Lennox International Inc.メーカーG61MPの使用説明書/サービス説明書
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Page 1 © 2003 Lennox Industries Inc. Corp. 0308−L6 G61MP Service Literature Revised 10−2004 G61MP SERIES UNITS G61MP series units are high−ef ficiency multi−position (up- flow , downflow , horizontal right and lef t) gas furnaces manufactured with Lennox Duralok Plus t heat exchang- ers formed of aluminized steel.
Page 2 SPECIFICA TIONS Gas Ht i ModelNo. G61MP−36B−045 G61MP−36B−070 G61MP−48C−090 G61MP−60C−090 Heating Performance High Fi Input− Btuh (kW) 44,000 (12.9) 66,000 (19.3) 88,000 (25.8) 88,000 (25.8) Performance g Fire Output− Btuh (kW) 41,000 (12.
Page 3 SPECIFICA TIONS Gas Ht i ModelNo. G61MP−48C−1 10 G61MP−60C−1 10 G61MP−60D−135 Heating Performance High Fi re Input− Btuh (kW) 1 10,000 (32.2) 1 10,000 (32.2) 132,000 (38.7) P er f ormance g Output− Btuh (kW) 104,000 (30.
Page 4 BLOWER DA T A G61MP−36B−045 PERFORMANCE (Less Filter) External St atic Air V olume / Watt s at Different Blower Speeds External St atic Pressure High Medium−High Medium−Low Low in. w.g. Pa cfm L/s W att s cfm L/s W att s cfm L/s Watt s cfm L/s W att s 0.
Page 5 BLOWER DA T A G61MP−60C−090 PERFORMANCE (Less Filter) − Single Side Return Air − Air volumes in bold require field fabricated transi- tion to accommodate 20 x 25 x 1 in. (508 x 635 x 25 mm) air filter in order to maintain proper air velocity .
Page 6 BLOWER DA T A G61MP−60C−1 10 PERFORMANCE (Less Filter) − 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. External St atic P Air V olume / Watt s at Different Blower Speeds Pressure High Medium−High Medium−Low Low in.
Page 7 G61MP P ARTS ARRANGEMENT FIGURE 1 TOP CAP CABINET BURNER BOX ASSEMBLY SIGHT GLASS DuralokPlus TM HEA T EXCHANGER ASSEMBLY CONDENSER COIL CONTROL BOX DOOR INTERLOCK SWITCH COLD HEADER (COLLECTOR.
Page 8 I−UNIT COMPONENTS G61MP unit components are shown in figure 1. The gas valve, combustion air inducer and burners can be ac- cessed by removing the burner access panel. Electrical component s are in the control box (figure 2) found in the blower section.
Page 9 onds. A f ter a total of five trials for ignition (including the ini- tial trial), the control goes into W atchguard−Flame Failure mode. A f ter a 60−minute reset period, the control will begin the ignition sequence again. Th e SureLight control board has an added feature that pro- longs the life of the ignitor .
Page 10 TWO−ST AGE INTEGRA TED CONTROL BOARD FIGURE 4 THERMOST A T CONNECTIONS (TB1) DIP SWITCHES 1 − 4 LEDs W915 F ACTOR Y INST ALLED JUMPER (MUST CLIP FOR 2 ST AGE COOL) DIP SWITCH(ES) FUNCTION .
Page 1 1 T ABLE 6 DIAGNOSTIC CODES Diagnostic LEDs are labeled DS1 and DS2. See figure 4 for location of diagnostic LEDs. DS1 DS2 DESCRIPTION SIMUL T ANEOUS SLOW FLASH SIMUL T ANEOUS SLOW FLASH Power on − Normal operation. Also signaled during cooling and continuous fan.
Page 12 C−Heating Component s 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 flame envelope of the left−most burner .
Page 13 6. Clamshell Heat Exchanger G61MP units use a n aluminized steel primar y and s tain - less steel secondary heat exchanger assembly . Heat is transferr ed t o the air stream from all surfaces of the heat exchanger . The shape of the heat exchanger ensures maximum ef ficiency .
Page 14 On heat demand (first or second stage) the switch senses that the combustion air inducer is operating. It closes a cir- cuit to the furnace control when pressure inside the cold end header box decreases to a certain set point. Se t points vary depending on unit size.
Page 15 12. Combustion Air Inducer (B6) All G 61MP u nits use a combustion air inducer t o m ove a ir through the burners and heat exchanger during heating operation. The blower uses a PSC 120V AC motor . Th e motor operates during all heating operation and is con- trolled by the ignition control A3.
