User's Manual

ManualsBrandsLennox International Inc ManualsFurnaceEL280DF

Page 1

08/12

*2P0812*

506896−01

*P506896-01*

E 2012 Lennox Industries Inc.

Dallas, Texas, USA

DOWNFLOW

AIR FLOW

INSTALLATION

INSTRUCTIONS

EL280DF

MERIT

SERIES GAS FURNACE

DOWNFLOW AIR DISCHARGE

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

WARNING

Improper installation, adjustment, alteration, service

or maintenance can cause property damage, person-

al injury or loss of life. Installation and service must

be performed by a licensed professional installer (or

equivalent), service agency or the gas supplier.

CAUTION

As with any mechanical equipment, personal injury

can result from contact with sharp sheet metal

edges. Be careful when you handle this equipment.

Table of Contents

Unit Dimensions 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EL280DF Gas Furnace 3. . . . . . . . . . . . . . . . . . . . . . . . . .

Shipping and Packing List 3. . . . . . . . . . . . . . . . . . . . . . . .

Safety Information 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Use of Furnace as a Construction Heater 4. . . . . . . . . . .

General 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Combustion, Dilution & Ventilation Air 5. . . . . . . . . . . . . .

Downflow Installation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting Equipment 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filters 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Duct System 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Venting 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gas Piping 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Integrated Control 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unit Start−Up 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gas Pressure Adjustment 25. . . . . . . . . . . . . . . . . . . . . . . .

Proper Combustion 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High Altitude 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Other Unit Adjustments 27. . . . . . . . . . . . . . . . . . . . . . . . . .

Heating Sequence of Operation 28. . . . . . . . . . . . . . . . . . .

Service 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair Parts List 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start Up and Performance Checklist 31. . . . . . . . . . . . . . .

Litho U.S.A.

Summary of content (32 pages)

