Lennox G61MPV Service Manual
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Lennox G61MPV Service Manual

G61mpv series
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See also: Service Manual , User's Information Manual
Service Literature
G61MPV series units are high−efficiency multi−position
(upflow, downflow, horizontal right and left) gas furnaces
manufactured with Lennox Duralok Plust heat exchang-
ers formed of an aluminized steel primary with a stainless
steel secondary condensing coil. G61MPV units are avail-
able in heating capacities of 44,000 to 132,000 Btuh
(13.0.0 to 38.6 kW) and cooling applications from 2 to 5
tons (7.0 kW to 17.5 kW). Refer to Engineering Handbook
for proper sizing.
Units are factory equipped for use with natural gas. Kits are
available for conversion to LPG operation. G61MPV model
units are equipped with the two−stage variable speed inte-
grated SureLight® control. All G61MPV units meet the Cali-
fornia Nitrogen Oxides (NO
sonal Efficiency requirements. All units use a redundant gas
valve to assure safety shut−off as required by C.S.A.
All specifications in this manual are subject to change. Pro-
cedures outlined in this manual are presented as a recom-
mendation only and do not supersede or replace local or
state codes. In the absence of local or state codes, the
guidelines and procedures outlined in this manual (except
where noted) are recommendations only and do not consti-
tute code.

TABLE OF CONTENTS

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II Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
III Start Up
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IV Heating System Service Checks
V Typical Operating Characteristics
VI Maintenance
. . . . . . . . . . . . . . . . . . . . . . . . . .
VII Wiring and Sequence of Operation
VIII Field Wiring and Jumper Setting
IX Control Board Troubleshooting
G61MPV SERIES UNITS
) Standards and California Sea-
x
Page 2
Page 4
Page 23
Page 24
Page 47
Page 61
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Page 62
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Page 67
Page 68
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Page 71
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Page 86
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Page 91
Corp. 0310−L7
Revised 03−2008
Improper installation, adjustment, alteration, service
or maintenance can cause property damage, person-
al injury or loss of life. Installation and service must
be performed by a qualified installer, service agency
or the gas supplier.
Sharp edges.
Be careful when servicing unit to avoid sharp edges
which may result in personal injury.
Page 1
G61MPV
IMPORTANT
WARNING
Electric shock hazard. Can cause injury
or death. Before attempting to perform
any service or maintenance, turn the
electrical power to unit OFF at discon-
nect switch(es). Unit may have multiple
power supplies.
WARNING
© 2003 Lennox Industries Inc.

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Questions and answers

Jamie
February 6, 2025

Rollout circuit open or previously open 5 + 1 red led hard lockout.

0
1 comments:
Mr. Anderson
February 10, 2025

A 5 + 1 red LED flash code on a Lennox G61MPV furnace indicates a hard lockout due to a rollout circuit open or previously opened. This means that the rollout switch has detected excessive heat or a flame rollout condition, which could be caused by issues such as a blocked heat exchanger, restricted airflow, or burner problems. This is a critical safety feature designed to prevent potential hazards. A trained and qualified professional should inspect and repair the furnace.

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Summary of Contents for Lennox G61MPV

  • Page 1 Units are factory equipped for use with natural gas. Kits are available for conversion to LPG operation. G61MPV model units are equipped with the two−stage variable speed inte- grated SureLight® control. All G61MPV units meet the Cali- fornia Nitrogen Oxides (NO ) Standards and California Sea- sonal Efficiency requirements.

  • Page 2: Specifications

    SPECIFICATIONS Model No. G61MPV G61MPV G61MPV G61MPV Heating −36B−045 −36B−070 −36B−071 −36C−090 Performance Performance High Fire Input − Btuh 44,000 66,000 66,000 88,000 Output − Btuh 39,000 61,000 62,000 79,000 Temperature rise range − _F 20 − 50 45 − 75 45 −...

  • Page 3: Accessories

    OPTIONAL ACCESSORIES − MUST BE ORDERED EXTRA B" Width Models C" Width Models D" Width Models FILTER KITS Air Filter and Horizontal (end) Size of filter − in. 87L96 − 18 x 25 x 1 87L97 − 20 x 25 x 1 87L98 −...

