Lenox Lennox Merit Series Gas Furnace Upflow/Horizontal air discharge. Bedienungsanleitung

Page 1 06/1 1 *2P0611* 506810−01 *P506810-01*  201 1 Lennox Industries Inc. Dallas, T exas, USA AIR FLOW UPFLOW AIR FLOW AIR FLOW HORIZONT AL RIGHT HORIZONT AL LEFT INST ALLA TION INSTRUCTIONS ML180UHE MERIT ® SERIES GAS FURNACE UPFLOW / HORIZONT AL AIR DISCHARGE 506810−01 06/201 1 Supersedes 506732−01 THIS MANUAL MUST BE LEFT WITH THE HO[...]

Page 2 Unit Dimensions − inches (mm) 2 Flue outlet may be horizontal but furnace must be vented vertically 3 Optional external side return air filter kit cannot be used with the optional RAB Return Air Base. 1 NOTE − 60C and 60D units that require air volumes over 1800 cfm (850 L/s) must have one of the following: 1. Single side return air with[...]

Page 3 Part s Arrangement FIGURE 1 Control Box (includes integrated control, interlock switch and transformer) Gas V alve Burner Box (includes sensor , ignitor and rollout switches) Combustion Air Inducer Combustion Air Inducer Pressure Switch Heat Exchanger Upper Access Panel Blower Access Panel Primary Limit (under combustion air inducer) Make−[...]

Page 4 ML180UHE Gas Furnace The M L180UHE unit i s shipped ready f or inst allation i n the upflow or h orizontal ri ght position (for h orizontal lef t posi - tion the combustion air pressure switch must be moved) fueled b y natural gas. A c onversion k it ( ordered sep arate- ly) i s r equired f or u se i n L P/Propane gas applications. The furna[...]

Page 5 Inst alled in Combination with a Cooling Coil When this furnace is used with cooling units, it shall be installed in parallel with, o r on the up stream side o f, cooling units to avoid condensation in the heating compartment. See f igure 2. W ith a p arallel f low arrangement, a d amper (or other means t o control t he flow o f air) must a [...]

Page 6  Do not install the f urnace where drafts might blow direct- ly into it. This could cause improper combustion and un- safe operation.  Do not block the furnace combustion air openings with clothing, boxes, doors, etc. Air is needed for proper combustion and safe unit operation.  When the furnace is installed in an attic or other ins[...]

Page 7 Unconfined Sp ace An unconfined space is an area such as a basement or large equipment room with a volume greater than 50 cubic feet (1.42 m 3 ) 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 separated b y a door . Though an area [...]

Page 8 EQUIPMENT IN CONFINED SP ACE ALL AIR FROM OUTSIDE (Inlet Air from Crawlspace and Outlet Air to V entilated Attic) NOTE−The inlet and outlet air openings shall each have a free area of at least one square inch (645 mm 2 ) per 4,000 Btu (1.17 kW) per hour of the tot al input rating of all equipment in the enclosure. VENTILA TION LOUVERS (Eac[...]

Page 9 Setting Equipment W ARNING Do not inst all the furnace on its front or it s back. Do no t connect the return ai r ducts to the back of the fur- nace. Doing so will adversely affect the operation of the safety control devices, which could result in per- sonal injury or death. The ML180UHE gas furnace can be installed as shipped in either the [...]

Page 10 Return Air −− Up flow Applications Return air can be brought in through the b ottom or either side o f the furnace installed in an upflow a pplication. If t he furnace i s inst alled o n a plat form w ith bottom r eturn, m ake an a irtight s eal between t he b ottom of the f urnace a nd the platform to ensure that the furnace operates p[...]

Page 1 1 Removing the Bottom Panel Remov e the two screws that secure the bottom cap to the furnace. Pivot the bottom cap down to release the bottom panel. Once the bottom p anel has been removed, reinstall the bottom cap. See figure 1 1. Removing the Bottom Panel FIGURE 1 1 Screw Bottom Panel Bottom Cap Horizontal Application Installation Clearanc[...]

