Lennox EL280UH, Installation Instructions Manual

Page 1: ...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 Parts Arrangement 3 EL280UH Gas Furnace 4 Shipping and Packing List 4 Safety Information 4 Use of Furnace as a Co...

Page 2: ...cally 3 Optional External Side Return Air Filter Kit is not for use with the optional Return Air Base 1 NOTE 60C and 60D size units that require air volumes over 1800 cfm 850 L s must have one of the following 1 Single side return air with transition to accommodate 20 x 25 x 1 in 508 x 635 x 25 mm cleanable air filter Required to maintain proper air velocity 2 Single side return air with optional ...

Page 3: ...Air Inducer Gas Valve and Manifold Assembly Limit Switch under collector box Collector Box Heat Exchanger Integrated Control Indoor Blower and Motor Assembly removed from cabinet Indoor Blower and Motor Assembly installed in cabinet Make Up Box Transformer Door Interlock Switch ...

Page 4: ...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 ...

Page 5: ...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 EL280UH units may be used for heating of buildings or structures under construction if the following conditions are met D The vent system must be permanently installed per these installation instructions D A room thermostat must control...

Page 6: ...all EL280UH furnaces to ensure efficient and safe operation You must consider combustion air needs and requirements for exhaust vents and gas piping A portion of this information has been reprinted with per mission from the National Fuel Gas Code ANSI Z223 1 This reprinted material is not the complete and official posi tion of the ANSI on the referenced subject which is repre sented only by the st...

Page 7: ...square inches 64516 mm2 FIGURE 3 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 mm2 per 1 000 Btu 29 kW per hour of total input rating of all gas fired equipment in the confined space Each opening m...

Page 8: ...ne square inch 645 mm2 per 4 000 Btu 1 17 kW per hour of the total input rating of all equip ment in the enclosure CHIMNEY OR GAS VENT WATER HEATER OUTLET AIR VENTILATION LOUVERS Each end of attic INLET AIR Ends 12 in above bottom FURNACE FIGURE 5 EQUIPMENT IN CONFINED SPACE ALL AIR FROM OUTSIDE OUTLET AIR INLET AIR WATER HEATER CHIMNEY OR GAS VENT NOTE Each air duct opening shall have a free area...

Page 9: ...moved 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 FIGURE 7 RIGID LEG remove shipping bolt and washer EL280UH090P48B and EL280UH110P48C with 1 2 HP BLOWER MOTOR Upflow Applications Allow for clearances to combustible materials as indicated on the unit nameplate Minimum clearances for closet or al cove inst...

Page 10: ...ngle Side Return Air with transition and filter FIGURE 10 Optional Return Air Base Upflow Applications Only For use with A B C and D cabinets NOTE Optional Side Return Air Filter Kits are not for use with Optional Return Air Base 1 Both the unit return air opening and the base return air opening must be covered by a single plenum or IAQ cabinet Minimum unit side return air opening dimensions for u...

Page 11: ...tic or a crawl space Either suspend the furnace from roof rafters or floor joists as shown in figure 13 or install the furnace on a platform as shown in figure 14 Typical Horizontal Application Unit Suspended in Attic or Crawlspace FIGURE 13 Bracket Bottom Cap Metal Strap 3 16 inch Air Flow NOTE Heavy gauge perforated sheet metal straps may be used to suspend the unit from roof rafters or ceiling ...

Page 12: ...ri 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 Supply...

Page 13: ...e See figure 15 Lift and rotate the as sembly 90 degrees clockwise or counter clockwise to either the 3 o clock position or to 9 o clock position and re secure with four screws Gasket should be left in place 2 Use tin snips to cut preferred opening on the cabinet for repositioning the flue outlet Use the cut out piece as a cover plate to patch unused opening on cabinet UPFLOW POSITION Left Side Ve...

Page 14: ... switch wires Re install pressure switch on the other side of orifice plate and re connect pressure switch hose S Re secure pressure switch wires by either pulling excess wires through the blower compartment and securing with supplied wire tie or coil excess wire and secure to the gas manifold FLOW AIR Pressure Switch Flue Transition Make Up Box Collector Box HORIZONTAL RIGHT POSITION Top Vent Dis...

Page 15: ... inches 152 mm from the furnace vent outlet See figure 23 Venting Using a Masonry Chimney The following additional requirements apply when a lined masonry chimney is used to vent this furnace Masonry chimneys used to vent Category I 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 24 and...

Page 16: ... or relined with suitable materials or replaced with a gas vent or chimney suitable for venting EL280UH 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 Never connect a Category I appliance to a chimney that is servicin...

