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S e r v i c e L i t e r a t u r e
EL280DFEK series units are 80% efficiency gas furnaces
used for downflow applications only, manufactured with
Lennox Duralok heat exchangers formed of aluminized
steel. Units are available in heating capacities of 66,000 to
88,000 Btuh and cooling applications up to 4 tons. Refer
to Engineering Handbook for proper sizing.
Units are factory equipped for use with natural gas. Kits
are available for conversion to LPG operation. EL280DFE
model units are equipped with the SureLight® integrated
control. All units use a redundant gas valve to assure safe-
ty shut-off as required by CSA.
All specifications in this manual are subject to change.
Procedures outlined in this manual are presented as a
recommendation only and do not supersede or replace lo-
cal or state codes. In the absence of local or state codes,
the guidelines and procedures outlined in this manual (ex-
cept where noted) are recommendations only and do not
constitute code.
WARNING
Improper
installation,
service or maintenance can cause property damage,
personal injury or loss of life. Installation and service
must
be performed by a licensed professional
HVAC installer or equivalent, service agency, or the
gas supplier.
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 2
Blower Performance Data . . . . . . . . . . . . . . . . . . Page 3
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . Page 4
I Unit Components . . . . . . . . . . . . . . . . . . . . . . . . Page 5
IInstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 20
III Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 20
IV Heating System Service Checks . . . . . . . . . Page 22
V Typical Operating Characteristics . . . . . . . . . Page 24
VI Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . Page 25
VII Low GWP Applivcation . . . . . . . . . . . . . . . . . . . . Page 28
VIII Wiring and Sequence of Operation . . . . . . Page 31
IX Field Wiring and DIP Switch Settings . . . . Page 34
X Troubleshooting Flow Chart . . . . . . . . . . . . . Page 38
UNIT INFORMATION
UNIT INFORMATION
100167
EL280DFEK With R454B SERIES UNITS
adjustment,
alteration,
Electric shock hazard. Can cause injury
or death. Before attempting to perform
any service or maintenance, turn the
electrical power to unit OFF at disconnect
switch(es). Unit may have multiple power
supplies.
As with any mechanical equipment, contact with
sharp sheet metal edges can result in personal
injury. Take care while handling this equipment and
wear gloves and protective clothing.
This furnace is equipped with an ignition control
factory enabled for use with Lennox A2L refrigerant
systems.
Disabling
functionality on A2L system is prohibited by safety
codes. Refer to furnace installation instructions for
non-A2L and non-Lennox refrigerant system setup.
Page 1
EL280DFEK
C C C C
I I I I
HI
HI
WARNING
CAUTION
WARNING
the
refrigerant
detection
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Summary of Contents for Lennox EL280DFEK
- Page 1 S e r v i c e L i t e r a t u r e EL280DFEK With R454B SERIES UNITS EL280DFEK series units are 80% efficiency gas furnaces used for downflow applications only, manufactured with Lennox Duralok heat exchangers formed of aluminized steel.
- Page 2 SP EC IF ICAT IO NS Model EL280DF070E36AK EL280DF090E48BK Heating AFUE Performance High Input - Btuh 66,000 88,000 Fire Output - Btuh 52,000 69,000 Temperature rise range - °F 30 - 60 35 - 65 Gas Manifold Pressure (in. w.g.) 3.5 / 10.0 3.5 / 10.0 Nat.
- Page 3 BLOWER DATA EL280DF070E36AK PERFORMANCE (Less Filter) Air Volume / Watts at Various Blower Speeds External Static High Medium-High Medium Medium-Low Pressure (Black) (Brown) (Blue) (Yellow) (Red) in. w.g. Watts Watts Watts Watts Watts 0.10 1426 1298 1158 0.20 1406 1275 1132 0.30 1362...
- Page 4 PARTS IDENTIFICATION Top Cap Secondary Limit Indoor Blower Control Box (includes integrated control, transformer and door switch) Internal Flue Pipe Assembly Heat Exchanger Combustion Air Inducer Burner Box Assembly Primary Limit Gas Valve Access Panel FIGURE 1 Page 4...
- Page 5 I-UNIT COMPONENTS 3. Circuit Breaker (CB8) A 24V circuit breaker is also located in the control box. Unit components are shown in FIGURE 1. The gas valve, The switch provides overcurrent protection to the trans- combustion air inducer and burners can be accessed by former (T1).
- Page 6 Electronic Ignition The unit will switch to second stage heat after a “recog- nition period”. DIP switch 2, labeled SECOND STAGE At the beginning of the heat cycle the integrated control DELAY, is factory set in the OFF position for a 7 minute monitors the first stage and second stage combustion air recognition period.
