Lennox International Inc. EL280DF User's Manual
Contents
1. erly Replacement filters must be rated for high velocity air flow 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 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 3 Label the wires from gas valve rollout switches prima ry limit switch and make up box then disconnect them 4 Disconnect gas supply piping Remove the four screws securing the burner manifold assembly to the vestibule panel and remove the assembly from the unit 5 Remove 4 screws securing burner box and remove burner box 6 To dean 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 Actual 7 Reinstall burner box manifold assembly and burner box cover 8 Reconnect all wires 9 Reconnect gas supply piping 10 Turn on power and gas supply to un2. 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 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 m3 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 Page 5 Confined Space A confined space is an area with a volume less than 50 cu bic feet 1 42 m3 per 1 000 Btu 29 kW per hour of the combined input rating of all appliances installed in that space This definition inc
3. which provides a cooling blow er off delay of 45 seconds If the switch is toggled to the ON position it will provide a 2 second cooling blower off delay On Board Link W951 On board link W951 is a clippable connection between ter minals R and O on the integrated control W951 must be cut when the furnace is installed in applications which include a heat pump unit and a thermostat which features dual fuel use If the link is left intact terminal O will remain ener gized eliminating the HEAT MODE in the heat pump On Board Link W915 On board link W915 is a clippable connection between ter minals Y1 and Y2 on the integrated control W915 must be cut if two stage cooling will be used If the link is not cut the outdoor unit will operate in second stage cooling only Unit Start Up FOR YOUR SAFETY READ BEFORE LIGHTING AWARNING 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 AWARNING 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 ACAUTION Before attempting to perform any service or m
4. accessory rated up to one amp can be connected to this terminal with the neutral leg Page 18 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 integrated control configuration This terminal is energized in the heating mode when the combustion air inducer is operat ing Any humidifier rated up to one amp can be connected to this terminal with the neutral leg of the circuit being con nected to one of the provided neutral terminals If a humidi fier rated at greater than one amp is connected to this termi nal 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 e The furnace requires 120 volts 10 Range 108 volts to 132 volts
5. cleaned following final construction clean up e All furnace operating conditions including ignition in put rate temperature rise and venting must be verified according to these installation instructions 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 EL280DF furnace e 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 e Do not install the furnace where drafts might blow direct ly into it This could cause improper combustion and un safe operation e Do not block the furnace combustion air openings with clothing boxes doors etc Air is needed for proper combustion and safe unit operation e 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 e Gas furnaces shall be installed by a licensed plumb er or fitter only e The gas cock must be T handle type e When a furnace is installed in an attic the passage way to and service area surrounding the equipment shall be floored Page 4 AWARNING The State of California has d
6. e The furnace operates at 60 Hz 5 Range 57 Hz to 63 Hz e 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 e Generator should have a wave form distortion of less than 5 total harmonic distortion THC Thermostat Install the room thermostat according to the instructions provided with the thermostat See table 9 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 low heat speed when there is no cooling or heating demand 2 When the EL280DF is operating in the high fire or low fire heating mode the indoor blower will run on the cor responding heating speed 3 When the EL280DF is operating in the low cool or the high cool cooling mode the indoor blower will run on the corresponding cooling speed Page 19 Thermostat 1 Heat 1 Cool NOTE Use DIP switch 2 to set sec ond stage heat ON delay OFF10 minutes ON 15 minutes 1 Heat 2 Cool NOTE Use DIP switch 2 to set sec ond stage heat ON delay OFF 10 minutes ON 15 minutes TABLE 9 Field Wiring Applications DIP Switch Settings and On Board Links S
7. inches Lateral L feet 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 Page 14 TABLE 6 Vent Connector Capacity Type B Double Wall Vents with Type B Double Wall Connectors Serving Two or More Category I Appliances Vent and Connector Diameter D inches Connector Rise Oo e os I R Appliance Input Rating in Thousands of Btu Per Hour 38 wo ao S SC A A CW vj fj W w N OH N O CT Got Got Got Goal Cu ao oi opa 44 40 44 47 43 47 50 50 53 55 54 57 62 64 w w w w Wi TABLE 7 Common Vent Capacity Type B Double Wall Vents with Type B Double Wall Connectors Serving Two or More Category Appliances Common Vent Diameter D inches ene ne Se D E ed Appliance Input Rating in Thousands of Btu Per Hour FAN FAN FAN NAT FAN FAN FAN NAT FAN FAN FAN NAT FAN FAN FAN NAT E E WE ENT DE ec E n ee Oc a a a E C AL A AN K O n A pon A e n DAL ANAL on A n CR on oo on A n ko n Ca AE e A L AL A Leon n ANNE JAN A A AL A DAL JA A E A a MA Page 15 Removal of the Furnace f
