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EL180DFE
Service Literature
Corp. 1301-L1
Revised 09/2017
EL180DFE series units are mid-efficiency gas furnaces used for downflow applications only, manufactured with
Lennox Duralok t heat exchangers formed of aluminized steel. EL180DFE units are available in heating capacities of 44,000 to 110,000 Btuh and cooling applications 1.5 to 5 tons. Refer to Engineering Handbook for proper sizing.
Units are factory equipped for use with natural gas. Kits are available for conversion to LP/Propane operation.
EL180DFE model units are equipped with a hot surface igni tion system and a constant torque ECM motor. The motor is programmed to provide constant torque at each of the five selectable speed taps. All units use a redundant gas valve to assure safety shut-off as required by C.S.A.
All specifications in this manual are subject to change. Pro cedures outlined in this manual are presented as a recom mendation only and do not supersede or replace local or state codes. In the absence of local or state codes, the guidelines and procedures outlined in this manual (except where noted) are recommended only and do not constitute code.
WARNING
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 HVAC in staller (or equivalent), service agency or the gas sup plier.
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARNING
Electric shock hazard. Can cause injury or death. Before attempting to perform any service or maintenance, turn the electrical power to unit OFF at discon nect switch(es). Unit may have multiple power supplies.
WARNING
Fire Hazard. Use of aluminum wire with this product may result in a fire, causing property dam age, severe injury or death. Use copper wire only with this product.
Blower Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . .
I Unit Components . . . . . . . . . . . . . . . . . . . . . . . .
II Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAUTION
Failure to use properly sized wiring and circuit breaker may result in property damage. Size wiring and circuit breaker(s) per Product Specifications bulletin (EHB) and unit rating plate.
III Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IV Heating System Service Checks . . . . . . . . .
V Typical Operating Characteristics . . . . . . . . .
VI Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . .
VII Wiring and Sequence of Operation . . . . . .
Page 1
CAUTION
As with any mechanical equipment, contact with sharp sheet metal edges can result in personal in jury. Take care while handling this equipment and wear gloves and protective clothing.
© 2017 Lennox Industries Inc.
SPECIFICATIONS
Gas
Heating
Performance
Model No.
EL 180DF045E36A EL 180DF070E36B EL 180DF090E48B EL 180DF110E60C
1 AFUE 80% 80% 80% 80%
Input - Btuh 44,000 66,000 88,000 110,000
Output - Btuh 35,200 52,800 70,400 88,000
Temperature rise range - °F 15 - 45 30 - 60 30 - 60 30 - 60
Gas Manifold Pressure (in. w.g.)
Nat. Gas / LPG/Propane
3.5 / 10.0
3.5 / 10.0
3.5 / 10.0
3.5 / 10.0
High Static - in. w.g.
0.50
0.50
0.50
0.50
Connections in.
Flue connection - in. round
Gas pipe size IPS
4
1/2
4
1/2
4
1/2
4
1/2
Indoor
Blower
Wheel nom. dia. x width - in.
Motor output - hp
10 x 8
1/2
10 x 10
1/2
10 x 10
3/4
11-1/2 x 10
1
Tons of add-on cooling 1.5 - 3 1.5 - 3 2.5 - 4 3 - 5
Air Volume Range - cfm 355 - 1430 310 - 1345 680 - 1750 990 - 2410
Electrical
Data
Voltage
Blower motor full load amps 6.8
120 volts - 60 hertz - 1 phase
6.8
8.4
10.9
Shipping Data
Maximum overcurrent protection lbs. - 1 package
12
113
12
128
12
140
12
160
1
NOTE - Filters and provisions for mounting are not furnished and must be field provided.
Annual Fuel Utilization Efficiency based on DOE test procedures and according to FTC labeling regulations. Isolated combustion system rating for non-weatherized furnaces.
OPTIONAL ACCESSORIES - MUST BE ORDERED EXTRA
“A” Width
Models
CABINET ACCESSORIES
11M59 Downflow Combustible Flooring Base
FILTERS
1 Downflow Filter Cabinet
No. and Size of filter - in.
51W06
(1) 20 x 16 x 1
NIGHT SERVICE KITS
Night Service Kit
Safety Service Kit
1 Cleanable polyurethane, frame-type filter.
84W47
89W19
“B” Width
Models
11M60
51W07
(2) 20 x 20 x 1
84W47
89W19
“C” Width
Models
11M61
51W08
(2) 20 x 20 x 1
84W47
89W19
GAS HEAT ACCESSORIES
Input
045
070
090
110
High Altitude
Pressure Switch Kit
Natural Gas to
LPG/Propane Kit
0 - 4500 ft.
4501 - 7500 ft. 7501 - 10,000 ft.
0 - 7500 ft.
7501 - 10,000 ft.
No Change No Change 80W51 11K49 11K44
No Change
No Change
No Change
80W52
80W52
80W57
80W51
80W51
80W52
11K49
11K49
11K49
11K44
11K44
11K44
LPG/Propane to Natural Gas Kit
0 - 7500 ft.
73W81
73W81
73W81
73W81
Natural Gas
High Altitude
Orifice Kit
7501 - 10,000 ft.
73W37
73W37
73W37
73W37
Page 2
BLOWER DATA
E L180DF045E36A PERFORMANCE (Less Filter)
External
Static
Pressure in. w.g.
cfm
High
Watts
Air Volume / Watts at Various Blower Speeds
Medium-High cfm Watts cfm
Medium
Watts
Medium-Low cfm Watts
0.00
0.10
0.20
1430
1400
1375
285
285
300
1215
1175
1145
180
185
200
1035
995
950
120
130
140
995
885
840
110
100
110
0.30
0.40
0.50
0.60
0.70
0.80
1335
1320
1275
1245
1215
1175
315
325
335
345
355
365
1120
1075
1045
1000
970
925
210
220
230
235
245
255
915
870
835
785
745
695
145
155
165
170
180
185
790
745
715
655
605
555
115
125
135
140
150
155 cfm
930
850
725
665
625
565
520
355
400
Low
Watts
100
90
85
95
100
105
115
130
130
E L180DF070E36B PERFORMANCE (Less Filter)
External
Static
Pressure in. w.g.
