80UHG

Corp. 9728−L12
Service Literature Revised 01−2002

80UHG series units are mid−efficiency gas furnaces used

for upflow or horizontal applications only, manufactured
with tubular heat exchangers formed of aluminized steel.
80UHG units are available in heating capacities of 45,000
to 120,000 Btuh and cooling applications up 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 LPG operation. 80UHG−1 model
units use electronic (direct spark) ignition. 80UHG−2 and −3
model units are equipped with the Lennox SureLight silicon
nitride ignition system. The 80UHGX unit meets the Califor8
nia Nitrogen Oxides (NOx) Standards and California Sea8
sonal Efficiency requirements. All units use a redundant gas
valve to assure safety shut−off as required by A.G.A. or
C.G.A. Units may be installed in upflow or horizontal posi8
tion.
All specifications in this manual are subject to change. Pro8
cedures outlined in this manual are presented as a recom8
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.
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Blower Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−4
High Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−6
I Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−15
II Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
III Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
IV Heating System Service Checks . . . . . . . . . . . 16−17
V Typical Operating Characteristics . . . . . . . . . . . . . . 18
VI Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19−20
VII Wiring and Sequence of Operation . . . . . . . . . 21−28
VIII SureLight Troubleshooting Guide . . . . . . . . . . 29−34

Page 1  1999 Lennox Industries Inc.

Litho U.S.A.
 SPECIFICATIONS
Model No. 80UHG2(X)Ć45 80UHG2(X)Ć60 80UHG3(X)Ć60 80UHG2(X)Ć75 80UHG3(X)Ć75 80UHG4(X)Ć75
Input Btuh (kW) 45,000 (13.2) 60,000 (17.6) 75,000 (22.0)
Output Btuh (kW) 36,900 (10.8) 49,200 (14.4) 61,700 (18.1) 61,700 (18.1)

A.F.U.E. 80.1% 80.5% 80.1% 80.0%
California Seasonal Efficiency 75.4% 76.4% 75.9% 76.8% 76.8% 76.3%
Flue size connection diameter Ċ in. (mm) round 3 (76) 4 (102)
Temperature rise range Ċ _F (_C) 30 Ć 60 (17 Ć 33) 45 Ć 75 (25 Ć 42)
High static cert. by A.G.A./C.G.A. Ċ in wg. (Pa) .50 (125)
Gas Piping Size I.P.S. Natural or LPG/propane 1/2 (13)

Blower wheel nominal in. 9x7 10 x 7 9x7 10 x 7 12 x 8

diameter x width mm 229 x 178 254 x 178 229 x 178 254 x 178 305 x 203
Blower motor output Ċ hp (W) 1/4 (187) 1/3 (224) 1/4 (187) 1/3 (224) 1/2 (373)
2, 2Ć1/2, 3,
Tons 1, 1Ć1/2 or 2 2, 2Ć1/2 or 3 1, 1Ć1/2 or 2 2, 2Ć1/2 or 3
Nominal cooling 3Ć1/2 or 4
that can be added 7.0, 8.8, 10.6,
kW 3.5, 5.3 or 7.0 7.0, 8.8 or 10.6 3.5, 5.3 or7.0 7.0, 8.8 or 10.6
12.3 or 14.1
Shipping weight Ċ lbs. (kg) 1 package 130 (59) 135 (61) 140 (64)
Electrical Characteristics 120 volts Ċ 60 hertz Ċ 1 phase (less than 12 amps) All models
Optional Accessories (Must Be Ordered Extra)
LPG/propane kit LBĆ69845L (38K84)
Twinning Kit 15L38 - 11lbs. (5 kg)
Up Flow/Horizontal Filter and Filter Rack Kits
Up-Flow/Horizontal Single (32J02) Ten Pack (66K64)
No. & sizeĂofĂfiltersĂ- in. (mm) (1) 16 x 20 x 1 (406 x 508 x 25)
Sidewall Power Venting Kit 79J15 Ċ 25 lbs. (11 kg)
Hanging Bracket Kit LBĆ69957 (46J66) Ċ 15 lbs. (8 kg)

SPECIFICATIONS
Model No. 80UHG3/4(X)Ć100 80UHG4/5(X)Ć100 80UHG3/4(X)Ć120 80UHG4/5(X)Ć120
Input Btuh (kW) 100,000 (29.3) 120,000 (35.2)
Output Btuh (kW) 82,000 (24.0) 98,400 (28.8)

A.F.U.E. 80.1% 80.0% 80.0% 80.1%
California Seasonal Efficiency 76.5% 77.0% Not Available 75.5%
Flue size connection diameter Ċ in. (mm) round 4 (102)
Temperature rise range Ċ _F (_C) 45 Ć 75 (25 Ć 42) 35 Ć 65 (19 Ć 36) 45 Ć 75 (25 Ć 42)
High static certified by A.G.A./C.G.A. Ċ in wg. (Pa) .50 (125) .65 (162) .50 (125)
Gas Piping Size I.P.S. Natural or LPG/propane 1/2 (13)

Blower wheel nominal in. 12 x 8 12 x 9 12 x 8 12 x 9

diameter x width mm 305 x 203 305 x 229 305 x 203 305 x 229
Blower motor output Ċ hp (W) 1/2 (373) 3/4 (560) 1/2 (373) 3/4 (560)

Nominal cooling Tons 2, 2Ć1/2, 3, 3Ć1/2 or 4 3Ć1/2, 4, 5 or 6 2, 2Ć1/2, 3, 3Ć1/2 or 4 3Ć1/2, 4, 5 or 6

that can be added kW 7.0, 8.8, 10.6, 12.3 or 14.1 12.3, 14.1, 17.6 or 21.1 7.0, 8.8, 10.6, 12.3 or 14.1 12.3, 14.1, 17.6or21.1
Shipping weight Ċ lbs. (kg) 1 package 175 (79)
Electrical Characteristics 120 volts Ċ 60 hertz Ċ 1 phase (less than 12 amps) All models
Optional Accessories (Must Be Ordered Extra)
LPG/propane kit LBĆ69845K (81J14)
Twinning Kit 15L38 (5 kg)
Up Flow/Horizontal Filter and Filter Rack Kits
Up-Flow/Horizontal Single (46J14) Ten Pack (66K65)
No. & sizeĂofĂfiltersĂ- in. (mm) (1) 20 x 20 x 1 (508 x 508 x 25)
Sidewall Power Venting Kit 79J15 Ċ 25 lbs. (11 kg)
Hanging Bracket Kit LBĆ69957 (46J66) Ċ 15 lbs. (8 kg)

Annual Fuel Utilization Efficiency based on U.S. DOE test procedures and according to FTC labeling regulations. Isolated combustion system rating for nonĆweatherized furnaces.
Polyurethane frame type filter is furnished with kit.

Page 2
 BLOWER DATA
80UHG2-45, 80UHG2-60 AND 80UHG2-75 BLOWER PERFORMANCE
External Static Air Volume at Various Blower Speeds
Pressure High MediumĆHigh MediumĆLow Low
in. w.g. Pa cfm L/s cfm L/s cfm L/s cfm L/s
0 0 1270 600 980 460 770 365 570 270
.05 12 1245 590 975 460 770 365 565 265
.10 25 1220 575 975 460 770 365 565 265
.15 37 1195 565 965 455 765 360 560 265
.20 50 1170 550 960 455 760 360 560 265
.25 62 1140 540 950 450 760 360 555 260
.30 75 1110 525 940 445 760 360 550 260
.40 100 1060 500 910 430 750 355 545 255
.50 125 990 465 880 415 740 350 540 255
.60 150 900 425 810 380 690 325 530 250
.70 175 800 380 740 350 630 295 520 245
NOTE Ċ All air data is measured external to unit with 1 in. (25 mm) cleanable filter (not furnished) in place. Also see Filter Air Resistance table

80UHG3-60 AND 80UHG3-75 BLOWER PERFORMANCE

External Static Air Volume at Various Blower Speeds
Pressure High MediumĆHigh MediumĆLow Low
in. w.g. Pa cfm L/s cfm L/s cfm L/s cfm L/s
0 0 1425 670 1240 585 1000 470 800 380
.05 12 1415 670 1230 580 995 470 800 380
.10 25 1400 660 1220 575 990 465 795 375
.15 37 1385 655 1200 565 985 465 795 375
.20 50 1370 645 1180 555 980 460 790 375
.25 62 1350 635 1160 545 970 460 780 370
.30 75 1330 630 1140 540 955 450 770 365
.40 100 1280 605 1095 515 925 435 750 355
.50 125 1210 570 1040 490 900 425 720 340
.60 150 1135 535 985 465 860 405 680 320
.70 175 1070 505 920 435 800 380 630 300
NOTE Ċ All air data is measured external to unit with 1 in. (25 mm) cleanable filter (not furnished) in place. Also see Filter Air Resistance table

80UHG4-75, 80UHG3/4-100 AND 80UHG3/4-120 BLOWER PERFORMANCE

External Static Air Volume at Various Blower Speeds
Pressure High MediumĆHigh Medium MediumĆLow Low
in. w.g. Pa cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s
0 0 1830 865 1600 755 1325 625 1070 505 880 415
.05 12 1815 855 1585 750 1320 625 1070 505 880 415
.10 25 1800 850 1570 740 1315 620 1070 505 880 415
.15 37 1875 885 1550 730 1310 620 1065 505 875 415
.20 50 1750 825 1530 720 1300 615 1060 500 875 415
.25 62 1725 815 1515 715 1290 610 1050 495 870 410
.30 75 1700 800 1500 710 1275 600 1040 490 870 410
.40 100 1650 780 1460 690 1245 590 1020 480 860 405
.50 125 1600 755 1420 670 1210 570 1000 470 840 395
.60 150 1550 730 1380 650 1170 550 980 460 820 385
.70 175 1480 700 1330 630 1130 535 960 455 790 375
NOTE Ċ All air data is measured external to unit with 1 in. (25 mm) cleanable filter (not furnished) in place. Also see Filter Air Resistance table

Page 3
 BLOWER DATA
80UHG4/5Ć100 AND 80UHG4/5Ć120 BLOWER PERFORMANCE
External Static Air Volume at Various Blower Speeds
Pressure High MediumĆHigh Medium MediumĆLow Low
in. w.g. Pa cfm L/s cfm L/s cfm L/s cfm L/s cfm L/s
0 0 2450 1155 2160 1020 1970 930 1700 800 1500 710
.05 12 2440 1150 2155 1015 1965 925 1695 800 1500 710
.10 25 2430 1145 2150 1015 1960 925 1690 800 1495 705
.15 37 2415 1140 2135 1010 1950 920 1685 795 1495 705
.20 50 2400 1135 2120 1000 1940 915 1680 795 1490 705
.25 62 2380 1125 2105 995 1930 910 1675 790 1480 700
.30 75 2360 1115 2090 985 1915 905 1670 790 1470 695
.40 100 2310 1090 2050 965 1870 880 1650 780 1440 680
.50 125 2260 1065 2000 945 1810 855 1610 760 1410 665
.60 150 2180 1030 1950 920 1750 825 1560 735 1370 645
.70 175 2100 990 1890 890 1700 800 1520 715 1330 630
NOTE Ċ All air data is measured external to unit with 1 in. (25 mm) cleanable filter (not furnished) in place. Also see Filter Air Resistance table

FILTER AIR RESISTANCE

cfm (L/s) in. w.g. (Pa)
0 (0) 0.00 (0)
200 (95) 0.01 (2)
400 (185) 0.03 (7)
600 (280) 0.04 (10)
800 (375) 0.06 (15)
1000 (470) 0.09 (22)
1200 (560) 0.12 (30)
1400 (655) 0.15 (37)
1600 (750) 0.19 (47)
1800 (845) 0.23 (57)
2000 (935) 0.27 (67)
2200 (1030) 0.33 (82)
2400 (1125) 0.38 (95)
2600 (1220) 0.44 (110)