8. opening shall have a free area of at least one square inch 645 mm per 2 000 Btu 59 kW per hour of the total input rating of all equipment in the enclosure If the equipment room is located against an outside wall and the air openings communicate directly with the outdoors each open ing shall have a free area of at least one square inch 645 mm per 4 000 Btu 1 17 kW per hour of the total input rating of all other equipment in the enclosure FIGURE 5 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 EL280DF UNIT SUPPLY AIR OPENING PLENUM TABLE 1 NON COMBUSTIBLE FLOOR OPENING SIZE Cabinet Width Front to Rear Side to Side abinet Wi Pin m m m NOTE Floor opening dimensions listed are 1 4 inch 6 mm larger than the unit op
9. shipped in the down flow position only Do not install the furnace hori zontally Select alocation 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 hp blower motors are equipped with three flexible legs and one rigid leg See figure 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 opera tion After the bolt and washer have been removed the rig id leg will not touch the blower housing UNITS WITH 1 2 HP BLOWER MOTOR RIGID LEG remove shipping bolt and washer FIGURE 11 AWARNING 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 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 Left Side Right Side Bottom MC e e rei poo EWO ee mo m sem f r o F
10. the chimney must be properly OTHER APPLIANCE FURNACE sized per provided venting tables or lined with listed metal lining system V NT H CONNECTOR PERMANENTLY SEALED FIREPLACE OPENING FIGURE 15 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 Metal Lined Masonry Chimney A SEALED MAX LENGTH SEE NOTE L e BELOW Sm MIN LENGTH AS imum SHORT AS PRACTICAL LE EXTERIOR CHIMNEY WITH METAL se LINER VENT CONNECTOR 4in 102 mm minimum l SU PERMANENTLY SEALED FIREPLACE OPENING NOTE 1 Re
11. 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 CHIMNEY OR GAS VENT EQUIPMENT IN CONFINED SPACE ALL AIR FROM OUTSIDE Inlet Air from Crawlspace and Outlet Air to Ventilated Attic ZASN VENTILATION LOUVERS Each end of attic FURNACE LOUVERS For unheated crawl space edi ss VENTILATION a OUTLET AIR WATER HEATER On NOTE The inlet and outlet air openings shall each have a free area of at least one square inch 645 mm2 per 4 000 Btu 1 17 kW per hour of the total input rating of all equipment in the enclosure EQUIPMENT IN CONFINED SPACE ALL AIR FROM OUTSIDE CHIMNEY All Air Through Ventilated Attic OR GAS VENT VENTILATION LOUVERS Each end of attic He INLET AIR Ends 12 in ai bottom ll WATER HEATER ICT ee in E Ee ES ES P E be Re DES Gr NOTE The inlet and outlet air openings shall each have a free area of at least one square inch 645 mm per 4 000 Btu 1 17 kW per hour of the total input rating of all equip ment in the enclosure FIGURE 4 FIGURE 3 EQUIPMENT IN CONFINED SPACE ALL AIR FROM OUTSIDE WATER HEATER ans OUTLETAIR INLETAIR _ AIR NOTE Each air duct
12. 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 Page 24 HIGH FIRE ADJUSTMENT MANIFOLD SCREW PRESSURE TAP under cap INLET PRESSURE POST 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 upper 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 upper 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 s
13. warning sticker to a visible area of the plenum near the vent pipe The warning sticker is provided in the bag assembly Order kit 66 W04 for additional stickers AWARNING Asphyxiation hazard The exhaust vent for this fur nace must be securely connected to the furnace flue transition at all times VENT CONNECTION DISCONNECTED VENT WARNING A STICKER ati FLUE TRANSITION COLLAR 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 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 Page 11 Common Venting Using Tile Lined Interior Masonry Chimney and Combined Vent Connector L MINIMUM LENGTH AS SHORT AS PRACTICAL TI FOR MAXIMUM LENGTH SEE NOTE TO LEFT NOTE Refer to provided venting tables for installations la mi INTERIOR TILE LINED MASONRY CHIMNEY YO NOTE
14. 2 2 469 6400 4400 3530 3020 2680 2480 2230 2080 1950 1840 63 5 67 713 181 22 124 59 99 95 85 51 75 88 70 22 63 14 58 89 55 22 52 10 3 3 068 11300 7780 6250 5350 A740 4290 3950 3670 3450 3260 76 2 77 927 319 98 220 30 176 98 151 49 134 22 121 47 111 85 103 92 97 69 92 31 NOTE Capacity given in cubic feet m3 of gas per hour and based on 0 60 specific gravity gas Zis MANUAL Left Side Piping AUTOMATIC 7 MAIN SHUT OFF Standard GAS VALVE VALVE MANUAL AUTOMATIC with manual MAIN SHUT OFF GAS VALVE shut off valve VALVE Say with manual shut off valve Mi N GROUND JOINT UNION IK 4 GROUND JOINT UNION DRIP LEG Tan Right Side Piping PROVIDED Alternate DRIP LEG AND INSTALLED NOTE BLACK IRON PIPE ONLY TO BE ROUTED INSIDE OF CABINET FIGURE 17 Page 17 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 ACAUTION 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 ign
