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INSTALLATION
E 2013 Lennox Industries Inc.
Dallas, Texas, USA
DOWNFLOW
INSTRUCTIONS
EL180DFE
ELITE® SERIES GAS FURNACE
DOWNFLOW AIR DISCHARGE
507140-01
01/2013
This is a safety alert symbol and should never be ignored.
When you see this symbol on labels or in manuals, be alert
to the potential for personal injury or death.
THIS MANUAL MUST BE LEFT WITH THE
HOMEOWNER FOR FUTURE REFERENCE
WARNING
Improper installation, adjustment, alteration, service
or maintenance can cause property damage, person
al injury or loss of life. Installation and service must
be performed by a licensed professional installer (or
equivalent), service agency or the gas supplier.
Litho U.S.A.
AIR FLOW
Table of Contents
Unit Dimensions 2................................
EL180DFE Gas Furnace 3.........................
Shipping and Packing List 3........................
Safety Information 3...............................
Use of Furnace as a Construction Heater 4...........
General 4........................................
Combustion, Dilution & Ventilation Air 5..............
Setting Equipment 9...............................
Filters 11..........................................
Duct System 11....................................
CAUTION
As with any mechanical equipment, personal injury
can result from contact with sharp sheet metal
edges. Be careful when you handle this equipment.
Venting 11........................................
Gas Piping 17.....................................
Electrical 19.......................................
Integrated Control 22...............................
Unit Start-Up 23...................................
Gas Pressure Adjustment 24........................
Proper Combustion 24..............................
High Altitude 24....................................
Other Unit Adjustments 25..........................
Service 27........................................
Repair Parts List 28................................
Start-Up & Performance Checklist 29.................
01/13
*2P0113*
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507140-01
*P507140-01*
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Unit Dimensions - inches (mm)
3−1/8
(79)
9/16
(14)
D
RETURN AIR
OPENING
B
FLUE OUTLET
(Top)
19−7/16
9/16
(14)
(494)
9/16
(14)
TOP VIEW
A
B
9/16
(14)
1−1/2 (38)
Front Panel
27−3/4
(705)
19−7/16
(494)
9/16
(14)
ELECTRICAL INLET
33
(838)
Supply
C
Air
EL180DF Model No.
045E36A 14-1/2 368 13-3/8 340 13 330 4-3/4 121
070E36B
090E48B
110E60C 21 533 19-7/8 504 19-1/2 495 8 203
in. mm in. mm in. mm in. mm
17-1/2 446 16-3/8 416 16 406 6-1/4 159
3/4
(19)
A B C D
5−3/8 (137) Right
2−3/16 (56) Left
6−5/8 (168) Right
7−1/8 (181) Left
(Either Side)
GAS PIPING INLET
(Either Side)
19−1/4
Supply
(489)
Air
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EL180DFE Gas Furnace
The EL180DFE gas furnace is shipped ready for installa
tion in the downflow position fueled by natural gas. A con
version kit (ordered separately) is required for use in LP/
Propane gas applications.
Shipping and Packing List
Package 1 of 1 contains
1 - Assembled EL180DFE unit
1 - Bag assembly containing the following:
2 - Screws
1 - Snap bushing
1 - Snap plug
1 - Wire tie
1 - Vent warning label
1 - Owner's manual and warranty card
The following items may be ordered separately:
1 - Thermostat
1 - LP/Propane changeover kit
1 - Combustible flooring base
1 - High altitude kit
Check equipment for shipping damage. If you find any
damage, immediately contact the last carrier.
Safety Information
DANGER
Danger of explosion.
There are circumstances in which odorant used with
LP/propane gas can lose its scent. In case of a leak,
LP/propane gas will settle close to the floor and may
be difficult to smell. An LP/propane leak detector
should be installed in all LP applications.
WARNING
Improper installation, adjustment, alteration, service
or maintenance can cause property damage, person
al injury or loss of life. Installation and service must
be performed by a licensed professional installer (or
equivalent), service agency or the gas supplier.
CAUTION
As with any mechanical equipment, personal injury
can result from contact with sharp sheet metal
edges. Be careful when you handle this equipment.
Certifications
EL180DFE units are CSA International certified.
In the USA, installation of gas furnaces must conform with
local building codes. In the absence of local codes, units
must be installed according to the current National Fuel
Gas Code (ANSI‐Z223.1). The National Fuel Gas Code is
available from the following address:
American National Standards Institute, Inc.
11 West 42nd Street
New York, NY 10036
Clearances
Adequate clearance must be made around the air open
ings into the vestibule area. In order to ensure proper unit
operation, combustion and ventilation air supply must be
provided according to the current National Fuel Gas Code.
Vent installations must be consistent with the National Fuel
Gas Code venting tables (in this instruction) and applicable
provisions of local building codes.
This furnace is CSA International certified for installation
clearances to combustible material as listed on the unit
nameplate and in the tables in figure 13. Accessibility and
service clearances must take precedence over fire protection
clearances.
Installed Locations
For installation in a residential garage, the furnace must
be installed so that the burner(s) and the ignition source
are located no less than 18 inches (457 mm) above the
floor. The furnace must be located or protected to avoid
physical damage by vehicles. When a furnace is installed
in a public garage, hangar, or other building that has a haz
ardous atmosphere, the furnace must be installed accord
ing to recommended good practice requirements and cur
rent National Fuel Gas Code.
NOTE - Furnace must be adjusted to obtain a temperature
rise within the range(s) specified on the unit nameplate. Fail
ure to do so may cause erratic limit operation and may also
result in premature heat exchanger failure.
This EL180DFE furnace must be installed so that its electri
cal components are protected from water.
Installed in Combination with a Cooling Coil
When this furnace is used with cooling units, it shall be
installed in parallel with, or on the upstream side of, cooling
units to avoid condensation in the heating compartment.
With a parallel flow arrangement, a damper (or other
means to control the flow of air) must adequately prevent
chilled air from entering the furnace (see figure 1). If the
damper is manually operated, it must be equipped to pre
vent operation of either the heating or the cooling unit, un
less it is in the full HEAT or COOL setting.
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GAS UNIT
Dampers
(open during heating
operation only)
AIR HANDLER
Dampers
(open during cooling
operation only)
FIGURE 1
When installed, this furnace must be electrically grounded
according to local codes. In addition, in the United States,
installation must conform with the current National Elec
tric Code, ANSI/NFPA No. 70. The National Electric Code
(ANSI/NFPA No. 70) is available from the following ad
dress:
National Fire Protection Association
1 Battery March Park
Quincy, MA 02269
NOTE - This furnace is designed for a minimum continu
ous return air temperature of 60°F (16°C) or an intermit
tent operation down to 55°F (13°C) dry bulb for cases
where a night setback thermostat is used. Return air tem
perature must not exceed 85°F (29°C) dry bulb.
The EL180DFE furnace may be installed in alcoves, clos
ets, attics, basements, garages, and utility rooms in the
downflow position.
This furnace design has not been CSA International
certified for installation in mobile homes, recreational
vehicles, or outdoors.
Use of Furnace as Construction Heater
Lennox does not recommend the use of EL180DFE units
as a construction heater during any phase of construction.
Very low return air temperatures, harmful vapors and op
eration of the unit with clogged or misplaced filters will dam
age the unit.
EL180DFE units may be used for heating of buildings or
structures under construction, if the following conditions
are met:
D The vent system must be permanently installed per
these installation instructions.
D A room thermostat must control the furnace. The use of
fixed jumpers that will provide continuous heating is not
allowed.
D The return air duct must be provided and sealed to the
furnace.
D Return air temperature range between 60°F (16°C) and
80°F (27°C) must be maintained.
D Air filters must be installed in the system and must be
maintained during construction.
D Air filters must be replaced upon construction comple
tion.
D The input rate and temperature rise must be set per the
furnace rating plate.
D One hundred percent (100%) outdoor air must be pro
vided for combustion air requirements during construc
tion. Temporary ducting may supply outdoor air to the
furnace. Do not connect duct directly to the furnace.
Size the temporary duct following these instructions in
section for Combustion, Dilution and Ventilation Air in a
confined space with air from outside.
D The furnace heat exchanger, components, duct system,
air filters and evaporator coils must be thoroughly
cleaned following final construction clean-up.
D All furnace operating conditions (including ignition, in
put rate, temperature rise and venting) must be verified
according to these installation instructions.
General
These instructions are intended as a general guide and do
not supersede local codes in any way. Consult authorities
having jurisdiction before installation.
In addition to the requirements outlined previously, the fol
lowing general recommendations must be considered
when installing a EL180DFE furnace:
D Place the furnace as close to the center of the air dis
tribution system as possible. The furnace should also be
located close to the chimney or vent termination point.
D Do not install the furnace where drafts might blow direct
ly into it. This could cause improper combustion and un
safe operation.
D Do not block the furnace combustion air openings with
clothing, boxes, doors, etc. Air is needed for proper
combustion and safe unit operation.
D When the furnace is installed in an attic or other insu
lated space, keep insulation away from the furnace.
NOTE - The Commonwealth of Massachusetts stipu
lates these additional requirements:
D Gas furnaces shall be installed by a licensed plumb
er or fitter only.
D The gas cock must be “T handle” type.
D When a furnace is installed in an attic, the passage
way to and service area surrounding the equipment
shall be floored.
