Lennox G61MP - Manuals - manualsarea.com

Page 4 - BLOWER DATA

Page 4 BLOWER DATA G61MP−36B−045 PERFORMANCE (Less Filter) External Static Air Volume / Watts at Different Blower Speeds External Static Pressure High Medium−High Medium−Low Low in. w.g. Pa cfm L/s Watts cfm L/s Watts cfm L/s Watts cfm L/s Watts 0.00 25 1555 735 630 1410 665 585 1190 560 520 1030 48...

Page 8 - I−UNIT COMPONENTS; CAUTION

Page 8 I−UNIT COMPONENTS G61MP unit components are shown in figure 1. The gasvalve, combustion air inducer and burners can be ac-cessed by removing the burner access panel. Electricalcomponents are in the control box (figure 2) found in theblower section.G61MP units are factory equipped with a botto...

Page 11 - TABLE 6; DIAGNOSTIC CODES; DESCRIPTION; B−Blower Compartment; FIGURE 5

Page 11 TABLE 6 DIAGNOSTIC CODES Diagnostic LEDs are labeled DS1 and DS2. See figure 4 for location of diagnostic LEDs. DS1 DS2 DESCRIPTION SIMULTANEOUS SLOW FLASH SIMULTANEOUS SLOW FLASH Power on − Normal operation.Also signaled during cooling and continuous fan. SIMULTANEOUS FAST FLASH SIMULTANEOU...

Page 12 - C−Heating Components; FIGURE 6

Page 12 C−Heating Components 3. Flame Sensor A flame sensor is located on the left side of the burner sup-port. See figure 6. The sensor is mounted through the bot-tom of the burner box and the tip protrudes into the flameenvelope of the left−most burner. The sensor can be re-moved for service witho...

Page 13 - Clamshell Heat Exchanger; FIGURE 8; Combustion Air Inducer; two

Page 13 6. Clamshell Heat Exchanger G61MP units use an aluminized steel primary and stain-less steel secondary heat exchanger assembly. Heat istransferred to the air stream from all surfaces of the heatexchanger. The shape of the heat exchanger ensuresmaximum efficiency. The combustion air inducer p...

Page 14 - ings will change as heat exchanger warms.

Page 14 On heat demand (first or second stage) the switch sensesthat the combustion air inducer is operating. It closes a cir-cuit to the furnace control when pressure inside the coldend header box decreases to a certain set point.Set points vary depending on unit size. See tables 8, 9 and10. The pr...

Page 16 - II−PLACEMENT AND INSTALLATION; OUTDOOR TERMINATION KITS AND CORRESPONDING EQUIVALENCIES; UNIT

Page 16 II−PLACEMENT AND INSTALLATION TABLE 11 OUTDOOR TERMINATION KITS AND CORRESPONDING EQUIVALENCIES Vent Pipe Length Equivalency (feet) UNIT MODEL VENT PIPE DIA. (in.) OutdoorExhaust Accelerator (Dia. X Length) OutdoorExhaust Accelerator (Dia. X Length) 1−1/2" Concen- tric Kit 2" Con- ce...

Page 17 - A−Vent Piping Guidelines; The G61MP can be installed as either a Non−Direct Vent

Page 17 A−Vent Piping Guidelines The G61MP can be installed as either a Non−Direct Vent or a Direct Vent gas central furnace. NOTE − In Non-Direct Vent installations, combustion air is taken from indoors and flue gases are discharged outdoors. In Direct Vent installations, combustion air is taken fr...

Page 18 - MINIMUM VENT PIPE LENGTHS; MAXIMUM VENT PIPE LENGTHS; B−PVC Joint Cementing Procedure; WARNING; NOTE − Time is critical at this stage. Do not allow prim-

Page 18 Use the following steps to correctly size vent pipe diameter. 1 − Determine the vent termination and its corresponding equivalent feet value according to table 11. 2 − Determine the number of 90° elbows required for both indoor and outdoor (e.g. snow riser) use. Calculate thecorresponding eq...

