Page 2 - Right
Page 2 G61MP Unit Dimensions − inches (mm) *Bottom Return Air Opening *Bottom Return Air Opening ELECTRICAL INLET (Either Side) SUPPLY AIR OPENING AIR FLOW FRONT VIEW SIDE VIEW TOP VIEW A B 9/16 (14) C 3/4 (19) 3/4 (19) 28−1/2 (724) 19−7/16 (378) 23−1/2 (597) 4−1/4 (108) 11−5/8 (295) Right 9−3/4 (24...
Page 3 - FIGURE 1
Page 3 G61MP Parts Arrangement G61MP PARTS IDENTIFICATION FIGURE 1 TOP CAP CABINET BURNER BOX ASSEMBLY SIGHT GLASS DuralokPlus TM HEAT EXCHANGER ASSEMBLY CONDENSER COIL CONTROL BOX DOOR INTERLOCK SWITCH COLD HEADER (COLLECTOR) BOX COMBUSTION AIR INDUCER BLOWER ACCESS DOOR BURNER ACCESS PANEL FLUE CO...
Page 4 - G61MP Gas Furnace; NOTE; Shipping and Packing List; Package 1 of 1 contains; DANGER; Safety Information; WARNING
Page 4 G61MP Gas Furnace The G61MP category IV gas furnace is shipped ready forinstallation 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. The bot-tom panel must be removed if the unit is to ...
Page 5 - Use of Furnace as Construction Heater
Page 5 In Canada, installation must conform with current NationalStandard of Canada CSA-B149 Natural Gas and PropaneInstallation Codes, local plumbing or waste water codesand other applicable local codes. In order to ensure proper unit operation in non−direct ventapplications, combustion and ventila...
Page 6 - General; Product contains fiberglass wool.; CAUTION
Page 6 D One hundred percent (100%) outdoor air must be pro-vided for combustion air requirements during construc-tion. Temporary ducting may supply outdoor air to thefurnace. Do not connect duct directly to the furnace.Size the temporary duct following these instructions insection for Combustion, D...
Page 7 - Unconfined Space; Air from Outside
Page 7 Z223.1/NFPA 54). This reprinted material is not the com-plete and official position of the ANSI on the referencedsubject, which is represented only by the standard in itsentirety. In Canada, refer to the standard CSA B149 installationcodes. CAUTION Do not install the furnace in a corrosive or...
Page 8 - FIGURE 4; FIGURE 5; Btu (1.17 kW) per hour of total input rating of all equipment; Installation − Setting Equipment
Page 8 FIGURE 4 EQUIPMENT IN CONFINED SPACE − ALL AIR FROM OUTSIDE (Inlet Air from Crawl Space and Outlet Air to Ventilated 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 per 1.17kW) per hour of the total input rating of ...
Page 9 - UPFLOW APPLICATION; The unit must be level from side to side. The unit may be
Page 9 FIGURE 7 SETTING EQUIPMENT UPFLOW APPLICATION DOWNFLOW APPLICATION HORIZONTAL APPLICATION 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. 1/2" max. 1/2" max. UNIT MUST BE LEVEL SI...
Page 10 - Upflow Applications; Installation Clearances; FIGURE 8; − Return air from single side with transition which will; Refer to Engineering Handbook for additional information.
Page 10 Upflow Applications The G61MP gas furnace can be installed as shipped inthe upflow position. Refer to figure 8 for clearances. Installation Clearances Top Bottom (Floor) Left Side Right Side Top/Plenum 1 in. (25 mm) *Front 0 Back 0 Sides 0 † Vent 0 Floor 0 ‡ *Front clearance in alcove instal...
Page 12 - Downflow Applications; Downflow Application Installation Clearances; Front to Rear
Page 12 Setting an Upflow Unit When the side return air inlets are used in an upflow ap-plication, it may be necessary to install leveling bolts on thebottom of the furnace. Use field−supplied corrosion−resist-ant 5/16 inch machine bolts (4) and nuts (8). See figure 12. NOTE − The maximum length of ...
Page 13 - B Cabinet
Page 13 Installation on Combustible Flooring (Using an Additive Base) 1 − When unit is installed on a combustible floor, an addi- tive base must be installed between the furnace andthe floor. The base must be ordered separately. Seetable 2 for opening size to cut in floor. CAUTION The furnace and ad...
