Lennox EL180DFE Series Unit Information
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- User manual (7 pages) ,
- Installation instructions manual (30 pages)
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Service Literature
EL180DFE series units are mid-efficiency gas furnaces
used for downflow applications only, manufactured with
Lennox Duralokt heat 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
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Parts Identification
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II Installation
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IV Heating System Service Checks
V Typical Operating Characteristics
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Corp. 1301-L1
Revised 09/2017
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Page 5
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Page 17
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Page 24
Page 1
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.
EL180DFE
© 2017 Lennox Industries Inc.
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Summary of Contents for Lennox EL180DFE Series
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Page 1: Table Of Contents
EL180DFE Corp. 1301-L1 Service Literature Revised 09/2017 EL180DFE series units are mid-efficiency gas furnaces used for downflow applications only, manufactured with Lennox Duralokt heat 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. - Page 2 SPECIFICATIONS Model No. EL180DF045E36A EL180DF070E36B EL180DF090E48B EL180DF110E60C Heating AFUE Performance 44,000 66,000 88,000 110,000 Input - Btuh 35,200 52,800 70,400 88,000 Output - Btuh 15 - 45 30 - 60 30 - 60 30 - 60 Temperature rise range - °F 3.5 / 10.0 3.5 / 10.0 3.5 / 10.0...
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Page 3: Blower Data
BLOWER DATA EL180DF045E36A PERFORMANCE (Less Filter) External Air Volume / Watts at Various Blower Speeds Static High Medium-High Medium Medium-Low Pressure Watts Watts Watts Watts Watts in. w.g. 0.00 1430 1215 1035 0.10 1400 1175 0.20 1375 1145 0.30 1335 1120 0.40 1320... - Page 4 BLOWER DATA EL180DF110E60C PERFORMANCE (Less Filter) External Air Volume / Watts at Various Blower Speeds Static High Medium-High Medium Medium-Low Pressure Watts Watts Watts Watts Watts in. w.g. 0.00 2410 2095 1875 1700 1635 0.10 2385 2100 1830 1610 1505 0.20 2325 2010...
- Page 5 EL180DFE PARTS ARRANGEMENT Secondary Limit Blower Assembly Flue Chase Control Box (includes integrated control, transformer, inter lock switch and circuit breaker) Heat Exchanger Combustion Air Inducer Primary Limit (under combustion air inducer) Gas Valve Burner Box (includes sensor, ignitor and rollout switches) Access Panel FIGURE 1 Page 5...
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Page 6: Unit Components
I-UNIT COMPONENTS 4. Integrated Control (A92) 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 WARNING el. Electrical components are in the control box (figure 2) found in the blower section. - Page 7 TABLE 1 TABLE 3 4-Pin Terminal Designation 1/4” QUICK CONNECT TERMINALS PIN # FUNCTION 120HUM Humidifier 120VAC Combustion Air Inducer Line LINE 120VAC Ignitor Line XFMR Transformer 120VAC Combustion Air Inducer Neutral CIRC Indoor blower 120VAC Ignitor Neutral Indoor air quality accessory 120VAC TABLE 2 NEUTRALS Common 120VAC...
- Page 8 TABLE 4 (-02 Integrated Control) RED LED Diagnostic Codes / Status of Furnace Flash Code No power to control or board fault detected Heartbeat 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...
- Page 9 ELECTRONIC IGNITION 5 SEC É É Trial for Pre -Purge Ignitor Warm-up Blower “On”* Post Ignition Delay Purge É É É É É É É É É É É É É É É É É É É É É É É É É É DEMAND É...
- Page 10 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®. Page 10...
- Page 11 To Measure Flame Signal - Integrated Control: 6 - Turn supply voltage on and close thermostat contacts to cycle system. Use a digital readout meter capable of reading DC micro 7 - When main burners are in operation for two minutes, take amps.
- Page 12 8. Ignitor (Figure 6) NOTE - The EL180DFE furnace contains electronic The nitride ignitor used on EL180DFE units is made from a components that are polarity sensitive. Make sure that proprietary ceramic material. To check ignitor, measure its the furnace is wired correctly and is properly grounded. resistance and voltage.
- Page 13 The EL180DFE uses internally redundant gas valve to as sure safety shut-off. If the gas valve must be replaced, the EL180DFE series units are equipped with a combustion air same type valve must be used. pressure switch located on the combustion air inducer ori...
- Page 14 12. Blower Motor BLOWER WHEEL REPLACEMENT IMPORTANT Center Blower Wheel in Blower Housing Each blower is statically and dynamically bal anced as an assembly before installation in the unit. EL180DFE units are equipped with a constant torque ECM motor. It has a DC motor coupled to an electronic control module both contained in the same motor housing.
- Page 15 Multi−Meter (set to VAC) Multi−Meter (set to VAC) Test 1 Test 3 (if necesssary) Turn on power to unit. Check for 120 volts across terminals Check for 120 volts across terminals “CIRC” and “Neutrals” “L” and “N” on input plug P48. If voltage is present continue on the integrated control.
- Page 16 Replacing the Motor Module Motor Test 1. Disconnect electrical power to unit. 2. Remove unit access panel. 3. Unplug the two harnesses from the motor control mod ule. See figure 14. Unplug the Two Harness Connection TWO HARNESS FIGURE 16 CONNECTIONS TABLE 9 MOTOR...
