E 2013 Lennox Industries Inc.

Dallas, Texas, USA

INSTALLATION

INSTRUCTIONS

EL180DFE

ELITE ® SERIES GAS FURNACE

DOWNFLOW AIR DISCHARGE

507140-01

01/2013 Litho U.S.A.

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

DOWNFLOW

AIR FLOW

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.

Unit Dimensions

EL180DFE Gas Furnace

Shipping and Packing List

Table of Contents

Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Use of Furnace as a Construction Heater . . . . . . . . . . .

General

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Combustion, Dilution & Ventilation Air . . . . . . . . . . . . . .

Setting Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

3

3

3

4

4

5

9

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Duct System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

17

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Integrated Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

22

Unit Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gas Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . .

Proper Combustion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

24

24

High Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Other Unit Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . .

24

25

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start-Up & Performance Checklist . . . . . . . . . . . . . . . . .

27

28

29

01/13

*2P0113*

Page 1

507140-01

*P507140-01*

Unit Dimensions - inches (mm)

FLUE OUTLET

(Top)

3−1/8

(79)

D

A

B

9/16

(14)

1−1/2 (38)

Front Panel

9/16

(14)

B

RETURN AIR

OPENING

19−7/16

(494)

9/16

(14)

TOP VIEW

27−3/4

(705)

19−7/16

(494)

9/16

(14)

9/16

(14)

C

Supply

Air

3/4

(19)

33

(838)

5−3/8 (137) Right

2−3/16 (56) Left

6−5/8 (168) Right

7−1/8 (181) Left

ELECTRICAL INLET

(Either Side)

GAS PIPING INLET

(Either Side)

19−1/4

(489)

Supply

Air

EL180DF Model No.

045E36A

070E36B

090E48B

110E60C in.

14-1/2

17-1/2

21

A mm

368

446

533 in.

13-3/8

16-3/8

19-7/8

B mm

340

416

504 in.

13

16

19-1/2

C mm

330

406

495 in.

4-3/4

6-1/4

8

D mm

121

159

203

Page 2

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.

Page 3

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

D

D Gas furnaces shall be installed by a licensed plumb­ er or fitter only.

The gas cock must be “T handle” type.

When a furnace is installed in an attic, the passage­ way to and service area surrounding the equipment shall be floored.

Page 4

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 3 ) per 1,000 Btu (.29 kW) per hour of the com­ bined input rating of all appliances installed in that space.

This space also includes adjacent rooms which are not separated 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 3 ) per 1,000 Btu (.29 kW) per hour of the 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

Page 5

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

SPACE ALL AIR FROM INSIDE

CHIMNEY

OR GAS

VENT

FURNACE

WATER

HEATER

OPENINGS

(To Adjacent

Room)

NOTE - Each opening shall have a free area of at least one square inch (645 mm 2 ) per 1,000 Btu (.29 kW) per hour of the total input rat­ ing of all equipment in the enclosure, but not less than 100 square inches (64516 mm 2 ).

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.

Page 6

EQUIPMENT IN CONFINED SPACE

ALL AIR FROM OUTSIDE

(Inlet Air from Crawlspace and Outlet Air to Ventilated Attic)

CHIMNEY OR

GAS VENT

FURNACE

VENTILATION

LOUVERS

(For unheated crawl space)

VENTILATION LOUVERS

(Each end of attic)

OUTLET

AIR WATER

HEATER

INLET

AIR

CHIMNEY

OR GAS

VENT

NOTE-The inlet and outlet air openings shall each have a free area of at least one square inch (645 mm 2 ) per 4,000 Btu (1.17 kW) per hour of the total input rating of all equipment in the enclosure.

FIGURE 3

EQUIPMENT IN CONFINED SPACE

ALL AIR FROM OUTSIDE

(All Air Through Ventilated Attic)

VENTILATION LOUVERS

(Each end of attic)

OUTLET

AIR

CHIMNEY

OR GAS

VENT WATER

HEATER

EQUIPMENT IN

CONFINED SPACE

ALL AIR FROM

OUTSIDE

OUTLET AIR

FURNACE

FURNACE

INLET AIR

(Ends 12 in.

above bottom)

INLET AIR

WATER

HEATER

NOTE-The inlet and outlet air openings shall each have a free area of at least one square inch (645 mm 2 ) per 4,000

Btu (1.17 kW) per hour of the total input rating of all equip­ ment in the enclosure.

FIGURE 4

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 2 ) per 4,000 Btu (1.17 kW) per hour of the total input rating of all other equipment in the enclosure.

