Lennox EL180DFE Series Installation and operation manual

Page 1 ©2017 Lennox Industries Inc.
EL180DFE
Service Literature
Corp. 1301-L1
Revised 09/2017
EL180DFE series units are mid-efficiency gas furnaces
used for downflow applications only, manufactured with
Lennox Duraloktheat exchangers formed of aluminized
steel. EL180DFE units are available in heating capacities
of 44,000 to 110,000 Btuh and cooling applications 1.5 to 5
tons. Refer to Engineering Handbook for proper sizing.
Units are factory equipped for use with natural gas. Kits are
available for conversion to LP/Propane operation.
EL180DFE model units are equipped with a hot surface igni
tion system and a constant torque ECM motor. The motor is
programmed to provide constant torque at each of the five
selectable speed taps. All units use a redundant gas valve to
assure safety shut-off as required by C.S.A.
All specifications in this manual are subject to change. Pro
cedures outlined in this manual are presented as a recom
mendation only and do not supersede or replace local or
state codes. In the absence of local or state codes, the
guidelines and procedures outlined in this manual (except
where noted) are recommended only and do not constitute
code.
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 HVAC in
staller (or equivalent), service agency or the gas sup
plier.
TABLE OF CONTENTS
Specifications Page 2.............................
Blower Data Page 3..............................
Parts Identification Page 5.........................
I Unit Components Page 6........................
II Installation Page 17.............................
III Start Up Page 17..............................
IV Heating System Service Checks Page 17.........
V Typical Operating Characteristics Page 21.........
VI Maintenance Page 21..........................
VII Wiring and Sequence of Operation Page 24......
WARNING
Electric shock hazard. Can cause injury
or death. Before attempting to perform
any service or maintenance, turn the
electrical power to unit OFF at discon
nect switch(es). Unit may have multiple
power supplies.
WARNING
Fire Hazard. Use of aluminum wire with this
product may result in a fire, causing property dam
age, severe injury or death. Use copper wire only
with this product.
CAUTION
Failure to use properly sized wiring and circuit
breaker may result in property damage. Size wiring
and circuit breaker(s) per Product Specifications
bulletin (EHB) and unit rating plate.
CAUTION
As with any mechanical equipment, contact with
sharp sheet metal edges can result in personal in
jury. Take care while handling this equipment and
wear gloves and protective clothing.

Page 2
SPECIFICATIONS
Gas
Heating
Performance
Model No. EL180DF045E36A EL180DF070E36B EL180DF090E48B EL180DF110E60C
1AFUE 80% 80% 80% 80%
Input - Btuh 44,000 66,000 88,000 110,000
Output - Btuh 35,200 52,800 70,400 88,000
Temperature rise range - °F 15 - 45 30 - 60 30 - 60 30 - 60
Gas Manifold Pressure (in. w.g.)
Nat. Gas / LPG/Propane
3.5 / 10.0 3.5 / 10.0 3.5 / 10.0 3.5 / 10.0
High Static - in. w.g. 0.50 0.50 0.50 0.50
Connections
in.
Flue connection - in. round 4444
Gas pipe size IPS 1/2 1/2 1/2 1/2
Indoor
Blower
Wheel nom. dia. x width - in. 10 x 8 10 x 10 10 x 10 11-1/2 x 10
Motor output - hp 1/2 1/2 3/4 1
Tons of add-on cooling 1.5 - 3 1.5 - 3 2.5 - 4 3 - 5
Air Volume Range - cfm 355 - 1430 310 - 1345 680 - 1750 990 - 2410
Electrical
Data
Voltage 120 volts - 60 hertz - 1 phase
Blower motor full load amps 6.8 6.8 8.4 10.9
Maximum overcurrent protection 12 12 12 12
Shipping Data lbs. - 1 package 113 128 140 160
NOTE - Filters and provisions for mounting are not furnished and must be eld provided.
1 Annual Fuel Utilization Efciency based on DOE test procedures and according to FTC labeling regulations. Isolated combustion system rating for non-weatherized furnaces.
OPTIONAL ACCESSORIES - MUST BE ORDERED EXTRA
“A” Width
Models
“B” Width
Models
“C” Width
Models
CABINET ACCESSORIES
Downow Combustible Flooring Base 11M59 11M60 11M61
FILTERS
1 Downow Filter Cabinet 51W06 51W07 51W08
No. and Size of lter - in. (1) 20 x 16 x 1 (2) 20 x 20 x 1 (2) 20 x 20 x 1
NIGHT SERVICE KITS
Night Service Kit 84W47 84W47 84W47
Safety Service Kit 89W19 89W19 89W19
1 Cleanable polyurethane, frame-type lter.
GAS HEAT ACCESSORIES
Input
High Altitude
Pressure Switch Kit
Natural Gas to
LPG/Propane Kit
LPG/Propane
to Natural Gas Kit
Natural Gas
High Altitude
Orice Kit
0 - 4500 ft. 4501 - 7500 ft. 7501 - 10,000 ft. 0 - 7500 ft. 7501 - 10,000 ft. 0 - 7500 ft. 7501 - 10,000 ft.
045 No Change No Change 80W51 11K49 11K44 73W81 73W37
070 No Change 80W52 80W51 11K49 11K44 73W81 73W37
090 No Change 80W52 80W51 11K49 11K44 73W81 73W37
110 No Change 80W57 80W52 11K49 11K44 73W81 73W37

