Lennox International Inc. EL180UHE Furnace User Manual
Contents
1. FLUE TRANSITION COLLAR VENT PIPE min 6 length FIGURE 22 ry SEE NOTE 4 22 BELOW MIN LENGTH AS EXTERIOR SHORT AS PRACTICAL CHIMNEY WITH e METAL LINER t VENT CONNECTOR 4 in 102 mm minimum 5 ft 1 5 m minimum FURNACE PERMANENTLY SEALED FIREPLACE OPENING OTHER APPLIANCE NOTE 1 Refer to the provided venting tables for installations Refer to the capacity requirements shown in the provided venting tables FIGURE 23 AWARNING Asphyxiation hazard The exhaust vent for this fur nace must be securely connected to the furnace flue transition at all times 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 e The chimney is currently serving at least one drafthood equipped ap2. Collector Box Goyer Flate Pressure Switch AIR t FLOW e Cut combustion air inducer tubing from 9 to 5 to avoid interference with inducer motor FIGURE 17 Page 13 HORIZONTAL LEFT POSITION Vent Discharge Vent Pipe gt p NE Pressure Switch AN Transition e Cover Plate 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 18 HORIZONTAL LEFT POSITION Side Vent Discharge Pressure Switch Vent Pipe Collector Box Make Up Box Cut combustion air inducer tubing from 9 to 7 to avoid inter ference with inducer motor e 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 s
3. 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 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 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 14 All venting pipe passing through floors walls and ceil Page 17 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 can extend into pass through any circulation air duct or plenum 16 Vent connectors serving Category appliances shall not be connect
4. 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 Page 11 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 agas 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 then be distributed through
5. cove installations are shown in figure 7 Upflow Application Installation Clearances Left Side Right Side Type of Vent m rem rem 2 1 4 in 57 2 1 4 in 57 mm 9 9 Front clearance alcove installation must be 24 610 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 on a combustible floor do not install the furnace directly on carpeting tile or other combustible materials other than wood flooring 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 7 Page 8 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 60C and 60D units that require air volumes over 1800 cfm 850 L s must have one of the following 1 Singl
6. Dampers open during pens operation only Heating Unit Installed Upstream of Cooling Coil jd E Cooling Coil FIGURE 1 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 29 dry bulb The EL180UHE 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 EL180UHE 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 EL180UHE units may be used for heating of buildings or structures under construction if the
7. HEATING MODE COOLING MODE GAS MANIFOLD PRESSURE W C INDOOR BLOWER AMPS 2 TEMPERATURE DROP Return Duct Temperature 5 INDOOR BLOWER AMPS COMBUSTION SAMPLE CO2 CO PPM TEMPERATURE RISE 5 TOTAL EXTERNAL STATIC dry coil Supply Duct Temperature Supply External Static Return Duct Temperature ____ Return External Static Total External Static DRAIN LINE L Leak Free Temperature Rise TOTAL EXTERNAL STATIC dry coil Supply External Static Return External Static Total External Static THERMOSTAT L Adjusted and Programmed L Operation Explained to Owner Contractor s Name Telephone Checklist Completed Job Address Technician s Name Page 32
8. Remove the screw se curing the burner box cover and remove cover Re move the four screws securing the burner manifold as sembly to the vestibule panel and remove the assembly from the unit To clean 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 33 shows burner detail Reinstall burner box manifold assembly and burner box cover Re install gas supply and turn on electrical pwer to fur nace ML180UHE BURNER ASSEMBLY amp REMOVAL Rollout Switches 090 110 135 units Rollout Switches Ignitor Sensor Manifold And Gas Valve FIGURE 33 Retention Rings Cross Over 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 EL180UH045E36A 01 All service must be performed by a licensed professional installer or equivalent service 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 Page 30 Flame sensor Heat exchanger assem
