Home

Lenox Furnace ML180UHE User's Manual

1. s o 24 t 39 x s j m s wow j z r j s z __ x 99 s m m 2 m 3 2 738 799 r r m z z s _ m 39 1 29 34 2 59 j 5 3 3 1 s 2 L z 1 39 L z L sz L J Page 20 TABLE 7 Vent Connector Capacity Type B Double Wall Vents with Single Wall Metal Connectors Serving Two or More Category Appliances Vent and Connector Diameter D inches Appliance Input Rating in Thousands of Btu Per Hour MAX MAX wa 1 19 25 ws t Cr a r 2 230 8 23 anc qon n ws m5 82 252 t 29 ETE 2 j s s s rs t 2 3 s 1 NOTE Single appliance venting configurations with zero lateral lengths are assumed to have no elbows in the vent system For all other vent configurations the vent system is assumed to have two 90 elbows For each additional 90 elbow or equivalent for example two 45 elbows equal one 90 elbow beyond two the maximum capacity listed in the venting table should be reduced by 10 percent 0 90 x maxi mum listed capacity TABLE 8 Common Vent Capacity Type B Double Wall Vents with Single Wall Metal Connectors Serving Two or More Category Appliances Common Vent Diameter D inches Appliance Input Rating in Thousands of Btu Per Hour Page 21 Removal of the Furnace from Common Vent In the event that an existing furnace
2. ML180UH135E60D PERFORMANCE Less Filter Air Volume Watts at Different Blower Speeds External Bottom Return Air Side Return Air with Optional Return Single Side Return Air Air volumes in bold require field Static Air Base Return Air from Both Sides or Return Air from fabricated transition to accommodate 20 x 25 x 1 in air filter Pressure Bottom and One Side in order to maintain proper air velocity in w g High Med High Medium Med Low Low High Med High Medium Med Low Low cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts 0 00 2495 755 2295 590 2045 435 1845 315 1650 230 2365 725 2295 575 2005 410 1820 300 1635 235 0 10 2440 780 2220 620 2015 445 1820 330 1615 245 2350 745 2210 595 2000 435 1745 320 1530 230 0 20 2390 790 2175 640 1935 470 1735 350 1550 255 2330 775 2175 625 1945 455 1730 330 1490 250 0 30 2360 805 2140 655 11895 490 1720 370 1485 275 2245 785 2135 645 1895 475 1655 355 1425 265 0 40 2285 835 2125 675 1850 510 1660 380 1455 290 2215 810 2085 660 1840 495 1600 375 1385 285 0 50 2240 860 2060 690 11815 535 1610 400 1415 310 2175 825 2045 680 1815 505 1590 390 1340 290 0 60 2225 865 2015 715 1785 550 1535 420 1330 320 2125 845 1995 700 1765 530 1525 405 1300 310 0 70 2160 895 1955
3. 10 7 J s P s s s 20 x opm 15 m a 155 959 L9 112 195 A 520 2 e z 2 s 10 28 64 38 133 50 229 62 351 sw m 34 3 m e z 322 o m o z o s s s x 2 J G e J 3 42 sa es n 35 j 3 s r s 26 7 3 m s s s u 3 sa Co NA 1 N 2 s 2 2 4 m 346 NOTE Single appliance venting configurations with zero lateral lengths are assumed to have no elbows in the vent system For all other vent configurations the vent system is assumed to have two 90 elbows For each additional 90 elbow or equivalent for example two 45 elbows equal one 90 elbow beyond two the maximum capacity listed in the venting table should be reduced by 10 percent 0 90 x maxi mum listed capacity Page 18 TABLE 4 Capacity of Type B Double Wall Vents with Single Wall Metal Connectors Serving a Single Category Appliance Vent and Connector Diameter D inches erui ma a ma J ma sms 3 L feet Appliance Input Rating in Thousands of Btu Per Hour 4 w ww m s 2 u poer x s s m Jj s P T a 59 159 958 18 x s sm sa 7 m J m t 38 z i et 1397 x r T m s m J s s r m t
4. 9 PIERS rere adoret ren iS aua eu sas EP RAE 12 Duct System ua 12 Venting eee mede de tale ale sa 13 06 11 ANU A Pagen Gas Piping cie mee meer deine 23 Electrical 25 Integrated Control 28 Unit Start Up 29 Gas Pressure Adjustment 30 High Altitude sessio rr ee bes 30 Proper Combustion 30 Other Unit Adjustments 31 Blower Performance Data 33 M P 35 Planned Service oc eee eee ese ns 37 Repair Parts List 37 Integrated Control Diagnostic Codes 38 Troubleshooting 39 506810 01 Unit Dimensions inches mm 1NOTE 60C and 60D units that require air volumes 3 1 8 79 over 1800 cfm 850 L s must have one of the following 1 Single side return air with transition to accommodate t A 20 x 25 x 1 in 508 x 635 x 25 mm cleanable ai
5. Masonry chimneys used to vent Category central fur naces must be either tile lined or lined with a listed metal lining system or dedicated gas vent Unlined masonry chimneys are prohibited See figures 24 and 25 for com mon venting A chimney with one or more sides exposed to the outside of the structure is considered to be an exterior chimney An exterior masonry chimney that is not tile lined must be lined with B1 vent or a listed insulated flexible metal vent An exterior tile lined chimney that is sealed and capped may be lined with a listed uninsulated flexible metal vent If the existing chimney will not accommodate a listed metal liner either the chimney must be rebuilt to accommodate one of these liners or an alternate approved venting meth od must be found Insulation for the flexible vent pipe must be an encapsu lated fiberglass sleeve recommended by the flexible vent pipe manufacturer See figure 24 Refer to the tables and the venting information contained in these instructions to properly size and install the venting system AIMPORTANT Once the venting system is installed attach the Dis connected Vent warning sticker to a visible area of the plenum near the vent pipe See figure 23 The warning sticker is provided in the bag assembly Or der kit 66W04 for additional stickers AWARNING Asphyxiation hazard The exhaust vent for this fur nace must be securely connected to the furnace flue transition
6. 7780 6250 5350 4740 4290 3950 3670 3450 3260 76 2 77 927 319 98 220 30 176 98 151 49 134 22 121 47 111 85 103 92 97 69 92 31 NOTE Capacity given in cubic feet m of gas per hour and based on 0 60 specific gravity gas Page 23 Left Side Piping Standard MANUAL MAIN SHUT OFF VALVE With 1 8 Plugged Shown GROUND DRIP LEG MANUAL MAIN SHUT OFF GROUND JOINT UNION DRIP LEG gt Horizontal Application Right Side Air Discharge AUTOMATIC GAS VALVE AUTOMATIC GAS VALVE FIELD PROVIDED AND INSTALLED NOTE BLACK IRON PIPE ONLY TO BE ROUTED INSIDE OF CABINET FIGURE 26 Horizontal Applications Possible Gas Piping Configurations MANUAL MAIN SHUT OFF VALVE GROUND JOINT UNION DRIP LEG gt FIELD PROVIDED AND INSTALLED NOTE BLACK IRON PIPE ONLY TO BE ROUTED INSIDE OF CABINET FIGURE 27 Page 24 MANUAL AIN SHUT OFF VALVE With 1 8 in NPT Plugged Tap Shown GROUND JOINT UNION DRIP LEG Right Side Piping Alternate Horizontal Application Left Side Air Discharge MANUAL YS MAIN SHUT OFF VALVE GROUND JOINT UNION bn DRIP LEG Leak Check After gas piping is completed carefully check all piping connections factory and field installed for gas leaks Use a leak detecting solution or other preferred means NOTE If emergency shutoff is necessary shut off the ma
7. 735 1755 570 1500 440 1265 340 2095 865 1950 710 1700 545 1485 420 1260 325 0 80 2105 905 1925 750 1715 580 1435 450 1215 345 2065 880 1890 725 11680 565 1415 445 11205 345 Page 34 AWARNING ELECTRICAL SHOCK FIRE OR EXPLOSION HAZARD Failure to 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 Before servicing disconnect all electrical power to furnace When servicing controls label all wires prior to dis connecting Take care to reconnect wires correctly Verify proper operation after servicing At the beginning of each heating season a qualified techni cian should check the system as follows Blower Check the blower wheel for debris and clean if necessary The blower motors are prelubricated for extended bearing life No further lubrication is needed AWARNING The blower access panel must be securely in place when the blower and burners are operating Gas fumes which could contain carbon monoxide can be drawn into living space resulting in personal inju ry or death Filters All ML180UHE filters are installed external to the unit Fil ters should be inspected monthly Clean or replace the fil ters when necessary to ensure that the furnace operates properly Re
8. Em p Ec Low ao 9 wA t N t con ea 7 ww r NA N NOTE Single appliance venting m zero os lengths are assumed to have no PTT in the vent TT For all other vent configurations the vent system is assumed to have two 90 elbows For each additional 90 elbow or equivalent for example two 45 elbows equal one 90 elbow beyond two the maximum capacity listed in the venting table should be reduced by 10 percent 0 90 x maxi mum listed capacity 39 7 58 3 xw i xs Eme ar 39 7 NA Page 19 TABLE 5 Vent Connector Capacity Type B Double Wall Vents with Type B Double Wall Connectors Serving Two or More Category Appliances Vent and Connector Diameter D inches Connector Rie r s R Appliance Input Rating in Thousands of Btu Per Hour 38 81 wo wj oj j N OL AINI OJA N N N of N N wo N wj j o oy o 44 40 44 47 43 47 50 50 53 55 54 57 62 64 wo O AB TABLE 6 Common Vent Capacity Type B Double Wall Vents with Type B Double Wall Connectors Serving Two or More Category Appliances Common Vent Diameter D inches amn J Sm omn J 7mh Appliance Input Rating in Thousands of Btu Per Hour FAN FAN FAN NAT FAN FAN FAN
9. If necessary adjust the blower speed to maintain the temperature rise within the range shown on the unit nameplate Increase the blower speed to decrease the temperature Decrease the blower speed to increase the temperature rise Failure to adjust the temperature rise may cause erratic limit operation Fan Control The heat fan on time of 30 seconds is not adjustable The heat fan off delay amount of time that the blower operates after the heat demand has been satisfied may be adjusted by changing the jumper position across the five pins on the integrated control The unit is shipped with a factory fan off delay setting of 90 seconds The fan off delay affects com fort and is adjustable to satisfy individual applications Ad just the fan off delay to achieve a supply air temperature between 90 and 110 F at the moment that the blower is de energized Longer off delay settings provide lower re turn air temperatures shorter settings provide higher re turn air temperatures See figure 36 Page 31 HEAT FAN OFF TIME IN SECONDS HEAT OFF DELAY JUMPER POSITION PINI PIN2 PIN PINS PIN3 PIM PM PINS NO JUMPER 180 To adjust fan off timing reposition jumper across pins to achieve desired setting 90 Second 120 Second off Time off Time 180 Second off Time 60 Second off Time FIGURE 36 Thermostat Heat Anticipation Set the heat anticipator setting if adjustable according to
10. Seconds for One Revolution ML180UHE Unit L Natural LP 2 cu ft DIAL 160 160 400 045 204 65 82 164 5 68 136 LP 2500 btu cu ft 110 135 Natural 1000 btu cu ft eo 2070 272 Furnace should operate at least 5 minutes before check ing gas flow Determine time in seconds for two revolu tions of gas through the meter Two revolutions assures a more accurate time Divide by two and compare to time in table 11 If manifold pressure matches table 13 and rate is incorrect check gas orifices for proper size and restric tion Remove temporary gas meter if installed NOTE To obtain accurate reading shut off all other gas appliances connected to meter Supply Pressure Measurement A threaded plug on the inlet side of the gas valve provides access to the supply pressure tap Remove the threaded plug install a field provided barbed fitting and connect a manometer to measure supply pressure See table 13 for proper line pressure Replace the threaded plug after mea surements have been taken Manifold Pressure Measurement 1 Remove the threaded plug from the outlet side of the gas valve and install a field provided barbed fitting Connect to a manometer to measure manifold pres sure 2 Start unit and allow 5 minutes for unit to reach steady state 3 While waiting for the unit to stabilize observe the flame Flame should be stable and should not lift from burner Natural gas sho
11. Turn on power and gas supply to unit 21 Set thermostat and check for proper operation 22 Check all piping connections factory and field for gas leaks Use a leak detecting solution or other preferred means 23 If aleak is detected shut gas and electricity off and repair leak 24 Repeat steps 24 and 26 until no leaks are detected 25 Replace access panel Page 35 ML180UHE BURNER COMBUSTION AIR INDUCER ASSEMBLY amp HEAT EXCHANGER REMOVAL Gasket Flue Transition i 60000000 Pressure Switch Rollout Switches CS 00000000 090 110 135 units Rollout Switches Ignitor X Heat Exchanger 045 and 070 units Sensor Cross Over Manifold And Gas Valve FIGURE 37 Remove 5 screws if necessary either side of cabinet NOx Insert FIGURE 38 A CAUTION Some soaps used for leak detection are corrosive to certain metals Carefully rinse piping thoroughly af ter leak test has been completed Do not use matches candles flame or other sources of ignition to check for gas leaks Page 36 Planned Service The following items should be checked during an annual inspection Power to the unit must be shut off for the service techni cian s 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 Burners Must be inspected for rust dirt or signs of water Ve