Page 19 - C− Venting Practices; Exhaust Piping; IN UPFLOW OR DOWNFLOW DIRECT OR NON-DIRECT VENT APPLICATIONS

Page 19 C− Venting 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 was commonly vented with another gas appliance, the size of the existing vent pipe for that gas appli...

Page 20 - TYPICAL EXHAUST PIPE CONNECTIONS; HORIZONTAL DIRECT OR NON-DIRECT VENT; IMPORTANT; Intake Piping

Page 20 FIGURE 14 TYPICAL EXHAUST PIPE CONNECTIONS HORIZONTAL DIRECT OR NON-DIRECT VENT APPLICATIONS (Horizontal Right-Hand Air Discharge Application Shown) G61MP−36B−045G61MP−36B−070 G61MP−48C−090G61MP−60C−090 G61MP−48C−110*G61MP−60C−110* G61MP−60C−135* G61MP−36B−045G61MP−36B−070 G61MP−48C−090G61MP...

Page 21 - UPFLOW OR DOWNFLOW DIRECT VENT APPLICATIONS; TYPICAL AIR INTAKE PIPE CONNECTIONS; HORIZONTAL DIRECT VENT APPLICATIONS; Follow the next three steps when installing the unit in; TYPICAL AIR INTAKE PIPE CONNECTIONS; UPFLOW OR HORIZONTAL NON-DIRECT

Page 21 TYPICAL AIR INTAKE PIPE CONNECTIONS UPFLOW OR DOWNFLOW DIRECT VENT APPLICATIONS (Right-Hand Exit in Upflow Application Shown) FIGURE 15 PLUG (Must be glued in place) G61MP−36B−045G61MP−36B−070 G61MP−48C−090G61MP−60C−090 G61MP−48C−110*G61MP−60C−110* G61MP−60C−135* G61MP−36B−045G61MP−36B−070 G...

Page 22 - DOWNFLOW NON-DIRECT VENT APPLICATIONS; ELL; the intake air routing should be modi-; CARBON MONOXIDE POISONING HAZARD!

Page 22 TYPICAL AIR INTAKE PIPE CONNECTIONS DOWNFLOW NON-DIRECT VENT APPLICATIONS (Right-Hand Exit in Downflow Applications Shown) FIGURE 18 PLUG (Must be glued in place) 6 in. Max. PLUG (Must be glued in place) Downflow Additive Flloor Base 18 in. Downflow Evaporator Coil 2" 2" SWEEP ELL 2&...

Page 25 - EXHAUST PIPE TERMINATION SIZE REDUCTION

Page 25 Details of Intake and Exhaust Piping Terminations forDirect Vent Installations NOTE − In Direct Vent installations, combustion air is takenfrom outdoors and flue gases are discharged to outdoors. Intake and exhaust pipes may be routed either horizontallythrough an outside wall or vertically ...

Page 27 - Front View; G61MP DIRECT VENT APPLICATION

Page 27 FIGURE 27 12" MIN. (305) Above Grade COVER EXHAUST VENT WITH 1/2" (13) FOAM INSULATION Front View Side View DIRECT VENT TERMINATION WALL TERMINATION KIT (22G44, 44J40, 30G28 or 81J20) EXTENDED VENT FOR GRADE CLEARANCE Inches (mm) ÉÉÉÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉÉÉÉ 5" (127) 5-1/2" (140) EX...

Page 28 - G61MP NON−DIRECT VENT APPLICATION

Page 28 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 (.9m) as shown infigure 12. Refer to figure 31 for proper piping method.When exhaust piping must be run up an outside wall,any reduction in exhaus...

Page 29 - Do

Page 29 hose clamp.Condensate line must be sloped downward away fromcondensate trap to drain. If drain level is above con-densate trap, condensate pump must be used. Con-densate drain line should be routed within the condi-tioned space to avoid freezing of condensate andblockage of drain line. If th...

