Lennox EL180UHNEK Series Unit Information

With r-454b series units

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Installation instructions manual (41 pages)

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S e r v i c e L i t e r a t u r e

EL180UHNEK series units are mid-efficiency gas furnac-

es used for upflow or horizontal applications only, manu-

factured with heat exchangers formed of aluminized steel

tubes. EL180UHNEK units are available in heating capac-

ities of 40,000 to 100,000 Btuh and cooling applications 2

to 5 tons. Refer to Engineering Handbook for proper siz-

ing.

EL180UHNEK model units are equipped with a hot sur-

face ignition system. The EL180UHNEK unit meets the

new California 14 ng/J Nitrogen Oxides (NOx) Standards

and California Seasonal Efficiency requirements. All units

use a redundant gas valve to assure safety shut-off as

required by

C.S.A.

All specifications in this manual are subject to change.

Procedures outlined in this manual are presented as a

recommendation only and do not supersede or replace lo-

cal 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

This furnace is equipped with an ignition control

factory enabled for use with A2L refrigerant systems.

Disabling the refrigerant detection functionality on

A2L system is prohibited by safety codes. Refer

to furnace installation instructions for refrigerant

system setup.

TABLE OF CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2

Blower Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3

Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . Page 5

Twinning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 6

I Unit Components . . . . . . . . . . . . . . . . . . . . . . . . Page 7

II Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page2I

II Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 21

IV Heating Systems Checks . . . . . . . . . . . . . . . Page 21

V Typical Operating Characteristics . . . . . . . . . Page 29

VI Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . Page 30

VII Low GWP Application. . . . . . . . . . . . . . . . . . . . . .Page 33

VIII Wiring and Sequence of Operation

IX-Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . .Page 37

UNIT INFORMATION

EL180UHNEK With R-454B SERIES UNITS

. . . . . . Page 36

100157

Improper installation, adjustment, alteration, service

or maintenance can cause property damage, personal

injury or loss of life. Installation and service must be

performed by a licensed professional HVAC installer or

equivalent, service agency, or the gas supplier.

Electric shock hazard. Can cause injury

or death. Before attempting to perform

any service or maintenance, turn the

electrical power to unit OFF at disconnect

switch(es). Unit may have multiple power

supplies.

Page 1

EL180UHNEK

WARNING

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Summary of Contents for Lennox EL180UHNEK Series