12. VENT FURNACE OPENINGS To Adjacent Room NOTE Each opening shall have a free area of at least one square inch 645 mm per 1 000 Btu 29 kW per hour of the total input rat ing of all equipment in the enclosure but not less than 100 square inches 64516 mm FIGURE 3 Air from Inside If the confined space that houses the furnace adjoins a space categorized as unconfined air can be brought in by providing two permanent openings between the two spaces Each opening must have a minimum free area of 1 square inch 645 mm per 1 000 Btu 29 kW per hour of total input rating of all gas fired equipment in the confined space Each opening must be at least 100 square inches 64516 mm One opening shall be within 12 inches 305 mm of the top of the enclosure and one opening within 12 inches 305 mm of the bottom See figure 3 Air from Outside If air from outside is brought in for combustion and ventila tion the confined space must have two permanent open ings One opening shall be within 12 inches 305 mm of the top of the enclosure and one opening within 12 inches 305 mm of the bottom These openings must communicate di rectly or by ducts with the outdoors or spaces crawl or at tic that freely communicate with the outdoors or indirectly through vertical ducts Each opening shall have a minimum free area of 1 square inch 645 mm per 4 000 Btu 1 17 kW per hour of total input rating of all equipment in the en
13. closure See figures 4 and 5 When communicating with the outdoors through horizontal ducts each opening shall have a minimum free area of 1 square inch 645 mm per 2 000 Btu 56 kW per total input rating of all equipment in the enclosure See figure 6 When ducts are used they shall be of the same cross sec tional area as the free area of the openings to which they connect The minimum dimension of rectangular air ducts shall be no less than 3 inches 75 mm In calculating free area the blocking effect of louvers grilles or screens must be considered If the design and free area of protective cov ering is not known for calculating the size opening required it may be assumed that wood louvers will have 20 to 25 per cent free area and metal louvers and grilles will have 60 to 75 percent free area Louvers and grilles must be fixed in the open position or interlocked with the equipment so that they are opened automatically during equipment operation Page 7 EQUIPMENT IN CONFINED SPACE ALL AIR FROM OUTSIDE Inlet Air from Crawlspace and Outlet Air to Ventilated Attic CHIMNEY OR GAS VENT VENTILATION LOUVERS Each end of attic FURNACE AIR WATER HEATER VENTILATION LOUVERS For unheated crawl space NOTE The inlet and outlet air openings shall each have a free area of at least one square inch 645 mm per 4 000 Btu 1 17 kW per hour of the total input rating of all equipment in the enclosure FIGURE 4 EQUIPM
14. tions 1 Vent diameter recommendations and maximum allow able piping runs are found in the provided venting tables 2 In no case should the vent or vent connector diameter be less than the diameter specified in the provided venting tables 3 The minimum vent capacity determined by the sizing tables must be less than the low fire input rating and the maximum vent capacity must be greater than the high fire input rating 4 Single appliance vents If the vertical vent or tile lined chimney has a larger diameter or flow area than the vent connector use the vertical vent diameter to de termine the minimum vent capacity and the vent connector diameter to determine the maximum vent capacity The flow area of the vertical vent however shall not exceed 7 times the flow area of the listed ap pliance categorized vent area drafthood outlet area or flue collar area unless designed according to approved engineering methods 5 Multiple appliance vents The flow area of the largest section of vertical vent or chimney shall not exceed 7 times the smallest listed appliance categorized vent area drafthood outlet area or flue collar area unless de signed according to approved engineering methods Page 16 6 Venting Using Tile Lined Interior Masonry Chimney and Combined Vent Connector d zx MINIMUM LENGTH AS SHORT AS PRACTICAL INTERIOR TILE LINED FOR MAXIMUM LENGTH SEE NOTE TO LEFT MASONRY CHIMNEY NOTE Refer t
15. 16 Vent connectors serving Category appliances shall two consecutive table size diameters over the size of not be connected to any portion of mechanical draft the draft hood outlet or flue collar outlet systems operating under positive pressure such as 20 Do not install a manual damper barometric draft regu Category III or IV venting systems lator or flue restrictor between the furnace and the 17 If vent connectors are combined prior to entering the chimney common vent the maximum common vent capacity 21 When connecting this appliance to an existing dedi listed in the common venting tables must be reduced by cated or common venting system you must inspect the 10 the equivalent of one 90 elbow 0 90 x maximum venting system s general condition and look for signs common vent capacity of corrosion The existing vent pipe size must conform 18 The common vent diameter must always be at least as to these instructions and the provided venting tables If large as the largest vent connector diameter the existing venting system does not meet these re 19 In no case shall the vent connector be sized more than quirements it must be resized TABLE 3 Capacity of Type B Double Wall Vents with Type B Double Wall Connectors Serving a Single Category Appliance Vent and Connector Diameter D inches Appliance Input Rating in Thousands of Btu Per Hour MIC MAX ui CMN C MAX io MN e Tor MIC is MIN S EI
16. 2 sec on 1 2 sec off remains off for 3 sec then repeats Last 10 error codes are stored in memory including when power is shut off to the unit To recall Note press and release button most recent will be displayed first LED off for 3 sec then next error code is displayed etc To clear error codes depress and hold button longer than 5 seconds Page 38 Troubleshooting Heating Sequence of Operation HEATING SEQUENCE OF OPERATION NORMAL HEATING MODE ABNORMAL HEATING MODE GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER DELAY OFF E 2 CONTROL SELF CHECK LED SLOW FLASH RESET CONTROL BY TURNING MAIN POWER OFF IS POLARITY CORRECT LED FLASHES CODE 1 POLARITY REVERSED NO IS THERE A PROPER GROUND LED FLASHES CODE 2 IMPROPER GROUND YES NO LED FLASHES CODE 13 LOW LINE VOLTAGE IS VOLTAGE S CONTROL WILL NOT RESPOND TO A CALL FOR ABOVE 70 VOLTS HEATING UNTIL VOLTAGE RISES ABOVE 75 VOLTS YES LED FLASHES CODE 8 ROLLOUT SWITCH OPEN NO GAS VALVE OFF COMBUSTION AIR INDUCER ON INDOOR BLOWER ON SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES YES AND POWER IS RESET OR T STAT IS INTERRUPTED FOR MINIMUM OF 1 SECOND LED FLASHES CODE 12 FLAME SENSED BURNER OFF NO WITHOUT GAS VALVE ENERGIZED Flame sensed without gas valve energized GAS VALVE OFF COMBUSTION AIR INDUCER ON INDOOR BLOWER ON HEATING SPEED NORMAL OPERATION LED SLOW FLASH YES THERMOSTAT CALLS FOR HEAT LED
17. CHOKE USED ON AND 1 HP ONLY Si N FIELD SUPPLIED ACC WIRE PE MARY GA A USE COPPER CONDUCTORS ONLY A R REQUIRED ON SOME OUTDOOR UNITS FLAME ROLLOUT FLAME ROLLOUT SWITCH 7 LINE VOLTAGE FIELD INSTALLED SWITCH CLASS I VOLTAGE FIELD WIRING DENOTES OPTIONAL COMPONENTS UGQGUJ J156 A92 INTEGRATED CONTROL m F1 SECONDARY Ti GAS LIMIT TRANSFORMER 298 a DIAGNOSTIC PUSH BUTTON INTERLOCK 521 SECONDARY GAS LIMIT P135 J135 P49 FIGURE 33 TABLE 10 CIRC Indoor blower 120VAC EAC Indoor air quality accessory 120VAC NEUTRALS Common 120VAGC O 0 VOOU Il BLOWER OFF DELAY RED GED RECALL BUTTON FIGURE 34 Page 28 Unit Start Up FOR YOUR SAFETY READ BEFORE LIGHTING AWARNING Do not use this furnace if any part has been under water A flood damaged furnace is extremely dan gerous Attempts to use the furnace can result in fire or explosion Immediately call a qualified ser vice technician to inspect the furnace and to replace all gas controls control system parts and electrical parts that have been wet or to replace the furnace if deemed necessary AWARNING If overheating occurs or if gas supply fails to shut off shut off the manual gas valve to the appliance before shutting off electrical supply A CAUTION Before attempting to perform any service or mainte nance turn the electrical power to unit OFF at dis connect switch BEF
18. agency or gas supplier Cabinet Parts Upper access panel Blower panel Top cap Control Panel Parts Transformer Integrated control Door interlock switch Circuit breaker Blower Parts Blower wheel Blower housing Motor Motor mounting frame Motor power choke Blower housing cutoff plate Heating Parts Flame sensor Heat exchanger assembly Gas manifold Combustion air inducer Gas valve Main burner cluster Main burner orifices Pressure switch Ignitor Primary limit control Flame rollout switch s Secondary limit Page 37 Integrated Control Diagnostic Codes RED LED Flash Code Diagnostic Codes Status of Furnace No power to control or board fault detected os Improper Earth Ground improper Ear Ground Bumerfalodtolon during headeren OOOO pwFameSgna chedfamesemor OOOO O 5 Watchavard burr faled to ig exceeded number of reas or recydes ___ 7 Primary Secondary Limit Open or Watchguard Mode Limit Switch Open longer than 3 min utes i _ Pressure Switch failed to close or opened during heat demand Watchguard Pressure Switch opened 5 times during one heat demand Pressure Switch stuck closed prior to activation of combustion air inducer 12 i i CHR Flame Sensed without gas valve energized A Heartbeat is indicated by a Slow Flash 1 sec on 1 sec off repeating Note Error codes are indicated by a Rapid Flash the LED flashes X times at 1
19. device for integrated control lockout caused by ignition failure This type of lockout is usually due to low gas line pressure After one hour of continuous thermostat demand for heat the Watchguard will re set and remake thermostat demand to the furnace and automatically reset the inte grated control to begin the ignition sequence Page 32 BLOWER DATA ML180UH045E36A PERFORMANCE Less Filter External Air Volume Watts at Various Blower Speeds Static High Medium High Medium Medium Low Low Pressure in w g cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts 0 00 1380 265 1155 165 995 120 975 115 945 105 0 10 1345 270 1120 175 950 120 880 105 865 100 0 20 1320 285 1080 190 900 125 805 105 700 85 0 30 1290 295 1055 200 875 135 750 110 640 90 0 40 1265 310 1010 205 825 145 710 120 595 95 0 50 1230 315 990 215 790 155 660 125 535 100 0 60 1190 330 945 230 750 165 630 135 500 110 0 70 1165 340 915 235 705 170 570 140 435 115 0 80 1130 350 880 245 670 180 535 150 380 120 ML180UH070E36B PERFORMANCE Less Filter External Air Volume Watts at Various Blower Speeds Static High Medium High Medium Medium Low Low Pressure in w g cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts 0 00 1415 265 1330 170 1215 135 1175 125 1075 85 0 10 1415 280 1295 170 1145 145 1130 130 955 95 0 20 135
20. for the required clearances that are listed on the unit nameplate Also consider gas supply connections electrical supply vent connection and installation and service clearances 24 inches 610 mm at unit front The unit must be level NOTE Units with 1 2 or 3 4 hp blower motors are equipped with three flexible legs and one rigid leg See figure 7 The rigid leg is equipped with a shipping bolt and a flat white plastic washer rather than the rubber mounting grommet used with a flexible mounting leg The bolt and washer must be removed before the furnace is placed into op eration After the bolt and washer have been removed the rigid leg will not touch the blower housing Units with 1 2 or 3 4 HP Blower Motor RIGID LEG remove shipping bolt and washe FIGURE 7 Upflow Applications Allow for clearances to combustible materials as indicated on the unit nameplate Minimum clearances for closet or al cove installations are shown in figure 8 Upflow Application Installation Clearances Left Side Right Side Bottom Type of Vent ee ont 2 1 4 in 57 2 1 4 57 mm Front clearance in alcove installation must be 24 in 610 mm Maintain a minimum of 24 in 610 mm for front service access 4 1 2 if single wall vent pipe is used For installation a combustible floor do not install the furnace directly on carpeting tile or other combustible materials other than wood flo