Page 14 - Horizontal Applications; Suspended Installation of Horizontal Unit
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 as a unit heater. Eithersuspend the furnace as shown in figure 18, or install thefurnace on a field−fabricated raised platform...
Page 15 - Return Air −− Horizontal Applications
Page 15 Lennox part number 56J18). Position the supportframe on top of the blocks and install the unit on theframe. Leave 5−1/2 inches for service clearance forcondensate trap. 3 − Route auxiliary drain line so that water draining from this outlet will be easily noticed by the homeowner. Ifnecessary...
Page 16 - Filters; Furnace; Duct System; Pipe & Fittings Specifications
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. Table3 lists recommended filter sizes.A filter must be in place whenever the unit is operating. TABLE 3 Furnace Cabinet Width Filter Size Side Return Bottom Return ...
Page 18 - Vent Piping Guidelines
Page 18 Vent Piping Guidelines The G61MP can be installed as either a Non−Direct Ventor 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 from o...
Page 20 - Joint Cementing Procedure
Page 20 Joint Cementing Procedure All cementing of joints should be done according to thespecifications outlined in ASTM D 2855. WARNING DANGER OF EXPLOSION! Fumes from PVC glue may ignite during systemcheck. Allow fumes to dissipate for at least 5 minutesbefore placing unit into operation. 1 − Meas...
Page 21 - Venting Practices; Exhaust Piping; IN UPFLOW OR DOWNFLOW DIRECT OR NON
Page 21 Venting Practices The thickness of construction through which vent pipesmay be installed is 24" (610mm) maximum and 3" (76mm)minimum. If a G61MP furnace replaces a furnace whichwas commonly vented with another gas appliance, the sizeof the existing vent pipe for that gas appliance mu...
Page 22 - TYPICAL EXHAUST PIPE CONNECTIONS; HORIZONTAL DIRECT OR NON; IMPORTANT; Intake Piping
Page 22 FIGURE 24 TYPICAL EXHAUST PIPE CONNECTIONS HORIZONTAL DIRECT OR NON − DIRECT VENT APPLICATIONS (Horizontal Right − Hand Air Discharge Application Shown) 2" 2" 2" *2" 2−1/2", 3", OR 4" DO NOT transitionfrom smaller to largerpipe size in horizontalruns of exhaust pi...
Page 23 - TYPICAL AIR INTAKE PIPE CONNECTIONS; Follow the next three steps when installing the unit in; TYPICAL AIR INTAKE PIPE CONNECTIONS
Page 23 TYPICAL AIR INTAKE PIPE CONNECTIONS UPFLOW OR DOWNFLOW DIRECT VENT APPLICATIONS (Right − Hand Exit in Upflow Application Shown) FIGURE 25 PLUG (Must be glued in place) *Limit pipe length to 4" in G61MP−110,−111, −135 applications. −36B−045−−36B−070−36B−071−48C−090−60C−090−60C−091 −36B−04...
Page 24 - DOWNFLOW NON; ELL; the intake air routing should be modi-
Page 24 TYPICAL AIR INTAKE PIPE CONNECTIONS DOWNFLOW NON − DIRECT VENT APPLICATIONS (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. Downflow Evaporator Coil 2" 2" SWEEP EL...
Page 29 - Side View
Page 29 FIGURE 33 12" (305) ABOVE AVERAGE SNOW ACCUMULATION EXHAUST EXHAUST TERMINATION INTAKE TERMINATION INTAKE Inches (mm) DIRECT VENT CONCENTRIC ROOFTOP TERMINATION (71M80, 69M29 or 60L46) FIELD−PROVIDED REDUCER MAY BE REQUIRED TO ADAPT LARGER VENT PIPE SIZE TO TERMINATION FIGURE 34 EXHAUST ...
Page 30 - G61MP DIRECT VENT APPLICATION; − Exhaust piping must terminate straight out or up as
Page 30 FIGURE 38 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) ÉÉÉÉÉÉÉÉÉ 5" (127) 5-1/2" (140) EXHAUST AIR INTAKE AIR GRADE 12" (305) 8&...
Page 31 - − If exhaust piping must be run up a side wall to position; G61MP NON−DIRECT VENT APPLICATION; − The condensate trap provided with the unit is
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 (.9m) as shown infigure 22. Refer to figure 42 for proper piping method.When exhaust piping must be run up an outside wall,any reduction in exhau...