Page 3
BLOWER DATA
EL180DF045E36A PERFORMANCE (Less Filter)
External
Static
Pressure
in. w.g.
Air Volume / Watts at Various Blower Speeds
High Medium-High Medium Medium-Low Low
cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts
0.00 1430 285 1215 180 1035 120 995 110 930 100
0.10 1400 285 1175 185 995 130 885 100 850 90
0.20 1375 300 1145 200 950 140 840 110 725 85
0.30 1335 315 1120 210 915 145 790 115 665 95
0.40 1320 325 1075 220 870 155 745 125 625 100
0.50 1275 335 1045 230 835 165 715 135 565 105
0.60 1245 345 1000 235 785 170 655 140 520 115
0.70 1215 355 970 245 745 180 605 150 355 130
0.80 1175 365 925 255 695 185 555 155 400 130
EL180DF070E36B PERFORMANCE (Less Filter)
External
Static
Pressure
in. w.g.
Air Volume / Watts at Various Blower Speeds
High Medium-High Medium Medium-Low Low
cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts
0.00 1475 275 1345 170 1225 135 1185 125 1110 105
0.10 1430 290 1275 175 1190 145 1155 135 1005 95
0.20 1400 295 1230 190 1125 160 1110 150 900 100
0.30 1360 310 1205 205 1085 160 1055 155 845 115
0.40 1310 325 1155 210 1050 175 1000 165 790 115
0.50 1280 335 1110 220 985 185 950 180 705 130
0.60 1250 350 1060 235 935 195 865 185 645 135
0.70 1220 355 1000 245 865 205 815 195 590 140
0.80 1165 365 935 250 795 210 750 200 480 145
EL180DF090E48B PERFORMANCE (Less Filter)
External
Static
Pressure
in. w.g.
Air Volume / Watts at Various Blower Speeds
High Medium-High Medium Medium-Low Low
cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts
0.00 1750 385 1550 265 1430 205 1355 185 1195 130
0.10 1725 390 1495 270 1390 220 1320 195 1145 140
0.20 1695 405 1470 285 1340 235 1280 210 1105 145
0.30 1660 415 1425 300 1290 240 1225 215 1040 160
0.40 1615 430 1395 310 1250 255 1185 230 1005 170
0.50 1570 450 1360 325 1210 265 1145 240 945 180
0.60 1545 465 1295 340 1165 280 1085 255 865 185
0.70 N/A N/A 1265 350 1120 295 1040 265 810 200
0.80 N/A N/A 1215 365 1080 305 1000 275 755 210

Page 4
BLOWER DATA
EL180DF110E60C PERFORMANCE (Less Filter)
External
Static
Pressure
in. w.g.
Air Volume / Watts at Various Blower Speeds
High Medium-High Medium Medium-Low Low
cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts
0.00 2410 625 2095 405 1875 295 1700 225 1635 180
0.10 2385 630 2100 415 1830 310 1610 240 1505 190
0.20 2325 650 2010 440 1760 330 1570 255 1375 195
0.30 2280 675 1940 460 1705 340 1500 260 1320 210
0.40 2235 690 1895 475 1635 365 1440 285 1265 225
0.50 2165 710 1845 490 1595 380 1380 300 1200 235
0.60 2125 735 1800 510 1545 390 1320 310 1170 250
0.70 2090 740 1755 530 1510 405 1285 325 1100 260
0.80 2035 760 1700 540 1460 425 1255 345 1030 275

Page 5
EL180DFE PARTS ARRANGEMENT
FIGURE 1
Primary Limit
(under combustion
air inducer)
Gas Valve
Burner Box
(includes sensor, ignitor
and rollout switches)
Combustion
Air Inducer
Heat Exchanger
Flue Chase
Blower Assembly
Secondary Limit
Access Panel
Control Box
(includes integrated control, transformer,
inter lock switch and circuit breaker)

