Lennox International Inc. Elite Series Gas Furnace Upflow/Horizontal Air Discharge manual

Page 1 02/12 *2P0212* 506894−01 *P506894-01* E 2012 Lennox Industries Inc. Dallas, T exas, USA UPFLOW HORIZONT AL LEFT HORIZONT AL RIGHT AIR FLOW AIR FLOW AIR FLOW INST ALLA TION INSTRUCTIONS EL280UH ELITE ® SERIES GAS FURNACE UPFLOW / HORIZONT AL AIR DISCHARGE 506894−01 02/2012 THIS MANUAL MUST BE LEFT WITH THE HOMEOWNER FOR FUTURE REFERENCE [...]

Page 2 Unit Dimensions − inches (mm) AIR FLOW 23 (584) (19) 3/4 (19) 1 Bottom Return Air Opening GAS PIPING INLET (Either Side) Side Return Air Opening (Either Side) 1 Bottom Return Air Opening FLUE OUTLET (T op) ELECTRICAL INLET (Either Side) SUPPL Y AIR OPENING FRONT VIEW SIDE VIEW TOP VIEW A B 9/16 (14) C D 3/4 27 − 3/4 (705) 19 − 7/16 (49[...]

Page 3 Part s Arrangement FIGURE 1 Combustion Air Pressure Switch Combustion Air Inducer Gas V alve 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 T ransformer Door Int[...]

Page 4 EL280UH Gas Furnace The EL280UH unit is shipped ready for installation in the upflow or h orizontal r ight position (for h orizontal lef t posi - tion the combustion a ir pressure s witch must be moved). The f urnace is s hipped with the bottom p anel in place. The b o t t o m pan e l mu s t b e re m o v e d if t h e un i t is to be in s t a[...]

Page 5 Inst alled in Combination with a Cooling Coil When this furnace is used with cooling units, it shall be installed in parallel with, o r on the up stream side o f, cooling units to avoid condensation in the heating compartment. See f igure 2. W ith a p arallel f low arrangement, a d amper (or other means t o control t he flow o f air) must a [...]

Page 6 D Do not install the f urnace where drafts might blow direct- ly into it. This could cause improper combustion and un- safe operation. D Do not block the furnace combustion air openings with clothing, boxes, doors, etc. Air is needed for proper combustion and safe unit operation. D When the furnace is installed in an attic or other insu- lat[...]

Page 7 Unconfined Sp ace An unconfined space is an area such as a basement or large equipment room with a volume greater than 50 cubic feet (1.42 m 3 ) 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 b y a door . Though an area [...]

Page 8 EQUIPMENT IN CONFINED SP ACE ALL AIR FROM OUTSIDE (Inlet Air from Crawlspace and Outlet Air to V entilated Attic) NOTE−The inlet and outlet air openings shall each have a free area of at least one square inch (645 mm 2 ) per 4,000 Btu (1.17 kW) per hour of the tot al input rating of all equipment in the enclosure. VENTILA TION LOUVERS (Eac[...]

Page 9 Setting Equipment W ARNING Do not inst all the furnace on its front or it s back. Do no t connect the return ai r ducts to the back of the fur- nace. Doing so will adversely affect the operation of the safety control devices, which could result in per- sonal injury or death. The E L280UH gas furnace can be inst alled as shipped in either the[...]

Page 10 Return Air −− Up flow Applications Return air can be brought in through the b ottom or either side o f t he furnace i nstalled in a n u pflow a pplication. I f the furnace i s installed on a plat form w ith b ottom r eturn, m ake an a irtight s eal between the bottom of t he f urnace and the platform to ensure t hat t he f urnace o pera[...]

Page 1 1 Removing the Bottom Panel Remov e the two screws that secure the bottom cap to the furnace. Pivot the bottom cap down to release the bottom panel. Once the bottom p anel has been removed, reinstall the bottom cap. See figure 1 1. Removing the Bottom Panel FIGURE 1 1 Screw Bottom Panel Bottom Cap Horizontal Application Installation Clearanc[...]

Page 12 Horizontal Application Unit Installed on Plat form FIGURE 14 clearances. GAS ENTRY VENT PIPE See the unit nameplate for Line contact is permissible but not preferred SERVICE PLA TFORM W ARNING Improper inst allation of the f urnace can result in per- sonal injury or death. Combustion and flue products must never be allowed to enter the retu[...]

Page 13 V enting A 4−inch diameter flue transition is factory-installed on the combustion air inducer outlet of all models. Figure 16 shows the combustion air inducer as shipped from the factory . FIGURE 15 Mounting Screws Location Mounting Screws UPFlow Position FIGURE 16 UPFLOW POSITION T op V ent Discharge FLOW AIR Pressure Switch Flue T ransi[...]

