is needed for proper
combustion and safe unit operation.
•When the furnace is installed in an attic or other insu-
lated space, keep insulation away from the furnace.
Page 5

, WARNING ACAUTION
In the past, there was no problem in bringing in sufficient out-
door air for combustion, Infiltration provided all the air that
was needed, In today's homes, tight construction practices
make it necessary to bring in air from outside for combus-
tion. Take into account that exhaust fans, appliance vents,
chimneys, and fireplaces force additional air that could be
used for combustion out of the house, Unless outside air is
brought into the house for combustion, negative pressure
(outside pressure is greater than inside pressure) will build
to the point that a downdraft can occur in the furnace vent
pipe or chimney, As a result, combustion gases enter the liv-
ing space creating a potentially dangerous situation,
In the absence of local codes concerning air for combus-
tion and ventilation, use the guidelines and procedures in
this section to install G60DFV(X) furnaces to ensure effi-
cient and safe operation, You must consider combustion air
needs and requirements for exhaust vents. A portion of this
information has been reprinted with permission from the
National Fuel Gas Code (ANSI-Z223.1). This reprinted ma-
terial is not the complete and official position of the ANSI on
the referenced subject, which is represented only by the
standard in its entirety,
In Canada, refer to the standard CSA B149 installation
codes,
,CAUTION
All gas-fired appliances require air for the combustion pro-
cess. If sufficient combustion air is not available, the fur-
nace or other appliances will operate inefficiently and un-
safely. Enough air must be provided to meet the needs of all
fuel-burning appliances and appliances such as exhaust
fans which force air out of the house, When fireplaces, ex-
haust fans, or clothes dryers are used at the same time as
the furnace, much more air is necessary to ensure proper
combustion and to prevent a downdraft. Insufficient air
causes incomplete combustion which can result in carbon
monoxide,
In addition to providing combustion air, fresh outdoor air
dilutes contaminants in the indoor air. These contami-
nants may include bleaches, adhesives, detergents, sol-
vents and other contaminants which can corrode furnace
components.
The requirements for providing air for combustion and ven-
tilation depend largely on whether the furnace is installed in
an unconfined or a confined space,
Unconfined Space
An unconfined space is an area such as a basement or
large equipment room with a volume greater than 50 cubic
feet (1,42 m3) per 1,000 Btu (.29 kW) per hour of the com-
bined input rating of all appliances installed in that space.
This space also includes adjacent rooms which are not
separated by a door. Though an area may appear to be un-
confined, it might be necessary to bring in outdoor air for
combustion if the structure does not provide enough air by
Page 6

infiltration,Ifthefurnaceis locatedin a buildingoftight
constructionwithweatherstrippingandcaulkingaround
thewindowsanddoors,followtheproceduresintheair
fromoutsidesection,
ConfinedSpace
Aconfinedspaceisanareawithavolumelessthan50cu-
bicfeet(1,42m3)per1,000Btu(,29kW)perhourofthe
combinedinputratingofall appliancesinstalledin that
space.Thisdefinitionincludesfurnaceclosetsor small
equipmentrooms,
Whenthefurnaceisinstalledsothatsupplyductscarryair
circulatedbythefurnacetoareasoutsidethespacecontain-
ingthefurnace,thereturnairmustbehandledby ducts
whicharesealedtothefurnacecasingandwhichterminate
outsidethespacecontainingthefurnace,Thisisespecially
importantwhenthefurnaceismountedonaplatformina
confinedspacesuchasaclosetorsmallequipmentroom.
Evenasmallleakaroundthebaseoftheunitattheplatform
oratthereturnairductconnectioncancauseapotentially
dangerousnegativepressurecondition.Airforcombustion
andventilationcanbebroughtintotheconfinedspaceeither
frominsidethebuildingorfromoutside,
__ EQUIPMENT IN CONFINED
CHIMNEY 'L_ J_._SPACE ALL AIR FROM INSIDE
OR GAS
_ WATER
HEATER
FURNACE /os
(To Adjacent
Room)
I I I I I II II I I I I I I II I
i i
I I I I
NOTE -Each opening shall have a free area of at least one square
inch (645 mm 2)per 1,000 Btu (.29 kW) per hour of the total input rat-
ing of all equipment in the enclosure, but not less than 100 square
inches (64516 ram2).
FIGURE 2
Air from Inside
If the confined space that houses the furnace adjoins a
space categorized as unconfined, air can be brought in by
providing two permanent openings between the two
spaces, Each opening must have a minimum free area of 1
square inch (645 mm2) per 1,000 Btu (.29 kW) per hour of
total input rating of all gas-fired equipment in the confined
space, Each opening must be at least 100 square inches
(64516 mm2), One opening shall be within 12 inches (305
mm) of the top of the enclosure and one opening within 12
inches (305 mm) of the bottom, See figure 2,
Air from Outside
If air from outside is brought in for combustion and ventila-
tion, the confined space must have two permanent open-
ings, One opening shall be within 12 inches (305 mm) of the
top of the enclosure and one opening within 12 inches (305
mm) of the bottom, These openings must communicate di-
rectly or by ducts with the outdoors or spaces (crawl or at-
tic) that freely communicate with the outdoors or indirectly
through vertical ducts, Each opening shall have a minimum
free area of 1 square inch (645 mm 2) per 4,000 Btu (1,17
kW) per hour of total input rating of all equipment in the en-
closure, See figures 3 and 4. When communicating with
the outdoors through horizontal ducts, each opening shall
have a minimum free area of 1 square inch (645 mm2) per
2,000 Btu (.56 kW) per total input rating of all equipment in
the enclosure, See figure 5,
When ducts are used, they shall be of the same cross-sec-
tional area as the free area of the openings to which they
connect. The minimum dimension of rectangular air ducts
shall be no less than 3 inches (75 mm). In calculating free
area, the blocking effect of louvers, grilles, or screens must
be considered. If the design and free area of protective cov-
ering is not known for calculating the size opening required,
it may be assumed that wood louvers will have 20 to 25 per-
cent free area and metal louvers and grilles will have 60 to
75 percent free area, Louvers and grilles must be fixed in the
open position or interlocked with the equipment so that they
are opened automatically during equipment operation.
Page 7