FIGURE 5

Page 7

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

PROPERLY

SIZED FLOOR

OPENING

SUPPLY AIR PLENUM

DOWNFLOW

COMBUSTIBLE

FLOORING BASE

EL180DFE UNIT

OPENING

FIGURE 6

SUPPLY AIR

PLENUM

TABLE 1

NON-COMBUSTIBLE FLOOR OPENING SIZE

Cabinet Width

Front to Rear

in.

mm

Side to Side in.

mm

A (14.5”)

B (17.5”)

19-3/4

19-3/4

502

502

13-1/4

16-1/4

337

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.

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

Front to Rear Side to Side

Cabinet Width in.

mm in.

mm

A (14.5”)

B (17.5”)

22

22

559

559

15-3/4

18-3/4

400

476

C (21”) 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.

Page 8

Setting Equipment

EL180DFE UNIT

COOLING COIL

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.

PROPERLY

SIZED FLOOR

OPENING

PLENUM

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

HEMMED EDGE

Side View

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.

Install the EL180DFE gas furnace as shipped in the downflow position only. Do not install the furnace hori­ zontally.

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

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.

Page 9

Horizontal

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

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 Right Side

Bottom

Type of Vent

Connector

Type C Type B1

Top

*Front

Back

Sides

Vent

Floor

1 in. (25 mm)

2-1/4 in. (57 mm)**

0

0†

6 in. (152 mm)

NC††

1 in. (25 mm)

2-1/4 in. (57 mm)

0

0

1 in. (25 mm)

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.

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.

Page 10

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).

Cabinet Width

A (14-1/2”)

B (17-1/2”)

C (21”)

TABLE 3

Return Air Filter Size (inches)

14 x 25 x 1 (1)

16 x 25 x 1 (1)

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 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

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

“DISCONNECTED VENT”

WARNING

STICKER

FIGURE 14

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

MINIMUM LENGTH = AS SHORT AS PRACTICAL.

FOR MAXIMUM LENGTH SEE NOTE TO LEFT

INTERIOR TILE-LINED

MASONRY CHIMNEY

NOTE- Refer to provided venting tables for installations.

NOTE - the chimney must be properly sized per provided venting tables or lined with listed metal lining system.

VENT

CONNECTOR

OTHER

APPLIANCE

PERMANENTLY

SEALED FIREPLACE

OPENING

FURNACE

FIGURE 15

Page 12

Common Venting Using Metal-Lined Masonry Chimney

SEALED

5 ft. (1.5 m) minimum

MAX. LENGTH

-- SEE NOTE

BELOW.

MIN. LENGTH -- AS

SHORT AS PRACTICAL

EXTERIOR

CHIMNEY WITH

METAL

LINER

4 in. (102 mm) minimum

VENT CONNECTOR

FURNACE

OTHER

APPLIANCE

PERMANENTLY

SEALED FIREPLACE

OPENING

NOTE 1 - Refer to the provided venting tables for installations.

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

TABLE 4

Connector Diameter inches (mm)

3 (76)

4 (102)

5 (127)

6 (152)

7 (178)

Maximum Horizontal

Connector Length feet (m)

4-1/2 (1.37)

6 (1.83)

7-1/2 (2.29)

9 (2.74)

10-1/2 (3.20)

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

TABLE 5

Capacity of Type B Double-Wall Vents with Type B Double-Wall Connectors

Serving a Single Category I Appliance

Height

H

(feet)

Lateral

L

(feet)

MIN

3 Inch

MAX

Vent and Connector Diameter - D (inches)

4 Inch 5 Inch

Appliance Input Rating in Thousands of Btu Per Hour

MIN MAX MIN MAX MIN

6 Inch

MAX

6

8

10

15

20

30

176

327

226

219

178

171

164

295

194

187

251

157

153

149

276

206

195

349

250

242

262

249

237

214

229

217

206

374

283

275

54

0

20

39

25

42

51

0

23

41

0

27

39

47

0

51

61

0

18

38

48

57

66

88

50

59

69

0

14

36

104

191

136

130

109

103

98

175

118

113

152

97

94

91

165

121

112

202

149

143

150

141

132

113

133

124

116

213

166

160

41

0

15

30

16

32

39

0

17

32

0

18

30

36

0

40

48

0

14

29

37

44

53

73

38

46

55

0

13

28

51

94

69

65

57

53

49

88

61

57

78

51

49

46

84

59

53

97

75

71

70

64

58

NA

64

58

52

100

81

77

30

0

11

22

12

23

28

0

12

23

0

13

21

25

0

29

35

0

10

21

27

33

56

NA

28

34

48

0

9

21

10

0

2

5

8

0

2

5

2

5

4

6

0

0

2

10

15

0

2

5

10

15

20

30

10

15

20

0

2

5

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).