15. A 15 second pre purge follows once 128 closes NOTE If the low fire pressure switch does not close the combustion air inducer will switch to high fire After a 15 second pre purge the high fire pressure switch will close and the unit will begin operation on high fire After 10 to 20 seconds of high fire operation the unit will switch to low fire NOTE If the furnace is operating on continuous fan mode terminal R and G are energized the combustion air in ducer will energize on high speed the gas valve will ener gize on second stage heat and the furnace will operate on high fire Furnace will stay on high fire for 60 seconds then switch to low fire 2 SureLight control begins 20 second ignitor warm up period 3 Gas valve opens on first stage for a 4 second trial for ignition Ignitor stays energized during the trial or until flame sensed 4 Flame is sensed gas valve remains on first stage heat ignitor de energizes 5 After 30 second delay indoor blower B3 is energized on low heat speed The furnace will stay in this mode until first stage de mand is satisfied OR a second stage heat demand is initiated 6 Second stage heat demand initiated A 30 second sec ond stage recognition period begins 7 The combustion air inducer ramps up to high heat speed 8 102 high heat prove switch closes and the gas valve energizes second stage heat 9 B3 indoor blower switches to high heat speed Single Stage Th
16. E COOLING MODE O GAS MANIFOLD PRESSURE W C INDOOR BLOWER AMPS 4 TEMPERATURE DROP Return Duct Temperature Supply Duct Temperature Temperature Drop COMBUSTION SAMPLE CO2 CO PPM INDOOR BLOWER AMPS 4 TEMPERATURE RISE 5 TOTAL EXTERNAL STATIC dry coil Supply Duct Temperature Supply External Static Return Duct Temperature Return External Static Total E I ic Temper ture Rise otal External Static DRAIN LINE 5 TOTAL EXTERNAL STATIC dry coil O Leak Free Supply External Static Return External Static Total External Static THERMOSTAT LI Adjusted and Programmed L Operation Explained to Owner Contractor s Name Telephone Checklist Completed Job Address Technician s Name Page 32
17. GC 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 appliances shall not be connected to any portion of mechanical draft systems operating under positive pressure such as Category Il 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 Page 13 19 In no case shall the vent connector be sized more than cated or common venting system you must inspect the two consecutive table size diameters over the size of venting system s general condition and look for signs the draft hood outlet or flue collar outlet l of corrosion The existing vent pipe size must conform 20 Do not install a manual damper barometric draft regu to these instructions and the provided venting tables If lator or flue restrictor between the furnace and the the existing venting system does not meet these re chimney quirements it must be resized 21 When connecting this appliance to an existing dedi TABLE 5 Capacity of Type B Double Wall Vents with Type B Double Wall Connectors Serving a Single Category Appliance Vent and Connector Diameter D
18. ION THICKNESS AND TERMINATION age INTEGRATED JUMPER W915 FROM Yi TO Y2 LABELED 2 STAGE COMPR IS FACTORY INSTALLED AT A92 CONTROL BOARD LEAVE IN FOR ONE STAGE COOL COMBUSTION AIR LO O INDUCER MOTOR D D 102 128 THERMOSTAT CUT JUMPER FOR TWO STAGE COOL Lac O HIGH HEAT Low HEAT THERMOSTAT PRESSURE PRESSURE THERMOSTAT HEAT ANTICIPATION SETTING 50 AMP HONEYWELL VALVE 43 AMPJWHITE RODGERS VALVE COOL OFF DELAY 2ND STG DELAY si ROOM THERMOSTAT FACTORY DEFAULT IS FOR A TWO STAGE 2 STAGE THERMOSTAT HEAT COOL TERMINAL 1 IS USED FOR ERROR CODE RECALL ONLY SEE INSTALLATION INSTRUCTIONS FOR DETAILS USE COPPER CONDUCTORS ONLY IMPORTANT TO PREVENT MOTOR BURNOUT NEVER CONNECT MORE THAN ONE MOTOR LEAD TO ANY ONE CONNECTION PARK TERMINAL IS A UNPOWERED TERMINAL Tower R33 ALL UNUSED MOTOR LEADS MUST BE WIRED FLAME FLAME pin TO THE PARK TERMINAL ROLLOUT SENSOR e CUT W951 JUMPER FROM O TO R LABELED SWITCH HEAT PUMP AT A92 CONTROL BOARD S51 ase WHEN USED FOR DUAL FUEL APPLICATIONS LINE XFMR Hk INTEGRATED CONTROL e EAC FLAME SENSE 0005 S102 HIGH HEAT PRESSURE SWITCH SEE BLOWER SPEED CHART COMBUSTION AIR INDUCER MOTOR R33 IGNITOR S128 LOW HEAT PRESSURE SWITCH HUMIDIFIER KE aa ou A92 LINE VOLTAGE FIELD INSTALLED CLASS II VOLTAGE FIELD WIRING INTEGRATED JIS6 a DENOTES OPTIONAL COMPONENTS St PIS6 EQU
19. IPMENT GROUND INDOOR BLOWER MOTOR FIGURE 20 Page 22 Integrated Control TWO STAGE INTEGRATED CONTROL 1 4 QUICK CONNECT TERMINALS COOC 2 2 120 VAC OUTPUT TO HUMIDIFIER 120 VAC OUTPUT TO ELECTRONIC AIR CLEANER 120 VAC OUTPUT TO TRANSFORMER L 120 VAC INPUT TO CONTROL SENSE 120 VAC OUTPUT TO FLAME SENSER NEUTRALS 120 VAC NEUTRAL PARK DEAD TERMINAL FOR UNUSED BLOWER LEAD HEAT LOW 120 VAC OUTPUT TO CIRC BLWR LOW HT SPEED STATUS Li H HEAT HIGH COOL LOW 120 VAC OUTPUT TO CIRC BLWR E COM NS DIAGNOSTIC LEDs HIGH HEAT AND LOW COOL SPEED COOL HIGH 120 VAC OUTPUT TO CIRC BLWR HIGH COOL SPEED THERMOSTAT CONNECTIONS TB1 HEAT DEMAND FROM IST STAGE T STAT HEAT DEMAND FROM 2ND STAGE T STAT MANUAL FAN FROM T STAT die THERMOSTAT 2nd STAGE COOL SIGNAL SWITCHES THERMOSTAT ist STAGE COOL SIGNAL THERMOSTAT SIGNAL GROUND CONNECTED TO TRANSFORMER GROUND TR amp CHASIS GROUND GRD ON BOARD CLASS 2 VOLTAGE TO THERMOSTAT ERROR CODE RECALL H 24V HUMIDIFIER OUTPUT L LENNOX SYSTEM OPERATION MONITOR 0 THERMOSTAT SIGNAL TO HEAT PUMP REVERSING VALVE DIP SWITCH FUNCTIONS DIP SWITCH ES FUNCTION 1 2 Stage T stat 2 2nd Stage Dela 3 amp 4 Heat Off Dela 5 Cool Off Dela Selects t stat type single or two stage Second stage ON delay single stage t stat Heating fan OFF dela Cooling fan OFF dela FIGURE 21 EL280DF units are equipped wit