Page 16 II−PLACEMENT AND INST ALLA TION T ABLE 1 1 OUTDOOR TERMINA TION KITS AND CORRESPONDING EQUIV ALENCIES V ent Pipe Length Equivalency (feet) UNIT MODEL VENT PIPE DIA. (in.) Outdoor Exhaust Accelerator (Dia. X Length) Outdoor Exhaust Accelerator (Dia.
Page 17 A−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-Direc t V ent installations, combustion air is taken f rom i ndoors and f lue g ases are d ischarged outdoors.
Page 18 Us e the following steps to correctly size vent pipe diameter . 1 − Determine the vent termination and its corresponding equivalent feet value according to table 1 1. 2 − Determine the number of 90° elbows required for both indoor and out door (e.
Page 19 C− 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 20 FIGURE 14 TYPICAL EXHAUST PIPE CONNECTIONS HORIZONT AL DIRECT OR NON-DIRECT VENT APPLICA TIONS (Horizontal Right-Hand Air Discharge Application Shown) G61MP−36B−045 G61MP−36B−070 G61MP.
Page 21 TYPICAL AIR INT AKE PIPE CONNECTIONS UPFLOW OR DOWNFLOW DIRECT VENT APPLICA TIONS (Right-Hand Exit in Upflow Application Shown) FIGURE 15 PLUG (Must be glued in place) G61MP−36B−045 G61MP.
Page 22 TYPICAL AIR INT AKE PIPE CONNECTIONS DOWNFLOW NON-DIRECT VENT APPLICA TIONS (Right-Hand Exit in Downflow Applications Shown) FIGURE 18 PLUG (Must be glued in place) 6 in.
Page 23 3 − T o the extent that it is pr actical, clos e all building doors and windows and all doors between the space in which the appliances connected to the venting sys tem are lo- cated and other spaces of the building. 4 − C lose fir eplace damper s.
Page 24 FIGURE 19 VENT TERMINA TION CLEARANCES FOR INST ALLA TIONS IN THE USA AND CANADA* A − Clearance above grade − 12 in. (305mm) minimum. B − Clearance to window or door that may be opened − for vent inst allations in USA − 12 in. (305mm) minimum.
Page 25 Details o f Intake and Exhaust Pi ping T erminations f o r Direct V ent Installations NOTE − In Direct Vent installations, combustion air is taken from outdoors and flue gases are disc harged to outdoors. Intake and ex haust pipes may be routed either horiz ontally through a n o utside w all o r v ertically t hr ough the roof.
Page 26 FIGURE 22 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 27 FIGURE 27 12" MIN. (305) Above Grade 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 8.
Page 28 3. I f 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 29 hose clamp. Condensate li ne must be sloped downward away from condensate 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 sp ace to avoid freezing of condensate and blockage of drain line.
Page 30 III−ST ART-UP A−Preliminary and Seasonal Checks 1 − Inspect electric al wiring, both field and factory ins talled for loose connections . T ighten as required. 2 − Check volt age at disconnect switch. V oltage must be within range listed on the nameplate.
Page 31 WHITE RODGERS 36E SERIES GAS V AL VE GAS V AL VE SHOWN IN OFF POSITION HIGH FIRE MANIFOLD PRESSURE ADJUSTMENT ON SIDE (under cap) MANIFOLD PRESSURE T AP ON SIDE INLET PRESSURE T AP ON SIDE LOW.
Page 32 When checking piping connections for gas leaks , us e pre - ferred means. Kitc hen detergents can cause har mful corro - sion on various metals used i n gas piping. Use of a specialty Gas Leak Detector is strongly rec ommended. It is available through Lennox under part number 31B2001.
Page 33 T ABLE 17 High 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−1 10 7 .
FIGURE 3 8 TRANSDUCER (P ART #78H5401) FIGURE 40 ST A TIC PRESSURE TEST Page 34 J−Flame Signal A microamp DC meter is needed to check the flame signal on the ignition control. Flame (microamp) signal is an electrical current which passes from the furnace control through the sensor during unit opera - tion.
Page 35 D−Blower Speed T aps Blower speed tap changes are made on the SureLight con- trol board. See figure 4. The unused tap must be secured on dummy terminals "P ARK " on the SureLight board.
Page 36 FIGURE 41 Remove and discard two shipping screws. G61MP−135 ONL Y 9 − Remove 3/8 inch rubber cap from condensate drain plug and drain. Replace cap af ter draining. 10 − Disconnect condensate drain line from the conden- sate trap. Remove condensate trap (it may be neces- sary to cut drain pipe).
Page 37 Cleaning the Burner Assembly 1 − T urn 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 t he gas supply line from the gas valve.
Page 38 VII− Wiring and Sequence of Operation.