  • Page 4: Blower Data

    First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 442 cfm. G61MPV−36B−045 BLOWER MOTOR WATTS Motor Watts @ Various External Static Pressures −...
  • Page 5 First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 458 cfm. G61MPV−36B−070 BLOWER MOTOR WATTS Motor Watts @ Various External Static Pressures −...
  • Page 6 First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 458 cfm. G61MPV−36B−071 BLOWER MOTOR WATTS Motor Watts @ Various External Static Pressures −...
  • Page 7 First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 479 cfm. G61MPV−36C−090 BLOWER MOTOR WATTS Motor Watts @ Various External Static Pressures −...
  • Page 8 First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 449 cfm. G61MPV−60C−090 BLOWER MOTOR WATTS Motor Watts @ Various External Static Pressures −...
  • Page 9 First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 449 cfm. G61MPV−60C−090 BLOWER MOTOR WATTS Motor Watts @ Various External Static Pressures −...
  • Page 10 First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 449 cfm. G61MPV−60C−090 BLOWER MOTOR WATTS Motor Watts @ Various External Static Pressures −...
  • Page 11 First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 458 cfm. G61MPV−60C−091 BLOWER MOTOR WATTS Motor Watts @ Various External Static Pressures −...
  • Page 12 First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 458 cfm. G61MPV−60C−091 BLOWER MOTOR WATTS Motor Watts @ Various External Static Pressures −...
  • Page 13 First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 458 cfm. G61MPV−60C−091 BLOWER MOTOR WATTS Motor Watts @ Various External Static Pressures −...
  • Page 14 First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 463 cfm. G61MPV−60C−110 BLOWER MOTOR WATTS Motor Watts @ Various External Static Pressures −...
  • Page 15 First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 463 cfm. G61MPV−60C−110 BLOWER MOTOR WATTS Motor Watts @ Various External Static Pressures −...
  • Page 16 First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 463 cfm. G61MPV−60C−110 BLOWER MOTOR WATTS Motor Watts @ Various External Static Pressures −...
  • Page 17 First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 458 cfm. G61MPV−60C−111 BLOWER MOTOR WATTS Motor Watts @ Various External Static Pressures −...
  • Page 18 First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 458 cfm. G61MPV−60C−111 BLOWER MOTOR WATTS Motor Watts @ Various External Static Pressures −...
  • Page 19 First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 458 cfm. G61MPV−60C−111 BLOWER MOTOR WATTS Motor Watts @ Various External Static Pressures −...
  • Page 20 First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 470 cfm. G61MPV−60D−135 BLOWER MOTOR WATTS Motor Watts @ Various External Static Pressures −...
  • Page 21 First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 470 cfm. G61MPV−60D−135 BLOWER MOTOR WATTS Motor Watts @ Various External Static Pressures −...
  • Page 22 First stage COOL (two−stage air conditioning units only) is approximately 70% of the same second stage COOL speed position. Continuous Fan Only speed is approximately 38% of the same second stage COOL speed position − minimum 500 cfm. Lennox Harmony IIIt Zone Control Applications − Minimum blower speed is 470 cfm. G61MPV−60D−135 BLOWER MOTOR WATTS Motor Watts @ Various External Static Pressures −...
  • Page 23 G61MPV PARTS ARRANGEMENT TOP CAP DuralokPlus HEAT EXCHANGER ASSEMBLY CABINET BURNER BOX ASSEMBLY GAS VALVE AND MANIFOLD FLUE COLLAR COMBUSTION AIR PRESSURE PROVE SWITCHES (36B−045 has 2 single switches) WARM HEADER (COLLECTOR) COMBUSTION AIR INDUCER CONDENSER COIL BURNER PRIMARY LIMIT...
  • Page 24 3. Circuit Breaker (CB8) A 24V circuit breaker is also located in the control box. G61MPV unit components are shown in figure 1. The gas The switch provides overcurrent protection to the trans- valve, combustion air inducer and burners can be ac- former (T1).
  • Page 25 After the 15−second pre−purge period, the SureLight ignitor warms up for 20 seconds after which the gas valve opens for a 4−second trial for ignition. The ignitor energizes during the trial until flame is sensed. If ignition is not proved during TWO−STAGE, VARIABLE SPEED INTEGRATED the 4−second period, the control will try four more times with CONTROL BOARD...
  • Page 26 TABLE 1 TABLE 3 SureLight Control / Blower Control Terminals SureLight Control 12Pin Terminal Designation LINE Line 120VAC Neutral PIN # Function XFMR Transformer 120VAC Neutral Gas Valve High Fire Electronic Air Cleaner 120VAC Neutral Second Stage Pressure Switch CIRC Indoor Blower 120VAC Neutral Not Used Humidifier 120VAC Neutral...