20. LENNOX 2012 Lennox Industries Inc Dallas Texas USA DOWNFLOW AIR FLOW INSTALLATION INSTRUCTIONS EL280DF MERIT SERIES GAS FURNACE DOWNFLOW AIR DISCHARGE Technical Publications Litho U S A 506896 01 08 2012 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 AWARNING 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 ACAUTION As with any mechanical equipment personal injury can result from contact with sharp sheet metal edges Be careful when you handle this equipment Table of Contents Unit Dimensions EL280DF Gas Furnace Shipping and Packing List aaaea Safety Information e eee eee eee eee Use of Furnace as a Construction Heater General EE Combustion Dilution amp Ventilation Air Downflow Installation Setting Equipment eeeereeeooeoon FIETS ars mirak tek dds Mh doe tle A Duct Syste evi au ke alos ayi aka ede ames 08 12 OIA TTT 2 Venting WEE 11 3 GAS PIPING dere ete ies bY awe d 16 3 Electrical iii ee ee 18 Integrat
21. able 9 for field wiring The power supply wiring must meet Class 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 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 EL280DF furnace contains electronic compo nents 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
22. ainte 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 EL280DF unit will be equipped with a gas control switch Use only your hand to move the switch Never 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 EL280DF 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 AWARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or death Gas Valve Operation Figure 22 1 STOP Read the safety information at the beginning of this section 2 Set the thermostat to the lowest setting 3 Turn off all electrical power to the unit 4 This furnace is equipped with an ignition device which automatically lights the burners Do not try to light the burners by hand 5 Remove the upper 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
23. at is initiated If the switch is toggled to the ON position it will provide a 15 minute delay before second stage heat is initiated This switch is only activated when the thermostat selector jumper is positioned for SINGLE stage thermostat use Switches 3 and 4 Heating Blower Off Delay The heating blower on delay of 45 seconds is not adjustable The heating blower off delay time that the blower operates after the heating demand has been satisfied can be ad justed by moving switches 3 and 4 on the integrated con trol The unit is shipped from the factory with a heating blower off delay of 90 seconds The heating blower off delay affects comfort and is adjustable to satisfy individual applications Adjust the blower off delay to achieve a sup ply air temperature between 90 and 110 F at the exact moment that the blower is de energized Longer off delay Page 23 settings provide lower supply air temperatures shorter set tings provide higher supply air temperatures Table 10 pro vides the blower off timings that will result from different switch settings TABLE 10 Heating Blower Off Delay Switch Settings Blower Off Delay Switch 3 Seconds of On 90 e aoo o ON Si Switch 5 Cooling Blower Off Delay The cooling blower off delay time that the blower operates after the cooling demand has been satisfied can be adjusted by moving switch 5 on the integrated control The switch is fac tory set in the OFF position
24. cal 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 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 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 tables 5 and NO TAG 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 maxi mum listed capacity 8 The common venting tables 6 7 NO TAG and NO TAG 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 Wu 1 O LI TABLE 4 inches Ee Connector Connector Length feet m feet m 9 If the common vertical vent is offset the maximum common vent capacity listed in the common venting tables should b
25. ccording 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 apublic 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 EL280DF 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
26. 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 AIR HANDLER Dampers open during cooling operation only Dampers open during heating 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 EL280DF furnace may be installed in alcoves closets attics basements garages and utility rooms in the down flow position This furnace design has not been CSA International certified for installation in mobile homes recreational vehicles or outdoors Use of Furnace as Constru
27. ction Heater Lennox does not recommend the use of EL280DF 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 EL280DF units may be used for heating of buildings or structures under construction if the following conditions are met e The vent system must be permanently installed per these installation instructions e A room thermostat must control the furnace The use of fixed jumpers that will provide continuous heating is not allowed e The retum air duct must be provided and sealed to the furnace e Return air temperature range between 60 F 16 C and 80 F 27 C must be maintained e Air filters must be installed in the system and must be maintained during construction e Air filters must be replaced upon construction comple tion e The input rate and temperature rise must be set per the furnace rating plate e 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 e The furnace heat exchanger components duct system air filters and evaporator coils must be thoroughly