0.00
0.10
0.20
0.30
0.40
0.50
0.60
cfm
1475
1430
1400
1360
1310
1280
1250
High
Watts
275
290
295
310
325
335
350
Air Volume / Watts at Various Blower Speeds
Medium-High cfm
1345
1275
1230
1205
1155
1110
1060
Watts
170
175
190
205
210
220
235 cfm
1225
1190
1125
1085
1050
985
935
Medium
Watts
135
145
160
160
175
185
195
Medium-Low cfm
1185
1155
1110
1055
1000
950
865
Watts
125
135
150
155
165
180
185
0.70
0.80
1220
1165
355
365
1000
935
245
250
865
795
205
210
815
750
195
200 cfm
1110
1005
900
845
790
705
645
590
480
Low
Watts
105
95
100
115
115
130
135
140
145
E L180DF090E48B PERFORMANCE (Less Filter)
External
Static
Pressure in. w.g.
cfm
High
Watts
Air Volume / Watts at Various Blower Speeds
Medium-High cfm Watts cfm
Medium
Watts
Medium-Low cfm Watts
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
1750
1725
1695
1660
1615
1570
1545
N/A
N/A
385
390
405
415
430
450
465
N/A
N/A
1550
1495
1470
1425
1395
1360
1295
1265
1215
265
270
285
300
310
325
340
350
365
1430
1390
1340
1290
1250
1210
1165
1120
1080
205
220
235
240
255
265
280
295
305
1355
1320
1280
1225
1185
1145
1085
1040
1000
185
195
210
215
230
240
255
265
275 cfm
1195
1145
1105
1040
1005
945
865
810
755
Low
Watts
130
140
145
160
170
180
185
200
210
Page 3
BLOWER DATA
E L180DF110E60C PERFORMANCE (Less Filter)
External
Static
Pressure in. w.g.
cfm
High
Watts
Air Volume / Watts at Various Blower Speeds
Medium-High cfm Watts cfm
Medium
Watts
Medium-Low cfm Watts
0.00
0.10
0.20
2410
2385
2325
625
630
650
2095
2100
2010
405
415
440
1875
1830
1760
295
310
330
1700
1610
1570
225
240
255
0.30
0.40
0.50
0.60
0.70
0.80
2280
2235
2165
2125
2090
2035
675
690
710
735
740
760
1940
1895
1845
1800
1755
1700
460
475
490
510
530
540
1705
1635
1595
1545
1510
1460
340
365
380
390
405
425
1500
1440
1380
1320
1285
1255
260
285
300
310
325
345 cfm
1635
1505
1375
1320
1265
1200
1170
1100
1030
Low
Watts
180
190
195
210
225
235
250
260
275
Page 4
Blower Assembly
EL180DFE PARTS ARRANGEMENT
Secondary Limit
Flue Chase
Control Box
(includes integrated control, transformer, inter lock switch and circuit breaker)
Primary Limit
(under combustion air inducer)
Combustion
Air Inducer
Gas Valve
Burner Box
(includes sensor, ignitor and rollout switches)
Heat Exchanger
Access Panel
FIGURE 1
Page 5
I-UNIT COMPONENTS
EL180DFE unit components are shown in figure 1.The gas
valve, combustion air inducer and burners can be ac cessed by removing the heating compartment access pan
el. Electrical components are in the control box (figure 2)
found in the blower section.
WARNING
Electric Shock Hazard. Can cause injury or death. Unit must be properly grounded in accordance with national and local codes.
CAUTION
Electrostatic discharge can affect elec tronic components. Take precautions to neutralize electrostatic charge by touching your hand and tools to metal prior to handling the control.
1. Control Transformer (T1)
A transformer located in the control box provides power to the low voltage section of the unit. Transformers on all models are rated 40VA with a 120V primary and a 24V sec ondary.
2. Door Interlock Switch (S51)
A door interlock switch is wired in series with line voltage.
When the blower door is removed the unit will shut down.
CONTROL BOX EL180DFE
INTEGRATED CONTROL
(A92)
DOOR INTERLOCK
SWITCH (S51)
CIRCUIT
BREAKER
(CB8)
TRANSFORMER
(T1)
FIGURE 2
3. Circuit Breaker (CB8)
A 24V circuit breaker is also located in the control box. The switch provides overcurrent protection to the transformer
(T1). The breaker is rated at 3A at 32V. If the current ex ceeds this limit the breaker will trip and all unit operation will shutdown. The breaker can be manually reset by pressing the button on the face.
4. Integrated Control (A92)
WARNING
Shock hazard.
Disconnect power before servicing. Control is not field repairable. If control is inoperable, simply re place entire control.
Can cause injury or death. Unsafe operation will re sult if repair is attempted.
The hot surface ignition control system consisting of an in
6). The integrated control and ignitor work in combination
to ensure furnace ignition and ignitor durability. The inte grated control, controls all major furnace operations. The integrated control also features a RED LED for trouble shooting and two accessory terminals rated at (1) one
amp. See table 4 or 5 for troubleshooting diagnostic
codes. The nitride ignitor is made from a non-porous, high strength proprietary ceramic material that provides long life and trouble free maintenance.
Electronic Ignition (Figure 4)
On a call for heat the integrated control monitors the com bustion air inducer pressure switch. The control will not be gin the heating cycle if the pressure switch is closed (bypassed). Once the pressure switch is determined to be open, the combustion air inducer is energized. When the differential in the pressure switch is great enough, the pres sure switch closes and a 15-second pre-purge begins. If the pressure switch is not proven within 2-1/2 minutes, the integrated control goes into Watchguard-Pressure Switch mode for a 5-minute re-set period.
After the 15-second pre-purge period, the ignitor warms up for 20 seconds during which the gas valve opens at 19 sec onds for a 4-second trial for ignition. The ignitor remains energized for the first 3 seconds during the 4 second trial. If ignition is not proved during the 4-second period, the inte grated control will try four more times with an inter purge and warm-up time between trials of 35 seconds. After a to tal of five trials for ignition (including the initial trial), the inte grated control goes into Watchguard-Flame Failure mode.
After a 60-minute reset period, the integrated control will begin the ignition sequence again.
Page 6
PIN #
1
2
3
4
PIN #
6
7
4
5
1
2
3
8
9
10
11
12
TABLE 1
4-Pin Terminal Designation
FUNCTION
Combustion Air Inducer Line
Ignitor Line
Combustion Air Inducer Neutral
Ignitor Neutral
TABLE 2
12-Pin Terminal Designations
FUNCTION
High Limit Output
Not Used
24V Line
Not Used
Rollout Switch Out
24V Neutral
High Limit Input
Ground
Gas Valve Common
Pressure Switch In
Rollout Switch In
Gas Valve Out
INTEGRATED CONTROL
(Automatic Hot Surface Ignition System)
TABLE 3
120HUM
LINE
XFMR
CIRC
EAC
NEUTRALS
HUM24
1/4” QUICK CONNECT TERMINALS
Humidifier 120VAC
120VAC
Transformer 120VAC
Indoor blower 120VAC
Indoor air quality accessory 120VAC
COOL
HEAT
FAN
PARK (no power)
FS
24 COM
Common 120VAC
Humidifier 24VAC
3/16” QUICK CONNECT TERMINALS
Cooling tap 24VAC
Heating tap 24VAC
Continuous blower 24 VAC
Park terminal for speed taps
Flame sense
Common 24VAC
RED LED
RECALL BUTTON
FIGURE 3
BLOWER OFF DELAY
Page 7
RED LED
Flash Code
Off
Heartbeat 1
1
2
3
6
7
4
5
10
11
12
8
9
13
Note 1
Note
Note
RED LED
Flash Code 2
Off
Heartbeat 1
Continuous Rapid Flash
1
2
5
6
3
4
7
8
9
10
11
12
13
Note 1
Note 2
Note3
TABLE 4 (-02 Integrated Control)
Diagnostic Codes / Status of Furnace
No power to control or board fault detected
Control powered - displayed during all modes of operation if no errors are detected
Reverse Line Voltage Polarity
Improper Earth Ground
Burner failed to light, or lost flame during heat demand
Low Flame Signal - check flame sensor
Watchguard - burner failed to light, exceeded maximum number of retries or recycles.