Page 17: ...ent capacity listed in the common venting tables should be 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 ...

Page 18: ...ance Height H feet Lateral L feet Vent and Connector Diameter D inches 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 6 0 0 78 0 152 0 251 0 375 2 13 51 18 97 27 157 32 232 4 21 49 30 94 39 153 50 227 6 25 46 36 91 47 149 59 223 8 0 0 84 0 165 0 276 0 415 2 12 57 16 109 25 178 28 263 5 23 53 32 103 42 171 53 255 8 28 49 39 98 51 164 ...

Page 19: ... 225 115 337 5 51 63 75 128 102 216 144 326 10 NA NA 95 116 128 201 182 308 15 NA NA NA NA 158 186 220 290 20 0 35 96 54 200 78 346 114 537 2 37 74 56 148 78 248 113 375 5 50 68 73 140 100 239 141 363 10 NA NA 93 129 125 223 177 344 15 NA NA NA NA 155 208 216 325 20 NA NA NA NA 186 192 254 306 30 0 34 99 53 211 76 372 110 584 2 37 80 55 164 76 281 109 429 5 49 74 72 157 98 271 136 417 10 NA NA 91 ...

Page 20: ...5 1 21 50 33 89 47 142 64 220 2 22 53 35 96 49 153 66 235 3 24 55 36 102 51 163 68 248 20 1 21 54 33 99 46 157 62 246 2 22 57 34 105 48 167 64 259 3 23 60 35 110 50 176 66 271 30 1 20 62 31 113 45 181 60 288 2 21 64 33 118 47 190 62 299 3 22 66 34 123 48 198 64 309 TABLE 6 Common Vent Capacity Type B Double Wall Vents with Type B Double Wall Connectors Serving Two or More Category I Appliances Ven...

Page 21: ...9 278 2 51 62 81 115 117 185 177 290 3 54 64 85 119 122 193 185 300 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...

Page 22: ... 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 appliances not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts...

Page 23: ...urnished by the installer external to the unit The union must be of the ground joint type IMPORTANT Compounds used on threaded joints of gas piping must be resistant to the actions of liquified petro leum gases NOTE If emergency 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 TABLE 9 Gas Pipe Capaci...

Page 24: ...gged Tap Shown NOTE BLACK IRON PIPE ONLY TO BE ROUTED INSIDE OF CABINET FIGURE 26 GROUND JOINT UNION DRIP LEG MANUAL MAIN SHUT OFF VALVE GROUND JOINT UNION DRIP LEG MANUAL MAIN SHUT OFF VALVE GROUND JOINT UNION DRIP LEG MANUAL MAIN SHUT OFF VALVE Horizontal Applications Possible Gas Piping Configurations Horizontal Application Left Side Air Discharge Horizontal Application Right Side Air Discharge...

Page 25: ...LUG Electrical ELECTROSTATIC DISCHARGE ESD Precautions and Procedures 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 of the cabinet The make up box may be moved to the right side of the furn...

Page 26: ...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 Generator Use Voltage Re...

Page 27: ...wo Stage Cooling W951 Heat Pumps 1 Heat 1 Cool NOTE Use DIP switch 2 to set sec ond stage heat ON delay OFF10 minutes ON 15 minutes ON Intact Intact S1 T STAT CONTROL TERM STRIP OUTDOOR UNIT 1 Heat 2 Cool NOTE Use DIP switch 2 to set sec ond stage heat ON delay OFF 10 minutes ON 15 minutes ON Cut Intact S1 T STAT CONTROL TERM STRIP OUTDOOR UNIT ...

Page 28: ...IP Switch Settings and On Board Links See figure 33 Wiring Connections DIP Switch 1 W915 Two Stage Cooling W951 Heat Pumps 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 STRIP OUTDOOR UNIT ...

Page 29: ...P48C 110P60C 135P60D 070XP36A 090XP48B 110XP60C EL280UH070P24A EL280UH070P36A EL280UH090P36B EL280UH090P48B EL280UH110P48C BROWN BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BROWN BROWN BROWN BROWN YELLOW YELLOW YELLOW YELLOW YELLOW YELLOW YELLOW RED RED RED RED RED RED RED RED RED RED YELLOW YELLOW YELLOW BROWN BROWN BROWN BROWN BROWN 0112 BURNER ASSY GND 8 8 DELAY G WHITE RODGERS ...

