Lennox International Inc Furnace ML180DFE SERIES User Manual

E 2011 Lennox Industries Inc.  
Dallas, Texas, USA  
506735−01  
05/2011  
ML180DFE  
SERIES  
GAS FURNACE  
Litho U.S.A.  
WARNING  
FIRE OR EXPLOSION HAZARD.  
Failure to follow safety warnings exact-  
ly could result in serious injury, death,  
or property damage.  
WHAT TO DO IF YOU SMELL GAS:  
Do not store or use gasoline or other  
flammable vapors and liquids in the  
vicinity of this or any other ap-  
pliance.  
D Do not try to light any appliance.  
D Do not touch any electrical switch; do not  
use any phone in your building.  
D Leave the building immediately.  
D Immediately call your gas supplier from a  
neighbor’s phone. Follow the gas supplier’s  
instructions.  
Installation and service must be  
performed by a qualified installer,  
service agency or the gas supplier.  
D If you cannot reach your gas supplier, call  
the fire department.  
05/11  
506735−01  
*P506735-01*  
*2P0511*  
 
3 − DO NOT store chlorine or fluorine products near unit  
or introduce these products into the combustion air.  
These products can cause furnace corrosion.  
WARNING  
Do not set thermostat below 60°F (16°C) in heating  
mode. Setting thermostat below 60°F (16°C) reduces  
the number of heating cycles. Damage to the unit  
may occur that is not covered by the warranty.  
4 − DO NOT draw return air from a room where this fur-  
nace, or any other gas appliance (ie., a water heat-  
er), is installed. When return air is drawn from a room,  
a negative pressure is created in the room. If a gas ap-  
pliance is operating in a room with negative pressure,  
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 distributed throughout the house by the  
furnace duct system.  
WARNING  
If overheating occurs or if gas supply fails to shut off,  
shut off the manual gas valve to the furnace before  
shutting off electrical supply.  
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 licensed pro-  
fessional service technician (or equivalent) to in-  
spect 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 neces-  
sary.  
WARNING  
The blower door must be securely in place when the  
blower and burners are operating. Gas fumes, which  
could contain carbon monoxide, can be drawn into  
the living space resulting in personal injury or death.  
Your furnace is a gas appliance. It is critical that the gas  
supplied to the unit be completely burned to avoid the pro-  
duction of carbon monoxide gas. Complete combustion of  
the gas requires, but is not limited to, correct gas pressure  
and gas flow rate, adequate combustion, air, and proper  
venting.  
NOTICE  
Any additions, changes, or conversions required in  
order for the appliance to satisfactorily meet the ap-  
plication needs must be made by a licensed profes-  
sional installer (or equivalent) using factory−speci-  
fied and approved parts.  
WARNING  
Carbon monoxide gas is invisible, odorless and  
toxic.  
Exposure to carbon monoxide gas can cause personal inju-  
ry and even death to all occupants, including pets. Any item  
that is powered by or gives off heat from a combustion pro-  
cess (including lawn mowers, automobiles, and fireplaces)  
has the potential to produce carbon monoxide gas. Because  
of this, Lennox recommends the use of a carbon monox-  
ide detector in your home, even if you do not own gas  
appliances. Reliable detectors are available at reasonable  
retail prices. Contact your Lennox dealer for more details  
about this investment in your safety.  
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), a service agency, or the gas supplier.  
Safety Instructions  
1 − Keep the furnace area clear and free of combustible  
material, gasoline, and other flammable vapors and  
liquids. If it is installed in an insulated area, the furnace  
must be kept free of insulating material. Insulating ma-  
terial may be combustible.  
Your furnace is designed to meet standards set by nation-  
al agencies, and to operate safely when properly installed  
and maintained. However, the unit’s performance can be  
greatly impacted by the individual installation and the op-  
erating environment. It is your responsibility to ensure that  
this appliance is maintained. Proper maintenance is criti-  
cal for your safety and the satisfactory operation of the  
product. Lennox strongly recommends annual in-  
spection and maintenance of this appliance. Contact  
2 − DO NOT obstruct air flow to unit. Unit must receive an  
unobstructed flow of combustion and ventilating air.  
DO NOT block or obstruct air openings on the furnace  
or air openings to the area in which the furnace is  
installed. Take care to maintain established clear-  
ances surrounding the furnace.  
Page 3  
 