Not Used
Primary or Secondary Limit Open or Watchguard Mode - Limit Switch Open longer than 3 minutes
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
Notes
A ”Heartbeat” is indicated by a ”Slow Flash” - 1 sec on 1 sec off, repeating
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 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.
TABLE 5 (-03 Integrated Control)
Diagnostic Codes / Status of Furnace
No power to control or board fault detected
Normal Operation - Idle, Continuous Fan, Cool
Call For Heat / Burner Operation
Reverse Line Voltage Polarity
Improper Earth Ground
Burner failed to light, or lost flame during heat demand
Low Flame Signal - check flame sensor
Watchguard - burner failed to light, exceeded maximum number of retries or recycles.
Ignitor Circuit Failure - not available on this control
Primary or Secondary Limit Open or Watchguard Mode - Limit Switch Open longer than 3 minutes
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
Notes
A ”Heartbeat” is indicated by a ”Slow Flash” - 1 sec on 1 sec off, repeating
Error codes are indicated by a “rapid flash” - the LED flashes X times at ½ second on ½ second off, remains off for 3 seconds then repeats.
Last 10 error codes are stored in memory including when power is shut off to the unit. - To recall, 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 8
1 15
ELECTRONIC IGNITION
34 38 80 5 SEC
ÉÉ
ON
OFF
Pre -Purge Ignitor Warm-up
Trial for
Ignition
Blower “On”*
Delay
Post
Purge
ÉÉ
DEMAND
CAI
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
IGNITOR
GAS VALVE
INDOOR BLOWER
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉ ÉÉÉÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉ
*Blower on time will be 30 seconds after flame is sensed. Blower off time will depend on “OFF TIME” Setting.
Fan Time Control
Heating Fan On Time
The fan on time of 30 seconds is not adjustable.
Heating Fan Off Time
Fan off time (time that the blower operates after the heat demand has been satisfied) can be adjusted by moving the
FIGURE 4
Cooling Fan Off Time
The control has a 45 second fan off delay after cooling de mand has been met. This delay is factory set and not ad justable.
HEAT FAN‐OFF TIME IN SECONDS jumper to a different setting. The unit is shipped with a fac tory fan off setting of 90 seconds. For customized comfort, monitor the supply air temperature once the heat demand is satisfied. Note the supply air temperature at the instant the blower is de-energized.
Adjust the fan-off delay to achieve a supply air temperature between 90° - 110° at the instant the blower is de-ener gized. (Longer delay times allow for lower air temperature, shorter delay times allow for higher air temperature). See
Cooling Fan On Time
The fan on time is 2 seconds and is not adjustable.
NO JUMPER
To adjust fan-off timing, reposition jumper across pins to achieve desired setting.
60 Second off Time
90 Second off Time
120 Second off Time
180 Second off Time
FIGURE 5
Page 9
Rollout Switch
(Alternate Location)
Rollout Switch
Sensor
EL180DFE HEATING COMPONENTS
Internal Flue Pipe
Orifice Plate
Gaskets
Ignitor
Collector Box
Pressure Switch
Combustion Air Inducer
Gas Valve / Manifold Assembly
5. Flame Rollout Switches (Figure 6)
Flame rollout switch (S47) is a high temperature limit. Each furnace is equipped with two identical switches. The limit is a N.C. SPST manual‐reset limit connected in series with the integrated control A92. When S47 senses rollout, the integrated control immediately stops ignition and closes the gas valve. If unit is running and flame rollout is detected, the gas valve will close and integrated control will be dis abled. Rollout can be caused by a blocked heat exchanger, blocked flue or lack of combustion air. The switch has a fac tory setpoint of 210°F and cannot be adjusted. To manually reset a tripped switch, push the reset button located on the control.
6. Primary Limit Control
FIGURE 6
A flame sensor is located on the left side of the burner sup port. The sensor is mounted on the flame rollout plate and the tip protrudes into the flame envelope of the left-most burner. The sensor can be removed for service (clean us ing steel wool) without removing any part of the burners.
During operation, flame is sensed by current passed through the flame and sensing electrode. The integrated control allows the gas valve to remain open as long as flame signal is sensed.
A microamp DC meter is needed to check the flame signal on the integrated control.
Flame (microamp) signal is an electrical current which passes from the integrated control to the sensor during unit operation.
Current passes from the sensor through the flame to ground to complete a safety circuit.
The primary limit on EL180DFE units is located in the heating
vestibule panel under the combustion air inducer. See figure 1.
When excess heat is sensed in the heat exchanger, the limit will open. If the limit is open, the integrated control energizes the supply air blower and closes the gas valve. The limit auto matically resets when unit temperature returns to normal. The switch must reset within three minutes or SureLight ® control will go into Watchguard for one hour. The switch is factory set and cannot be adjusted. The switch may have a different setpoint for each unit model number. If limit switch must be replaced, refer to Lennox ProductZone repair parts list on
Lennox DaveNet®.
Page 10
To Measure Flame Signal - Integrated Control:
Use a digital readout meter capable of reading DC micro
amps. See figure 7 and table 6 for flame signal check.
1 - Set the meter to the DC amps scale.
2 - Turn off supply voltage to control.
3 - Remove sensor wire from integrated control.
4 - Connect (-) lead to flame sensor wire.
5 - Connect (+) lead to Terminal FS on integrated control.
6 - Turn supply voltage on and close thermostat contacts to cycle system.
7 - When main burners are in operation for two minutes, take reading.
TABLE 6
Normal
Flame Signal in Microamps
Low Drop Out
1.5
0.5 - 1.4
0.4
Measuring Flame Signal
(upflow furnace shown)
Flame
Sensor
Remove Sensor Wire from
Integrated Control and
Connect Alligator Clip ( − ) to Flame Sensor Lead
Flame Sensor
Wire
Integrated
Control
(+)
Flame Sensor
Terminal
(+) To Control
Sensor
Terminal
Remove Sensor Wire from
Integrated Control and
Connect Alligator Clip (+) to Terminal on Control
DIGITAL METER
Set dial to measure dc microamps
( − ) To flame sensor
Red Collar
Indicates
Positive Lead
(+)
FIGURE 7
Page 11
The nitride ignitor used on EL180DFE units is made from a proprietary ceramic material. To check ignitor, measure its resistance and voltage. A value of 39 to 70 ohms indicates a good ignitor. Voltage to the ignitor should be 120VAC.