  • Page 27: Status Codes

    (2) second pauses. One blink equals approximatley 100 CFM. DS7−ON indicaties the DS to R" jumper has not been cut. When the jumper is cut the system will be operating with LENNOX HARMONY IIt (See Harmony Installation Instructions) or YELLOW with the CCB1 Efficiency Plus control.
  • Page 28 S Motor runs at 50% for 30 seconds. S Motor then runs at 82% for approximately 7−1/2 min- Switch 4 −− Not used in G61MPV application. utes. If demand has not been satisfied after 7−1/2 min- Switches 5 and 6 −− Cooling Mode Blower Speed −−...
  • Page 29 60 SEC. DEMAND erate unless the jumper is cut. Refer to table 21 for opera- tion sequence in applications including a G61MPV, CCB1 and single−speed outdoor unit. Table 22 gives the opera- tion sequence in applications with a two−speed outdoor Ramping Option D unit.

  • Page 30: Integrated Control Board(A92)

    SureLight Board 100870 NOTE − Board 100870 provides a regulated 95 volts G61MPV −7 and later units are equipped with the Lennox the ignitor. two−stage, variable speed integrated SureLight control Two Stage Operation / Thermostat Selection Jumper board.
  • Page 31 THERMOSTAT CONNECTIONS (TB1) DIAGNOSTIC LEDs INDOOR HEATING BLOWER DIP SWITCHES SWITCHES H= 24V HUMIDIFIER OUTPUT L= LENNOX SYSTEM OPERATION MONITOR FUTURE USE 1= FUTURE USE ON−BOARD JUMPERS DIP SWITCH FUNCTIONS HTG DIP SWITCH(ES) FUNCTION T’stat Heat Stages (single or two−stage) Second Stage ON Delay (single−stage t’stat)

  • Page 32: G61Mpv Integrated Control Configuration

    FIGURE 6 Page 32...