9. 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 10 for manifold pressure and table 11 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 27 10 Manifold Pressure Settings at all Altitudes Input Size 0 2000 ft 2001 4500 ft 4501 7500 ft 7501 10 000 ft 5 045 LP propane 5 070 110 135 LPipropane Ws Las s NEN 0 4 5 11 Pressure Switch and Gas Conversion Kits at all Altitudes High Altitude LP Propane to Model High Altitude Pressure Switch Kit Natural Gas Burner Natural Gas to EP Propane Natural Gas Burner ode Burner Orifice Kit u Input Size Orifice Kit Orifice Kit 0 4500 ft 4501 7500 ft 7501 10 000 ft 7501 10 000 ft 0 7500 ft 7501 10 000 ft 0 7500 ft 090 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 equipp
10. 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 OUTLET FURNACE AIR WATER HEATER VENTILATI LOUVERS For unheated crawl space L 1 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 3 EQUIPMENT 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 ee OUTLET AIR FURNACE FURNACE INLET AIR Ends 12 in ii above bottom CA INLET AIR l WATER HEATER T T Ig Ue S S S S S S S S OO NOTE Each air duct opening shall have a free area of at least one square inch 645 mm per 2 000 Btu 59 kW per hour of the total NOTE The inlet and outlet air openings shall each have a input rating of all equipment in the enclosure If fhe equipment room free area of at least one square inch 645 mm 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 mm
11. actions of liquified petro vious mode of operation leum gases 7 If a venting problem is found during any of the preced NOTE If emergency shutoff is necessary shut off the main ing tests the common venting system must be modi fied to correct the problem manual gas valve and disconnect main power to the fur nace The installer should properly label these devices Page 20 6 Gas Pipe Capacity ft3 hr m3 hr Nominal internal Length of Pipe feet m Iron Pipe Size Diameter 17 799 1 69 1 58 3 4 824 360 247 199 170 151 137 126 117 110 19 05 20 930 10 19 7 00 5 63 4 81 4 28 3 87 3 56 3 31 3 11 1 1 049 678 466 374 320 284 257 237 220 207 25 4 26 645 19 19 13 19 10 59 9 06 8 04 7 27 6 71 6 23 5 86 1 1 4 1 380 1350 957 768 657 583 528 486 452 424 31 75 35 052 38 22 27 09 22 25 18 60 16 50 14 95 13 76 12 79 12 00 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 98 502 713 2 2 067 4020 2760 2220 1900 1680 1520 1400 1300 1220 2 1 2 2 469 6400 4400 3530 3020 2680 2480 2230 2080 1950 63 5 67 713 181 22 124 59 99 95 85 51 75 88 70 22 63 14 58 89 55 22 3 3 068 11300 7780 6250 5350 4740 4290 3950 3670 3450 76 2 77 9
12. 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 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 100 outdoor air must be pro vided for combustion air requirements during construc tion Temporary ducting may supply outdoor air to the furnace 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 filters 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
13. 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 apublic 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 EL180UHE furnace must be installed so that its elec trical components are protected from water Page 3 Installed in Combination with a Cooling 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 1 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 1 Heating Unit Installed Parallel to Cooling Coil Dampers open during heating operation only lel d T Cooling Coil TS
14. necessary reposition the combustion air inducer pres sure switch and or make up box as needed per the follow ing steps See figures 16 through 20 1 Remove the four mounting screws figure 14 which secure the combustion air inducer pressure switch assembly to the orifice plate Lift the assembly and ro tate it 90 degrees clockwise or counterclockwise to ei ther the 3 o clock position or to 9 o clock position Re secure with four screws Gasket should be left in place 2 Use tin snips to cut preferred opening on the cabinet for repositioning the flue outlet Use the cut out piece as a cover plate to patch unused opening on cabinet Page 12 UPFLOW POSITION Left Side Vent Discharge Cover Plate Pressure Switch Collector Box Flue Transition AIR t FLOW 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 16 UPFLOW POSITION Right Side Vent Discharge Flue Transition Vent Pipe
15. per 4 000 Btu 1 17 kW per hour of the total input rating of all other equipment in the enclosure FIGURE 4 FIGURE 5 Page 7 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 EL180UHE gas furnace can be installed as shipped in either the upflow position or the horizontal position Select a location that allows 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 6 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 washd FIGURE 6 Upflow Applications Allow for clearances to combustible materials as indicated on the unit nameplate Minimum clearances for closet or al