See figure 8 for resistance, and voltage check.
Test 1
Check ignitor circuit for correct resistance .
Remove 4-pin plug from control.
Check ohms reading across terminals 2 and 4.
If value is correct (39 to 70 ohms), this is the only test needed.If the reading on the meter is not correct,
(0 or infinity) then a second test is needed.
NOTE - The EL180DFE furnace contains electronic components that are polarity sensitive. Make sure that the furnace is wired correctly and is properly grounded.
Test 1
Integrated Control Bo
Detail
Test 2
Check ignitor for correct resistance .
Seperate the 2-pin jack-plug near the manifold and check resistance of ignitor at the plug. Reading should be between 39 and 70 ohms. If the reading is correct, then the problem is with the wiring between the jack-plug and the control. If reading is not correct, the issue is the ignitor.
Integrated Control Board
Detail
Test 3
Check ignitor for correct voltage
Insert meter probes into terminals 2 and 4 (use small diameter probes in order not to damage plug).
Check voltage during 20 second ignitor warm up period.
Voltage should read 120 volts + 10%. If voltage reads below these values, check for correct supply voltage to furnace.
FIGURE 8
Page 12
Integrated Control Board
Detail
The EL180DFE uses internally redundant gas valve to as sure safety shut-off. If the gas valve must be replaced, the same type valve must be used.
24VAC terminals and valve switch are located on the valve. All terminals on the gas valve are connected to wires from the in tegrated control. 24V applied to the terminals energizes the valve.
Inlet and outlet pressure taps are located on the valve. A regu lator adjustment screw is located on the valve.
LPG changeover kits are available from Lennox. Kits include burner orifices and a gas valve regulator spring.
10. Combustion Air Inducer (B6)
All EL180DFE units use a combustion air inducer to move air through the burners and heat exchanger during heating operation. The blower uses a 120VAC motor. The motor operates during all heating operation and is controlled by integrated control A92. The inducer also operates for 15 seconds before burner ignition (pre‐purge) and for 5 sec onds after the gas valve closes (post‐purge).
A pressure switch mounted on the combustion air inducer ori fice plate is used to prove inducer operation. The combustion
air inducer orifice will be different for each model. See table 7
for orifice sizes. The switch monitors air pressure in the induc er housing. During normal operation, the pressure in the housing is negative. If pressure becomes less negative (sig nifying any obstruction in the flue) the pressure switch opens.
When the proving switch opens, the integrated control (A92) immediately de-energizes the gas valve to prevent burner operation.
TABLE 7
EL180DFE Unit C.A.I. Orifice Size
045E36A
070E36B
090E48B
110E60C
1.045”
1.316”
1.531”
1.690”
MULTI − METER
SET TO MEASURE OHMS
11. Combustion Air Inducer
Pressure Switch (S18)
EL180DFE series units are equipped with a combustion air pressure switch located on the combustion air inducer ori fice bracket. The switch is connected to the combustion air inducer housing by means of a flexible silicone hose. It mon itors negative air pressure in the combustion air inducer housing.
The switch is a single‐pole single‐throw proving switch elec trically connected to the furnace control. The purpose of the switch is to prevent burner operation if the combustion air in ducer is not operating or if the flue becomes obstructed.
On start‐up, the switch senses that the combustion air in ducer is operating. It closes a circuit to the integrated con trol when pressure inside the combustion air inducer de creases to a certain set point. Set points vary depending on
unit size. See table 8. The pressure sensed by the switch is
negative relative to atmospheric pressure. If the flue be comes obstructed during operation, the switch senses a loss of negative pressure (pressure becomes more equal with atmospheric pressure) and opens the circuit to the in tegrated control and gas valve. A bleed port on the switch allows relatively dry air in the vestibule to purge switch tub ing, to prevent condensate build up.
TABLE 8
EL180DFE
045E36A
070E36B
090E48B
110E60C
Make inches w.c.
Break + 0.05
-0.75
-0.80
-0.75
-0.80
-0.60
-0.65
-0.60
-0.65
The switch is factory set and is not field adjustable. It is a safety shut‐down control in the furnace and must not be bypassed for any reason. If switch is closed or by-passed, the integrated control will not initiate ignition at start up.
Troubleshooting
See figure 9 for measuring operating pressure and check
ing resistance in the pressure switch.
Remove tubing from
CAI and insert “Tee” and additional tubing.
High
Field Provided Tubing
To CAI Port
To Pressure Switch
+
or
FIGURE 9
Page 13
Low
12. Blower Motor
IMPORTANT
Each blower is statically and dynamically bal anced as an assembly before installation in the unit.
EL180DFE 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 speed taps. Each tap requires 24 volts to en ergize.
Input Voltage Requirements
The circuit is designed to be operated with AC voltage. To enable a tap requires 12 to 33VAC. Expected current draw will be less than 20mA.
Troubleshooting the Motor
Troubleshooting the motor is an easy process. Follow steps below.
1- Shut off power to unit.
2- Remove input plugs P48 and P49 from motor. See
figure 13 for troubleshooting procedure.
If correct voltage is present in tests 1 and 2 and motor is not operating properly, replace motor. The motor is not field re pairable.
If replacing the indoor blower motor or blower wheel is nec essary, placement is critical. The blower wheel must be cen
tered in the blower housing as shown in figure 10. When re
placing the indoor blower motor the set screw must be aligned and tightened with the motor shaft as shown in figure
13. Secondary Limit Controls
The secondary limit is located in the blower compartment on
the back side of the blower housing. See figure 12. When ex
cess heat is sensed in the blower compartment, the limit will open. If the limit is open, the furnace control energizes the sup ply air blower and closes the gas valve. The limit automatically resets when unit temperature returns to normal. The secon dary limit cannot be adjusted.
BLOWER WHEEL REPLACEMENT
Center Blower Wheel in Blower Housing
FIGURE 10
ALIGN AND TIGHTEN SET SCREW WITH
FLAT SIDE OF MOTOR SHAFT
Housing Hub
Set Screw
Motor
Shaft
FIGURE 11
SECONDARY LIMIT CONTROL
Secondary Limit
Blower Assembly
FIGURE 12
Page 14
P49
5
4
3
2
1
Multi − Meter
(set to VAC)
12
0
N
G
L
C
Test 1
P48
Turn on power to unit. Check for 120 volts across terminals
“L” and “N” on input plug P48. If voltage is present continue to test 2. If voltage is not present problem may be may be up stream of plug P48 and proceed to test 3.
Multi − Meter
(set to VAC)
12
0
Test 3 (if necesssary)
Check for 120 volts across terminals “CIRC” and “Neutrals” on the integrated control. If voltage is present, problem is with the harness. If voltage is not present problem may be may be with the integrated control.
P49
5
4
3
2
1
Multi − Meter
(set to VAC)
24
Multi − Meter
(set to VAC)
24
N
G
L
C
P48
Test 2
Switch thermostat to CONTINUOUS FAN MODE. Check for
24 volts across terminal “C” on inpult plug P48and speed tap used for continuous fan. (1, 2, 3, 4 or 5) on input plug P49. If
24 volts is not present problem may be up stream of plug P49.
