Instruction/ maintenance manual of the product Gas Units Lennox International Inc.
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Page 1 08/09 *2P0809* 506406−01 *P506406-01* E 2009 Lennox Industries Inc. Dallas, T exas, USA THIS MANUAL MUST BE LEFT WITH THE HOMEOWNER FOR FUTURE REFERENCE INST ALLA TION INSTRUCTIONS G61MP SERIES UNITS GAS UNITS 506406−01 08/2009 Supersedes 505,124M T able of Content s Unit Dimensions 2 .
Page 2 G61MP Unit Dimensions − inches (mm) *Bottom Return Air Opening *Bottom Return Air Opening ELECTRICAL INLET (Either Side) SUPPL Y AIR OPENING AIR FLOW FRONT VIEW SIDE VIEW TOP VIEW A B 9/16 (1.
Page 3 G61MP Parts Arrangement G61MP P ARTS IDENTIFICA TION FIGURE 1 TOP CAP CABINET BURNER BOX ASSEMBLY SIGHT GLASS DuralokPlus TM HEA T EXCHANGER ASSEMBLY CONDENSER COIL CONTROL BOX DOOR INTERLOCK S.
Page 4 G61MP Gas Furnace Th e G6 1M P category IV ga s fu r na c e is sh i pped ready for installation in the upflow , downflow , horizontal left air dis- charge or horizontal right air discharge position. The fur- nace is shipped with the bottom panel in place.
Page 5 In Canada, installation must conform with current National S tandard of Canada CSA-B149 Natural Gas and Propane Installation Codes, local plumbing or waste water codes and other applicable local codes.
Page 6 D One hundred percent (100%) outdoor air must be pro- vided for combustion air requirements during construc- tion. T emporary ducting may supply outdoor air to the furnace.
Page 7 Z223.1/NFP A 5 4). T his reprinted material is n ot the com - plete and official position of the ANSI on the referenced subject, which is represented only by the standard in it s entirety . In Canada, refer to the standard CSA B149 inst allation codes.
Page 8 FIGURE 4 EQUIPMENT IN CONFINED SP ACE − ALL AIR FROM OUTSIDE (Inlet Air from Crawl Space and Outlet Air to V entilated Attic) NOTE −The inlet and outlet air openings shall each have a free area of at least one square inch per 4,000 Btu (645mm 2 p er 1.
Page 9 FIGURE 7 SETTING EQUIPMENT UPFLOW APPLICA TION DOWNFLOW APPLICA TION HORIZONT AL APPLICA TION FRONT VIEW SIDE VIEW FRONT VIEW END VIEW FRONT VIEW SIDE VIEW AIR FLOW AIR FLOW AIR FLOW UNIT FRONT AIR FLOW AIR FLOW UNIT FRONT UNIT FRONT 1/2" max.
Page 10 Up flow Applications The G61MP gas furnace can be installed as shipped in the up flow position. Refer to figure 8 for clearances . Installation Clearances To p Bottom (Floor) Left Side Right Side T op/Plenum 1 in. (25 mm) *Front 0 Back 0 Sides 0 † V ent 0 Floor 0 ‡ *Front clearance in alcove inst allation must be 24 in.
Page 11 FIGURE 9 Optional Return Air Base (Upflow Applications Only −− For use with B, C and D cabinet s only) 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.
Page 12 Setting an Upflow Unit When the side return air inlets are used in an up flow ap- plication, it may be necessary to inst all leveling bolts on the bottom of the furnace. Use field−supplied corrosion−resist- an t 5/16 inch machine bolts (4) and nuts (8).
Page 13 Inst allation on Combustible Flooring (Using an Additive Base) 1 − When unit is inst alled on a combustible floor , an addi- tive base must be installed between the furnace and the floor . The base must be ordered separately . See table 2 for opening size to cut in floor .
Page 14 Horizontal Applications The G61MP furnace can be installed in horizontal applica- tions with either right− or left−hand air discharge. The G61MP may also be installed a s a unit heater . E ither suspend the furnace as shown in figure 18 , or install the furnace on a field−fabricated raised platform.
Page 15 Lennox part number 56J18). Position the support frame on top of the blocks and install the unit on the frame. Leave 5−1/2 inches for service clearance for condensate trap. 3 − Route auxiliary drain line so that water draining from this outlet will be easily noticed by the homeowner .
Page 16 Filters This unit is not equipped with a filter or rack. A field−pro- vided filter is required for the unit to operate properly . T able 3 lists recommended filter sizes.
Page 17 Use P VC p rimer a nd s olvent cement o r A BS s olvent c ement meeting ASTM specifications, refer to T able 4. As an alter - nate, use all p urpose cement, to bond ABS, PVC, or CPVC pipe when using f ittings and pipe m ade of the same materi- als.