16. 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 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 O 1 TABLE 8 GAS METER CLOCKING CHART Seconds for One Revolution i EL180UHE Unit Tcuft T2cu ft Dial DIAL 045 8 60 400 110 135 Natural 1000 btu cu ft EC el LP 2500 btu cu ft 80 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 8 If manifold pressure matches table 10 and rate is incorrect check gas orifices for proper size and restric tion Remove temporary gas me
17. 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 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 that space This space also includes adjacent rooms which are not Page 5 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 m 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 e
18. 0UHE 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 unit nameplate Minimum clearances for closet or al cove installations are shown in figure 11 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 12 or install the furnace on a platform as shown in figure 13 Typical Horizontal Application Unit Suspended in Attic or Crawlspace Metal Strap Bracket FIGURE 12 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 10 Page 10 CAUTION If this unit is being installe
19. 27 319 98 220 30 176 98 151 49 134 22 121 47 111 85 103 92 97 69 NOTE Capacity given in cubic feet m3 of gas per hour and based on 0 60 specific gravity gas Left Side Piping MANUAL Standard ZS AIN SHUT OFF AUTOMATIC MANUAL GAS VALVE Z VALVE MAIN SHUT OFF AUTOMATIC With 1 8 in NPT VALVE Plugged Tap With 1 8 in e des QASMALVE Shown Plugged Tap Shown GROUND JOINT GROUND JOINT UNION DRIP LEG Right Side Piping PROVIDED Alternate DRIP LEG AND INSTALLED NOTE BLACK IRON PIPE ONLY BE ROUTED INSIDE OF CABINET FIGURE 25 Page 21 100 50 1 42 1 42 104 2 94 2 94 195 400 11 33 600 17 00 1160 1840 52 10 3260 92 31 inches inches 10 20 30 40 50 60 70 80 90 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 12 7 17 799 4 87 3 34 2 69 2 29 2 03 1 84 1 69 1 58 1 47 11 86 5 52 Horizontal Applications Possible Gas Piping Configurations MANUAL MAIN SHUT OFF VALVE MANUAL MAIN Ore Horizontal Application Left Side Air Discharge GROUND JOINT UNION GROUND DRIP LEG DRIP LEG gt MANUAI MAIN SHUT OFF VALVE Sine JOINT UNION FIELD PROVIDED gt a AND INSTALLED Horizontal Application Right Side Air Disch
20. AN NAT FAN FAN FAN NAT SS 38 939 5 38 9 x 4 13 Ca w ms 3 x 3 __ 39 9 1 9 4 1 9 1 5 Page 19 Removal of the Furnace from Common Vent 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 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 In the event that an existing furnace 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 re 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 cou
21. LENNOX 2013 Lennox Industries Inc Dallas Texas USA HORIZONTAL LEFT AIR FLOW HORIZONTAL RIGHT Unit Dimensions 2 EL180UHE Gas Furnace 3 Shipping and Packing List 3 Safety Information 3 Use of Furnace as a Construction Heater 4 General 1c is bpexebRD 4 Combustion Dilution amp Ventilation Air 5 Setting 8 FilletS hee eru ars 11 Duct Systemi dade RM ena 11 Mic 12 01 13 Page 1 INSTALLATION INSTRUCTIONS EL180UHE ELITE SERIES GAS FURNACE UPFLOW HORIZONTAL AIR DISCHARGE 507138 01 01 2013 il Pr 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 ACAUTION As with any mechanical equipment personal injury can result from contact with sharp sheet metal edges Be careful when you ha
22. S MUST BE WIRED TO A PARK TERMINAL A DO NOT USE RED LOW SPEED MOTOR LEAD FOR HEATING SPEED ON 045 X E36A 070 X E36B 110 X E60C AND 135E60D UNITS RESULTING TEMPERATURE RISE WILL BE OUTSIDE OF RISE RANGE L13 POWER CHOKE USED ON 1 HP ONLY A USE COPPER CONDUCTORS ONLY 51 ROOM THERMOSTAT THERMOSTAT HEAT ANTICIPATION SETTINGS 65 AMP HONEYWELL VALVE 92 INTEGRATED CONTROL BROWN 2 GREEN YELLOW BURNER ASSY GROUND 8 92 INTEGRATED CONTROL FIGURE 29 Page 24 Integrated Control EE Diagnostic Codes Status of Furnace No power to control or board fault detected Board fault detected 1 Rollout Switch Open 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 Flame Sensed without gas valve energized Low Line Voltage Note 1 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 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 press Note 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 long