HIGH ALTITUDE DERATE

Refer to table below for manifold pressure settings for The combustion air inducer prove switches are factory
Installations at different altitudes and different fuels. set and are not to be adjusted.
NOTE-In Canada, certification for installations over At elevations of 4500 ft. (1372m) or greater, change factory
4500 ft. (1372m) above sea level is the jurisdictionof installed pressure switch to switch listed in table below.
the local authorities.
PRESSURE SWITCH
UNIT MODEL
PART NUMBER
Manifold Absolute Pressure in. w.c. (kPa)
80UHG-45 NO CHANGE
ALTITUDE ft. (m)
80UHG-60 NO CHANGE
0-4500 4500-5500 5500-6500 6500-7500
FUEL
(0-1372) (1372-1676) (1676-1981) (1982-2286) 80UHG-75 88J8001
NAT 3.5 (0.87) 3.4 (0.85) 3.3 (0.82) 3.2 (0.80) 80UHG-100 18L2401
LP 9.5 (2.36) 9.2 (2.29) 8.9 (2.21) 8.6 (2.14) 80UHG-120 18L2401

Page 4
 VENT ADAPTER
80UHG PARTS IDENTIFICATION CABINET TOP

HEAT EXCHANGER
ASSEMBLY

FLUE BOX

COMBUSTION AIR PROVE

INDUCER SWITCH
80UHG
CABINET

FRONT ACCESS
PANEL
BURNER
ASSEMBLY

TRANSFORMER

CONTROL
BOARD SECONDARY
LIMITS CABINET
BOTTOM

BLOWER ASSEMBLY

DOOR INTERLOCK SWITCH

FIGURE 1

HEATING COMPONENTS (shown in horizontal position) PRIMARY LIMIT

ROLLOUT SWITCH (2)

COMBUSTION AIR
PROVE SWITCH

MANIFOLD

Left

Bottom Back
BURNERS

Front
Top

Right
HEAT EXCHANGER

GAS VALVE
COMBUSTION AIR INDUCER

COLLECTOR

FIGURE 2

Page 5
 80UHG BURNER ASSEMBLY (shown in upflow position)
-2 MODEL SHOWN

SURELIGHT ROLLOUT
IGNITOR SWITCHES

BURNER BOX
TOP
VEST PANEL
UPPER
BURNER
MOUNTING
RAIL

LOWER
BURNER
MOUNTING
RAIL

FLAME
BURNER
SENSOR HEAT EXCHANGER

PRIMARY LIMIT
Top

Back
ORIFICE Left
GAS VALVE
Right
Front
BURNER BOX
MANIFOLD
Bottom

FIGURE 3
I-UNIT COMPONENTS (Figures 1, 2, 3)
80UHG unit components are shown in figure 1. The gas
valve, combustion air inducer and burners can be acĆ
cessed by removing the burner access panel. Electrical
components are mounted to the blower housing.
80UHG units are factory equipped with bottom return air panĆ
els in place. The panels are designed to be field removed as
required for bottom air return. Knockout panels are provided
for side return air.
ELECTROSTATIC DISCHARGE (ESD)
Precautions and Procedures
CAUTION
Electrostatic discharge can affect electronic
components. Take precautions during furnace
installation and service to protect the furnace's
electronic controls. Precautions will help to
avoid control exposure to electrostatic disĆ
charge by putting the furnace, the control and
the technician at the same electrostatic potenĆ
tial. Neutralize electrostatic charge by touching
hand and all tools on an unpainted unit surface,
such as the gas valve or blower deck, before perĆ
forming any service procedure.
1- Control Transformer (T1)
A transformer located on the blower housing provides
power to the low voltage section of the unit. Transformers
on all models are rated 30VA with a 120V primary and a
24V secondary.
2-Door Interlock Switch (S51)
A door interlock switch rated 16A at 125VAC is wired in seĆ
ries with line voltage. When the blower door is removed the
unit will shut down.
DANGER
Shock hazard.
Spark related components contain high voltage.
Disconnect power before servicing. Control is
not field repairable. If control is inoperable, simĆ
ply replace entire control.
Can cause injury or death. Unsafe operation will
result if repair is attempted.

Page 6
3− Furnace Control (A3)
80UHG−2, −3 Models
80UHG−2 and −3 model units are equipped with the Len8
nox SureLight ignition system. The system consists of
ignition control board (figure 6 with control terminal desig8
nations in table 4) and ignitor (figure 7). The board and ig8
nitor work in combination to ensure furnace ignition and
ignitor durability. The SureLight integrated board controls
all major furnace operations. The board also features two
LED lights for troubleshooting and two accessory termi8
nals rated at (4) four amps. See table 3 for troubleshoot8
ing diagnostic codes. Table 1 and 2 show jack plug termi8
nal designations. Units equipped with the SureLight
board can be used with either electronic or electro−me8
chanical thermostats without modification. The Sur8
eLight ignitor is made of durable silicon−nitride. Ignitor
longevity is also enhanced by voltage ramping by the
control board. The board finds the lowest ignitor tempera8
ture which will successfully light the burner, thus increas8
ing the life of the ignitor. Each time power is applied to the
furnace, the SureLight board performs a selfcheck in8
cluding energizing the combustion air blower for a period
of 1 second.
TABLE 1
SureLight BOARD J156 (J2) TERMINAL
DESIGNATIONS
PIN # FUNCTION
1 Combustion Air Inducer Line
2 Ignitor Line
3 Combustion Air Inducer Neutral
4 Ignitor Neutral
TABLE 2
SureLight BOARD J58 (J1) TERMINAL
DESIGNATIONS
PIN # FUNCTION
1 Primary Limit / Pressure Switch Out
2 Secondary Limit
3 24V
4 Not Used
5 Rollout Switch In
6 24V
7 Primary Limit In
8 Ground
9 Gas Valve In
10 Pressure Switch In
11 Rollout Switch Out
12 Gas Valve Out
Page 7
a−Electronic Ignition (See Figure 5)
On a call for heat the SureLight control monitors the com8
bustion air inducer pressure switch. The control will not be8
gin the heating cycle if the prove switch is closed (by−
passed). Once the prove switch is determined to be open,
the combustion air inducer is energized. When the differ8
ential in the prove switch is great enough, the prove switch
closes and a 15−second pre−purge begins. If the prove
switch is not proven within 2−1/2 minutes, the control goes
into Watchguard−Pressure Switch mode for a 5−minute re−
set period.
After the 15−second pre−purge period, the SureLight igni8
tor warms up for 20 seconds during which the gas valve
opens at 19 seconds for a 4−second trial for ignition. The
ignitor stays energized for the first second of the 4−second
trial. 80UHG units equipped with control 10M9301: ignitor
remains energized during the 4 second trial until flame is
sensed. If ignition is not proved during the 4−second peri8
od, the control will try four more times with an inter purge
and warm−up time between trials of 35 seconds. After a to8
tal of five trials for ignition (including the initial trial), the
control goes into Watchguard−Flame Failure mode. After a
60−minute reset period, the control will begin the ignition
sequence again.
The SureLight control board has an added feature that
prolongs the life of the ignitor. After a successful ignition,
the SureLight control utilizes less power to energize the ig8
nitor on successive calls for heat. The control continues to
ramp down the voltage to the ignitor until it finds the lowest
amount of power that will provide a successful ignition.
This amount of power is used for 255 cycles. On the 256th
call for heat, the control will again ramp down until the low8
est power is determined and the cycle begins again.
b−Fan Time Control
The fan on time of 45 seconds is not adjustable. Fan off
time (time that the blower operates after the heat demand
has been satisfied) can be adjusted by flipping the dip
switches located on the SureLight integrated control. The
unit is shipped with a factory fan off setting of 90 seconds.
Fan off time will affect comfort and is adjustable to satisfy
individual applications. See figure 4.
FANOFF TIME ADJUSTMENT
60sec. 90sec. 120sec. 180sec.
To adjust fan−off timing, flip dip switch to desired setting.
FIGURE 4
The SureLight board is equipped with two LED lights for troubleshooting. The diagnostic codes are listed below in table 3.
TABLE 3
DIAGNOSTIC CODES
MAKE SURE TO ID LED’S CORRECTLY: REFER TO INSTALLATION INSTRUCTIONS FOR CONTROL BOARD LAYOUT.

LED #1 LED #2 DESCRIPTION

SIMULTANEOUS SIMULTANEOUS Power − Normal operation
SLOW FLASH SLOW FLASH Also signaled during cooling and continues fan.
SIMULTANEOUS FAST SIMULTANEOUS FAST
FLASH FLASH Normal operation − signaled when heating demand initiated at thermostat.

Primary or Secondary limit open. Units with board 12L69: Limit must close within
5 trials for ignition or board goes into one hour limit Watchguard. Units with board
SLOW FLASH ON
56L84: Limit must close within 3 minutes or board goes into one hour limit Watch8
guard.
Pressure switch open or has opened 5 times during a single call for heat; OR:
OFF SLOW FLASH Blocked inlet/exhaust vent; OR: Condensate line blocked; OR: Pressure switch
closed prior to activation of combustion air blower.
ALTERNATING SLOW ALTERNATING SLOW
FLASH FLASH Watchguard − burners fail to ignite.
SLOW FLASH OFF Flame sensed without gas valve energized.
ON SLOW FLASH Rollout switch open. OR: 9 pin connector improperly attached.
ON ON
ON OFF Circuit board failure or control wired incorrectly.
OFF ON
FAST FLASH SLOW FLASH Main power polarity reversed. Switch line and neutral.
SLOW FLASH FAST FLASH Low flame signal. Measures below 0.2 microAmps. Replace flame sense rod.
ALTERNATING FAST ALTERNATING FAST Improper main ground or line voltage below 75 volts; OR: Broken ignitor; OR:
FLASH FLASH Open ignitor circuit.
NOTE − Slow flash equals 1 Hz (one flash per second). Fast flash equals 3 Hz (three flashes per second). Drop out flame sense current < 0.15 microAmps

SureLight Control Ignition Sequence

(Control 56L8401 ONLY)

ÉÉ
1 15 34 35 38 80 5 SEC

ÉÉ ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
ON Pre −Purge Ignitor Warmup Trial for Blower HOn" Post

ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
OFF Ignition Delay Purge

ÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
DEMAND
CA

ÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉ
B
IGNITOR
GAS VALVE
INDOOR BLOWER
ÉÉÉÉÉÉÉÉÉ
*Blower on time will be 45 seconds after ignition. Blower off time will depend on HOFF TIME" Setting.