Page 1 S e r v i c e L i t e r a t u r e EL180UHNEK With R-454B SERIES UNITS EL180UHNEK series units are mid-efficiency gas furnac- es used for upflow or horizontal applications only, manu- factured with heat exchangers formed of aluminized steel tubes.
Page 2 S PECIFIC ATIO N S Model EL180UH EL180UH EL180UH EL180UH Heating 040NE36AK 060NE36AK 080NE48BK 100NE60CK Performance AFUE Input - Btuh 40,000 60,000 80,000 100,000 Output - Btuh 33,000 48,000 64,000 80,000 Temperature rise range - °F 20 - 50 30 - 60 30 –...
Page 3 HIGH A LTITUD E OPERATION Units may be installed at altitudes up to 7500 ft. above sea level without any modification. R EFRIG ERA NT DE TECTION SYSTEM ( RDS) CO M P O NENTS Description Order No. 27V53 Refrigerant Detection System (RDS) Coil Sensor Kit B LO WER DATA EL180UH040NE36AK PERFORMANCE (Less Filter) Air Volume / Watts at Various Blower Speeds...
Page 4 EL180UH080NE48B PERFORMANCE (Less Filter) Air Volume / Watts at Various Blower Speeds External Static High Medium-High Medium Medium-Low Pressure (Black) (Brown) (Blue) (Yellow) (Red) in. w.g. Watts Watts Watts Watts Watts 0.00 1881 1709 1560 1495 1293 0.10 1828 1640 1503 1440 1240...
Page 5 Heat Exchanger Combustion Air Inducer Gas Valve Screen Reducer 2” PVC Pipe 2 ½” Length Elbow Intake Air Elbow Control Box (includes integrated control, Inner Access Access Panel interlock switch and transformer) Panel Blower Assembly Power Choke (4 and 5 Ton Only) FIGURE 1 Page 5...
Page 6 The 24 VAC secondary of the two systems must be in Twinning phase. All thermostat connections are made to one control The control board in this furnace is equipped with a provi- only. See diagram below. sion to ”twin” (interconnect) two(2) adjacent furnaces with The twinned furnace without thermostat connections is a common plenum such that they operate as one (1) large to have the call for heat supplied by an external 24VAC...
Page 7 I-UNIT COMPONENTS 3. Circuit Breaker (CB8) A 24V circuit breaker is also located in the control box. The EL180UHNEK unit components are shown in FIGURE switch provides overcurrent protection to the transform- 1.The gas valve, combustion air inducer and burners can er (T1).
Page 8 Indoor Blower Operation DIP Switch Settings TABLE 1 The heat fan-on time of 30 seconds is not adjustable The 1/4” QUICK CONNECT TERMINALS heat fan-off delay (amount of time that the blower oper- 120V HUM POWER FOR HUMIDIFIER (120 VAC ates after the heat demand has been satisfied) may be LINE INCOMING POWER LINE (120 VAC)
Page 9 Single Stage, Constant, Torque, Non-Communicating 107792-XX FIGURE 3 Indoor Blower Speeds 1 - When the thermostat is set to “FAN ON,” the indoor blower will run continuously on the fan speed when there is no cooling or heating demand. See TABLE 11 2 - When the EL180UHNEK is running in the heating mode, the indoor blower will run on the heating speed.
Page 10 On Board Links Must NOT Be Cut To Select Thermostat Wiring Connections AC ON System Options Heat / Cool FURNACE OUTDOOR T'STAT TERM. STRIP UNIT DO NOT CUT ANY ON-BOARD LINKS FIGURE 4 Wiring Connections On Board Links Must Be Cut To Select Thermostat Heat Pump Options Dual Fuel...
Page 11 TABLE 4 Integrated Diagnostic Codes/Status of Equipment Code Diagnostic Codes/Status of Equipment Indoor Blower Operation: Continuous Fan only mode Defrost mode Idle mode (Decimal blinks at 1 Hertz -- 0.5 second ON, 0.5 second OFF). Cooling stage (1 second ON, 0.5 second OFF) 1 or 2 displayed / Pause / Repeat codes. Dehumidification mode (1 second ON, 1 second OFF) / Pause / Repeat Codes).
Page 12 The sensor #1 is of a type not suitable for use in the application. incorrect Replace the sensor with a Lennox approved replacement part. This fault clears when a sensor suitable for the application is detected by the furnace control board, but blower will latch for a minimum of 5 minutes.
Page 13 TABLE 4 Continued Code Diagnostic Codes/Status of Equipment Action Required to Clear and Recover E164 Low GWP Test Low GWP Test mode activates by manually engaging Low GWP test button. Normal operations resumes and code clears automatically after 1-minute E200 Hard lockout - Rollout circuit open or previously Correct cause of rollout trip, or replace flame rollout switch.