23. arge NOTE BLACK IRON PIPE ONLY TO BE ROUTED INSIDE OF CABINET DRIP LEG FIGURE 26 Leak Check After gas piping is completed carefully check all piping DUTOIT AVE ISOLATE connections factory and field installed for gas leaks Use WILL NOT HOLD GAS VALVE a leak detecting solution or other preferred means NORMAL TEST FURNACE PRESSURE NOTE If emergency shutoff is necessary shut off the main 1 8 NPT PLUG manual gas valve and disconnect the main power to the furnace The installer should properly label these devices FIGURE 27 Some soaps used for leak detection are corrosive to ELECTROSTATIC DISCHARGE ESD certain metals Carefully rinse piping thoroughly af ter leak test has been completed Do not use Precautions and Procedures matches candles flame or other sources of ignition to check for gas leaks CAUTION Electrostatic discharge can affect elec The furnace must be isolated by closing its individual tronic components Take precautions manual shut off valve and disconnecting from from the gas to neutralize electrostatic charge by supply system during any pressure testing of the gas sup touching your hand and tools to metal ply system at pressures greater than 1 2 psig 3 48 kPa 14 prior to handling the control inches w c 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 A RTANT to the right side of
24. before installation In addition to the requirements outlined previously the fol lowing general recommendations must be considered when installing a EL180UHE 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 4 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 additional 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 The State of California has determined that this prod uct may contain or produce a chemical or chemicals in very low doses which may cause serious illness or death It may also cause cancer birth defects or reproductive harm Combustion Dilution amp Ventilation Air In the past there was no problem in bringing in sufficient out door air for combustio
25. bly 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 Start Up amp Performance Check List UNIT SET UP typical Unit Model Number Serial Number 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 Line Voltage AIR upflow furnace shown Filter RETURN AIR x Page 31 L LJ LJ LJ L LJ 9 LJ L 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 UNIT OPERATION typical Combustion COs SUPPLY AIR Gas Manifold Pressure Q Thermostat Temperatures L upflow furnace shown Filter RETURN AIR
26. cal equipment personal injury can result from contact with sharp sheet metal edges Be careful when you handle this equipment Certifications EL180UHE 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 Vent 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 7 and 11 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
27. d in a space serviced by an exhaust fan power exhaust fan or other device which may create a negative pressure in the space take care when sizing the inlet air opening The in let air opening must be sized to accommodate the maximum voiume of exhausted air as weii as the maximum volume of combustion air required for all gas appliances serviced by this space Horizontal Application Unit Installed on Platform Line contact is permissible but not preferred See the unit nameplate for clearances FIGURE 13 AWARNING Improper installation of the furnace can result in per sonal injury or death Combustion and flue 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 conta
28. d to the common venting system are located nace The piping must be supported at proper intervals and other spaces of the building Turn on clothes dry every 8 to 10 feet 2 44 to 3 01 m with suitable hang ers and any appliances not connected to the common ers or straps Install a drip leg in vertical pipe runs to the venting system Turn on any exhaust fans such as unit range hoods ang batirgom S0 hey wil oper 5 A 1 8 N P T plugged tap or pressure post is located ate at maximum speed Do not operate a summer ex i haust fan Closefireolace dampers on the gas valve to facilitate test gauge connection P P See figure 31 4 Follow the lighting instructions Turn on the appliance that is being inspected Adjust the thermostat so that 6 In some localities codes may require the installation of the appliance operates continuously a manual main shut off valve and union furnished by 5 After the burner have operated for 5 minutes test for the installer external to the unit The union must be of leaks of flue gases at the draft hood relief opening Use the ground joint type the flame of a match or candle 6 After determining that each appliance connected to the A common venting system is venting properly step 3 return all doors widows exhaust fans fireplace damp Compounds used on threaded joints of gas piping ers and any other gas burning appliances to their pre must be resistant to the
29. diameter recommendations and maximum allow able piping runs are found in the provided venting tables In no case should the vent or vent connector diameter be less than the diameter specified in the provided venting tables 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 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 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 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 table 3 are assumed to have no elbows in the vent system For all other vent co