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WARNING
The State of California has determined that this prod
uct may contain or produce a chemical or chemicals,
in very low doses, which may cause serious illness
or death. It may also cause cancer, birth defects or
reproductive harm.
Combustion, Dilution & Ventilation Air
In the past, there was no problem in bringing in sufficient out
door air for combustion. Infiltration provided all the air that
was needed. In today's homes, tight construction practices
make it necessary to bring in air from outside for combus
tion. Take into account that exhaust fans, appliance vents,
chimneys, and fireplaces force additional air that could be
used for combustion out of the house. Unless outside air is
brought into the house for combustion, negative pressure
(outside pressure is greater than inside pressure) will build
to the point that a downdraft can occur in the furnace vent
pipe or chimney. As a result, combustion gases enter the liv
ing space creating a potentially dangerous situation.
In the absence of local codes concerning air for combus
tion and ventilation, use the guidelines and procedures in
this section to install EL180DFE furnaces to ensure effi
cient and safe operation. You must consider combustion air
needs and requirements for exhaust vents. A portion of this
information has been reprinted with permission from the
National Fuel Gas Code (ANSI‐Z223.1). This reprinted ma
terial is not the complete and official position of the ANSI on
the referenced subject, which is represented only by the
standard in its entirety.
CAUTION
Do not install the furnace in a corrosive or contami
nated atmosphere. Meet all combustion and ventila
tion air requirements, as well as all local codes.
All gas‐fired appliances require air for the combustion pro
cess. If sufficient combustion air is not available, the fur
nace or other appliances will operate inefficiently and un
safely. Enough air must be provided to meet the needs of all
fuel‐burning appliances and appliances such as exhaust
fans which force air out of the house. When fireplaces, ex
haust fans, or clothes dryers are used at the same time as
the furnace, much more air is necessary to ensure proper
combustion and to prevent a downdraft. Insufficient air
causes incomplete combustion which can result in carbon
monoxide.
CAUTION
Insufficient combustion air can cause headaches,
nausea, dizziness or asphyxiation. It will also cause
excess water in the heat exchanger resulting in rust
ing and premature heat exchanger failure. Excessive
exposure to contaminated combustion air will result
in safety and performance related problems. Avoid
exposure to the following substances in the combus
tion air supply:
Permanent wave solutions
Chlorinated waxes and cleaners
Chlorine base swimming pool chemicals
Water softening chemicals
De‐icing salts or chemicals
Carbon tetrachloride
Halogen type refrigerants
Cleaning solvents (such as perchloroethylene)
Printing inks, paint removers, varnishes, etc.
Hydrochloric acid
Cements and glues
Antistatic fabric softeners for clothes dryers
Masonry acid washing materials
In addition to providing combustion air, fresh outdoor air
dilutes contaminants in the indoor air. These contami
nants may include bleaches, adhesives, detergents, sol
vents and other contaminants which can corrode furnace
components.
The requirements for providing air for combustion and ven
tilation depend largely on whether the furnace is installed in
an unconfined or a confined space.
Unconfined Space
An unconfined space is an area such as a basement or
large equipment room with a volume greater than 50 cubic
feet (1.42 m
bined input rating of all appliances installed in that space.
This space also includes adjacent rooms which are not
separated by a door. Though an area may appear to be un
confined, it might be necessary to bring in outdoor air for
combustion if the structure does not provide enough air by
infiltration. If the furnace is located in a building of tight
construction with weather stripping and caulking around
the windows and doors, follow the procedures in the air
from outside section.
Confined Space
A confined space is an area with a volume less than 50 cu
bic feet (1.42 m
combined input rating of all appliances installed in that
space. This definition includes furnace closets or small
equipment rooms.
When the furnace is installed so that supply ducts carry air
circulated by the furnace to areas outside the space contain
ing the furnace, the return air must be handled by ducts
which are sealed to the furnace casing and which terminate
3
) per 1,000 Btu (.29 kW) per hour of the com
3
) per 1,000 Btu (.29 kW) per hour of the
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outside the space containing the furnace. This is especially
important when the furnace is mounted on a platform in a
confined space such as a closet or small equipment room.
Even a small leak around the base of the unit at the platform
or at the return air duct connection can cause a potentially
dangerous negative pressure condition. Air for combustion
and ventilation can be brought into the confined space either
from inside the building or from outside.
EQUIPMENT IN CONFINED
CHIMNEY
OR GAS
VENT
FURNACE
NOTE - Each opening shall have a free area of at least one square
inch (645 mm
ing of all equipment in the enclosure, but not less than 100 square
inches (64516 mm
2
) per 1,000 Btu (.29 kW) per hour of the total input rat
2
).
SPACE ALL AIR FROM INSIDE
WATER
HEATER
OPENINGS
(To Adjacent
Room)
FIGURE 2
Air from Inside
If the confined space that houses the furnace adjoins a
space categorized as unconfined, air can be brought in by
providing two permanent openings between the two
spaces. Each opening must have a minimum free area of 1
square inch (645 mm
2
) per 1,000 Btu (.29 kW) per hour of
total input rating of all gas-fired equipment in the confined
space. Each opening must be at least 100 square inches
(64516 mm
2
). One opening shall be within 12 inches (305
mm) of the top of the enclosure and one opening within 12
inches (305 mm) of the bottom. See figure 2.
Air from Outside
If air from outside is brought in for combustion and ventila
tion, the confined space must have two permanent open
ings. One opening shall be within 12 inches (305 mm) of the
top of the enclosure and one opening within 12 inches (305
mm) of the bottom. These openings must communicate di
rectly or by ducts with the outdoors or spaces (crawl or at
tic) that freely communicate with the outdoors or indirectly
through vertical ducts. Each opening shall have a minimum
free area of 1 square inch (645 mm
2
) per 4,000 Btu (1.17
kW) per hour of total input rating of all equipment in the en
closure. See figures 3 and 4. When communicating with
the outdoors through horizontal ducts, each opening shall
have a minimum free area of 1 square inch (645 mm
2
) per
2,000 Btu (.56 kW) per total input rating of all equipment in
the enclosure. See figure 5.
When ducts are used, they shall be of the same cross-sec
tional area as the free area of the openings to which they
connect. The minimum dimension of rectangular air ducts
shall be no less than 3 inches (75 mm). In calculating free
area, the blocking effect of louvers, grilles, or screens must
be considered. If the design and free area of protective cov
ering is not known for calculating the size opening required,
it may be assumed that wood louvers will have 20 to 25 per
cent free area and metal louvers and grilles will have 60 to
75 percent free area. Louvers and grilles must be fixed in the
open position or interlocked with the equipment so that they
are opened automatically during equipment operation.
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CHIMNEY OR
GAS VENT
FURNACE
(Inlet Air from Crawlspace and Outlet Air to Ventilated Attic)
VENTILATION LOUVERS
(Each end of attic)
EQUIPMENT IN CONFINED SPACE
ALL AIR FROM OUTSIDE
OUTLET
AIR
WATER
HEATER
CHIMNEY
OR GAS
VENT
FURNACE
VENTILATION
LOUVERS
(For unheated crawl space)
NOTE-The inlet and outlet air openings shall each have a free area of at least one square inch (645
2
mm
) per 4,000 Btu (1.17 kW) per hour of the total input rating of all equipment in the enclosure.
INLET
AIR
FIGURE 3
EQUIPMENT IN CONFINED SPACE
ALL AIR FROM OUTSIDE
(All Air Through Ventilated Attic)
VENTILATION LOUVERS
(Each end of attic)
OUTLET
AIR
INLET AIR
(Ends 12 in.
above bottom)
FURNACE
CHIMNEY
OR GAS
VENT
CONFINED SPACE
WATER
HEATER
OUTLET AIR
INLET AIR
EQUIPMENT IN
ALL AIR FROM
OUTSIDE
NOTE-The inlet and outlet air openings shall each have a
free area of at least one square inch (645 mm
Btu (1.17 kW) per hour of the total input rating of all equip
ment in the enclosure.
FIGURE 4
WATER
HEATER
2
) per 4,000
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NOTE - Each air duct opening shall have a free area of at least
one square inch (645 mm
2
) per 2,000 Btu (.59 kW) per hour of
the total input rating of all equipment in the enclosure. If the
equipment room is located against an outside wall and the air
openings communicate directly with the outdoors, each open
ing shall have a free area of at least one square inch (645 mm
per 4,000 Btu (1.17 kW) per hour of the total input rating of all
other equipment in the enclosure.
FIGURE 5
2
)
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Downflow Installation
Downflow unit installs in three ways: on non-combustible
flooring, on combustible flooring using a downflow com
bustible flooring base, or on a reverse-flow cooling cabinet.
Do not drag the unit across the floor.
Installation on Non-Combustible Flooring (Figure 6)
1 - Cut floor opening keeping in mind clearances listed on
unit rating plate. Also keep in mind gas supply connec
tions, electrical supply, flue and air intake connections
and sufficient installation and servicing clearances.
See table 1 for correct floor opening size.
2 - Flange warm air plenum and lower the plenum into the
opening.
3 - Set the unit over the plenum and seal the plenum to
the unit.
4 - Ensure that the seal is adequate.
CAUTION
The furnace and downflow combustible flooring
base shall not be installed directly on carpeting, tile,
or other combustible material other than wood floor
ing.