FIGURE 5

Page 8
 SURELIGHT INTEGRATED CONTROL BOARD TABLE 4
TERMINAL DESIGNATIONS
COOL-H Blower - Cooling Speed (120VAC)
HEAT-H Blower - Heating Speed (120VAC)
EAC-H Electronic Air Cleaner (120VAC)
HUM-H Humidifier (120VAC)
XFMR-H Transformer (120VAC)
LINE-H Input (120VAC)
LINE-N Input (Neutral)
XFMR-N HUM-N Humidifier (Neutral)
EAC-N Electronic Air Cleaner (Neutral)
XFMR-N Transformer (Neutral)
CIR-N Not Used
PARK
(FLAME SENSE)

Flame
sense
SureLight Ignitor

SURELIGHT IGNITOR

FIGURE 6
4-Flame Sensor 80UHG -2 models
A flame sensor is located on the left side of the burner
support. See figure 8. The sensor is mounted on a
FIGURE 7
bracket in the burner support and the tip protrudes
into the flame envelope of the left-most burner. The NORMAL FLAME SIGNAL u 0.2 MICROAMPS
LOW FLAME SIGNAL v 0.2 MICROAMPS
sensor is fastened to burner supports and can be reĆ MINIMUM FLAME SIGNAL v 0.15 MICROAMPS

moved for service without removing any part of the

burners. During operation, flame is sensed by current 1/4 in. 7 mm 11/16 in. 18 mm
 1/32 in. 0.79  1/32 in. 0.79
passed through the flame and sensing electrode. The mm
mm
SureLight control allows the gas valve to remain open BURNER 3/16 in.
as long as flame signal is sensed. 4.7 mm
NOTE - The 80UHG furnace contains electronic
components that are polarity sensitive. Make sure that
the furnace is wired correctly and is properly
grounded.
FLAME
SIDE VIEW SENSOR END VIEW

FIGURE 8

Page 9
5- Furnace Control (A3) 80UHG-1 Model
80UHG units are equipped with an integrated ignition/blower
control (EGCĆ2) which controls ignition, safety circuits,
blower operation, fan off timing, and allows for thermostat
connection and troubleshooting. The EGCĆ2 is a printed
circuit board which is divided into two sections, 120 and
24VAC. Line voltage comes into the board on the 120VAC
side. See figure 10. Terminal designations are listed in
tables 6 and 7.
Ignition Control
80UHG units use the EGC-2 direct spark integrated
ignition control. The EGC-2 controls and monitors the
entire sequence of operation. On a call for heat from the
thermostat the control monitors the combustion air inĆ
ducer prove switch. The control will not begin the heatĆ
ing cycle if the prove switch is closed (byĆpassed). Once
the prove switch is determined to be open, the combustion
air inducer is energized. When the differential in pressure
across the prove switch is great enough, the prove switch
closes and a 15 second preĆpurge period begins. If the
prove switch does not close within 2 1/2 minutes, the conĆ
trol goes into 5 minute watchguard. After the preĆpurge peĆ
riod, the gas valve will open and ignition (spark) will be atĆ
tempted for 10 seconds. After ignition, the control initiates a
ten second flame stabilization period. The flame stabiĆ
lization period allows the burners to heat up and the
flame to stabilize. Once flame is established, the control will
constantly monitor the burner flame using flame rectification.
Flame failure response time is 0.8 seconds.
If the initial attempt for ignition fails, the sequence is reĆ
peated up to five times. After the fifth trial, the control goes into
Watchguard"*. During watchguard mode, the entire unit will
be deĆenergized for one hour. After one hour the control will
repeat the ignition sequence. Watchguard may be manually
reset by breaking and remaking thermostat demand.
*NOTE-If flame is established beyond the 10 second flame
stabilization period then lost, the control resets for five more
ignition trials. The control can be reset five times during one
unsatisfied thermostat demand, providing a maximum
of 25 trials for ignition.
Safety Circuits
During the entire heating demand the control monitors the
safety circuits. If the primary or secondary heating limits
open, the control deĆenergizes the main gas valve and
combustion air blower while the indoor blower remains enĆ
ergized. When the limit automatically resets, the ignition seĆ
quence also resets. If either of the limits trip five consecuĆ
tive times during one unsatisfied thermostat demand, the
control will go into watchguard for one hour.
The control monitors main valve voltage. If voltage is sensed
Page 10
when no voltage should be present, the control deĆenergizes
the combustion air inducer which terminates voltage to the
valve. The system goes into hard lockĆout which is reset only
by removing power to the unit.
If flame is sensed when no flame should be present, the conĆ
trol will energize the combustion and indoor blowers. The
unit will remain locked in this sequence until the flame is no
longer sensed or the main power is turned off to reset the
control.
The rollĆout circuit is also monitored by the EGCĆ2 control. If
the switch opens, the control will deĆenergize the gas
valve, combustion air inducer, and indoor blower. The
unit will remain deĆenergized until the switch is manualĆ
ly reset.
DANGER
Shock hazard. Avoid personal injury. Make sure to
disconnect power before changing fan off" timing.
Blower Operation / Fan Off Timings
Fan off" timing (time that the blower operates after the heat
demand has been satisfied) can be adjusted by moving the
jumper on the EGCĆ2 blower control board. Figure 9 shows
the various fan off" timings and how jumper should be posiĆ
tioned. To adjust fan off " timing, gently disconnect jumper
and reposition across pins corresponding with new timing.
Unit is shipped with a factory fan off" setting of 180 seconds.
Fan on" time is factory set at 45 seconds following the
opening of the main gas valve and is not adjustable.
Fan off" time will affect comfort and efficiency and is adĆ
justable to satisfy individual applications. The fan off" timĆ
ing is initiated after a heating demand but not after a coolĆ
ing demand.
NOTEĊIf fan off" time is set too low, residual heat in
heat exchanger may cause primary limit S10 to trip, reĆ
sulting in frequent cycling of blower. If this occurs, adjust
blower to longer fan off" time setting.
FANĆOFF TIME ADJUSTMENT
TIMING To adjust fanĆoff timing:
JUMPER Remove jumper from EGCĆ2 and select
one of the other pin combinations to
achieve the desired time.
TIMING PINS
180
60 (seconds)
Leave jumper off for
240 second fanĆoff timing.
120 90
FIGURE 9
 Thermostat Connection TABLE 5
Thermostat wires are connected to the terminal strip EGCĆ2 DIAGNOSTIC CODES
found on the EGCĆ2 control board. DIAG #2 DIAG #1 DIagnostic Condition
Power ON". Normal Operation. InĆ
Troubleshooting Simultaneous Simultaneous creased flash rate indicates there
Flash Flash is a heating demand.
The EGCĆ2 control board is equipped with two diagnostic
Primary or Secondary
green LEDs to indicate the mode of failure. The LED lights On Flash Limit Switch Open.
are marked DIAG #1 and DIAG #2. The codes are given in AutoĆReset Switch.
Pressure Switch Watchguard,
table 5. Flash Off pressure switch opened during
operation.
A slotted edge connector is also provided for the Lennox
Alternate Alternate Flash Watchguard, burners
Diagnostic Module (part number 11K75). See figure 10. Flash failed to ignite.
When connected to the EGCĆ2 control board, the module disĆ Off Flash Flame sensed without
valve energized.
plays (in words) the diagnostic condition. RollĆout Switch Open.
Flash On ManualĆReset Switch.
Continuous Circuit board selfĆcheck failure or
On Continuous On ignition/blower control
is wired incorrectly.

80UHG-1 MODEL INTEGRATED CONTROL (EGC-2)

(Shown as installed in horizontal left hand application)
(See tables 6 and 3 for terminal designations)
8 9 10 11 12 13 14 15

7
6
5
4
DIAGNOSTIC LEDS

DIAGNOSTIC MODULE BLOWER TIME

ADJUSTMENT
JUMPER

THERMOSTAT
TERMINAL STRIP
(DETACHABLE)

EDGE 1 4 7
CONNECTION
2 8
5

3 6 9
DIAGNOSTIC CODE ERASE JUMPER 3 2 1
24VAC (Remove power to control and short pins for
PLUG P20 10 seconds to erase previous code.)

FIGURE 10

Page 11
 TABLE 6 SUPPLY AIR BLOWER
BLOWER CONTROL A15 TERMINAL DESIGNATIONS AND SECONDARY LIMITS SECONDARY
Terminal LIMITS (S21)
Designation Type Function
(See fig. 10)
R Screw Strip 24VAC to Thermostat (Red)
Manual Fan Input from Thermostat Top
G Screw Strip Back
(Green) Left
W Screw Strip Heat Demand Input from Thermostat Right
(White) Front
Cool Demand Input from Thermostat Bottom
Y Screw Strip (Yellow)
C Screw Strip Common Ground to Thermostat
1 1/4" Spade 24VAC Hot from Transformer
2 1/4" Spade 24VAC Return to Transformer
3 1/4" Spade 24VAC Ground
4, 5, 6 1/4" Spade 120VAC Return - 120VAC Common
120VAC Return - 120VAC Common BLOWER
7 1/4" Spade Input MOTOR
8 1/4" Spade Combustion Blower (Line Voltage)
MOTOR
9 1/4" Spade Heat Only Accessory (Line Voltage)
CAPACITOR
10 1/4" Spade 120VAC Hot to Transformer
11 1/4" Spade 120VAC Hot Input To Remove Blower From Unit: Remove Bolts and
12, 13 1/4" Spade Accessories (Line Voltage) Wiring Jackplugs. Then Slide Out Front of Unit.
14 1/4" Spade ACB Cool Speed (Line Voltage)
15 1/4" Spade ACB Heat Speed (Line Voltage)
FIGURE 11
7-Combustion Air Inducer (B6)
TABLE 7
All 80UHG units use a combustion air inducer to move air
EGCĆ2 CONTROL JACK/PLUG 20 TERMINAL DESIGNATIONS
through the burners and heat exchanger during heating
Pin # Function
operation. The blower uses a 120VAC motor. The motor
1 Rollout Switch Out
2 Spare operates during all heating operation and is controlled by
3 Gas Valve Common furnace control A3. The blower also operates for 15 seĆ
4 Pressure Switch Return conds before burner ignition (preĆpurge) and for 5 seconds
5 Hi Limit Return / Pressure Switch Out after the gas valve closes (postĆpurge)
6 Flame Sensor
7 Gas Valve Out A proving switch connected to the combustion air inducer
8 High Limit Out housing is used to prove combustion air inducer operation.
9 Rollout Switch Return The switch monitors air pressure in the blower housing. DurĆ
6-Blower Motors and Capacitors ing normal operation, the pressure in the housing is negaĆ
tive. If pressure becomes less negative (signifying an obĆ
All 80UHG units use direct drive blower motors. All motors
struction) the prove switch opens. When the prove switch
used are 120V permanent split capacitor motors to ensure
opens, the furnace control (A3) immediately closes the gas
maximum efficiency. See table 8 for ratings.
valve to prevent burner operation.
TABLE 8
80UHG BLOWER RATINGS 120V 1PH 8-Flame Rollout Switches (S47)
BLOWER MOTOR HP CAP Flame rollout switch is a high temperature limit located on
80UHG2 1/4 5MFD 370V top of the burner box. Each furnace is equipped with two
80UHG3 1/3 5MFD 370V
identical switches. One switch is located over the leftmost
80UHG3/4 1/2 7.5MFD 370V
80UHG4 1/2 7.5MFD 370V burner and the other switch is located over the rightmost
80UHG4/5 3/4 40MFD 370V burner. The limit is a N.C. SPST manualĆreset limit conĆ
80UHG5/6 3/4 40MFD 370V nected in series with the ignition control A3. When S47