Page 14 Horizontal Position FIGURE 19 HORIZONT AL LEFT POSITION T op V ent Discharge S Disconnect pressure switch hose from barbed fitting on the pres- sure switch assembly . Remove pressure switch assembly (1 screw) and cut wire tie to free pressure switch wires. Re−install pressure switch on the other side of orifice plate and re−connect pres[...]

Page 15 The EL280UH series units are classified as fan−assisted Category I furnaces when vertically vented according to the latest edition of National Fuel Gas Code (NFP A 54 / ANSI Z223.1) in the USA. A fan−assisted Category I fur- nace is a n appliance equipped with an integral mechanical means to either draw or force combustion products thro[...]

Page 16 FIGURE 24 Common V enting Using Met al−Lined Masonry Chimney 4 in. (102 mm) minimum MIN. LENGTH −− AS SHORT AS PRACTICAL MAX. LENGTH −− SEE NOTE 1 BELOW . SEALED PERMANENTL Y SEALED FIREPLACE OPENING EXTERIOR CHIMNEY WITH MET AL LINER VENT CONNECTOR NOTE 1 − Refer to the provided venting tables for installations. Refer to the ca[...]

Page 17 FIGURE 25 Common V enting Using Tile−Lined Interior Masonry Chimney and Combined V ent Connector 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. PERMANENTL Y SE[...]

Page 18 16 − V ent connectors serving Category I appliances shall not be connected to any portion of mechanical draft systems operating under positive pressure such as Category III or IV venting systems. 17 − If vent connectors are combined prior to entering the common vent, the maximum common vent capacity listed i n t he c ommon v enting tabl[...]

Page 19 T ABLE 4 Cap acity of T ype B Double−Wall V ents with Single−W all Metal Connectors Serving a Single Category I Appliance Height H (feet) Lateral L (feet) V ent 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 38 77 59 151 85 249 126[...]

Page 20 T ABLE 5 V ent Connector Capacity T ype B Double−W all V ents with T ype B Double−W all Connectors Serving T wo or More Category I Appliances V ent Height H (feet) Connector Rise R (feet) V ent 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 MI[...]

Page 21 T ABLE 7 V ent Connector Capacity T ype B Double−W all V ents with Single−W all Metal Connectors Serving T wo or More Category I Appliances Height H (feet) Lateral L (feet) V ent 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 1 NA NA[...]

Page 22 Removal of the Furnace from Common V ent 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 t he f ollowing test w hile e ach a ppliance i s operat - ing a nd the other app[...]

Page 23 Gas Piping Gas s upply p iping s hould n ot a llow m ore t han 0 .5"W .C. d rop in pressure between gas meter and unit. Supply gas pipe must not be smaller than unit gas connection. CAUTION If a flexible gas connector is required or allowed by the authority that has jurisdiction, black iron pipe shall be in st alled at the gas valve an[...]

Page 24 GROUND JOINT UNION AUTOMA TIC GAS V AL VE FIELD PROVIDED AND INST ALLED GROUND JOINT UNION Lef t Side Piping (St andard) Right Side Piping (Alternate) AUTOMA TIC GAS V AL VE DRIP LEG DRIP LEG MANUAL MAIN SHUT−OFF VA LV E (With 1/8 in. NPT Plugged T ap Shown) MANUAL MAIN SHUT−OFF VA LV E (With 1/8 in. NPT Plugged T ap Shown) NOTE − BLA[...]

Page 25 Leak Check After gas piping is completed, carefully check all piping connections (f act ory− and field−inst alled) for gas leaks. Use a leak detecting solution or other preferred means. NOTE − I f emergency shutoff is necessary , shut off the main manual gas valve and disconnect the main power to the furnace. The installer should prop[...]

Page 26 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 the provided unit wiring diagram and the field wiring diagram shown in fi gu[...]

Page 27 T ABLE 10 Field Wiring Applications Thermost at DIP Switch Settings and On−Board Links (See figure 33) Wiring Connections DIP Switch 1 W915 T wo−St age Cooling W951 Heat Pump s 1 Heat / 1 Cool NO TE − Use DI P switch 2 to set sec - ond−stage heat ON delay . OFF10 minutes. ON−15 minutes. ON Intact Intact S1 T’STAT CONTROL TERM. S[...]

Page 28 T ABLE 10 Field Wiring Applications (Continued) Thermost at DIP Switch Settings and On−Board Links (See figure 33) Wiring Connections DIP Switch 1 W915 T wo−St age Cooling W951 Heat Pump s 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[...]