EL180DFE UNIT
SUPPLY AIR PLENUM
PROPERLY
SIZED FLOOR
OPENING
DOWNFLOW
COMBUSTIBLE
FLOORING BASE
EL180DFE UNIT
OPENING
SUPPL Y AIR
PLENUM
FIGURE 6
TABLE 1
NON-COMBUSTIBLE FLOOR OPENING SIZE
Cabinet Width
A (14.5”) 19-3/4 502 13-1/4 337
B (17.5”) 19-3/4 502 16-1/4 413
C (21”) 19-3/4 502 19-3/4 502
NOTE - Floor opening dimensions listed are 1/4 inch (6 mm) larger than
the unit opening. See unit dimensions on page 2.
Front to Rear Side to Side
in. mm in. mm
Installation on Combustible Flooring (Figure 7)
1 - When unit is installed on a combustible floor, a down
flow combustible flooring base must be installed be
tween the furnace and the floor. The base must be or
dered separately.
See table 2 for opening size to cut in floor.
FIGURE 7
TABLE 2
COMBUSTIBLE FLOOR OPENING SIZE
Cabinet Width
A (14.5”)
B (17.5”)
C (21”)
Front to Rear Side to Side
in. mm in. mm
22 559 15-3/4 400
22 559 18-3/4 476
22 559 22-3/4 578
2 - After opening is cut, set combustible flooring base into
opening.
3 - Check sealing strips on combustible flooring base to
make sure they are properly glued and positioned.
4 - Lower supply air plenum into downflow combustible
flooring base until plenum flanges seal against the
strips.
NOTE - Be careful not to damage sealing strips. Check
for a tight seal.
5 - Set the furnace over the plenum.
6 - Ensure that the seal between the furnace and plenum
is adequate.
Installation on Cooling Cabinet (Figure 8)
1 - Refer to reverse-flow coil installation instructions for
correctly sized opening in floor and installation of cabi
net.
NOTE - Downflow combustible flooring kit is not used
2 - When cooling cabinet is in place, set and secure the
furnace according to the instructions that are provided
with the cooling coil. Secure the furnace to the cabinet.
3 - Seal the cabinet and check for air leaks.
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PROPERLY
SIZED FLOOR
OPENING
EL180DFE UNIT
COOLING COIL
PLENUM
Setting Equipment
WARNING
Do not install the furnace on its front, back or in the
horizontal position. See figure 12. Do not connect the
return air ducts to the back of the furnace. Doing so
will adversely affect the operation of the safety con
trol devices, which could result in personal injury or
death.
Install the EL180DFE gas furnace as shipped in the
downflow position only. Do not install the furnace hori
zontally.
FIGURE 8
Return Air Opening -- Downflow Units
The following steps should be taken when installing ple
num:
1 - Bottom edge of plenum should be flanged with a
hemmed edge (See figure 9).
PLENUM
SECURE FROM
OUTSIDE CABINET
Side View
HEMMED EDGE
SEALING STRIP
(Field Provided)
CABINET SIDE PANEL
FIGURE 9
2 - Sealing strip should be used.
3 - In all cases, plenum should be secured to top flanges
of furnace with sheet metal screws.
SECURE FROM IN
SIDE CABINET
PLENUM
Side View
HEMMED EDGE
Select a location that allows for the required clearances
that are listed on the unit nameplate. Also consider gas
supply connections, electrical supply, vent connection,
and installation and service clearances [24 inches (610
mm) at unit front]. The unit must be level.
NOTE - Units with 1/2 and 3/4 hp blower motors are
equipped with three flexible legs and one rigid leg. See fig
ure 11. The rigid leg is equipped with a shipping bolt and a
flat white plastic washer (rather than the rubber mounting
grommet used with a flexible mounting leg). The bolt and
washer must be removed before the furnace is placed
into operation. After the bolt and washer have been re
moved, the rigid leg will not touch the blower housing.
UNITS WITH 1/2 AND 3/4 HP BLOWER MOTOR
RIGID LEG
remove shipping bolt and washer
FIBERGLASS
SEALING STRIP
(Field Provided)
CABINET SIDE
PANEL
FIGURE 10
4 - In closet installations, it may be impossible to install
sheet metal screws from the outside. In this case,
make plenum with a removable front and install
screws from the inside (See figure 10).
5 - Make certain that an adequate seal is made.
FIGURE 11
WARNING
The blower access panel must be securely in place
when the blower and burners are operating. Gas
fumes, which could contain carbon monoxide, can
be drawn into living space resulting in personal inju
ry or death.
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Page 10
Front
Back
FIGURE 12
Downflow Application
Allow for clearances to combustible materials as indicated
on the unit nameplate. Minimum clearances for closet or al
cove installations are shown in figure 13.
Downflow Application Installation Clearances
Top
Horizontal
CAUTION
If this unit is being installed in a space serviced by
an exhaust fan, power exhaust fan, or other device
which may create a negative pressure in the space,
take care when sizing the inlet air opening. The in
let air opening must be sized to accommodate the
maximum volume of exhausted air as well as the
maximum volume of combustion air required for
all gas appliances serviced by this space.
Left Side
Bottom
Type of Vent
Connector
Top 1 in. (25 mm) 1 in. (25 mm)
*Front 2-1/4 in. (57 mm)** 2-1/4 in. (57 mm)
Back 0 0
Sides 0† 0
Vent 6 in. (152 mm) 1 in. (25 mm)
Floor NC†† NC††
*Front clearance in alcove installation must be 24 in. (610 mm).
Maintain a minimum of 24 in. (610 mm) for front service access.
** 4-1/2 in. if a single wall vent pipe is used.
†Left side requires 3 in. if a single wall vent is used on 14 -1/2 in. cab
inets, or 2 in. if a single wall vent is used on 17 - 1/2 in. cabinets.
††The furnace may be installed on a combustible wood floor if an
optional additive base is installed between the furnace and the
combustible floor.
Type C Type B1
Right Side
FIGURE 13
WARNING
Improper installation of the furnace can result in per
sonal injury or death. Combustion and flue products
must never be allowed to enter the return air system
or the living space. Use screws and joint tape to seal
the return air system to the furnace.
In platform installations with bottom return air, the
furnace should be sealed airtight to the return air ple
num. A door must never be used as a portion of the
return air duct system. The base must provide a
stable support and an airtight seal to the furnace. Al
low absolutely no sagging, cracks, gaps, etc.
The return and supply air duct systems must never
be connected to or from other heating devices such
as a fireplace or stove, etc. Fire, explosion, carbon
monoxide poisoning, personal injury and/or proper
ty damage could result.
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Filters
This unit is not equipped with a filter or rack. A field-pro
vided high-velocity filter is required for the unit to operate
properly. Table 3 lists recommended filter sizes.
A filter must be in place any time the unit is operating.
IMPORTANT
If a highefficiency filter is being installed as part of
this system to ensure better indoor air quality, the fil
ter must be properly sized. Highefficiency filters
have a higher static pressure drop than standardef
ficiency glass/foam filters. If the pressure drop is too
great, system capacity and performance may be re
duced. The pressure drop may also cause the limit to
trip more frequently during the winter and the indoor
coil to freeze in the summer, resulting in an increase
in the number of service calls.
Before using any filter with this system, check the
specifications provided by the filter manufacturer
against the data given in the appropriate Lennox
Product Specifications bulletin. Additional informa
tion is provided in Service and Application Note
ACC002 (August 2000).
TABLE 3
Cabinet Width
A (14-1/2”) 14 x 25 x 1 (1)
B (17-1/2”) 16 x 25 x 1 (1)
C (21”) 20 x 25 x 1 (1)
Duct System
Use industry‐approved standards (such as those pub
lished by Air Conditioning Contractors of America or Ameri
can Society of Heating, Refrigerating and Air Conditioning
Engineers) to size and install the supply and return air duct
system. This will result in a quiet and low‐static system that
has uniform air distribution.
NOTE - Do not operate the furnace in the heating mode
with an external static pressure that exceeds 0.5 inches
w.c. Higher external static pressures may cause erratic lim
it operation.
Ensure that you have made a seal between the supply air
plenum and the furnace and between the furnace and the
return air plenum.
Return Air Filter Size (inches)
Return Air Plenum
Return air must not be drawn from a room where this
furnace, or any other gas-fueled appliance (i.e., water
heater), or carbon monoxide-producing device (i.e.,
wood fireplace) is installed. When return air is drawn
from a room, a negative pressure is created in the room. If
a gas appliance is operating in a room with negative pres
sure, the flue products can be pulled back down the vent
pipe and into the room. This reverse flow of the flue gas
may result in incomplete combustion and the formation
of carbon monoxide gas. This toxic gas might then be dis
tributed throughout the house by the furnace duct sys
tem.
Venting
A 4-inch diameter flue transition is factory‐installed on all
models. Modifying or removing the flue transition will
cause the unit to operate unsafely and will void the unit
certification. The vent connector does not require insula
tion.
The EL180DFE series units are classified as fan-assisted
Category I furnaces when vertically vented according to
the latest edition of National Fuel Gas Code (NFPA 54 /
ANSI Z223.1). A fan-assisted Category I furnace is an ap
pliance equipped with an integral mechanical means to ei
ther draw or force combustion products through the com
bustion chamber and/or heat exchanger.
