Lennox International Inc. SL280DFV manual

Page 1 06/1 1 *2P0611* 506710−01 *P506710-01*  201 1 Lennox Industries Inc. Dallas, T exas, USA DOWNFLOW AIR FLOW CAUTION As with any mechanical equipment, personal injury can result from cont act with sharp sheet met al edges. Be careful when you handle this equipment. This is a safety alert symbol and should never be ignored. When you see th[...]

Page 2 Unit Dimensions − inches (mm) GAS PIPING INLET (Either Side) FLUE OUTLET (T op) ELECTRICAL INLET (Either Side) RETURN AIR OPENING FRONT VIEW SIDE VIEW TOP VIEW A B C D 3/4 (19) 27 − 3/4 (7705) 19 − 1/4 (489) 6 − 5/8 (168) Right 7 − 1/8 (181) Left 5 − 3/8 (137) Right 2 − 1/8 (54) Left 33 (838) 19 − 7/16 (494) 9/16 (14) B Suppl[...]

Page 3 Part s Arrangement FIGURE 1 BLOWER ASSEMBL Y INTERNAL FLUE PIPE ASSEMBL Y FLUE CHASE GASKET DOOR INTERLOCK SWITCH HEA T EXCHANGER COMBUSTION AIR INDUCER COMBUSTION AIR INDUCER PRESSURE SWITCHES GAS V AL VE BURNER BOX ASSEMBL Y INNER BLOWER ACCESS P ANEL ACCESS P ANEL CONTROL BOX (Includes two−stage integrated control, transformer and circu[...]

Page 4 SL280DFV Gas Furnace The S L280DFV gas furnace is equipped w ith a t wo−stage, variable speed integrated control. the control is compat - ible with: Communicating thermostat s − icomfort T ouch ® . Non−communicating thermostat s − ComfortSense or oth- er conventional thermost ats. Control systems − Harmony III Zone Control Syst[...]

Page 5 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 HEA T or COOL setting. FIGURE 1 AIR HANDLER GAS UNIT Dampers (open during cooling operation only) Dampers (open during heating operation onl[...]

Page 6 D The gas cock must be T handle" type. D Whe n a furnace is installed in an attic, the passage- way to and service area surrounding the equipment shall be floored. W ARNING Product cont ains fiberglass wool. Disturbing the insulation in this product during inst allation, maintenance, or rep air will expose you to fiberglass wool. Bre[...]

Page 7 Confined Sp ace A confined space is an area with a volume less than 50 cu- bic feet (1.42 m 3 ) 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. When the furnace is installed so that supply ducts carry air circulated b y [...]

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 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 . Inst allation on Non−Combustible Flooring (Figure 6) 1 − Cu t floor opening keeping in mind cleara[...]

Page 10 SL280DFV UNIT COOLING COIL PLENUM FIGURE 8 PROPERL Y SIZED FLOOR OPENING Return Air Opening −− Downflow Unit s The following steps should be taken when inst alling ple- num: 1 − Bottom edge of plenum should be flanged with a hemmed edge (See figure 9). SECURE FROM OUTSIDE CABINET HEMMED EDGE PLENUM SEALING STRIP (Field Provided) CABIN[...]

Page 1 1 FIGURE 12 Front Back Horizont al Downflow Application Allow for clearances to combustible materials as indi- cated on the unit nameplate. Minimum clearances for closet or alcove installations are shown in figure 13. Downflow Application Installation Clearances To p Bottom Left Side Right Side T ype of V ent Connector T ype C T ype B1 To p [...]

Page 12 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 si z e and inst all the supply and return air duct system. This will result in a quiet and low-st atic system that has uniform air distribution. [...]

Page 13 FIGURE 15 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 14 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 outdoor[...]

Page 15 18 − The common vent d iameter must a lways be a t least a s large as the largest vent connector diameter . 19 − I n no case, shall the vent connector be sized more than two consecutive table size diameters over the size of the draft hood outlet or flue collar outlet. 20 − Do not install a manual damper , barometric draft regu- lator [...]

Page 16 T ABLE 6 Cap acity of T ype B Double−W all 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 12[...]

Page 17 T ABLE 7 V ent Connector Capacity T ype B Double−W all V ents with T ype B Double−Wall 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 MIN[...]

Page 18 T ABLE 9 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 NR NR[...]

Page 19 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 att ached appliances. Conduct t he following test w hile each a ppliance is o perat - ing a nd t he o ther a [...]

Page 20 T ABLE 1 1 Gas Pipe Cap acity − f t 3 /hr (m 3 /hr) Nominal Iron Pipe Size inches (mm) Internal Diameter inches (mm) Length of Pipe − feet (m) 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) 175 (4.96) 120 (3.40) 97 (2.75) 82 (2.32) 73 (2.07) [...]

