Lennox G60UHV User manual

_;_,2006 Lennox Industries Inc.
Dallas, Texas, USA
INSTALLATION
INSTRUCTIONS
G60UHV(X) Series
GAS FURNACE _-_") Technical
505,121M _--_.L_Publications
09/2006
Supersedes 06/2006 Lithe U.S.A.
RETAIN THESE INSTRUCTIONS
FOR FUTURE REFERENCE
Unit Dimensions ................................ 2
G60UHV(X) Parts Arrangement ................... 3
G60UHV(X) Gas Furnace ........................ 4
Shipping and Packing List ........................ 4
Safety Information ............................... 4
General ........................................ 5
Combustion, Dilution & Ventilation Air .............. 6
Setting Equipment ............................... 9
Filters .......................................... 13
Duct System .................................... 13
Venting ........................................ 13
Gas Piping ..................................... 21
Electrical ....................................... 22
Integrated Control Board Settings ................. 28
Unit Start-Up ................................... 37
Gas Pressure Adjustment ........................ 38
High Altitude Information ......................... 38
Other Unit Adjustments .......................... 38
Heating Sequence of Operation ................... 39
Service ........................................ 40
Repair Parts List ................................ 42
Ignition Control Board Diagnostic Codes ........... 43
Troubleshooting ................................. 44
Start-Up & Performance Check List ................ 50
AWARNING
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.
09/06
iiiHiinlnlllllllllnllllllllllllllllll Page1 505,121M IIIlllllllllllllllllllllllllllllllllllllllllll

*NOTE - 60C and 60D units that require air volumes
over 1800 cfm (850 L/s) must have one of the following:
1. Return air from single side with transition which will
accommodate 20 x 25 x 1 in. (508 x 635 x 25 mm)
cleanable air filter. (Required to maintain proper air
velocity.)
2. Return air from single side with optional RAB Return
Air Base.
3. Return air from bottom.
4. Return air from both sides.
5. Return air from bottom and one side.
Refer to Engineering Handbook for additional information.
**Flue outlet may be horizontal but furnace must be
vented vertically
_Optional external side return air filter kit cannot be used
with the optional RAB Return Air Base.
3/4 (19) -I_
<1-9/16 (14)
_OPTIONAL
EXTERNAL
SIDE RETURN
AIR FILTER KIT
(Either Side)
14-3/4
(375)
(406)
5/8 (16)
|/ 3/4(19)
*Bottom Return
Air Opening
FRONT VIEW
40
(1016)
3"3/4 (95)-I_1 F
D
FLUE OUTLET
(Top)
_OPTIONAL _---'---'--_----__--_. I
EXTERNAL _ _ 23-3/4 t603_
SIDE RETURN - II - • ,- uI
AIR FILTER KIT I_-._ 25 (635) =I
(Either Side) TOP VIEW
TOP VIEW
3-1/4 (83) Right --I 4
8-1/8 (206) Left |3-31, L
-_ (95)
=I_._
t
l \
14 (356) Right
13-1/4 (337) Left
4-7/8 (124) Right
2-1/4 (57) Left
28-1/2
(724)
n._ 19-7/16._
(494)
23-1/2
(597)
4-1/4 *Bottom Return
(108) Air Opening
SIDE VIEW
ABCD
Model No. in. mm in. mm in. mm in. mm
G6OUHV-36A-070 14-1/2 368 13-3/8 340 13 330 4-1/2 114
G6OUHV-36B-090 17-1/2 446 16-3/8 416 16 406 6 152
G6OUHV-6OC-O9O, 21 533 19-7/8 454 19-1/2 495 7-3/4 197
G6OUHV-60C-110
G6OUHV-6OD-135 24-1/2 622 23-3/8 546 23 584 9-1/2 241
9/16
'91-(14)
Page 2

Gasket
Flue
Transition
FlueBoxGasket
Flue
Collector
Box
Combustion Air
Orifice
Combustion Air
Pressure Switch Assembly
(two switches)
./ Combustion Air Inducer
Flame Sensor Limit Shield
_Flame Rollout Switches \
Air Intake _ _ Primary \/I
Cover _ Limit
Burner //__ I
Box Tol I Kz'2 I
NOx Insert
Gas Valve
Gas
Orifices Gasket
Heat Exchanger
Sight
Glass
Burner
Box Cover
Bracket
Burner Box Bottom
Control Transformer
Ignitor
Circuit Breaker
Air Deflector
G60UH-60C-110
Units Only
\
Secondary Limit(s)
Power Choke
(1 hp Only)
Variable Speed
Blower Motor
Two-Stage, Variable Speed
Integrated Control Board Door Interlock Switch
FIGURE 1
Page 3