30. e 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 refrigerants 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
31. e side return air with transition to accommodate 20 25 x 1 in 508 x 635 x 25 mm cleanable air filter Re quired to maintain proper air velocity See figure 8 2 Single side return air with optional return airbase See fig ure 9 3 Bottom return air 4 Return air from both sides 5 Bottom and one side return air Refer to Engineering Handbook for additional information Optional Return Air Base Single Side Return Air with transition and filter 20 X25 X1 508mm X 635mm X 25mm Cleanable Filter Return Air Plenum Transition FIGURE 8 Upflow Applications Only For use with A B C and D cabinets FURNACE WITHOUT EORR IAQ CABINET ASINGLE QUALITY RETURN AIR CABINET PLENUM AIR FLOW PCO Filter MUST Cabinet etc COVER BOTH UNIT AND RETURN AIR BASE OPENINGS J 4 1 2 368 A Width e ET 17 1 2 446 B Width 50W98 AIR BASE 21 533 C Width 50W99 24 1 2 622 D Width 51W00 ages FT a Overall Maximum X Minimum 11 279 T 2 122 7716 1 Unit side return air 14 356 570 PNE NEL etis 5 5 3 SIDE RETURN 143 AIR OPENINGS Either Side 23 584 26 7 8 683 SIDE VIEW NOTE Optional Side Return Air Filter Kits are not for use with Optional Return Air Base 1 Both the unit return air ope
32. ed 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 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 b
33. ed 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 ina horizontal application The panel may also be removed in upflow applications Shipping and Packing List Package 1 of 1 contains 1 Assembled EL180UHE 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 find any damage immediately contact the last carrier 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 ACAUTION As with any mechani
34. ed to any portion of mechanical draft systems operating under positive pressure such as Category III or IV venting systems 17 If vent connectors are combined prior to entering the common vent the maximum common vent capacity listed in the common venting tables must be reduced by 1096 the equivalent of one 90 elbow 0 90 x maximum common vent capacity 18 The common vent diameter must always be at least as large as the largest vent connector diameter 19 In no case shall the vent connector be sized more than two consecutive table size diameters over the size of the draft hood outlet or flue collar outlet 20 Do not install a manual damper barometric draft regu lator or flue restrictor between the furnace and the chimney 21 When connecting this appliance to an existing dedi cated or common venting system you must inspect the venting system s general condition and look for signs of corrosion The existing vent pipe size must conform to these instructions and the provided venting tables If the existing venting system does not meet these re quirements it must be resized 3 Capacity of Double Wall Vents with Double Wall Connectors Serving a Single Category Appliance Vent and Connector Diameter D inches um ih L feet Appliance Input Rating in Thousands of Btu Per Hour Ean See CAE aa i a ir ar a p
35. ent 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 closure See figures 3 and 4 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 5 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 6
36. er than 5 seconds TABLE 7 Automatic Hot Surface Ignition System 110 JEE A NEUTRALS PARE power BLOWER OFF DELAY BEREED RECALL BUTTON FIGURE 30 Page 25 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 ACAUTION Before attempting to perform any service or mainte nance turn the electrical power to unit OFF at dis connect switch BEFORE 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 EL180UHE 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 EL180UHE units are equipped with an automatic ignition system Do not attempt to manually light bu
37. er that is suitable 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 EL180UHE 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 30 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 30 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 circuit 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 t
38. etween 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 32 Page 28 HEAT FAN OFF TIME IN SECONDS HEAT OFF DELAY JUMPER POSITION PINI PIN2 PIN2 PIN3 PIN3 PIM PINS 180 NO JUMPER 80 To adjust fan off timing reposition jumper across pins to achieve desired setting 90 Second 120 Second off Time off Time 60 Second off Time 180 Second off Time FIGURE 32 Constant Torque Motor EL180UHE 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 te