Proceed to test 4.
FIGURE 13
Page 15
Test 4 (if necessary)
Check for 24 volts across terminals “24 COM” and “FAN” ter minals on the integrated control. If voltage is present, prob lem is with the harness. If voltage is not present problem may be may be with the integrated control
Replacing the Motor Module
1. Disconnect electrical power to unit.
2. Remove unit access panel.
3. Unplug the two harnesses from the motor control mod
Motor Test
Unplug the Two Harness Connection
TWO HARNESS
CONNECTIONS
MOTOR
MOTOR CONTROL MODULE
FIGURE 14
Scale
2 M
200 K
20 K
2 K
200
FIGURE 16
TABLE 9
Measurement range in words two megohm-two million ohms two hundred kilo-ohm-two hundred thousand ohms twenty kilo-ohm-twenty thousand ohms two kilo-ohm two-thousand ohms two hundred ohms ohms
0 - 2,000,000
0 - 200,000
0 - 20,000
0 - 2,000
0 - 200
4. Remove the two hex head bolts securing the motor
control module to the motor (see figure 15).
Remove the Hex Head Bolts
REMOVE BOTH HEX
HEAD BOLTS
FIGURE 15
5. Slide the motor control module away from the motor to access and disconnect the internal three wire connec tor. It is not necessary to remove blower motor itself.
Set both hex head bolts aside.
Motor Module Installation
All replacement motor control modules look similar; how ever, each module is designed for a specific motor size. It is very important to make sure that you are using the correct replacement motor control module. USE OF THE WRONG
MOTOR CONTROL MODULE MAY RESULT IN UNEX
PECTED UNIT OPERATION.
1. Verify electrical power to unit is disconnected.
2. Connect three-wire harness from motor to control module.
3. Mount new motor control module to motor using two hex head bolts
removed in figure 15. Torque bolts
to 22 inch pounds or 1/16 th clock turn as exampled to the right.
4. Reconnect the two harnesses to the motor control module.
9
10
8
11 12
7
6
1/16
TURN
1
2
4
3
5
5. The electrical connectors of the motor should be facing
down to form a drip loop (figure17). This will directs
moisture away from the motor and its electric connec tions on the motor.
Drip Loop
If any motor fails the below tests, do not install the new con trol module. The motor is defective and it also must be re placed. The new control can fail if placed on a defective mo tor.
1. Using an ohmmeter check the resistance from any one of the motor connector pins to the aluminum end plate of the motor. This resistance should be greater than
100k ohms.
2. Check the resistances between each of the three mo tor connector pins. These should all read approxim ately the same resistance within an ohm.
3. Check to see if the blower wheel spins freely.
Page 16
BACK OF CONTROL
MODULE
FIGURE 17
CONNECTOR
ORIENTATION
BETWEEN 4 AND 8
O'CLOCK
DRIP LOOP
II- PLACEMENT AND INSTALLATION
Make sure unit is installed in accordance with installation instructions and applicable codes.
III- START‐UP
A- Heating Start‐Up
WARNING
Shock and burn hazard.
EL180DFE units are equipped with a hot surface ignition system. Do not attempt to light manually.
Gas Valve Operation
MANIFOLD
PRESSURE
ADJUSTMENT
SCREW
MANIFOLD
PRESSURE
OUTLET
PORT
INLET
PRESSURE
PORT
GAS VALVE SHOWN IN ON POSITION
FIGURE 18
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 heating compartment access panel.
6 - Move gas valve switch to OFF position . Do not
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.
8 - Move gas valve switch to ON position . Do not force.
9 - Replace the heating compartment 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 the 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 heating compartment access panel.
4 - Move gas valve switch to OFF position . Do not
5 - Replace the heating compartment access panel.
B- Safety or Emergency Shutdown
Disconnect main power to unit. Close manual and main gas valves.
C- Extended Period Shutdown
Turn off thermostat or set to “UNOCCUPIED” mode. Close all gas valves (both internal and external to unit) to guaran tee no gas leaks into combustion chamber. Turn off power to unit. All access panels and covers must be in place and secured.
IV-HEATING SYSTEM SERVICE CHECKS
A- C.S.A. Certification
All units are C.S.A. design certified without modifications.
Refer to the EL180DFE Installation Instruction.
B- 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.
Compounds used on gas piping threaded joints should be resistant to action of liquefied petroleum gases.
C- Testing Gas Piping
CAUTION
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.
IMPORTANT
In case emergency shutdown is required, turn off the main shut‐off valve and disconnect the main power to unit. These controls should be properly labeled by the installer.
WARNING
Do not over torque (800 in-lbs) or under torque (350 in-lbs) when attaching the gas piping to the gas valve.
When pressure testing gas lines, the gas valve must be dis connected and isolated. Gas valves can be damaged if
subjected to more than 0.5 psig (14” W.C.). See figure 19
. If the pressure is equal to or greater than 0.5 psig (14”W.C.), close the manual shut-off valve before pressure testing to isolate furnace from gas supply.
Page 17
GAS PIPING TEST PROCEDURE
MANUAL MAIN SHUT-OFF VALVE
WILL NOT HOLD TEST PRESSURE
IN EXCESS OF 0.5 PSIG (14”W.C.)
CAP
GAS VALVE
FIELD PROVIDED
LINE PRESSURE TAP
FIGURE 19
When checking piping connections for gas leaks, use pre ferred means. Kitchen detergents can cause harmful corro sion on various metals used in gas piping. Use of a specialty
Gas Leak Detector is strongly recommended. It is available through Lennox under part number 31B2001. See Corp.
8411-L10, for further details.
Do not use matches, candles, flame or any other source of ignition to check for gas leaks.
D- Gas Pressure Adjustment
Gas Flow (Approximate)
EL180DFE
Unit
TABLE 10
GAS METER CLOCKING CHART
Seconds for One Revolution
Natural
1 cu ft
Dial
2 cu ft
Dial
1 cu ft
Dial
LP
2 cu ft
DIAL
-045
-070
-090
-110
80
55
41
33
160
110
82
66
200
136
102
82
-135 27 54 68
Natural-1000 btu/cu ft LP-2500 btu/cu ft
400
272
204
164
136
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 10. If manifold pressure matches table 12 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.
E- Supply and Manifold Pressure
Supply Pressure Measurement
1 - Remove the threaded plug from the inlet side of the gas valve and install a field-provided barbed fitting.
Connect to a test gauge to measure supply pressure.
2 - Start unit and allow 5 minutes for unit to reach steady state.
3 - After allowing unit to stabilize for 5 minutes, record supply pressure and compare to value given in table
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 test gauge 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
5 - Shut unit off and remove manometer as soon as an ac curate reading has been obtained. Take care to re place pressure tap plug .