Page 12 Horizontal Application Unit Installed on Plat form FIGURE 14 clearances. GAS ENTRY VENT PIPE See the unit nameplate for Line contact is permissible but not preferred SERVICE PLA TFORM W ARNING Improper inst allation of the f urnace can result in per- sonal injury or death. Combustion and flue products must never be allowed to enter the retu[...]

Page 13 V enting A 4−inch diameter flue transition is factory-installed on the combustion air inducer outlet of all models. Figure 16 shows the combustion air inducer as shipped from the factory . FIGURE 15 Mounting Screws Location Mounting Screws Flue T ransition FIGURE 16 UPFLOW POSITION T op V ent Discharge FLOW AIR Collector Box V ent Pipe Fl[...]

Page 14 HORIZONT AL LEFT POSITION T op V ent Discharge FIGURE 19  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. [...]

Page 15 The ML180UHE series units are classified as fan−assisted Category I furnaces when vertically vented according to the latest edition of National Fuel Gas Code (NFP A 54 / ANSI Z223.1) in the USA. A fan−assisted Category I fur- nace is a n appliance equipped with an integral mechanical means to either draw or force combustion products thr[...]

Page 16 FIGURE 24 Common V enting Using Metal−Lined Masonry Chimney 4 in. (102 mm) minimum MIN. LENGTH −− AS SHORT AS PRACTICAL MAX. LENGTH −− SEE NOTE 1 BELOW . SEALED PERMANENTL Y SEALED FIREPLACE OPENING EXTERIOR CHIMNEY WITH MET AL LINER VENT CONNECTOR NOTE 1 − Refer to the provided venting tables for installations. Refer to the cap[...]

Page 17 FIGURE 25 Common V enting Using Tile−Lined Interior Masonry Chimney and Combined V ent Connector MINIMUM LENGTH = AS SHORT AS PRACTICAL. FOR MAXIMUM LENGTH SEE NOTE TO LEFT INTERIOR TILE−LINED MASONRY CHIMNEY NOTE − the chimney must be properly sized per provided venting tables or lined with listed metal lining system. PERMANENTL Y SE[...]

Page 18 16 − V ent connectors serving Category I appliances shall not be connected 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 i n t he c ommon v enting t ab[...]

Page 19 T ABLE 4 Cap acity of T ype B Double−Wall V ent s with Single−Wall Met al Connectors Serving a Single Category I Appliance Height H (feet) Lateral L (feet) V ent and Connector Diameter − D (inches) 3 Inch 4 Inch 5 Inch 6 Inch Appliance Input Rating in Thousands of Btu Per Hour MIN MAX MIN MAX MIN MAX MIN MAX 6 0 38 77 59 151 85 249 12[...]

Page 20 T ABLE 5 V ent Connector Capacity T ype B Double−W all V ent s with T ype B Double−Wall Connectors Serving T wo or More Category I Appliances V ent Height H (feet) Connector Rise R (feet) V ent and Connector Diameter − D (inches) 3 Inch 4 Inch 5 Inch 6 Inch Appliance Input Rating in Thousands of Btu Per Hour MIN MAX MIN MAX MIN MAX MI[...]

Page 21 T ABLE 7 V ent Connector Capacity T ype B Double−W all V ents with Single−W all Metal Connectors Serving T wo or More Category I Appliances Height H (feet) Lateral L (feet) V ent and Connector Diameter − D (inches) 3 Inch 4 Inch 5 Inch 6 Inch Appliance Input Rating in Thousands of Btu Per Hour MIN MAX MIN MAX MIN MAX MIN MAX 6 1 NA NA[...]

Page 22 Removal of the Furnace from Common V ent 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 t he following test while each a ppliance is operat- ing a nd t he o ther a ppli[...]

Page 23 Gas Piping Gas s upply p iping s hould n ot a llow m ore t han 0 .5"W .C. d rop in pressure between gas meter and unit. Supply gas pipe must not be smaller than unit gas connection. CAUTION If a flexible gas connector is required or allowed by the authority that has jurisdiction, black iron pipe shall be in st alled at the gas valve an[...]