Page 30: ...VAC OUTPUT TO FLAME SENSOR 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 DIP SWITCH ES FUNCTION 1 2 Stage T stat Selects t stat type single or two stage 2 2nd Stage Delay Second stage ON delay single...

Page 31: ...onds 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 ...

Page 32: ...e 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 34 7 Wait five minutes to clear out any...

Page 33: ...e post located on the gas valve provides access to the manifold pressure See figure 34 Back out the 3 32 hex screw one turn connect a piece of 5 16 tubing and connect to a manometer to measure manifold pres sure NOTE Pressure test adapter kit 10L34 is available from Lennox to facilitate manifold pressure measurement 1 Connect test gauge to manifold pressure post figure 34 gas valve 2 Ignite unit o...

Page 34: ...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 TABLE 15 Pressure Switch and Gas Conversion Kits at all Altit...

Page 35: ...vide lower return air temperatures shorter settings provide higher return air temperatures Thermostat Heat Anticipation Set the heat anticipator setting if adjustable according to the amp draw listed on the wiring diagram that is attached to the unit NOTE Do not secure the electrical conduit directly to the air ducts or structure HEAT FAN OFF TIME IN SECONDS FIGURE 35 60sec 90sec 120sec 180sec 1 2...

Page 36: ...l 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 S102 high heat prove switch closes and the gas valve energizes second stage heat 9 B3 indoor blower switches to high heat speed Single Stage Thermostat Two Stage Heat Dip Swi...

Page 37: ...1535 580 1305 493 0 30 1840 698 1705 643 1500 551 1305 474 0 40 1770 664 1635 594 1460 517 1280 445 0 50 1665 625 1560 567 1410 483 1225 420 0 60 1585 595 1470 523 1330 451 1190 391 0 70 1470 561 1365 483 1260 421 1115 368 0 80 1355 514 1230 433 1155 392 1020 338 NOTES All air data is measured external to unit without filter not furnished field provided EL280UH110P48C PERFORMANCE Less Filter Exter...

Page 38: ...1640 689 1425 567 NOTES All air data is measured external to unit without filter not furnished field provided EL280UH135P60D PERFORMANCE Less Filter External Static Pressure in w g Air Volume Watts at Different Blower Speeds Bottom Return Air Side Return Air with Optional Return Air Base Return Air from Both Sides or Return Air from Bottom and One Side Single Side Return Air Air volumes in bold re...

Page 39: ...cation is needed WARNING 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 EL280UH filters are installed external to the unit Filters should be inspected monthly Clean or replace the filters when necessary to ensure that the furna...

Page 40: ...eakage 5 Remove the collector box located behind the combus tion air inducer Be careful with the collector box gas ket If the gasket is damaged it must be replaced to prevent leakage 6 Disconnect gas supply piping Remove the screw se curing the burner box cover and remove cover Re move the four screws securing the burner manifold as sembly to the vestibule panel and remove the assembly from the un...

Page 41: ...ector box and combustion air assembly Reinstall all screws to the collector box and combustion air inducer Failure to replace all screws may cause leaks Inspect gaskets for any damage and replace if necessary 17 Reinstall burner box manifold assembly and burner box cover EL280UH NOx INSERTS FIGURE 37 NOx Insert FIGURE 38 Remove 5 screws if necessary either side of cabinet 1 2 3 4 5 18 Reconnect al...

Page 42: ...t nec essary to temporarily shut down the furnace until the items can be repaired or replaced Instruct the homeowners to pay attention to their furnace Situations can arise between annual furnace in spections that may result in unsafe operation For instance items innocently stored next to the furnace may obstruct the combustion air supply This could cause incomplete combustion and the production o...

Page 43: ...RD LOCKOUT CODES 5 1 Hard lockout Rollout circuit open or previously opened 5 2 Control failed self check internal error control will restart if error recovers 5 3 No Earth ground control will restart if error recovers 5 4 Reversed line voltage polarity control will restart if the error recovers 5 6 Low secondary 24VAC voltage Error Code Storage The ignition control stores the last ten error codes...

Page 44: ...T IS CYCLED OFF ON FOR 3 SEC MINIMUM NO YES FIRST LOW STAGE PRESSURE SWITCH CONTACTS OPEN NO GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF CONTROL REMAINS UNTIL PRESSURE SWITCH IS DETECTED OPEN STATUS ERROR CODE 2 4 YES GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF CONTROL WILL NOT ATTEMPT SECOND STAGE OPERATION DURING THIS HEAT DEMAND FIRST STAGE OPERATION WILL BE ATTEMP...