Page 21 Leak Check After gas piping is completed, carefully check all piping connections (f ac t ory− and field−installed) 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 22 2 − Holes are on both sides of the furnace cabinet to facili- tate wiring. 3 − Install a sep arate (properly sized) disconnect switch near the furnace so that power can be turned off for servicing. 4 − Before connecting the thermostat or the power wiring, check to make sure the wires will be long enough for servicing at a later date. [...]

Page 23 Generator Use − V olt age Requirement s The following requirements must be kept in mind when specifying a generator for use with this equipment:  The furnace requires 120 volts (Range: 102 volts to 132 volts)  The furnace operates at 60 Hz + 5% (Range: 57 Hz to 63 Hz)  The furnace integrated control requires both correct polarity[...]

Page 24 FIGURE 22 Optional Accessories for use with any icomfort T ouch ® System NOTE: 24V UV LIGHT APPLICA TIONS In an icomfort by Lennox  system, neither furnace nor air handler trans- former will have adequate V A to power 24V UV light applications. An additional transformer for UV light applications is required. icomfort T ouch ® THERMOST [...]

Page 25 T ABLE 13 SL280 Field Wiring Applications With Conventional Thermost at Thermost at DIP Switch Settings and On−Board Links (See figure 25) Wiring Connections DIP Switch 1 Thermost at Heating St ages On Board Links Must Be Cut T o Select System Options 1 Heat / 1 Cool NO TE − Us e DIP switch 2 to set second−stage heat ON delay . OFF−[...]

Page 26 T ABLE 13 SL280 Field Wiring Applications With Conventional Thermost at (Continued) Thermost at DIP Switch Settings and On−Board Links (See figure 25) Wiring Connections DIP Switch 1 Thermost at Heating St ages On Board Links Must Be Cut T o Select System Options 2 Heat / 2 Cool OFF CUT ON−BOARD LINK W915 2 ST AGE COMPR S1 T’STAT FURN[...]

Page 27 T ABLE 13 SL280 Field Wiring Applications With Conventional Thermost at (Continued) Thermost at DIP Switch Settings and On−Board Links (figure 25) Wiring Connections DIP Switch 1 Thermost at Heating St ages On Board Links Must Be Cut T o Select System Options Dual Fuel Single S t age Heat Pump ComfortSense 7000 L7724U thermostat w/ dual f[...]

Page 28 T ABLE 13 SL280 Field Wiring Applications With Conventional Thermost at (Continued) Thermost at DIP Switch Settings and On−Board Links (figure 25) Wiring Connections DIP Switch 1 Thermost at Heating St ages On Board Links Must Be Cut T o Select System Options Dual Fuel Single S t age Heat Pump ComfortSense 7000 L7724U thermostat w/ dual f[...]

Page 29 SL280DFV Schematic Wiring Diagram FIGURE 23[...]

Page 30 TYPICAL SL280DFV FIELD WIRING DIAGRAM FIGURE 24 FIELD INST ALLED CLASS II 24V FIELD INST ALLED LINE VOL T AGE[...]

Page 31 Integrated Control FIGURE 25 THERMOST A T CONNECTIONS (TB1) 1/4" QUICK CONNECT TERMINALS RS−BUS LINK (TB82, future use) I+ = DA T A HIGH CONNECTION I − = DA T A LOW CONNECTION RS−BUS OUTDOOR (TB83) R = 24V AC I + = DA T A HIGH CONNECTION I − = DA T A LOW CONNECTION C = 24V AXC COMMON RS−BUS INDOOR (TB84) R = 24V AC I + = DA T[...]

Page 32 Integrated Control DIP Switch Settings − Conventional Thermost at (non−communi- cating) SL280DFV units are equipped with a two−st age, variable speed integrated control. This control manages ignition timing, heating mode fan off delays and indoor blower speeds based on selections made using the control dip switches and jumpers. The co[...]

Page 33 NOTE − The off portion of the selected ramp profile also ap- plies during heat pump operation in dual fuel applications. T ABLE 17 Cooling Mode Blower Speed Ramping Ramping Option Switch 9 Switch 10 A (Factory) Off Of f B Off On C On Off D On On Ramping Option A (Factory Selection)  Motor runs at 50% for 30 seconds.  Motor then runs[...]

Page 34 On−Board Links Note: In icomfort t systems with a conventional outdoor unit (non−communicating), the on−board clippable links must be set to properly configure the system W ARNING Carefully review all configuration information pro- vided. Failure to properly set DIP switches, jumpers and on−board links can result in improper operati[...]