21. main power to the fur nace The installer should properly label these devices TABLE 9 Gas Pipe Capacity ft3 hr m3 hr Nominal Iron Pipe Internal Length of Pipe feet m inches inches 10 20 30 40 50 60 70 80 90 100 mm mm 3 048 6 096 9 144 12 192 15 240 18 288 21 336 24 384 27 432 30 480 1 2 622 172 118 95 81 72 65 60 56 52 50 E d em eie no oa 3 4 824 360 247 199 170 151 137 126 117 110 104 19 05 20 930 10 19 7 00 5 63 A 81 A 28 3 87 3 56 3 31 3 11 2 94 1 1 049 678 466 374 320 284 257 237 220 207 195 254 26 645 19 19 13 19 10 59 9 06 8 04 7 27 6 71 6 23 5 86 5 52 1 1 4 1 380 1350 957 768 657 583 528 486 452 424 400 31 75 35 052 38 22 27 09 22 25 18 60 16 50 14 95 13 76 12 79 12 00 11 33 95 13 12 1 1 2 1 610 2090 1430 1150 985 873 791 728 677 635 38 1 40 894 59 18 40 49 32 56 27 89 24 72 22 39 20 61 19 17 17 98 38 1 4049 32 56 27 89 24 72 2 2 067 4020 2760 2220 1900 1680 1520 1400 1300 1220 1160 eis es crass 600 17 00 34 2 1 2 2 469 6400 4400 3530 3020 2680 2480 2230 2080 1950 1840 63 5 67 713 181 22 124 59 99 95 85 51 75 88 70 22 63 14 58 89 55 22 52 10 3 3 068 11300
22. the amp draw listed on the wiring diagram that is attached to the unit Constant Torque Motor ML180UHE units are equipped with a constant torque ECM motor It has a DC motor coupled to an electronic control module both contained in the same motor housing The mo tor is programmed to provide constant torque at each of the five selectable speeds The motor has five speed taps Each tap requires 24 volts to energize Input Voltage Requirements The circuit is designed to be operated with AC voltage A voltage of 12 to 33VAC is required to energize the motor Expected current draw will be less than 20mA Blower Speeds Follow the steps below to change the blower speeds 1 Turn off electrical power to furnace 2 Remove blower access panel 3 Disconnect existing speed tap at integrated control speed terminal NOTE Termination of any unused motor leads must be insulated 4 Place unused blower speed tap on integrated control PARK terminal or insulate 5 Refer to blower speed selection chart on unit wiring dia gram for desired heating or cooling speed See Blower performance data beginning on the next page 6 Connect selected speed tap at integrated control speed terminal 7 Resecure blower access panel 8 Turn on electrical power to furnace 9 Recheck temperature rise Electronic Ignition The integrated control has an added feature of an internal Watchguard control The feature serves as an automatic re set
23. unit nameplate Minimum clearances for closet or al cove installations are shown in figure 12 This furnace may be installed in either an attic or a crawl space Either suspend the furnace from roof rafters or floor joists as shown in figure 13 or install the furnace on a platform as shown in figure 14 Typical Horizontal Application Unit Suspended in Attic or Crawlspace Metal FIGURE 13 NOTE Heavy gauge perforated sheet metal straps may be used to suspend the unit from roof rafters or ceiling joists When straps are used to suspend the unit in this way support must be provided for both the ends The straps must not interfere with the plenum or exhaust pip ing installation Cooling coils and supply and return air plenums must be supported separately NOTE When the furnace is installed on a platform in a crawlspace it must be elevated enough to avoid water damage and to allow the evaporator coil to drain Return Air Horizontal Applications Return air must be brought in through the end of a furnace installed in a horizontal application The furnace is equipped with a removable bottom panel to facilitate installation See figure 11 Page 11 Horizontal Application Unit Installed on Platform Line contact is permissible but not preferred See the unit nameplate for clearances ENTRY FIGURE 14 AWARNING Improper installation of the furnace can result in per sonal injury or death Combustion and fl
24. 0 2 9 Pipropane 168 C C 130 _ TABLE 14 Pressure Switch and Gas Conversion Kits at all Altitudes 0 4500 ft 4501 7500 ft High Altitude Model High Altitude Pressure Switch Kit Natural Gas Burner Input Size Orifice Kit 7501 10 000 ft 7501 10 000 ft 0 7500 ft 7501 10 000 ft 0 7500 ft LP Propane to Natural Gas Burner Orifice Kit Natural Gas to LP Propane Burner Orifice Kit No Change 73W37 70W89 76W15 73W81 NOTE A natural to L P propane gas changeover kit is necessary to convert this unit Refer to the changeover kit installation instruction for the conversion procedure Other Unit Adjustments Primary and Secondary Limits The primary limit is located on the heating compartment vestibule panel The secondary limits if equipped are lo cated in the blower compartment attached to the back side of the blower These auto reset limits are factory set and re quire no adjustment Flame Rollout Switches These manually reset switches are located on the burner box Pressure Switch The pressure switch is located in the heating compartment adjacent to the combustion air inducer The switch checks for proper combustion air inducer operation before allow ing ignition trial The switch is factory set and requires no adjustment Temperature Rise After the furnace has been started and supply and return air temperatures have been allowed to stabilize check the temperature rise
25. 2 feet 46 m for each inch 25 mm of common vent diameter 10 The vent pipe should be as short as possible with the least number of elbows and angles required to com plete the job Route the vent connector to the vent us ing the shortest possible route 11 A vent connector shall be supported without any dips or sags and shall slope a minimum of 1 4 inch 6 4 mm per linear foot 305 mm of connector back toward the appliance Vent connectors shall be firmly attached to the furnace flue collar by self drilling screws or other approved means except vent connectors of listed type B vent material which shall be assembled according to the manufacturer s instructions Joints between sections of single wall connector piping shall be fastened by screws or other approved means 13 When the vent connector used for Category ap pliances must be located in or pass through a crawl space attic or other areas which may be cold that por tion of the vent connector shall be constructed of listed double wall type B vent material or material having equivalent insulation qualities All venting pipe passing through floors walls and ceil ings must be installed with the listed clearance to com bustible materials and be fire stopped according to lo cal codes In absence of local codes refer to NFGC 2223 1 15 No portion of the venting system extend into pass through any circulation air duct or plenum 12 14 Page 17
26. 5 290 1225 185 1110 150 1080 140 885 100 0 30 1330 300 1190 200 1060 160 1035 155 825 110 0 40 1290 310 1155 205 1015 175 970 160 770 120 0 50 1245 325 1115 215 980 180 930 170 695 125 0 60 1225 335 1045 230 920 190 865 180 625 135 0 70 1190 350 1000 235 855 205 790 190 540 140 0 80 1160 365 925 245 790 205 735 200 445 145 ML180UH090E48B PERFORMANCE Less Filter External Air Volume Watts at Various Blower Speeds Static High Medium High Medium Medium Low Low Pressure in w g cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts 0 00 1785 380 1570 270 1440 220 1995 190 1190 120 0 10 1755 395 1535 275 1420 230 1350 205 1140 130 0 20 1730 415 1505 290 1380 245 1310 215 1110 145 0 30 1690 435 1460 305 1345 260 1275 230 1065 155 0 40 1645 440 1435 320 1310 270 1240 240 1010 165 0 50 1615 455 1395 335 1265 285 1180 255 955 180 0 60 1590 470 1350 350 1210 290 1150 265 915 185 0 70 1545 475 1300 360 1175 305 1095 275 860 200 0 80 N A N A 1270 370 1140 310 1040 285 820 210 Page 33 BLOWER DATA ML180UH090E60C PERFORMANCE Less Filter Air Volume Watts at Different Blower Speeds External Bottom Return Air Side Return Air with Optional Return Single Side Return Air Air volumes in bold require field Static Air Base Return Air from Both Sides or Return Air from fabricated transition to accommodate 20 x 25 x 1 in air filter Pressure Bottom and One Side in order to maint
27. ALVE DE ENERGIZED COMBUSTION AIR WATCHGUARD INDUCER ON INDOOR BLOWER OFF WITH MODE DELAY HAS CAB PRESSURE SWITCH CLOSED COMB AIR INDUCER CONTINUES 5 SECOND WITHIN 2 5 MINUTES POST PURGE AFTER T STAT DEMAND IS SATISFIED INDOOR AIR BLOWER COMPLETES SELECTED OFF 5 MINUTE PRESSURE SWITCH DELAY BEFORE SHUTTING OFF WATCHGUARD MODE Page 40 Troubleshooting Cooling Sequence of Operation COOLING SEQUENCE OF OPERATION NORMAL COOLING MODE ABNORMAL COOLING MODE POWER ON IGNITION CONTROL MAIN POWER ON GAS VALVE OFF COMBUSTION AIR INDUCER OFF CONTROL SELF DIAGNOSTIC CHECK INDOOR BLOWER OFF WITH NORMAL DELAY IS CONTROL OPERATING NORMALLY SIGNAL CIRCUIT BOARD FAILURE AT LED INTERRUPT MAIN POWER TO RESET CONTROL LED FLASHES CODE 2 IMPROPER GROUND IS THERE A PROPER GROUND a CONTROL WILL CONTINUE TO CALL FOR COOLING IN THIS CONDITION LED FLASHES CODE 1 POLARITY REVERSED IS POLARITY CORRECT CONTROL WILL CONTINUE TO CALL FOR COOLING IN THIS CONDITION IS VOLTAGE LED FLASHES CODE 13 LOW VOLTAGE CONTROL ABOVE 70 VOLTS WILL CONTINUE TO CALL FOR COOLING IN THIS CONDITION LED FLASHES CODE 8 ROLLOUT SWITCH OPEN GAS VALVE OFF COMBUSTION AIR INDUCER ON INDOOR SEE Ie SOLE SS BLOWER ON SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES AND MAIN POWER IS INTERRUPTED OR THERMOSTAT IS CYCLED OFF ON FOR 1 SEC MINIMUM LED SLOW FLASH RATE REMAINS UNCHANGED THROUGHOUT COOLING CYCLE THERMOSTAT CALLS FOR C
28. Cut combustion air inducer tubing from 9 to 5 to avoid If necessary reposition the combustion air inducer pres interference with inducer motor sure switch and or make up box as needed per the follow ing steps See figures 17 through 21 FIGURE 18 Page 13 HORIZONTAL LEFT POSITION Vent Pipe Top Vent Discharge d Pressure AN Transition e Cover Plate g Pressure Switch Vent Pipe 7 Switch 3 E Make Up Box Collector Box Disconnect pressure switch hose from barbed fitting on the pressure switch assembly Remove pressure switch assembly 1 screw and cut wire tie to free pressure switch wires Re install pressure switch on the other side of orifice plate and re connect pressure switch hose Re secure pressure switch wires Either pull excess wires through the blower compartment and secure using supplied wire tie or coil excess wire and secure to the gas manifold FIGURE 19 HORIZONTAL LEFT POSITION Side Vent Discharge Make Up Box Collector Box Cut combustion air inducer tubing from 9 to 7 to avoid inter ference with inducer motor Disconnect pressure switch hose from barbed fitting on the pressure switch assembly Remove pressure switch assembly 1 screw and cut wire tie to free pressure switch wires Re install pressure s
29. Drop TOTAL EXTERNAL STATIC dry coil Supply External Static Return External Static Total External Static DRAIN LINE Leak Free THERMOSTAT L Adjusted and Programmed L Operation Explained to Owner Telephone Checklist Completed Technician s Name Page 44
30. ENT IN EQUIPMENT IN CONFINED SPACE CONFINED SPACE ALL AIR FROM OUTSIDE ALL AIR FROM CHIMNEY All Air Through Ventilated Attic OUTSIDE OR GAS WATER VENTILATION LOUVERS HEATER Each end of attic lll dub dj OUTLET AIR FURNACE FURNACE INLET AIR Ends 12 in rl above bottom T INLET AIR WATER HEATER D NOTE Each air duct opening shall have a free area of at least one square inch 645 mm2 per 2 000 Btu 59 kW per hour of the total inlet and outlet air openings shall each have a input rating of all equipment in the enclosure If the equipment room free area of at least one square inch 645 per 4 000 is located against an outside wall and the air openings communi Btu 1 17 kW per hour of the total input rating of all equip cate directly with the outdoors each opening shall have a free area ment in the enclosure of at least one square inch 645 mm2 per 4 000 Btu 1 17 kW per hour of the total input rating of all other equipment in the enclosure FIGURE 5 FIGURE 6 Page 8 AWARNING Do not install the furnace on its front or its back Do not connect the return air ducts to the back of the fur nace Doing so will adversely affect the operation of the safety control devices which could result in per sonal injury or death The ML180UHE gas furnace can be installed as shipped in either the upflow position or the horizontal position Select alocation that allows