28. e Each opening must be at least 100 square inches 64516 mm2 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 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 mm2 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
29. e 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 EL280DF UNIT H PROPERLY N l COOLING COIL SIZED FLOOR Dr PLENUM OPENING gan ee pee ae e ae 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 PA EDGE 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 Side View SEALING STRIP Field Provided PLENUM SECURE FROM IN SIDE CABINET Side View HEMMED EDGE FIBERGLASS SEALING STRIP Field Provided PANEL CABINET SIDE 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 AWARNING Do not install the furnace on its front back or in the horizontal position See figure 12 Do not connect the return air ducts to the back of the furnace Doing so will adversely affect the operation of the safety con trol devices which could result in personal injury or death Install the EL280DF gas furnace as
30. e house by the furnace duct sys tem 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 EL280DF series units are classified as fan assisted Category furnaces when vertically vented according to the latest edition of National Fuel Gas Code NFPA 54 ANSI 2223 1 A fan assisted Category 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 2223 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 AIMPORTANT Once the venting system is installed attach the Dis connected Vent
31. e 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 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 NF
32. ed Control 23 SE OC n 24 4 Gas Pressure Adjustment esoe 25 4 Proper Combustion e eee ee eee roooon 26 5 High Altitude eee 26 8 Other Unit Adjustments eeeooe 27 Heating Sequence of Operation 28 9 EIER ive mama Aes a vl Me bwin l e Da a a ja de a atann 29 10 Repair Parts list 30 11 Start Up and Performance Checklist 31 506896 01 pagesi N NAUA e A Unit Dimensions inches mm RETURN AIR OPENING FLUE OUTLET EE Top f 494 t 9 16 14 TOP VIEW 1 1 2 38 27 3 4 Front Panel 705 19 7 16 494 7 pa ET INLET Either Side 3 8 137 Right GAS PIPING INLET 3 16 56 Left he Either Side 6 5 8 168 Right 1 8 181 Left Supply J 3 4 19 1 4_ Supply Air ig 489 Air Page 2 EL280DF Gas Furnace The EL280DF gas furnace is shipped ready for installation in the downflow position fueled by natural gas A conver sion kit ordered separately is required for use in LP Pro pane gas applications Shipping and Packing List Package 1 of 1 contains 1 Assembled EL280DF 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 k
33. ee figure 21 W915 Two Stage W951 Cooling Heat Pumps Intact Intact Intact Page 20 Wiring Connections CONTROL OUTDOOR TERM STRIP UNIT si CONTROL OUTDOOR T STAT TERM STRIP UNIT e Es oo gB 8 8 TABLE 9 Field Wiring Applications Continued DIP Switch Settings and On Board Links See figure 21 W915 Thermostat Two Stage W951 Wiring Connections Cooling Heat Pumps 2 Heat 2 Cool OFF Cut Intact Si CONTROL OUTDOOR ee me E EI Ca anis ane a Green ONE EE 2 Heat 1 Cool OFF Intact Intact s1 CONTROL OUTDOOR T STAT TERM STRIP UNIT e e e 2225 ser ar Page 21 EL280DF Schematic Wiring Diagram S1 ROOM THERMOSTAT S SECONDARY VOODOO GAS LIMIT BLOWER SPEED CHART FACTORY CONNECTED SPEER TAPS SPEEDS SECONDARY HI Te oe HEAT PARK O70P36A BLACK YELLOW RED BROWN 4 e E a n L on tJ Mi S BLOWER SPEED SELECTION ourpoor Yo UNIT bo SEN BLACK BROWN YELLOW RED C4 CAPACITOR TYPICAL SYSTEM SHOWN FOR 2 HEAT 2 COOL WITH JACKPLUG CHART n E Ze E EN be Eeer EQUIPMENT AND ACCESSORIES pubes MACKZELUG COMB AIR INDUCER WARNII ELECTRIC SHOCK HAZARD CAN CAUSE INJURY DR DEATHUNIT MUST BE GROUNDED IN ACCORDANCE WITH NATIONAL AND LOCAL CODES IF ANY WIRE IN THIS APPLIANCE IS REPLACED IT MUST BE REPLACED WITH WIRE OF LIKE SIZE CAZZO RATING INSULAT
34. ening See unit dimensions on page 2 Installation on Combustible Flooring Figure 7 1 When unitis 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 A 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 EL280DF UNIT SUPPLY AIR PLENUM DOWNFLOW COMBUSTIBLE FLOORING BASE PROPERLY SIZED FLOOR OPENING FIGURE 7 TABLE 2 COMBUSTIBLE FLOOR OPENING SIZE Front to Rear Side to Side e 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 furnac
35. ergency 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 16 TABLE 8 Gas Pipe Capacity ft hr m3 hr Nominal Length of Pipe feet m Iron Pipe Internal 9 a m Diameter a inches 10 20 30 40 50 60 70 80 90 100 mim mm 3 048 6 096 9 144 12 192 15 240 18 288 21 336 24 384 27 432 30 480 112 622 172 118 ES Si 72 65 60 56 52 50 12 7 17 799 4 87 3 34 269 229 2 03 1 84 1 69 1 58 1 47 1 42 11 86 1 42 104 2 94 1 1 049 25 4 26 645 3 2 1 84 3 4 ES 360 247 199 170 151 137 126 117 110 19 05 20 930 10 19 7 00 5 63 4 81 4 28 3 87 3 56 3 31 3 11 2 94 8 7 27 1 1 4 1 380 31 75 35 052 4 81 678 466 374 320 284 257 237 220 207 195 19 19 13 19 10 59 9 06 8 04 7 27 6 71 6 23 5 86 5 52 1350 957 768 657 583 528 486 452 424 400 38 22 27 09 22 25 18 60 16 50 14 95 13 76 12 79 12 00 11 33 1 1 2 1 610 2090 1430 1150 985 873 791 728 677 635 600 38 1 40 894 59 18 40 49 32 56 27 89 24 72 22 39 20 61 19 17 17 98 17 00 2 2 067 4020 2760 2220 1900 1680 1520 1400 1300 1220 1160 50 8 52 502 113 83 78 15 62 86 53 80 47 57 43 04 39 64 36 81 34 55 32 844 2 1