Page 35 BLO WER D A T A SL280DF070V36A BLOWER PERFORMANCE (less lter) 0 through 0.8 in. w .g. (Heating) and 0 through 1.0 in. w .g. (Cooling) External Static Pressure Range HEA TING 1 Heating Speed DIP Switch Settings First Stage Heating Speed - cfm Second Stage Heating Speed - cfm +24% 1065 1 170 +18% 1010 111 5 +12% 960 1055 +6% 910 1000 Facto[...]

Page 36 BLO WER D A T A SL280DF090V60C BLOWER PERFORMANCE (less lter) 0 through 0.8 in. w .g. (Heating) and 0 through 1.0 in. w .g. (Cooling) External Static Pressure Range HEA TING 1 Heating Speed DIP Switch Settings First Stage Heating Speed - cfm Second Stage Heating Speed - cfm +24% 1540 1695 +18% 1465 1615 +12% 1390 1530 +6% 1320 1450 Facto[...]

Page 37 T ABLE 20 SL280DFV , Non−Communicating Thermostat with Humidity Control Feature and Single−S peed Out door Unit OPERA TING SEQUENCE SYSTEM DEMAND SYSTEM RESPONSE System Condition S tep Thermostat Demand Relative Humidity Compressor Blower CFM (COOL) Comments Y1 O G W 1 S t atus D NO CALL FOR DEHUMIDIFICA TION Normal Operation 1 On On On[...]

Page 38 T ABLE 21 SL280DFV , Non−Communicating Thermostat with Humidity Control Feature and T wo−Speed Out door Unit OPERA TING SEQUENCE SYSTEM DEMAND SYSTEM RESPONSE System Condition S tep Thermostat Demand Relative Humidity Compressor Blower CFM (COOL) Comments Y1 Y2 O G W 1 W 2 S t atus D NO CALL FOR DEHUMIDIFICA TION Normal Operation − Y1[...]

Page 39 Unit St art−Up FOR YOUR SAFETY READ BEFORE LIGHTING W ARNING D o not use this furnace if any part has been underwa- ter . Immediately call a licensed professional service technician (o r equivalent) to inspect the furnace and to replace any part of the control system and any gas control which has been under water . W ARNING If overheating[...]

Page 40 12− If the appliance will not operate, follow the instructions T urning Off Gas to Unit" and call your service techni- cian or gas supplier . T urning Off Gas to Unit 1 − Set the thermostat to the lowest setting. 2 − Tur n of f all electrical power to the unit if service is to be performed. 3 − Remove the upper access panel.[...]

Page 41 High Altitude The manifold pressure, gas orifice and pressure switch may require adjustment or replacement to ensure proper operation at higher altitudes. T ables 24 through 27 shows manifold pressure, pressures switch and gas conversion kits at all altitudes. IMPORT ANT For safety , shut unit off and remove manometer as soon as an accurate[...]

Page 42 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 t h e b l ower comp artment, att ached to the back side of the blower . These limits are factory set and require no adjustment. Flame Rollout Switch This manually [...]

Page 43 Applications Using A Single−St age Thermost at See figure 29 for ignition control sequence B − Heating Sequence −− Control Thermost at Selection DIP Switch 1 ON in Single−St age" Position NOTE − In these applications, two−stage heat will be initi- ated by the integrated control if heating demand has not been satisfied [...]

Page 44 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 45 SL280DFV BURNER, COMBUSTION AIR INDUCER ASSEMBL Y & HEA T EXCHANGER REMOV AL FIGURE 30 heat exchanger gasket collector box orifice plate internal flue pipe pressure switch combustion air inducer burners burner box assembly burner box cover plate manifold and gas valve gasket retention rings cross over heat exchanger gasket collector box[...]

Page 46 12 − T o clean the combustion air inducer visually inspect and using a wire brush clean where necessary . Use com- pressed air to clean off debris and any rust. 13− Reinstall heat exchanger in vestibule. (Replace the five screws in the cabinet from step 10 if removed). 14− Reinstall collector box, combustion air assembly , inter- nal [...]

Page 47 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 b e i ns[...]

Page 48 Integrated Control Diagnostic Modes Display Action (when button released) No change (idle)* Remain in idle mode Solid E" Enter diagnostic recall mode Solid D" Discharge Air Installed Solid F" Enter flame signal mode Solid P" (variable speed only) Program unit capacity/size (Unit Code)** * No change implies th[...]

Page 49 Integrated Control Diagnostic Codes (continued) Code Diagnostic Codes/S t atus of Equipment Action Required to Clear and Recover E 105 Device communication problem − No other devices on RS BUS (Commu- nication system). Equipment is unable to communicate. Indicates numerous message errors. In most cases errors are related to electrical noi[...]