31. FLASHES CODE 7 PRIMARY LMIT LED SLOW FLASH OPEN COMBUSTION AIR INDUCER OFF INDOOR BLOWER ON YES PRIMARY LIMIT SWITCH CLOSED LED FLASHES CODE 11 PRESSURE SWITCH CLOSED GAS VALVE OFF COMBUSTION AIR IS COMBUSTION AIR INDUCER OFF INDOOR BLOWER PRESSURE SWITCH OPEN OFF WITH DELAY YES Sequence holds until pressure switch opens or thermostat resets control IS COMBUSTION AIR INDUCER ENERGIZED YES LED FLASHES CODE 9 PRESSURE SWITCH FAILED HAS COMBUSTION AIR PRESSURE TO CLOSE OR OPENED DURING HEAT DEMAND SWITCH CLOSED IN 2 5 MINUTES PRESSURE SWITCH IS IN WATCHGUARD MODE GAS E VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF WITH DELAY IS 5 MINUTE RESET PERIOD COMPLETE CONTINUED NEXT PAGE Page 39 Troubleshooting Heating Sequence of Operation Continued HEATING SEQUENCE CONTINUED NORMAL HEATING MODE ABNORMAL HEATING MODE 15 SECOND COMBUSTION AIR INDUCER PREPURGE INITIATED BY CLOSED PRESSURE SWITCH YES LED FLASHES CODE 13 NO LOW LINE VOLTAGE IGNITOR WARM UP 20 SECONDS lt IS VOLTAGE ABOVE 70 VOLTS ONCE VOLTAGE IS ABOVE 75 VOLTS HEATING YES SEQUENCE RESTARTS 4 SECOND TRIAL FOR IGNITION GAS VALVE OPENS IGNITOR ENERGIZED FOR FIRST 3 SECONDS OF THE TRIAL GAS VALVE OFF COMBUSTION AIR INDUCER ON INDOOR BLOWER OFF HAS CONTROL FAILED TO SENSE FLAME FOR FIVE CONSECUTIVE TRIES DURING A SINGLE FLAME STABILIZATION PERIOD HEAT DEMAND 4 SECONDS FLAME RECTIFICATI
32. HE furnace may be installed in alcoves clos ets attics basements garages crawl spaces and utility rooms in the upflow or horizontal position This furnace design has not been CSA International certified for installation in mobile homes recreational vehicles or outdoors Use of Furnace as Construction Heater Lennox does not recommend the use of ML180UHE units as a construction heater during any phase of construction Very low return air temperatures harmful vapors and op eration of the unit with clogged or misplaced filters will dam age the unit ML180UHE units may be used for heating of buildings or structures under construction if the following conditions are met e The vent system must be permanently installed per these installation instructions e A room thermostat must control the furnace The use of fixed jumpers that will provide continuous heating is not allowed e The return air duct must be provided and sealed to the furnace e Return air temperature range between 60 F 16 C and 80 27 must be maintained e Air filters must be installed in the system and must be maintained during construction e Air filters must be replaced upon construction comple tion e The input rate and temperature rise must be set per the furnace rating plate e One hundred percent 10096 outdoor air must be pro vided for combustion air requirements during construc tion Temporary ducting may supply outdoor air to the fu
33. I Z223 1 in the USA A fan assisted Category fur nace is an appliance equipped with an integral mechanical means to either draw or force combustion products through the combustion chamber and or heat exchanger The ML180UHE is not approved for use with horizontal venting NOTE Use these instructions as a guide They do not su persede local codes This furnace must be vented accord ing to all local codes these installation instructions and the provided venting tables in these instructions The venting tables in this manual were extracted from the National Fuel Gas Code NFPA 54 ANSI Z223 1 and are provided as a guide for proper vent installation Proper ap plication termination construction and location of vents must conform to local codes having jurisdiction In the ab sence of local codes the NFGC serves as the defining doc ument Use self drilling sheet metal screws or a mechanical fas tener to firmly secure the vent pipe to the round collar of the flue transition If self drilling screws are used to attach the vent pipe it is recommended that three be used Drive one self drilling screw through the front and one through each side of the vent pipe and collar See figure 23 Install the first vent connector elbow at a minimum of six inches 152 mm from the furnace vent outlet See figure Venting Using a Masonry Chimney The following additional requirements apply when a lined masonry chimney is used to vent this furnace
34. LENNOX 2011 Lennox Industries Inc Dallas Texas USA z 9 cz lt il HORIZONTAL LEFT INSTALLATION INSTRUCTIONS ML180UHE MERIT SERIES GAS FURNACE UPFLOW HORIZONTAL AIR DISCHARGE 506810 01 06 2011 Technical Supersedes 506732 01 Publications Litho U S A THIS MANUAL MUST BE LEFT WITH THE HOMEOWNER FOR FUTURE REFERENCE This is a safety alert symbol and should never be ignored When you see this symbol on labels or in manuals be alert to the potential for personal injury or death AWARNING 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 licensed professional installer or equivalent service agency or the gas supplier A CAUTION As with any mechanical equipment personal injury can result from contact with sharp sheet metal edges Be careful when you handle this equipment Table of Contents Unit Dimensions 2 Parts Arrangement 3 ML180UHE Gas Furnace 4 Shipping and Packing List 4 Safety Information 4 Use of Furnace as a Construction Heater 5 General Reed eaa Haba d ard s 5 Combustion Dilution amp Ventilation Air 6 Setting Equipment
35. ND LOCAL CODES 1 Line voltage is applied to L1 and N the T1 low voltage transformer is energized and line voltage is applied to B3 indoor blower 2 S47rollout switch es must be closed in order for 24V from transformer to be output on integrated control R to power thermostat 3 When there is a call for heat W1 of the thermostat energizes W of the furnace control with 24VAC 4 92 integrated control runs self check S10 primary limit and S21 secondary limit contacts are found to be closed Call for heat can continue 5 92 integrated control energizes combustion air inducer S18 combustion air pressure switch closes Once S18 closes a 15 second pre purge follows 6 92 integrated control energizes ignitor A 20 second warm up period begins 7 GV1 gas valve opens for a 4 second trial for ignition 8 Flame is sensed gas valve remains open for the heat call 9 After 30 second delay from flame sensed A92 integrated control applies 24vVAC to Heat speed of B3 indoor blower 10 When heat demand is satisfied W1 of the indoor thermostat de energizes W of A92ignition control which de energizes GV1 gas valve B6 combustion air inducer continues a 5 second post purge period and B3 indoor blower completes a selected OFF time delay FIGURE 32 Page 27 TYPICAL ML180UHE FIELD WIRING DIAGRAM 120VAC COMBUSTION IF USED AIRINDUCER COMBUSTION AIR G PROVING SWITCH C P84 L13 POWER
36. ON CURRENT LED SIGNAL WATCHGUARD FAILURE CODE CHECK CAN FLAME BE PROVEN WITHIN WATCHGUARD MODE GAS VALVE OFF 4 SECONDS AFTER GAS VALVE OPENS COMBUSTION AIR INDUCER OFF 0 5 microamps INDOOR BLOWER OFF WITH DELAY IS 60 MINUTE RESET PERIOD COMPLETE YES FLAME PRESENT HAS CONTROL RESET IGNITION SEQUENCE FOUR TIMES LED FLASHES CODE 7 PRIMARY LIMIT LED FLASHES CODE 4 LOW FLAME OPEN GAS VALVE FLAME SIGNAL 1 5 MICROAMPS OR GREATER SIGNAL Does not affect operation of control INDOOR BLOWER ON NALLIMIT SWITCH AFTER 30 SECOND DELAY LED FLASHES CODE 7 PRIMARY LIMIT OPEN OPEN UNTIL MAIN YES Y GAS VALVE DE ENERGIZED POWER IS NO COMBUSTION AIR INDUCER DE ENERGIZED INTERRUPTED OR PRIMARY LIMIT SWITCH CLOSED INDOOR BLOWER ON UNTIL SWITCH CLOSES l STAT IS CYCLED LIMIT SWITCH CLOSED OFF ON FOR SEG MINIMUM 60 MINUTE WATCHGUARD PE YES HAS PRIMARY LIMIT RESET TIME EXCEEDED 3 MINUTES IS 60 MIN PERIOD COMPLETE LED FLASHES CODE 8 ROLLOT SWITCH OPEN ROLLOUT SWITCH CLOSED GAS VALVE POWER OFF COMBUSTION AIR INDUCER POWER ON INDOOR BLOWER ON SEQUENCE HOLDS UNTIL ROLLOUT SWITCH IS RESET AND MAIN POWER IS INTERRUPTED OR COMBUSTION AIR PRESSURE SWITCH CLOSED YES HAS PRESSURE SWITCH OPENED 5 TIMES IN THE SAME HEAT DEMAND LED FLASHES THERMOSTAT DEMAND SATISFIED 10 THERMOSTAT IS CYCLED OFF ON FOR 1 SEC MINIMUM YES 1 HR PRESSURE SWITCH LED SLOW FLASH GAS V
37. OOLING COMPRESSOR CONTACTOR AND SYSTEM FAN ENERGIZED WITH 2 SECOND DELAY COOLING SPEED EAC TERM ENERGIZED THERMOSTAT OPENS COMPRESSOR OFF SYSTEM FAN AND EAC TERM OFF WITH 45 SECOND DELAY Page 41 Troubleshooting Continuous Fan Sequence of Operation CONTINUOUS FAN SEQUENCE OF OPERATION LED SLOW FLASH RATE REMAINS UNCHANGED THROUGHOUT SEQUENCE MANUAL FAN SELECTION MADE AT THERMOSTAT CONTROL G ENERGIZES SYSTEM FAN AT FAN SPEED EAC TERMINAL IS ENERGIZED THERMOSTAT CALLS FOR HEAT W THERMOSTAT CALLS FOR COOLING SYSTEM FAN CONTINUES FAN SPEED WITHOUT YES INTERRUPTION EAC TERMINAL REMAIN ON HUM TERMINAL IS ENERGIZED WITH COMBUSTION SYSTEM FAN SWITCHED TO COOL SPEED AIR BLOWER EAC TERM REMAINS ON THERMOSTAT OPENS SYSTEM FAN SWITCHES TO HEAT SPEAD AFTER 30 SECOND DELAY EAC AND HUM TERMINAL REMAIN ON MANUAL FAN SELECTION MADE AT THERMOSTAT CONTROL G ENERGIZES SYSTEM FAN AT FAN SPEED EAC TERM ENERGIZED HUM TERMINAL OFF AFTER POST PURGE BY COMBUSTION AIR BLOWER SYTEM FAN SWITCHES TO FAN SPEED AFTER BLOWER OFF DELAY EAC CONTINUES WITHOUT INTERRUPTION Page 42 Start Up amp Performance Check List UNIT SET UP typical Unit Model Number Serial Number Line Voltage Gas Supply Pressure AIR upflow furnace shown Filter a RE
38. ORE LIGHTING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor The gas valve on the ML180UHE unit is equipped with a gas control switch Use only your hand to move the switch Never use tools If the switch will not turn or if the control switch will not move by hand do not try to repair it Placing the furnace into operation ML180UHE units are equipped with an automatic ignition system Do not attempt to manually light burners on these furnaces Each time the thermostat calls for heat the burners will automatically light The ignitor does not get hot when there is no call for heat on units with an automatic ignition system AWARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or death Gas Valve Operation Figure 35 1 STOP Read the safety information at the beginning of this section 2 Setthe thermostat to the lowest setting 3 Turn off all electrical power to the unit 4 This furnace is equipped with an ignition device which automatically lights the burners Do not try to light the burners by hand 5 Remove the upper access panel 6 Move switch on gas valve to OFF Do not force See figure 35 7 Wait five minutes to clear out any gas If you then smell gas STOP Immediately call your gas supplier from a neighbor s phone Follow the g
39. TURN AIR HOUUS UUULO GAS SUPPLY Natural Gas LP Propane Gas Piping Connections Tight Leak Tested Supply Line Pressure W C VENT EXHAUST PIPE Secure to Unit Elbows Secured to Pipe Roof Flashing water tight Vent Pipe Supported Page 43 L L L LJ LJ LJ LJ LJ L DUCT SYSTEM SUPPLY AIR DUCT Sealed Insulated if necessary Registers Open and Unobstructed RETURN DUCT Sealed Filter Installed and Clean Grilles Unobstructed INTEGRATED CONTROL DIP Switches Set if applicable Appropriate Links in Place if applicable VOLTAGE CHECK Supply Voltage Electrical Connections Tight Combustion Gas Manifold Pressure Q Ihermostat UNIT OPERATION typical R SUPPLY AIR Temperatures Filter RETURN AIR 2 HEATING MODE COOLING MODE GAS MANIFOLD PRESSURE W C INDOOR BLOWER AMPS COMBUSTION SAMPLE CO2 CO PPM 5 INDOOR BLOWER AMPS TEMPERATURE RISE Supply Duct Temperature Return Duct Temperature Temperature Rise TOTAL EXTERNAL STATIC dry coil Supply External Static Return External Static Total External Static Contractor s Name Job Address 4 TEMPERATURE DROP Return Duct Temperature Supply Duct Temperature Temperature
40. UCER JACK PLUG INDUCER IGNITER SENSOR P159 JACK PLUG IGNITION NOTE IF ANY WIRE IN THIS APPLIANCE IS REPLACED IT DOOR 1 MUST BE REPLACED WITH WIRE OF LIKE SIZE INTERLOCK RATING INSULATION THICKNESS AND TERMINATION A92 INTEGRATED CONTROL Sa Gar SECONDARY R REQUIRED ON SOME OUTDOOR UNITS Ti GAS LIMIT UNUSED MOTOR LEADS MUST BE WIRED TO A TRANSFORMER 51 ROOM THERMOSTAT aD PARK TERMINAL DIAGNOSTIC PUSH BUTTON S21 A DO NOT USE RED LOW SPEED MOTOR LEAD FOR SECONDARY HEATING SPEED ON 045 X E36A 070 X E36B 110 X E60C GAS LIMIT AND 135E60D UNITS RESULTING TEMPERATURE RISE WILL BE OUTSIDE OF RISE RANGE a 113 POWER CHOKE USED ON AND 1 HP ONLY RGM THERMOSTAT USE COPPER CONDUCTORS ONLY P49 B3 THERMOSTAT HEAT ANTICIPATION SETTINGS INDOOR S5AMP HONEYWELL VALVE BLOWER MOTOR 50 AMP WHITE RODGERS VALVE A92 INTEGRATED CONTROL PARK TERMINALS ARE UNPOWERED TERMINALS ALL OUTDOOR P48 UNIT LINE VOLTAGE FIELD INSTALLED mA CLASS Il VOLTAGE FIELD WIRING 78 DENOTES OPTIONAL COMPONENTS EQUIPMENT GROUND IL AS POWER CHOKE FLAME WHITE SENSOR PINK COMBUSTION AIR INDUCER MOTOR 1 24 92 INTEGRATED CONTROL YELLOW GND WARNING ELECTRIC SHOCK HAZARD CAN CAUSE INJURY OR DEATH UNIT MUST BE GROUNDED IN ACCORDANCE WITH NATIONAL A