36. ermostat Two Stage Heat Dip Switch set at SINGLE 1 SureLight control energizes combustion air inducer B6 on low heat speed Combustion air inducer runs until 128 low heat prove switch contacts close switch must close within 2 1 2 minutes or control goes into Watchguard Pressure Switch mode High heat prove switch S102 may also close A 15 second pre purge follows once S128 closes NOTE If the low fire pressure switch does not close the combustion air inducer will switch to high fire After a 15 second pre purge the high fire pressure switch will close and the unit will begin operation on high fire After 10 to 20 seconds of high fire operation the unit will switch to low fire NOTE If the furnace is operating on continuous fan mode terminal R and G are energized the combustion air in ducer will energize on high speed the gas valve will ener gize on second stage heat and the furnace will operate on high fire Furnace will stay on high fire for 60 seconds then switch to low fire 2 SureLight control begins 20 second ignitor warm up period 3 Gas valve opens on first stage for a 4 second trial for ignition Ignitor stays energized during the trial or until flame sensed 4 Flame is sensed gas valve remains on first stage heat ignitor de energizes 5 After 30 second delay indoor blower B3 is energized on low heat speed 6 A 10 minute factory set or 15 minute field set second stage heat dela
37. ersion kits TABLE 12 AIMPORTANT High Fire 6 8 7 4 7 5 9 0 42 81 50 60 For safety shut unit off and remove manometer as soon as an accurate reading has been obtained Take care to replace pressure tap plug TABLE 13 Manifold Pressure Settings at all Altitudes Manifold Manifold Manifold Supply Line Pressure in wg Pressure in wg Pressure in wg Pressure 0 4500 ft 4501 7500 ft 7501 10 000 ft 2 in w g Low Fire High Fire Low Fire High Fire Low Fire High Fire 3 3 3 1 7 5 1 5 2 1 7 5 5 woe CAN j a oo a ooo 8 E R SE a B woe as f o j a o f a 8 a E AN KE E 1 This is the only permissible derate for these units 2 Natural gas high altitude orifice kit required 3 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 NOTE Units may be installed at altitudes up to 4500 ft above sea level without modifications Natural 4 TABLE 14 Pressure Switch and Gas Conversion Kits at all Altitudes e a F a High Altitude s LP Propane to A High Altitude Pressure Switch Kit Natural Gas Kit LP Propane Gas Kit Natural Kit 0 4500 ft 4501 7500 ft 7501 10 000 ft 7501 10 000 ft 0 7500 ft 7501 10 000 ft 0 7500 ft Min A 000 No Change No Change 73W36 73W37 77W07 77W11 77W09 us NOTE A natural to L P propane gas changeover kit is necessary to convert this unit Refer to the change
38. etermined 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 re productive harm Combustion Dilution 8 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 EL280DF furnaces to ensure efficient 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 re
39. fer 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 AIMPORTANT 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 e The chimney is currently serving at least one drafthood equipped appliance e 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
40. gnitor Integrated control Primary limit control Door interlock switch Flame rollout switch Circuit breaker Secondary limit Page 30 Start Up 8 Performance Check List UNIT SET UP typical Unit Model Number Serial Number O LI LI LI LI LI LI LI LI GAS SUPPLY Natural Gas L LP Propane Gas Piping Connections Tight Leak Tested Supply Line Pressure W C VENT EXHAUST PIPE Secure to Unit Elbows Secured to Pipe Roof Flashing water tight Vent Pipe Supported Gas Supply Pressure Line Voltage supe AIR gt upflow furnace shown Filter RETURN AIR 7 e Page 31 LI LI LI LI LI LI LI DUCT SYSTEM SUPPLY AIR DUCT Sealed Insulated if necessary Registers Open and Unobstructed RETURN DUCT Sealed Filter Installed and Clean Grilles Unobstructed INTEGRATED CONTROL DIP Switches Set if applicable L Appropriate Links in Place if applicable LI VOLTAGE CHECK Supply Voltage Electrical Connections Tight UNIT OPERATION typical bd Combustion CO SUPPLY AIR Gas Manifold Pressure Ii Temperatures Filter RETURN AIR Z Z HEATING MOD
41. h a two stage integrated control This control manages ignition timing and fan off delays based on selections made using the control DIP switches and jumpers The control includes an internal watchguard feature which automatically resets the ignition control when it has been locked out After one hour of con tinuous thermostat demand for heat the watchguard will break and remake thermostat demand to the furnace and automatically reset the control to relight the furnace DIP Switch Settings Switch 1 Thermostat Selection This unit may be used with either a single stage or two stage thermostat The thermostat selection is made using a DIP switch which must be properly positioned for the particular application The DIP switch is factory positioned for use with a two stage thermostat If a single stage thermostat is to be used the DIP switch must be repositioned Select OFF for two stage heating operation con trolled by a two stage heating thermostat factory set ting b Select ON for two stage heating operation con trolled by a single stage heating thermostat This set ting provides a timed delay before second stage heat is initiated Switch 2 Second Stage Delay Used with Single Stage Thermostat Only This switch is used to deter mine the second stage on delay when a single stage ther mostat is being used The switch is factory set in the OFF position which provides a 10 minute delay before second stage he