NOTE - Use these instructions as a guide. They do not su
persede local codes. This furnace must be vented accord
ing to all local codes, these installation instructions, and the
provided venting tables in these instructions
The venting tables in this manual were extracted from the
National Fuel Gas Code (NFPA 54 / ANSI Z223.1) and are
provided as a guide for proper vent installation. Proper ap
plication, termination, construction and location of vents
must conform to local codes having jurisdiction. In the ab
sence of local codes, the NFGC serves as the defining doc
ument.
Refer to the tables and the venting information contained in
these instructions to properly size and install the venting
system.
IMPORTANT
Once the venting system is installed, attach the “Dis
connected Vent” warning sticker to a visible area of
the plenum near the vent pipe. The warning sticker
is provided in the bag assembly. Order kit 66W04 for
additional stickers.
Page 11
Page 12
WARNING
Asphyxiation hazard. The exhaust vent for this fur
nace must be securely connected to the furnace flue
transition at all times.
VENT CONNECTION
FLUE TRANSITION
COLLAR
FIGURE 14
“DISCONNECTED VENT”
WARNING
STICKER
Use self-drilling sheet metal screws or a mechanical fas
tener to firmly secure the vent pipe to the round collar of the
flue transition. If self-drilling screws are used to attach the
vent pipe, it is recommended that three be used. Drive one
self-drilling screw through the front and one through each
side of the vent pipe and collar. See figure 14.
Install the first vent connector elbow at a minimum of six
inches (152 mm) from the furnace vent outlet.
Masonry chimneys used to vent Category I central fur
naces must be either tile‐lined or lined with a listed metal
lining system or dedicated gas vent. Unlined masonry
chimneys are prohibited. See figures 15 and 16 for com
mon venting.
Venting Using a Masonry Chimney
The following additional requirements apply when a lined
masonry chimney is used to vent this furnace.
A chimney with one or more sides exposed to the outside of
the structure is considered to be an exterior chimney.
An exterior masonry chimney that is not tile-lined must be
lined with B1 vent or a listed insulated flexible metal vent.
An exterior tile-lined chimney that is sealed and capped
may be lined with a listed uninsulated flexible metal vent.
If the existing chimney will not accommodate a listed metal
liner, either the chimney must be rebuilt to accommodate
one of these liners or an alternate approved venting meth
od must be found.
Insulation for the flexible vent pipe must be an encapsu
lated fiberglass sleeve recommended by the flexible vent
pipe manufacturer. See figure 16.
Common Venting Using Tile-Lined Interior Masonry Chimney and Combined Vent Connector
NOTE- Refer to provided venting
tables for installations.
MINIMUM LENGTH = AS SHORT AS PRACTICAL.
FOR MAXIMUM LENGTH SEE NOTE TO LEFT
OTHER
APPLIANCE
FURNACE
FIGURE 15
VENT
CONNECTOR
INTERIOR TILE-LINED
MASONRY CHIMNEY
NOTE - the chimney must be properly
sized per provided venting tables or
lined with listed metal lining system.
PERMANENTLY
SEALED FIREPLACE
OPENING
Page 12
Page 13
Common Venting Using Metal-Lined Masonry Chimney
SEALED
MAX. LENGTH
-- SEE NOTE
5 ft. (1.5 m)
minimum
VENT CONNECTOR
4 in. (102 mm)
minimum
OTHER
APPLIANCE
NOTE 1 - Refer to the provided venting tables for installations.
BELOW.
MIN. LENGTH -- AS
SHORT AS PRACTICAL
FURNACE
EXTERIOR
CHIMNEY WITH
METAL
LINER
PERMANENTLY
SEALED FIREPLACE
OPENING
FIGURE 16
DO NOT insulate the space between the liner and the
chimney wall with puffed mica or any other loose gran
ular insulating material
IMPORTANT
SINGLE appliance venting of a fan‐assisted furnace
into a tile‐lined masonry chimney (interior or outside
wall) is PROHIBITED. The chimney must first be lined
with either type B1 vent or an insulated single wall
flexible vent lining system which has been sized ac
cording to the provided venting tables and the vent
pipe manufacturer's instructions.
A fan-assisted furnace may be commonly vented into an
existing lined masonry chimney if the following conditions
are met:
S The chimney is currently serving at least one drafthood
equipped appliance
S The vent connectors and chimney are sized according
to the provided venting tables.
If type B1 double‐wall vent is used inside a chimney, no oth
er appliance can be vented into the chimney. The outer wall
of type B1 vent pipe must not be exposed to flue products.
A type B1 vent or masonry chimney liner shall terminate
above the roof surface with a listed cap or a listed roof as
sembly according to the terms of their respective listings
and the vent manufacturer's instructions.
When inspection reveals that an existing chimney is not
safe for the intended purpose, it shall be rebuilt to conform
to nationally recognized standards, lined or relined with
suitable materials, or replaced with a gas vent or chimney
suitable for venting EL180DFE series units. The chimney
passageway must be checked periodically to ensure that it
is clear and free of obstructions.
Do not install a manual damper, barometric draft regulator,
or flue restrictor between the furnace and the chimney.
Never connect a Category I appliance to a chimney that is
servicing a solid-fuel appliance. If a fireplace chimney flue
is used to vent this appliance, the fireplace opening must
be permanently sealed.
A type B or listed chimney lining system that passes
through an unused masonry chimney flue is not considered
to be exposed to the outdoors.
General Venting Requirements
Vent all EL180DFE furnaces according to these instruc
tions:
1 - Vent diameter recommendations and maximum allow
able piping runs are found in the provided venting
tables.
2 - In no case should the vent or vent connector diameter
be less than the diameter specified in the provided
venting tables.
3 - The minimum vent capacity determined by the sizing
tables must be less than the low fire input rating and the
maximum vent capacity must be greater than the high
fire input rating.
4 - Single appliance vents - If the vertical vent or tile‐lined
chimney has a larger diameter or flow area than the
vent connector, use the vertical vent diameter to de
termine the minimum vent capacity and the vent
connector diameter to determine the maximum vent
capacity. The flow area of the vertical vent, however,
shall not exceed 7 times the flow area of the listed ap
pliance categorized vent area, drafthood outlet area or
flue collar area unless designed according to approved
engineering methods.
5 - Multiple appliance vents - The flow area of the largest
section of vertical vent or chimney shall not exceed 7
times the smallest listed appliance categorized vent
area, drafthood outlet area or flue collar area unless de
signed according to approved engineering methods.
6 - The entire length of single wall metal vent connector
shall be readily accessible for inspection, cleaning,
and replacement.
7 - Single appliance venting configurations with zero lat
eral lengths (table 5) are assumed to have no elbows in
the vent system. For all other vent configurations, the
vent system is assumed to have two 90° elbows. For
each additional 90° elbow or equivalent (for example
two 45° elbows equal one 90° elbow) beyond two, the
maximum capacity listed in the venting table should be
reduced by 10% (0.90 x maximum listed capacity).
8 - The common venting tables (6 and 7) were generated
using a maximum horizontal vent connector length of
1-1/2 feet (.46 m) for each inch (25 mm) of connector
diameter as follows:
Page 13
Page 14
TABLE 4
Connector Diameter
inches (mm)
3 (76) 4-1/2 (1.37)
4 (102) 6 (1.83)
5 (127) 7-1/2 (2.29)
6 (152) 9 (2.74)
7 (178) 10-1/2 (3.20)
Maximum Horizontal
Connector Length feet (m)
9 - If the common vertical vent is offset, the maximum
common vent capacity listed in the common venting
tables should be reduced by 20%, the equivalent of two
90° elbows (0.80 x maximum common vent capacity).
The horizontal length of the offset shall not exceed
1‐1/2 feet (.46 m) for each inch (25 mm) of common
vent diameter.
10 - The vent pipe should be as short as possible with the
least number of elbows and angles required to com
plete the job. Route the vent connector to the vent us
ing the shortest possible route.
11 - A vent connector shall be supported without any dips
or sags and shall slope a minimum of 1/4 inch (6.4 mm)
per linear foot (305 mm) of connector, back toward the
appliance.
12 - Vent connectors shall be firmly attached to the furnace
flue collar by self-drilling screws or other approved
means, except vent connectors of listed type B vent
material which shall be assembled according to the
manufacturer's instructions. Joints between sections
of single wall connector piping shall be fastened by
screws or other approved means.
13 - When the vent connector used for Category I ap
pliances must be located in or pass through a crawl
space or other areas which may be cold, that portion of
the vent connector shall be constructed of listed
double‐wall type B vent material or material having
equivalent insulation qualities.
14 - All venting pipe passing through floors, walls, and ceil
ings must be installed with the listed clearance to com
bustible materials and be fire stopped according to lo
cal codes. In absence of local codes, refer to NFGC
(Z223.1).
15 - No portion of the venting system can extend into, or pass
through any circulation air duct or plenum.
16 - Vent 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 in the common venting tables must be reduced by
10%, the equivalent of one 90° elbow (0.90 x maximum
common vent capacity).
18 - The common vent diameter must always be at least as
large as the largest vent connector diameter.
19 - In no case, shall the vent connector be sized more than
two consecutive table size diameters over the size of
the draft hood outlet or flue collar outlet.
20 - Do not install a manual damper, barometric draft regu
lator or flue restrictor between the furnace and the
chimney.
21 - When connecting this appliance to an existing dedi
cated or common venting system, you must inspect the
venting system's general condition and look for signs
of corrosion. The existing vent pipe size must conform
to these instructions and the provided venting tables. If
the existing venting system does not meet these re
quirements, it must be resized.