Page 12
senses rollout, the ignition control immediately stops igniĆ
tion and closes the gas valve. If unit is running and flame
rollout is detected, the gas valve will close and ignition conĆ
trol will be disabled. Rollout can be caused by a blocked
flue or lack of combustion air. The switch is factory set and
cannot be adjusted. The setpoint will be printed on the side of
the limit. The switch can be manually reset. To manually reĆ
set a tripped switch, push the reset button located on the
control.
ROLLOUT SWITCH (S47)
MANUAL
RESET BUTTON
FIGURE 12
9-Primary Limit Control (S10)
LIMIT CONTROL FOR
80UHG SERIES UNITS
THIS TYPE AUTOĆRESET LIMIT
IS USED FOR THE PRIMARY LIMIT (S10) AND
RIGHT SECONDARY LIMIT (S21)
(see FIGURE 11)
FIGURE 13
The primary limit (S10) on 80UHG units is located in the
middle of the heating vestibule panel. When excess heat is
sensed in the heat exchanger, the limit will open. If the limit is
tripped, the furnace control energizes the supply air blower
and closes the gas valve. The limit automatically resets when
unit temperature returns to normal. The switch is factory set
and cannot be adjusted. The switch may have a different
setpoint for each unit model number. However, the setpoint
will be printed on the side of the limit.
10-Secondary Limit Controls (S21)
The secondary limit (S21) on 80UHG units is located in the
blower compartment in the back side of the blower housing.
When excess heat is sensed in the blower compartment, the
limit will open. If the limit is tripped, the furnace control enerĆ
gizes the supply air blower and closes the gas valve. The limit
automatically resets when unit temperature returns to normal.
The switch is factory set and cannot be adjusted. The setĆ
point will be printed on the limit.
Page 13
Two limits are supplied in each furnace. 80UHG3, 80UHG4
and 80UHG4/5 model units built prior to Apri 1999, will
have one each of style shown in figures 13 and 14. If stick
limit (figure 14) suffers frm nuisance trips on the above
model units and the furnace is in the horizontal position, reĆ
place with limit kit no. 50L98. All 80UHG2 model units will
have one of each style shown in figures 13 and 14.
SECONDARY LIMIT CONTROL (S21)
FOR 80UHG SERIES UNITS
THIS TYPE AUTOĆRESET LIMIT IS
INSULATING COVER
USED FOR THE LEFT SECONDARY
SPADE CONNECTORS
LIMIT (S21) (see FIGURE 11)
LIMIT
LIMIT
INSULATING COVER (s)
FIGURE 14
11-Spark Electrode and Flame Sensor
80UHG-1 Models
Figure 17 shows the arrangement of flame sensor, spark
electrode and burners. The ignition control uses direct
spark to ignite the rightmost burner and the burners crossĆ
light to the left. The flame sensor uses flame rectification to
sense combustion. A flame retention ring in the end of
each burner is used to maintain correct flame length and
shape and to keep the flame from lifting off the burner
head.
Figure 18 shows the gap between tip of the electrodes and
the burner surface, and the gap between the sensor and
burner surface.
12-Gas Valve
The 80UHG uses a gas valve manufactured by HoneyĆ
well or White Rodgers. The valve is internally redundant to
assure safety shut-off. If the gas valve must be replaced,
the same type valve must be used.
24VAC terminals and gas control knob are located on top of
the valve. All terminals on the gas valve are connected to
wires from the electronic ignition control. 24V applied to the
terminals energizes the valve.
Inlet and outlet pressure taps are located on the valve. A reguĆ
lator adjustment screw (figures 15 and 16) is located on the
valve.
LPG changeover kits are available from Lennox. Kit s include
burner orifices and a gas valve regulator conversion kit.
 WHITE RODGERS 36E SERIES GAS VALVE HONEYWELL VR8205 SERIES GAS VALVE
MANIFOLD MANIFOLD
MANIFOLD PRESSURE PRESSURE
PRESSURE ADJUSTMENT OUTLET
ADJUSTMENT SCREW
SCREW

MANIFOLD ON
PRESSURE
OUTLET
OFF

GAS VALVE SHOWN IN OFF POSITION

GAS VALVE SHOWN IN OFF POSITION

FIGURE 15 FIGURE 16
Top
TYPICAL BURNER/ELECTRODE ORIENTATION 23/32 in.
80UHG-1 MODEL SHOWN (18 mm) Right Left
1/8"(+1/64") UPPER BURNER
BURNER MANIFOLD ORIFICE
MOUNTING RAIL Bottom

LOWER BURNER
SPARK ELECTRODE GROUND FLAME RETENTION RING MOUNTING RAIL FLAME SENSOR

FIGURE 17

SPARK ELECTRODE TO BURNER GAP

13-Combustion Air Blower Prove
80UHG-1 MODEL SHOWN Switch (S18)
BURNER 5/16 in. 80UHG series units are equipped with a combustion air
(7 mm) prove switch located on the vestibule panel. The switch is
connected to the combustion air inducer housing by means
of a flexible silicone hose. It monitors air pressure in the
combustion air blower housing.
SPARK The switch is a singleĆpole singleĆthrow pressure switch
ELECTRODE electrically connected to the furnace control. The purpose
SPARK ELECTRODE
of the switch is to prevent burner operation if the combusĆ
FLAME SENSOR TO BURNER GAP tion air blower is not operating or if the flue becomes obĆ
BURNER 5/16 in. structed.
(7 mm)

FLAME SENSOR
FIGURE 18

Page 14
 PROVE SWITCH
COMBUSTION AIR INDUCER
PROVE SWITCH
Normally Open
Closes on Negative Pressure
Sensing Tube
Attaches to Top
Side Of Blower
Top
Back
Right
PROVE
SWITCH
Left
Front
Bottom
FIGURE 19
On startĆup, the switch senses that the combustion air
blower is operating. It closes a circuit to the furnace control
when pressure inside the combustion air blower deĆ
creases to a certain set point. Set points vary depending
on unit size. The pressure sensed by the switch is relative
to atmospheric pressure. If the flue becomes obstructed
during operation, the switch senses a loss of negative
pressure (pressure becomes more equal with atmospherĆ
ic pressure) and opens the circuit to the furnace control
and gas valve. A bleed port on the switch allows dry relativĆ
ity air in the vestibule to purge switch tubing, to prevent
condensate build up. The switch also has an internal inline
orifice, designed to prevent nuisance shut downs due to
erratic vent pressure fluctuations.
The switch is factory set and is not field adjustable. It is a
safety shutĆdown control in the furnace and must not be
by-passed for any reason. If switch is closed or by-passed,
the control will not initiate ignition at start up.
II-PLACEMENT AND INSTALLATION
Make sure unit is installed in accordance with installation
instructions and applicable codes.
III-STARTĆUP
A-Preliminary and Seasonal Checks
1 - Inspect electrical wiring, both field and factory installed
for loose connections. Tighten as required.
2 - Check voltage at disconnect switch. Voltage must be
within range listed on the nameplate. If not, consult the
power company and have voltage condition corrected
before starting unit.
Page 15
B-Heating StartĆUp
WARNING
Shock and burn hazard.
80UHG-1 units are equipped with a direct spark igniĆ
tion system. Do not attempt to light manually.
1 - STOP! Read the safety information at the beginning
of this section.
2 - Set thermostat to lowest setting.
3 - Turn off all electrical power to appliance.
4 - This appliance is equipped with an ignition device
which automatically lights the burners. Do not try to
light the burners by hand.
5 - Remove top access panel.
6 - White Rodgers 36E Gas Valve -- Switch lever to
OFF. See figure 15.
Honeywell VR8205 Gas Valve -- Turn knob on gas
valve clockwise to OFF. Do not force. See figĆ
ure 16.
7 - Wait five (5) minutes to clear out any gas. If you then
smell gas, STOP! Close manual main shut-off valve to
the furnace. Immediately call your gas supplier from a
neighbor's phone. Follow the gas supplier's instructions.
If you do not smell gas go to next step.
8 - White Rodgers 36E Gas Valve -- Switch gas valve lever
to ON.
Honeywell VR8205 Gas Valve -- Turn knob on gas
valve counterclockwise to ON. Do not force.
9 - Replace access panel.
10- Turn on all electrical power to unit.
11- Set thermostat to desired setting.
NOTE–When unit is initially started, steps 1 through 11
may need to be repeated to purge air from pilot line.
12- If the appliance will not operate, follow the instructions
To Turn Off Gas To Unit".
Turning Off Gas To Unit
1 - Set thermostat to lowest setting.
2 - Turn off all electrical power to unit if service is to be
performed.
3 - Remove access panel.
4 - Switch lever on White Rodgers gas valve to OFF; turn
knob on Honeywell valve clockwise to OFF. Do not
force.
5 - Replace access panel.
C-Safety or Emergency Shutdown
Turn off unit power. Close manual and main gas valves.
D-Extended Period Shutdown
Turn off thermostat or set to UNOCCUPIED" mode. Close
all gas valves (both internal and external to unit) to guaranĆ
tee no gas leak into combustion chamber. Turn off power
to unit. All access panels, covers and vent caps must be in
place and secured.
IV-HEATING SYSTEM SERVICE CHECKS
A-A.G.A./C.G.A. Certification
All units are A.G.A. and or C.G.A. design certified without
modifications. Refer to the 80UHG Operation and InstallaĆ
tion Instruction Manual Information.
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
IMPORTANT
In case emergency shutdown is required, turn off
the main shutĆoff valve and disconnect the main
power to unit. These controls should be properly
labeled by the installer.
When pressure testing gas lines, the gas valve must be
disconnected and isolated. Gas valves can be damaged if
subjected to more than 0.5psig (14" W.C.). See figure 20. If
the pressure is equal to or less than 0.5psig (14"W.C.), use
the manual shut-off valve before pressure testing to isoĆ
late furnace from gas supply.
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 20
When checking piping connections for gas leaks, use preĆ
ferred means. Kitchen detergents can cause harmful corroĆ
sion on various metals used in gas piping. Use of a specialty
Gas Leak Detector is strongly recommended. It is available
Page 16
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-Testing Gas Supply Pressure
When testing supply gas pressure, connect test gauge to
inlet pressure tap (field provided). See figure 20. Check
gas line pressure with unit firing at maximum rate. Low
pressure may result in erratic operation or underfire. High
pressure can result in permanent damage to gas valve or
overfire. For 80UHG-45,60 and 75 BTUH natural gas
units, operating pressure at the unit must be a minimum
4.5"W.C. For the 80UHG-100 and 120 BTUH units, the opĆ
erating pressure must be a minimum of 5.0"W.C. For L.P.
gas units, operating pressure at unit gas connection must
be a minimum of 11.0" W.C.
On multiple unit installations, each unit should be checked
separately, with and without other units operating. Supply
pressure must fall within range listed in previous paraĆ
graph.
E-Check Manifold Pressure
After line pressure has been checked and adjusted, check
manifold pressure. Move pressure gauge to outlet presĆ
sure tap located on unit gas valve (GV1). Checks of manĆ
ifold pressure are made as verification of proper regulator
adjustment. Manifold pressure for the 80UHG can be meaĆ
sured at any time the gas valve is open and is supplying gas
to the unit. Normal manifold pressure for natural gas units is
3.5 in. W.C. For LP/propane gas the correct manifold presĆ
sure is 9.5 in. W.C.
IMPORTANT
For safety, connect a shutĆoff valve between the
manometer and the gas tap to permit shut off of
gas pressure to the manometer.
TABLE 9
GAS VALVE REGULATION
Unit (Fuel) Operating Pressure (outlet) in. W.C.
Natural 3.5 +0 -0.3
L.P. 9.5 + 0.5
The gas valve is factory set and should not require adĆ
justment. All gas valves are factory regulated. See
table 9. See specifications section of this manual for
High Altitude manifold pressure settings.
Manifold Adjustment Procedure: To Measure Flame Signal - Ignition Control:
1 - Connect a test gauge to outlet pressure tap on gas A transducer (Part
valve. Start unit and allow 5 minutes for unit to reach TRANSDUCER
#78H5401 available from
steady state. (PART #78H5401)
Lennox Repair Parts) is
2 - While waiting for the unit to stabilize, notice the flame. required to measure
Flame should be stable and should not lift from burner.
flame signal if meter used
Natural gas should burn blue. L.P. gas should burn
will not read a low micro
mostly blue with some orange streaks.
amp signal. ĂSeeĂfigĆ
3 - After allowing unit to stabilize for 5 minutes, record FIGURE 21
ureĂ21. The transducer
manifold pressure and compare to values given in
table 9. converts microamps to volts on a 1:1 conversion. Flame sigĆ
nal should for the EGC control should be 1.0 - 5.0 with a lock-
NOTE-Shut unit off and remove manometer as soon as
out signal of .45 nominal microamps, therefore a reading of
an accurate reading has been obtained. Take care to
1.0 - 5.0 nominal volts should be read on the meter. Flame
replace pressure tap plug.
signal for the SureLight control should read 0.7 microamps
F- Proper Gas Flow (Approximate) with a lockout signal of .15 microamps. A digital readout meter
Furnace should operate at least 5 minutes before must be used. The transducer plugs into most meters.
checking gas flow. Determine time in seconds for two See figure 22 for proper use of transducer.
revolutions of gas through the meter. (Two revoluĆ
1 - Set the volt meter to the DC voltage scale. Insert
tions assures a more accurate time.) Divide by two transducer into the VDC and common inputs. ObĆ
and compare to time in table 10 below. Adjust manĆ serve correct polarities. Failure to do so results in
ifold pressure on gas valve to match time needed. negative (-) values.
NOTE- To obtain accurate reading, shut off all other 2 - Turn off supply voltage to control.
gas appliances connected to meter. 3 - Disconnect ignition control flame sensor wire from the
TABLE 10 flame sensor.
GAS METER CLOCKING CHART 4 - Connect (-) lead of the transducer to flame sensor.
5 - Connect (+) lead of transducer to the ignition control senĆ
Seconds for One Revolution
sor wire.
80UHG Natural LP
6 - Turn supply voltage on and close thermostat contacts to
U it
Unit 1 cu ft 2 cu ft 1 cu ft 2 cu ft cycle system.
Dial Dial Dial DIAL
7 - When main burners are in operation for two minutes, take
-45 80 160 200 400 reading. Remember 1 DC volt = 1 DC microamp.
-60 60 120 150 300
NOTE-MUST USE DIGITAL METER
-100 36 72 90 180
-120 30 60 75 150
Natural-1000 btu/cu ft LP-2500 btu/cu ft