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Page 17: Start Up
II- PLACEMENT AND INSTALLATION 2 - Turn off all electrical power to the unit if service is to be performed. Make sure unit is installed in accordance with installation 3 - Remove the heating compartment access panel. instructions and applicable codes. 4 - Move gas valve switch to OFF position. - Page 18 Gas Leak Detector is strongly recommended. It is available 4 - After allowing unit to stabilize for 5 minutes, record through Lennox under part number 31B2001. See Corp. manifold pressure and compare to value given in table 8411-L10, for further details.
- Page 19 TABLE 12 Supply and Manifold Pressure Settings at all Altitudes Supply Pressure Model in.wg. 0-4500 ft 4501-7500 ft 7501 - 10,000 ft Input Size 13.0 LP/propane 10.0 10.0 10.0 11.0 13.0 13.0 LP/propane 10.0 10.0 10.0 11.0 13.0 13.0 LP/propane 10.0 10.0 10.0...
- Page 20 H- Proper Ground and Voltage CHECK VOLTAGE BETWEEN LINE HOT AND LINE NEUTRAL A poorly grounded furnace can contribute to premature ig nitor failure. Use the following procedure to check for ground and voltage to the integrated control. 1 - Measure the AC voltage between Line Neutral (spade terminals) and “C”...
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Page 21: Maintenance
At the beginning of each heating season, and to comply hole or insulation. Seal around the hose with perma with the Lennox Limited Warranty, your system should be gum. Connect the zero end of the manometer to the checked by a licensed professional technician (or equiva... - Page 22 Service and Application Note H049. specifications provided by the filter manufacturer 2 - Verify that system total static pressure and airflow set against the data given in the appropriate Lennox tings are within specific operating parameters. Product Specifications bulletin. Additional informa...
- Page 23 EL180DFE BURNER, COMBUSTION AIR INDUCER ASSEMBLY & HEAT EXCHANGER REMOVAL gasket gasket orifice plate flue chase internal flue pipe combustion air inducer Rollout Switch (Alternate Location) collector box Rollout Switch heat exchanger pressure switch Sensor retention rings cross over FIGURE 24 11- To clean the combustion air inducer visually inspect and 21- If a leak is detected, shut gas and electricity off and repair leak.
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Page 24: Wiring And Sequence Of Operation
VII- Wiring and Sequence of Operation EL180DFE Schematic Wiring Diagram and Sequence of Operation Line voltage is applied to L1 and N. The T1 low voltage transformer is energized, and line voltage is applied to B3 indoor blower. S47 rollout switch(es) must be closed in order for 24V from transformer to be output on integrated control ”R” to power thermostat. When there is a call for heat, W1 of the thermostat energizes W of the furnace control with 24VAC. - Page 25 Troubleshooting: Heating Sequence of Operation HEATING SEQUENCE OF OPERATION ABNORMAL HEATING MODE NORMAL HEATING MODE POWER ON GAS VALVE OFF. COMBUSTION AIR INDUCER OFF. INDOOR BLOWER DELAY OFF. CONTROL SELF-CHECK OKAY? LED SLOW FLASH (RESET CONTROL BY TURNING MAIN POWER OFF.) LED FLASHES CODE 1 - POLARITY REVERSED.
- Page 26 Troubleshooting: Heating Sequence of Operation (Continued) HEATING SEQUENCE CONTINUED NORMAL HEATING MODE ABNORMAL HEATING MODE 15‐SECOND COMBUSTION AIR INDUCER PREPURGE INITIATED BY CLOSED PRESSURE SWITCH. LED FLASHES CODE 13 - LOW LINE VOLTAGE. ONCE VOLTAGE IS ABOVE IGNITOR WARM‐UP -- 20 SECONDS. IS VOLTAGE ABOVE 70 VOLTS? 75 VOLTS, HEATING SEQUENCE RESTARTS.
- Page 27 Troubleshooting: Cooling Sequence of Operation COOLING SEQUENCE OF OPERATION NORMAL COOLING MODE ABNORMAL COOLING MODE POWER ON IGNITION CONTROL MAIN POWER ON. GAS VALVE OFF. COMBUSTION AIR INDUCER OFF. INDOOR BLOWER OFF WITH NORMAL DELAY. CONTROL SELF DIAGNOSTIC CHECK. SIGNAL CIRCUIT BOARD FAILURE AT LED. IS CONTROL OPERATING NORMALLY? INTERRUPT MAIN POWER TO RESET CONTROL.
- Page 28 Troubleshooting: Continuous Fan Sequence of Operation CONTINUOUS FAN SEQUENCE OF OPERATION LED: SLOW FLASH RATE REMAINS UNCHANGED THROUGHOUT SEQUENCE. MANUAL FAN SELECTION MADE AT THERMOSTAT. CONTROL (G) ENERGIZES SYSTEM FAN AT FAN SPEED. EAC TERMINAL IS ENERGIZED. THERMOSTAT CALLS FOR HEAT (W). SYSTEM FAN CONTINUES FAN SPEED WITHOUT THERMOSTAT CALLS FOR COOLING.