Page 14
Page 15
TABLE 5
Capacity of Type B Double-Wall Vents with Type B Double-Wall Connectors
Serving a Single Category I Appliance
Vent and Connector Diameter - D (inches)
Height
H
(feet)
6
8
10
15
20
30
NOTE - Single appliance venting configurations with zero lateral lengths are assumed to have no elbows in the vent system. For all other
vent configurations, the vent system is assumed to have two 90° elbows. For each additional 90° elbow or equivalent (for example two 45°
elbows equal one 90° elbow) beyond two, the maximum capacity listed in the venting table should be reduced by 10 percent (0.90 x maxi
mum listed capacity).
Lateral
L
(feet)
0 0 78 0 152 0 251 0 375
2 13 51 18 97 27 157 32 232
4 21 49 30 94 39 153 50 227
6 25 46 36 91 47 149 59 223
0 0 84 0 165 0 276 0 415
2 12 57 16 109 25 178 28 263
5 23 53 32 103 42 171 53 255
8 28 49 39 98 51 164 64 247
0 0 88 0 175 0 295 0 447
2 12 61 17 11 8 23 194 26 289
5 23 57 32 11 3 41 187 52 280
10 30 51 41 104 54 176 67 267
0 0 94 0 191 0 327 0 502
2 11 69 15 136 20 226 22 339
5 22 65 30 130 39 219 49 330
10 29 59 40 121 51 206 64 315
15 35 53 48 112 61 195 76 301
0 0 97 0 202 0 349 0 540
2 10 75 14 149 18 250 20 377
5 21 71 29 143 38 242 47 367
10 28 64 38 133 50 229 62 351
15 34 58 46 124 59 217 73 337
20 48 52 55 116 69 206 84 322
0 0 100 0 213 0 374 0 587
2 9 81 13 166 14 283 18 432
5 21 77 28 160 36 275 45 421
10 27 70 37 150 48 262 59 405
15 33 64 44 141 57 249 70 389
20 56 58 53 132 66 237 80 374
30 NA NA 73 11 3 88 214 104 346
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
Page 15
Page 16
Vent
Height
H
(feet)
6
8
10
15
20
30
TABLE 6
Vent Connector Capacity
Type B Double-Wall Vents with Type B Double-Wall Connectors
Serving Two or More Category I Appliances
Connector
Rise
R
(feet)
1 22 37 35 66 46 106 58 164
2 23 41 37 75 48 121 60 183
3 24 44 38 81 49 132 62 199
1 22 40 35 72 49 114 64 176
2 23 44 36 80 51 128 66 195
3 24 47 37 87 53 139 67 210
1 22 43 34 78 49 123 65 189
2 23 47 36 86 51 136 67 206
3 24 50 37 92 52 146 69 220
1 21 50 33 89 47 142 64 220
2 22 53 35 96 49 153 66 235
3 24 55 36 102 51 163 68 248
1 21 54 33 99 46 157 62 246
2 22 57 34 105 48 167 64 259
3 23 60 35 110 50 176 66 271
1 20 62 31 113 45 181 60 288
2 21 64 33 118 47 190 62 299
3 22 66 34 123 48 198 64 309
3 Inch 4 Inch 5 Inch 6 Inch
MIN MAX MIN MAX MIN MAX MIN MAX
Vent and Connector Diameter - D (inches)
Appliance Input Rating in Thousands of Btu Per Hour
TABLE 7
Common Vent Capacity
Type B Double-Wall Vents with Type B Double-Wall Connectors
Serving Two or More Category I Appliances
Vent
Height
H
(feet)
6 92 81 140 11 6 204 161 309 248
8 101 90 155 129 224 178 339 275
10 110 97 169 141 243 194 367 299
15 125 112 195 164 283 228 427 352
20 136 123 215 183 314 255 475 394
30 152 138 244 210 361 297 547 459
FAN + FAN FAN + NAT FAN + FAN FAN + NAT FAN + FAN FAN + NAT FAN + FAN FAN + NAT
4 Inch 5 Inch 6 Inch 7 Inch
Appliance Input Rating in Thousands of Btu Per Hour
Common Vent Diameter - D (inches)
Page 16
Page 17
Removal of the Furnace from Common Vent
In the event that an existing furnace is removed from a
venting system commonly run with separate gas ap
pliances, the venting system is likely to be too large to
properly vent the remaining attached appliances.
Conduct the following test while each appliance is operat
ing and the other appliances (which are not operating) re
main connected to the common venting system. If the
venting system has been installed improperly, you must
correct the system as indicated in the general venting re
quirements section.
Resize the common venting system to the minimum
vent pipe size determined by using the appropriate
tables in Appendix G. (These are in the current stan
dards of the National Fuel Gas Code ANSI Z223.1.
Gas Piping
Gas supply piping should not allow more than 0.5”W.C. drop
in pressure between gas meter and unit. Supply gas pipe
must not be smaller than unit gas connection.
WARNING
CARBON MONOXIDE POISONING HAZARD
Failure to follow the steps outlined below for each
appliance connected to the venting system being
placed into operation could result in carbon mon
oxide poisoning or death.
The following steps shall be followed for each ap
pliance connected to the venting system being
placed into operation, while all other appliances
connected to the venting system are not in
operation:
1 - Seal any unused openings in the common venting sys
tem.
2 - Inspect the venting system for proper size and horizontal
pitch. Determine that there is no blockage, restriction,
leakage, corrosion, or other deficiencies which could
cause an unsafe condition.
3 - Close all building doors and windows and all doors be
tween the space in which the appliances remaining
connected to the common venting system are located
and other spaces of the building. Turn on clothes dry
ers and any appliances not connected to the common
venting system. Turn on any exhaust fans, such as
range hoods and bathroom exhausts, so they will oper
ate at maximum speed. Do not operate a summer ex
haust fan. Close fireplace dampers.
4 - Follow the lighting instructions. Turn on the appliance
that is being inspected. Adjust the thermostat so that
the appliance operates continuously.
5 - After the main burner has operated for 5 minutes, test
for leaks of flue gases at the draft hood relief opening.
Use the flame of a match or candle, or smoke from a
cigarette, cigar, or pipe.
6 - After determining that each appliance connected to the
common venting system is venting properly, (step 3)
return all doors, widows, exhaust fans, fireplace damp
ers, and any other gas-burning appliances to their pre
vious mode of operation.
7 - If a venting problem is found during any of the preced
ing tests, the common venting system must be modi
fied to correct the problem.
CAUTION
If a flexible gas connector is required or allowed by
the authority that has jurisdiction, black iron pipe
shall be installed at the gas valve and extend outside
the furnace cabinet. The flexible connector can then
be added between the black iron pipe and the gas
supply line.
Gas Supply
1 - This unit is shipped standard for left or right side instal
lation of gas piping. Connect the gas supply to the pip
ing assembly.
2 - When connecting the gas supply piping, consider fac
tors such as length of run, number of fittings, and fur
nace rating to avoid excessive pressure drop. Table 8
lists recommended pipe sizes for typical applications.
3 - The gas piping must not run in or through air ducts,
clothes chutes, gas vents or chimneys, dumb waiters,
or elevator shafts.
4 - The piping should be sloped 1/4 inch (6.4 mm) per 15
feet (4.57 m) upward toward the meter from the fur
nace. The piping must be supported at proper intervals
[every 8 to 10 feet (2.44 to 3.01 m)] with suitable hang
ers or straps. Install a drip leg inside vertical pipe runs
to the unit.
5 - A 1/8” N.P.T. plugged tap or pressure post is located
on the gas valve to facilitate test gauge connection.
See figure 22.
6 - In some localities, codes may require the installation of
a manual main shut‐off valve and union (furnished by
the installer) external to the unit. The union must be of
the ground joint type.
IMPORTANT
Compounds used on threaded joints of gas piping
must be resistant to the actions of liquified petro
leum gases.
NOTE - If emergency shutoff is necessary, shut off the main
manual gas valve and disconnect main power to the fur
nace. The installer should properly label these devices.
Page 17
Page 18
TABLE 8
Gas Pipe Capacity - ft
Nominal
Iron Pipe
Size
inches
(mm)
1/2
(12.7)
3/4
(19.05)
1
(25.4)
1-1/4
(31.75)
1-1/2
(38.1)
2
(50.8)
2-1/2
(63.5)
3
(76.2)
NOTE - Capacity given in cubic feet (m3 ) of gas per hour and based on 0.60 specific gravity gas.