PAGE 1
INSTALLATION INSTRUCTIONS EL280DF E 2012 Lennox Industries Inc. Dallas, Texas, USA MERIT® SERIES GAS FURNACE DOWNFLOW AIR DISCHARGE 506896−01 08/2012 Litho U.S.A. This is a safety alert symbol and should never be ignored. When you see this symbol on labels or in manuals, be alert to the potential for personal injury or death.
PAGE 2
Unit Dimensions − inches (mm) 3−1/8 (79) 9/16 (14) D RETURN AIR OPENING B FLUE OUTLET (Top) 19−7/16 (494) 9/16 (14) 9/16 (14) TOP VIEW 27−3/4 (705) 1−1/2 (38) Front Panel A 19−7/16 (494) 9/16 (14) B 9/16 (14) AIR FLOW 33 (838) ELECTRICAL INLET (Either Side) 5−3/8 (137) Right 2−3/16 (56) Left GAS PIPING INLET (Either Side) 6−5/8 (168) Right 7−1/8 (181) Left C Model No. Supply Air 19−1/4 Supply (489) Air 3/4 (19) A B C EL280DF070P36A in. 14−1/2 mm 368 in.
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EL280DF Gas Furnace The EL280DF gas furnace is shipped ready for installation in the downflow position fueled by natural gas. A conversion kit (ordered separately) is required for use in LP/Propane gas applications.
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D D D AIR HANDLER GAS UNIT D D Dampers Dampers (open during cooling operation only) (open during heating operation only) D D 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 Electric Code, ANSI/NFPA No. 70. The National Electric Code (ANSI/NFPA No.
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WARNING CAUTION The State of California has determined that this product may contain or produce a chemical or chemicals, in very low doses, which may cause serious illness or death. It may also cause cancer, birth defects or reproductive harm. Insufficient combustion air can cause headaches, nausea, dizziness or asphyxiation. It will also cause excess water in the heat exchanger resulting in rusting and premature heat exchanger failure.
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Confined Space A confined space is an area with a volume less than 50 cubic 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 includes furnace closets or small equipment rooms.
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EQUIPMENT IN CONFINED SPACE ALL AIR FROM OUTSIDE (Inlet Air from Crawlspace and Outlet Air to Ventilated Attic) CHIMNEY OR GAS VENT VENTILATION LOUVERS (Each end of attic) OUTLET AIR FURNACE WATER HEATER INLET AIR VENTILATION LOUVERS (For unheated crawl space) 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.
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Downflow Installation CAUTION Downflow unit installs in three ways: on non−combustible flooring, on combustible flooring using a downflow combustible flooring base, or on a reverse−flow cooling cabinet. Do not drag the unit across the floor. The furnace and downflow combustible flooring base shall not be installed directly on carpeting, tile, or other combustible material other than wood flooring.
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Setting Equipment EL280DF UNIT WARNING Do not install the furnace on its front, back or in the horizontal position. See figure 12. Do not connect the return air ducts to the back of the furnace. Doing so will adversely affect the operation of the safety control devices, which could result in personal injury or death. COOLING COIL PROPERLY SIZED FLOOR OPENING PLENUM Install the EL280DF gas furnace as shipped in the downflow position only. Do not install the furnace horizontally.
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Front Horizontal Back FIGURE 12 Downflow Application Allow for clearances to combustible materials as indicated on the unit nameplate. Minimum clearances for closet or alcove installations are shown in figure 13. Downflow Application Installation Clearances Top Left Side Right Side Bottom WARNING Improper installation of the furnace can result in personal injury or death. Combustion and flue products must never be allowed to enter the return air system or the living space.
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Duct System Use industry-approved standards (such as those published by Air Conditioning Contractors of America or American 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.
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Common Venting Using Tile−Lined Interior Masonry Chimney and Combined Vent Connector NOTE− Refer to provided venting tables for installations. MINIMUM LENGTH = AS SHORT AS PRACTICAL. FOR MAXIMUM LENGTH SEE NOTE TO LEFT INTERIOR TILE−LINED MASONRY CHIMNEY NOTE − the chimney must be properly sized per provided venting tables or lined with listed metal lining system.
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Never connect a Category I appliance to a chimney that is servicing a solid−fuel appliance. If a fireplace chimney flue is used to vent this appliance, the fireplace opening must be permanently sealed. A type B or listed chimney lining system that passes through an unused masonry chimney flue is not considered to be exposed to the outdoors.
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cated or common venting system, you must inspect the 19 − In no case, shall the vent connector be sized more than 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. of corrosion. The existing vent pipe size must conform 20 − Do not install a manual damper, barometric draft reguto these instructions and the provided venting tables.
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TABLE 6 Vent Connector Capacity Type B Double−Wall Vents with Type B Double−Wall Connectors Serving Two or More Category I Appliances Vent Height H (feet) 6 8 10 15 20 30 Vent and Connector Diameter − D (inches) Connector Rise R (feet) 3 Inch 4 Inch 5 Inch 6 Inch Appliance Input Rating in Thousands of Btu Per Hour MIN MAX MIN MAX MIN MAX MIN MAX 1 22 37 35 66 46 106 58 164 2 23 41 37 75 48 121 60 183 3 24 44 38 81 49 132 62 199 1 22 40 35 72 49 114 64
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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 standards of the National Fuel Gas Code ANSI Z223.1. Removal of the Furnace from Common Vent In the event that an existing furnace is removed from a venting system commonly run with separate gas appliances, the venting system is likely to be too large to properly vent the remaining attached appliances.