Page 6
I-UNIT COMPONENTS
EL180DFE unit components are shown in figure 1.The gas
valve, combustion air inducer and burners can be ac
cessed by removing the heating compartment access pan
el. Electrical components are in the control box (figure 2)
found in the blower section.
WARNING
Electric Shock Hazard. Can cause
injury or death. Unit must be properly
grounded in accordance with national
and local codes.
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.
1. Control Transformer (T1)
A transformer located in the control box provides power to
the low voltage section of the unit. Transformers on all
models are rated 40VA with a 120V primary and a 24V sec
ondary.
2. Door Interlock Switch (S51)
A door interlock switch is wired in series with line voltage.
When the blower door is removed the unit will shut down.
FIGURE 2
CONTROL BOX EL180DFE
DOOR INTERLOCK
SWITCH (S51)
INTEGRATED CONTROL
(A92)
TRANSFORMER
(T1)
CIRCUIT
BREAKER
(CB8)
3. Circuit Breaker (CB8)
A 24V circuit breaker is also located in the control box. The
switch provides overcurrent protection to the transformer
(T1). The breaker is rated at 3A at 32V. If the current ex
ceeds this limit the breaker will trip and all unit operation will
shutdown. The breaker can be manually reset by pressing
the button on the face.
4. Integrated Control (A92)
WARNING
Shock hazard.
Disconnect power before servicing. Control is not
field repairable. If control is inoperable, simply re
place entire control.
Can cause injury or death. Unsafe operation will re
sult if repair is attempted.
The hot surface ignition control system consisting of an in
tegrated control (figure 3 with control terminal designa
tions in tables 1, 2 and 3), flame sensor and ignitor (figure
6). The integrated control and ignitor work in combination
to ensure furnace ignition and ignitor durability. The inte
grated control, controls all major furnace operations. The
integrated control also features a RED LED for trouble
shooting and two accessory terminals rated at (1) one
amp. See table 4 or 5 for troubleshooting diagnostic
codes. The nitride ignitor is made from a non-porous, high
strength proprietary ceramic material that provides long
life and trouble free maintenance.
Electronic Ignition (Figure 4)
On a call for heat the integrated control monitors the com
bustion air inducer pressure switch. The control will not be
gin the heating cycle if the pressure switch is closed (by-
passed). Once the pressure switch is determined to be
open, the combustion air inducer is energized. When the
differential in the pressure switch is great enough, the pres
sure switch closes and a 15-second pre-purge begins. If
the pressure switch is not proven within 2-1/2 minutes, the
integrated control goes into Watchguard-Pressure Switch
mode for a 5-minute re-set period.
After the 15-second pre-purge period, the ignitor warms up
for 20 seconds during which the gas valve opens at 19 sec
onds for a 4-second trial for ignition. The ignitor remains
energized for the first 3 seconds during the 4 second trial. If
ignition is not proved during the 4-second period, the inte
grated control will try four more times with an inter purge
and warm-up time between trials of 35 seconds. After a to
tal of five trials for ignition (including the initial trial), the inte
grated control goes into Watchguard-Flame Failure mode.
After a 60-minute reset period, the integrated control will
begin the ignition sequence again.

Page 7
TABLE 1
4-Pin Terminal Designation
PIN # FUNCTION
1Combustion Air Inducer Line
2Ignitor Line
3Combustion Air Inducer Neutral
4Ignitor Neutral
TABLE 2
12-Pin Terminal Designations
PIN # FUNCTION
1High Limit Output
2Not Used
324V Line
4Not Used
5Rollout Switch Out
624V Neutral
7High Limit Input
8 Ground
9Gas Valve Common
10 Pressure Switch In
11 Rollout Switch In
12 Gas Valve Out
TABLE 3
1/4” QUICK CONNECT TERMINALS
120HUM Humidifier 120VAC
LINE 120VAC
XFMR Transformer 120VAC
CIRC Indoor blower 120VAC
EAC Indoor air quality accessory 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
FS Flame sense
24 COM Common 24VAC
FIGURE 3
INTEGRATED CONTROL
(Automatic Hot Surface Ignition System)
BLOWER OFF DELAY
RED LED RECALL BUTTON

Page 8
TABLE 4 (-02 Integrated Control)
RED LED
Flash Code Diagnostic Codes / Status of Furnace
Off No power to control or board fault detected
Heartbeat1Control powered - displayed during all modes of operation if no errors are detected
1Reverse Line Voltage Polarity
2Improper Earth Ground
3Burner failed to light, or lost flame during heat demand
4Low Flame Signal - check flame sensor
5Watchguard - burner failed to light, exceeded maximum number of retries or recycles.
6Not Used
7Primary or Secondary Limit Open or Watchguard Mode - Limit Switch Open longer than 3 minutes
8Rollout Switch Open
9Pressure 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
Note
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 5 (-03 Integrated Control)
RED LED
Flash Code2Diagnostic Codes / Status of Furnace
Off No power to control or board fault detected
Heartbeat1Normal Operation - Idle, Continuous Fan, Cool
Continuous Rapid Flash Call For Heat / Burner Operation
1Reverse Line Voltage Polarity
2Improper Earth Ground
3Burner failed to light, or lost flame during heat demand
4Low Flame Signal - check flame sensor
5Watchguard - burner failed to light, exceeded maximum number of retries or recycles.
6Ignitor Circuit Failure - not available on this control
7Primary or Secondary Limit Open or Watchguard Mode - Limit Switch Open longer than 3 minutes
8Rollout Switch Open
9Pressure 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 2 Error codes are indicated by a “rapid flash” - the LED flashes X times at ½ second on ½ second off, remains off for 3
seconds then repeats.
Note3
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.