41. ace such as the gas valve or blower deck before performing any service procedure The unit is equipped with a field make up box on the left hand side of the cabinet The make up box may be moved to the right side of the furnace to facilitate installation If the make up box is moved to the right side clip the wire ties that bundle the wires together The excess wire must be pulled into the blower compartment Secure the excess wire to the existing harness to protect it from damage INTERIOR MAKE UP BOX INSTALLATION Right Side FIGURE 29 INTERIOR MAKE UP BOX INSTALLATION Left side FIGURE 30 Refer to figure 32 for schematic wiring diagram and trou bleshooting and figure 33 for field wiring The power supply wiring must meet Class 1 restrictions Protected by either a fuse or circuit breaker select circuit protection and wire size according to unit nameplate NOTE Unit nameplate states maximum current draw Maximum over current protection allowed is 15 AMP Holes are on both sides of the furnace cabinet to facilitate wiring Install a separate properly sized disconnect switch near the furnace so that power can be turned off for servicing Page 25 Before connecting the thermostat check to make sure the wires will be long enough for servicing at a later date Make sure that thermostat wire is long enough to facilitate future removal of blower for ser
42. ain proper air velocity in w g High Med High Medium Med Low Low High Med High Medium Med Low Low cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts 0 00 2255 640 1940 420 1750 310 1580 230 1485 185 2290 655 1980 425 1775 310 1605 235 1495 195 0 10 2200 655 1910 440 1705 315 1535 240 1385 190 2250 675 11945 445 1730 320 1555 245 1400 190 0 20 2150 675 1865 450 1655 340 1490 260 1340 205 2210 695 1885 465 1680 340 1510 265 1350 205 0 30 2125 695 1835 475 1635 355 1450 275 1285 215 2165 715 1850 475 1645 355 1470 275 11285 215 0 40 2090 715 1800 495 1585 370 1405 285 1235 230 2135 720 1810 490 1595 370 1410 290 1225 230 0 50 2060 735 1760 510 1545 385 1370 305 1200 245 2070 735 1765 515 1545 390 1370 305 1180 245 0 60 2020 750 1725 525 1515 405 1320 320 1145 255 2030 760 1715 530 1495 405 1325 320 1140 255 0 70 1980 765 1680 540 1465 420 1265 330 1105 270 1990 775 1685 540 1450 425 1265 330 1095 270 0 80 1935 785 1635 560 1420 435 1225 350 1055 285 1950 795 1645 560 1415 435 1225 345 1040 285 ML180UH110E60C PERFORMANCE Less Filter Air Volume Watts at Different Blower Speeds External Bottom Return Air Side Return Air with Optional Return Sing
43. as suppliers instruc tions If you do not smell gas go to next step MANIFOLD PRESSURE ADJUSTMENT MANIFOLD PRESSURE OUTLET SCRE E P AA PORT INLET PRESSURE PORT GAS VALVE SHOWN IN ON POSITION FIGURE 35 8 Move switch on gas valve to ON Do not force See fig ure 35 9 Replace the upper access panel 10 Turn on all electrical power to to the unit 11 Set the thermostat to desired setting NOTE When unit is initially started steps 1 through 11 may need to be repeated to purge air from gas line 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 Remove the upper access panel 4 Move switch on gas valve to OFF Do not force 5 Replace the upper access panel Failure To Operate If the unit fails to operate check the following 1 Is the thermostat calling for heat 2 Are access panels securely in place 3 Is the main disconnect switch closed 4 15 there a blown fuse or tripped circuit breaker 5 Is the filter dirty or plugged Dirty or plugged filters will cause the limit control to shut the unit off 6 Is gas turned on at the meter 7 15 the manual main shut off valve open 8 15 the internal manual shut off valve open 9 Is the unit ignition syste
44. at all times VENT CONNECTION UPFLOW AND HORIZONTAL POSITION DISCONNECTED VENT WARNING STICKER NM VENT PIPE min 6 length DDDDD DDD DDDDD DDDDU FLUE TRANSITION COLLAR VENT PIPE min 6 length FIGURE 23 Page 15 Common Venting Using Metal Lined Masonry Chimney i SEALED MAX LENGTH SEE NOTE 1 22 BELOW 5 MIN LENGTH AS imum SHORT AS PRACTICAL EXTERIOR CHIMNEY WITH METAL LINER VENT CONNECTOR Y 4 in 102 mm minimum FURNACE PERMANENTLY SEALED FIREPLACE OPENING NOTE 1 Refer to the provided venting tables for installations Refer to the capacity requirements shown in the provided venting tables FIGURE 24 DO NOT insulate the space between the liner and the chimney wall with puffed mica or any other loose gran ular insulating material AIMPORTANT SINGLE appliance venting of a fan assisted furnace into a tile lined masonry chimney interior or outside wall is PROHIBITED The chimney must first be lined with either type B1 vent or an insulated single wall flexible vent lining system which has been sized ac cording to the provided venting tables and the vent pipe manufacturer s instructions A fan assisted furnace may be commonly vented into an existing lined masonry chimney if the following conditions are met The chimney is currently servi
45. ector can then be added between the black iron pipe and the gas supply line Gas Supply 1 This unit is shipped standard for left or right side instal lation of gas piping or top entry in horizontal applica tions Connect the gas supply to the piping assembly 2 When connecting the gas supply piping consider fac tors such as length of run number of fittings and fur nace rating to avoid excessive pressure drop Table 9 lists recommended pipe sizes for typical applications 3 The gas piping must not run in or through air ducts clothes chutes gas vents or chimneys dumb waiters or elevator shafts 4 The piping should be sloped 1 4 inch 6 4 mm per 15 feet 4 57 m upward toward the meter from the fur nace The piping must be supported at proper intervals every 8 to 10 feet 2 44 to 3 01 m with suitable hang ers or straps Install a drip leg in vertical pipe runs to the unit 5 A 1 8 N P T plugged tap or pressure post is located on the gas valve to facilitate test gauge connection See figure 35 6 In some localities codes may require the installation of a manual main shut off valve and union furnished by the installer external to the unit The union must be of the ground joint type AIMPORTANT Compounds used on threaded joints of gas piping must be resistant to the actions of liquified petro leum gases NOTE If emergency shutoff is necessary shut off the main manual gas valve and disconnect
46. el and remove the assembly from the unit 7 NOX units only Remove screw securing NOX insert Remove NOX insert See figure 38 8 Remove screws from both sides top and bottom of vestibule panel 9 Remove heat exchanger It may be necessary to spread cabinet side to allow more room If so remove five screws from the left side or right side of cabinet See figure 39 10 Backwash using steam Begin from the burner opening on each clam Steam must not exceed 275 11 To dean burners run a vacuum cleaner with a soft brush attachment over the face of burners Visually inspect in side the burners and crossovers for any blockage caused by foreign matter Remove any blockage Figure 37 shows burner detail 12 To clean the combustion air inducer visually inspect and using a wire brush clean where necessary Use com pressed air to clean off debris and any rust 13 Reinstall heat exchanger in vestibule Replace the five screws in the cabinet from step 10 if removed 14 NOx units only Replace NOx inserts 15 Reinstall collector box and combustion air assembly Reinstall all screws to the collector box and combustion air inducer Failure to replace all screws may cause leaks Inspect gaskets for any damage and replace if necessary 16 Reinstall burner box and manifold assembly 17 Reconnect all wires 18 Reconnect top cap and vent pipe to combustion air in ducer outlet 19 Reconnect gas supply piping 20
47. find any damage immediately contact the last carrier A DANGER Danger of explosion There are circumstances in which odorant used with LP propane gas can lose its scent In case of a leak LP propane gas will settle close to the floor and may be difficult to smell An LP propane leak detector should be installed in all LP applications AWARNING 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 licensed professional installer or equivalent service agency or the gas supplier A CAUTION As with any mechanical equipment personal injury can result from contact with sharp sheet metal edges Be careful when you handle this equipment Certifications ML180UHE units are CSA International certified to ANSI Z21 47 In the USA installation of gas furnaces must conform with local building codes In the absence of local codes units must be installed according to the current National Fuel Gas Code ANSI Z223 1 The National Fuel Gas Code is available from the following address American National Standards Institute Inc 11 West 42nd Street New York NY 10036 Clearances Adequate clearance must be made around the air open ings into the vestibule area In order to ensure proper unit operation combustion and ventilation air supply must be provided according to the current National Fuel Gas Code Ve
48. hat space This space also includes adjacent rooms which are not separated by a door Though an area may appear to be un confined it might be necessary to bring in outdoor air for combustion if the structure does not provide enough air by infiltration If the furnace is located in a building of tight construction with weather stripping and caulking around the windows and doors follow the procedures in the air from outside section Confined Space A confined space is an area with a volume less than 50 cu bic feet 1 42 m3 per 1 000 Btu 29 kW per hour of the combined input rating of all appliances installed in that space This definition includes furnace closets or small equipment rooms When the furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space contain ing the furnace the return air must be handled by ducts which are sealed to the furnace casing and which terminate outside the space containing the furnace This is especially important when the furnace is mounted on a platform in a confined space such as a closet or small equipment room Even a small leak around the base of the unit at the platform or at the return air duct connection can cause a potentially dangerous negative pressure condition Air for combustion and ventilation can be brought into the confined space either from inside the building or from outside EQUIPMENT IN CONFINED SPACE ALL AIR FROM INSIDE CHIMNEY OR GAS
49. hen be distributed throughout the house by the furnace duct system In upflow applications the return air can be brought in through the bottom or either side of the furnace If a fur nace with bottom return air is installed on a platform make an airtight seal between the bottom of the furnace and the platform to ensure that the unit operates properly and safely Use fiberglass sealing strips caulking or equiva lent sealing method between the plenum and the furnace cabinet to ensure a tight seal If a filter is installed size the return air duct to fit the filter frame Page 12 1 Remove the four mounting screws figure 15 which Venting secure the combustion air inducer pressure switch A 4 inch diameter flue transition is factory installed on the assembly to the orifice plate Lift the assembly and ro combustion air inducer outlet of all models Figure 16 tate it 90 degrees clockwise or counterclockwise to ei shows the combustion air inducer as shipped from the ther the 3 o clock position or to 9 o clock position Re factory secure with four screws Gasket should be left in place 2 Use tin snips to cut preferred opening on the cabinet Mounting Screws Location for repositioning the flue outlet Use the cut out piece Flue Transition as a cover plate to patch unused opening on cabinet Mounting Screws UPFLOW POSITION Left Side Vent Discharge Cover Plate Pressure Switch Make Up Collec