  • Page 33: Status/Error Description

    TABLE 15 FLASH CODE STATUS / ERROR DESCRIPTION (X + Y) 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. LED flashes X times at 2Hz, remains off for two seconds, flashes Y times at 2Hz, remains off for four X + Y seconds, then repeats.
  • Page 34 Dip Switch Settings operation during the cooling mode. The table below pro- vides the cooling mode blower speeds that will result from Heating Operation DIP Switch Settings different switch settings. Refer to blower tables at the front Switch 1 −− Thermostat Selection −− This unit may be used of this manual for corresponding cfm values.
  • Page 35 (SignatureStat) gives the operation sequence in applica- flash rapidly or may display a single flash, depending upon tions with a two−speed outdoor unit. the activity. TABLE 21 G61MPV, CCB1 and Single−Speed Outdoor Unit OPERATING MODE SYSTEM DEMAND SYSTEM RESPONSE Blower CFM...
  • Page 36 TABLE 22 OPERATING SEQUENCE G61MPV, CCB1 and Two−Speed Outdoor Unit OPERATING MODE SYSTEM DEMAND SYSTEM RESPONSE System Thermostat *Relative Humidity ****Compressor Blower CFM Comments Condition Demand (EfficiencyPlus Lights) Speed (COOL) **49% of HIGH Compressor demand and indoor No demand. Acceptable...
  • Page 37 With Heat Pump − Cut W914 (R to DS) & W951 (R to O) on SureLight board Dave Lennox SignatureStat to use for this application − 51M26 1 heat / 1 cool or 51M28 − 2 heat / 2 cool for heat pumps *Dehumidification blower speed is 70% of COOL speed.
  • Page 38 With Heat Pump − Cut W914 (R to DS) & W951 (R to O) on SureLight board Dave Lennox SignatureStat to use for this application − 51M27 2 heat / 2 cool or 51M28 − 2 heat / 2 cool for heat pumps *Normal operation first stage cooling blower speed is 70% of COOL speed.
  • Page 39 The length of time each pulse ing. See figure 7. All G61MPV units are equipped with two sec- stays on is called the pulse width." By varying the pulse width ondary limts.
  • Page 40 Power Choke (L13) ing to change speed taps. A choke coil is used on G61MPV 5 ton 1 hp units. The choke is located on the blower housing and is used to supress DANGER transient current spikes.
  • Page 41 MOTOR SPEED CONTROL WITH D.C. PULSE-WIDTH MODULATION Motor speed is determined by the size of the electrical pulse sent to the motor windings. The longer the pulse, the faster the motor. OUTPUT FROM CONTROLLER TO MOTOR WINDINGS WINDINGS TURNED OFF WINDINGS TURNED ON Ç...
  • Page 42 C−Heating Components NOTE − The G60DFV(X) furnace contains electronic components that are polarity sensitive. Make sure that 6. Ignitor the furnace is wired correctly and is properly grounded. The SureLight ignitor is made of durable silicon nitride. Ig- nitor longevity is enhanced by controlling voltage to the ig- 7.
  • Page 43 5/16" 10. Primary Limit Control (S10) Figure 16 shows the primary limit (S10) used on G61MPV units located in the heating vestibule panel. S10 is provided with a shield on some models (figure 16) and must not be re- moved.
  • Page 44 See figure 17. When measuring the pressure differential, readings should be G61MPV−045 units have two single swithes as shown in fig- taken at the prove switch. Lack of differential usually indicates ure 18. The switches are connected to the cold end header...
  • Page 45 NOTE − Both sides of the cold end header box are negative. 14. Combustion Air Inducer (B6) However the (+) port reads less negative pressure than the All G61MPV units use a two−speed combustion air induc- (−) port. er (CAI) to move air through the burners and heat ex- changer during heating operation.
  • Page 46 TABLE 25 TABLE 29 7501’ to 10,000’ 95% Furnaces G61MPV Unit C.A.I. Orifice Size Set Point Set Point −045 0.719" G61MPV Unit Second Stage First Stage −070 0.938" −071 0.75" 0.70" −071 0.880" −091 1.20" 0.90" −090 1.063" −111 0.85"...
  • Page 47 II−PLACEMENT AND INSTALLATION TABLE 32 OUTDOOR TERMINATION KITS AND CORRESPONDING EQUIVALENCIES Vent Pipe Length Equivalency (feet) Outdoor Outdoor 2" Wall Exhaust Exhaust 1−1/2" 2" Con- 3" Con- VENT 2" Wall 3" Wall Kit with 2" Wall Accelerator Accelerator Concen- centric centric PIPE UNIT...
