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Lennox EL296UH045XE36B User Manual

Lennox EL296UH045XE36B
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© 2014 Lennox Industries Inc.
Corp. 1246-L10
EL296UHE
Service Literature
Revised 03/2014
EL296UHE SERIES UNITS
EL296UHE series units are high efficiency condensing gas
furnaces used for upflow or horizontal applications only,
manufactured with Lennox Duralokt heat exchangers
formed of aluminized steel. EL296UHE units are available
in heating capacities of 44,000 to 132,000 Btuh and cooling
applications up to 5 tons. Refer to Product Specifications
Manual for proper sizing.
Units are factory equipped for use with natural gas. Kits are
available for conversion to LPG operation. EL296UHE
model units are equipped with the SureLight
®
two-stage
integrated control. EL296UHE unit meets the California Ni
trogen Oxides (NO
x
) Standards and California Seasonal
Efficiency requirements. All units use a redundant gas
valve to assure safety shut-off as required by C.S.A.
All specifications in this manual are subject to change. Pro
cedures outlined in this manual are presented as a recom
mendation only and do not supersede or replace local or
state codes. In the absence of local or state codes, the
guidelines and procedures outlined in this manual (except
where noted) are recommendations only and do not consti
tute code.
TABLE OF CONTENTS
Specifications Page 2.............................
I Unit Components Page 7........................
II Installation Page 22.............................
III Start Up Page 44..............................
IV Heating System Service Checks Page 45.........
V Typical Operating Characteristics Page 49.........
VI Maintenance Page 50..........................
VII Wiring and Sequence of Operation Page 53......
VIII Field Wiring and Jumper Settings Page 56.......
X Troubleshooting Page 60........................
WARNING
Improper installation, adjustment, alteration, service
or maintenance can cause property damage, person
al injury or loss of life. Installation and service must
be performed by a licensed professional HVAC in
staller (or equivalent), service agency or the gas sup
plier.
WARNING
Sharp edges.
Be careful when servicing unit to avoid sharp edges
which may result in personal injury.

Table of Contents

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Lennox EL296UH045XE36B Specifications

General IconGeneral
ModelEL296UH045XE36B
TypeGas Furnace
Efficiency Rating96% AFUE
Heating Capacity44, 000 BTU/h
StagesTwo-Stage
Fuel TypeNatural Gas
WarrantyLimited Lifetime Heat Exchanger

Summary

UNIT INFORMATION

EL296UHE SERIES UNITS

Overview of high efficiency condensing gas furnaces for upflow or horizontal applications.

SPECIFICATIONS

Gas Heating Performance

Details AFUE, input, output, temperature rise, and gas pressure for heating.

Connections

Specifies pipe sizes for intake, exhaust, gas, and condensate drain.

Indoor Blower

Lists blower wheel diameter, motor output, cooling tons, and air volume.

Electrical Data

Provides voltage, amps, and overcurrent protection ratings.

Shipping Data

Indicates unit weight and package details.

OPTIONAL ACCESSORIES - ORDER SEPARATELY

CABINET ACCESSORIES

Items for mounting and structural support of the furnace.

CONDENSATE DRAIN KITS

Accessories for managing condensate removal.

FILTER KITS

Options for air filtration and rack systems.

TERMINATION KITS

Components for venting exhaust and intake pipes.

BLOWER DATA

EL296UH045XE36B PERFORMANCE (Less Filter)

Blower CFM and Watts at various static pressures for a specific model.

EL296UH070XE36B PERFORMANCE (Less Filter)

Blower CFM and Watts at various static pressures for a specific model.

EL296UH090XE48C PERFORMANCE (Less Filter)

Blower CFM and Watts at various static pressures for a specific model.

EL296UH110XE60C PERFORMANCE (Less Filter)

Blower CFM and Watts at various static pressures for a specific model.

EL296UH135XE60D PERFORMANCE (Less Filter)

Blower CFM and Watts at various static pressures for a specific model.

EL296UHE PARTS IDENTIFICATION

Major Components Overview

Diagram labeling key parts like heat exchanger, gas valve, ignitor.

I-UNIT COMPONENTS

Control Box

Enclosure for electrical components including transformer, breaker, and control.

Integrated Control (A92)

SureLight® two-stage control managing ignition, blower, and safety features.

Electronic Ignition

System's automatic ignition process and safety checks for heating cycles.

INTEGRATED CONTROL CONFIGURATION GUIDE

THERMOSTAT SELECTION

Setting the control for single-stage or two-stage thermostat operation.

HEATING BLOWER-OFF DELAY

Adjusting the blower run time after a heating cycle ends.

COOLING BLOWER-OFF DELAY

Adjusting the blower run time after a cooling cycle ends.