50. igerants Cleaning solvents such as perchloroethylene Printing inks paint removers varnishes etc Hydrochloric acid Cements and glues Antistatic fabric softeners for clothes dryers Masonry acid washing materials All gas fired appliances require air for the combustion pro cess If sufficient combustion air is not available the fur nace or other appliances will operate inefficiently and un safely Enough air must be provided to meet the needs of all fuel burning appliances and appliances such as exhaust fans which force air out of the house When fireplaces ex haust fans or clothes dryers are used at the same time as the furnace much more air is necessary to ensure proper combustion and to prevent a downdraft Insufficient air causes incomplete combustion which can result in carbon monoxide In addition to providing combustion air fresh outdoor air dilutes contaminants in the indoor air These contami nants may include bleaches adhesives detergents sol vents and other contaminants which can corrode furnace components The requirements for providing air for combustion and ven tilation depend largely on whether the furnace is installed in an unconfined or a confined space Page 6 Unconfined Space An unconfined space is an area such as a basement or large equipment room with a volume greater than 50 cubic feet 1 42 m3 per 1 000 Btu 29 kW per hour of the com bined input rating of all appliances installed in t
51. in manual gas valve and disconnect the main power to the furnace The installer should properly label these devices ACAUTION Some soaps used for leak detection are corrosive to certain metals Carefully rinse piping thoroughly af ter leak test has been completed Do not use matches candles flame or other sources of ignition to check for gas leaks The furnace must be isolated by closing its individual manual shut off valve and disconnecting from from the gas supply system during any pressure testing of the gas sup ply system at pressures greater than 1 2 psig 3 48 kPa 14 inches w c AIMPORTANT When testing pressure of gas lines gas valve must be disconnected and isolated See figure 28 Gas valves can be damaged if subjected to pressures greater than 1 2 psig 3 48 kPa 14 inches w c MANUAL MAIN SHUT OFF VALVE WILL NOT HOLD NORMAL TEST PRESSURE 1 8 NPT PLUG ISOLATE GAS VALVE FURNACE FIGURE 28 ELECTROSTATIC DISCHARGE ESD Precautions and Procedures ACAUTION Electrostatic discharge can affect electronic com ponents Take precautions during furnace installa tion and service to protect the furnace s electronic controls Precautions will help to avoid control ex posure to electrostatic discharge by putting the fur nace the control and the technician at the same electrostatic potential Neutralize electrostatic charge by touching hand and all tools on an un painted unit surf
52. ircuit being con nected to one of the provided neutral terminals If a humidi fier rated at greater than one amp is connected to this termi nal it is necessary to use an external relay relay One 24V H 1 4 spade terminal is provided on the furnace integrated control See figure 34 for integrated control con figuration The terminal is energized in the heating mode when the combustion air inducer is operating and the pres sure switch is closed Any humidifier rated up to 0 5 amp can be connected to this terminal with the ground leg of the circuit connected to ground or the C terminal Generator Use Voltage Requirements The following requirements must be kept in mind when specifying a generator for use with this equipment The furnace requires 120 volts 10 Range 108 volts to 132 volts e furnace operates at 60 Hz 5 Range 57 Hz to 63 Hz e furnace integrated control requires both polarity and proper ground Both polarity and proper grounding should be checked before attempting to operate the furnace on either permanent or temporary power e Generator should have a wave form distortion of less than 596 total harmonic distortion Thermostat Install the room thermostat according to the instructions provided with the thermostat See figure 31 for thermostat designations If the furnace is being matched with a heat pump refer to the FM21 installation instruction or appropri ate dual fuel thermos
53. is removed from a venting system commonly run with separate gas ap pliances the venting system is likely to be too large to properly vent the remaining attached appliances Conduct the following test while each appliance is operat ing and the other appliances which are not operating main connected to the common venting system If the venting system has been installed improperly you must correct the system as indicated in the general venting re quirements section A WARNING CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon mon oxide poisoning or death The following steps shall be followed for each ap pliance connected to the venting system being placed into operation while all other appliances connected to the venting system are not in operation 1 Sealany unused openings in the common venting sys tem 2 Inspect the venting system for proper size and horizontal pitch Determine that there is no blockage restriction leakage corrosion or other deficiencies which could cause an unsafe condition 3 Close all building doors and windows and all doors be tween the space in which the appliances remaining connected to the common venting system are located and other spaces of the building Turn on clothes dry ers and any appliances not connected to the common venting system Turn on an
54. le Side Return Air Air volumes in bold require field Static Air Base Return Air from Both Sides or Return Air from fabricated transition to accommodate 20 x 25 x 1 in air filter Pressure Bottom and One Side in order to maintain proper air velocity in w g High Med High Medium Med Low Low High Med High Medium Med Low Low cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts 0 00 2230 635 1945 430 1715 295 1555 230 1470 185 2315 645 1990 415 1780 300 1610 230 1510 200 0 10 2180 655 1905 445 1690 305 1510 240 1340 175 2260 655 11945 425 1740 315 11550 240 1400 185 0 20 2135 680 1865 465 1630 330 1470 260 1280 190 2210 680 1895 450 1680 335 1510 255 1350 200 0 30 2090 695 1830 480 11595 345 1440 275 1235 200 2165 700 11850 465 1650 355 1455 275 1285 210 0 40 2050 715 1785 495 1550 360 1385 285 1175 210 2130 715 1830 485 1585 365 1395 285 1230 225 0 50 2025 730 1740 520 1500 375 1340 300 1130 225 2095 730 1770 500 1535 385 1365 300 1175 235 0 60 2010 750 1710 535 1470 390 1305 320 1080 240 2055 755 1725 515 1495 400 1305 315 1135 250 0 70 1965 755 1670 555 1420 410 1255 330 1015 255 2000 765 1675 535 1465 410 1255 325 1080 265 0 80 1905 785 1635 560 11380 425 1215 350 975 270 1965 785 1640 555 1400 425 1210 345 1025 275
55. m m O0000 O0000 DDDDD oo000 AIR FLOW I nhi Transition FIGURE 9 Optional Return Air Base Upflow Applications Only For use with A B C and D cabinets FURNACE FRONT F WITHOUT IAQ CABINET ASINGLE INDOOR AIR RETURN AIR QUALITY CABINET PLENUM PCO Filter MUST Cabinet etc COVER BOTH UNIT AND RETURN AIR BASE OPENINGS AIR FLOW R 14 1 2 368 A Width ane OPTIONAL 17 1 2 446 B Width 50W98 IR BASE 21 533 C Width 50W99 24 1 2 622 D Width 51W00 5 123 584 Overall Maximum Minimum 11 279 m Maximum 1 Unit side return air 14 356 RES cg e SIDE RETURN AIR OPENINGS Either Side Overall Maximu 5 5 8 143 SIDE VIEW NOTE Optional Side Return Air Filter Kits are not for use with Optional 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 Minimum unit side return air opening dimensions for units requiring 1800 cfm or more of air W x H 23 x 11 in 584 x 279 mm The opening can be cut as needed to accommodate
56. m in lock out If the unit locks out again call the service technician to inspect the unit for blockages 10 Is pressure switch closed Obstructed flue will cause unit to shut off at pressure switch Check flue and outlet for blockages Page 29 11 Are flame rollout switches tripped If flame rollout switches are tripped call the service technician for in spection Heating Sequence Of Operation follow steps below or see Figure 32 for more detail 1 When thermostat calls for heat combustion air blower starts 2 Combustion air pressure switch proves blower opera tion Switch is factory set and requires no adjustment 3 After a 15 second prepurge the hot surface ignitor en ergizes 4 After a 20 second ignitor warm up period the gas valve solenoid opens A 4 second trial for ignition peri od begins 5 Gas is ignited flame sensor proves the flame and the combustion process continues 6 If flame is not detected after first ignition trial the igni tion control will repeat steps 3 and 4 four more times before locking out the gas valve WATCHGUARD flame failure mode The ignition control will then auto matically repeat steps 1 through 6 after 60 minutes 7 To interrupt the 60 minute WATCHGUARD period move thermostat from Heat to OFF then back to Heat Heating sequence then restarts at step 1 Gas Pressure Adjustment Gas Flow Approximate TABLE 11 GAS METER CLOCKING CHART
57. ndraft can occur in the furnace vent pipe or chimney As a result combustion gases enter the liv ing space creating a potentially dangerous situation In the absence of local codes concerning air for combus tion and ventilation use the guidelines and procedures in this section to install ML180UHE furnaces to ensure effi cient and safe operation You must consider combustion air needs and requirements for exhaust vents A portion of this information has been reprinted with permission from the National Fuel Gas Code ANSI Z223 1 This reprinted ma terial is not the complete and official position of the ANSI on the referenced subject which is represented only by the standard in its entirety ACAUTION Do not install the furnace in a corrosive or contami nated atmosphere Meet all combustion and ventila tion air requirements as well as all local codes ACAUTION Insufficient combustion air can cause headaches nausea dizziness or asphyxiation It will also cause excess water in the heat exchanger resulting in rust ing and premature heat exchanger failure Excessive exposure to contaminated combustion air will result in safety and performance related problems Avoid exposure to the following substances in the combus tion air supply Permanent wave solutions Chlorinated waxes and cleaners Chlorine base swimming pool chemicals Water softening chemicals De icing salts or chemicals Carbon tetrachloride Halogen type refr
58. ng Coil When this furnace is used with cooling units it shall be installed in parallel with or on the upstream side of cooling units to avoid condensation in the heating compartment See figure 2 With a parallel flow arrangement a damper or other means to control the flow of air must adequately pre vent chilled air from entering the furnace If the damper is manually operated it must be equipped to prevent operation of either the heating or the cooling unit unless it is in the full HEAT or COOL setting See figure 2 Heating Unit Installed Parallel to Cooling Coil Dampers open during heating operation only L em L Cooling Coil Dampers open during cooling operation only Heating Unit Installed Upstream of Cooling Coil FE Cooling FIGURE 2 When installed this furnace must be electrically grounded according to local codes In addition in the United States installation must conform with the current National Elec tric Code ANSI NFPA No 70 The National Electric Code ANSI NFPA No 70 is available from the following ad dress National Fire Protection Association 1 Battery March Park Quincy MA 02269 NOTE This furnace is designed for a minimum continu ous return air temperature of 60 F 16 C or an intermit tent operation down to 55 F 13 C dry bulb for cases where a night setback thermostat is used Return air tem perature must not exceed 85 F 29 C dry bulb The ML180U
59. ng at least one drafthood equipped appliance The vent connectors and chimney are sized according to the provided venting tables If type B1 double wall vent is used inside a chimney no oth er appliance can be vented into the chimney The outer wall of type B1 vent pipe must not be exposed to flue products A type B1 vent or masonry chimney liner shall terminate above the roof surface with a listed cap or a listed roof as sembly according to the terms of their respective listings and the vent manufacturer s instructions When inspection reveals that an existing chimney is not safe for the intended purpose it shall be rebuilt to conform to nationally recognized standards lined or relined with suitable materials or replaced with a gas vent or chimney suitable for venting ML180UHE series units The chimney passageway must be checked periodically to ensure that it is clear and free of obstructions Do not install a manual damper barometric draft regulator or flue restrictor between the furnace and the chimney Never connect a Category appliance to a chimney that is servicing a solid fuel appliance If a fireplace chimney flue is used to vent this appliance the fireplace opening must be permanently sealed A type B or listed chimney lining system that passes through an unused masonry chimney flue is not considered to be exposed to the outdoors General Venting Requirements Vent all ML180UHE furnaces according to these instruc