  • Page 48 NOTE − The exhaust pipe should be offset a minimum of 12 inches to avoid the possibility of water droplets being re- The G61MPV can be installed as either a Non−Direct leased from the exhaust termination. The minimum ex- Vent or a Direct Vent gas central furnace.
  • Page 49 4" diameter pipe †On G61MPV−071, −091 and −111 units, sweep elbows must be used for all 90° elbows in the venting system when 2", 2−1/2" or 3" vent pipe is used. 5 ft. plus 2 elbows of 2−1/2" 3" or 4"...
  • Page 50 Exhaust piping and condensate trap must be may be installed is 24" (610mm) maximum and 3/4" installed on the same side of the unit in upflow and (19mm) minimum. If a G61MPV furnace replaces a furnace dowflow applications. which was commonly vented with another gas appliance, 2.
  • Page 51 FIGURE 22 Intake Piping TYPICAL EXHAUST PIPE CONNECTIONS HORIZONTAL DIRECT OR The G61MPV furnace may be installed in either direct vent NON−DIRECT VENT APPLICATIONS or non−direct vent applications. In non−direct vent applica- (Horizontal Right−Hand Air Discharge Application Shown) tions, when intake air will be drawn into the furnace from the surrounding space, the indoor air quality must be consid- *Limit pipe length to 2"...
  • Page 52 G61MPV−60C−110* G61MPV−60C−111* G61MPV−60C−111* G61MPV−60D−135* *Limit pipe length to 2" in G61MPV−110, −111 and −135 applications. FIGURE 24 Follow the next three steps when installing the unit in Non- TYPICAL AIR INTAKE PIPE CONNECTIONS Direct Vent applications where combustion air is taken HORIZONTAL DIRECT VENT APPLICATIONS from indoors and flue gases are discharged outdoors.
  • Page 53 2 − Use a sheet metal screw to secure the intake pipe to the After the G61MPV gas furnace has been started, the fol- connector, if desired. A pilot indentation is provided in the...
  • Page 54 Doing so will cause freeze−ups and may block the terminations. doors. The G61MPV is then classified as a non-direct vent, Category IV gas furnace. In Non-Direct Vent applica- tions, the vent termination is limited by local building IMPORTANT codes.
  • Page 55 VENT TERMINATION CLEARANCES FOR INSTALLATIONS IN THE USA AND CANADA* − G61MPV VENT TERMINATION − AIR INLET OF OTHER APPLIANCE less than 10 ft (3.048M) A − Clearance above grade − 12 in. (305mm) minimum. E − Clearance to non−mechanical air supply inlet or outlet for vent installations in USA −...
  • Page 56 Intake and exhaust pipes may be routed either horizontally TABLE 35 EXHAUST PIPE TERMINATION SIZE REDUCTION through an outside wall or vertically through the roof. In at- G61MPV tic or closet installations, vertical termination through the Exhaust Pipe Size Termination Pipe Size MODEL roof is preferred.
  • Page 57 EXHAUST VENT EXHAUST 12" (305) ABOVE TERMINATION AVERAGE SNOW ACCUMULATION Inches (mm) Front View INTAKE VENT INTAKE TERMINATION 1/2" (13) Foam Insulation Side View in Unconditioned Space FIELD−PROVIDED FIELD− REDUCER MAY BE REQUIRED PROVIDED EXHAUST VENT TO ADAPT LARGER VENT REDUCER MAY PIPE SIZE TO TERMINATION BE REQUIRED...
  • Page 58 É É É É É É É É É É Front View DIRECT VENT TERMINATION WALL TERMINATION KIT (22G44, 44J40, 30G28 or 81J20) EXTENDED VENT FOR GRADE CLEARANCE FIGURE 36 G61MPV DIRECT VENT APPLICATION Inches(mm) SIZE TERMINATION STRAIGHT−CUT OR USING EXISTING CHIMNEY PIPE PER TABLE ANGLE−CUT IN DIRECTION...
  • Page 59 NON−DIRECT VENT WALL RING TERMINATION (15F74) FIGURE 40 NOTE − In upflow applications where side return G61MPV NON−DIRECT VENT APPLICATION air filter is installed on same side as the conden- USING EXISTING CHIMNEY sate trap, filter rack must be installed beyond condensate trap to avoid interference.
  • Page 60 If this is not possible, a heat COUPLING cable kit may be used on the condensate trap and line. Heating cable kit is available from Lennox in various CLEAN−OUT ACCESS lengths; 6 ft. (1.8m) − kit no. 26K68; 24 ft. (7.3m) − kit (both sides) no.
  • Page 61 5 − Remove the upper access panel. The gas valve on the G61MPV may be equipped with ei- ther a gas control knob or gas control lever. Use only your 6 − Honeywell VR8205 Gas Valve − Turn knob on gas hand to push the lever or turn the gas control knob.