2 − Set the thermostat to the lowest setting.  
3 − Turn off all electrical power to the unit.  
your Lennox dealer for an inspection by a licensed profes-  
sional service technician (or equivalent).  
4 − This furnace is equipped with an ignition device which  
automatically lights the burners. Do not try to light the  
burners by hand.  
DANGER  
Danger of explosion.  
5 − Remove the heating access panel.  
6 − Move switch on gas valve to OFF. See figure 2.  
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.  
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.  
Do not attempt to bleed the gas lines of air. Call your  
local gas provider.  
8 − Move switch on gas valve to ON. See figure 2.  
MANIFOLD  
MANIFOLD  
PRESSURE  
PRESSURE  
ADJUSTMENT  
OUTLET  
Start−Up & Operation Information  
SCREW  
WARNING  
If you do not follow these instructions exactly, a fire  
or explosion may result causing property damage,  
personal injury or death.  
INLET  
PRESSURE PORT  
BEFORE PLACING THE UNIT INTO OPERATION, 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.  
GAS VALVE SHOWN IN ON POSITION  
FIGURE 2  
9 − Replace the heating access panel.  
10 − Turn on all electrical power to to the unit.  
11 − Set the thermostat to desired setting.  
The gas valve on the 180DFE will be equipped with a gas  
control switch. Use only your hand to move the switch.  
Never use tools. If the switch will not move by hand, do  
not try to repair it. Call a licensed professional service  
technician (or equivalent). Force or attempted repair  
may result in a fire or explosion.  
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 section  
ꢀTurning Off Gas to the Unit" and call your licensed  
professional service technician (or equivalent).  
Placing the ML180DFE furnace into operation:  
ML180DFE units are equipped with an ignition system.  
Do not attempt to manually light burners on this furnace.  
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 this ignition system.  
Turning Off Gas to the 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 heating access panel.  
4 − Move switch on gas valve OFF.  
5 − Replace the upper access panel.  
Operating the Gas Valve (Figure 2)  
1 − STOP! Read the safety information at the beginning of  
this section.  
Page 4  
 
 
Annually (before heating season) inspect furnace venting  
system, vent cap, heat exchanger, and burners for corro-  
sion, deterioration, or deposits of debris. Remove any ob-  
structions.  
Filters  
All 180DFE filters are installed external to the unit. Filters  
should be inspected monthly. Clean or replace the filters  
when necessary to ensure proper furnace operation. Re-  
placement filters must be rated for high velocity airflow.  
Table 1 lists recommended filter size.  
Inspect the furnace for obvious signs of deterioration.  
Inspect the furnace venting system to make sure it is in  
place, physically sound, and without holes, corrosion, or  
blockage.  
A filter must be in place when the unit is operating.  
TABLE 1  
Vent pipe must be clear and free of obstructions and must  
slope upward away from the furnace.  
Cabinet Width  
Return Air Filter Size (inches)  
A (14−1/2")  
B (17−1/2")  
C (21")  
14 x 25 x 1 (1)  
16 x 25 x 1 (1)  
20 x 25 x 1 (1)  
Inspect the furnace return air duct connection to ensure  
duct is sealed to the furnace and terminates outside the  
space containing the furnace.  
Inspect the physical support of the furnace to guarantee  
that it is sound without sagging, cracks or gaps around  
base and it maintains seal between base and support.  
Maintenance  
A licensed professional service technician (or equivalent)  
should inspect the complete system each season (heating  
and cooling). The following maintenance procedures  
should only be conducted by a licensed professional ser-  
vice technician (or equivalent). Do not attempt to service  
the unit in any way.  
During a seasonal check the service technician will con-  
duct a combustion analysis. The technician will also in-  
spect the indoor blower, burner flames, electrical connec-  
tions and the venting system.  
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  
ELECTRICAL SHOCK, FIRE,  
OR EXPLOSION HAZARD.  
WARNING  
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.  
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.  
When servicing controls, label all wires prior to dis-  
connecting. Take care to reconnect wires correctly.  
Verify proper operation after servicing.  
Burner Flame  
CAUTION  
Venting System  
To ensure proper operation, a licensed professional  
service technician (or equivalent) should check the  
burner flame and conduct a combustion analysis  
annually.  
WARNING  
Asphyxiation Hazard  
Electrical  
The exhaust vent for this furnace must be leak−free  
and must be securely connected to the furnace flue  
collar at all times.  
1 − Check all wiring for loose connections.  
2 − Check for the correct voltage at the furnace (furnace  
operating).  
For your safety and to fulfill the terms of the limited  
warranty, a licensed professional service technician  
(or equivalent) must annually inspect this furnace  
and its vent system.  
3 − Check amp−draw on the blower motor with blower ac-  
cess panel in place.  
Motor Nameplate__________Actual__________  
Page 5  
 