Page 30 - A−Preliminary and Seasonal Checks; Shock and burn hazard.; Honeywell VR8205 Gas Valve −

Page 30 III−START-UP A−Preliminary and Seasonal Checks 1 − Inspect electrical wiring, both field and factory installed for loose connections. Tighten as required. 2 − Check voltage at disconnect switch. Voltage must be within range listed on the nameplate. If not, consult thepower company and have v...

Page 31 - C−Safety or Emergency Shutdown; C−Testing Gas Piping

Page 31 WHITE RODGERS 36E SERIES GAS VALVE GAS VALVE SHOWN IN OFF POSITION HIGH FIRE MANIFOLD PRESSURE ADJUSTMENT ON SIDE (under cap) MANIFOLD PRESSURE TAP ON SIDE INLET PRESSURE TAP ON SIDE LOW FIRE MANIFOLD PRESSURE ADJUSTMENT ON SIDE (under cap) FIGURE 36 8 − Honeywell VR8205 Gas Valve − Turn kno...

Page 32 - G− Proper Combustion

Page 32 When checking piping connections for gas leaks, use pre-ferred means. Kitchen detergents can cause harmful corro-sion on various metals used in gas piping. Use of a specialtyGas Leak Detector is strongly recommended. It is availablethrough Lennox under part number 31B2001. See Corp.8411−L10,...

Page 33 - Tap Water; Increasing

Page 33 TABLE 17High Heat Unit CO 2 % For Nat CO 2 % For L.P. G61MP−36B−045 6.5 − 7.5 7.4 − 8.4 G61MP−36B−070 6.5 − 7.5 7.4 − 8.4 G61MP−48C−090 6.9 − 7.9 7.8 − 8.8 G61MP−60C−090 6.9 − 7.9 7.8 − 8.8 G61MP−48C−110 7.2 − 8.2 8.1 − 9.1 G61MP−60C−110 7.2 − 8.2 8.1 − 9.1 G61MP−60D−135 7.4 − 8.4 8.3 − 9.3 ...

Page 34 - J−Flame Signal; To Measure Flame Signal − Ignition Control:; B−Temperature Rise; To Measure Temperature Rise:; C−External Static Pressure

FIGURE 38 TRANSDUCER (PART #78H5401) FIGURE 40 STATIC PRESSURE TEST Page 34 J−Flame Signal A microamp DC meter is needed to check the flame signalon the ignition control.Flame (microamp) signal is an electrical current which passesfrom the furnace control through the sensor during unit opera-tion. C...

Page 37 - Cleaning the Burner Assembly

Page 37 Cleaning the Burner Assembly 1 − Turn off electrical and gas power supplies to furnace. Remove upper and lower furnace access panels. 2 − Mark all gas valve wires and disconnect them from the valve. 3 − Disconnect the gas supply line from the gas valve. Re- move gas valve/manifold assembly. ...

Page 38 - VII− Wiring and Sequence of Operation

Page 39 - Sequence of Operation; SureLight Control Self Check

Page 39 Sequence of Operation Sequence depends on type thermostat used. G61MPunits are applicable for single stage or two stage ther-mostats. Both type thermostats are described below.Thermostat jumper E20 dictates which mode unit willoperate in. See flow chart for more sequence detail. SureLight Co...

Page 40 - CONTINUED ON NEXT PAGE

Page 40 HEATING SEQUENCE OF OPERATION NORMAL AND ABNORMAL HEATING MODE CONTROL SELF−CHECK OKAY? YES GAS VALVE OFF. COMBUSTION AIR INDUCER OFF. INDOOR BLOWER OFF. (RESET CONTROL BY TURNING MAIN POWER OFF.) DS1 ON, DS2 ON NO POLARITY REVERSED. DS1 −− FAST FLASH DS2 −− SLOW FLASH POWER ON POLARITY OKAY...

Page 42 - CONTINUED

Page 42 HEATING SEQUENCE OF OPERATION LOW FLAME SIGNAL (Does not affect control operation) DS1 SLOW FLASH, DS2 FAST FLASH. FLAME SIGNAL ABOVE ( u 0.22 microamps) NO YES CONTINUED ON NEXT PAGE YES SINGLE−STAGE THERMOSTAT MODE (E20 SET AT SINGLE") TWO STAGE THERMOSTAT MODE (E20 SET AT TWO") YE...