42. he 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 5 Page 27 Heating Sequence of Operation When there is a call for heat the integrated control runs a self check The control checks for S10 primary limit S21 secondary limit s and S47 rollout switch normally closed contacts The control also checks for S102 high heat and 128 low heat prove switch normally open contacts Once self check is complete and all safety switches are opera tional heat call can continue Two Stage Thermostat Two Stage Heat Dip Switch set at TWO 1 SureLight control energizes combustion air inducer B6 on low heat speed Combustion air inducer runs until 128 low heat prove switch contacts close switch must close within 2 1 2 minutes or control goes into Watchguard Pressure Switch mode High heat prove switch S102 may also close
43. hut 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 11 Are flame rollout switches tripped If flame rollout switches are tripped call the service technician for in spection Gas Pressure Adjustment Gas Flow Approximate TABLE 11 GAS METER CLOCKING CHART Seconds for One Revolution EL280DF Natura CP 2 cu ft DIAL We 045 204 m s e j e 135 Natural 1000 btu cu ft e 7 LP 2500 btu cu ft Furnace should operate at least 5 minutes before check ing gas flow Determine time in seconds for two revolu tions of gas through the meter Two revolutions assures a more accurate time Divide by two and compare to time in table 11 If manifold pressure matches table 13 and rate is incorrect check gas orifices for proper size and restric tion Remove temporary gas meter if installed NOTE To obtain accurate reading shut off all other gas appliances connected to meter Supply Pressure Measurement An inlet post located on the gas valve provides access to the supply pressure See figure 22 Back out the 3 32 hex screw one turn connect a piece of 5 16 tubing and connect to a manometer to measure supply pressure See
44. it 11 Set thermostat and check for proper operation 12 Check all piping connections factory and field for gas leaks Use a leak detecting solution or other preferred means A 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 13 If a leak is detected shut gas and electricity off and repair leak 14 Repeat steps 12 and 13 until no leaks are detected 15 Replace access panel Page 29 EL280DF BURNER COMBUSTION AIR INDUCER ASSEMBLY 8 HEAT EXCHANGER REMOVAL burner box assembly burners retention rings cross over FIGURE 24 Repair Parts List Blower Parts Blower wheel The following repair parts are available through indepen Blower housing dent Lennox dealers When ordering parts include the Motor complete furnace model number listed on the CSA Interna Motor mounting frame tional nameplate Example EL280DF110P60C Blower housing cutoff plate All service must be performed by a licensed profes sional installer or equivalent service agency or gas Heating Parts supplier Flame Sensor Heat exchanger assembly Gas manifold Cabinet Parts Combustion air inducer Main access panel Gas valve Blower access panel Main burner cluster Top cap Main burner orifices Control Panel Parts Pressure switches Transformer I
45. it Check equipment for shipping damage If you find any damage immediately contact the last carrier Safety Information A 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 AWARNING 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 ACAUTION As with any mechanical equipment personal injury can result from contact with sharp sheet metal edges Be careful when you handle this equipment Certifications EL280DF 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 a
46. ition 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 AIMPORTANT 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 ELECTROSTATIC DISCHARGE ESD Precautions and Procedures 4 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 ofthe 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 Cut the two wire ties to extend power wires for right side only FIGURE 19 Refer to figure 20 for schematic wiring diagram and trou bleshooting and t
47. izes A filter must be in place any time the unit is operating TABLE 3 Cabinet Width Return Air Filter Size inches A 14 1 2 14x25x1 1 B 17 1 2 16 x 25 x 1 1 20 x 25 x1 1 Page 10 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 th
48. ludes 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 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 S OPENINGS To Adjacent Room NOTE Each opening shall have a free area of at least one square inch 645 mm 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 mm2 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 per 1 000 Btu 29 kW per hour of total input rating of all gas fired equipment in the confined spac