6 - Start unit and perform leak check. Seal leaks if found.
F- 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 carbon monoxide reading should not exceed 100 ppm.
EL180DFE Unit
045
TABLE 11
CO
2
% For Nat CO
2
%
For LP
070
090
110
6.8 - 7.4
7.5 - 9.0
The maximum carbon monoxide reading is 100 ppm.
G- High Altitude
The manifold pressure may require adjustment and com bustion air pressure switch may need replacing to ensure
and gas conversion kits.
IMPORTANT
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 18
TABLE 12
Supply and Manifold Pressure Settings at all Altitudes
Model
Input Size
045
070
090
110
Gas
Nat
LP/propane
Nat
LP/propane
Nat
LP/propane
Nat
LP/propane
0-4500 ft
3.5
10.0
3.5
10.0
3.5
10.0
3.5
10.0
4501-7500 ft
3.5
10.0
3.3
10.0
3.3
10.0
3.3
10.0
7501 - 10,000 ft
3.5
10.0
3.5
10.0
3.5
10.0
3.5
10.0
11.0
4.5
11.0
4.5
11.0
Supply Pressure in.wg.
Min
4.5
11.0
4.5
Max
13.0
13.0
13.0
13.0
13.0
13.0
13.0
13.0
TABLE 13
Pressure Switch and Gas Conversion Kits at all Altitudes
Model
Input Size
High Altitude Pressure Switch Kit
High Altitude
Natural Gas Burner
Orifice Kit
7501 - 10,000 ft
Natural Gas to LP/Propane
Burner Orifice Kit
LP/Propane to
Natural Gas Burner
Orifice Kit
0 - 7500 ft
045
070
090
110
0-4500 ft
No Change
4501-7500 ft 7501 - 10,000 ft
No Change
80W52
No Change
80W52
80W51 73W37
0 - 7500 ft
11K49
7501 - 10,000 ft
11K44 73W81
NOTE -
A natural to LP./Propane gas changeover kit is necessary to convert this unit. Refer to the changeover kit installation instruction for the conversion procedure.
Page 19
H- Proper Ground and Voltage
A poorly grounded furnace can contribute to premature ig nitor failure. Use the following procedure to check for ground and voltage to the integrated control.
1 - Measure the AC voltage between Line Neutral (spade terminals) and “C” terminal (low voltage terminal
block) on the integrated control. See figure 20. A wide
variation in the voltage between Line Neutral and “C” as a function of load indicates a poor or partial ground.
Compare the readings to the table below. If the read ings exceed the maximum shown in table 1, make re pairs before operating the furnace.
2 - In addition, measure the AC voltage from Line Hot to
Line Neutral (spade terminals) on the integrated con
trol. See figure 21. This voltage should be in the range
of 97 to 132 Vac
TABLE 14
Furnace Status
Power On Furnace Idle
CAI / Ignitor Energized
Indoor Blower Energized
Measurement VAC
Expected Maximum
0.3
0.75
Less than 2
2
5
10
CHECK VOLTAGE BETWEEN LINE NEUTRAL
AND LOW VOLTAGE “C” TERMINAL
CHECK VOLTAGE BETWEEN LINE HOT
AND LINE NEUTRAL
FIGURE 20
FIGURE 21
V-TYPICAL OPERATING CHARACTERISTICS
A-Blower Operation and Adjustment
NOTE- The following is a generalized procedure and does not apply to all thermostat controls.
1 - Blower operation is dependent on thermostat control system.
2 - Generally, blower operation is set at thermostat sub base fan switch. With fan switch in ON position, blower operates continuously. With fan switch in AUTO position, blower cycles with demand or runs continuously while heating or cooling circuit cycles.
3 - Depending on the type of indoor thermostat, blower and entire unit will be off when the system switch is in
OFF position.
B-Temperature Rise (Figure 22)
Temperature rise for EL180DFE units depends on unit in put, blower speed, blower horsepower and static pressure as marked on the unit rating plate. The blower speed must be set for unit operation within the range of “TEMP. RISE
°
F” listed on the unit rating plate.
Page 20
TEMPERATURE RISE
Supply Duct Temperature
Return Duct Temperature _
Temperature Rise =
Upflow Furnace Shown
Supply Air
EXTERNAL STATIC PRESSURE
Supply Duct Static
Return Duct Static +
Total Duct Static =
(dry coil)
Upflow Furnace Shown
Supply Air
Return Air Return Air
FIGURE 23
High
Low or
+ -
FIGURE 22
C-External Static Pressure
1 - Tap locations shown in figure 23 .
2 - Punch a 1/4” diameter hole in supply and return air ple nums. Insert manometer hose flush with inside edge of hole or insulation. Seal around the hose with perma gum. Connect the zero end of the manometer to the discharge (supply) side of the system. On ducted sys tems, connect the other end of manometer to the return duct as above.
3 - With only the blower motor running and the evaporator coil dry, observe the manometer reading. Adjust blow er motor speed to deliver the air desired according to the job requirements. For heating speed external static pressure drop must not be more than 0.5” W.C. For cooling speed external static pressure drop must not be more than 0.8” W.C.
4 - Seal the hole when the check is complete.
VI-MAINTENANCE
Annual Furnace Maintenance
At the beginning of each heating season, and to comply with the Lennox Limited Warranty , your system should be checked by a licensed professional technician (or equiva lent) as follows:
1- Check wiring for loose connections, voltage at indoor unit and amperage of indoor motor
.
2- Check the condition of the belt and shaft bearings if ap plicable.
3- Inspect all gas pipe and connections for leaks
.
D-Blower Speed Taps
Blower speed tap changes are made on the integrated con trol. See figure NO TAG. The heating tap is connected to the “HEAT” terminal and the cooling tap is connected to the
“COOL” terminal. The continuous blower tap is connected to the “FAN” terminal. Unused taps must be secured on dummy terminals labeled ”PARK. To change out existing speed tap, turn off power and switch out speed tap with tap connected to “PARK”. See blower speed tap table on unit diagram for motor tap colors for each speed.
Page 21
4- Check the cleanliness of filters and change if necessary
(monthly).
Cabinet Width
A (14-1/2”)
B (17-1/2”)
C (21”)
TABLE 15
Return Air Filter Size (inches)
14 x 25 x 1 (1)
16 x 25 x 1 (1)
20 x 25 x 1 (1)
IMPORTANT
If a highefficiency filter is being installed as part of this system to ensure better indoor air quality, the fil ter must be properly sized. Highefficiency filters have a higher static pressure drop than standardef 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
ACC002 (August 2000).
5- Check the condition and cleanliness of burners and heat exchanger and clean if necessary.
6- Check the cleanliness of blower assembly and clean the housing, blower wheel and blower motor if neces sary
.
The blower motors are prelubricated for extended bearing life. No further lubrication is needed.
7- Inspect the combustion air inducer and clean if neces sary.