CHIMNEY OR
GAS VENT
EQUIPMENT IN CONFINED SPACE
ALL AIR FROM OUTSIDE
(Inlet Air from Crawlspace and Outlet Air to Ventilated Attic)
VENTILATION LOUVERS
(Each end of attic)
I ...... I
OUTLET
FURNACE AIR WATER
HEATER
VENTILATION INLET
LOUVERS AIR
(For unheated crawl !
I
rlTm nTm
I- -I I- -I
NO TE- The inlet and outlet air openings shall each have a free area of at least one square inch (645
mm2) per 4,000 Btu (1.17 kW) per hour of the total input rating of all equipment in the enclosure.
FIGURE 3
CHIMNEY
OR GAS
VENT
EQUIPMENT IN CONFINED SPACE
ALL AIR FROM OUTSIDE
(All Air Through Ventilated Attic)
VENTILATION LOUVERS
(Each end of attic)
FURNACE INLET AIR
(Ends 12 in._)
HEATER
NO TE- The inlet and outlet air openings shall each have a
free area of at least one square inch (645 mm 2)per 4,000
Btu (1.17 kW) per hour of the total input rating of all equip-
ment in the enclosure.
EQUIPMENT IN
CONFINED SPACE
ALL AIR FROM
OUTSIDE
FURNACE
NOTE -Each air duct opening shall have a free area of at least
2
one square inch (645 mm ) per 2,000 Btu (.59 kW) per hour of
the total input rating of all equipment in the enclosure, ff the
equipment room is located against an outside wall and the air
openings communicate directly with the outdoors, each open-
ing shaft have a free area of at least one square inch (645 mm2)
per 4,000 Btu (1.17 kW) per hour of the total input ratlng of all
other equipment in the enclosure.
FIGURE 4FIGURE 5
Page 8