Page 9
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉÉÉÉ
ÉÉ
DEMAND
CAI
GAS VALVE
15
ON
OFF
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
ÉÉ
38
ÉÉÉÉÉÉÉÉÉÉ
IGNITOR
341
Pre -Purge Ignitor Warm-up Trial for
Ignition Post
Purge
5 SEC80
*Blower on time will be 30 seconds after flame is sensed. Blower off time will depend on “OFF TIME” Setting.
INDOOR BLOWER
ÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉ
Blower “On”*
Delay
ELECTRONIC IGNITION
FIGURE 4
Fan Time Control
Heating Fan On Time
The fan on time of 30 seconds is not adjustable.
Heating Fan Off Time
Fan off time (time that the blower operates after the heat
demand has been satisfied) can be adjusted by moving the
jumper to a different setting. The unit is shipped with a fac
tory fan off setting of 90 seconds. For customized comfort,
monitor the supply air temperature once the heat demand
is satisfied. Note the supply air temperature at the instant
the blower is de-energized.
Adjust the fan-off delay to achieve a supply air temperature
between 90° - 110° at the instant the blower is de-ener
gized. (Longer delay times allow for lower air temperature,
shorter delay times allow for higher air temperature). See
figure 5.
Cooling Fan On Time
The fan on time is 2 seconds and is not adjustable.
Cooling Fan Off Time
The control has a 45 second fan off delay after cooling de
mand has been met. This delay is factory set and not ad
justable.
HEAT FAN‐OFF TIME IN SECONDS
To adjust fan-off timing, reposition jumper across pins to
achieve desired setting.
NO JUMPER
FIGURE 5
60 90
120
180
60 90
120
180
60 90
120
180
60 90
120
180
60 Second
off Time
90 Second
off Time
120 Second
off Time
180 Second
off Time

Page 10
EL180DFE HEATING COMPONENTS
FIGURE 6
Gaskets
Collector Box
Orifice Plate
Pressure Switch
Combustion Air Inducer
Internal Flue Pipe
Sensor
Rollout Switch
Rollout Switch
(Alternate Location)
Gas Valve / Manifold Assembly
Ignitor
5. Flame Rollout Switches (Figure 6)
Flame rollout switch (S47) is a high temperature limit. Each
furnace is equipped with two identical switches. The limit is
a N.C. SPST manual‐reset limit connected in series with
the integrated control A92. When S47 senses rollout, the
integrated control immediately stops ignition and closes
the gas valve. If unit is running and flame rollout is detected,
the gas valve will close and integrated control will be dis
abled. Rollout can be caused by a blocked heat exchanger,
blocked flue or lack of combustion air. The switch has a fac
tory setpoint of 210°F and cannot be adjusted. To manually
reset a tripped switch, push the reset button located on the
control.
6. Primary Limit Control
The primary limit on EL180DFE units is located in the heating
vestibule panel under the combustion air inducer. See figure 1.
When excess heat is sensed in the heat exchanger, the limit
will open. If the limit is open, the integrated control energizes
the supply air blower and closes the gas valve. The limit auto
matically resets when unit temperature returns to normal. The
switch must reset within three minutes or SureLight®control
will go into Watchguard for one hour. The switch is factory
set and cannot be adjusted. The switch may have a different
setpoint for each unit model number. If limit switch must be
replaced, refer to Lennox ProductZone repair parts list on
Lennox DaveNet®.
7. Flame Sensor (Figure 6)
A flame sensor is located on the left side of the burner sup
port. The sensor is mounted on the flame rollout plate and
the tip protrudes into the flame envelope of the left-most
burner. The sensor can be removed for service (clean us
ing steel wool) without removing any part of the burners.
During operation, flame is sensed by current passed
through the flame and sensing electrode. The integrated
control allows the gas valve to remain open as long as
flame signal is sensed.
A microamp DC meter is needed to check the flame signal
on the integrated control.
Flame (microamp) signal is an electrical current which passes
from the integrated control to the sensor during unit operation.
Current passes from the sensor through the flame to ground to
complete a safety circuit.