Page 18 V ent Piping Guidelines The G61MP can be inst alled as either a N on−Direct V ent or a Direct V ent gas central furnace. NOTE − In Non-Direct V ent installations, combustion air is taken f rom indoors a nd f lue gases a re discharged outdoors.
Page 19 Us e the following steps to correctly size vent pipe diameter . Refer to V ent Pipe Size Determination Worksheet on page 53. 1 − Determine the vent termination and its corresponding equivalent feet value according to table 5. 2 − Determine the number of 90° elbows required for both indoor and out door (e.
Page 20 Joint Cementing Procedure All cementing of joint s should be done according to the specifications outlined in ASTM D 2855. W ARNING DANGER OF EXPLOSION! Fumes from PVC glue may ignite during system check. A ll ow f umes to dissip ate for at least 5 minutes before placing unit into operation.
Page 21 V enting Practices The thickness of construction through which vent pipes may be installed is 24" (610mm) maximum and 3" (76mm) minimum. If a G61MP furnace replaces a furnace which wa s commonly vented with another gas appliance, the size of the existing vent pipe for that gas appliance must be checked.
Page 22 FIGURE 24 TYPICAL EXHAUST PIPE CONNECTIONS HORIZONT AL DIRECT OR NON − DIRECT VENT APPLICA TIONS (Horizontal Right − Hand Air Discharge Application Shown) 2" 2" 2" *2" 2−1/2", 3", OR 4" DO NOT transition from smaller to larger pipe size in horizontal runs of exhaust pipe.
Page 23 TYPICAL AIR INT AKE PIPE CONNECTIONS UPFLOW OR DOWNFLOW DIRECT VENT APPLICA TIONS (Right − Hand Exit in Upflow Application Shown) FIGURE 25 PLUG (Must be glued in place) *Limit pipe length to 4" in G61MP−1 1 0, −1 1 1, −135 applications.
Page 24 TYPICAL AIR INT AKE PIPE CONNECTIONS DOWNFLOW NON − DIRECT VENT APPLICA TIONS (Right − Hand Exit in Downflow Applications Shown) FIGURE 28 PLUG (Must be glued in place) 6 in. Max. PLUG (Must be glued in place) Downflow Additive Flloor Base 18 in.
Page 25 General Guidelines for V ent T erminations In Non-Direct V ent applications, combustion air is taken from i ndoor s and the flue gases a re d ischarged t o the out - doors. T he G 61MP is t hen c lassified a s a non-direct vent, Category IV gas furnace.
Page 26 FIGURE 29 VENT TERMINA TION CLEARANCES FOR NON−DIRECT VENT INST ALLA TIONS IN THE USA AND CANADA K D E L B C F G A B J A M I H INSIDE CORNER DET AIL VENT TERMINAL AIR SUPPL Y INLET AREA WHER.
Page 27 FIGURE 30 VENT TERMINA TION CLEARANCES FOR DIRECT VENT INST ALLA TIONS IN THE USA AND CANADA K D E L B C F G A B J A M I H INSIDE CORNER DET AIL VENT TERMINAL AIR SUPPL Y INLET AREA WHERE TERM.
Page 28 Details o f I ntake and Exhaust Piping T erminations f or Direct V ent Installations NOTE − In Direct V ent installati ons, combus tion air is taken from outdoors and flue gases are dis charged to outdoors. Intake and ex haust pipes may be routed either horizontally through a n o utside w all o r v ertically t hrough the roof.
Page 29 FIGURE 33 12" (305) ABOVE A VERAGE SNOW ACCUMULA TION EXHAUST EXHAUST TERMINA TION INT AKE TERMINA TION INT AKE Inches (mm) DIRECT VENT CONCENTRIC ROOFTOP TERMINA TION (71M80, 69M29 or 60.
Page 30 FIGURE 38 COVER EXHAUST VENT WITH 1/2" (13) FOAM INSULA TION Front View Side View DIRECT VENT TERMINA TION W ALL TERMINA TION KIT (22G44, 44J40, 30G28 or 81J20) EXTENDED VENT FOR GRADE CL.
Page 31 3 − If exhaust piping must be run up a side wall to position above snow accumulation or other obstructions, pip- ing must be supported every 3 feet (.
Page 32 NOTE − The condensate trap drain stubs (both sides) have an outer diameter which will accept a standard 3/4" PVC coupling. The inner diameter of each stub will accept standard 1/2" diameter PVC pipe. NOTE − Vinyl tubing may be used for condensate drain.
Page 33 Gas Piping CAUTION If a flexible gas connector is required or allowed by the authority that has jurisdiction, black iron pipe shall b e inst alled at the gas valve and extend out side the furnace cabinet. W ARNING Do not exceed 600 in−lbs (50 ft−lbs) torque when at- taching the gas piping to the gas valve.