SET DIAL TO MEASURE VDC

IMPORTANT
For safety, shut unit off and remove manometer as RED COLLAR
INDICATES
soon as an accurate reading has been obtained. (+)
POSITIVE
Take care to replace pressure tap plug. LEAD

G-Flame Signal (-)

A microamp DC meter is needed to check the flame signal

on the ignition control. (-) TO
Flame (microamp) signal is an electrical current which passes FLAME SENSOR
from the furnace control through the sensor during unit operaĆ
(+) TO
tion. Current passes from the sensor through the flame to IGNITION
ground to complete a safety circuit. CONTROL
SENSOR
WIRE

FIGURE 22

Page 17

WARNING
Fire and explosion hazard.
These instructions MUST be followed exactly.
Can cause a fire or explosion resulting in property
damage, personal injury or loss of life.
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 subĆ
base fan switch. With fan switch in ON position, blower
operates continuously on heating speed. 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
Temperature rise for 80UHG units depends on unit input,
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 AIR TEMP. RISE
°F" listed on the unit rating plate.
To Measure Temperature Rise:
1 - Place plenum thermometers in the supply and return
air plenums. Locate supply air thermometer in the first
horizontal run of the plenum where it will not pick up raĆ
diant heat from the heat exchanger.
2 - Set thermostat to highest setting.
3 - After plenum thermometers have reached their highĆ
est and steadiest readings, subtract the two readings.
The difference should be in the range listed on the unit
rating plate. If the temperature is too low, decrease
blower speed. If temperature is too high, first check
the firing rate. Provided the firing rate is acceptable, inĆ
crease blower speed to reduce temperature. To
change blower speed taps see the Blower Speed Taps
section in this manual.
Page 18
C-External Static Pressure
1 - Tap locations shown in figure 23.
2 - Punch a 1/4" diameter hole STATIC PRESSURE
TEST
in supply and return air pleĆ
nums. Insert manometer MANOMETER
hose flush with inside edge
of hole or insulation. Seal
around the hose with perĆ
magum. Connect the zero 80UHG UNIT
end of the manometer to the FIGURE 23
discharge (supply) side of the system. On ducted sysĆ
tems, connect the other end of manometer to the reĆ
turn duct as above. For systems with non-ducted reĆ
turns, leave the other end of the manometer open to
the atmosphere.
3 - With only the blower motor running and the evaporator
coil dry, observe the manometer reading. Adjust blowĆ
er motor speed to deliver the air desired according to
the job requirements.
4 - External static pressure drop must not be more than
0.5" W.C.
5 - Seal around the hole when the check is complete.
D-Blower Speed Taps Leadless Motors
80UHG-1 Models
Blower speed tap selection is accomplished by changing the
taps at the blower motor harness connector. Disconnect harĆ
ness connector from motor to expose speed selectors.
Blower speed selections are listed in table 11.
To Change Blower Speed:
1 - Turn off electric power to furnace.
2 - Remove blower access door.
Disconnect blower motor harness from motor.
3 - Select desired speeds for heating and cooling. (Red =
heating, Black = cooling, White = common).
4 - Depress harness connector tab to release wire termiĆ
nal. Select connector location for new speed (refer to
unit wiring diagram). Insert wire terminal until it is seĆ
curely in place. See figure 24.
5 - Replace harness connector to motor.
TABLE 11
 BLOWER SPEED TAP SELECTION VI-MAINTENANCE
Leaded Motors HARNESS At the beginning of each heating season, the system
CONNECTOR should be checked as follows:
A-Filters
Return air filter is not supplied with unit. See Optional AcĆ
cessaries section in this manual for filter and rack size. A
filter must be used in order to ensure long life and proper
operation. The filter is located in the return air duct or return
air register. Filters must be cleaned or replaced when dirty
to assure proper unit operation.
B- Heat Exchanger and Burners
DEPRESS TAB TO RELEASE
WIRE TERMINAL. SELECT
Due to dimples designed in the heat exchanger, cleanĆ
CONNECTOR LOCATION ing is not recommended. Removal is for inspection
FOR NEW SPEED (REFER TO only.
UNIT WIRING DIAGRAM). INĆ
SERT WIRE UNTIL IT IS SEĆ NOTE-Use papers or protective covering in front of furĆ
MOTOR
CURELY IN PLACE. nace while cleaning furnace.
FIGURE 24 To clean burners:
1 - Remove screws holding upper burner mounting rail (figĆ
E-Blower Speed Taps Leaded Motors
ure 17). Remove rail.
80UHG-2 Models 2 - Slide burners off each orifice pull burners from heat exĆ
Blower speed tap changes are made on the SureLight changer.
control board. See figure 6. Unused taps must be secured
3 - Clean holes in burner head (retention ring) with a wire
on two dummy terminals labeled "PARK on the SureLight
board. The heating tap is connected to the "HEAT-H " terĆ brush. See figure 17.
minal and the cooling tap is connected to the "COOL-H" 4 - With a shop vacuum or rags, clean out soot and scale
terminal. The continuous blower tap is the same as the deposits from burners.
heating tap. 5 - Remove screws securing flue box to vestibule panel.
To change existing heat tap, turn off power then switch out Remove flue box from unit. Leave combustion air
speed tap on "HEAT-H" with tap connected to "PARK" .
blower attached to flue box.
See table 12 for blower motor tap colors for each speed.
TABLE 12 6 - With a shop vacuum or rags, clean out soot and scale
deposits from heat exchanger tubes and flue box. If turĆ
bulators are removed (figure 1) make sure they are reĆ
installed before reassembling units.
7 - Inspect heat exchanger for corrosion damage, holes or
cracks.
8 - Replace burners making sure to fully engage on orifice.
Resecure burner mounting rail and flue box. Inspect flue
box gasket. Replace gasket if necessary.
9 - Slide heat exchanger into cabinet and reĆsecure heat
exchanger screws.
10 - Reinstall filler piece making sure that there is a good
seal between the cabinet sides, blower and deck and
filler piece. Use silicon caulking to fill in any potential
gaps.
11 - ReĆsecure flue pipe, gas piping and access panels.
12 - Carefully check all piping connections (factory and
field) for gas leaks. Use a leak detecting solution or othĆ
er preferred means.
12 - Turn on gas and electrical supply.

Page 19
 HEAT EXCHANGER REMOVAL (unit shown in horizontal position)

REMOVE SCREWS (4)

Left

Back
Bottom
Top

SLIDE ENTIRE ASSEMBLY OUT OF CABINET Front

FIGURE 25
CAUTION
Potential for gas leaks, fire or explosion.
Some soaps used for leak detection are corrosive
to certain metals. Carefully clean piping thorĆ
oughly after leak detection has been completed.
Can cause damage to piping resulting in gas
leaks, fire or explosion.
C-Supply Air Blower
1 - Check and clean blower wheel.
2 - Motors used on the Lennox 80UHG series units are
permanently lubricated and need no further luĆ
brication.
Right
D-Flue and Chimney
Flue must conform to all AGA/GAMA venting requireĆ
ments. Flue pipe deteriorates from the inside out and must
be disconnected in order to check thoroughly. Check flue
pipe, chimney and all connections for tightness and to
make sure there is no blockage or leaks.
E-Electrical
1 - Check all wiring for loose connections.
2 - Check for correct voltage.
3 - Check amp-draw on blower motor.

Page 20
VII- Wiring and Sequence of Operation

80UHG-1 MODEL WITH EGC CONTROL (SEE FLOW CHARTS ON THE FOLLOWING TWO PAGES):
1 - When disconnect is closed, 120V is routed through door
interlock switch (S51) to feed the line voltage side of the
ignition control (A3) and transformer T1 primary. Door inĆ
terlock switch must be closed for A3 and T1 to receive
voltage.
2 - T1 supplies 24VAC to terminal 24VAC" on A3. In turn,
terminal R" of A3 supplies 24VAC to terminal R" of the
indoor thermostat (not shown).
3 - When there is a call for heat, W1 of the thermostat enĆ
ergizes W of the ignition control with 24VAC.
4 - CAB of the ignition control energizes the combustion air
inducer (B6). When the combustion air inducer
nears full speed, combustion air prove switch (S18)
closes. Switch must close within 2 1/2 minutes or
control goes into 5 minute Watchguard Pressure
Switch delay.
5 - When S18 closes, assuming primary limit (S10) and
secondary limit (S21) are closed, a 15 second pre-purge
begins. After the pre-purge period the ignition control
starts ignition spark and opens main gas valve.
6 - After 45 seconds, ignition control (A3) energizes the
indoor blower (B3).
7 - When heat demand is satisfied, W1 of the thermostat deĆ
energizes W of the ignition control and the gas valve is
immediately deĆenergized. The combustion air inducer
immediately stops. The indoor blower runs for a desigĆ
nated fan off" period (60-240 seconds) as set by jumper
on ignition control.