67

0

22

49

28

53

64

0

26

52

0

32

50

59

0

64

76

0

20

47

59

70

80

104

62

73

84

0

18

45

267

502

339

330

263

255

247

447

289

280

375

232

227

223

415

315

301

540

377

367

405

389

374

346

351

337

322

587

432

421

Page 15

Vent

Height

H

(feet)

6

8

10

15

20

30

Vent

Height

H

(feet)

6

8

10

15

20

30

Connector

Rise

R

(feet)

1

2

3

1

1

2

3

1

2

3

2

3

3

1

1

2

2

3

TABLE 6

Vent Connector Capacity

Type B Double-Wall Vents with Type B Double-Wall Connectors

Serving Two or More Category I Appliances

MIN

22

23

24

22

22

23

24

23

24

21

22

24

21

22

23

20

21

22

3 Inch

MAX

40

44

47

43

37

41

44

47

50

50

53

55

54

57

60

62

64

66

Vent and Connector Diameter - D (inches)

4 Inch 5 Inch

Appliance Input Rating in Thousands of Btu Per Hour

MIN MAX MIN MAX

35

36

37

34

35

37

38

36

37

33

35

36

33

34

35

31

33

34

66

75

81

72

80

87

78

86

92

89

96

102

99

105

110

113

118

123

46

48

49

49

51

53

49

51

52

47

49

51

46

48

50

45

47

48

106

121

132

114

128

139

123

136

146

142

153

163

157

167

176

181

190

198

MIN

64

66

67

65

58

60

62

67

69

64

66

68

62

64

66

60

62

64

6 Inch

4 Inch

FAN + FAN

92

101

110

125

136

152

TABLE 7

Common Vent Capacity

Type B Double-Wall Vents with Type B Double-Wall Connectors

Serving Two or More Category I Appliances

FAN + NAT

81

90

97

112

123

138

Common Vent Diameter - D (inches)

5 Inch 6 Inch

Appliance Input Rating in Thousands of Btu Per Hour

FAN + FAN FAN + NAT FAN + FAN FAN + NAT

140

155

169

195

215

244

116

129

141

164

183

210

204

224

243

283

314

361

161

178

194

228

255

297

FAN + FAN

309

339

367

427

475

547

7 Inch

FAN + NAT

248

275

299

352

394

459

MAX

164

183

199

176

195

210

189

206

220

220

235

248

246

259

271

288

299

309

Page 16

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.

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.

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.

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

TABLE 8

Gas Pipe Capacity - ft 3 /hr (m 3 /hr)

1-1/4

(31.75)

1-1/2

(38.1)

2

(50.8)

2-1/2

(63.5)

3

(76.2)

Nominal

Iron Pipe

Size inches

(mm)

1/2

(12.7)

3/4

(19.05)

1

(25.4)

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)

172

(4.87)

360

(10.19)

678

(19.19)

1350

(38.22)

2090

(59.18)

4020

(113.83)

6400

(181.22)

11300

(319.98)

20

(6.096)

118

(3.34)

247

(7.00)

466

(13.19)

957

(27.09)

1430

(40.49)

2760

(78.15)

4400

(124.59)

7780

(220.30)

30

(9.144)

95

(2.69)

199

(5.63)

374

(10.59)

768

(22.25)

1150

(32.56)

2220

(62.86)

3530

(99.95)

6250

(176.98)

40

(12.192)

81

(2.29)

170

(4.81)

320

(9.06)

657

(18.60)

985

(27.89)

1900

(53.80)

3020

(85.51)

5350

(151.49)

Length of Pipe - feet (m)

50

(15.240)

72

(2.03)

151

(4.28)

284

(8.04)

583

(16.50)

873

(24.72)

1680

(47.57)

2680

(75.88)

4740

(134.22)

60

(18.288)

65

(1.84)

137

(3.87)

257

(7.27)

528

(14.95)

791

(22.39)

1520

(43.04)

2480

(70.22)

4290

(121.47)

70

(21.336)

NOTE - Capacity given in cubic feet (m 3 ) of gas per hour and based on 0.60 specific gravity gas.