Page 50 Integrated Control Diagnostic Codes (continued) E 131 Corrupted control parameters (V erify configuration of system). Communi- cating only . Reconfigure the system. Replace control if heating or cooling is not available. Only applicable in the communicating mode, not in startup. Exit from Com- missioning and Execute ’Set Factory Default m[...]

Page 51 Integrated Control Diagnostic Codes (continued) Code Diagnostic Codes/S t atus of Equipment Action Required to Clear and Recover E 223 Low pressure switch failed open. Check pressure (inches w .c.) of low pressure switch closing on heat call. Measure operating pressure (inches w .c.). Inspect vent and combustion air in- ducer for correct op[...]

Page 52 Integrated Control Diagnostic Codes (continued) E 272 Sof t lockout − Exceeded maximum number of recycles. Last recycle due to the pressure switch opening. Check operation of low pressure switch to see if it is stuck closed on heat call. Check pressure (inches w .c.) of high pressure switch closing on heat call. Measure operating pressure[...]

Page 53 Integrated Control Diagnostic Codes (continued) Code Diagnostic Codes/S t atus of Equipment Action Required to Clear and Recover E 312 Restricted air flow in cooling or continuous fan mode is lower than cfm setting. W arning Only . Restricted airflow − Indoor blower is running at a reduced CFM (Cutback Mode − The variable speed motor ha[...]

Page 54 Integrated Control Diagnostic Codes (continued) E 406 LSOM − Compressor open st art circuit. Required amount of current is not passing through S t art current transformer . Clears the error after cur- rent is sensed in ST ART sensor , or after power re- set. E 407 LSOM − Compressor open run circuit. Required amount of current is not pas[...]

Page 55 Program Unit Cap acity/Size Mode Power−Up − Number displayed represents by integrated control unit size code (furnace model and capacity). If three horizont al bars are displayed followed by continuous E203, furnace control does not recognize unit size code. Configure per the following: Furnace control in IDLE mode No heating, cooling o[...]

Page 56 T roubleshooting: Heating Sequence of Operation HIGH LIMIT SWITCH CLOSED? LOW PRESSURE SWITCH OPEN? INDUCER ON PRE − PURGE (15 SECONDS) 1ST ST AGE GAS V AL VE ENERGIZED FLAME SENSED WITHIN 4 SECONDS? (LOW HEA T SPEED) HEA T F AN OFF DELA Y (LOW HEA T SPEED) AFTER HEA T F AN OFF DELA Y (LOW HEA T SPEED) YES YES YES YES ERROR CODE FLASHES O[...]

Page 57 T roubleshooting: Heating Sequence of Operation (Continued) WHEN USED WITH A SINGLE ST AGE THERMOSTA T , SET SW1 TO THE ON POSITION IN DIP SWITCH S4. IF THE HIGH FIRE PRESSURE SWITCH DOES NOT CLOSE WITHIN 5 A TTEMPTS, THE SYSTEM WILL OPERA TE A T LOW FIRE FOR THE REMAINDER OF THE CALL FOR HEA T REQUEST . 2ND ST AGE GAS V ALVE ENERGIZED ONL [...]

Page 58 T roubleshooting: Heating Sequence of Operation (Continued) 2ND ST AGE HEA T RUN MODE: 1ST OR 2ND ST AGE CALL FOR HEA T . ALL INPUTS MONITORED (LIMIT , PRESSURE, CALL FOR HEA T/COOL, FLAME LEVEL) 2ND ST AGE CALL FOR HEA T SA TISFIED? NO YES DE − ENERGIZE 2ND ST AGE GAS V AL VE INDUCER SPEED SWITCHED TO LOW SPEED 1 2 3 1ST ST AGE HEA T 1ST[...]

Page 59 T roubleshooting: Cooling Sequence of Operation (Continued) 1ST ST AGE COOLING REQUEST RECEIVED ENERGIZE 1ST ST AGE COOLING CONT ACTOR (COMPRESSOR & F AN) 2ND ST AGE COOLING REQUEST? NO YES YES YES NO 1ST ST AGE COOLING REQUEST STILL ACTIVE? NO YES YES ENERGIZE 2ND ST AGE COOLING CONT ACTOR (COMPRESSOR & F AN) DE − ENERGIZE 2ND ST[...]

Page 60 T roubleshooting: Continuous Fan Sequence of Operation CALL FOR F AN CALL FOR F AN REMOVED? YES NO NO REQUEST FOR HEA T RECEIVED? REQUEST FOR COOLING RECEIVED? GO TO CALL FOR 1ST ST AGE HEA T YES GO TO CALL FOR COOLING 1 1 1 4 YES NO CALL FOR FAN INDOOR BLOWER ON CONTINUOUS F AN SPEED MAINT AIN INDOOR BLOWER A T CONTINUOUS F AN MAINT AIN IN[...]