39. g or heating demand 2 When the EL180UHE 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 23 EL180UHE Schematic Wiring Diagram COMBUSTION AIR INDUCER 518 COMBUSTION AIR PROVING SWITCH ON OFF oo GAS VALVE GV1 PRIMARY GA J159 P159 IGNITER FLAME ROLLOUT SWITCH BURNERS FLAME SENSOR DOOR INTERLOCK F1 1 TRANSFORMER 51 ROOM THERMOSTAT DIAGNOSTIC PUSH BUTTON OUTDOOR UNIT INDOOR BLOWER MOTOR LINE VOLTAGE FIELD INSTALLED CLASS II VOLTAGE FIELD WIRING 78 DENOTES OPTIONAL COMPONENTS EQUIPMENT GROUND pm BLACK CIRC 4 3 POWER CHOKE FLAME WHITE SENSOR PINK COMBUSTION AIR INDUCER MOTOR YELLOW WARNING ELECTRIC SHOCK HAZARD CAN CAUSE INJURY OR DEATH UNIT MUST BE GROUNDED IN ACCORDANCE WITH NATIONAL AND LOCAL CODES BLOWER SPEED CHART FACTORY CONNECTED SPEED TAPS UNIT COOL HEAT PARK BLACK BLUE RED BROWN YELLOW 135E60D BROWN BLUE BLACK YELLOW BLOWER SPEED SELECTION AE a LO SPEED TAPS BLACK BROWN BLUE YELLOW RED JAcKPLUGCHART _ NOTE IF ANY WIRE IN THIS APPLIANCE IS REPLACED IT MUST BE REPLACED WITH WIRE OF LIKE SIZE RATING INSULATION THICKNESS AND TERMINATION A R REQUIRED ON SOME OUTDOOR UNITS PARK TERMINALS ARE UNPOWERED TERMINALS ALL UNUSED MOTOR LEAD
40. in 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 IMPORTANT If a high efficiency filter is being installed as part of this system to ensure better indoor air quality the fil ter must be properly sized High efficiency filters have a higher static pressure drop than standard ef ficiency glass foam filters If the pressure drop is too great system capacity and performance may be re duced The pressure drop may also cause the limit to trip more frequently during the winter and the indoor coil to freeze in the summer resulting in an increase in the number of service calls Before using any filter with this system check the specifications provided by the filter manufacturer against the data given in the appropriate Lennox Product Specifications bulletin Additional informa tion is provided in Service and Application Note ACC 00 2 August 2000 A filter must be in place any time the unit is operating TABLE 1 cantera ea enon Raa 7 Cabinet Width A 14 1 2 16X25X1 1 20 X 25 X 1 1 17 1 2 16 X 25 X 1 1 16 X 25 X 1 1 D 24 1 2 16 X25 X1 2 24 X25 X 1 1 Duct System Use industry approved standards such as those pub lished by Air Conditioning Contractors of America or Ameri
41. ional Return Air Base EXTERNAL a 23 3 4 SIDE RETURN 603 AIR FILTER KIT lag 25 Either Side 635 TOP VIEW 1 1 2 38 27 3 4 Front Panel 705 A 3 1 4 83 9 1t 14 9 16 14 3 76 Right 19 7 16 l aa 7 178 Left 494 i apr FLUE OUTLET Either Side Gui GAS PIPING INLET 9 1 8 232 Right 3 OPTIONAL 8 5 8 219 Lett EXTERNAL ither Side ENgBuummmmmmumu SIDE RETURN a aeeececeaeaa p AIRFILTERKIT i s Either Side a 33 5 3 8 137 Right_ ELECTRICAL INLET 838 2 3 4 70 Left e Either Side P i 1 1 23 38 14 3 4 x 584 z n Side Return 14 16 Air Opening 356 UT 406 n Either Side AIR FLOW Y IoT oy Y 1 15 16 49 y 5 8 19 C 34 19 3 1 4 23 1 2 19 83 597 1 Bottom Return 1Bottom Return Air Opening Air Opening FRONT VIEW SIDE VIEW EL180UHE Model No 045 X E36A 070 X E36B 090 X E48B 090E60C 110 X E60C 533 135E60D 24 1 2 622 EL180UHE Gas Furnace The EL180UHE unit is shipped ready for installation in the upflow or horizontal right position for horizontal left posi tion the combustion air pressure switch must be moved fuel
42. ld result in carbon mon shall be installed at the gas valve and extend outside the furnace cabinet The flexible connector can then be added between the black iron pipe and the gas 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 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 1 Seal any unused openings in the common venting sys 2 When connecting the gas supply piping consider fac t i tors such as length of run number of fittings and fur nace rating to avoid excessive pressure drop Table 6 2 Inspect the venting system for proper size and horizontal lists recommended pipe sizes for typical applications pitch Determine that there is no blockage restriction 3 The gas piping must not run in or through air ducts leakage corrosion or other deficiencies which could clothes chutes gas vents or chimneys dumb waiters cause an unsafe condition or elevator shafts Close all building doors and windows and all doors be 4 The piping should be sloped 1 4 inch 6 4 mm per 15 tween the space in which the appliances remaining feet 4 57 m upward toward the meter from the fur connecte
43. n 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 downdraft 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 EL180UHE 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 caus