8- Evaluate the heat exchanger integrity by inspecting the heat exchanger per the AHRI heat exchanger inspec tion procedure. This procedure can be viewed at www.ahrinet.org
9- Ensure sufficient combustion air is available to the fur nace. Fresh air grilles and louvers (on the unit and in the room where the furnace is installed) must be properly sized, open and unobstructed to provide combustion air
.
10 Inspect the furnace venting system to make sure it is in place, structurally sound, and without holes, corrosion, or blockage. Vent system must be free and clear of ob structions and must slope upward away from the fur nace
.
Vent system should be installed per the National
Fuel Gas Code
14 Verify operation of CO detectors and replace batteries as required.
Perform a general system test. Turn on the furnace to check operating functions such as the start-up and shut-off operation.
1 - Check the operation of the ignition system, inspect and clean flame sensor. Check microamps before and after. Check controls and safety devices (gas valve, flame sensor, temperature limits). Consult Service
Manual for proper operating range. Thermal Limits should be checked by restricting airflow and not dis connecting the indoor blower. For additional details, please see Service and Application Note H049.
2 - Verify that system total static pressure and airflow set tings are within specific operating parameters.
3 - Clock gas meter to ensure that the unit is operating at the specified firing rate. Check the supply pressure and the manifold pressure. On two-stage gas furnaces check the manifold pressure on high fire and low fire. If manifold pressure adjustment is necessary, consult the Service Literature for unit specific information on adjusting gas pressure. Not all gas valves are ad justable . Verify correct temperature rise.
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, top cap, flue chase and internal flue pipe assembly 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 panel and remove the assembly from the unit.
7 - Remove screws from both sides, top and bottom of vestibule panel.
8 - 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.
11 Inspect the furnace return air duct connection to ensure the duct is sealed to the furnace. Check for air leaks on supply and return ducts and seal where necessary
.
12 Check the condition of the furnace cabinet insulation and repair if necessary.
9- Back wash using steam. Begin from the burner opening on each clam. Steam must not exceed 275°F.
13 Perform a complete combustion analysis during the fur nace inspection to ensure proper combustion and oper ation. Consult Service Literature for proper combustion values.
10- 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
Page 22
EL180DFE BURNER, COMBUSTION AIR INDUCER ASSEMBLY &
HEAT EXCHANGER REMOVAL gasket flue chase internal flue pipe combustion air inducer
Rollout Switch
(Alternate Location)
Rollout Switch
Sensor orifice plate gasket collector box pressure switch retention rings heat exchanger cross over
FIGURE 24
11- 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.
21- If a leak is detected, shut gas and electricity off and repair leak.
22- Repeat steps 21 and 23 until no leaks are detected.
12- Reinstall heat exchanger in vestibule. (Replace the five screws in the cabinet from step 10 if removed).
23- Replace access panel.
Remove five screws if necessary
(either side of cabinet) 13- Reinstall collector box, combustion air assembly, inter nal flue pipe and flue chase. Seal with high tempera ture RTV . 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.
14- Reinstall burner box, manifold assembly and burner box cover.
15- Reconnect all wires.
16- Reconnect top cap and vent pipe to combustion air in ducer outlet.
4
17- Reconnect gas supply piping.
18- Turn on power and gas supply to unit.
19- Set thermostat and check for proper operation.
20- Check all piping connections, factory and field, for gas leaks. Use a leak detecting solution or other preferred means. Some soaps used for leak detection are corrosive to certain metals. Carefully rinse piping thoroughly after leak test has been completed. Do not use matches, candles, flame or other sources of ignition to check for gas leaks.
5
FIGURE 25
1
3
2
Page 23
VII- Wiring and Sequence of Operation
EL180DFE Schematic Wiring Diagram and Sequence of Operation
3
10
1
2 4
5
7
5
9
6
8
1
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 S47 rollout 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 A92 integrated control runs a self-check. S10 primary limit and S21 secondary limit contacts are found to be closed. Call for heat can continue.
5 A92 integrated control energizes B6 combustion air inducer. S18 combustion air pressure switch closes . Once S18 closes, a 15-second pre-purge follows.
6 A92 integrated control energizes R33 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 24VAC to Heat speed of B3 indoor blower.
10 - When heat demand is satisfied, W1 of the indoor thermostat de-energizes W of A92 integrated 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.
Page 24
Troubleshooting: Heating Sequence of Operation
HEATING SEQUENCE OF OPERATION
ABNORMAL HEATING MODE
NORMAL HEATING MODE
POWER ON
CONTROL SELF-CHECK OKAY?
NO
GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.
INDOOR BLOWER DELAY OFF.
LED SLOW FLASH
(RESET CONTROL BY TURNING MAIN POWER OFF.)
YES
IS POLARITY CORRECT?
YES
IS THERE A PROPER GROUND?
YES
NO
NO
LED FLASHES CODE 1 - POLARITY REVERSED.
LED FLASHES CODE 2 - IMPROPER GROUND.
NO
IS VOLTAGE
ABOVE 70 VOLTS?
LED FLASHES CODE 13 - LOW LINE VOLTAGE.
CONTROL WILL NOT RESPOND TO A CALL FOR
HEATING UNTIL VOLTAGE RISES ABOVE 75 VOLTS.
YES
ROLLOUT SWITCH CLOSED?
YES
NO
LED FLASHES CODE 8 - ROLLOUT SWITCH OPEN.
GAS VALVE OFF. COMBUSTION AIR INDUCER ON.
INDOOR BLOWER ON.
SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES
AND POWER IS RESET OR T'STAT IS INTERRUPTED
FOR MINIMUM OF 1 SECOND.
NO
BURNER OFF?
( Flame sensed without gas valve energized )
YES
NORMAL OPERATION:
LED SLOW FLASH
YES
THERMOSTAT CALLS FOR HEAT:
LED SLOW FLASH
YES
PRIMARY LIMIT SWITCH. CLOSED?
YES
IS COMBUSTION AIR
PRESSURE SWITCH OPEN?
YES
IS COMBUSTION AIR INDUCER
ENERGIZED?
YES
HAS COMBUSTION AIR PRESSURE
SWITCH CLOSED IN 2.5 MINUTES?
YES
CONTINUED NEXT PAGE
NO
NO
NO
LED FLASHES CODE 12 - FLAME SENSED
WITHOUT GAS VALVE ENERGIZED.
GAS VALVE OFF. COMBUSTION AIR INDUCER ON.
INDOOR BLOWER ON HEATING SPEED.
LED FLASHES CODE 7 - PRIMARY LMIT
OPEN. COMBUSTION AIR INDUCER
OFF.INDOOR BLOWER ON
LED FLASHES CODE 11 - PRESSURE
SWITCH CLOSED.
GAS VALVE OFF COMBUSTION AIR
INDUCER OFF. INDOOR BLOWER
OFF WITH DELAY.
(Sequence holds until pressure switch opens or thermostat resets control.)
NO
LED FLASHES CODE 9 - PRESSURE SWITCH FAILED
TO CLOSE OR OPENED DURING HEAT DEMAND.