- Page 7 TWO STAGE CONSTANT TORQUE, NON-COMMUNICATING 107897-XX FIGURE 4 TABLE 2 TABLE 3 THERMOSTAT INPUT TERMINALS LOW GWP INTERFACE LOW STAGE HEAT LGWP1 LOW GWP SENSOR #1 INTERFACE HIGH STAGE HEAT LGWP2 LOW GWP SENSOR # 2 INTERFACE ALARM INTERFACE TO LOW GWP LEAK AUDIBLE ALARM (DRY CONTACT) LOW STAGE COOL (when W915 is clipped) ZONE...
- Page 8 TABLE 4 DIAGNOSTIC CODES / STATUS OF FURNACE CODE IDLE MODE (DECIMALBLINKS AT 1 HERTZ -- 0.5 SECONDS ON, 0.5 SECONDS OFF INDOOR BLOWER OPERATION: CONTINUOUS FAN MODE (COSTANT TORQUE ONLY) INDOOR BLOWER OPERATION: FOLLOWED BY CFM SETTING FOR INDOOR BLOWER (1 SECOND ON, 0.5 SECOND OFF) / CFM SETTING FOR MODE DISPLAYED (VARIALBE SPEED ONLY) COOLING STAGE (1 SECOND ON, 0.5 SECOND OFF) 1 OR 2 DISPLAYED / PAUSE / REPEAT...
- Page 9 TABLE 4 Continued SOFT LOCKOUT FAULTS (60 MINUTES) GAS VALVE RELAY (1ST OR 2ND STAGE) CONTACT SHORTED E205 HOT SURFACE IGNITOR (HSI) SENSED OPEN E207 SOFT LOCKOUT-FLAME FAILURE ON IGNITION, IGNITION RETRY>MAX, LAST FAILED E270 RETRY DUE TO FLAME FAILURE SOFT LOCKOUT-PRESSURE SWITCH OPEN, IGNITION RETRY>MAX, LAST FAILED RETRY E271 DUE TO LPSW OPEN...
- Page 10 INTEGRATED CONTROL CONFIGURATION 2ND STAGE HEAT ON DELAY 7 MIN UPSTAGE DELAY 12 MIN UPSTAGE DELAY COOLING BLOWER-OFF DELAY HEATING BLOWER −OFF DELAY *45 SECOND 90 SECOND COOL BLOWER HTG BLOWER OFF DELAY OFF DELAY 60 SECOND HTG BLOWER OFF DELAY 2 SECOND COOL BLOWER 120 SECOND...
- Page 11 Integrated Control DIP Switches TABLE 5 Units are equipped with a two-stage integrated control. Blower Off Heating Mode Delay Switch Settings This control manages ignition timing, heating mode fan Blower Off Delay off delays and indoor blower speeds based on selections Switch 3 Switch 4 Seconds...
- Page 12 2 - 2 When the EL280DFEK is operating in the high-fire or low-fire heating mode, the indoor blower will run on the corresponding heating speed. See TABLE 9 for allowable heating speeds. 3 - When the EL280DFEK is operating in the low cool or the high cool cooling mode, the indoor blower will run on the corresponding cooling speed.
- Page 13 Each blower is statically and dynamically balanced in Blower Housing as an assembly before installation in the unit. EL280DFEK units are equipped with a constant torque ECM motor. It has a DC motor coupled to an electronic control module both contained in the same motor housing.
- Page 14 Multi−Meter (set to VAC) Multi−Meter (set to VAC) "9A” Test 3 (if necessary) NOTE- Ignition control illustration is typical "7A” Check for 120 volts across terminals “L1” and “Neutrals” on the integrated control. If voltage is present, problem is with the har Turn power on to unit.
- Page 15 Replacing the Motor Module Motor Test NOTE - Not all motors have field replaceable control mod- ules. Only motors that utilize a 4 pin power connector and 5 pin signal connector as shown below may have replace- able controls. Motors that use a 3 pin power connector and 6 pin signal connector do not have field replaceable control modules.
- Page 16 The switch may have a different set point for each unit valve. A wire harness connects the terminals from the gas model number. See Lennox Repair Parts Handbook if limit valve to the electronic ignition control. 24V applied to the switch must be replaced.
- Page 17 HEATING COMPONENTS Ignitor Burners Rollout Switch Sensor Gas Valve Manifold and Gas Orifices FIGURE 13 Page 17...
- Page 18 Ignitor Check Test 1 Check ignitor circuit for correct resistance Remove HSI/CAI 5−pin plug from control. Check ohms reading across terminals 1 and 5. If value is correct, this is the only test needed. If the reading on the meter is not correct, (0 or infinity) then a second test is needed.