CONTINUOUS FAN SETTINGS

Configuring the blower for continuous operation at different speeds.

Onboard Links

On-board jumper settings for system options like dehum and heat pump.

B- Indoor Blower Motor

Input Voltage Requirements

Specifies the AC voltage needed to energize blower motor speed taps.

Troubleshooting the Motor

Steps for diagnosing and resolving issues with the indoor blower motor.

Replacing the Motor Module

Motor Test

Procedures for checking the motor control module's resistance and functionality.

Motor Module Installation

Steps for correctly installing a replacement motor control module.

C- Heating Components

Ignitor

Description and resistance check for the SureLight® ignitor.

Flame Sensor

Location, function, and signal check for the flame sensor.

Gas Valve

Details on the redundant safety shut-off gas valve.

Flame Rollout Switches (S47)

High temperature limit switches that shut off ignition on rollout.

Burners

Information on factory-set inshot burners requiring no adjustment.

Primary Limit Control (S10)

Over-temperature limit switch in the heat exchanger vestibule.

EL296UHE Ignitor Check

Test 1

Checking ignitor circuit resistance across control terminals.

Test 2

Checking ignitor resistance at the manifold jack-plug.

Test 3

Verifying correct voltage supply to the ignitor during warm-up.

7. Combustion Air Inducer (B6) and Cold End Header Box

Combustion Air Inducer Pressure Switch (S18) (Figure 16)

Monitors pressure differential to prove inducer operation and prevent ignition.

II-PLACEMENT AND INSTALLATION

PRIMER & SOLVENT CEMENT

Approved materials and procedures for joining PVC, CPVC, and ABS pipes.

CANADA PIPE & FITTING & SOLVENT CEMENT

Specific requirements for venting systems in Canada (ULC S636).

POLYPROPYLENE VENTING SYSTEM

Information on approved polypropylene vent pipe options.

Joint Cementing Procedure

General Cementing Steps

Detailed procedure for applying primer and solvent cement to pipe joints.

Venting Practices

Piping Suspension Guidelines

Requirements for supporting vent pipes to prevent strain and sagging.

Removal of the Furnace from Common Vent

Procedures and considerations when replacing a furnace in a common vent system.

Exhaust Piping (Figures 19, 21 and 22)

Exhaust Pipe Routing Guidelines

Instructions for routing and supporting exhaust piping.

Piping Size Process

Vent Pipe Sizing Steps

Step-by-step guide to correctly sizing vent pipe diameter based on capacity and elbows.

TYPICAL EXHAUST AND INTAKE PIPE CONNECTIONS IN UPFLOW DIRECT OR NON-DIRECT VENT APPLICATIONS

Upflow Non-Direct Vent Intake Configurations

Diagrams showing intake piping configurations for non-direct vent upflow installations.

Horizontal Non-Direct Vent Intake Configurations

Diagrams illustrating intake piping for non-direct vent horizontal installations.

General Guidelines for Vent Terminations

EQUIPMENT IN CONFINED SPACE (Attic Inlet)

Requirements for air intake and exhaust when furnace is in a confined attic space.

EQUIPMENT IN CONFINED SPACE (Crawlspace Inlet)

Requirements for air intake and exhaust in a confined crawlspace.

VENT TERMINATION CLEARANCES FOR NON-DIRECT VENT INSTALLATIONS

Clearance Requirements (US and Canada)

Table detailing required clearances for vent terminals from building features.

VENT TERMINATION CLEARANCES FOR DIRECT VENT INSTALLATIONS

Clearance Requirements (US and Canada)

Table outlining required clearances for direct vent terminals.

Details of Intake and Exhaust Piping Terminations for Direct Vent Installations

Intake and Exhaust Pipe Routing Guidelines

Guidelines for routing intake and exhaust pipes, including separation and termination.

FIELD FABRICATED WALL TERMINATION

ALTERNATE TERMINATIONS (TEE & 45 DEGREE ELBOWS)

Installation details for field-fabricated wall terminations using tees and elbows.

Details of Exhaust Piping Terminations for Non-Direct Vent Applications

Exhaust Pipe Termination Guidelines

Rules for terminating exhaust piping, including sizing and routing.

Condensate Piping

CONDENSATE TRAP AND PLUG LOCATIONS (Upflow)

Location of condensate trap and plug for upflow installations.

Field Provided Drain Components

Components used for field-supplied condensate drain assemblies.

Condensate Trap Locations (Upflow with Remote Trap)

Condensate Trap with Optional Overflow Switch

Configuration of condensate trap with an optional overflow switch.

EL29UHE With Evaporator Coil Using A Separate Drain

Evaporator Coil Separate Drain Setup

Diagram for draining condensate from evaporator coil separately.