60

(1.69)

126

(3.56)

237

(6.71)

486

(13.76)

728

(20.61)

1400

(39.64)

2230

(63.14)

3950

(111.85)

80

(24.384)

56

(1.58)

117

(3.31)

220

(6.23)

452

(12.79)

677

(19.17)

1300

(36.81)

2080

(58.89)

3670

(103.92)

90

(27.432)

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

VALVE

Left Side Piping

(Standard)

AUTOMATIC

GAS VALVE

(with manual shut-off valve)

GROUND

JOINT

UNION

DRIP LEG

AUTOMATIC

GAS VALVE

(with manual shut-off valve)

FIELD

PROVIDED

AND INSTALLED

NOTE - BLACK IRON PIPE ONLY TO BE ROUTED INSIDE OF CABINET

FIGURE 17

MANUAL

MAIN SHUT-OFF

VALVE

GROUND

JOINT

UNION

DRIP LEG

Right Side Piping

(Alternate)

Page 18

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.

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

ISOLATE

GAS VALVE

FURNACE

1/8 NPT PLUG

CAP

FIGURE 18

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.

INTERIOR MAKE-UP BOX INSTALLATION

(Right Side)

MAKE-UP

BOX

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

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

EL180DFE Schematic Wiring Diagram

FIGURE 20

Page 21

Integrated Control

RED LED

Flash Code

7

8

9

5

6

10

11

12

13

Off

On

Heartbeat 1

3

4

1

2

BLOWER OFF DELAY

RECALL BUTTON RED LED

Diagnostic Codes / Status of Furnace

Note 1

Note

Note

No power to control or board fault detected

Board fault detected,

Control powered - displayed during all modes of operation if no errors are detected

Reverse Line Voltage Polarity

Improper Earth Ground

Burner failed to light, or lost flame during heat demand

Low Flame Signal - check flame sensor

Watchguard - burner failed to light, exceeded maximum number of retries or recycles.

Ignitor Circuit Failure - not available on this control

Primary or Secondary Limit Open or Watchguard Mode - Limit Switch Open longer than 3 minutes

Rollout Switch Open

Pressure Switch failed to close or opened during heat demand

Watchguard - Pressure Switch opened 5 times during one heat demand

Pressure Switch stuck closed prior to activation of combustion air inducer

Flame Sensed without gas valve energized

Low Line Voltage

Notes

A ”Heartbeat” is indicated by a ”Slow Flash” - 1 sec on 1 sec off, repeating

Error codes are indicated by a ”Rapid Flash” - the LED flashes X times at 1/2 sec on 1/2 sec off, remains off for 3 sec, then repeats

Last 10 error codes are stored in memory including when power is shut off to the unit. - To recall, press and release button, most recent will be displayed first, LED off for 3 sec, then next error code is displayed, etc. To clear error codes, depress and hold button longer than 5 seconds.

TABLE 9

INTEGRATED CONTROL

(Automatic Hot Surface Ignition System)

120HUM

LINE

XFMR

CIRC

EAC

NEUTRALS

HUM24

COOL

HEAT

FAN

PARK (no power)

FLAME/FS

24 COM

1/4” QUICK CONNECT TERMINALS

Humidifier 120VAC

120VAC

Transformer 120VAC

Indoor blower 120VAC

Indoor air quality accessorie 120VAC

Common 120VAC

Humidifier 24VAC

3/16” QUICK CONNECT TERMINALS

Cooling tap 24VAC

Heating tap 24VAC

Continuous blower 24 VAC

Park terminal for speed taps

Flame sense

Common 24VAC

FIGURE 21

Page 22

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.

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

MANIFOLD

PRESSURE

OUTLET

PORT

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.

INLET

PRESSURE

PORT

GAS VALVE SHOWN IN ON POSITION

FIGURE 22

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.

Page 23

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.

Gas Pressure Adjustment

Gas Flow (Approximate)

TABLE 10

-045

-070

GAS METER CLOCKING CHART

Seconds for One Revolution

EL180DFE Unit

Natural

1 cu ft

Dial

2 cu ft

Dial

80

55

160

110

1 cu ft

Dial

200

136

LP

2 cu ft

DIAL

400

272

-090

-110

-135

41

33

27

82

66

54

102

82

68

Natural-1000 btu/cu ft LP-2500 btu/cu ft

204

164

136

Furnace should operate at least 5 minutes before check­ ing gas flow. Determine time in seconds for two revolu­ tions of gas through the meter. (Two revolutions assures a more accurate time.) Divide by two and compare to time

in table 10 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.

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.

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.