60. ning Contractors of America or Ameri can Society of Heating Refrigerating and Air Conditioning Engineers to size and install the supply and return air duct System This will result in a quiet and low static system that has uniform air distribution NOTE Do not operate the furnace in the heating mode with an external static pressure that exceeds 0 5 inches w c Higher external static pressures may cause erratic lim it operation Supply Air Plenum If the furnace is installed without a cooling coil a removable access panel must be installed in the supply air duct The access panel should be large enough to permit inspection either by smoke or reflected light of the heat exchanger for leaks after the furnace is installed The furnace access panel must always be in place when the furnace is operat ing and it must not allow leaks into the supply air duct sys tem Return Air Plenum NOTE Return air must not be drawn from a room where this furnace or any other gas fueled appliance i e water heater or carbon monoxide producing de vice i e wood fireplace is installed When return air is drawn from a room a negative pres sure is created in the room If a gas appliance is operating in a room with negative pressure the flue products can be pulled back down the vent pipe and into the room This reverse flow of the flue gas may result in incomplete com bustion and the formation of carbon monoxide gas This toxic gas might t
61. nt installations must be consistent with the National Fuel Gas Code venting tables in this instruction and applicable provisions of local building codes This furnace is CSA International certified for installation clearances to combustible material as listed on the unit nameplate and in the tables in figures 8 and 12 Accessibility and service clearances must take precedence over fire protection clearances NOTE For installation on combustible floors the furnace shall not be installed directly on carpeting tile or other combustible material other than wood flooring Installed Locations For installation in a residential garage the furnace must be installed so that the burner s and the ignition source are located no less than 18 inches 457 mm above the floor The furnace must be located or protected to avoid physical damage by vehicles When a furnace is installed in a public garage hangar or other building that has a haz ardous atmosphere the furnace must be installed accord ing to recommended good practice requirements and cur rent National Fuel Gas Code Temperature Rise NOTE Furnace must be adjusted to obtain a temperature rise within the range specified on the unit nameplate Failure to do so may cause erratic limit operation and may result in premature heat exchanger failure This ML180UHE furnace must be installed so that its elec trical components are protected from water Page 4 Installed in Combination with a Cooli
62. nt pipe Must be inspected for signs of water damaged or sagging pipe or disconnected joints Unit appearance Must be inspected for rust dirt signs of water burnt or damaged wires or components Blower access panel Must be properly in place and pro vide a seal between the return air and the room where the furnace is installed Return air duct Must be properly attached and provide an air seal to the unit Operating performance Unit must be observed during operation to monitor proper performance of the unit and the vent system Combustion gases Flue products must be analyzed and compared to the unit specifications See table 12 Problems detected during the inspection may make it nec essary to temporarily shut down the furnace until the items can be repaired or replaced Instruct the homeowners to pay attention to their furnace Situations can arise between annual furnace in spections that may result in unsafe operation For instance items innocently stored next to the furnace may obstruct the combustion air supply This could cause incomplete combustion and the production of carbon monoxide gas Repair Parts List The following repair parts are available through independent Lennox dealers When ordering parts include the complete furnace model number listed on the CSA International nameplate Example ML180UHE045P24A 01 All service must be performed by a licensed professional installer or equivalent service
63. o provided venting g tables for installations NOTE the chimney must be properly OTHER APPLIANCE FURNACE sized per provided venting tables or lined with listed metal lining system VENT TS CONNECTOR PERMANENTLY SEALED FIREPLACE OPENING FIGURE 25 The entire length of single wall metal vent connector shall be readily accessible for inspection cleaning and replacement Single appliance venting configurations with zero lat eral lengths tables 3 and 4 are assumed to have no elbows in the vent system For all other vent configura tions the vent system is assumed to have two 90 el bows For each additional 90 elbow or equivalent for example two 45 elbows equal one 90 elbow beyond two the maximum capacity listed in the venting table should be reduced by 1096 0 90 x maximum listed ca pacity The common venting tables 5 6 7 and 8 were gen erated using a maximum horizontal vent connector length of 1 1 2 feet 46 m for each inch 25 mm of connector diameter as follows TABLE 2 inches mm Connector Length feet m If the common vertical vent is offset the maximum common vent capacity listed in the common venting tables should be reduced by 20 the equivalent of two 90 elbows 0 80 x maximum common vent capacity The horizontal length of the offset shall not exceed 1 1
64. ombustion Air Inducer Combustion Air Inducer Pressure Switch Burner Box includes sensor ignitor and rollout switches Primary Limit hea under ES combustion air inducer Control Box includes integrated control interlock switch and transformer p af f J Secondary Limits Ka V sy Blower Assembly Blower Access Panel Power Choke 4 and 5 Ton Only FIGURE 1 Page 3 ML180UHE Gas Furnace The ML180UHE unitis shipped ready for installation in the upflow or horizontal right position for horizontal left posi tion the combustion air pressure switch must be moved fueled by natural gas A conversion kit ordered separate ly is required for use in LP Propane gas applications The furnace is shipped with the bottom panel in place The bot tom panel must be removed if the unit is to be installed in a horizontal application The panel may also be removed in upflow applications Shipping and Packing List Package 1 of 1 contains 1 Assembled ML180UHE unit 1 Bag assembly containing the following 2 Screws 1 Snap bushing 1 Snap plug 1 Wire tie 1 Vent warning label 1 Owner s manual and warranty card The following items may be ordered separately 1 Thermostat 1 Suspension kit for horizontal installations 1 LP Propane changeover kit 1 Return air base 1 High altitude kit 1 Side filter kit Check equipment for shipping damage If you
65. oring TLeft side requires 3 inches if a single wall vent is used on 14 1 2 inch cabinets or 2 inches if a single wall vent pipe is used on 17 1 2 inch cabinets FIGURE 8 Page 9 Return Air Upflow Applications Return air can be brought in through the bottom or either side of the furnace installed in an upflow application If the furnace is installed on a platform with bottom return make an airtight seal between the bottom of the furnace and the platform to ensure that the furnace operates properly and safely The furnace is equipped with a removable bottom panel to facilitate installation Markings are provided on both sides of the furnace cabinet for installations that require side return air Cut the furnace cabinet at the maximum dimensions shown on page 2 NOTE 60 60D units that require air volumes over 1800 cfm 850 L s must have one of the following 1 Single side return air with transition to accommodate 20 x 25 x 1 in 508 x 635 x 25 mm cleanable air filter Re quired to maintain proper air velocity See figure 9 2 Single side return air with optional return airbase See fig ure 10 3 Bottom return air 4 Return air from both sides 5 Bottom and one side return air Refer to Engineering Handbook for additional information Single Side Return Air with transition and filter 20 X 25 X 1 508mm X 635mm X 25mm A Cleanable Filter Return Air Plenum
66. placement filters must be rated for high veloc ity airflow Table 1 lists recommended filter sizes Flue And Chimney 1 Check flue pipe chimney and all connections for tight ness and to make sure there is no blockage 2 Check unit for proper draft Electrical 1 Check all wiring for loose connections 2 Check for the correct voltage at the furnace furnace operating Correct voltage is 120VAC 1096 3 Check amp draw on the blower motor with blower ac cess panel in place Unit Nameplate Actual Cleaning the Heat Exchanger and Burners NOTE Use papers or protective covering in front of the fur nace during cleaning 1 Turn off both electrical and gas power supplies to fur nace 2 Remove flue pipe and top cap some applications top cap can remain from the unit 3 Label the wires from gas valve rollout switches prima ry limit switch and make up box then disconnect them 4 Remove the screws that secure the combustion air in ducer pressure switch assembly to the collector box Carefully remove the combustion air inducer to avoid damaging blower gasket If gasket is damaged it must be replaced to prevent leakage 5 Remove the collector box located behind the combus tion air inducer Be careful with the collector box gas ket If the gasket is damaged it must be replaced to prevent leakage 6 Disconnect gas supply piping Remove the four screws securing the burner manifold assembly to the vestibule pan
67. plenum or IAQ cabinet while maintaining dimensions shown Side return air openings must be cut in the field There are cutting guides stenciled on the cabinet for the side return air opening The size of the opening must not extend beyond the markings on the furnace cabinet 2 To minimize pressure drop the largest opening height possible up to 14 inches 356 mm is preferred FIGURE 10 Page 10 Removing the Bottom Panel Remove the two screws that secure the bottom cap to the furnace Pivot the bottom cap down to release the bottom panel Once the bottom panel has been removed reinstall the bottom cap See figure 11 Removing the Bottom Panel Bottom Cap Horizontal Application Installation Clearances vooon Bottom Vent Connector sS 2 1 4 in 57 mm 2 1 4 in 57 mm om m f Front clearance in alcove installation must be 24 in 610 mm Maintain a minimum of 24 in 610 mm for front service access 4 1 2 in if single wall vent pipe is used For installations on a combustible floor do not install the furnace directly on carpeting tile or other combustible materials other than wood flooring FIGURE 12 Horizontal Applications The ML180UHE furnace can be installed in horizontal ap plications Order horizontal suspension kit 51W10 from Lennox or use equivalent suspension method Allow for clearances to combustible materials as indicated on the
68. r I filter Required to maintain proper air velocity D 2 Single side return with optional return air base 3 Bottom return air 4 Return air from both sides SUPPLY AIR 5 Bottom and one side return air OPENING See Blower Performance Tables for additional information 2Flue outlet may be horizontal but furnace must be e vented vertically p 3Optional external side return air filter kit cannot be used with the optional RAB Return Air Base I 3 OPTIONAL 23 3 4 EXTERNAL 603 gt SIDE RETURN 25 AIR FILTER 635 gt Either Side TOP VIEW 3 4 19 27 3 4 Front Panel 705 A 3 1 4 83 3 76 Right 19 7 16 lt 9 16 B 96 12 6 3 4 171 Left 494 14 y J a 2 FLUE OUTLET t Either Side 9 1 8 232 Right OPTIONAL 8 5 8 219 Left eter ste SIDE RETURN Y AIR FILTER KIT QM Either Side 5 3 8 137 Right GAS PIPING INLET 838 1 9 16 40 Left Either Side 2 i ELECTRICAL 23 1 1 2 14 3 A INLET Either Side rat 584 gt lt 38 375 1 pas Return nee 16 i ir Opening 406 Eons Either Side Y Y Y Y 1 15 16 49 5 8 3 4 e 34 16 9 e i Bottom Return 9 1Bottom Return Air Opening Air Opening FRONT VIEW SIDE VIEW ML180UHE Model No in mm 1442 1 2 045 X E36A 070 X E36B 090 X E48B 090E60C 110 X E60C 19 7 8 19 1 2 T35E60D 24172 23 38 oa Page 2 Parts Arrangement Make Up Box Heat Exchanger C