Page 21
 80UHG-1 HEATING SEQUENCE OF OPERATION
NORMAL HEATING MODE
CONTROL MAIN POWER ON"
FLAME OFF?
YES
CONTROL SELF-CHECK OKAY?
YES
ROLL-OUT SWITCH CLOSED
YES
LED: SLOW FLASH RATE
THERMOSTAT CALLS FOR HEAT
LED: FAST FLASH RATE
COMB. AIR INDUCER PRESSURE SWITCH OPEN?
YES
COMBUSTION AIR INDUCER ON?
HTG ACC. TERM. ENERGIZED?
YES
PRESSURE SWITCH CLOSED WITHIN 2.5 MIN.?
YES
COMB. AIR INDUCER PREPURGE (15 seconds)
IGNITION TRIAL (10 seconds) -- START IGNITION
SPARK, OPEN MAIN GAS VALVE.
HAS FLAME REGISTERED WITHIN 10 SECONDS
AFTER IGNITION TRIAL?
YES
IS FLAME SENSED AFTER 10 SECOND
FLAME RECTIFICATION PERIOD?
YES
INDOOR AIR BLOWER ON.
(Fixed 45-second delay)
PRIMARY/SECONDARY LIMITS MONITORED IN
HEAT CYCLE. ARE SWITCHES CLOSED?
YES
PRESSURE SWITCH CLOSED?
YES
THERMOSTAT OPENS
LED: SLOW FLASH RATE
COMB. AIR INDUCER OFF (5 sec. delay)
HTG ACC. TERM. DE-ENERGIZED.
INDOOR AIR BLOWER OFF (After selected 60, 90,
120, 180, or 240 delay)?
ABNORMAL HEATING MODE
GAS VALVE OFF. COMB. INDUCER ON. INDOOR
BLOWER ON HEAT SPEED. SEQUENCE HOLDS UNTIL
NO FLAME SENSED OR MAIN POWER IS INTERRUPTED
NO
AND RESET. DIAG. CODE: 1- FLASHING; 2-OFF
(FLAME SENSED WITHOUT VALVE ENERGIZED)
NO
GAS VALVE, COMB. INDUCER AND INDOOR BLOWER
(WITH DELAY) OFF. REMOVE POWER TO RESET
NO
CONTROL. DIAG. CODE: BOTH ON (CONTROL
SELF-CHECK FAILURE OR INCORRECT WIRING)
GAS VALVE, COMB. BLOWER AND INDOOR BLOWER
(WITH DELAY) OFF. SEQUENCE HOLDS UNTIL
ROLL-OUT SWITCH IS MANUALLY CLOSED.
DIAG. CODE: 1-ON;
2-FLASHING (FLAME ROLL-OUT OPEN)
NO
GAS VALVE, COMB. INDUCER AND INDOOR BLOWER
(WITH DELAY) OFF. SEQUENCE HOLDS UNTIL
PRESSURE SWITCH CLOSES OR THERMOSTAT
RESETS CONTROL. DIAG. CODE: 1-OFF;
NO 2-FLASHING (C.A.B. PRESSURE SWITCH OPEN)
YES
PRESSURE SWITCH WATCHGUARD CONDITION:
GAS VALVE, COMB. INDUCER AND INDOOR BLOWER
(WITH DELAY) OFF. DIAG. CODE: 1-OFF /
2-FLASHING (C.A.B. PRESSURE SWITCH OPEN) IS 5
MINUTE RESET PERIOD COMPLETE?
NO GAS VALVE OFF. COMB. INDUCER ON. INDOOR
BLOWER (WITH 45 DELAY) ON. HAS CONTROL FAILED
FLAME SENSE 5 TIMES DURING ONE HEAT DEMAND?
IF YES, SYSTEM GOES INTO 60 MIN.WATCHGUARD.
NO DIAG. CODE: 1-ALT. FLASHING / 2-ALT. FLASHING IF
NO, GO TO COMB. AIR BLOWER ON?"
HAS CONTROL RESET IGNITION SEQUENCE 5 TIMES
IF YES, SYSTEM GOES INTO 60 MIN. WATCHGUARD.
DIAG. CODE: 1-ALT. FLASHING / 2-ALT. FLASHING IF
NO, GO TO COMB. AIR BLOWER ON?"
NO GAS VALVE OFF. COMB. INDUCER OFF. INDOOR
BLOWER ON UNTIL LIMIT CLOSES. DIAG.
CODE: 1-FLASHING / 2-ON (LIMIT OPEN)
NO IS LIMIT NOW CLOSED?
YES
HAS PRIMARY LIMIT OPENED 5 TIMES DURING
ONE UNSATISFIED HEAT DEMAND. IF YES,
SYSTEM GOES INTO 60 MIN.WATCHGUARD.
DIAG. CODE: 1-FLASHING / 2-ON
IF NO, GO TO COMB. AIR BLOWER ON?"
GAS VALVE, COMB. INDUCER AND INDOOR BLOWER
(WITH DELAY) OFF. DIAG. CODE: 1-OFF / 2-FLASHING NO
(C.A.B. PRESSURE SWITCH OPEN) HAS C.A.B.
PRESSURE SWITCH CLOSED IN 2.5 MINUTES?
YES
Page 22
 80UHG-1 COOLING SEQUENCE OF OPERATION
LED: Slow flash rate.
REMAINS UNCHANGED THROUGHOUT COOLING CYCLE.

THERMOSTAT CALLS FOR COOLING.

COMPRESSOR CONTACTOR AND SYSTEM FAN

ENERGIZED AT COOLING SPEED AFTER
1 SECOND DELAY. ACC TERMINAL ENERGIZED.

THERMOSTAT OPENS.

COMPRESSOR OFF.

SYSTEM FAN AND ACC TERMINAL OFF AFTER

0 SECONDS.

80UHG-1 MANUAL CONTINUOUS FAN SEQUENCE OF OPERATION

LED: Slow flash rate.

REMAINS UNCHANGED THROUGHOUT SEQUENCE.

CONTINUOUS FAN SELECTION MADE AT THERMOSTAT.

CONTROL ENERGIZES SYSTEM FAN AT HEATING SPEED.
ACC TERMINAL ENERGIZED.

THERMOSTAT CALLS FOR HEAT. HTG ACC. TERM. ENERGIZED

WITH COMB. AIR INDUCER

NO YES

SYSTEM FAN REMAINS ON HEATING SPEED AFTER

THERMOSTAT CALLS FOR COOLING.
SELECTED DELAY. ACC TERM. REMAINS ENERGIZED.
YES NO
SYSTEM FAN SWITCHED TO COOLING THERMOSTAT OPENS.
SPEED. ACC TERMINAL REMAINS ENERGIZED.

SYSTEM FAN SWITCHED OFF AFTER DELAY.

THERMOSTAT OPENS. ACC TERMINAL DE-ENERGIZED.

SYSTEM FAN SWITCHES TO HEATING SPEED

AND ENERGIZES ACC TERMINAL. BOTH REMAIN ON
UNTIL CONTINUOUS FAN IS SWITCHED OFF AT THERMOSTAT.

Page 23
80UHG-2 MODEL WITH SURELIGHT CONTROL
1 - When there is a call for heat, W1 of the thermostat
energizes W of the furnace control with 24VAC.
2 - S10 primary limit switch and S47 rollout switch
are closed. Call for heat can continue.
3 - SureLight control energizes combustion air blowĆ
er B6. Combustion air inducer runs until S18 comĆ
bustion air prove switch closes (switch must close
within 2-1/2 minutes or control goes into 5 minute
Watchguard Pressure Switch delay). Once S18
closes, a 15-second pre-purge follows.
4 - SureLight control energizes ignitor. A 20-second
warm-up period begins.
Page 24
5 - Gas valve opens for a 4-second trial for ignition
(ignitor will remain energized for the first second).
6 - Flame is sensed, gas valve remains open for the
heat call.
7 - After 45-second delay, SureLight control enerĆ
gizes indoor blower B3.
8 - When heat demand is satisfied, W1 of the indoor
thermostat de-energizes W of the SureLight conĆ
trol which de-energizes the gas valve. CombusĆ
tion air inducer B6 continues a 5-second post-
purge period, and indoor blower B3 completes a
selected OFF time delay.
 HEATING SEQUENCE OF OPERATION

NORMAL HEATING MODE ABNORMAL HEATING MODE

POWER ON GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

INDOOR BLOWER DELAY OFF.
LED #1 ON
CONTROL SELF-CHECK OKAY? NO LED #2 ON
(RESET CONTROL BY TURNING MAIN POWER OFF.)
YES
YES
IS POLARITY REVERSED? POLARITY REVERSED.
LED #1 -- FAST FLASH
LED #2 -- SLOW FLASH
NO

NO LED SIGNALS WAITING ON CALL FROM

IS VOLTAGE THERMOSTAT. CONTROL WILL NOT RESPOND
ABOVE 75 VOLTS? UNTIL VOLTAGE RISES ABOVE 75 VOLTS.

YES
GAS VALVE OFF. COMBUSTION AIR INDUCER ON.
NO
INDOOR BLOWER ON.
ROLLOUT SWITCH CLOSED? LED #1 -- ON. LED #2 -- SLOW FLASH.
YES SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES.

GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

NO
BURNER OFF? INDOOR BLOWER ON HEATING SPEED.
(CONTINUOUS FLAME CHECK) LED #1 -- SLOW FLASH
LED #2 -- OFF
YES
NO NORMAL OPERATION:
LED #1 -- SLOW FLASH
LED #2 -- SLOW FLASH
YES
THERMOSTAT CALLS FOR HEAT:
LED #1 -- FAST FLASH
LED #2 -- FAST FLASH COMBUSTION AIR INDUCER OFF.
INDOOR BLOWER ON
YES LED #1 SLOW FLASH RATE
NO
PRIMARY AND SECONDARY LIMIT SWITCH. LED #2 -- ON
CLOSED?
GAS VALVE OFF.
YES COMBUSTION AIR INDUCER OFF.
NO INDOOR BLOWER OFF WITH DELAY.
IS COMBUSTION AIR
PRESSURE SWITCH OPEN? LED #1 OFF
LED #2 SLOW FLASH
YES (Sequence holds until pressure switch
IS COMBUSTION AIR BLOWER closes or thermostat resets control.)
ENERGIZED?
YES
PRESSURE SWITCH IS IN WATCHGUARD MODE.
HAS COMBUSTION AIR PRESSURE NO GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.
SWITCH CLOSED IN 2.5 MINUTES? INDOOR BLOWER OFF WITH DELAY.
LED #1 -- OFF. LED #2 -- SLOW FLASH.
YES
IS 5ĆMINUTE RESET PERIOD COMPLETE?

CONTINUED NEXT PAGE

Page 25
 HEATING SEQUENCE CONTINUED
NORMAL HEATING MODE ABNORMAL HEATING MODE

158SECOND COMBUSTION AIR INDUCER PREPURGE

INITIATED BY CLOSED PRESSURE SWITCH.
IS VOLTAGE ABOVE 75 VOLTS? NO
YES
NO YES
NO LEDS SIGNAL
IGNITOR WARM8UP −− 20 SECONDS. IS THERE A PROPER GROUND? ALTERNATING
YES FAST FLASH
YES YES NO
48SECOND TRIAL FOR IGNITION. IS IGNITOR INTACT AND CONNECTED?
GAS VALVE OPENS. IGNITOR ENERGIZED FOR 1
SECOND AFTER VALVE OPENS. CONTROL
10M9301: IGNITOR ENERGIZED DURING TRIAL GAS VALVE OFF. COMBUSTION AIR INDUCER ON.
UNTIL FLAME SENSED. INDOOR BLOWER OFF.
NO NO
YES HAS CONTROL FAILED TO SENSE FLAME FOR
FLAME STABILIZATION PERIOD. FIVE CONSECUTIVE TRIES DURING A SINGLE
HEAT DEMAND?
4 SECONDS
YES
FLAME RECTIFICATION CURRENT WATCHGUARD MODE. GAS VALVE OFF.
CHECK. CAN FLAME BE PROVEN WITHIN COMBUSTION AIR INDUCER OFF.
4 SECONDS AFTER GAS VALVE OPENS? INDOOR BLOWER OFF WITH DELAY
(u0.15 microamps) LEDs SIGNAL WATCHGUARD FAILURE CODE.
IS 608MINUTE RESET PERIOD COMPLETE?
YES
YES
NO NO
FLAME PRESENT? HAS CONTROL RESET IGNITION
SEQUENCE FOUR TIMES?
YES LOW FLAME SIGNAL LIMIT SWITCH
NO
(Does not affect operation of control) WATCHGUARD
FLAME SIGNAL ABOVE 0.2 MICROAMPS? LED #1 −− SLOW FLASH MODE. GAS VALVE
YES LED #2 −− FAST FLASH OFF. COMB. AIR
INDUCER OFF.
INDOOR BLOWER ON DELAY BEGINS INDOOR BLOWER
(45 seconds.) OFF WITH DELAY.
GAS VALVE DE−ENERGIZED.
YES COMBUSTION AIR INDUCER DE−ENERGIZED. LED#1−SLOW
FLASH LED#2− ON.
PRIMARY AND SECONDARY LIMIT NO INDOOR BLOWER ON UNTIL SWITCH CLOSES.
LED #1 −− SLOW FLASH. LED #2 −− ON. IS 60−MINUTE
SWITCHES CLOSED? RESET PERIOD
IS LIMIT SWITCH CLOSED?
COMPLETE?
YES
HAS PRIMARY SECONDARY NO
YES LIMIT RESET (CLOSED) YES
WITHIN 3 MINUTES?