Page 34 GROUND JOINT UNION DRIP LEG MANUAL MAIN SHUT−OFF VA LV E GROUND JOINT UNION DRIP LEG MANUAL MAIN SHUT−OFF VA LV E (With 1/8 in. NPT Plugged T ap Shown) GROUND JOINT UNION DRIP LEG MANUAL M.
Page 35 Electrical ELECTROST A TIC DISCHARGE (ESD) Precautions and Procedures CAUTION Electrostatic discharge can affect electronic com- ponents. T ake precautions during furnace inst alla- tion and service to protect the furnace’s electronic controls.
Page 36 9 − On e 24V H" terminal is provided on the furnace control board terminal block. Any humidifier rated up to 0.5 amp can be connected to this terminal with the ground leg of the circuit being connected to either ground or th e C" terminal.
Page 37 T ABLE 10 Field Wiring Applications Thermost at DIP Switch Settings and On−Board Links (Figure 52) Wiring Connections DIP Switch 1 W915 (Y1 to Y2) T wo−St age Cooling W951 (O to R) Heat Pumps 1 Heat / 1 Cool NOTE − Use DI P switch 2 to set sec - ond−stage heat ON delay .
Page 38 T ABLE 10 Field Wiring Applications (Continued) Thermost at DIP Switch Settings and On−Board Links (Figure 52) Wiring Connections DIP Switch 1 W915 (Y1 to Y2) T wo−St age Cooling W951 (O to R) Heat Pumps 2 Heat / 2 Cool OFF Cut Intact S1 T’STAT CONTROL TERM.
Page 39 FIGURE 52 TWO−ST AGE INTEGRA TED CONTROL BOARD THERMOST A T CONNECTIONS (TB1) 1/4" QUICK CONNECT TERMINALS DIP SWITCH FUNCTIONS DIP SWITCHES DIAGNOSTIC LEDs ON−BOARD JUMPERS 1= ERROR .
Page 40 INTEGRA TED CONTROL BOARD DIP SWITCH SETTINGS AND JUMPERS FIGURE 53.
Page 41 TYPICAL G61MP WIRING DIAGRAM FIGURE 54.
Page 42 Integrated Control Board G61MP units are equipped with a two−stage integrated control. This control manages ignition timing and fan of f delays based on selections made using the control DIP switches and jumpers.
Page 43 CAUTION Before attempting to perform any service or mainte- nance, turn the electrical power to unit OFF at dis- connect switch. Priming Condensate T rap The c ondensate trap should be p rimed w ith w ater prior to start−up to ensure proper condensate drainage.
Page 44 12− If the appliance will not operate, follow the instructions T urning Off Gas to Unit" and call your service techni- cian or gas supplier . T urning Off Gas to Unit 1 − Set the thermostat to the lowest setting. 2 − Turn of f all electrical power to the unit if se rvice is to be performed.
Page 45 T ABLE 13 Manifold Pressure (Outlet) inches w .c. Model Number Fuel Altitude (feet) 0−2000 2001−4500 4501−5500 5501−6500 6501−7500 7501−10000 Low Fire High Fire Low Fire High Fiire Low Fire High Fiire Low Fire High Fiire Low Fire High Fiire Low Fire High Fiire 045, 070, 090, 1 10, 135 Natural 1.
Page 46 T esting for Proper V enting and Sufficient Combustion Air for Non−Direct V ent Applications W ARNING CARBON MONOXIDE POISONING HAZARD! Failure to follow the step s outlined below for each appliance connected to the venting system being placed into operation could result in carbon monox- ide poisoning or death.
Page 47 2 − Check for the correct voltage at the furnace (furnace operating). 3 − Check amp-draw on the blower motor . Motor Nameplate__________Actual__________ NOTE − Do not secure the electrical conduit directly to the air ducts or structure.
Page 48 Blower Performance Dat a G61MP−36B−045 PERFORMANCE (Less Filter) External St atic Pressure in. w .g. Air V olume / W att s at Different Blower Speeds High Medium− High Medium− Low Low cfm W atts cfm W att s cfm Watt s cfm Wa t ts 0.00 1555 630 1410 585 1 190 520 1030 435 0.
Page 49 G61MP−60C−090 PERFORMANCE (Less Filter) External St atic Pressure in. w .g. Air V olume / W att s at Different Blower Speeds 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.
Page 50 Blower Performance Dat a G61MP−60C−1 10 PERFORMANCE (Less Filter) External St atic Pressure in. w .g. Air V olume / W att s at Different Blower Speeds Air V olume / W atts at Different Blower S peeds 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.
Page 51 G61MP−60D−135 PERFORMANCE (Less Filter) External St atic Pressure in. w .g. Air V olume / W att s at Different Blower Speeds Air V olume / W atts at Different Blower S peeds 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.