- Page 19 To Measure Flame Signal - Integrated Control: 6 - Turn supply voltage on and close thermostat con- tacts to cycle system. Use a digital readout meter capable of reading DC mi- 7 - When main burners are in operation for two min- croamps.
- Page 20 NOTE - Each furnace model uses a unique CAI. Refer to Lennox Repair Parts listing for correct inducer for replace- ment. A pressure switch connected to the combustion air induc- er orifice plate is used to prove inducer operation.
- Page 21 3 - Remove access panel. WHITE RODGERS GAS VALVE 4 - Turn switch on gas valve to OFF. Do not force. See FIGURE 17. HIGH FIRE ADJUSTMENT SCREW LOW FIRE ADJUSTMENT 5 - Replace access panel. MANIFOLD (under cap) SCREW PRESSURE TAP Failure To Operate (under cap)
- Page 22 Use of a specialty Gas Leak Detector is strongly recommended. It All units are CSA design certified without modifications. is available through Lennox under part number 31B2001. Refer to the EL280DFE Installation Instruction. See Corp. 8411-L10, for further details.
- Page 23 G- Proper Combustion TABLE 14 Furnace should operate minimum 15 minutes with correct GAS METERING CLOCKING CHART manifold pressure and gas flow rate before checking com- Natural 1000 btu/cu ft LP 2500 btu/cu ft bustion. See sections E- and F-. Take combustion sample EL280DFE Seconds For One Revolution beyond the flue outlet and compare to the table below.
- Page 24 V-TYPICAL OPERATING CHARACTERISTICS C-External Static Pressure A-Blower Operation and Adjustment 1 - Tap locations shown in FIGURE 20. 2 - Punch a 1/4” diameter hole in supply and return air ple- 1 - Blower operation is dependent on thermostat control nums.
- Page 25 At the beginning of each heating season, and to comply erly sized, open and unobstructed to provide combus- tion air. with the Lennox Limited Warranty, your system should be checked by a licensed professional technician (or equiva- 10- Inspect the furnace venting system to make sure it is...
- Page 26 Cleaning the Heat Exchanger and Burners 5 - Remove the collector box located behind the combus- tion air inducer. Be careful with the collector box gas- NOTE - Use papers or protective covering in front of the ket. If the gasket is damaged, it must be replaced to furnace during cleaning.
- Page 27 10- Back wash using steam. Begin from the burner open- 22- If a leak is detected, shut gas and electricity off and repair leak. ing on each clam. Steam must not exceed 275°F. 23- Repeat steps 21 and 23 until no leaks are detected. 11- To clean burners, run a vacuum cleaner with a soft brush attachment over the face of burners.
- Page 28 VII-Low GWP Application WARNING For use with Lennox approved evaporator coil and LGWP sensors only. Use original manufacturer recommended LGWP sensors if using non Lennox approved evaporator coil. CONNECTING THE FURNACE CONTROL BOARD SENSOR. See FIGURE 25 and follow steps below: 1 - Route sensor wire #1 through provided grommet.
- Page 29 FURNACE CONTROL BOARD LOW GWP MODES OF NOTE - The HVAC system may not maintain a cooling or OPERATION heating setpoint if a significant leak exists. Any refrigerant leaks that remain unaddressed for an extended time may The modes of operation for the furnace control board are cause the HVAC system to shut down on a low refrigerant Initializing, Normal, Leak Detected, and Fault.
- Page 30 LGWP TEST BUTTON FUNCTIONALITY External Alarm (For applications with external alarms wired directly to the The furnace control board is equipped with a Test/Reset furnace control board) push button. The Test button can be used to perform sev- The furnace control board triggers the external alarm sys- eral functions, depending on the mode of operation of the tem when it enters Leak Detected mode.
- Page 31 VIII-WIRING AND SEQUENCE OF OPERATION Page 31...
- Page 32 Electronic Ignition When the delay ends, the indoor blower motor is ener- gized on the low fire heating speed, the HUM contacts The two-stage integrated control used in EL280DFE(X) close energizing the humidifier and 120V ACC terminal is units has an added feature of an internal Watchguard energized.
- Page 33 Applications Using A Single-Stage Thermostat 4 - After the 20-second warm-up period has ended, the gas valve is energized on low fire (first stage) and ig- See FIGURE 27 for ignition control sequence nition occurs. At the same time, the control module B - Heating Sequence - Integrated Control Thermostat sends a signal to begin an indoor blower 30-second Selection DIP Switch 1 ON in “Single-Stage”...
- Page 34 IX-FIELD WIRING AND DIP SWITCH SETTINGS DIP Switch Settings and On-Board Links DIP Switch 1 On Board Links Must Be Cut To Select Thermostat Thermostat Wiring Connections System Options Heating Stages 1 Heat / 1 Cool FURNACE OUTDOOR T'STAT TERM. STRIP UNIT NOTE - Use DIP switch 2 to set...