Page 29 FIGURE 3 1 120V EAC F ACTORY DEFAUL T IS FOR A 2 ST AGE THERMOST A T 9 9 1 2 3 4 5 6 7 8 9 10 11 12 TERMINAL #1 IS USED FOR ERROR CODE RECALL ONL Y . SEE INST ALLA TION INSTRUCTIONS FOR DET AILS. K1 K4 K9 K6 K8 HI HEA T LO HEA T K10 K11 24V POWER IS PROVIDED FOR OPTIONAL HUMIDIFIER DURING HEA T DEMAND 2011 EL280UH110P60C EL280UH135P60D EL28[...]

Page 30 TYPICAL EL280UH FIELD WIRING DIAGRAM FIGURE 32 FIGURE 33 TWO−ST AGE INTEGRA TED CONTROL THERMOST A T CONNECTIONS (TB1) 1/4" QUICK CONNECT TERMINALS DIP SWITCH FUNCTIONS DIP SWITCHES DIAGNOSTIC LEDs ON−BOARD LINKS 1= ERROR CODE RECALL H= 24V HUMIDIFIER OUTPUT L= LENNOX SYSTEM OPERA TION MONITOR SENSE = 120 V AC OUTPUT TO FLAME SENSO[...]

Page 31 Integrated Control EL280UH units are equipped with a two−st age integrated control. This control manages ignition timing and fan off delays based on selections made using the control DIP switches. The control includes an internal watchguard fea- ture which automatically resets the integrated control when it has been locked out. After one [...]

Page 32 Unit St art−Up FOR YOUR SAFETY READ BEFORE LIGHTING W ARNING Do not use this furnace if any part has been under- water . A flood−damaged furnace is extremely dan- gerous. Attempt s to use the furnace can result in fire or explosion. Immediately call a qualified ser- vice t echnician t o inspect the f urnace and to r eplace all g as cont[...]

Page 33 9 − Is t he u nit i gnition s ystem i n lock out? If the u nit l ocks o ut again, call the service technician to inspect the unit for blockages. 10 − Is pressure switch closed? Obstructed flue will cause unit t o shut of f a t pressure switch. Check flue and outlet for blockages. 1 1 − Are flame rollout switches tripped? If flame roll[...]

Page 34 T ABLE 14 Manifold Pressure Settings at all Altitudes Unit Input Gas Manifold Pressure in.wg. 0−4500 ft. Manifold Pressure in.wg. 4501−7500 ft. 1 Manifold Pressure in.wg. 7501 − 10,000 ft. 2 Supply Line Pressure in. w .g. Low Fire High Fire Low Fire High Fire Low Fire High Fire Min Max 070 Natural 1.7 3.5 1.6 3.4 1.7 3.5 4.5 13.0 LP/p[...]

Page 35 Other Unit Adjustment s Primary and Secondary Limit s The primary limit is located on the heating compartment vestibule panel. The secondary limits (if equipped) are lo- cated in th e b l ower comp artment, att ached to the back side of the blower . These auto reset limits are factory−set and re - quire no adjustment. Flame Rollout Switch[...]

Page 36 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 contact s. The control also checks for S102 high heat and S128 low heat prove switch normally open contact s. Once self check is compl[...]

Page 37 BLOWER DA T A EL280UH070P24A PERFORMANCE (Less Filter) External Static Pressure in. w .g. Air V olume / Watts at V arious Blower Speeds High Medium Low cfm W atts cfm Watts cfm W atts 0.10 1 135 439 990 369 845 299 0.20 111 5 429 975 358 820 289 0.30 1085 410 955 348 790 279 0.40 1045 389 925 335 775 270 0.50 1015 374 885 321 735 260 0.60 9[...]

Page 38 BLOWER DA T A EL280UH1 10P60C PERFORMANCE (Less Filter) External Static Pressure in. w .g. Air V olume / 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 require eld fabricat[...]

Page 39 Service W ARNING 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 fur[...]

Page 40 Cleaning the Heat Exchanger and Burners NOTE − Use p apers or protective covering in front of the fur- nace during cleaning. 1 − T urn off both electrical and gas power supplies to fur- nace. 2 − Remove flue pipe and top cap (some applications top cap can remain ) from the unit. 3 − Label the wires from gas valve, rollout switches, [...]

Page 41 9 − Remove screws from both sides, top and bottom of vestibule panel. 10 − Remove heat exchanger . It may be necessary to spread cabinet side to allow more room. If so, remove five screws from the left side or right side of cabinet. See figure 38. 1 1 − Backwash using steam. Begin from the burner opening on each clam. S team must not [...]