  • Page 62 Gas Leak Detector is strongly recommended. It is available all gas valves (both internal and external to unit) to guaran- through Lennox under part number 31B2001. See Corp. tee no gas leak into combustion chamber. Turn off power to 8411−L10, for further details.
  • Page 63 Manifold pressure for the G61MPV can be mea- NOTE− To obtain accurate reading, shut off all other gas sured at any time the gas valve is open and is supplying gas appliances connected to meter.
  • Page 64 The pH scale is a measurement of acidity and alkalinity. The following scale shows the relative pH of some common liquids as compared with condensate of G61MPV units. The concentration of the acidity of all these fluids including the condensate is very low and harmless. Page 64...
  • Page 65 TABLE 40 Conversion Kit Requirements and Manifold Pressures for Models −045, −070, −090, −110 and −135 Manifold Pressure at Altitude altitudes 0−4500 ft. 4501−7500 ft. 7501−10,000 Model Low Fire High Fire (0−1372 m) (1373−2286 m) (2287−3048 m) Input Size Required Required Required Pressure...
  • Page 66 TABLE 42 Manifold Pressures at Different Altitudes for Models −071, −091 and −111 Altitude 0 − 2000 ft. 2001 − 4500 ft. 4501 − 5500 ft. 5501 − 6500 ft. 6501 − 7500 ft. 7501 − 10,000 Model (0 − 610 m) (611 −...
  • Page 67 OFF position. Lennox Repair Parts) is B−Temperature Rise required to measure flame Temperature rise for G61MPV units depends on unit input, signal if meter used will not blower speed, blower horsepower and static pressure as read a low micro amp sig- marked on the unit rating plate.
  • Page 68 Set burner box assembly aside. G61MPV−135 only − be drawn into living space resulting in personal inju- Remove and discard two additional shipping screws.
  • Page 69 10 − Disconnect condensate drain line from the conden- 23 − Re-secure the supporting screws along the vestibule sate trap. Remove condensate trap (it may be neces- sides and bottom to the cabinet. sary to cut drain pipe). Remove screws that secure 24 −...
  • Page 70 11 − Replace the blower compartment access panel. which secure burner box assembly to vest panel. Re- move burner box from the unit. G61MPV−135 only − 12 − Refer to instruction on verifying gas and electrical con- Remove and discard two additional shipping screws.
  • Page 71 VII− Wiring and Sequence of Operation A−SureLight Board 49M59 Page 71...
  • Page 72 E20 set at SINGLE" Sequence depends on type thermostat used. 1− SureLight control energizes combustion air inducer B6 G61MPV units are applicable for single stage or two on low heat speed. Combustion air inducer runs until stage thermostats. Both type thermostats are de- S128 low heat prove switch contacts close (switch scribed below.
  • Page 73 C−Flow Chart SureLight Board 49M59 HEATING SEQUENCE OF OPERATION NORMAL AND ABNORMAL HEATING MODE GAS VALVE OFF. COMBUSTION AIR INDUCER POWER ON OFF. INDOOR BLOWER OFF. CHECK FOR BROKEN IGNITOR OR OPEN IGNITER CIRCUIT. DS 1 AND DS 2 ALTERNATING FAST FLASH. CONTROL SELF−CHECK OKAY? GAS VALVE OFF.
  • Page 74 HEATING SEQUENCE OF OPERATION CONTINUED THERMOSTAT CALLS FOR HEAT DS1 AND DS2 SIMULTANEOUS FAST FLASH (Refer to box A on previous page) FIRST−STAGE (LOW FIRE) PRESSURE GAS VALVE OFF. COMBUSTION AIR INDUCER SWITCH CLOSED WITHIN 2.5 MINUTES? OFF. INDOOR BLOWER OFF. UNIT WILL RETRY AFTER 5−MINUTE WAIT PERIOD.
  • Page 75 HEATING SEQUENCE OF OPERATION CONTINUED THERMOSTAT CALLS FOR HEAT. DS1 AND DS2 SIMULTANEOUS FAST FLASH. SEE BOX A. FLAME SIGNAL ABOVE (w0.23 microamps) LOW FLAME SIGNAL (Does not affect control operation) DS1 SLOW FLASH, DS2 FAST FLASH. SINGLE−STAGE THERMOSTAT MODE TWO STAGE THERMOSTAT MODE (E20 SET AT SINGLE") (E20 SET AT TWO")
  • Page 76 HEATING SEQUENCE OF OPERATION CONTINUED SEE BOX A NORMAL OPERATION DS1 AND DS2 SIMULTANEOUS SLOW FLASH. SEE BOX B THERMOSTAT CALLS FOR HEAT DS 1 AND DS 2 SIMULTANEOUS FAST FLASH GAS VALVE OFF. COMBUSTION AIR INDUCER OFF. IS PRIMARY, SECONDARY, BACKUP INDOOR BLOWER ON.