Internal
Diameter
inches
(mm)
.622
(17.799)
.824
(20.930)
1.049
(26.645)
1.380
(35.052)
1.610
(40.894)
2.067
(52.502)
2.469
(67.713)
3.068
(77.927)
10
(3.048)20(6.096)30(9.144)40(12.192)50(15.240)60(18.288)70(21.336)80(24.384)90(27.432)
172
(4.87)
360
(10.19)
678
(19.19)
1350
(38.22)
2090
(59.18)
4020
(113.83)
6400
(181.22)
11300
(319.98)
118
(3.34)
247
(7.00)
466
(13.19)
957
(27.09)
1430
(40.49)
2760
(78.15)
4400
(124.59)
7780
(220.30)
95
(2.69)
199
(5.63)
374
(10.59)
768
(22.25)
1150
(32.56)
2220
(62.86)
3530
(99.95)
6250
(176.98)
81
(2.29)
170
(4.81)
320
(9.06)
657
(18.60)
985
(27.89)
1900
(53.80)
3020
(85.51)
5350
(151.49)
3
/hr (m3/hr)
Length of Pipe - feet (m)
72
(2.03)
151
(4.28)
284
(8.04)
583
(16.50)
873
(24.72)
1680
(47.57)
2680
(75.88)
4740
(134.22)
65
(1.84)
137
(3.87)
257
(7.27)
528
(14.95)
791
(22.39)
1520
(43.04)
2480
(70.22)
4290
(121.47)
60
(1.69)
126
(3.56)
237
(6.71)
486
(13.76)
728
(20.61)
1400
(39.64)
2230
(63.14)
3950
(111.85)
56
(1.58)
117
(3.31)
220
(6.23)
452
(12.79)
677
(19.17)
1300
(36.81)
2080
(58.89)
3670
(103.92)
52
(1.47)
110
(3.11)
207
(5.86)
424
(12.00)
635
(17.98)
1220
(34.55)
1950
(55.22)
3450
(97.69)
100
(30.480)
50
(1.42)
104
(2.94)
195
(5.52)
400
(11.33)
600
(17.00)
1160
(32.844)
1840
(52.10)
3260
(92.31)
MANUAL
MAIN SHUT-OFF
VALV E
GROUND
JOINT
UNION
Left Side Piping
(Standard)
DRIP LEG
AUTOMATIC
GAS VALVE
AUTOMATIC
GAS VALVE
(with manual
shut-off valve)
FIELD
PROVIDED
AND INSTALLED
NOTE - BLACK IRON PIPE ONLY TO BE ROUTED INSIDE OF CABINET
(with manual
shut-off valve)
FIGURE 17
MANUAL
MAIN SHUT-OFF
VALV E
GROUND
JOINT
UNION
DRIP LEG
Right Side Piping
(Alternate)
Page 18
Page 19
Leak Check
After gas piping is completed, carefully check all piping
connections (factory- and field-installed) for gas leaks. Use
a leak detecting solution or other preferred means.
NOTE - If emergency shutoff is necessary, shut off the main
manual gas valve and disconnect the main power to the
furnace. The installer should properly label these devices.
CAUTION
Some soaps used for leak detection are corrosive to
certain metals. Carefully rinse piping thoroughly af
ter leak test has been completed. Do not use
matches, candles, flame or other sources of ignition
to check for gas leaks.
INTERIOR MAKE-UP BOX INSTALLATION
(Right Side)
MAKE-UP
BOX
The furnace must be isolated from the gas supply system
by closing its individual manual shut‐off valve during any
pressure testing of the gas supply system at pressures
greater than or equal to 1/2 psig (3.48 kPa, 14 inches w.c.).
IMPORTANT
When testing pressure of gas lines, gas valve must
be disconnected and isolated. See figure 18. Gas
valves can be damaged if subjected to pressures
greater than 1/2 psig (3.48 kPa, 14 inches w.c.).
MANUAL MAIN
SHUT-OFF VALVE
WILL NOT HOLD
NORMAL TEST
PRESSURE
1/8 NPT PLUG
CAP
FIGURE 18
ISOLATE
GAS VALVE
FURNACE
Electrical
ELECTROSTATIC DISCHARGE (ESD)
Precautions and Procedures
CAUTION
Electrostatic discharge can affect elec
tronic components. Take precautions
to neutralize electrostatic charge by
touching your hand and tools to metal
prior to handling the control.
The unit is equipped with a field make-up box on the left
hand side of the cabinet. The make-up box may be moved
to the right side of the furnace to facilitate installation. If the
make-up box is moved to the right hand side, clip the wire
ties that bundle the wires together. Secure the excess wire
to the existing harness to protect it from damage.
Cut the two wire ties to extend power wires for right side only
FIGURE 19
Refer to figure 20 for schematic wiring diagram,
troubleshooting and field wiring.
The power supply wiring must meet Class I restrictions.
Protected by either a fuse or circuit breaker, select circuit
protection and wire size according to unit nameplate.
NOTE - Unit nameplate states maximum current draw.
Maximum over-current protection allowed is 15 AMP.
Holes are on both sides of the furnace cabinet to facilitate
wiring.
Install a separate (properly sized) disconnect switch near
the furnace so that power can be turned off for servicing.
Before connecting the thermostat, check to make sure the
wires will be long enough for servicing at a later date. Make
sure that thermostat wire is long enough to facilitate future
removal of blower for service.
Complete the wiring connections to the equipment. Use the
provided unit wiring diagram shown in figure 20. Use
18-gauge wire or larger that is suitable for Class II rating for
thermostat connections.
Electrically ground the unit according to local codes or, in
the absence of local codes, according to the current Na
tional Electric Code (ANSI/NFPA No. 70). A green ground
wire is provided in the field make-up box.
NOTE - The EL180DFE furnace contains electronic
components that are polarity sensitive. Make sure that the
furnace is wired correctly and is properly grounded.
Accessory Terminals
One line voltage “EAC” 1/4” spade terminal is provided on
the furnace integrated control. See figure 21 for integrated
control configuration. This terminal is energized when the
indoor blower is operating. Any accessory rated up to one
amp can be connected to this terminal with the neutral leg
Page 19
Page 20
of the circuit being connected to one of the provided neutral
terminals. If an accessory rated at greater than one amp is
connected to this terminal, it is necessary to use an exter
nal relay.
One line voltage “HUM” 1/4” spade terminnal is provided
on the furnace integrated control. See figure 21 for inte
grated control configuration. This terminal is energized in
the heating mode when the combustion air inducer is
operating. Any humidifier rated up to one amp can be con
nected to this terminal with the neutral leg of the circuit be
ing connected to one of the provided neutral terminals. If a
humidifier rated at greater than one amp is connected to
this terminal, it is necessary to use an external relay relay.
One 24V ”H” 1/4” spade terminal is provided on the furnace
integrated control. See figure 21 for integrated control con
figuration. The terminal is energized in the heating mode
when the combustion air inducer is operating and the pres
sure switch is closed. Any humidifier rated up to 0.5 amp
can be connected to this terminal with the ground leg of the
circuit connected to ground or the ”C” terminal.
Generator Use - Voltage Requirements
The following requirements must be kept in mind when
specifying a generator for use with this equipment:
S The furnace requires 120 volts +
10% (Range: 108
volts to 132 volts).
S The furnace operates at 60 Hz +
5% (Range: 57 Hz to
63 Hz).
S The furnace integrated control requires both proper
polarity and proper ground. Both polarity and proper
grounding should be checked before attempting to op
erate the furnace on either permanent or temporary
power.
S Generator should have a wave form distortion of less
than 5% total harmonic distortion.
Thermostat
Install the room thermostat according to the instructions
provided with the thermostat. See figure 20 for thermostat
designations. If the furnace is being matched with a heat
pump, refer to the FM21 installation instruction or appropri
ate dual fuel thermostat instructions.
Indoor Blower Speeds
1 - When the thermostat is set to “FAN ON,” the indoor
blower will run continuously on the fan speed when
there is no cooling or heating demand.
2 - When the EL180DFE is running in the heating mode,
the indoor blower will run on the heating speed.
3 - When there is a cooling demand, the indoor blower will
run on the cooling speed.
Page 20
Page 21
EL180DFE Schematic Wiring Diagram
FIGURE 20
Page 21
Page 22
Integrated Control
RED LED
Flash Code
Diagnostic Codes / Status 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 Voltage Polarity
2 Improper Earth Ground
3 Burner failed to light, or lost flame during heat demand
4 Low Flame Signal - check flame sensor
5 Watchguard - burner failed to light, exceeded maximum number of retries or recycles.
6 Ignitor Circuit Failure - not available on this control
7 Primary or Secondary Limit Open or Watchguard Mode - Limit Switch Open longer than 3 minutes
8 Rollout Switch Open
9 Pressure Switch failed to close or opened during heat demand
10 Watchguard - Pressure Switch opened 5 times during one heat demand
11 Pressure Switch stuck closed prior to activation of combustion air inducer
12 Flame Sensed without gas valve energized
13 Low Line Voltage
Notes
Note 1 A ”Heartbeat” is indicated by a ”Slow Flash” - 1 sec on 1 sec off, repeating
Note
Error codes are indicated by a ”Rapid Flash” - the LED flashes X times at 1/2 sec on 1/2 sec off, remains
off for 3 sec, then repeats
Last 10 error codes are stored in memory including when power is shut off to the unit. - To recall, press
Note
and release button, most recent will be displayed first, LED off for 3 sec, then next error code is displayed,
etc. To clear error codes, depress and hold button longer than 5 seconds.
INTEGRATED CONTROL
(Automatic Hot Surface Ignition System)
BLOWER OFF DELAY
RECALL BUTTON
RED LED
TABLE 9
1/4” QUICK CONNECT TERMINALS
120HUM Humidifier 120VAC
LINE 120VAC
XFMR Transformer 120VAC
CIRC Indoor blower 120VAC
EAC Indoor air quality accessorie 120VAC
NEUTRALS Common 120VAC
HUM24 Humidifier 24VAC
3/16” QUICK CONNECT TERMINALS
COOL Cooling tap 24VAC
HEAT Heating tap 24VAC
FAN Continuous blower 24 VAC
PARK (no power) Park terminal for speed taps
FLAME/FS Flame sense
24 COM Common 24VAC
FIGURE 21
Page 22
Page 23
Unit Start-Up
FOR YOUR SAFETY READ BEFORE LIGHTING
WARNING
Do not use this furnace if any part has been under
water. A flood-damaged furnace is extremely dan
gerous. Attempts to use the furnace can result in
fire or explosion. Immediately call a qualified ser
vice technician to inspect the furnace and to replace
all gas controls, control system parts, and electrical
parts that have been wet or to replace the furnace,
if deemed necessary.