Page 45: ...ONDS AFTER GAS VALVE OPENS u0 20 microamps GAS VALVE OFF COMBUSTION AIR INDUCER ON INDOOR BLOWER OFF STATUS LED HEARTBEAT HAS CONTROL FAILED TO SENSE FLAME FOR FIVE CONSECUTIVE TRIES DURING A SINGLE HEAT DEMAND YES THERMOSTAT CALLS FOR HEAT STATUS LED HEARTBEAT Refer to box A on previous page YES FLAME PRESENT NO HAS CONTROL RESET IGNITION SEQUENCE FOUR 4 TIMES WATCHGUARD MODE STATUS ERROR CODE 4 ...

Page 46: ...FIRST STAGE HEAT DEMAND SATISFIED GAS VALVE OFF COMBUSTION AIR INDUCER OFF FOLLOWING POST PURGE INDOOR BLOWER OFF WITH DELAY STATUS LED PULSE YES SECOND STAGE HEAT DEMAND SECOND STAGE HEAT DEMAND REQUIRED NO SECOND STAGE PRESSURE SWITCH CLOSED ABNORMAL FLASH CODE NOTE IF SECOND STAGE PRESSURE SWITCH WAS ORIGINALLY FOUND CLOSED ABNORMAL CODE WILL FLASH SECOND STAGE PRESSURE SWITCH CLOSED AT BEGINNI...

Page 47: ...MODE DIP SWITCH SET AT SINGLE YES YES FIRST AND SECOND STAGE HEAT DEMAND SATISFIED SIMULTANEOUSLY STATUS LED HEARTBEAT YES GAS VALVE OFF COMBUSTION AIR INDUCER OFF AFTER 5 SECOND LOW SPEED POST PURGE PERIOD INDOOR BLOWER OFF DELAY INITIATED ON LOW HEAT SPEED STATUS LED HEARTBEAT DEMAND FOR HEAT SATISFIED POWER ON STAND BY STATUS LED PULSE YES SECOND STAGE HEAT DEMAND SATISFIED STATUS LED HEARTBEAT...

Page 48: ...IZED NO IS THERE PROPER GROUND YES NO INDOOR BLOWER ENERGIZED ON FIRST STAGE COOL SPEED AFTER 2 SECOND DELAY FIRST STAGE DEMAND FOR COOL SATISFIED NO THERMOSTAT CALLS FOR SECOND STAGE COOL COMPRESSOR AND CONDENSER FAN DE ENERGIZED INDOOR BLOWER DE ENEGIZED YES INDOOR BLOWER RAMPS UP TO SECOND STAGE COOL SPEED SECOND STAGE DEMAND FOR COOL SATISFIED YES UNIT RETURNS TO FIRST STAGE COOL SIGNAL IMPROP...

Page 49: ...S TO LOW HEAT SPEED FIRST STAGE HEAT DEMAND SATISFIED YES NO THERMOSTAT CALLS FOR SECOND STAGE HEAT YES INDOOR BLOWER SWITCHES TO HIGH HEAT SPEED AFTER 30 SECOND RECOGNITION PERIOD SECOND STAGE HEAT DEMAND SATISFIED YES YES INDOOR BLOWER RAMPS DOWN TO LOW HEAT SPEED INDOOR BLOWER RAMPS TO FIRST STAGE COOLING SPEED AFTER A 2 SECOND DELAY FIRST STAGE COOL DEMAND SATISFIED YES NO SECOND STAGE COOL DE...

Page 50: ...ested Supply Line Pressure W C ________ 1 VENT EXHAUST PIPE Secure to Unit Elbows Secured to Pipe Vent Pipe Supported 2 Roof Flashing water tight 3 DUCT SYSTEM SUPPLY AIR DUCT Sealed Insulated if necessary Registers Open and Unobstructed RETURN DUCT Sealed Filter Installed and Clean Grilles Unobstructed 4 5 INTEGRATED CONTROL DIP Switches Set if applicable Appropriate Links in Place if applicable ...

Page 51: ...____ 5 COOLING MODE INDOOR BLOWER AMPS______ 3 TEMPERATURE DROP Return Duct Temperature _________ Supply Duct Temperature _ _______ 4 5 6 7 DRAIN LINE Leak Free THERMOSTAT Adjusted and Programmed Operation Explained to Owner RETURN AIR RETURN AIR SUPPLY AIR 6 7 Blower Motor Amps 3 Thermostat 2 Combustion CO2 Duct Static Gas Manifold Pressure 1 4 5 Temperatures Filter Temperature Drop _________ TOT...