DLF4 "Manufactured in North America" OWNER'S AND INSTALLER'S MANUAL for Double Loop (Central) Furnaces Models: DLF30B & DLF40B U.S. Pat. #5201024 Can. Pat.
1 Table of Contents General Information General Operation .................................................................................................................................................................... 2 Terminology ............................................................................................................................................................................ 3 Safety Information Safety Precautions ...........................................................
2 General Information • This manual provides information for correct installation procedures and electrical connections for Steffes ETS Double Loop Furnaces, Models DLF30B and DLF40B. The information in this manual will help you utilize the product's many features and ensure many years of safe, reliable operation. Read all the information contained within this manual before installing the system. Store this manual in a safe place for future reference.
General Information (cont'd) 3 2 TERMINOLOGY This manual contains terms which may need explanation. The table below lists some of these terms and a brief description of each. TERM DEFINITION Automatic Charge Control Method of brick core charge regulation where a sensor monitors outdoor temperature to automatically adjust the brick core temperature setting in relation to the outdoor temperature. Brick Core Charge Level The amount of heat that is stored in the heater’s brick core.
4 Safety Information 1 SAFETY PRECAUTIONS 2 BUILT-IN SAFETY DEVICES 1. DO NOT energize the furnace while disassembled or without ceramic heat storage brick in place. 2. As is true with all heating appliances, materials that may produce explosive or flammable gases MUST NOT be used or stored near the furnace. 3. Be sure the minimum clearance requirements specified in this manual are never violated. 4. This unit may be connected to more than one branch circuit.
Furnace Control Panel 5 Furnace operation is automatic; however, the user can manually operate it by changing settings on its control panel. (See Figure 1 for reference to location of the control panel and circuit breakers on the furnace.
6 Furnace Control Panel (cont'd) SUMMER/WINTER Toggle Switch This toggle switch will vary core charging in the furnace. It allows for a reduced heating capacity during the summer months if the user prefers to leave the furnace "ON" for emergency heat purposes during this time. (Refer to Table 1, Brick Core Charging Schedule, in this manual for more information on charging levels in relation to the position of this switch and outdoor temperature.
Operating the Furnace 1 7 FURNACE START-UP On startup of the furnace, you may experience some odors relating to first time operation of the heating compo nents. There may also be an odor associated with dust accumulation in the system if the furnace is shutdown for an extended period of time. Upon restart, allowing the furnace to charge to its maximum brick core charge level will help expel these odors in a timely manner.
8 Operating the Furnace (cont'd) BRICK CORE CHARGING SCHEDULE Table 1 During brick core charging, the heating elements are staged "ON" and "OFF" in 6.4kW increments (maximum). SUMMER/WINTER SWITCH POSITION OUTDOOR AIR TEMP. (ºF) CHARGE LEVEL kW INPUT (MAX) DLF30B DLF40B CORETEMP. ºF (Nominal) Winter 55* 1 9.6 12.8 500 Winter 35 2 19.2 25.6 900 Winter 15 3 28.8 38.4 1,350 Summer 35 1 9.6 12.8 500 Summer 15 3 28.8 38.
Installing The Furnace 1 9 SHIPPING The furnace is shipped disassembled for ease in handling and moving into location where it is to be installed. (Refer to Table 2 for information on the items shipped with each furnace.
Installing The Furnace 10 (cont'd) FIGURE 3 3 CLEARANCE REQUIREMENTS 3" MIN CLEARANCE The minimum clearances required when installing the furnace into any area are as follows: TOP VIEW Back and Sides = 3 inches (from combustible material) Top = 6 inches (from combustible material) Front = 36 inches (for ease of servicing) Furnace Right Side and Air Duct = 2 inches Furnace Left Side and Air Duct = zero clearance Sides of Furnace Ducts = zero clearance The clearance areas must be kept open and free of
Installing The Heater (cont'd) Step 7 11 Adjust the leveling legs (48) on the bottom of the base assembly (50) once it is set in final position. The leveling legs must not be extended more than one inch. The base MUST NOTE set securely on all four legs to prevent rocking of the furnace and/or twisting of the heat exchanger. Step 8 Set the brick storage cabinet on the base assembly (50) taking care not to damage the wiring har nesses (65 & 70).
12 Step 13 Installing The Heater (cont'd) Connect the brown thermocouple lead wire (79) in the wiring harnesses to the core temperature sensor (68). The yellow wire of the thermocouple lead attaches to the screw stud marked with a yellow dot. The red wire attaches to the screw stud marked with a red dot.