WARNING
If overheating occurs or if gas supply fails to shut off,
shut off the manual gas valve to the appliance before
shutting off electrical supply.
CAUTION
Before attempting to perform any service or mainte
nance, turn the electrical power to unit OFF at dis
connect switch.
BEFORE LIGHTING smell all around the appliance area for
gas. Be sure to smell next to the floor because some gas is
heavier than air and will settle on the floor.
The gas valve on the EL180DFE unit is equipped with a gas
control switch. Use only your hand to move the switch. Nev
er use tools. If the switch will not turn or if the control switch
will not move by hand, do not try to repair it.
Placing the furnace into operation:
EL180DFE units are equipped with an automatic ignition
system. Do not attempt to manually light burners on these
furnaces. Each time the thermostat calls for heat, the
burners will automatically light. The ignitor does not get
hot when there is no call for heat on units with an automatic
ignition system.
WARNING
If you do not follow these instructions exactly, a fire
or explosion may result causing property damage,
personal injury or death.
Gas Valve Operation (Figure 22)
1 - STOP! Read the safety information at the beginning of
this section.
2 - Set the thermostat to the lowest setting.
3 - Turn off all electrical power to the unit.
4 - This furnace is equipped with an ignition device which
automatically lights the burners. Do not try to light the
burners by hand.
5 - Remove the access panel.
6 - Move switch on gas valve to OFF. Do not force. See
figure 22.
7 - Wait five minutes to clear out any gas. If you then smell
gas, STOP! Immediately call your gas supplier from a
neighbor's phone. Follow the gas supplier's instruc
tions. If you do not smell gas go to next step.
MANIFOLD
PRESSURE
ADJUSTMENT
SCREW
INLET
PRESSURE
PORT
8 - Move switch on gas valve to ON. Do not force. See fig
ure 22.
9 - Replace the access panel.
10- Turn on all electrical power to to the unit.
11- Set the thermostat to desired setting.
NOTE - When unit is initially started, steps 1 through 11
may need to be repeated to purge air from gas line.
12- If the appliance will not operate, follow the instructions
“Turning Off Gas to Unit” and call your service techni
cian or gas supplier.
Turning Off Gas to Unit
1 - Set the thermostat to the lowest setting.
2 - Turn off all electrical power to the unit if service is to be
performed.
3 - Remove the access panel.
4 - Move switch on gas valve to OFF. Do not force.
5 - Replace the upper access panel.
Failure To Operate
If the unit fails to operate, check the following:
1 - Is the thermostat calling for heat?
2 - Are access panels securely in place?
3 - Is the main disconnect switch closed?
4 - Is there a blown fuse or tripped circuit breaker?
5 - Is the filter dirty or plugged? Dirty or plugged filters will
cause the limit control to shut the unit off.
6 - Is gas turned on at the meter?
7 - Is the manual main shut‐off valve open?
8 - Is the internal manual shut‐off valve open?
9 - Is the unit ignition system in lock out? If the unit locks out
again, call the service technician to inspect the unit for
blockages.
10 - Is pressure switch closed? Obstructed flue will cause
unit to shut off at pressure switch. Check flue and outlet
for blockages.
GAS VALVE SHOWN IN ON POSITION
FIGURE 22
MANIFOLD
PRESSURE
OUTLET
PORT
Page 23
Page 24
11 - Are flame rollout switches tripped? If flame rollout
switches are tripped, call the service technician for in
spection.
Heating Sequence Of Operation
(follow steps below or see Figure 20 for more detail)
1 - When thermostat calls for heat, combustion air blower
starts.
2 - Combustion air pressure switch proves blower opera
tion. Switch is factory-set and requires no adjustment.
3 - After a 15-second prepurge, the hot surface ignitor en
ergizes.
4 - After a 20-second ignitor warm-up period, the gas
valve solenoid opens. A 4-second trial for ignition peri
od begins.
5 - Gas is ignited, flame sensor proves the flame, and the
combustion process continues.
6 - If flame is not detected after first ignition trial, the igni
tion control will repeat steps 3 and 4 four more times
before locking out the gas valve (“WATCHGUARD”
flame failure mode). The ignition control will then auto
matically repeat steps 1 through 6 after 60 minutes.
7 - To interrupt the 60-minute “WATCHGUARD” period,
move thermostat from “Heat” to “OFF” then back to
“Heat.” Heating sequence then restarts at step 1.
Supply Pressure Measurement
A threaded plug on the inlet side of the gas valve provides
access to the supply pressure tap. Remove the threaded
plug, install a field-provided barbed fitting and connect a
manometer to measure supply pressure. Furnace should
operate at least 5 minutes before checking supply pres
sure. See table 12 for proper supply pressure. Replace the
threaded plug after measurements have been taken.
Manifold Pressure Measurement
1 - Remove the threaded plug from the outlet side of the
gas valve and install a field-provided barbed fitting.
Connect to a manometer to measure manifold pres
sure.
2 - Start unit and allow 5 minutes for unit to reach steady
state.
3 - While waiting for the unit to stabilize, observe the
flame. Flame should be stable and should not lift from
burner. Natural gas should burn blue.
4 - After allowing unit to stabilize for 5 minutes, record
manifold pressure and compare to value given in table
12.
NOTE - Shut unit off and remove manometer as soon as an
accurate reading has been obtained. Take care to remove
barbed fitting and replace threaded plug.
Gas Pressure Adjustment
Gas Flow (Approximate)
TABLE 10
GAS METER CLOCKING CHART
Seconds for One Revolution
EL180DFE Unit
-045 80 160 200 400
-070 55 110 136 272
-090 41 82 102 204
-110 33 66 82 164
-135 27 54 68 136
Natural-1000 btu/cu ft LP-2500 btu/cu ft
Furnace should operate at least 5 minutes before check
ing gas flow. Determine time in seconds for two revolu
tions of gas through the meter. (Two revolutions assures a
more accurate time.) Divide by two and compare to time
in table 10 below. If manifold pressure matches table 12
and rate is incorrect, check gas orifices for proper size and
restriction. Remove temporary gas meter if installed.
NOTE - To obtain accurate reading, shut off all other gas
appliances connected to meter.
Natural LP
1 cu ft
Dial
2 cu ft
Dial
1 cu ft
Dial
2 cu ft
DIAL
Proper Combustion
Furnace should operate a minimum 15 minutes with cor
rect manifold pressure and gas flow rate before checking
combustion. Take combustion sample beyond the flue out
let and compare to the tables below. The maximum car
bon monoxide reading should not exceed 50 ppm.
TABLE 11
EL180DFE Unit
-045
-070
-090
-110
CO2%
For
Nat
6.8 - 7.4 7.5 - 9.0
CO2%
L.P.
For
High Altitude
The manifold pressure may require adjustment and com
bustion air pressure switch may need replacing to ensure
proper combustion at higher altitudes. Refer to table 12 for
manifold pressure and table 13 for pressure switch change
and gas conversion kits.
IMPORTANT
For safety, shut unit off and remove manometer as
soon as an accurate reading has been obtained.
Take care to replace pressure tap plug.
Page 24
Page 25
TABLE 12
Manifold Pressure Settings at all Altitudes
Model
Input Size
045
070
090
110
Model
Input Size
045
070 80W52
090 No Change
110 80W52
High Altitude Pressure Switch Kit
0-4500 ft 4501-7500 ft 7501 - 10,000 ft 7501 - 10,000 ft 0 - 7500 ft 7501 - 10,000 ft 0 - 7500 ft
No Change
LP/propane 10.0 10.0 10.0 11.0 13.0
LP/propane 10.0 10.0 10.0 11.0 13.0
LP/propane 10.0 10.0 10.0 11.0 13.0
LP/propane 10.0 10.0 10.0 11.0 13.0
No Change
Supply Pressure
Gas 0-4500 ft 4501-7500 ft 7501 - 10,000 ft
Nat 3.5 3.5 3.5 4.5 13.0
Nat 3.5 3.3 3.5 4.5 13.0
Nat 3.5 3.3 3.5 4.5 13.0
Nat 3.5 3.3 3.5 4.5 13.0
in.wg.
Min Max
TABLE 13
Pressure Switch and Gas Conversion Kits at all Altitudes
High Altitude
Natural Gas Burner
Orifice Kit
80W51 73W37 70W89 76W15 73W81
Natural Gas to LP/Propane
Burner Orifice Kit
LP/Propane to
Natural Gas Burner
Orifice Kit
NOTE - A natural to L.P. propane gas changeover kit is necessary to convert this unit. Refer to the changeover kit installation instruction for the conversion
procedure.
Other Unit Adjustments
air temperatures have been allowed to stabilize, check the
temperature rise. If necessary, adjust the blower speed to
Primary and Secondary Limits
The primary limit is located on the heating compartment
vestibule panel. The secondary limits (if equipped) are lo
cated in the blower compartment, attached to the back side
of the blower. These auto reset limits are factory-set and re
quire no adjustment.