Page 32 - Do
Page 32 NOTE − The condensate trap drain stubs (both sides) have an outer diameter which will accept a standard3/4" PVC coupling. The inner diameter of each stubwill accept standard 1/2" diameter PVC pipe. NOTE − Vinyl tubing may be used for condensate drain. Tubing must be 1−1/4" OD X 1...
Page 33 - Gas Piping; Leak Check; FIRE OR EXPLOSION HAZARD; Upflow Application
Page 33 Gas Piping CAUTION If a flexible gas connector is required or allowed bythe authority that has jurisdiction, black iron pipeshall be installed at the gas valve and extend outsidethe furnace cabinet. WARNING Do not exceed 600 in−lbs (50 ft−lbs) torque when at-taching the gas piping to the gas...
Page 34 - Horizontal Application; TABLE 9
Page 34 GROUND JOINT UNION DRIP LEG MANUAL MAIN SHUT−OFF VALVE GROUND JOINT UNION DRIP LEG MANUAL MAIN SHUT−OFF VALVE (With 1/8 in. NPT Plugged Tap Shown) GROUND JOINT UNION DRIP LEG MANUAL MAIN SHUT−OFF VALVE Horizontal Applications Possible Gas Piping Configerations Horizontal Application Left−Sid...
Page 35 - Electrical; Precautions and Procedures; INTERIOR MAKE−UP BOX INSTALLATION
Page 35 Electrical ELECTROSTATIC DISCHARGE (ESD) Precautions and Procedures CAUTION Electrostatic discharge can affect electronic com-ponents. Take precautions during furnace installa-tion and service to protect the furnace’s electroniccontrols. Precautions will help to avoid control ex-posure to el...
Page 39 - TWO−STAGE INTEGRATED CONTROL BOARD; DIP SWITCH FUNCTIONS
Page 39 FIGURE 52 TWO−STAGE INTEGRATED CONTROL BOARD THERMOSTAT CONNECTIONS (TB1) 1/4" QUICK CONNECT TERMINALS DIP SWITCH FUNCTIONS DIP SWITCHES DIAGNOSTIC LEDs ON−BOARD JUMPERS 1= ERROR CODE RECALLH= 24V HUMIDIFIER OUTPUTL= DO NOT USE SENSE = 120 VAC OUTPUT TO FLAME SENSER NEUTRALS= 120 VAC NEU...
Page 40 - INTEGRATED CONTROL BOARD DIP SWITCH SETTINGS AND JUMPERS
Page 40 INTEGRATED CONTROL BOARD DIP SWITCH SETTINGS AND JUMPERS FIGURE 53
Page 41 - TYPICAL G61MP WIRING DIAGRAM
Page 42 - Integrated Control Board; Select OFF; Unit Start−Up
Page 42 Integrated Control Board G61MP units are equipped with a two−stage integratedcontrol. This control manages ignition timing and fan offdelays based on selections made using the control DIPswitches and jumpers. The control includes an internalwatchguard feature which automatically resets the i...
Page 44 - Gas Pressure Adjustment; Do not attempt to make adjustments to the gas valve.
Page 44 12− If the appliance will not operate, follow the instructions Turning Off Gas to Unit" and call your service techni-cian or gas supplier. Turning Off Gas to Unit 1 − Set the thermostat to the lowest setting. 2 − Turn off all electrical power to the unit if service is to be performed. 3 ...
Page 45 - High Altitude Information
Page 45 TABLE 13 Manifold Pressure (Outlet) inches w.c. Model Number Fuel Altitude (feet) 0−2000 2001−4500 4501−5500 5501−6500 6501−7500 7501−10000 LowFire HighFire LowFire HighFiire LowFire HighFiire LowFire HighFiire LowFire HighFiire LowFire HighFiire 045, 070, 090, 110,135 Natural 1.7 3.5 1.7 3....
Page 46 - CARBON MONOXIDE POISONING HAZARD!; Other Unit Adjustments; Primary and Secondary Limits
Page 46 Testing for Proper Venting and Sufficient Combustion Air for Non−Direct Vent Applications WARNING CARBON MONOXIDE POISONING HAZARD! Failure to follow the steps outlined below for eachappliance connected to the venting system beingplaced into operation could result in carbon monox-ide poisoni...