69. rnace Do not connect duct directly to the furnace Size the temporary duct following these instructions in section for Combustion Dilution and Ventilation Air in a confined space with air from outside e The furnace heat exchanger components duct system air fillers and evaporator coils must be thoroughly cleaned following final construction clean up e All furnace operating conditions including ignition in put rate temperature rise and venting must be verified according to these installation instructions These instructions are intended as a general guide and do not supersede local codes in any way Consult authorities having jurisdiction before installation In addition to the requirements outlined previously the fol lowing general recommendations must be considered when installing a ML180UHE furnace e Place the furnace as close to the center of the air dis tribution system as possible The furnace should also be located close to the chimney or vent termination point Page 5 e Do not install the furnace where drafts might blow direct ly into it This could cause improper combustion and un safe operation e Do not block the furnace combustion air openings with clothing boxes doors etc Air is needed for proper combustion and safe unit operation e When the furnace is installed in an attic or other insu lated space keep insulation away from the furnace NOTE The Commonwealth of Massachusetts stipu lates these addi
70. tat instructions ML180UHE and CONDENSING UNIT THERMOSTAT DESIGNATIONS Refer to specific thermostat and outdoor unit Thermostat Furnace Condensing Unit A CONDENSING POWER UNIT HEAT CONDENSING UNIT COOLING INDOOR BLOWER A CONDENSING UNIT COMMON COMMON NOTE R REQUIRED ON SOME OUTDOOR UNITS FIGURE 31 Indoor Blower Speeds 1 When the thermostat is set to FAN ON the indoor blower will run continuously on the fan speed when there is no cooling or heating demand 2 When the ML180UHE is running in the heating mode the indoor blower will run on the heating speed 3 When there is a cooling demand the indoor blower will run on the cooling speed Page 26 ML180UHE Schematic Wiring Diagram and Sequence of Operation COMBUSTION 518 BLOWER SPEED CHART AIRINDUCER COMBUSTION AIR CONNECTED SPEED TAPS PROVING SWITCH HEAT D O45 QE36A oropQe3eB 090 48 BLACK BLUE BROWN YELLOW 090 60 eese RED 10 X E60C 135E60D BROWN BLUE BLACK YELLOW GAS VALVE BLOWER SPEED SELECTION Z PRIMARY GA LIMIT SPEED TAPS BLACK BROWN BLUE YELLOW J159 FLAME ROLLOUT 159 FLAME ROLLOUT citer ms SWITCH JACK PLUG CHART JACK PLUG INDOOR BLOWER POWER BURNERS JACK PLUG INDOOR BLOWER SPD TAP JACK PLUG BURNER CONTROL Q L O O O O JACK PLUG COMB AIR IND
71. tional requirements e Gas furnaces shall be installed by a licensed plumb er or fitter only e The gas cock must be T handle type e When a furnace is installed in an attic the passage way to and service area surrounding the equipment shall be floored AWARNING Product contains fiberglass wool Disturbing the insulation in this product during installation maintenance or repair will expose you to fiberglass wool Breathing this may cause lung cancer Fiberglass wool is known to the State of Cal ifornia to cause cancer Fiberglass wool may also cause respiratory skin and eye irritation To reduce exposure to this substance or for further information consult material safety data sheets available from address shown below or contact your supervisor Lennox Industries Inc P O Box 799900 Dallas TX 75379 9900 Combustion Dilution amp Ventilation Air In the past there was no problem in bringing in sufficient out door air for combustion Infiltration provided all the air that was needed In today s homes tight construction practices make it necessary to bring in air from outside for combus tion Take into account that exhaust fans appliance vents chimneys and fireplaces force additional air that could be used for combustion out of the house Unless outside air is brought into the house for combustion negative pressure outside pressure is greater than inside pressure will build to the point that a dow
72. tor FIGURE 15 UPFLOW POSITION Top Vent Discharge Vent Pipe Flue Transition an ft rov Gas supply piping must be brought into the unit from the right side in order to accommodate the flue pipe Cut Combustion air inducer tubing from 9 to 8 to avoid inter ference with inducer motor Remove make up box assembly 2 screws and cut wire tie to free make up box wires Re install make up box on other side of cabinet Re secure make up box wires Either pull excess wires through the blower compartment and secure using supplied wire tie or coil excess wire and secure to the gas manifold FIGURE 17 UPFLOW POSITION Right Side Vent Discharge Cover Plate Flue Transition Vent Pipe Flue Transition Pressure Collector Box Switch Collector Box Pressure Switch AIR 0 FLOW FIGURE 16 AIMPORTANT The unit will not vent properly with the flue transition pointed down in the 6 o clock position The combustion air inducer may be rotated clock wise or counterclockwise by 90 to allow for top or side vent discharge in all applications When the unit is installed the flue transition must be in the 9 o clock 12 o clock or 3 o clock position AIR FLOW e
73. ue products must never be allowed to enter the return air system or the living space Use screws and joint tape to seal the return air system to the furnace In platform installations with bottom return air the furnace should be sealed airtight to the return air ple num A door must never be used as a portion of the return air duct system The base must provide a stable support and an airtight seal to the furnace Al low absolutely no sagging cracks gaps etc The return and supply air duct systems must never be connected to or from other heating devices such as a fireplace or stove etc Fire explosion carbon monoxide poisoning personal injury and or proper ty damage could result AWARNING The blower access panel must be securely in place when the blower and burners are operating Gas fumes which could contain carbon monoxide can be drawn into living space resulting in personal inju ry or death This unit is not equipped with a filter or rack A field pro vided high velocity filter is required for the unit to operate properly Table 1 lists recommended filter sizes A filter must be in place any time the unit is operating TABLE 1 Furnace Cabinet Width Side Return Bottom Return A 14 1 2 16 X 25 X1 1 14X25X1 1 B 17 1 2 16X25 X1 1 16X25 X1 1 16X25X1 1 20X25X1 1 D 24 1 2 16 X25 X 1 2 24 X 25 X 1 1 Duct System Use industry approved standards such as those pub lished by Air Conditio
74. uld burn blue 4 After allowing unit to stabilize for 5 minutes record manifold pressure and compare to value given in table 13 NOTE Shut unit off and remove manometer as soon as an accurate reading has been obtained Take care to remove barbed fitting and replace threaded plug Proper Combustion Furnace should operate a minimum 15 minutes with cor rect manifold pressure and gas flow rate before checking combustion Take combustion sample beyond the flue out let and compare to the tables below The maximum car bon monoxide reading should not exceed 50 ppm TABLE 12 a e 999 72 78 75 90 High Altitude The manifold pressure may require adjustment and com bustion air pressure switch may need replacing to ensure proper combustion at higher altitudes Refer to table 13 for manifold pressure and table 14 for pressure switch change and gas conversion kits AIMPORTANT For safety shut unit off and remove manometer as soon as an accurate reading has been obtained Take care to replace pressure tap plug Page 30 TABLE 13 Manifold Pressure Settings at all Altitudes LP propane LP propane 10 0 10 0 Na K 0 2000 ft 2001 4500 ft 4501 7500 ft 7501 10 000 ft oe l i lt ae M 3 s a 2 s jus mo 18 o 9 3 5 3 2 045 5 3 2 070 110 5 5 135 3 5 3 5 ss m ws 5s x s m Go 7 283 s o 3 0 28 27 3
75. vice Complete the wiring connections to the equipment Use the provided unit wiring diagram and the field wiring diagram shown in figure 33 Use 18 gauge wire or larger that is suit able for Class II rating for thermostat connections Electrically ground the unit according to local codes or in the absence of local codes according to the current Na tional Electric Code ANSI NFPA No 70 A green ground wire is provided in the field make up box NOTE The ML180UHE furnace contains electronic components that are polarity sensitive Make sure that the furnace is wired correctly and is properly grounded Accessory Terminals One line voltage EAC 1 4 spade terminal is provided on the furnace integrated control See figure 34 for integrated control configuration This terminal is energized when the indoor blower is operating Any accessory rated up to one amp can be connected to this terminal with the neutral leg of the circuit being connected to one of the provided neutral terminals If an accessory rated at greater than one amp is connected to this terminal it is necessary to use an exter nal relay One line voltage HUM 1 4 spade terminal is provided on the furnace integrated control See figure 34 for integrated control configuration This terminal is energized in the heating mode when the combustion air inducer is operat ing Any humidifier rated up to one amp can be connected to this terminal with the neutral leg of the c
76. witch on the other side of orifice plate and re connect pressure switch hose Re secure pressure switch wires Either pull excess wires through the blower compartment and secure using supplied wire tie or coil excess wire and secure to the gas manifold FIGURE 20 Page 14 Make Up Box HORIZONTAL RIGHT POSITION Top Vent Discharge Vent Pipe Pressure Switch Flue Transition Cover Plate gt Collector Box Gas supply piping must be brought into the unit from the bot tom in order to accommodate the flue pipe Cut combustion air inducer tubing from 9 to 8 to avoid inter ference with inducer motor Remove make up box assembly 2 screws and cut wire tie to free make up box wires Re install make up box on other side of cabinet Re secure make up box wires Either pull excess wires through the blower compartment and secure using supplied wire tie or coil excess wire and secure to the gas manifold FIGURE 21 HORIZONTAL RIGHT POSITION Side Vent Discharge no modifications necessary Pressure Switch Vent Pipe Flue Transition Collector Box FIGURE 22 The ML180UHE series units are classified as fan assisted Category furnaces when vertically vented according to the latest edition of National Fuel Gas Code NFPA 54 ANS
77. y exhaust fans such as range hoods and bathroom exhausts so they will oper ate at maximum speed Do not operate a summer ex haust fan Close fireplace dampers 4 Follow the lighting instructions Turn on the appliance that is being inspected Adjust the thermostat so that the appliance operates continuously 5 After the burner have operated for 5 minutes test for leaks of flue gases at the draft hood relief opening Use the flame of a match or candle 6 After determining that each appliance connected to the common venting system is venting properly step 3 return all doors widows exhaust fans fireplace damp ers and any other gas burning appliances to their pre vious mode of operation If a venting problem is found during any of the preced ing tests the common venting system must be modi fied to correct the problem N Resize the common venting system to the minimum vent pipe size determined by using the appropriate tables in Appendix G These are in the current stan dards of the National Fuel Gas Code ANSI Z223 1 Page 22 Gas Piping Gas supply piping should not allow more than 0 5 W C drop in pressure between gas meter and unit Supply gas pipe must not be smaller than unit gas connection ACAUTION If a flexible gas connector is required or allowed by the authority that has jurisdiction black iron pipe shall be installed at the gas valve and extend outside the furnace cabinet The flexible conn

Lenox Furnace ML180UHE User's Manual

Contents

Download Pdf Manuals

Related Search

Related Contents