Page 14 The switch is factory set and cannot be adjust- 5. Combustion Air Inducer (B6) ed. The switch may have a different set point for each unit model number. See Lennox Repair Parts Handbook if limit All EL180UHNEK units use a combustion air inducer to switch must be replaced.
Page 15 6. Combustion Air Inducer Prove Switch (S18) COMBUSTION AIR PRESSURE SWITCH EL180UHNEK series units are equipped with a com- bustion air pressure switch (FIGURE 8) located near the gas valve. The switch is connected to the combustion air inducer housing by means of a flexible silicone hose. It monitors negative air pressure in the intake air elbow.
Page 16 System Operating Pressure Measurement System Operating Pressure FIGURE 9 Page 16...
Page 17 Ignitor Check Out Test 1 Remove HSI/CAI 4-pin plug from control Check ohms reading across terminals 1and 5 Ohm value should be between 39 - 70. Meter (set to ohms) Integrated control detail Test 2 Seperate the 2-pin jack plug near the manifold and check resistance of the ignitor.
Page 18 C- Blower Compartment BLOWER WHEEL REPLACEMENT IMPORTANT Center Blower Wheel in Blower Housing Each blower is statically and dynamically balanced as an assembly before installation in the unit. 1. Indoor Motor EL180UHNEK 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.
Page 19 Multi−Meter (set to V AC) Multi-met (set to VAC) "9A” Test 3 (if necessary) NOTE- Ignition control illustration is typical "7A” Check for 120 volts across terminals “L1” and “Neutrals” on the Turn power on to unit. Check for 120 volts integrated control.
Page 20 Replacing the Motor Module Motor Test NOTE - Not all motors have field replaceable control mod- ules. Only motors that utilize a 4 pin power connector and 5 pin signal connector as shown below may have replace- able controls. Motors that use a 3 pin power connector and 6 pin signal connector do not have field replaceable control modules.
Page 21 II- PLACEMENT AND INSTALLATION 12 - If the appliance will not operate, follow the instructions “Turning Off Gas to Unit” and call the Make sure unit is installed in accordance with installation gas supplier. instructions and applicable codes. Turning Off Gas to Unit NOTE - For any Low GWP refrigerant systems with ex- posed line set joints installed in the same space, each 1 - Set the thermostat to the lowest setting.
Page 22 Air Orifice Replacment specialty Gas Leak Detector is strongly recommended. It Manifold Pressure / Signal Pressure is available through Lennox under part number 31B2001. See Corp. 8411-L10, for further details. 1 - Turn off the electrical power and gas supply to the furnace.
Page 23 Combustion TABLE 11 Furnace should operate minimum 15 minutes with correct Capacity Manifold Pressure manifold and system operating pressure before checking combustion. TABLE 13 shows acceptable combustion. The maximum carbon monoxide reading should not ex- 0.0 - 0.10 ceed 100ppm. TABLE 13 Acceptable CO Levels...
Page 24 Air Orifice Replacement TYPE B - Removing Air Intake Adapter From The Outside of Cabinet Do not replace the air orifice until the problem has been determined. If the unit has difficulty igniting the air orifice is oversized and brings in too much combustion air. If the unit ignites but with loud noise, go to Troubleshooting.
Page 25 TABLE 14 Air Orifice Replacement Capacity & Dash Difficult Igniting or Noisy Production (Need less combustion air) Single-Stage Catalog Air Orifice Size (Part Air Orifice Size (Part #) Catalog Number Models Number 0.745 (25) 23A27 0.730 (31) 25B92 1.030(30) 24G44 1.000 (02) 19X30 1.030 (30)
Page 26 Troubleshooting Poor Ignition and Noise Issues Is gas supply pressure Is the incoming voltage between 4.5” to 10” wc between 108V and 132V? Call a licensed electrician Call a licensed plumber or the electric comp. or the gas comp. Is the Combustion Air Intake assembled and installed correctly? See Figure 25.
Page 27 Troubleshooting Poor Ignition and Noise Issues Continued 060 models only: Install 30 in. air intake pipe. See figure 25. Troubleshooting is complete Is ignition or noise issue resolved ? Install Low Profile Combustion Air Intake Kit Catalog No. 25B23 Is ignition or noise issue resolved Troubleshooting is complete Contact tech support Page 27...