Page 48 - Blower Performance Data
Page 48 Blower Performance Data G61MP−36B−045 PERFORMANCE (Less Filter) External Static Pressure in. w.g. Air Volume / Watts at Different Blower Speeds High Medium− High Medium− Low Low cfm Watts cfm Watts cfm Watts cfm Watts 0.00 1555 630 1410 585 1190 520 1030 435 0.10 1515 605 1385 555 1190 485 1...
Page 49 - − Air volumes in bold require field
Page 49 G61MP−60C−090 PERFORMANCE (Less Filter) External Static Pressure in. w.g. Air Volume / Watts at Different Blower Speeds Bottom Return Air, Side Return Air with Optional RABReturn Air Base, Return Air from Both Sides or ReturnAir from Bottom and One Side. Single Side Return Air − Air volumes ...
Page 52 - Heating Sequence of Operation
Page 52 Heating Sequence of Operation NOTE − The thermostat selection DIP switch on the control board is factory−set in the TWO−STAGE" position. Applications Using a Two−Stage Thermostat A − Heating Sequence −− Control Board ThermostatSelection DIP switch in Two−Stage" Position (FactorySetti...
Page 53 - Service
Page 53 Service WARNING ELECTRICAL SHOCK, FIRE, OR EXPLOSION HAZARD. Failure to follow safety warnings exactly could resultin dangerous operation, serious injury, death orproperty damage.Improper servicing could result in dangerous opera-tion, serious injury, death, or property damage.Before servici...
Page 55 - Planned Service
Page 55 Planned Service A service technician should check the following items dur-ing 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...
Page 56 - Ignition Control Board Diagnostic Codes; FLASH CODE
Page 56 Ignition Control Board Diagnostic Codes FLASH CODE (X + Y) STATUS / ERROR DESCRIPTION FLASH CODE DESCRIPTIONS Pulse A 1/4 second flash followed by four seconds of off time. Heartbeat Constant 1/2 second bright and 1/2 second dim cycles. X + Y LED flashes X times at 2Hz, remains off for two s...
Page 57 - Troubleshooting: Heating Sequence of Operation; HEATING SEQUENCE OF OPERATION; CONTINUED ON NEXT PAGE
Page 57 Troubleshooting: Heating Sequence of Operation 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.) NO POLARITY REVERSED. STATUS ERROR CODE 5 + 4. P...
Page 59 - CONTINUED
Page 59 Troubleshooting: Heating Sequence of Operation (Continued) HEATING SEQUENCE OF OPERATION LOW FLAME SIGNAL (Does not affect control operation) STATUS ERROR CODE 1 + 2. FLAME SIGNAL ABOVE ( u 1.40 microamps) NO YES CONTINUED ON NEXT PAGE YES SINGLE−STAGE THERMOSTAT MODE (DIP SWITCH SET AT SING...
Page 61 - Troubleshooting: Cooling Sequence of Operation; COOLING SEQUENCE OF OPERATION
Page 61 Troubleshooting: Cooling Sequence of Operation COOLING SEQUENCE OF OPERATION SIGNAL POLARITY REVERSED. CONTROL WILL CONTINUE TO CALL FOR COOLING IN THIS CONDITION. STATUS ERROR CODE 5 + 4. POWER ON YES IS POLARITY REVERSED? THERMOSTAT CALLS FOR FIRST−STAGE COOL. COMPRESSOR AND CONDENSER FAN ...
Page 62 - Flame Sensor
Page 62 Troubleshooting: Continuous Fan Sequence of Operation 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. THERMOSTAT CALLS FOR FIRST−STAGE HEAT. THERMOSTAT CALLS FOR FIRST STAGE COOL...
Page 63 - Vent Pipe Sizing Worksheet; Equivalent Feet; G61MP Start−Up & Performance Check List; Heating Section
Page 63 Vent Pipe Sizing Worksheet Proposed vent pipe size : ______ Termination kit catalog number : _____________Vent pipe equivalency value from table 5 : ______ Total number of 90° elbows required (indoors and outdoors)______ X 5 = ______ equivalent feet of pipe Total number of 45° elbows require...
Page 64 - Requirements for Commonwealth of Massachusetts; Modifications to NFPA−54, Chapter 10
Page 64 Requirements for Commonwealth of Massachusetts Modifications to NFPA−54, Chapter 10 Revise NFPA−54 section 10.8.3 to add the following re-quirements: For all side wall, horizontally vented, gas−fueled equipment installed in every dwelling, building or structure used inwhole or in part for re...
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