- Page 35 DIP Switch Settings and On-Board Links DIP Switch 1 On Board Links Must Be Cut To Select Thermostat Thermostat Wiring Connections System Options Heating Stages 2 Heat / 2 Cool FURNACE OUTDOOR (M30 T-stat) T'STAT TERM. STRIP UNIT CUT ON-BOARD LINK W915 2 STAGE COMPR...
- Page 36 DIP Switch Settings and On-Board Links DIP Switch 1 Wiring Connections Thermostat On Board Links Must Be Cut To Select Thermostat Heating System Options Stages Dual Fuel FURNACE HEAT PUMP T'STAT TERM. STRIP Single Stage Heat Pump CUT ON-BOARD LINK (M30 T-stat) W951 67M41*...
- Page 37 DIP Switch Settings and On-Board Links DIP Switch 1 Wiring Connections Thermostat On Board Links Must Be Cut To Select Thermostat Heating System Options Stages Dual Fuel FURNACE HEAT PUMP T'STAT TERM. STRIP Single Stage Heat Pump CUT ON-BOARD LINK (M30 T-stat) W951 67M41*...
- Page 38 X-TROUBLESHOOTING HEATING SEQUENCE OF OPERATION NORMAL AND ABNORMAL HEATING MODE POWER ON GAS VALVE OFF. COMBUSTION AIR INDUCER OFF. INDOOR BLOWER OFF. (RESET CONTROL BY CONTROL SELF-CHECK OKAY? TURNING MAIN POWER OFF.) POLARITY REVERSED. POLARITY OKAY? STATUS ERROR CODE 5 + 4. IS THERE A SIGNAL HOLDS UNTIL UNIT IS PROPERLY GROUNDED.
- Page 39 HEATING SEQUENCE OF OPERATION CONTINUED THERMOSTAT CALLS FOR HEAT STATUS LED - HEARTBEAT. (Refer to box A on previous page) GAS VALVE OFF. COMBUSTION AIR INDUCER FIRST-STAGE (LOW FIRE) PRESSURE OFF. INDOOR BLOWER OFF. UNIT WILL RETRY SWITCH CLOSED WITHIN 2.5 MINUTES? AFTER 5-MINUTE WAIT PERIOD.
- Page 40 HEATING SEQUENCE OF OPERATION CONTINUED THERMOSTAT CALLS FOR HEAT. STATUS LED -- HEARTBEAT. SEE BOX A. FLAME SIGNAL ABOVE ( 1.40 microamps) LOW FLAME SIGNAL (Does not affect control operation) STATUS ERROR CODE 1 + 2. SINGLE-STAGE THERMOSTAT MODE TWO STAGE THERMOSTAT MODE (DIP SWITCH SET AT “ON”) (DIP SWITCH SET AT “OFF”) START SECOND-STAGE RECOGNITION...
- Page 41 HEATING SEQUENCE OF OPERATION CONTINUED SEE BOX A NORMAL OPERATION. SEE BOX B THERMOSTAT CALLS FOR HEAT. RETURN TO FIRST-STAGE HEAT MODE. FIRST-STAGE CONTINUES UNTIL SECOND- STAGE PRESSURE SWITCH CAN BE PROVEN SECOND-STAGE (HIGH FIRE) HEAT or HEAT DEMAND IS SATISFIED. A FIVE (5) PRESSURE SWITCH CLOSED? MINUTE WAIT PERIOD IS INITIATED BEFORE RETRY.
- Page 42 COOLING SEQUENCE OF OPERATION POWER ON SIGNAL POLARITY REVERSED. CONTROL WILL CONTINUE TO CALL FOR COOLING IS POLARITY REVERSED? IN THIS CONDITION. STATUS ERROR CODE 5 + 4. SIGNAL IMPROPER GROUND AT LED. CONTROL WILL CONTINUE TO CALL FOR COOLING IS THERE IN THIS CONDITION.
- Page 43 CONTINUOUS LOW SPEED FAN SEQUENCE OF OPERATION MANUAL FAN SELECTION MADE AT THERMOSTAT. AFTER 2 SECOND DELAY, INDOOR BLOWER IS ENERGIZED ON CONTINUOUS FAN SPEED. THERMOSTAT CALLS FOR FIRST STAGE COOL. THERMOSTAT CALLS FOR FIRST-STAGE HEAT. INDOOR BLOWER RAMPS TO FIRST STAGE AFTER 45-SECOND DELAY, INDOOR BLOWER COOLING SPEED AFTER A 2-SECOND DELAY.
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