Page 52 Heating Sequence of Operation NOTE − The thermostat selectio n DIP switch on the control board is fac tory−s et in the TWO−ST AGE " position.
Page 53 Service W ARNING ELECTRICAL SHOCK, FIRE, OR EXPLOSION HAZARD. Failure t o follow safety warnings exactly could result in dangerous operation, serious injury , death or property damage. Improper servicing could result in dangerous opera- tion, serious injury , death, or property damage.
Page 54 17 − Remove the primary limit from the vestibule panel. 18 − Remove two screws from the front cabinet flange at th e blower deck. S pread cabinet sides slightly to allow clearance for removal of heat exchanger . 19 − Remove screws along vestibule sides and bottom which secure vestibule panel and heat exchanger as- sembly to cabinet.
Page 55 Planned Service A service technician should check the following items dur- in g an annual inspection. Power to the unit must be shut off for safety . Fresh air grilles and louvers (on the unit and in the room where the furnace is installed) − Must be open and unob- structed to provide combustion air .
Page 56 Ignition Control Board Diagnostic Codes FLASH CODE (X + Y) ST A TUS / ERROR DESCRIPTION FLASH CODE DESCRIPTIONS Pulse A 1/4 second flash followed by four seconds of off time.
Page 57 T roubleshooting: Heating Sequence of Operation HEA TING SEQUENCE OF OPERA TION NORMAL AND ABNORMAL HEA TING MODE CONTROL SELF−CHECK OKA Y? YES GAS V AL VE OFF . COMBUSTION AIR INDUCER OFF . INDOOR BLOWER OFF . (RESET CONTROL BY TURNING MAIN POWER OFF .
Page 58 T roubleshooting: Heating Sequence of Operation (Continued) HEA TING SEQUENCE OF OPERA TION FIRST−ST AGE (LOW FIRE) PRESSURE SWITCH CLOSED WITHIN 2.5 MINUTES? GAS V AL VE OFF . COMBUSTION AIR INDUCER OFF . INDOOR BLOWER OFF . UNIT WILL RETR Y AFTER 5−MINUTE WAIT PERIOD.
Page 59 T roubleshooting: Heating Sequence of Operation (Continued) HEA TING SEQUENCE OF OPERA TION LOW FLAME SIGNAL (Does not affect control operation) ST A TUS ERROR CODE 1 + 2.
Page 60 T roubleshooting: Heating Sequence of Operation (Continued) HEA TING SEQUENCE OF OPERA TION SEE BOX B THERMOST A T CALLS FOR HEA T . SEE BOX A NORMAL OPERA TION. YES NO RETURN T O FIRST−ST AGE HEA T MODE. FIRST−ST AGE CONTINUES UNTIL SECOND− ST AGE PRESSURE SWITCH CAN BE PROVEN or HEA T DEMAND IS SA TISFIED.
Page 61 T roubleshooting: Cooling Sequence of Operation COOLING SEQUENCE OF OPERA TION SIGNAL POLARITY REVERSED. CONTROL WILL CONTINUE TO CALL FOR COOLING IN THIS CONDITION. ST A TUS ERROR CODE 5 + 4. POWER ON YES IS POLARITY REVERSED? THERMOST A T CALLS FOR FIRST−ST AGE COOL.
Page 62 T roubleshooting: Continuous Fan Sequence of Operation CONTINUOUS LOW SPEED F AN SEQUENCE OF OPERA TION MANUAL F AN SELECTION MADE A T THERMOST A T . AFTER 2 SECOND DELA Y , INDOOR BLOWER IS ENERGIZED ON CONTINUOUS F AN SPEED. THERMOST A T CALLS FOR FIRST−ST AGE HEA T .
Page 63 V ent Pipe Sizing Worksheet Proposed vent pipe size : ______ T ermination kit catalog number : _____________ V ent pipe equivalency value from t able 5 : ______ T ot al number of 90° elbows required (indoors and out doors) ______ X 5 = ______ equivalent feet of pipe T ot al number of 45° elbows required (indoors and out doors) ______ X 2.
Page 64 Requirement s for Commonwealth of Massachusett s Modifications to NFP A−54, Chapter 10 Revise N FP A−54 section 10.8.3 to add the following re- quirement s: For all side wall, horizont all.
An important point after buying a device Lennox International Inc. Gas Units (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Lennox International Inc. Gas Units yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Lennox International Inc. Gas Units - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Lennox International Inc. Gas Units you will learn all the available features of the product, as well as information on its operation. The information that you get Lennox International Inc. Gas Units will certainly help you make a decision on the purchase.
If you already are a holder of Lennox International Inc. Gas Units, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Lennox International Inc. Gas Units.
However, one of the most important roles played by the user manual is to help in solving problems with Lennox International Inc. Gas Units. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Lennox International Inc. Gas Units along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