Page 24 GROUND JOINT UNION AUTOMA TIC GAS V AL VE FIELD PROVIDED AND INST ALLED GROUND JOINT UNION Lef t Side Piping (St andard) Right Side Piping (Alternate) AUTOMA TIC GAS V AL VE DRIP LEG DRIP LEG MANUAL MAIN SHUT−OFF VA LV E (With 1/8 in. NPT Plugged T ap Shown) MANUAL MAIN SHUT−OFF VA LV E (With 1/8 in. NPT Plugged T ap Shown) NOTE − BLA[...]

Page 25 Leak Check After gas piping is completed, carefully check all piping connections (f act ory− and field−inst alled) for gas leaks. Use a leak detecting solution or other preferred means. NOTE − I f emergency shutoff is necessary , shut off the main manual gas valve and disconnect the main power to the furnace. The installer should prop[...]

Page 26 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 diagram and the field wiring diagram shown in fi gu[...]

Page 27 1 − Line voltage is applied to L1 and N. the T1 low voltage transformer is energized, and line volt age 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 ther mostat. 3 − When there is a call for heat, W1 of the thermos[...]

Page 28 TYPICAL ML180UHE FIELD WIRING DIAGRAM FIGURE 33 FIGURE 34 INTEGRA TED CONTROL (Automatic Hot Surface Ignition System) BLOWER OFF DELA Y RED LED RECALL BUTTON T ABLE 10 1/4" QUICK CONNECT TERMINALS 120HUM Humidifier 120V AC LINE 120V AC XFMR T ransformer 120V AC CIRC Indoor blower 120V AC EAC Indoor air quality accessory 120V AC NEUTRAL[...]

Page 29 Unit St art−Up FOR YOUR SAFETY READ BEFORE LIGHTING W ARNING Do not use this furnace if any part has been under- water . A flood−damaged furnace is extremely dan- gerous. Attempt s to use the furnace can result in fire or explosion. Immediately call a qualified ser- vice t echnician t o inspect t he furnace a nd to r eplace all g as con[...]

Page 30 1 1 − Are flame rollout switches tripped? If flame rollout switches are tripped, call the service technician for in- spection. Heating Sequence Of Operation (follow step s below or see Figure 32 for more detail) 1 − Wh en thermostat calls for heat, combustion air blower starts. 2 − Combustion air pressure switch proves blower opera- t[...]

Page 31 T ABLE 13 Manifold Pressure Settings at all Altitudes Model Input Size Gas 0−2000 ft 2001−4500 ft. 4501−7500 f t 7501 − 10,000 f t Line Pressure in.wg. Min Max 045 Nat 3.5 3.2 3.0 3.5 4.5 13.0 LP/propane 10.0 10.0 10.0 10.0 1 1.0 13.0 070 Nat 3.5 3.2 2.8 3.5 4.5 13.0 LP/propane 10.0 10.0 10.0 10.0 1 1.0 13.0 090 Nat 3.5 3.2 2.7 3.5 [...]

Page 32 HEA T F AN-OFF TIME IN SECONDS T o adjust fan−off timing, reposition jumper across pins to achieve desired setting. NO JUMPER FIGURE 36 60 90 120 180 60 90 120 180 60 90 120 180 60 90 120 180 60 Second off T ime 90 Second off T ime 120 Second off T ime 180 Second off T ime Thermost at Heat Anticipation Set the heat anticipator setting (if[...]

Page 33 BLO WER D A T A ML180UH045E36A PERFORMANCE (Less Filter) External Static Pressure in. w .g. Air V olume / W atts at V arious Blower Speeds High Medium-High Medium Medium-Low Low cfm W atts cfm Watts cfm W atts cfm W atts cfm W atts 0.00 1380 265 1 155 165 995 120 975 11 5 945 105 0.10 1345 270 1 120 175 950 120 880 105 865 100 0.20 1320 285[...]

Page 34 BLO WER D A T A ML180UH1 10E60C PERFORMANCE (Less Filter) External Static Pressure in. w .g. Air V olume / W atts at Different Blower Speeds Bottom Return Air , Side Return Air with Optional Return Air Base, Return Air from Both Sides or Return Air from Bottom and One Side. Single Side Return Air − Air volumes in bold require eld fabri[...]