Installing The Furnace (cont'd) 13 FIGURE 7 ¢ The second to last row, front, LAST (TOP) ROW middle brick must be the last brick installed. A shim may be used to hold the upper brick in place, or it is more easily accomplished by leaving the middle brick in the second to last row pulled about 4" SECOND TO LAST ROW forward from its intended MIDDLE BRICK position. In this position the brick will act as a support for the top middle brick.
Installing The Furnace 14 (cont'd) For air delivery, the furnace is equipped with a 4speed supply air blower which is factory wired to operate in medium low speed for heating and in medium high speed for cooling and a fan only thermostat setting. The blower speed may be adjusted for lower or higher output requirements. To do so, change the wiring on the blower speed selection terminals located on the supply air blower.
Installing The Furnace 15 LINE VOLTAGE ELECTRICAL CONNECTIONS In standard configuration, the furnace is wired for connection to 240V but are available with 208V or 277V heating elements as special factory orders. However, the blowers and furnace controls circuit must always be connected to 240V or 208V. The furnace is set up for multiple feed circuits. The 60 amp breakers located in the electrical compartment at the base of the furnace feed the core charging (element) circuits.
Installing The Furnace 16 (cont'd) Line Voltage Wiring Diagrams DLF30B 240V OR 208V UNITS ONLY FIGURE 9 NOTE Use copper or aluminum conductors rated for 75C or higher for field connection of this device. SUPPLY AIR BLOWER 1 8 5 3 4 2 3 1 2 3 1 N.C. N.C. 350 WHITE 350 350 CORE BLOWER YELLOW HEAT EXCHANGER LIMIT 135° FAN N.O. CONTROL 180° LIMIT HIGH R1 125 LIMIT N.O. STAGE 1 CHARGING SEQUENCOR COM. N.O. HOUSE BLOWER N.C. BLUE/BLACK N.O. 240v BLUE N.O. RED COM. 5uf Cap.
Installing The Furnace (cont'd) 17 DLF40B 240V OR 208V UNITS ONLY FIGURE 10 Use copper or aluminum conductors rated for 75C or higher for field connection of this device. HEATING ELEMENTS STAGING ROW # 2 TOP 2 9 1 8 7 2 6 1 5 3 4 2 3 1 2 3 1 350 WHITE 350 350 CORE BLOWER BLUE N.C. 15A N.O. STAGE 2 CHARGING SEQUENCER N.O. BLUE/BLACK N.O. 240v 5uf Cap. COM. RED 60A 60A 60A CHARGE HOUSE BLOWER N.O. CIRCUIT #3 COM. N.O. CIRCUIT #2 N.O. CIRCUIT #1 N.O.
18 Installing The Furnace (cont'd) DLF30B AND DLF40B 277V UNITS ONLY FIGURE 11 NOTE Use copper or aluminum conductors rated for 75C or higher for field connection of this device. The blowers and the controls circuit MUST be powered with 240V or 208V. SUPPLY AIR BLOWER N.C. E8 E7 2 E6 1 E5 3 E4 2 E3 1 E2 3 E1 240° N.C. N.C. N.C. N.C. N.C. N.C. N.C. HEAT EXCHANGER LIMIT 160° 180° N.C. N.C. LIMIT LIMIT HEATING SPEED BLUE/RED 3 SEE NOTE 1 N.C. N.O. 135° FAN CONTROL N.O.
Installing The Furnace 9 19 (cont'd) LOW VOLTAGE ELECTRICAL CONNECTIONS The outdoor temperature sensor, room thermostat, and peak control signal are low voltage wire connections to the furnace. All low voltage wiring must be segregated from line voltage circuits in the furnace. Low Voltage Wiring Diagram R WG C Y Y2Y3 AUX FIGURE 12 Hi SUMMER Lo OVERRIDE N.O. START CANCEL W G B R N.O. TO OUTDOOR SENSOR N.O. BACK VIEW OF SFIII N.O. N.O. N.O. N.C.
Installing The Furnace 20 (cont'd) Outdoor Temperature Sensor The outdoor temperature sensor provides outdoor temperature information for automatic charge regulation of the furnace. In standard configuration from the factory, the outdoor sensor is calibrated at 55oF, 35oF, and 15oF for initiating the level, 1 (1/3), 2 (2/3) and 3 (maximum) brick core charges.
Installing The Furnace (cont'd) 21 Mounting and Wiring Connections: Step 1 Attach the thermostat to a wall. Insulate the opening through which the thermostat wires runs. Failure to do so may affect the accuracy of the thermostat. Step 2 Disconnect power to the furnace and route low voltage wire between the thermostat and the furnace. Step 3 Route the wire into the furnace’s electrical compartment and to the front of the charge control circuit board (30).