EL180DFE Unit

TABLE 11

CO

2

% For

Nat

CO

2

%

L.P.

For

-045

-070

-090

-110

6.8 - 7.4

7.5 - 9.0

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

TABLE 12

Manifold Pressure Settings at all Altitudes

Model

Input Size

045

070

090

110

Gas

Nat

LP/propane

Nat

LP/propane

Nat

LP/propane

Nat

LP/propane

0-4500 ft

3.5

10.0

3.5

10.0

3.5

10.0

3.5

10.0

4501-7500 ft

3.5

10.0

3.3

10.0

3.3

10.0

3.3

10.0

7501 - 10,000 ft

3.5

10.0

3.5

10.0

3.5

10.0

3.5

10.0

4.5

11.0

4.5

11.0

4.5

11.0

Supply Pressure in.wg.

Min

4.5

11.0

Max

13.0

13.0

13.0

13.0

13.0

13.0

13.0

13.0

TABLE 13

Pressure Switch and Gas Conversion Kits at all Altitudes

Model

Input Size

045

070

090

110

High Altitude Pressure Switch Kit

High Altitude

Natural Gas Burner

Orifice Kit

7501 - 10,000 ft

Natural Gas to LP/Propane

Burner Orifice Kit

0 - 7500 ft 7501 - 10,000 ft

LP/Propane to

Natural Gas Burner

Orifice Kit

0 - 7500 ft 0-4500 ft

No Change

4501-7500 ft 7501 - 10,000 ft

No Change

80W52

80W51

No Change

80W52

73W37 70W89 76W15 73W81

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

Primary and Secondary Limits temperature rise. If necessary, adjust the blower speed to maintain the temperature rise within the range shown on

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.

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.

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

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

HEAT FAN‐OFF TIME IN SECONDS

NO JUMPER

To adjust fan-off timing, reposition jumper across pins to achieve desired setting.

60 Second off Time

90 Second off Time

120 Second off Time

180 Second off Time

FIGURE 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

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 + 10%.

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.

Page 27

rollout switch burner box assembly ignitor sensor

EL180DFE BURNER REMOVAL burners manifold and gas valve retention rings cross over

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

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

Start-Up & Performance Check List

UNIT SET UP

(typical)

Unit Model Number_______________

Serial Number___________________

2

Line Voltage

5

2

SUPPLY

AIR upflow furnace shown

1

1

Gas Supply Pressure

Filter

3

4

1

GAS SUPPLY

Natural Gas LP/Propane Gas

Piping Connections Tight

Leak Tested

Supply Line Pressure “ W.C.________

2

VENT / EXHAUST PIPE

Secure to Unit

Elbows Secured to Pipe

Roof Flashing (water tight)

Vent Pipe Supported

3 DUCT SYSTEM

SUPPLY AIR DUCT

Sealed

Insulated (if necessary)

Registers Open and Unobstructed

RETURN DUCT

Sealed

Filter Installed and Clean

Grilles Unobstructed

4

INTEGRATED CONTROL

DIP Switches Set (if applicable)

Appropriate Links in Place (if applicable)

5 VOLTAGE CHECK

Supply Voltage _____

Electrical Connections Tight

Page 29

UNIT OPERATION

(typical)

Combustion CO

2

2

SUPPLY

AIR

Gas Manifold Pressure

1

7 Thermostat

6 upflow furnace shown

Filter

Temperatures

4

Blower Motor Amps

3

Duct Static

5

1

2

3

HEATING MODE

GAS MANIFOLD PRESSURE “W.C._____

COMBUSTION SAMPLE CO

2

%

______

CO PPM_______

INDOOR BLOWER AMPS______

3

COOLING MODE

INDOOR BLOWER AMPS______

4

TEMPERATURE DROP

Return Duct Temperature _________

Supply Duct Temperature _ _______

Temperature Drop = _________

4

TEMPERATURE RISE

Supply Duct Temperature ________

Return Duct Temperature _ _____

Temperature Rise = ________

5

TOTAL EXTERNAL STATIC (dry coil)

Supply External Static _______

Return External Static + ______

Total External Static = _______

6

DRAIN LINE

Leak Free

5

TOTAL EXTERNAL STATIC (dry coil)

Supply External Static _______

Return External Static + ______

Total External Static = _______

7 THERMOSTAT

Adjusted and Programmed

Operation Explained to Owner

Contractor's: Name_________________________Telephone_____________Checklist Completed____________________

Job Address_____-________________________________Technician's Name___________________________________

Page 30