  • Page 77 COOLING SEQUENCE OF OPERATION POWER ON IS POLARITY REVERSED? SIGNAL POLARITY REVERSED. DS1 FAST FLASH, DS2 SLOW FLASH. SIGNAL IMPROPER GROUND AT DS. IS THERE IS VOLTAGE SIGNAL HOLDS PROPER GROUND? ABOVE 75 VOLTS? UNTIL UNIT IS PROPERLY GROUNDED. LOW VOLTAGE SIGNAL AT DS HOLDS UNTIL VOLTAGE RISES ABOVE 75 VOLTS.
  • Page 78 D−G61MPV with SureLight Board 100870 Page 78...
  • Page 79 Switch set at SINGLE" Sequence depends on type thermostat used. 1− SureLight control energizes combustion air inducer B6 G61MPV units are applicable for single stage or two on low heat speed. Combustion air inducer runs until stage thermostats. Both type thermostats are de- S128 low heat prove switch contacts close (switch scribed below.
  • Page 80 F−Flow Chart SureLight Board 100870 HEATING SEQUENCE OF OPERATION NORMAL AND ABNORMAL HEATING MODE POWER ON GAS VALVE OFF. COMBUSTION AIR INDUCER OFF. INDOOR BLOWER OFF. (RESET CONTROL BY CONTROL SELF−CHECK OKAY? TURNING MAIN POWER OFF.) POLARITY REVERSED. POLARITY OKAY? STATUS ERROR CODE 5 + 4.
  • Page 81 HEATING SEQUENCE OF OPERATION CONTINUED THERMOSTAT CALLS FOR HEAT STATUS LED − HEARTBEAT (Refer to box A on previous page) FIRST−STAGE (LOW FIRE) PRESSURE GAS VALVE OFF. COMBUSTION AIR INDUCER SWITCH CLOSED WITHIN 2.5 MINUTES? OFF. INDOOR BLOWER OFF. UNIT WILL RETRY AFTER 5−MINUTE WAIT PERIOD.
  • Page 82 HEATING SEQUENCE OF OPERATION CONTINUED THERMOSTAT CALLS FOR HEAT. STATUS LED −− HEARTBEAT. SEE BOX A. FLAME SIGNAL ABOVE (u1.40 microamps) LOW FLAME SIGNAL (Does not affect control operation) STATUS ERROR CODE 1 + 2. SINGLE−STAGE THERMOSTAT MODE TWO STAGE THERMOSTAT MODE (DIP SWITCH SET AT SINGLE") (DIP SWITCH SET AT TWO") START SECOND−STAGE RECOGNITION...
  • Page 83 HEATING SEQUENCE OF OPERATION CONTINUED SEE BOX A NORMAL OPERATION. SEE BOX B THERMOSTAT CALLS FOR HEAT. RETURN TO FIRST−STAGE HEAT MODE. FIRST−STAGE CONTINUES UNTIL SECOND− STAGE PRESSURE SWITCH CAN BE PROVEN SECOND−STAGE (HIGH FIRE) HEAT or HEAT DEMAND IS SATISFIED. A FIVE (5) PRESSURE SWITCH CLOSED? MINUTE WAIT PERIOD IS INITIATED BEFORE RETRY.
  • Page 84 COOLING SEQUENCE OF OPERATION POWER ON SIGNAL POLARITY REVERSED. CONTROL WILL CONTINUE TO CALL FOR COOLING IS POLARITY REVERSED? IN THIS CONDITION. STATUS ERROR CODE 5 + 4. SIGNAL IMPROPER GROUND AT LED. CONTROL WILL CONTINUE TO CALL FOR COOLING IS THERE IN THIS CONDITION.
  • Page 85 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 COOL. THERMOSTAT CALLS FOR FIRST−STAGE HEAT. INDOOR BLOWER RAMPS TO FIRST STAGE AFTER 45−SECOND DELAY, INDOOR BLOWER COOLING SPEED AFTER A 2−SECOND DELAY.
  • Page 86 VIII− Field Wiring Applications and Jumper Settings A−SureLight Board 49M59 TABLE 44 Field Wiring Applications Jumper Settings (See figure 4) Thermostat Thermostat Wiring Connections Wiring Connections W915 W914 W951 1 Heat / 1 Cool SINGLE Intact Intact Intact CONTROL OUTDOOR T’STAT TERM.
  • Page 87 TABLE 45 Field Wiring Applications (Continued) Jumper Settings (See figure 4) Thermostat Thermostat Wiring Connections Wiring Connections W915 W914 W951 1 Heat / 2 Cool SINGLE Intact CONTROL OUTDOOR CCB1 with CCB1 T’STAT TERM. STRIP UNIT NOTE − Use dip switch 3 to set second−stage HSXA19 heat ON delay.
  • Page 88 TABLE 46 Field Wiring Applications (Continued) Jumper Settings (See figure 4) Thermostat Thermostat Wiring Connections Wiring Connections W915 W914 W951 2 Heat / 1 Cool Intact Intact Intact CONTROL OUTDOOR T’STAT TERM. STRIP UNIT HSXB15 (LSOM) FM21 Heat Pump / 1 SINGLE Intact Intact...
  • Page 89 B−SureLight Board 100870 TABLE 47 Field Wiring Applications (Continued) Jumper Settings (See figure 5) W915 W914 Dehu- Two−Stage midification W951 Thermostat Wiring Connections DIP Switch 1 Cooling or Harmony Heat Pumps 1Heat / 1 Cool Intact Intact Intact CONTROL OUTDOOR T’STAT TERM.
  • Page 90 TABLE 48 Field Wiring Applications (Continued) Jumper Settings (See figure 5) W915 W914 Dehu- Two−Stage midification W951 Thermostat Wiring Connections DIP Switch 1 Cooling or Harmony Heat Pumps 2 Heat / 2 Cool Intact Intact CONTROL OUTDOOR T’STAT TERM. STRIP UNIT 2 Heat / 2 Cool Intact...