Page 39 Sequence of Operation Sequence depends on type thermost at used. G61MP units are applicable for single s tage or two stage ther- mostat s. Both type thermostat s are described below . Thermostat jumper E20 dictates which mode unit will operate in.
Page 40 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 .) DS1 ON, DS2 ON NO POLARITY REVERSED.
Page 41 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 .
Page 42 HEA TING SEQUENCE OF OPERA TION LOW FLAME SIGNAL (Does not affect control operation) DS1 SLOW FLASH, DS2 F AST FLASH. FLAME SIGNAL ABOVE ( u 0.
Page 43 HEA TING SEQUENCE OF OPERA TION ARE PRIMARY , SECONDARY , ROLLOUT AND BACKUP SECONDARY LIMIT SWITCHES CLOSED? NO GAS V AL VE OFF . COMBUSTION AIR INDUCER OFF . INDOOR BLOWER ON. DS1 SLOW FLASH, DS2 ON. HAS PRIMARY , SECONDARY , ROLLOUT OR BACKUP SECONDARY LIMIT SWITCH CLOSED WITHIN 3 MINUTES? NO LIMIT SWITCH WA TCHGUARD MODE.
Page 44 COOLING SEQUENCE OF OPERA TION SIGNAL POLARITY REVERSED. DS1 F AST FLASH, DS2 SLOW FLASH. POWER ON YES IS POLARITY REVERSED? THERMOST A T CALLS FOR FIRST−ST AGE COOL. COMPRESSOR AND CONDENSER F AN ENERGIZED. NO IS THERE PROPER GROUND? IS VOL T AGE ABOVE 75 VOL TS? LOW VOL T AGE SIGNAL A T DS HOLDS UNTIL VOL T AGE RISES ABOVE 75 VOL TS.
Page 45 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 (LOW HEA T / LOW COOL). THERMOST A T CALLS FOR FIRST−ST AGE HEA T . THERMOST A T CALLS FOR FIRST ST AGE COOL.
Page 46 VIII− Field Wiring Applications and Jumper Settings Field Wiring Applications Jumper Settings (See figure 4) Thermost at E20 W915 Y1 to Y2 Wiring Connections 1 Heat / 1 Cool NOTE − Us e dip switch 3 to set second−s tage heat ON delay . ON−10 minutes .
Page 47 Field Wiring Applications (Continued) Jumper Settings (See figure 4) Thermost at E20 W915 Y1 to Y2 Wiring Connections FM21 Heat Pump / 1 Cool SINGLE Leave Installed CONTROL TERM. STRIP FM21 75VA, 24V TRANSFORMER* *Disconnect existing furnace transformer and re- place with 75VA, 24V trans- former if defrost option to be used.
Page 48 IX−SURELIGHT ® CONTROL TROUBLESHOOTING CHART UPON INITIAL POWER UP , REMOVE ALL THERMOST A T DEMANDS TO THE UNIT PROBLEM: 1 UNIT F AILS T O OPERA TE IN THE COOLING , HEA TING , OR CONTINUOUS F AN MODE Condition Possible Cause Corrective Action / Comment s 1.
Page 49 PROBLEM 1: UNIT F AILS TO OPERA TE IN THE COOLING , HEA TING , OR CONTINUOUS F AN MODE Condition Possible Cause Corrective Action / Comment s 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.
Page 50 PROBLEM 2: UNIT F AILS T O FIRE IN THE HEA TING MODE, COMBUSTION AIR INDUCER DOES NOT ENERGIZE (CONT .). Condition Possible Cause Corrective Action/Comments 2.3 − Unit operates with a cooling and con- tinuous fan demand. − Combustion air inducer will not start with a Heating demand.
Page 51 PROBLEM 4: UNIT F AILS TO FIRE IN THE HEA TING MODE, COMBUSTION AIR BLOWER ENERGIZES, IGNITOR IS ENERGIZED. Condition Possible Cause Corrective Action/Comments 4.1 − Unit operates with a cooling and continuous fan demand. Combustion air inducer energizes 4.
Page 52 PROBLEM 5: BURNERS LIGHT WITH HEA TING DEMAND BUT UNIT SHUTS DOWN PREMA TUREL Y (CONT .) Condition Possible Cause Corrective Action/Comments 5.3 − Combustion air inducer energizes with a heating demand. − Burners light. − Roll−out switch trips during the heating demand.
Page 53 PROBLEM 6: CONTROL SIGNALS LOW FLAME SENSE DURING HEA TING MODE Condition Possible Cause Corrective Action/Comments 6.0 − Unit operates correctly but the diag- nostic lights flash low flame sense code 6.1.1 Sensor rod is improperly located on the burner .
Page 54 SERVICE NOTES.
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