Downflowunitinstallsinthreeways:onnon-combustible
flooring,oncombustibleflooringusinganadditivebase,or
ona reverse-flowcoolingcabinet,Donotdragtheunit
acrossthefloor.
Installation on Non-Combustible Flooring
1 - Cut floor opening keeping in mind clearances listed on
unit rating plate. Also keep in mind gas supply connec-
tions, electrical supply, flue and air intake connections
and sufficient installation and servicing clearances,
See table 1 for correct floor opening size.
2 - Flange warm air plenum and lower the plenum into the
opening.
3 - Set the unit over the plenum and seal the plenum to
the unit,
3 - Ensure that the seal is adequate,
TABLE 1
NON-COMBUSTIBLE FLOOR
Front to Rear
A Cabinet (14.5")
B Cabinet (17.5")
C Cabinet (21")
D Cabinet (24.5")
NOTE -Floor openin!
Model No. in.
19 - 3/4
19 - 3/4
19 - 3/4
19 - 3/4
mm
5O2
5O2
5O2
5O2
)PENING SIZE
Side to Side
in.
13 - 1/4
16 - 1/4
19 - 3/4
23- 1/4
mm
337
413
5O2
591
dimensions listed are 1/4 inch (6 mm) larger than
the unit opening. See unit dimensions on page 2.
Installation on Combustible Flooring
1 - When unit is installed on a combustible floor, an addi-
tive base must be installed between the furnace and
the floor. The base must be ordered separately for the
following cabinet sizes:
•A cabinet 14,5"-# 11M59
• B cabinet 17.5"-# 11M60
• C cabinet -21" # 11M60
• D cabinet 24,5" - # 11M61
See table 2 for opening size to cut in floor.
CAUTION
TABLE 2
ADDITIVE BASE FLOOR OPENING SIZE
Model No.
A Cabinet (14.5")
B Cabinet (17.5")
C Cabinet (21")
D Cabinet (24.5")
NOTE -Floor openin!
Frontto Rear
in. mm
22 559
22 559
22 559
22 559
Side to Side
in.
15-3/4
18-3/4
22 - 3/4
25 - 3/4
mm
400
476
578
654
dimensions listed are 1/4 inch (6 mm) larger than
unit opening. See unit dimensions on page 2.
2 - After opening is cut, set additive base into opening.
3 - Check fiberglass strips on additive base to make sure
they are properly glued and positioned,
4 - Lower supply air plenum into additive base until ple-
num flanges seal against fiberglass strips.
NOTE -Be careful not to damage fiberglass strips,
Check for a tight seal,
5 - Set the furnace over the plenum,
6 - Ensure that the seal between the furnace and plenum
is adequate.
G60DFV(X)UNI]
PROPERLY
SIZED FLOOR
OPENING \
SUPPLY AIR PLENUM
ADDITIVE BASE
FIGURE 6
Installation on Cooling Cabinet
1 - Refer to reverse-flow coil installation instructions for
correctly sized opening in floor and installation of cabi-
net,
2 - When cooling cabinet is in place, set and secure the
furnace according to the instructions that are provided
with the cooling coil, Secure the furnace to the cabinet,
3 - Seal the cabinet and check for air leaks.
Return Air Opening -- Downflow Units
The following steps should be taken when installing ple-
num:
1 - Bottom edge of plenum should be flanged with a
hemmed edge (See figure 7).
Side View
PLENI SECURE FROM
CABINET
HEMMED EDGE
FIBERGLASS SEALING
STRIP
(Field Provided)
CABINET SIDE PANEL
FIGURE 7
2 - Fiberglass sealing strips should be used,
3 - In all cases, plenum should be secured to top flanges
of furnace with sheet metal screws,
Page 9

nPLENUM
SECURE FROM IL¢/ Side View
INSIDE CABINET _EDGE
FIBERGLASS/ II
SEALING STRIP I
(Field Provided) PANEL"II
FIGURE 8
4 - In closet installations, it may be impossible to install
sheet metal screws from the outside. In this case,
make plenum with a removable front and install
screws from the inside (See figure 8).
5 - Make certain that an adequate seal is made,
AWARNING
Install the G60DFV(X) gas furnace as shipped. Do not
install the furnace horizontally.
Select a location that allows for the required clearances
that are listed on the unit nameplate. Also consider gas
supply connections, electrical supply, vent connection,
and installation and service clearances [24 inches (610
mm) at unit front]. The unit must be level.
NQ TE -Units with 1/2 hp blower motors are equipped with
three flexible legs and one rigid leg. The rigid leg is
equipped with a shipping bolt and a flat white plastic wash-
er (rather than the rubber mounting grommet used with a
flexible mounting leg). The bolt and washer must be re-
moved before the furnace is placed into operation. Af-
ter the bolt and washer have been removed, the rigid leg
will not touch the blower housing.
NOTE -G60DFV-60D-135 units are equipped with a ship-
ping pad under the blower housing. Remove the shipping
pad prior to operation.
_&WARNING
Downflow Application
Allow for clearances to combustible materials as indi-
cated on the unit nameplate. Minimum clearances for
closet or alcove installations are shown in figure 9.
Downflow Application Installation Clearances
Top
tq.................
I II
I II
I II
Left Side ................ Right Side
Bottom
Type of Vent Type C Type B1
Connector
Top 1 in. (25 ram) 1 in. (25 ram)
*Front 3 in. (76 ram) 3 in. (76 ram)
Back 0 0
Sides 0t- 0
Vent 6 in. (152 ram) 1 in. (25 ram)
Floor NC1-t NCtt
*Front clearance in alcove installation must be 24 in. (610 ram).
Maintain a minimum of 24 in. (610 ram) for front service access.
tLeft side requires 3 in. ifa single wall vent is used on 14 -1/2 in. cab-
inets, or 2 in. if a single wall vent is used on 17 -1/2 in. cabinets.
ttThe furnace may be installed on a combustible wood floor if an
optional additive base is installed between the furnace and the
combustible floor.
FIGURE 9
-&WARNING
Page 10