  • Page 91: Troubleshooting

    ® IX− SURELIGHT CONTROL TROUBLESHOOTING GUIDE A−SureLight Board 49M59 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 1.1.1 ACTION 1 −...
  • Page 92 PROBLEM 1: UNIT FAILS TO OPERATE IN THE COOLING, HEATING, OR CONTINUOUS FAN MODE Condition Possible Cause Corrective Action / Comments ACTION 1 − Check that the unit is properly 1.5.1 ground. − Diagnostic lights flash the improper ACTION 2 − Install a proper main ground to the Improper ground to the unit.
  • Page 93 PROBLEM 2: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR INDUCER DOES NOT ENERGIZE (CONT.). Condition Possible Cause Corrective Action/Comments 2.3.1 − Unit operates with a cooling and con- ACTION 1 − Check for correct wiring and loose tinuous fan demand.
  • Page 94 PROBLEM 4: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR BLOWER ENERGIZES, IGNITOR IS ENERGIZED. Condition Possible Cause Corrective Action/Comments ACTION 1 − Check line pressure at the gas valve. 4.1.1 Pressure should not exceed 13" WC for both nat- −...
  • Page 95 ACTION 2 − Seal leakage if possible, replace secondary heat exchanger, and heat exchanger if necessary, tag and return heat exchanger to proper Lennox personnel. combustion air blower. 5.3.4 ACTION 1 − Check for sooting deposits or other restrictions in the heat exchanger assembly.
  • Page 96 PROBLEM 6: CONTROL SIGNALS LOW FLAME SENSE DURING HEATING MODE Condition Possible Cause Corrective Action/Comments 6.1.1 ACTION 1 − Check the sensor rod for proper loca- − Unit operates correctly but the diag- tion on the burner. Properly locate the sensor rod Sensor rod is improperly located on or replace if rod cannot be located correctly.
  • Page 97 B−SureLight Board 100870 Two Stage Variable Speed Control Board 100870 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 Flash Code Possible Cause Corrective Action / Comments LED X + Y 1.1.1 ACTION 1 −...
  • Page 98 PROBLEM 2: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR BLOWER DOES NOT ENERGIZE Flash Code Corrective Action / Comments Possible Cause LED X + Y ACTION 1 − Check continuity across switch(es). 2.1.1 Switches reset automatically upon cool down. Unit operates with a cooling or ACTION 2 −...
  • Page 99 PROBLEM 4: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR INDUCER ENERGIZES, IGNITOR IS NOT ENERGIZED. Flash Code Possible Cause Corrective Action/Comments LED X + Y 4.1.1 ACTION 1 − Check for restricted vent. Remove all blockage. − Unit operates with a cooling and Prove switch does not close due to ACTION 2: Check for proper vent sizing.
  • Page 100 PROBLEM 5: UNIT FIRES ON LOW FIRE, FAILS TO GO TO HIGH FIRE OPERATION Flash Code Possible Cause Corrective Action/Comments LED X + Y 5.1.1 ACTION 1 − Check for restricted vent. Remove all blockage. − Unit light s normally during low fire Prove switch does not close due to ACTION 2: Check for proper vent sizing.
  • Page 101 PROBLEM 6: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR BLOWER ENERGIZES, IGNITOR IS ENERGIZED. Flash Code Possible Cause Corrective Action/Comments LED X + Y ACTION 1 − Check line pressure at the gas valve. 6.1.1 Pressure should not exceed 13" WC for both nat- Unit operates with a cooling and ural and propane.
  • Page 102 PROBLEM 7: BURNERS LIGHT WITH HEATING DEMAND BUT UNIT SHUTS DOWN PREMATURELY (CONT.) Flash Code Possible Cause Corrective Action/Comments LED X + Y ACTION 1 − Check that the manifold pressure matches value listed on nameplate. See installa- Combustion air inducer energizes 7.3.1 tion instructions for proper procedure.
  • Page 103 PROBLEM 7: BURNERS LIGHT WITH HEATING DEMAND BUT UNIT SHUTS DOWN PREMATURELY (CONT.) Flash Code Possible Cause Corrective Action/Comments LED X + Y ACTION 1 − Check that the sensor is properly lo- Combustion air inducer energizes 7.5.1 cated. with a heating demand. ACTION 2 −...
  • Page 104 ICM−2 WITH TWO STAGE VARIABLE SPEED CONTROL 120V to the motor must not be interrupted. All connections for check out will be from the volt- age source below (battery or 24V) to plug J46, after disconnecting from blower control board. REMOVE PLUG FROM BOARD CHECK−OUT PROCEDURE USING BATTERY CHECK−OUT PROCEDURE USING 24V SOURCE...

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G61mpv−36b−045G61mpv−36b−070G61mpv−36b−071G61mpv−36c−090G61mpv−60c−090G61mpv−60c−091 ... Show all

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