EL296UHE with Evaporator Coil Using a Common Drain

Evaporator Coil Common Drain Setup

Diagram for draining condensate from evaporator coil and furnace together.

TRAP / DRAIN ASSEMBLY USING 1/2" PVC OR 3/4" PVC

Condensate Drain Assembly Options

Diagrams for connecting and assembling condensate drain pipes and traps.

III-START-UP

Preliminary and Seasonal Checks

Pre-start-up checks for wiring, voltage, and condensate traps.

Heating Start-Up Procedure

Step-by-step procedure for safely starting the furnace for heating.

Priming Condensate Trap

Method for filling the condensate trap with water before operation.

Gas Valve Operation (Figure 50)

Instructions for operating the gas valve safely.

Failure To Operate Troubleshooting

Troubleshooting steps for common operational failures.

IV-HEATING SYSTEM SERVICE CHECKS

Gas Piping Safety and Checks

Safety precautions and checks related to gas piping installation.

Gas Piping Testing Procedures

Procedures for testing gas piping for leaks and pressure.

Testing Gas Supply Pressure

Method for measuring the incoming gas supply pressure.

Check Manifold Pressure

Steps to measure and verify gas manifold pressure.

MANIFOLD PRESSURE CHECK SET UP

Proper Gas Flow Measurement

Procedure for checking gas flow rate using a gas meter.

Proper Combustion Analysis

Guidelines for checking combustion analysis (CO2, CO) for optimal performance.

High Altitude Operation Adjustments

Considerations for adjusting pressure and orifices at higher altitudes.

I- Proper Ground and Voltage

Voltage Checks at Integrated Control

Procedures for verifying AC voltage at the integrated control terminals.

V-TYPICAL OPERATING CHARACTERISTICS

Blower Operation and Adjustment

How the blower operates based on thermostat settings and adjustments.

Temperature Rise Measurement

How to measure and set the temperature rise for optimal heating.

External Static Pressure Measurement

Measuring and adjusting static pressure for proper airflow.

VI-MAINTENANCE

Blower Maintenance

Routine checks and cleaning for the blower wheel and motor.

Filter Inspection and Replacement

Inspection, cleaning, and replacement of air filters.

Exhaust and Air Intake Pipe Checks

Checking vent pipes for tightness, blockages, and obstructions.

Electrical System Checks

Verifying wiring connections and motor voltage/amp draw.

Winterizing and Condensate Trap Care

Steps for preparing the unit for storage and maintaining the condensate trap.

Condensate Hose Screens Cleaning

Inspecting and cleaning screens in the condensate drain system.

Cleaning Heat Exchanger

Procedures for safely removing and cleaning the heat exchanger.

Cleaning the Burner Assembly (if needed)

Burner Cleaning Procedure

Steps for safely cleaning the furnace burners and inspecting for blockages.

VII- Wiring and Sequence of Operation

Wiring Diagram and Connections

Schematic illustrating electrical connections for furnace components and thermostat.

Sequence of Operation (Heating and Cooling)

Step-by-step process for heating and cooling cycles managed by the integrated control.

Electronic Ignition

Applications Using a Two-Stage Thermostat

Detailed heating sequence for two-stage thermostat operation.

Applications Using A Single-Stage Thermostat

Heating Sequence with Single-Stage Thermostat

Detailed heating sequence for single-stage thermostat operation.

VIII- EL296UHE Field Wiring Applications

1 Heat / 1 Cool Wiring Configuration

Wiring configuration for a single-stage heating and cooling system.

1 Heat / 2 Cool Wiring Configuration

Wiring for a two-stage heating and single-stage cooling system.

1 Heat / 2 Cool with Humidity Control Wiring

Wiring for two-stage heating, single-stage cooling with humidity control.

2 Heat / 2 Cool Wiring Configuration

Wiring for a two-stage heating and cooling system.

2 Heat / 2 Cool with Humidity Control Wiring

Wiring for two-stage heating/cooling with humidity control.

2 Heat / 1 Cool with Humidity Control Wiring

Wiring for two-stage heating and single-stage cooling with humidity control.

Dual Fuel Single Stage Heat Pump Wiring

Wiring for dual fuel systems with single-stage heat pump operation.

Dual Fuel Two Stage Heat Pump Wiring

Wiring for dual fuel systems with two-stage heat pump operation.

IX- Troubleshooting

Troubleshooting: Heating Sequence of Operation

Flowchart to diagnose issues during the furnace heating cycle.

Troubleshooting: Cooling Sequence of Operation

Flowchart to diagnose issues during the cooling cycle.

Troubleshooting: Continuous Fan Sequence of Operation

Flowchart for diagnosing problems with continuous fan operation.

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