Page 35 Service W ARNING 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 fur[...]

Page 36 ML180UHE BURNER, COMBUSTION AIR INDUCER ASSEMBL Y & HEA T EXCHANGER REMOV AL FIGURE 37 Heat Exchanger Gasket Collector Box Orifice Plate Flue T ransition Pressure Switch Combustion Air Inducer Manifold And Gas V alve Retention Rings Cross Over Ignitor Rollout Switches (−090, −1 10 −135 units) Sensor Rollout Switches (−045 and ?[...]

Page 37 Planned Service Th e following items should be checked during an annual inspection. Power to the unit must be shut of f for the service techni- cian’s safety . Fresh air grilles and louvers (on the unit and in the room where the furnace is installed) − Must be open and unob- structed to provide combustion air . Burners − Must be i nsp[...]

Page 38 Integrated Control Diagnostic Codes RED LED Flash Code Diagnostic Codes / St atus of Furnace Off No power to control or board fault detected On Board fault detected, Heartbeat 1 Control powered − displayed during all modes of operation if no errors are detected 1 Reverse Line V oltage Polarity 2 Improper Earth Ground 3 Burner failed to li[...]

Page 39 T roubleshooting: Heating Sequence of Operation HEA TING SEQUENCE OF OPERA TION NORMAL HEA TING MODE ABNORMAL HEA TING MODE CONTROL SELF−CHECK OKA Y? BURNER OFF? ( Flame sensed without gas valve energized ) NORMAL OPERA TION: LED SLOW FLASH NO YES YES GAS V AL VE OFF . COMBUSTION AIR INDUCER OFF . INDOOR BLOWER DELA Y OFF . LED SLOW FLASH[...]

Page 40 T roubleshooting: Heating Sequence of Operation (Continued) HEA TING SEQUENCE CONTINUED NORMAL HEA TING MODE ABNORMAL HEA TING MODE FLAME RECTIFICA TION CURRENT CHECK. CAN FLAME BE PROVEN WITHIN 4 SECONDS AFTER GAS V AL VE OPENS? (0.5 microamps) FLAME PRESENT? INDOOR BLOWER ON AFTER 30−SECOND DELA Y PRIMARY LIMIT SWITCH CLOSED? COMBUSTION[...]

Page 41 T roubleshooting: Cooling Sequence of Operation COOLING SEQUENCE OF OPERA TION NORMAL COOLING MODE ABNORMAL COOLING MODE IGNITION CONTROL MAIN POWER ON. CONTROL SELF DIAGNOSTIC CHECK. IS CONTROL OPERA TING NORMALL Y? YES LED FLASHES CODE 1 POLARITY REVERSED CONTROL WILL CONTINUE TO CALL FOR COOLING IN THIS CONDITION. POWER ON GAS V AL VE OF[...]

Page 42 T roubleshooting: Continuous Fan Sequence of Operation CONTINUOUS F AN SEQUENCE OF OPERA TION LED: SLOW FLASH RA TE REMAINS UNCHANGED THROUGHOUT SEQUENCE. MANUAL F AN SELECTION MADE A T THERMOST A T . CONTROL (G) ENERGIZES SYSTEM F AN A T FAN SPEED. EAC TERMINAL IS ENERGIZED. THERMOST A T CALLS FOR HEA T (W). THERMOST A T CALLS FOR COOLING [...]

Page 43 St art−Up & Performance Check List Unit Model Number_______________ Serial Number___________________ UNIT SET UP (typical) Gas Supply Pressure 1 2 2 1 SUPPL Y AIR Line V oltage 3 4 5 Filter RETURN AIR RETURN AIR GAS SUPPL Y Natural Gas LP/Propane Gas Piping Connections Tight Leak T ested Supply Line Pressure  W .C.________ 1 VENT /[...]

Page 44 Contractor’s: Name_________________________T elephone_____________Checklist Completed____________________ Job Address_____−________________________________T echnician’s Name___________________________________ UNIT OPERA TION (typical) 1 HEA TING MODE GAS MANIFOLD PRESSURE W .C._____ COMBUSTION SAMPLE CO 2 % ______ CO PPM_______ 2 I[...]