44. ndle this equipment Gas PIPING sees PEE rete xd sns 20 Electrical acie Rp o gu RA Epp 22 Integrated Control 25 Unit Start Up sesers res maat cee 26 Gas Pressure Adjustment 27 High Altitude ecole beak tne se 27 Proper Combustion 27 Other Unit Adjustments 28 Service xs ques dpt bod n ERE Y REC ADR e RR RN GN 29 Repair Parts List 30 Start Up Check List 31 507138 01 HINARI A Unit Dimensions inches mm 1 3 1 8 79 NOTE 60C and 60D size units that require air volumes over 1800 cfm 850 L s must have one of the following TE m i uugua 1 Single side return air with transition to accommodate D 20 x 25 x 1 in 508 x 635 x 25 cleanable air filter Required to maintain proper air velocity i 2 Single side return air with optional Return Air Base ee a 3 Bottom return air FLUE OUTLET SUPPLY AIR 4 Return air from both sides Top ifii OPENING 5 Bottom and one side return air See Blower Performance Tables for additional information n 2 Flue outlet be horizontal but furnace must be vented vertically _ 3 Optional External Side Return Air Filter Kit is not for use 3 OPTIONAL with the opt
45. nfigurations 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 0 90 x maximum listed capacity The common venting tables 4 and 5 were generated 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 Common Venting Using Tile Lined Interior Masonry Chimney and Combined Vent Connector MINIMUM LENGTH AS SHORT AS PRACTICAL FOR MAXIMUM LENGTH SEE NOTE TO LEFT NOTE Refer to provided venting tables for installations p 2d oT u A INTERIOR TILE LINED MASONRY CHIMNEY a 5 NOTE the chimney must be properly sized per provided venting tables or OTHER APPLIANCE VENT CONNECTOR FURNACE lined with listed metal lining system ES PERMANENTLY SEALED FIREPLACE OPENING FIGURE 24 Page 16 9 f 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 2 feet 46 m for each inch 25 mm of common vent diameter
46. ning 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 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 9 Page 9 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 10 Removing the Bottom Panel Bottom Cap Horizontal Application Installation Clearances Top Bottom Vent Connector EN NNNM EN 2 1 4 in 57 mm 2 1 4 in 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 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 11 Horizontal Applications The EL18
47. ntegral mechanical means to either draw or force combustion products through the combustion chamber and or heat exchanger The EL180UHE 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 2223 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 22 Install the first vent connector elbow at a minimum of six inches 152 mm from the furnace vent outlet See figure 22 Venting Using a Masonry Chimney The following additional requirements apply when a lined masonry chimney is used to vent this furnace Masonry chimneys used to vent Category central fur naces must be either tile lined
48. o use an external relay relay One 24V H 1 4 spade terminal is provided on the furnace integrated control See figure 30 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 e The furnace requires 120 volts 10 Range 108 volts to 132 volts e The furnace operates at 60 Hz 5 Range 57 Hz to 63 Hz e The 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 29 for thermostat designations If the furnace is being matched with a heat pump refer to the FM21 installation instruction or appropri ate dual fuel thermostat instructions 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 coolin
49. operate follow the instructions Turning Off Gas to Unit and call your service techni cian or gas supplier Turning Off Gas to Unit 1 Setthe 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 s 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 Is the manual main shut off valve open 8 Is the internal manual shut off valve open 9 Is unit ignition system 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 26 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 29 for more detail 1 When thermostat calls for heat combustion air blower starts 2 Combustion air pressure
50. or lined with a listed metal lining system or dedicated gas vent Unlined masonry chimneys are prohibited See figures 23 and 24 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 23 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 22 The warning sticker is provided in the bag assembly Or der kit 66W04 for additional stickers Page 14 VENT CONNECTION UPFLOW AND HORIZONTAL POSITION DISCONNECTED VENT WARNING STICKER VENT PIPE min 6 length DDDDD oooog DDDDD DDDDD
51. out 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 A 4 inch diameter flue transition is factory installed on the combustion air inducer outlet of all models Figure 15 shows the combustion air inducer as shipped from the factory Mounting Screws Location Flue Transition Mauntina Screws FIGURE 14 UPFLOW POSITION Top Vent Discharge Flue Vent Pipe Transition Pressure Switch Collector Box Make Up Box AIR FLOW FIGURE 15 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 o clock position If