PAGE 17
TABLE 8 Gas Pipe Capacity − ft3/hr (m3/hr) Nominal Iron Pipe Size inches (mm) Internal Diameter inches (mm) 10 (3.048) 20 (6.096) 30 (9.144) 40 (12.192) 50 (15.240) 60 (18.288) 70 (21.336) 80 (24.384) 90 (27.432) 100 (30.480) 1/2 (12.7) .622 (17.799) 172 (4.87) 118 (3.34) 95 (2.69) 81 (2.29) 72 (2.03) 65 (1.84) 60 (1.69) 56 (1.58) 52 (1.47) 50 (1.42) 3/4 (19.05) .824 (20.930) 360 (10.19) 247 (7.00) 199 (5.63) 170 (4.81) 151 (4.28) 137 (3.87) 126 (3.56) 117 (3.31) 110 (3.
PAGE 18
Leak Check INTERIOR MAKE−UP BOX INSTALLATION (Right Side) After gas piping is completed, carefully check all piping connections (factory− and field−installed) for gas leaks. Use a leak detecting solution or other preferred means. NOTE − If emergency shutoff is necessary, shut off the main manual gas valve and disconnect the main power to the furnace. The installer should properly label these devices. CAUTION Some soaps used for leak detection are corrosive to certain metals.
PAGE 19
of the circuit being connected to one of the provided neutral terminals. If an accessory rated at greater than one amp is connected to this terminal, it is necessary to use an external 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 operating.
PAGE 20
TABLE 9 Field Wiring Applications DIP Switch Settings and On−Board Links (See figure 21) Thermostat DIP Switch 1 W915 Two−Stage Cooling W951 Heat Pumps Wiring Connections 1 Heat / 1 Cool NOTE − Use DIP switch 2 to set second−stage heat ON delay. OFF10 minutes. ON−15 minutes. ON Intact Intact S1 T’STAT 1 Heat / 2 Cool NOTE − Use DIP switch 2 to set second−stage heat ON delay. OFF−10 minutes. ON−15 minutes. ON Cut Intact S1 T’STAT Page 20 CONTROL TERM. STRIP CONTROL TERM.
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TABLE 9 Field Wiring Applications (Continued) DIP Switch Settings and On−Board Links (See figure 21) Thermostat DIP Switch 1 W915 Two−Stage Cooling W951 Heat Pumps Wiring Connections 2 Heat / 2 Cool OFF Cut Intact S1 T’STAT CONTROL TERM. STRIP OUTDOOR UNIT 2 Heat / 1 Cool OFF Intact Intact S1 T’STAT CONTROL TERM.
PAGE 22
EL280DF Schematic Wiring Diagram FIGURE 20 Page 22
PAGE 23
Integrated Control TWO−STAGE INTEGRATED CONTROL 1/4" QUICK CONNECT TERMINALS 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 HEAT HIGH/ COOL LOW = 120 VAC OUTPUT TO CIRC BLWR −− HIGH HEAT AND LOW COOL SPEED COOL HIGH = 120 VAC OUTPUT TO CIRC BLWR −− HIGH COOL SPEED DIAGNOSTIC LEDs THERMOSTAT CONNECTIONS (TB1) DIP SWITCHES ON−BOARD LINKS 1= ERROR CODE RECALL H= 24V HUMIDIFIER OUTPUT L= LENN
PAGE 24
settings provide lower supply air temperatures; shorter settings provide higher supply air temperatures.Table 10 provides the blower off timings that will result from different switch settings.
PAGE 25
INLET PRESSURE POST MANIFOLD PRESSURE TAP Gas Pressure Adjustment HIGH FIRE ADJUSTMENT SCREW (under cap) Gas Flow (Approximate) GAS VALVE SHOWN IN ON POSITION FIGURE 22 8 − Move switch on gas valve to ON. Do not force. See figure 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.
PAGE 26
High Altitude Proper Combustion The manifold pressure may require adjustment and combustion air pressure switch may need replacing to ensure proper combustion at higher altitudes. Refer to table 13 for manifold pressure and table 14 for pressure switch change and gas conversion kits. Furnace should operate minimum 15 minutes with correct manifold pressure and gas flow rate before checking combustion. Table 12 shows acceptable combustion for ALL EL280DF models.
PAGE 27
Other Unit Adjustments HEAT FAN-OFF TIME IN SECONDS 60sec. Primary and Secondary Limits The primary limit is located on the heating compartment vestibule panel. The secondary limits (if equipped) are located in the blower compartment, attached to the back side of the blower. These auto reset limits are factory−set and require no adjustment. 1 2 3 4 90sec. 5 1 120sec. 2 3 4 5 180sec. Flame Rollout Switches These manually reset switches are located on the burner box.
PAGE 28
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 S128 low heat prove switch normally open contacts. Once self check is complete and all safety switches are operational, heat call can continue. Two−Stage Thermostat, Two Stage Heat. Dip Switch set at TWO".
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Electrical Service 1 − Check all wiring for loose connections. 2 − Check for the correct voltage at the furnace (furnace operating). Correct voltage is 120VAC + 10%. WARNING ELECTRICAL SHOCK, FIRE, OR EXPLOSION HAZARD. Failure to follow safety warnings exactly could result in dangerous operation, serious injury, death or property damage. Improper servicing could result in dangerous operation, serious injury, death, or property damage. Before servicing, disconnect all electrical power to furnace.
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EL280DF BURNER, COMBUSTION AIR INDUCER ASSEMBLY & HEAT EXCHANGER REMOVAL burner box assembly burners manifold and gas valve retention rings cross over FIGURE 24 Blower Parts Repair Parts List Blower wheel The following repair parts are available through indepenBlower housing dent Lennox dealers. When ordering parts, include the Motor complete furnace model number listed on the CSA InternaMotor mounting frame tional nameplate −− Example: EL280DF110P60C.
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Start−Up & Performance Check List UNIT SET UP (typical) Unit Model Number_______________ Serial Number___________________ 2 SUPPLY AIR Line Voltage 5 2 upflow furnace shown 1 3 Gas Supply Pressure Filter 1 RETURN AIR 4 1 3 GAS SUPPLY Natural Gas DUCT SYSTEM SUPPLY AIR DUCT LP/Propane Gas Sealed Piping Connections Tight Leak Tested Insulated (if necessary) Supply Line Pressure W.C.
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UNIT OPERATION (typical) Combustion CO2 2 SUPPLY AIR Gas Manifold Pressure 7 Thermostat Temperatures 6 upflow furnace shown 1 4 Filter Blower Motor Amps Duct Static 3 RETURN AIR COOLING MODE HEATING MODE 1 GAS MANIFOLD PRESSURE W.C.