TheG60UHV(X)gasfurnaceis equippedwitha two-
stage,variablespeedintegratedcontrol.Thiscontrolen-
surescompatibilitywithLennox'HarmonyIllzonecontrol
system,aswellasathermostatwhichprovideshumidity
control.EachG60UHV(X)unitisshippedreadyforinstal-
lationintheupfloworhorizontalposition(leftorright).The
furnaceisshippedwiththebottompanelinplace.Thebot-
tompanelmustberemovediftheunitistobeinstalledina
horizontalapplication.Thepanelmayalsoberemovedin
upflowapplications.
Package1of1contains
1- AssembledG60UHV(X)unit
1- Bagassemblycontainingthefollowing:
2-Screws
3-Wirenuts
1-Snapbushing
1-Snapplug
1-Wiretie
1-Vent warning label
1 -Owner's manual and warranty card
The following items may be ordered separately:
1- Thermostat
1 - Hanging bracket (for horizontal installations)
1 - Propane/LP changeover kit
1 - Return air base
1 - High altitude kit
1 - Side filter kit
Check equipment for shipping damage. If you find any
damage, immediately contact the last carrier.
,&WARNING
,&,CAUTION
G60UHV(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 and propane gas burning appliances and equip-
ment, local plumbing or waste water codes and other appli-
cable 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 Intemational certified for installation
clearances to combustible material as listed on the unit
nameplate and in the tables in figures 6 and 11.Accessibility
and service clearances must take precedence over fire
protection clearances.
NOTE- For installation on combustible floors, the furnace
shall not be installed directly on carpeting, tile, or other
combustible material other than wood flooring.
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 bw fire) within the range(s) specified on the unit
nameplate. Failure to do somay cause erratic limit operation.
This G60UHV(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.
Page 4

Wheninstalled,thisfurnacemustbeelectricallygrounded
accordingtolocalcodes.Inaddition,intheUnitedStates,
installationmustconformwiththecurrentNationalElec-
tricCode,ANSI/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 G60UHV(X) furnace may be installed in alcoves, clos-
ets, attics, basements, garages, and utility rooms in the up-
flow or horizontal 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 G60UHV(X) units
as a construction heater during any phase of construction.
Very low return air temperatures, harmful vapors and op-
eration of the unit with clogged or misplaced filters will dam-
age the unit.
G60UHV(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
aflowed.
• 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 instafled 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 a llcensedplumb-
er or gas fittter only.
• The gas cock must be "T handle" type.
• When afurnace 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 G60UHV(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

j 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 G60UHV(X) furnaces to ensure effi-
cient and safe operation. You must consider combustion air
needs and requirements for exhaust vents and gas piping.
A portion of this information has been reprinted with per-
mission from the National Fuel Gas Code (ANSI-Z223.1).
This reprinted material is not the complete and official posi-
tion of the ANSI on the referenced subject, which is repre-
sented 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,If thefurnaceis locatedin a buildingoftight
constructionwithweatherstrippingandcaulkingaround
thewindowsanddoors,followtheproceduresintheair
fromoutsidesection,
Confined Space
A confined space is an area with a volume less than 50 cu-
bic feet (1,42 m3) per 1,000 Btu (.29 kW) per hour of the
combined input rating of all appliances installed in that
space. This definition includes furnace closets or small
equipment rooms,
When the furnace is installed so that supply ducts carry air
circulated bythe furnace to areas outside the space contain-
ing the furnace, the return air must be handled by ducts
which are sealed to the furnace casing and which terminate
outside the space containing the furnace, This is especially
important when the furnace is mounted on a platform in a
confined space such as a closet or small equipment room.
Even a small leak around the base of the unit at the platform
or at the return air duct connection can cause a potentially
dangerous negative pressure condition, Air for combustion
and ventilation can be brought into the confined space either
from inside the building or from outside.
__EQUIPMENT IN CONFINED
CHIMNEY _ /_ SPACE ALL AIR FROM INSIDE
OR GAS
h
_ WiTER /
HEATER
FURNACE 1_
OPENINGS
(To Adjacent
Room)
,,,,j, ,, ,, ,, ,, ,,,: ,,
I I I I
NOTE -Each opening shall have afree 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 mm2) per 4,000 Btu (1,17
kW) per hour dtotal 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 mm 2) 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. Ifthe 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 altic)
I ...... I
OUTLET
FURNACE AIR WATER
HEATER
VENTILATION INLET
LOUVERS AIR
(For unheated crawl ._
_1 _rrrm rrrm I
NOTE-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.
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.
above bottom
HEATER
NO TE-The inlet and outlet air openings shaft 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 aft equip-
ment in the enclosure.
FIGURE 4
FIGURE 3
A _ EQUIPMENT IN
TT_. JJ_ CONFINED SPACE
I I "b__JY _ ALLAIRFROM
!lq!ll
NLET AI
II II l . . 1T-T. II II II IL_
I I I I I I I I I I I___J
IIIIIIIIIII
I I I I I I I I I I I I
NOTE -Each air duct opening shaft have a free area of at least
one square inch (645 mm 2)per 2,000 Btu (.59 kW) per hour of
the total input rating of aft equipment in the enclosure. If 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 rating of aft
other equipment in the enclosure.
FIGURE 5
Page 8