Page 44 - COOLING SEQUENCE OF OPERATION

Page 44 COOLING SEQUENCE OF OPERATION SIGNAL POLARITY REVERSED. DS1 FAST FLASH, DS2 SLOW FLASH. POWER ON YES IS POLARITY REVERSED? THERMOSTAT CALLS FOR FIRST−STAGE COOL. COMPRESSOR AND CONDENSER FAN ENERGIZED. NO IS THERE PROPER GROUND? IS VOLTAGE ABOVE 75 VOLTS? LOW VOLTAGE SIGNAL AT DS HOLDS UNTIL...

Page 45 - CONTINUOUS LOW SPEED FAN SEQUENCE OF OPERATION

Page 45 CONTINUOUS LOW SPEED FAN SEQUENCE OF OPERATION MANUAL FAN SELECTION MADE AT THERMOSTAT. AFTER 2 SECOND DELAY, INDOOR BLOWER IS ENERGIZED ON CONTINUOUS FAN SPEED (LOW HEAT / LOW COOL). THERMOSTAT CALLS FOR FIRST−STAGE HEAT. THERMOSTAT CALLS FOR FIRST STAGE COOL. YES YES BURNERS IGNITE AND IND...

Page 46 - VIII− Field Wiring Applications and Jumper Settings; Field Wiring Applications

Page 46 VIII− Field Wiring Applications and Jumper Settings Field Wiring Applications Jumper Settings (See figure 4) Thermostat E20 W915 Y1 to Y2 Wiring Connections 1 Heat / 1 Cool NOTE − Use dip switch 3to set second−stage heatON delay.ON−10 minutes. OFF−15minutes. SINGLE Leave Installed S1 T’STAT ...

Page 48 - UPON INITIAL POWER UP, REMOVE ALL THERMOSTAT DEMANDS TO THE UNIT; Condition

Page 48 IX−SURELIGHT ® CONTROL TROUBLESHOOTING CHART UPON INITIAL POWER UP, REMOVE ALL THERMOSTAT DEMANDS TO THE UNIT PROBLEM: 1 UNIT FAILS TO OPERATE IN THE COOLING, HEATING, OR CONTINUOUS FAN MODE Condition Possible Cause Corrective Action / Comments 1.1 − Both diagnostic lights fail to light up. ...

Page 49 - ENERGIZE

Page 49 PROBLEM 1: UNIT FAILS TO OPERATE IN THE COOLING, HEATING, OR CONTINUOUS FAN MODE Condition Possible Cause Corrective Action / Comments 1.5 − Diagnostic lights flash the improper main ground. 1.5.1 Improper ground to the unit. ACTION 1 − Check that the unit is properly ground. ACTION 2 − Inst...

Page 52 - PROBLEM 5: BURNERS LIGHT WITH HEATING DEMAND BUT UNIT SHUTS DOWN

Page 52 PROBLEM 5: BURNERS LIGHT WITH HEATING DEMAND BUT UNIT SHUTS DOWN PREMATURELY (CONT.) Condition Possible Cause Corrective Action/Comments 5.3 − Combustion air inducer energizeswith a heating demand. − Burners light. − Roll−out switch trips during theheating demand. − Diagnostic lights flash r...

Page 53 - PROBLEM 6: CONTROL SIGNALS LOW FLAME SENSE DURING HEATING MODE; FAN MODE; PROBLEM 8: RF STATIC DURING TIME FOR IGNITION

Page 53 PROBLEM 6: CONTROL SIGNALS LOW FLAME SENSE DURING HEATING MODE Condition Possible Cause Corrective Action/Comments 6.0 − Unit operates correctly but the diag-nostic lights flash low flame sensecode 6.1.1 Sensor rod is improperly located on the burner. ACTION 1 − Check the sensor rod for prop...

Page 54 - SERVICE NOTES