NO GAS VALVE POWER OFF.

ROLLOUT SWITCH CLOSED?
YES
COMBUSTION AIR PRESSURE
SWITCH CLOSED?
YES
THERMOSTAT DEMAND SATISFIED.
YES
LED #1 & #2 SIMULTANEOUS SLOW FLASHES.
YES
COMB. AIR INDUCER CONTINUES 58SECOND
POST PURGE AFTER T’STAT DEMAND IS SATISFIED.
INDOOR AIR BLOWER COMPLETES SELECTED
KOFF" DELAY BEFORE SHUTTING OFF.
COMBUSTION AIR INDUCER POWER ON.
INDOOR BLOWER ON
LED #1 −− ON. LED #2 −− SLOW FLASH.
SEQUENCE HOLDS UNTIL ROLLOUT SWITCH IS RESET
AND MAIN POWER IS INTERUPTED OR
NO THERMOSTAT IS CYCLED OFF/ON FOR 1 TO 20 SEC.
GAS VALVE DE−ENERGIZED.
COMBUSTION AIR INDUCER ON. YES
INDOOR BLOWER OFF WITH DELAY
LED #1 −− OFF. LED #2 −− SLOW FLASH.
HAS CAB SWITCH CLOSED IN 2.5 MINUTES?
NO
58MINUTE PRESSURE SWITCH
WATCHGUARD MODE.

Page 26
 COOLING SEQUENCE OF OPERATION
NORMAL COOLING MODE ABNORMAL COOLING MODE

POWER ON

IGNITION CONTROL MAIN POWER ON.

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.

CONTROL SELF DIAGNOSTIC CHECK.
IS CONTROL OPERATING NORMALLY?
YES
IS POLARITY REVERSED?
NO INDOOR BLOWER OFF WITH NORMAL DELAY.
SIGNAL CIRCUIT BOARD FAILURE AT LED.
INTERRUPT MAIN POWER TO RESET CONTROL.
YES
SIGNAL POLARITY REVERSED AT LED.

NO
NO
IS VOLTAGE LED SIGNALS WAITING ON CALL FROM
ABOVE 75 VOLTS? THERMOSTAT. CONTROL WILL NOT RESPOND
UNTIL VOLTAGE RISES ABOVE 75 VOLTS.

YES

NO GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

ROLLOUT SWITCH MONITORED CONTINUOUSLY. INDOOR BLOWER ON.
IS ROLLOUT SWITCH CLOSED? SIGNAL ROLLĆOUT SWITCH OPEN AT LED.
SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES.
YES
NO GAS VALVE OFF. COMBUSTION AIR INDUCER OFF.
CHECK FOR MAIN BURNER FLAME SENSE. INDOOR BLOWER OFF WITH NORMAL DELAY.
IS MAIN BURNER FLAME OFF? SIGNAL UNWANTED FLAME SENSED AT LED.
SEQUENCE HOLDS UNTIL FLAME IS NOT SENSED.
YES
LED: SLOW FLASH RATE REMAINS UNCHANGED
THROUGHOUT COOLING CYCLE.

THERMOSTAT CALLS FOR COOLING.

COMPRESSOR CONTACTOR AND SYSTEM FAN

ENERGIZED WITH 0ĆSECOND DELAY
(COOLING SPEED). EAC-H TERM. ENERGIZED.

THERMOSTAT OPENS.

COMPRESSOR OFF.

SYSTEM FAN AND ACC. TERM. OFF

WITH 0ĆSECOND DELAY.

Page 27
 SURELIGHT CONTROL
CONTINUOUS HEAT SPEED FAN SEQUENCE OF OPERATION

LED: SLOW FLASH RATE REMAINS

UNCHANGED THROUGHOUT SEQUENCE.

MANUAL FAN SELECTION MADE AT THERMOSTAT.

CONTROL (G) ENERGIZES SYSTEM FAN AT HEAT-H
HEAT SPEED. EAC-H TERMINAL IS ENERGIZED.

HUM-N TERM. ENERGIZES

THERMOSTAT CALLS FOR HEAT (W). WITH COMB. AIR BLOWER.
NO YES

SYSTEM FAN REMAINS ON HEAT-H

HEATING SPEED.

THERMOSTAT OPENS.
THERMOSTAT CALLS FOR COOLING.
YES NO

SYSTEM FAN SWITCHED TO COOL-H SPEED. HUM-N TERM. DE-ENERGIZES

EAC-H TERM. REMAINS ON. WITH COMB. AIR INDUCER

THERMOSTAT OPENS.
SYSTEM FAN REMAINS ON HEAT-H
HEATING SPEED.

MANUAL FAN SELECTION MADE AT THERMOSTAT.

CONTROL (G) ENERGIZES SYSTEM FAN AT HEAT-H
HEAT SPEED. EAC-H TERM. ENERGIZED.

Page 28
VIII-Troubleshooting-SureLight Control
SURELIGHT - TROUBLE SHOOTING GUIDE
UPON INITIAL POWER UP, REMOVE ALL THERMOSTAT DEMANDS TO THE UNIT

PROBLEM: 1 UNIT FAILS TO OPERATE IN THE COOLING, HEATING, OR CONTINUOUS FAN MODE
Condition Possible Cause Corrective Action / Comments
1.1 1.1.1
ACTION 1 - Check 120V main voltage.
- Both diagnostic lights fail to light up. Main voltage 120V not supplied to Determine cause of main power failure.
unit.
1.1.2 ACTION 1 - Check for correct wiring of 120V to
LED#1-Off power make up box and transformer.
LED#2-Off Miswiring of furnace or improper
ACTION 2 - Check 24V wiring to control board.
connections.
1.1.3 ACTION 1 - Replace fuse.
ACTION 2 - If fuse still blows, check for short.
Blown fuse
ACTION 1 - Check that door switch is activated
when door is closed.
1.1.4 ACTION 2 - Check wire connections to switch, reĆ
place loose connectors.
Door interlock switch failure. ACTION 3 - Check continuity of switch in closed
position. Replace if defective.
1.1.5 ACTION 1 - Check that transformer output is
24V. Replace if defective.
Transformer Failure.
1.1.6 ACTION 1 - If all the above items have been
checked, replace board.
Failed control board.
1.2 ACTION 1 - Manually reset the roll-out switch
1.2.1 by pushing the top button.
- Diagnostic lights flash the roll-out Roll-out switch open. ACTION 2 - Determine the cause of the roll-out
switch activation before leaving furnace.
code.
1.2.2 ACTION 1 - Check continuity across roll-out
switch. Replace roll-out switch if switch is reset
Roll-out switch failure. but does not have continuity.
LED#1-On, 1.2.3
LED#2-Slow Flash Miswiring or improper connections at ACTION 1 - Check wiring connections to switch.
switch
roll-out switch.
ACTION 1 - Check 12-pin connector for proper
1.2.4 connection to control board.
ACTION 2 - Check continuity of the multi plug
12 pin connector failure pin.
1.3
- On initial power-up the comb. air inĆ
ducer does not energize.
ACTION 1 - Check the 120V has line and neutral
- Diagnostic lights flash the reverse 1.3.1 correctly input into control.
polarity code. ACTION 2 - Reverse the line and neutral at the
120V main power polarity reversed.
120V field connection.

LED#1-Fast Flash,
LED#2-Slow Flash.
1.4
1.4.1 ACTION 1 - Check for 120V to combustion air
- On initial power up the combustion
Open combustion air inducer motor inducer. If no power, check wire and connecĆ
air inducer does not energize. tions.
- Diagnostic lights flash normal power circuit.
on operation.

1.4.2 ACTION 1 - If power is present at blower, replace

LED#1-Slow Flash Failed combustion air inducer motor. blower.
LED#2-Slow Flash

Page 29
PROBLEM 1: UNIT FAILS TO OPERATE IN THE COOLING, HEATING, OR CONTINUOUS FAN MODE

Condition Possible Cause Corrective Action / Comments

1.5 ACTION 1 - Check that the unit is properly
1.5.1 ground.
- Diagnostic lights flash the improper ACTION 2 - Install a proper main ground to the
Improper ground to the unit.
main g
ground. unit

1.5.2 ACTION 1 - Check 4-pin connector for proper

4-Pin connector is improperly atĆ
LED#1-Alternating Fast Flash
LED#2-Alternating
LED#2 Alternating Fast Flash tached to the circuit board.
1.5.3
Line voltage is below 75V.
installation. Correctly insert connector into conĆ
trol.
ACTION 1 - Check that the line voltage is above
75V. Determine cause of voltage drop and supĆ
ply correct voltage to the control.

1.5.4 ACTION 1 - Check for correct wiring and loose

connections in the ignitor circuit. Check mult-
Open ignitor circuit. plug connections for correct installation.

1.5.5 ACTION 1 - Unplug ignitor and read resistance

across ignitor. If resistance does not read beĆ
Broken or failed ignitor. tween 10.9 and 19.7 ohms, replace the ignitor.