22 Installing The Furnace (cont'd) Peak Control The heating elements in the furnace are controlled onpeak (not able to store heat in the brick core) via low voltage wiring. Connecting the furnace to load control signaling device: Step 1 Route a low voltage circuit from the power company's load control peak signaling device to the charge control circuit board (30) located inside the electrical compartment of the furnace.
Installing The Furnace 9 (cont'd) 23 FURNACE FINAL TEST PROCEDURE ____ 1. Check all electrical connections for proper termination placement and do a general inspection for tight connections, wire routing, etc. ____ 2. Energize the furnace. ____ 3. If the wall thermostat has an anticipator, set the anticipator 0.5 amps. ____ 4. Turn up wall thermostat to bring on a call for heat. Core blower (38) should run on its high speed with a cold brick core.
Furnace Specifications 24 MODEL DLF30B DLF40B 3 – 50 Amp circuits (120AmpX1.25=150Amp) 4 – 50 Amp circuits (160AmpX1.25=200Amp) 6 Amps (240V systems) 6 Amps (240V systems) 28.8 kW 38.
Exploded View Parts Diagram FIGURE 17 25
26 NOTE DWG. REF. NO. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. Furnace Parts List When ordering replacement parts, please include model number and serial number of the furnace.
27 Fur nace P ar ts List (cont'd) Furnace Par arts When ordering replacement parts, please include model number and serial number of the furnace. DWG. REF. NO. 42. 43. " 44. 45. " " 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. 74. 75. 76. 77. 78. 79.
28 Troubleshooting 1 Information BRICK CORE TEMPERATURE TESTING An approximate brick core charge level in the furnace can be measured by taking a millivolt reading on the core temperature sensor. This sensor is located on the right side of the storage brick cavity in the limit bar louvre area. (See drawing reference #68 in the Exploded View Parts Diagram.) The millivolt reading (DC) can be compared to the Core Temperature Graph below to correlate the reading to an approximate brick core tempera ture.
Troubleshooting Information 2 (cont'd) 29 TROUBLESHOOTING GUIDES Before starting any of the troubleshooting procedures, check voltage on the load side of all the furnace circuit breakers. Also, check for 24 VAC between each of the 3amp low voltage fuses and room thermostat terminal block “C” position on the charge control circuit board. These guides are based upon standard configuration of the furnace.
30 Troubleshooting Information (cont'd) B. PROBLEM: FURNACE WILL NOT DELIVER HEAT Lights Off Jumper room thermostat connections "R" and "W" terminal block positions on the charge control circuit board (30). With room thermostat call for heat, check LED's on charge control circuit board panel (30). "POWER ON" & "HEAT CALL" lights must both be ON. Lights On Core Blower Does Not Run Core Blower Does Not Run Check for core blower motor (38) operation.
Troubleshooting Information (cont'd) 31 Core Charging A. PROBLEM: FURNACE OVERCHARGES ON WARM DAY Lights Work Properly Check operation of outdoor temperature lights on charge control circuit board (30). With wires disconnected, check ohm Defective values of the resistor (66). Must be 175 ohm center to top & center to bottom. All Outdoor Temperature Lights Are "ON" Regardless of Outdoor Temperature Replace resistor (66). Check "AUTO/HIGH/LOW" toggle switch.
32 Troubleshooting Information (cont'd) B. PROBLEM: FURNACE WILL NOT CHARGE (FURNACE HAS NO CORE CHARGE) Check power company load control switch & furnace "OFFPEAK" light on the charge control circuit board (30) for proper operation. Continue following procedures in offpeak mode. Lights Inoperable Lights Operable No Lights Check "outdoor temp SENSOR" lights on the charge control circuit board (30). Off Check "ETS CHARGING" light on the charge control circuit board (30).
Troubleshooting Information (cont'd) 33 B. PROBLEM: FURNACE WILL NOT CHARGE (FURNACE HAS NO CORE CHARGE) continued... This portion of the troubleshooting flow chart is to test operation of the auxilairy control board. NOTE Furnaces built after January of 1998 were produced with this additional control.
34 Troubleshooting Information (cont'd) C: PROBLEM: FURNACE UNDERCHARGES Unit Undercharges on Cold Days Check daily kWh usage. Check charge control thermostat knob (33) for proper position. Less than Max Usage Proper Maximum Usage Ok Unit Undercharges on Warm Days Set the "AUTO/HIGH/LOW" toggle switch to the "HIGH" position.
Warranty Registering your purchase is an essential step to ensure warranty coverage. A Warranty Registration card is included with the Owner's Manual. Simply complete, detach the bottom portion, and return the card today. Retain the top portion of the card for your files. Your Steffes product is protected by one of the most comprehensive warranties and outstanding service networks in the industry. We welcome comments you have relating to the equipment.