PRESSURE SWITCH IS IN WATCHGUARD MODE. GAS
VALVE OFF. COMBUSTION AIR INDUCER OFF.
INDOOR BLOWER OFF WITH DELAY. IS 5‐MINUTE
RESET PERIOD COMPLETE?
YES
Page 25
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
NO
IGNITOR WARM‐UP -- 20 SECONDS.
YES
4‐SECOND TRIAL FOR IGNITION.
GAS VALVE OPENS. IGNITOR ENERGIZED FOR
FIRST 3 SECONDS OF THE TRIAL.
YES
FLAME STABILIZATION PERIOD.
4 SECONDS
IS VOLTAGE ABOVE 70 VOLTS?
YES
NO
LED FLASHES CODE 13 -
LOW LINE VOLTAGE.
ONCE VOLTAGE IS ABOVE
75 VOLTS, HEATING
SEQUENCE RESTARTS.
NO
GAS VALVE OFF. COMBUSTION AIR INDUCER ON.
INDOOR BLOWER OFF.
HAS CONTROL FAILED TO SENSE FLAME FOR
FIVE CONSECUTIVE TRIES DURING A SINGLE
HEAT DEMAND?
NO
YES
FLAME RECTIFICATION CURRENT
CHECK. CAN FLAME BE PROVEN WITHIN
4 SECONDS AFTER GAS VALVE OPENS?
(0.5 microamps)
YES
LED SIGNAL WATCHGUARD FAILURE CODE
WATCHGUARD MODE. GAS VALVE OFF.
COMBUSTION AIR INDUCER OFF.
INDOOR BLOWER OFF WITH DELAY
IS 60‐MINUTE RESET PERIOD COMPLETE?
YES
FLAME PRESENT?
NO
HAS CONTROL RESET IGNITION
SEQUENCE FOUR TIMES?
NO
YES
YES
FLAME SIGNAL 1.5 MICROAMPS OR GREATER?
YES
INDOOR BLOWER ON
AFTER 30-SECOND DELAY
YES
PRIMARY LIMIT SWITCH CLOSED?
YES
ROLLOUT SWITCH CLOSED?
YES
COMBUSTION AIR PRESSURE
SWITCH CLOSED?
YES
THERMOSTAT DEMAND SATISFIED.
YES
LED SLOW FLASH.
YES
COMB. AIR INDUCER CONTINUES 5‐SECOND
POST PURGE AFTER T'STAT DEMAND IS SATISFIED.
INDOOR AIR BLOWER COMPLETES SELECTED “OFF”
DELAY BEFORE SHUTTING OFF.
NO
LED FLASHES CODE 4 - LOW FLAME
SIGNAL.
(Does not affect operation of control)
NO
LED FLASHES CODE 7 - PRIMARY LIMIT OPEN
GAS VALVE DE-ENERGIZED.
COMBUSTION AIR INDUCER DE-ENERGIZED.
INDOOR BLOWER ON UNTIL SWITCH CLOSES.
LIMIT SWITCH CLOSED?
YES
YES
HAS PRIMARY LIMIT RESET
TIME EXCEEDED 3 MINUTES?
LED FLASHES CODE
7 - PRIMARY LIMIT
OPEN. GAS VALVE,
COMB. AIR INDUCER
AND INDOOR BLOW
ER OFF. LEDs SIG
NAL LIMIT SWITCH
OPEN UNTIL MAIN
POWER IS
INTERRUPTED OR
T'STAT IS CYCLED
OFF/ON FOR 1 SEC.
MINIMUM. 60-MINUTE
WATCHGUARD PE
RIOD STARTS AT
TIME LIMIT CLOSES.
IS 60-MIN. PERIOD
COMPLETE?
NO
NO
LED FLASHES CODE 8 - ROLLOT SWITCH OPEN.
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
THERMOSTAT IS CYCLED OFF/ON FOR 1 SEC. MINIMUM.
NO
HAS PRESSURE SWITCH OPENED 5 TIMES
IN THE SAME HEAT DEMAND?
NO YES
GAS VALVE DE-ENERGIZED. COMBUSTION AIR
INDUCER ON. INDOOR BLOWER OFF WITH
DELAY. HAS CAB PRESSURE SWITCH CLOSED
WITHIN 2.5 MINUTES?
NO
5‐MINUTE PRESSURE SWITCH
WATCHGUARD MODE.
YES
LED FLASHES
CODE 10
1 HR PRESSURE
SWITCH
WATCHGUARD
MODE
Page 26
Troubleshooting: Cooling Sequence of Operation
COOLING SEQUENCE OF OPERATION
NORMAL COOLING MODE
POWER ON
ABNORMAL COOLING MODE
IGNITION CONTROL MAIN POWER ON.
CONTROL SELF DIAGNOSTIC CHECK.
IS CONTROL OPERATING NORMALLY?
YES
IS THERE A PROPER GROUND?
YES
IS POLARITY CORRECT?
YES
IS VOLTAGE
ABOVE 70 VOLTS?
YES
NO
ROLLOUT SWITCH MONITORED CONTINUOUSLY.
IS ROLLOUT SWITCH CLOSED?
YES
NO
GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.
INDOOR BLOWER OFF WITH NORMAL DELAY.
SIGNAL CIRCUIT BOARD FAILURE AT LED.
INTERRUPT MAIN POWER TO RESET CONTROL.
NO
NO
LED FLASHES CODE 2 IMPROPER GROUND
CONTROL WILL CONTINUE TO CALL FOR COOLING
IN THIS CONDITION.
LED FLASHES CODE 1 POLARITY REVERSED
CONTROL WILL CONTINUE TO CALL FOR COOLING IN
THIS CONDITION.
NO
LED FLASHES CODE 13 LOW VOLTAGE. CONTROL
WILL CONTINUE TO CALL FOR COOLING
IN THIS CONDITION.
LED FLASHES CODE 8 ROLLOUT SWITCH OPEN. GAS
VALVE OFF. COMBUSTION AIR INDUCER ON. INDOOR
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 COOLING.
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 27
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).
NO YES
THERMOSTAT CALLS FOR COOLING.
YES
SYSTEM FAN SWITCHED TO COOL SPEED.
EAC TERM. REMAINS ON.
NO
SYSTEM FAN CONTINUES FAN SPEED WITHOUT
INTERRUPTION. EAC TERMINAL REMAIN ON.
HUM TERMINAL IS ENERGIZED WITH COMBUSTION
AIR BLOWER.
THERMOSTAT OPENS.
MANUAL FAN SELECTION MADE AT THERMOSTAT.
CONTROL (G) ENERGIZES SYSTEM FAN AT FAN
SPEED. EAC TERM. ENERGIZED.
SYSTEM FAN SWITCHES TO HEAT SPEAD AFTER 30
SECOND DELAY. EAC AND HUM TERMINAL REMAIN ON.
THERMOSTAT OPENS.
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 28
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