Page 28 H- Proper Ground and Voltage 2 - - In addition, measure the AC voltage from Line Hot to Line Neutral (spade terminals) on the A poorly grounded furnace can contribute to poor flame integrated control. See FIGURE 26. This voltage sense signal.
Page 29 V-TYPICAL OPERATING CHARACTERISTICS C-External Static Pressure 1 - Tap locations shown in FIGURE 28. A-Blower Operation and Adjustment 2 - Punch a 1/4” diameter hole in supply and return NOTE- The following is a generalized procedure air plenums. Insert manometer hose flush with and does not apply to all thermostat controls.
Page 30 AHRI heat exchanger At the beginning of each heating season, and to comply inspection procedure. This procedure can be with the Lennox Limited Warranty, your system should be viewed at www.ahrinet.org. See “Induced-draft checked by a licensed professional technician (or equiva- Furnace Heat Exchanger Inspection Procedure”.
Page 31 Cleaning the Heat Exchanger and Burners 12 - | Reinstall heat exchanger in vestibule. (Replace the five screws in the cabinet from step 10 if removed). NOTE - Use papers or protective covering in front of the 13 - | Reinstall the air fuel plenum and air intake furnace during cleaning.
Page 32 Heat Exchanger and Burner Removal Heat Exchanger Gaskets (replace) Air Fuel Plenum Gas Valve Air Intake Coupling Primary Limit FIGURE 31 Page 32...
Page 33 VII- Low GWP Application WARNING For use with Lennox approved evaporator coil and LGWP sensors only. Use original manufacturer recommended LGWP sensors if using non Lennox approved evaporator coil. CONNECTING THE FURNACE CONTROL BOARD SENSOR. See FIGURE 34 and follow steps below: FIGURE 33 1 - Route sensor wire #1 through provided grommet.
Page 34 FURNACE CONTROL BOARD LOW GWP MODES OF 2. The furnace control board activates the blower (high OPERATION speed). The blower purges refrigerant from the cabinet, plenum, and ductwork. The modes of operation for the furnace control board are Initializing, Normal, Leak Detected, and Fault. 3.
Page 35 LGWP TEST BUTTON FUNCTIONALITY External Alarm (For applications with external alarms wired directly to the The furnace control board is equipped with a Test/Reset furnace control board) push button. The Test button can be used to perform sev- The furnace control board triggers the external alarm sys- eral functions, depending on the mode of operation of the tem when it enters Leak Detected mode.
Page 36 VIII- Wiring and Sequence of Operation / Troubleshooting COMBUSTION AIR INDUCER COMBUSTION AIR PROVING SWITCH 120V ACC (IF USED) BLOWER SPEED CHART FACTORY CONNECTED SPEED TAPS UNIT COOL HEAT PARK BLACK YELLOW BROWN,BLUE GAS VALVE BLOWER SPEED SELECTION PRIMARY GAS BLUE SPEED TAPS BLACK...
Page 37 IX-Troubleshooting HEATING SEQUENCE OF OPERATION ABNORMAL HEATING MODE NORMAL HEATING MODE POWER ON GAS VALVE OFF. COMBUSTION AIR INDUCER OFF. INDOOR BLOWER DELAY OFF. CONTROL SELF-CHECK OKAY? (RESET CONTROL BY TURNING MAIN POWER OFF.) SEVEN SEGEMENT LED FLASHES E111 IS POLARITY CORRECT? - POLARITY REVERSED.
Page 38 HEATING SEQUENCE CONTINUED 15 SECOND COMBUSTION AIR INDUCER PREPURGE INITIATED BY CLOSED PRESSURE SWITCH. SEVEN SEGEMENT LED E110 LOW LINE VOLTAGE. ONCE VOLTAGE IS ABOVE IS VOLTAGE ABOVE 70 VOLTS? IGNITOR WARM UP -- 20 SECONDS. 75 VOLTS, HEATING SEQUENCE RESTARTS. 4 SECOND TRIAL FOR IGNITION.
Page 39 COOLING SEQUENCE OF OPERATION POWER ON IGNITION CONTROL MAIN POWER ON. GAS VALVE OFF. COMBUSTION AIR INDUCER OFF. INDOOR BLOWER OFF WITH NORMAL DELAY. CONTROL SELF DIAGNOSTIC CHECK. SIGNAL CIRCUIT BOARD FAILURE AT LED. IS CONTROL OPERATING NORMALLY? INTERRUPT MAIN POWER TO RESET CONTROL. SEVEN SEGEMENT LED FLASHES E117 IMPROPER GROUND IS THERE A PROPER GROUND? CONTROL WILL CONTINUE TO CALL FOR COOLING...
Page 40 CONTINUOUS FAN SEQUENCE OF OPERATION MANUAL FAN SELECTION MADE AT THERMOSTAT. CONTROL (G) ENERGIZES SYSTEM FAN AT FAN SPEED. EAC TERMINAL IS ENERGIZED. THERMOSTAT CALLS FOR HEAT (W). SYSTEM FAN CONTINUES FAN SPEED WITHOUT THERMOSTAT CALLS FOR COOLING. INTERRUPTION. EAC TERMINAL REMAIN ON. HUM TERMINAL IS ENERGIZED WITH COMBUSTION SYSTEM FAN SWITCHED TO COOL SPEED.

This manual is also suitable for:

El180uh040ne36ak El180uh060ne36ak El180uh080ne48bk El180uh100ne60ck