-&WARNING
The G60UHV(X) gas furnace can be installed as shipped
in either the upflow position or the horizontal position,
with right-hand or left-hand air discharge.
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.
NOTE -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 -G60UHV-60D-135 units are equipped with a ship-
ping pad under the blower housing. Remove the shipping
pad prior to operation.
Upflow Applications
Allow for clearances to combustible materials as indicated
on the unit nameplate, Minimum clearances for closet or al-
cove installations are shown in figure 6.
Upflow Application Installation Clearances
Top
Left Side
Bottom
Right Side
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 01- 0
Vent 6 in. (152 ram) 1 in. (25 ram)
Floor 05 05
*Front clearance in alcove installation must be 24 in. (610 ram).
Maintain a minimum of 24 in. (610 ram) for front service access.
SFor installation on a combustible floor, do not install the furnace
directly on carpeting, tile or other combustible materials other
than wood flooring.
1-Left side requires 3 inches if a single wall vent is used on 14-1/2
inch cabinets, or 2 inches if a single wall vent is used on 17-1/2
inch cabinets.
FIGURE 6
Page 9

Return Air -- Upflow Applications
Return air can be brought in through the bottom or either
side of the furnace installed in an upflow application, If the
furnace is installed on a platform with bottom return, make
an airtight seal between the bottom of the furnace and the
platform to ensure that the furnace operates properly and
safely. The furnace is equipped with a removable bottom
panel to facilitate installation,
Markings are provided on both sides of the furnace cabinet
for installations that require side return air. Cut the furnace
cabinet at the maximum dimensions shown on page 2.
NOTE -When air volumes over 1800 cfm (850 L/s) are
required with 60C or 60D models in an upflow applica-
tion, the following return air options are available:
1-Return air from single side with transition which will
accommodate 20 x 25 x I in. (508 x 635 x 25 ram) clean-
able air filter. (Required to maintain proper air velocity.)
See figure 7.
2-Return air from single side with optional RAB Return
Air Base. See figure 8.
3-Return air from bottom.
4-Return air from both sides.
5-Return air from bottom and one side.
Refer to Engineering Handbook for additional information,
Side Return Air
(with transition and filter)
20" X 25" X 1"
(508mm X635mm X 25mm)
Cleanable Filter
_/
Return Air
Plenum
FIGURE 7
Optional Return Air Base
(Upflow Applications Only -- For use with B, Cand D cabinets only)
J
t
AIR FLOW
14 "-_
L
7-1/4 (184)
vI
17-1/2 (446) RAB-B (98M60)
21 (533) RAB-C (98M58)
24-1/2 (622) RAB-D (98M59)
FRONT VIEW
OPTIONAL RAB
RETURN AIR BASE 7/8 .._
(22)
©
m 7
4;-.91-- 1 23 (584) f =1
102)1 Overall 1Minimum
(Maximum) 11 (279) I
2 Maximun_
1Unit side return air 1A 1356)_
Opening ___jl__ _
I5-5/8 SIDE RETURN
(143) AIR OPENINGS
(Either Side)
_1_ 23 (584)
I
I
122-7-16
(570)
Overall
'Maximum)
_J_
._ _ 3/4
(19)
91--- 27-5/8 (702)
SIDE VIEW
NOTE- Optional Side Return Air Filter Kits are not for use with RAB Return Air Base.
1 Both the unit return air opening and the base return air opening must be covered by a single plenum or IAQ cabinet.
Minimum unit side return air opening dimensions for units requiring 1800 cfm or more of air (W x H): 23 x 11 in. (584 x 279 mm).
The opening can be cut as needed to accommodate plenum or IAQ cabinet while maintaining dimensions shown.
Side return air openings must be cut in the field. There are cutting guides stenciled on the cabinet for the side return air
opening. The size of the opening must not extend beyond the markings on the furnace cabinet.
2 To minimize pressure drop, the largest opening height possible (up to 14 inches) is preferred.
NOTE- Optional Side Return Air Filter Kits are not for use with RAB Return Air Base.
FIGURE 8
Page 10