 
Your vigilance may pay off in early detection of a problem  
before either personal injury or property damage occurs.  
Do not hesitate to contact a qualified service technician as  
an investment in your well being.  
Service Reminder  
Call your Lennox service technician if the unit will not oper-  
ate. Before calling, always check the following to be sure  
service is required:  
Planned Service  
1 − Check that electrical disconnect switches are ON.  
2 − Check room thermostat for proper setting.  
3 − Replace any blown fuses or reset circuit breakers.  
4 − Gas valve should be ON.  
You should expect a service technician to check the follow-  
ing items during an annual inspection. Power to the unit  
must be shut off for the service technician’s safety.  
5 − Air filter should not be plugged, which will limit air flow.  
6 − Is gas turned on at meter?  
Fresh air grilles and louvers (on the unit and in the room  
where the furnace is installed) − Must be open and unob-  
structed to provide combustion air.  
7 − Is manual main shut−off valve open?  
Record the model and serial number of the furnace. These  
numbers are on the unit nameplate, which is located on the  
blower deck below the combustion air inducer.  
Burners − Must be inspected for rust, dirt, or signs of water.  
Vent pipe − Must be inspected for signs of water, damaged  
Serial Number __________________  
Model Number __________________  
or sagging pipe, or disconnected joints.  
Unit appearance − Must be inspected for rust, dirt, signs  
of water, burnt or damaged wires, or components.  
Safety Precautions  
If you discover any of the following, shut down your  
unit, and contact a Lennox dealer for an inspection by  
a licensed professional service technician (or equiva-  
lent).  
Blower access door − Must be properly in place and pro-  
vide a seal between the return air and the room where the  
furnace is installed.  
Return air duct − Must be properly attached and provide  
D If you repeatedly hear any new or unfamiliar sounds  
while your unit is operating, there may be a problem. For  
example, poorly performing burners can produce unfa-  
miliar noises.  
an air seal to the unit.  
Operating performance − Unit must be observed during  
operation to monitor proper performance of the unit and the  
vent system.  
D If you smell any unusual odors, your unit may be operat-  
ing improperly. For example, units can give off unfamil-  
iar odors if components are required to operate in ab-  
normal conditions.  
Combustion gases − Flue products must be analyzed and  
compared to the unit specifications.  
D Look for visible signs of a malfunctioning unit. Examples  
include unusual amounts of condensate on windows in-  
side your house, visibly burnt components or unusual  
dirt or rust accumulations on the vent pipe or in the unit.  
Problems detected during the inspection may make it nec-  
essary to temporarily shut down the furnace until the items  
can be repaired or replaced.  
D If you experience headache, nausea, fatigue, or dizzi-  
ness, the cause could be exposure to carbon monoxide  
gas. This is often misdiagnosed as the flu because  
symptoms are similar. If you suffer from flu−like symp-  
toms that are exaggerated at home, but seem to sub-  
side while you are away from the house, exposure to  
carbon monoxide could be the cause.  
Pay attention to your furnace. Situations can arise be-  
tween annual furnace inspections that may result in unsafe  
operation. For instance, items innocently stored next to the  
furnace may obstruct the combustion air supply. This could  
cause incomplete combustion and the production of car-  
bon monoxide gas.  
Page 6  
 
Repair Parts List  
The following repair parts are available through Lennox dealers. When ordering parts, include the complete furnace model  
number listed on the CSA International nameplate −− Example: 180DFE045P36B. All service must be done by a licensed  
professional installer (or equivalent), a service agency, or the gas supplier.  
Cabinet Parts  
Heating access panel  
Heating Parts  
Flame Sensor  
Blower access panel  
Top Cap  
Heat exchanger assembly  
Gas manifold  
Control Panel Parts  
Transformer  
Combustion air inducer  
Gas valve  
Integrated control  
Door interlock switch  
Main burner cluster  
Main burner orifices  
Pressure switch  
Ignitor  
Blower Parts  
Primary limit control  
Flame rollout switches  
Blower wheel  
Motor  
Motor mounting frame  
Motor power choke (3/4 and 1 hp)  
Blower housing cutoff plate  
WARNING  
Product contains fiberglass wool.  
Disturbing the insulation in this product during  
installation, maintenance, or repair will expose you  
to fiberglass wool. Breathing this may cause lung  
cancer. (Fiberglass wool is known to the State of Cal-  
ifornia to cause cancer.)  
Fiberglass wool may also cause respiratory, skin,  
and eye irritation.  
To reduce exposure to this substance or for further  
information, consult material safety data sheets  
available from address shown below, or contact your  
supervisor.  
Lennox Industries Inc.  
P.O. Box 799900  
Dallas, TX 75379−9900  
Page 7  
 

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