PROBLEM 2: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR BLOWER DOES
NOT ENERGIZE
Condition Possible Cause Corrective Action / Comments
2.1
ACTION 1 - Check continuity across switch(es).
- Unit operates with a cooling or conĆ 2.1.1 Switches reset automatically upon cool down.
tinuous fan demand. ACTION 2 - Check for restrictions on blower inlet
Primary or secondary (if equipped ) air (including filter) and outlet air. Determine
- Combustion air inducer will not start
limit open. cause for limit activation before placing unit back
with a Heating demand. in operation.
- Diagnostic
g lights
g flash the limit failure
mode.
d
2.1.2 ACTION 1 - Check for correct wiring and loose
Miswiring of furnace or improper conĆ connections. Correct wiring and/or replace any
LED#1-Slow Flash, nections at limit switch(es).
loose connections.
LED#2-On
2.2
- Unit operates with a cooling and conĆ 2.2.1 ACTION 1 - Check for correct wiring and loose
tinuous fan demand. Miswiring of furnace or improper conĆ connections. Correct wiring and/or replace any
- Combustion air inducer will not start nections to combustion air inducer. loose connections.
with a Heating demand.
- Diagnostic lights flash the pressure
switch failure code.
2.2.2 ACTION 1 - Check that the pressure switch is
open without the combustion air inducer operatĆ
LED#1-Off, Pressure switch stuck closed. ing. Replace if defective.
LED#2-Slow Flash

Page 30
 PROBLEM 2: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR INDUCER DOES
NOT ENERGIZE (CONT.).
Condition Possible Cause Corrective Action/Comments
2.3
- Unit operates with a cooling and conĆ 2.3.1 ACTION 1 - Check for correct wiring and loose
tinuous fan demand. connections. Correct wiring and/or replace any
Miswiring of furnace or improper conĆ
- Combustion air inducer will not start loose connections.
nections to combustion air inducer.
with a Heating demand.
- Diagnostic lights flash the pressure
switch failure code 2.5
2 5 minutes after
heating demand.
2.3.2 ACTION 1 - If there is 120V to combustion air inĆ
ducer and it does not operate, replace combusĆ
Combustion air inducer failure. tion air inducer.
LED#1-Off,
LED#2-Slow Flash
PROBLEM 3: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR BLOWER
ENERGIZES, IGNITOR IS NOT ENERGIZED.
Condition Possible Cause Corrective Action/Comments
3.1 3.1.1
ACTION 1 - Check that the pressure switch lines
- Unit operates with a cooling and Pressure switch does not close due are correctly routed. Correctly route pressure
continuous fan demand. to incorrect routing of the pressure switch lines.
- Combustion air inducer energizes switch lines.
with a heating demand.
demand
3.1.2
- Diagnostic lights flash the pressure ACTION 1 - Remove any obstructions from the
switch failure code 2.5 minutes after Pressure switch does not close due the pressure lines and/or taps.
heatingg demand. to obstructions in the pressure lines.
3.1.3 ACTION 1 - Check pressure switch lines for
leaks. Replace any broken lines.
LED#1 Off
LED#1-Off Pressure switch lines damaged
LED#2-Slow Flash 3.1.4 ACTION 1 - Check pressure switch lines for conĆ
densate. Remove condensate from lines. Check
Condensate in pressure switch line. that the condensate lines are located correctly.

ACTION 1 - Check the differential pressure

3.1.5
Pressure switchdoes not close due to
a low differential pressure across the
pressure switch.
across the pressure switch. This pressure
should exceed the set point listed on the
switch.
ACTION 2 - Check for restricted inlet vent. ReĆ
move all blockage.
ACTION 3 - Check for proper vent sizing and
run length. See installation instructions.

3.1.6
Wrong pressure switch installed in
the unit, or pressure switch is out of
calibration.
3.1.7
Miswiring of furnace or improper conĆ
nections at pressure switch.
3.1.8
Pressure switch failure.
ACTION 1 - Check that the proper pressure
switch is installed in the unit. Replace pressure
switch if necessary.
ACTION 1 - Check for correct wiring and loose
connections. Correct wiring and/or replace any
loose connections.
ACTION 1 - If all the above modes of failure have
been checked, the pressure switch may have
failed. Replace pressure switch and determine if
unit will operate.

Page 31
 PROBLEM 4: UNIT FAILS TO FIRE IN THE HEATING MODE, COMBUSTION AIR BLOWER
ENERGIZES, IGNITOR IS ENERGIZED.
Condition
4.1
- Unit operates with a cooling and
continuous fan demand.
- Combustion air inducer energizes
with Heating demand.
- Ignitor is energized but unit fails to
light.
LED#1-Alternating Slow Flash
LED#2-Alternating Slow Flash
Possible Cause Corrective Action/Comments
4.1.1
ACTION 1 - Check line pressure at the gas
valve. Pressure should not exceed 13" WC for
Check that gas is being supplied to both natural and propane. Line pressure should
read a minimum 4.5" WC for natural and 8.0"WC
the unit. for propane.
4.1.2
ACTION 1 - Check for correct wiring and loose
Miswiring of gas valve or loose conĆ connections. Correct wiring and/or replace any
nections at multi-pin control amp loose connections.
plugs or valve.
ACTION 1 - Check that 24V is supplied to the
gas valve approximately 35 seconds after heat
4.1.3 demand is initiated.
Defective gas valve or ignition conĆ ACTION 2 - Replace the valve if 24V is supplied
but valve does not open.
trol. ACTION 3 - Replace the control board if 24V is
not supplied to valve.

PROBLEM 5: BURNERS LIGHT WITH A HEATING DEMAND BUT UNIT SHUTS DOWN
PREMATURELY
Condition Possible Cause Corrective Action/Comments
5.1
- Burners fire with a heating deĆ
mand.
- Burners light but unit shuts off prior
to satisfying T-stat demand. 5.1.1 ACTION 1 - Check for restricted exhaust vent.
Remove all blockage.
- Diagnostic lights flash the pressure Low pressure differential at the presĆ ACTION 2: Check for proper vent sizing. See
switch code. sure switch. installation instructions.

LED#1-Off
LED#2-Slow Flash
5.2 5.2.1 ACTION 1 - Check that sensor is properly loĆ
- Combustion air inducer energizes Sensor or sensor wire is improperly cated and that the sense wire is properly atĆ
tached to both the sensor and the control.
with a heating demand. installed.
-BBurners
rners light b
butt fail to sta
stay lit
lit. ACTION 1 - Check for a broken sensor.
- After 5 tries the control diagnostics 5.2.2 ACTION 2 - Test continuity across the sense
flash the watchguard burners failed to Sensor or sensor wire is broken. wire. If wire or sensor are damaged replace
ignite code. the component.
ACTION 1 - Check for resistance between the
5.2.3 sensor rod and the unit ground.
Sensor or sensor wire is grounded to ACTION 2 - Check for resistance between the
LED#1-Alternating Slow Flash sensor wire and the unit ground.
LED#2-Alternating Slow Flash the unit. ACTION 3 - Correct any shorts found in circuit.
ACTION 1 - Check the microamp signal from
the burner flame. If the microamp signal is beĆ
low 0.20 microamps, check the sensor rod for
proper location or contamination.
ACTION 2 - Replace, clean, or relocate flame
5.2.4 sensor rod. If rod is to be cleaned, use steel
wool or replace sensor. DO NOT CLEAN ROD
Control does not sense flame. WITH SAND PAPER. SAND PAPER WILL
CONTRIBUTE TO THE CONTAMINATION
PROBLEM. NOTE: Do not attempt to bend
sensor rod.
ACTION 3 - Check that there is proper ground
to burner box. Repair as necessary.

Page 32
 PROBLEM 5: BURNERS LIGHT WITH HEATING DEMAND BUT UNIT SHUTS DOWN
PREMATURELY (CONT.)
Condition Possible Cause Corrective Action/Comments
5.3 ACTION 1 - Check that the manifold pressure
matches value listed on nameplate. See installaĆ
- Combustion air inducer energizes 5.3.1 tion instructions for proper procedure.
with a heating demand. ACTION 2 - Verify that the installed orifice size
- Burners light. Unit is firing above 100% of the match the size listed on the nameplate or instalĆ
nameplate input. lation instructions.
- Roll-out switch trips during the ACTION 3 - Check the input rate to verify rate
heating demand. matches value listed on nameplate.
- Diagnostic lights flash roll
roll-out
out fail
failĆ ACTION 1 - Tighten orifice until leak is sealed.
ure. 5.3.2 NOTE: Be careful not to strip orifice threads.
Gas orifices leak at the manifold conĆ ACTION 2 - Check for gas leakage at the
threaded orifice connection. Use approved
nection. method for leak detection (see unit instructions).
LED#1 On
LED#1-On
LED#2-Slow Flash ACTION 1 - Check for sooting deposits or other
5.3.3 restrictions in the heat exchanger assembly.
Clean assembly as outlined in instruction manuĆ
Insufficient flow through the heat exĆ al.
changer caused by a sooted or reĆ ACTION 2 - Check for proper combustion. See
stricted heat exchanger. NO TAG Heating System Service Checks secĆ
tion NO TAG.

5.3.4 ACTION 1 - Check that the burners are firing into

Burners are not properly located in the center of the heat exchanger openings. CorĆ
rect the location of the burners if necessary.
the burner box.
5.4 ACTION 1 -Check vent pipe and remove any obĆ
5.4.1 structions
- Combustion air inducer energizes
ACTION 2 - Check for correct exhaust vent
with a heating demand. Poor Venting installation. See instructions
- Burners light roughly and the unit
fails to stay lit. ACTION 1 - Remove burner and inspect the
- Diagnostic lights flash watchguard 5.4.2 cross-overs for burrs, or any restriction or if
flame failure. Improper burner cross-overs crossover is warped. Remove restriction or reĆ
place burners.

LED#1-Alternating Slow Flash 5.4.3 ACTION 1 - Remove gas orifices and inspect.
LED#2-Alternating Slow Flash Remove any burrs that are present or replace
Burrs in gas orifices orifice.

5.5
- Combustion air inducer energizes 5.5.1 ACTION 1 - Check that the sensor is properly loĆ
with a heating demand. cated.
Loose sensor wire connection ACTION 2 - Check that the sense wire is properĆ
- Burners light.
causes intermittent loss of flame sigĆ ly attached to both the sensor and the control.
- Diagnostic lights flash watch guard
nal. Pay extra attention to the pin connectors.
flame failure.
- NOTE" Unit might go into 60 minĆ
ute Watchguard mode depending on
intermittent nature of sensor signal.
5.5.2 ACTION 1 - Check for proper ground and repair
as necessary.
Poor ground to burner box
LED#1-Alternating Slow Flash
LED#2-Alternating Slow Flash

Page 33
 PROBLEM 6: CONTROL SIGNALS LOW FLAME SENSE DURING HEATING MODE
Condition Possible Cause Corrective Action/Comments
6.0 6.1.1 ACTION 1 - Check the sensor rod for proper
location on the burner. Properly locate the senĆ
- Unit operates correctly but the Sensor rod is improperly located on sor rod or replace if rod cannot be located corĆ
diagnostic lights flash low flame the burner. rectly.
sense code.
code
ACTION 1 - Check sensor rod for contamination
or coated surface. Clean the sensor rod with
6.1.2 steel wool or replace sensor. DO NOT USE
LED#1-Slow Flash SAND PAPER TO CLEAN ROD. SAND PAPER
LED#2-Fast Flash Sensor rod is contaminated. WILL CONTRIBUTE TO THE CONTAMIĆ
NATION PROBLEM.

PROBLEM 7: INDOOR BLOWER FAILS TO OPERATE IN COOLING, HEATING, OR CONTINUOUS

FAN MODE
Condition Possible Cause Corrective Action/Comments
7.0 7.1.1
ACTION 1- Correct wiring and/or replace any
- Indoor blower fails to operate in Miswiring of furnace or improper conĆ loose connections. Check for correct wiring and
continuous fan, cooling, or heating nections at control or indoor blower loose connections.
mode. motor.
ACTION 1 - Check for 120V at the various calls
7.1.2 for indoor blower by energizing "Y", "G", and "W"
individually on the low voltage terminal strip.
120V is not being supplied to the inĆ Note that when "W' is energized, the blower is
door air blower or blower motor failĆ delayed 45 seconds. If there is 120V to each moĆ
ure. tor tap but the blower does not operate, replace
the motor.

7.1.3 ACTION 1 - If there is not 120V when "Y", "G", or

"W" is energized, replace the control.
Defective control board
7.1.4
ACTION 1 - Replace capacitor
Defective run capacitor
PROBLEM 8: RF STATIC DURING TIME FOR IGNITION
Condition Possible Cause Corrective Action/Comments
8.0 8.1.2
ACTION 1 - Call Technical Support, Dallas.
- AM radio interference. Ignitor operation

Page 34