52. ow ee p xp pp ee a 9v jh ose nt a ips ee Lp sp eed ce r9 speres ep EE mE PM MEC ORG a 575 455 Juge ce sp oum a unl secu o NER UNT DNE ERR DECEDERE ONE EGRE ED ee or 3139 3139 ME NEUSS S Game 191 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 4 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 Ree unes eC 2 Appliance Input Rating in Thousands of Btu Per Hour TABLE 5 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 Appliance input Rating in Thousands ofBtuPerHour FANS FAN FAN NAT FAN FAN FAN NAT FAN FAN F
53. pliance 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 EL180UHE 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 Page 15 A type 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 ELT80UHE furnaces according to these instruc tions 1 5 5 Vent
54. rminal or insulate 1 Refer to blower speed selection chart on unit wiring dia gram for desired heating or cooling speed See Product Specifications manual for blower performance data 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 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 A WARNING 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 Blo
55. rners 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 31 1 STOP Read the safety information at the beginning of this section 2 Set the 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 31 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 gas supplier s instruc tions If you do not smell gas go to next step MANIFOLD PRESSURE MANIFOLD PRESSURE OUTLET PORT PRESSURE PORT GAS VALVE SHOWN IN ON POSITION FIGURE 31 8 Move switch on gas valve to ON Do not force See fig ure 31 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
56. specially 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 CHIMNEY OR GAS VENT EQUIPMENT IN CONFINED SPACE ALL AIR FROM INSIDE FURNACE X 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 2 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 mm2 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 2 Air from Outside If air from outside is brought in for combustion and ventila tion the confined space must have two perman
57. ter 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 10 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 should burn blue 4 After allowing unit to stabilize for 5 minutes record manifold pressure and compare to value given in table 10 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 9 Nat P
58. the furnace to facilitate installation If the When testing pressure of gas lines gas valve must make up box is moved to the right side clip the wire ties be disconnected and isolated See figure 27 Gas that bundle the wires together The excess wire must be valves can be damaged if subjected to pressures pulled into the blower compartment Secure the excess greater than 1 2 psig 3 48 kPa 14 inches w c wire to the existing harness to protect it from damage Page 22 INTERIOR MAKE UP BOX INSTALLATION Right Side FIGURE 28 Refer to figure 29 for schematic wiring diagram field wiring and trouble shooting The power supply wiring must meet Class 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 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 service Complete the wiring connections to the equipment Use the provided unit wiring and field wiring diagram shown in fig ure 29 Use 18 gauge wire or larg
59. wer 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 EL180UHE 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 Replacement 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 10 3 Check amp draw on the blower motor with blower ac cess panel in place Unit Nameplate Cleaning the 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 Actual Page 29 2 3 4 Label the wires from gas valve rollout switches prima ry limit switch and make up box then disconnect them Disconnect gas supply piping
60. witch 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 RIGHT POSITION Top Vent Discharge Vent Pipe Pressure Switch Flue Transition Cover Plate Collector Box aN 1 Make Up 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 20 HORIZONTAL RIGHT POSITION Side Vent Discharge no modifications necessary Make Up Box Pressure Switch Vent Pipe Flue Transition Collector Box FIGURE 21 The EL180UHE series units are classified as fan assisted Category furnaces when vertically vented according to the latest edition of National Fuel Gas Code NFPA 54 ANSI Z223 1 in the USA A fan assisted Category fur nace is an appliance equipped with an i
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