Flame Rollout Switches
These manually reset switches are located on the burner
box.
Pressure Switch
The pressure switch is located in the heating compartment
adjacent to the combustion air inducer. The switch checks
for proper combustion air inducer operation before allow
ing ignition trial. The switch is factory-set and requires no
adjustment.
Temperature Rise
After the furnace has been started, and supply and return
maintain the temperature rise within the range shown on
the unit nameplate. Increase the blower speed to decrease
the temperature. Decrease the blower speed to increase
the temperature rise. Failure to adjust the temperature rise
may cause erratic limit operation.
Fan Control
The heat fan-on time of 30 seconds is not adjustable. The
heat fan-off delay (amount of time that the blower operates
after the heat demand has been satisfied) may be adjusted
by changing the jumper position across the five pins on the
integrated control. The unit is shipped with a factory fan-off
delay setting of 90 seconds. The fan-off delay affects com
fort and is adjustable to satisfy individual applications. Ad
just the fan-off delay to achieve a supply air temperature
between 90° and 110°F at the moment that the blower is
de-energized. Longer off delay settings provide lower re
turn air temperatures; shorter settings provide higher re
turn air temperatures. See figure 23.
Page 25
Page 26
HEAT FAN‐OFF TIME IN SECONDS
NO JUMPER
To adjust fan-off timing, reposition jumper across pins to
60 Second
off Time
60
90
120
180
achieve desired setting.
90 Second
off Time
60
90
120
180
120 Second
off Time
60
90
120
180
180 Second
off Time
60
90
120
180
FIGURE 23
Constant Torque Motor
EL180DFE units are equipped with a permanent magnetic
indoor blower motor that provides constant torque. The mo
tor has five speed taps all referenced to the same signal
common. Each tap requires 24 volts to be energize.
Input Voltage Requirements
The circuit is designed to be operated with AC voltage. A
voltage of 12 to 33VAC is required to energize the motor.
Expected current draw will be less than 20mA.
Blower Speeds
Follow the steps below to change the blower speeds.
1 - Turn off electrical power to furnace.
2 - Remove blower access panel.
3 - Disconnect existing speed tap at integrated control
speed terminal.
NOTE - Termination of any unused motor leads must be
insulated.
4 - Place unused blower speed tap on integrated control
“PARK” terminal or insulate.
5 - Refer to blower speed selection chart on unit wiring dia
gram for desired heating or cooling speed. See Blower
performance data beginning on the next page.
6 - Connect selected speed tap at integrated control
speed terminal.
7 - Resecure blower access panel.
8 - Turn on electrical power to furnace.
9 - Recheck temperature rise.
Electronic Ignition
The integrated control has an added feature of an internal
Watchguard control. The feature serves as an automatic re
set device for integrated control lockout caused by ignition
failure. This type of lockout is usually due to low gas line
pressure. After one hour of continuous thermostat demand
for heat, the Watchguard will break and remake thermostat
demand to the furnace and automatically reset the inte
grated control to begin the ignition sequence.
Page 26
Page 27
Service
WARNING
ELECTRICAL SHOCK, FIRE,
OR EXPLOSION HAZARD.
Failure to follow safety warnings exactly could result
in dangerous operation, serious injury, death or
property damage.
Improper servicing could result in dangerous opera
tion, serious injury, death, or property damage.
Before servicing, disconnect all electrical power to
furnace.
When servicing controls, label all wires prior to dis
connecting. Take care to reconnect wires correctly.
Verify proper operation after servicing.
At the beginning of each heating season, a licensed profes
sional technician (or equivalent) should check the system
as follows:
Blower
Check the blower wheel for debris and clean if necessary.
The blower motors are prelubricated for extended bearing
life. No further lubrication is needed.
WARNING
The blower access panel must be securely in place
when the blower and burners are operating. Gas
fumes, which could contain carbon monoxide, can
be drawn into living space resulting in personal inju
ry or death.
Filters
All EL180DFE filters are installed external to the unit. Fil
ters should be inspected monthly. Clean or replace the fil
ters when necessary to ensure that the furnace operates
properly. Replacement filters must be rated for high veloc
ity airflow. Table 3 lists recommended filter sizes.
Flue And Chimney
1 - Check flue pipe, chimney and all connections for tight
ness and to make sure there is no blockage.
2 - Check unit for proper draft.
Electrical
1 - Check all wiring for loose connections.
2 - Check for the correct voltage at the furnace (furnace
operating). Correct voltage is 120VAC +
3 - Check amp-draw on the blower motor with blower ac
cess panel in place.
Unit Nameplate__________Actual__________
Cleaning the Burners
NOTE - Use papers or protective covering in front of the fur
nace during cleaning.
1 - Turn off both electrical and gas power supplies to fur
nace.
2 - Remove access panel.
3 - Label the wires from gas valve and rollout switches
then disconnect them.
4 - Mark and disconnect sensor wire from the sensor. Dis
connect plug from the ignitor at the burner box.
5 - Disconnect gas supply piping. Remove the four screws
securing the burner manifold assembly to the vestibule
panel and remove the assembly from the unit.
6 - Remove screws securing burner box and remove
burner box.
7- To clean burners, run a vacuum cleaner with a soft brush
attachment over the face of burners. Visually inspect in
side the burners and crossovers for any blockage
caused by foreign matter. Remove any blockage. Figure
24 shows burner detail.
8 - Reinstall the burner box assembly using the existing
four screws. Make sure that the burners line up in the
center of the burner ports.
9 - Reconnect the sensor wire and reconnect the 2-pin
plug to the ignitor wiring harness.
10 - Follow lighting instructions to light and operate fur
nace for 5 minutes to ensure that heat exchanger is
clean and dry and that furnace is operating properly.
11 - Replace access panel.
10%.
Page 27
Page 28
EL180DFE BURNER REMOVAL
rollout switch
burner box assembly
sensor
ignitor
burners
manifold and gas valve
FIGURE 24
Repair Parts List
The following repair parts are available through indepen
dent Lennox dealers. When ordering parts, include the
complete furnace model number listed on the CSA Interna
tional nameplate -- Example: EL180DF110E60C.
All service must be performed by a licensed profes
sional installer (or equivalent), service agency, or gas
supplier.
Cabinet Parts
Heating access panel
Blower access panel
Top cap
Control Panel Parts
Transformer
Integrated control
Door interlock switch
Circuit breaker
Blower Parts
Blower wheel
retention rings
cross over
Blower housing
Motor
Motor electronics
Power choke (1/2 and 3/4 hp only)
Motor mounting frame
Blower housing cutoff plate
Heating Parts
Flame Sensor
Heat exchanger assembly
Gas manifold
Combustion air inducer
Gas valve
Main burner cluster
Main burner orifices
Pressure switch
Ignitor
Primary limit control
Flame rollout switch
Secondary limit
Page 28
Page 29
Start-Up & Performance Check List
Unit Model Number_______________
UNIT SET UP
(typical)
2
2
1
GAS SUPPLY
1
Natural Gas
Piping Connections Tight
Leak Tested
Serial Number___________________
Line Voltage
5
Gas Supply Pressure
1
LP/Propane Gas
SUPPLY
AIR
upflow furnace shown
3
Filter
RETURN
RETURN
AIR
4
3
DUCT SYSTEM
AIR
SUPPLY AIR DUCT
Sealed
Insulated (if necessary)
Supply Line Pressure “ W.C.________
VENT / EXHAUST PIPE
2
Secure to Unit
Elbows Secured to Pipe
Roof Flashing (water tight)
Vent Pipe Supported
Page 29
Registers Open and Unobstructed
RETURN DUCT
Sealed
Filter Installed and Clean
Grilles Unobstructed
INTEGRATED CONTROL
4
DIP Switches Set (if applicable)
Appropriate Links in Place (if applicable)
5
VOLTAGE CHECK
Supply Voltage _____
Electrical Connections Tight
Page 30
UNIT OPERATION
(typical)
Combustion CO
2
Gas Manifold Pressure
1
Blower Motor Amps
3
7
2
Thermostat
SUPPLY
AIR
6
upflow furnace shown
RETURN
RETURN
AIR
AIR
Temperatures
4
Filter
Duct Static
5
HEATING MODE
GAS MANIFOLD PRESSURE “W.C._____
1
2
COMBUSTION SAMPLE CO
INDOOR BLOWER AMPS______
3
TEMPERATURE RISE
4
2%______
Supply Duct Temperature ________
Return Duct Temperature _ _____
Temperature Rise = ________
TOTAL EXTERNAL STATIC (dry coil)
5
Supply External Static _______
CO PPM_______
3
4
5
6
COOLING MODE
INDOOR BLOWER AMPS______
TEMPERATURE DROP
Return Duct Temperature _________
Supply Duct Temperature
Temperature Drop = _________
TOTAL EXTERNAL STATIC (dry coil)
Supply External Static _______
Return External Static + ______
Total External Static = _______
DRAIN LINE
Leak Free
Return External Static + ______
7
Total External Static = _______
THERMOSTAT
Adjusted and Programmed
Operation Explained to Owner
Contractor's: Name_________________________Telephone_____________Checklist Completed____________________
_ _______
Job Address_____-________________________________Technician's Name___________________________________
Page 30
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