49. over kit installation instruction for the conversion procedure Page 26 Other Unit Adjustments Primary and Secondary Limits The primary limit is located on the heating compartment vestibule panel The secondary limits if equipped are lo cated in the blower compartment attached to the back side of the blower These auto reset limits are factory set and re quire no adjustment Flame Rollout Switches These manually reset switches are located on the burner box Pressure Switch The pressure switch is located in the heating compartment adjacent to the combustion air inducer The switch checks for proper combustion air inducer operation before allow ing ignition trial The switch is factory set and requires no adjustment Temperature Rise After the furnace has been started and supply and return air temperatures have been allowed to stabilize check the temperature rise If necessary adjust the blower speed to maintain the temperature rise within the range shown on the unit nameplate Increase the blower speed to decrease the temperature Decrease the blower speed to increase the temperature rise Failure to adjust the temperature rise may cause erratic limit operation Fan Control The 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 DIP switches 3 and 4 See figure 23 and table 10 The unit is ship
50. ped with a factory fan off delay setting of 90 seconds The fan off delay affects comfort and is adjust able to satisfy individual applications Adjust the fan off delay to achieve a supply air temperature between 90 and 110 F at the moment that the blower is de energized Lon ger off delay settings provide lower return air temperatures shorter settings provide higher return air temperatures See figure 23 HEAT FAN OFF TIME IN SECONDS 60sec 90sec yi 1 1 2 3 45 1 2 3 45 120sec ON ON Aud EGR 1 2 3 45 3 180sec 5 To adjust fan off timing flip dip switch to desired setting FIGURE 23 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 Refer to blower speed selection chart on unit wiring dia gram for desired heating or cooling speed See Blower performance data beginning on t
51. presented only by the standard in its entirety ACAUTION 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 AGAUTION 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 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
52. rom 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 A 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 appliance
53. ron 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 A I 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 NO TAG 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 AIMPORTANT Compounds used on threaded joints of gas piping must be resistant to the actions of liquified petro leum gases NOTE If em
54. ront 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 tLeft 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 ttThe 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 AWARNING 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 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 s
55. s 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 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 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 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 A LI O 1 N LI 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 ACAUTION If a flexible gas connector is required or allowed by the authority that has jurisdiction black i
56. table 13 for supply line pressure Manifold Pressure NOTE Pressure test adapter kit 10L34 is available from Lennox to facilitate manifold pressure measurement 1 Connect test gauge to manifold pressure tap figure 22 gas valve 2 Ignite unit on high fire and let run for 5 minutes to allow for steady state conditions 3 After allowing unit to stabilize for 5 minutes record manifold pressure and compare to value given in table 13 4 If necessary make adjustments Figure 22 shows location of high fire adjustment screw 5 If an adjustment is made on high fire re check man ifold pressure on low fire Do not adjust low fire man ifold pressure If low fire manifold pressure is more than 1 2 above or below value specified in table 13 replace valve 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 Page 25 Proper Combustion High Altitude Furnace should operate minimum 15 minutes with correct The manifold pressure may require adjustment and com manifold pressure and gas flow rate before checking com bustion air pressure switch may need replacing to ensure bustion Table 12 shows acceptable combustion for ALL proper combustion at higher altitudes Refer to table 13 for EL280DF models The maximum carbon monoxide manifold pressure and table 14 for pressure switch change reading should not exceed 50 ppm and gas conv
57. with a gas vent or chimney suitable for venting EL280DF 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 Page 12 Never connect a Category 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 EL280DF furnaces according to these instructions 1 Vent diameter recommendations and maximum allow able piping runs are found in the provided venting tables 2 Inno 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 verti
58. y period begins 7 After the delay the combustion air inducer ramps up to high heat speed 8 102 high heat prove switch closes and the gas valve energizes second stage heat 9 B3 indoor blower switches to high heat speed Page 28 Service AWARNING 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 correctiy 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 AWARNING 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 EL280DF filters are installed external to the unit Filters should be inspected monthly Clean or replace the filters when necessary to ensure that the furnace operates prop
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