Page 42 Planned Service Th e following items should be checked during an annual inspection. Power to the unit must be shut of f for the service techni- cian’s safety . Fresh air grilles and louvers (on the unit and in the room where the furnace is installed) − Must be open and unob- structed to provide combustion air . Burners − Must be i nsp[...]

Page 43 Integrated Control Diagnostic Codes FLASH CODE (X + Y) ST A TUS / ERROR DESCRIPTION FLASH CODE DESCRIPTIONS Pulse A 1/4 second flash followed by four seconds of off time. Heartbeat Constant 1/2 second bright and 1/2 second dim cycles. X + Y LED flashes X times at 2Hz, remains off for two seconds, flashes Y times at 2Hz, remains off for four[...]

Page 44 T roubleshooting: Heating Sequence of Operation HEA TING SEQUENCE OF OPERA TION NORMAL AND ABNORMAL HEA TING MODE CONTROL SELF−CHECK OKA Y? YES GAS V AL VE OFF . COMBUSTION AIR INDUCER OFF . INDOOR BLOWER OFF . (RESET CONTROL BY TURNING MAIN POWER OFF .) NO POLARITY REVERSED. ST A TUS ERROR CODE 5 + 4. POWER ON POLARITY OKA Y? SIGNAL HOLD[...]

Page 45 T roubleshooting: Heating Sequence of Operation (Continued) HEA TING SEQUENCE OF OPERA TION FIRST−ST AGE (LOW FIRE) PRESSURE SWITCH CLOSED WITHIN 2.0 MINUTES? GAS V AL VE OFF . COMBUSTION AIR INDUCER OFF . INDOOR BLOWER OFF . UNIT WILL RETRY AFTER 5−MINUTE W AIT PERIOD. ST A TUS ERROR CODE 2 + 3. YES NO 15−SECOND COMBUSTION AIR INDUCE[...]

Page 46 T roubleshooting: Heating Sequence of Operation (Continued) HEA TING SEQUENCE OF OPERA TION LOW FLAME SIGNAL (Does not affect control operation) ST A TUS ERROR CODE 1 + 2. FLAME SIGNAL ABOVE ( u 1.40 microamps) NO YES CONTINUED ON NEXT P AGE YES SINGLE−ST AGE THERMOST A T MODE (DIP SWITCH SET A T SINGLE") TWO ST AGE THERMOST A T M[...]

Page 47 T roubleshooting: Heating Sequence of Operation (Continued) HEA TING SEQUENCE OF OPERA TION SEE BOX B THERMOST A T CALLS FOR HEA T . SEE BOX A NORMAL OPERA TION. YES NO RETURN TO FIRST−ST AGE HEA T MODE. FIRST−ST AGE CONTINUES UNTIL SECOND− ST AGE PRESSURE SWITCH CAN BE PROVEN or HEA T DEMAND IS SA TISFIED. A FIVE (5) MINUTE W AIT PER[...]

Page 48 T roubleshooting: Cooling Sequence of Operation COOLING SEQUENCE OF OPERA TION SIGNAL POLARITY REVERSED. CONTROL WILL CONTINUE TO CALL FOR COOLING IN THIS CONDITION. ST A TUS ERROR CODE 5 + 4. POWER ON YES IS POLARITY REVERSED? THERMOST A T CALLS FOR FIRST−ST AGE COOL. COMPRESSOR AND CONDENSER F AN ENERGIZED. NO IS THERE PROPER GROUND? YE[...]

Page 49 T roubleshooting: Continuous Fan Sequence of Operation CONTINUOUS LOW SPEED F AN SEQUENCE OF OPERA TION MANUAL F AN SELECTION MADE A T THERMOST A T . AFTER 2 SECOND DELA Y , INDOOR BLOWER IS ENERGIZED ON CONTINUOUS F AN SPEED. THERMOST A T CALLS FOR FIRST−ST AGE HEA T . THERMOST A T CALLS FOR FIRST ST AGE COOL. YES YES AFTER 45−SECOND D[...]

Page 50 St art−Up & Performance Check List Unit Model Number_______________ Serial Number___________________ UNIT SET UP (typical) Gas Supply Pressure 1 2 2 1 SUPPL Y AIR Line V oltage 3 4 5 Filter RETURN AIR RETURN AIR GAS SUPPL Y Natural Gas LP/Propane Gas Piping Connections Tight Leak T ested Supply Line Pressure  W .C.________ 1 VENT /[...]

Page 51 Contractor’s: Name_________________________T elephone_____________Checklist Completed____________________ Job Address_____−________________________________T echnician’s Name___________________________________ UNIT OPERA TION (typical) 1 HEA TING MODE GAS MANIFOLD PRESSURE W .C._____ COMBUSTION SAMPLE CO 2 % ______ CO PPM_______ 2 I[...]