Lennox EL296UH070XE36B, EL296UH135XE60D, EL296UH090XE48C, EL296UH110XE60C, EL296DFE Series, EL296DF045XE36B, EL296DF110XE60C, EL296DF070XE48B, EL296DF090XE48C Unit Information
Specifications and Main Features
Frequently Asked Questions
User Manual
Corp. 1246-L10
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
integrated control. EL296UHE unit meets the California Ni
trogen Oxides (NO
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.
SpecificationsPage 2.............................
I Unit ComponentsPage 7........................
II InstallationPage 22.............................
III Start UpPage 44..............................
IV Heating System Service ChecksPage 45.........
V Typical Operating CharacteristicsPage 49.........
VI MaintenancePage 50..........................
VII Wiring and Sequence of OperationPage 53......
VIII Field Wiring and Jumper SettingsPage 56.......
X TroubleshootingPage 60........................
) Standards and California Seasonal
x
TABLE OF CONTENTS
®
two-stage
EL296UHE
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.
NOTE - Filters and provisions for mounting are not furnished and must be eld provided.
1
Annual Fuel Utilization Efciency based on DOE test procedures and according to FTC labeling regulations. Isolated combustion system rating for non-weatherized
furnaces.
Model No. EL296UH045XE36BEL296UH070XE36BEL296UH090XE48C
1
AFUE96%95.5%95.7%
Input - Btuh44,00066,00088,000
Output - Btuh43,00064,00085,000
3.5 / 10.03.5 / 10.03.5 / 10.0
Input - Btuh29,00043,00057,000
Output - Btuh28,00042,00055,000
1.7 / 4.91.7 / 4.91.7 / 4.9
Cooling0.50.50.5
Gas pipe size IPS1/21/21/2
Motor output - hp1/21/23/4
SPECIFICATIONS
Gas
Heating
Performance
High
Fire
Temperature rise range - °F45-7555-85
Gas Manifold Pressure (in. w.g.)
Nat. Gas / LPG/Propane
Low
Fire
Temperature rise range - °F35 - 6540 - 70
Gas Manifold Pressure (in. w.g.)
Nat. Gas / LPG/Propane
High static - in. w.g.Heating0.50.5
Connections
Intake / Exhaust Pipe (PVC)2 / 22 / 2
in.
Condensate Drain Trap (PVC pipe) - i.d.3/43/4
with furnished 90° street elbow3/4 slip x 3/4 Mipt3/4 slip x 3/4 Mipt
with eld supplied (PVC coupling) - o.d.3/4 slip x 3/4 MPT3/4 slip x 3/4 MPT
Indoor
Wheel nominal diameter x width - in.11-1/2 x 1011-1/2 x 10
NOTE - Filters and provisions for mounting are not furnished and must be eld provided.
1
Annual Fuel Utilization Efciency based on DOE test procedures and according to FTC labeling regulations. Isolated combustion system rating for non-weatherized
Single Side Return Air − Air volumes in bold require eld
fabricated transition to accommodate 20 x 25 x 1 in. air lter
in order to maintain proper air velocity.
Single Side Return Air − Air volumes in bold require eld
fabricated transition to accommodate 20 x 25 x 1 in. air lter
in order to maintain proper air velocity.
Page 5
Gas Valve
EL296UHE PARTS IDENTIFICATION
Field Make Up Box
Burner Box Assembly
Heat Exchanger
Combustion
Air Inducer
Outer Access Panel
Pressure
Switch
Assembly
Door
Interlock
Switch
Inner Access Panel
Bag Assemblies
(shipping location)
Primary Limit
Constant Torque Indoor Blower Motor
Two-Stage Integrated Control
FIGURE 1
Page 6
I-UNIT COMPONENTS
EL296UHE unit components are shown in figure 1. The
gas valve, combustion air inducer and burners can be ac
cessed by removing the access panel. Electrical compo
nents are in the control box (figure 2) found in the blower
section.
EL296UHE units are factory equipped with a bottom return
air panel in place. The panel is designed to be field re
moved as required for bottom air return. Markings are pro
vided for side return air and may be cut out in the field.
3. Circuit Breaker (CB8)
A 24V circuit breaker is also located in the control box. The
switch provides overcurrent protection to the transformer
(T1). The breaker is rated 3A at 32V. If the current exceeds
this limit the breaker will trip and all unit operation will shut
down. The breaker can be manually reset by pressing the
button on the face. See figure 3.
CIRCUIT BREAKER CB8
PRESS TO RESET
FIGURE 3
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.
A- Control Box
1. Control Transformer (T1)
A transformer located in the control box provides power to
the low voltage section of the unit. Transformers on all
models are rated 40VA with a 120V primary and a 24V sec
ondary.
2. Door Interlock Switch (S51)
A door interlock switch is wired in series with line voltage.
When the inner blower access panel is removed the unit
will shut down.
CONTROL BOX EL296UHE
Transformer
WARNING
Shock hazard.
Disconnect power before servicing. Integrated
control is not field repairable. If control is inoper
able, simply replace entire control.
Can cause injury or death. Unsafe operation will re
sult if repair is attempted.
4. Integrated Control (A92)
Units are equipped with the SureLight
grated control. The system consists of a ignition / blower
control (figures 4 and 5) with control pin designations in
tables 1 and 2 and ignitor (figure 14). The control and ignitor
work in combination to ensure furnace ignition and ignitor
durability. The control provides gas ignition, safety checks
and indoor blower control with two-stage gas heating. The
furnace combustion air inducer, gas valve and indoor blow
er are controlled in response to various system inputs such
as thermostat signal, pressure and limit switch signal and
flame signal. The control features a seven-segment LED
display, indicating furnace status and error codes. The
LED flashes in single digits. For example using table 4 un
der LIMIT CODE, an “E” followed by “2” followed by “5” fol
lowed by “0”, the limit switch circuit is open. The control also
has two unpowered (dry) 1/4” contacts for a humidifier and
a 120 volt accessory terminal. Both rated at (1) one amp
each.
®
two-stage, inte
Circuit Breaker
SureLight
FIGURE 2
Interlock Switch
®
Integrated Control
Electronic Ignition
At the beginning of the heat cycle the integrated control
monitors the first stage and second stage combustion air
inducer pressure switch. The control will not begin the
heating cycle if the first stage pressure switch is closed (bypassed). Likewise the integrated control will not begin the
second stage heating cycle if the second stage pressure
switch is closed, and will remain in first stage heat. Howev
er, if the second stage pressure switch closes during the
first stage heat pre-purge, the control will allow second
stage heat. Once the first stage pressure switch is deter
mined to be open, the combustion air inducer is energized
on low (first stage) heat speed. When the differential in the
pressure switch is great enough, the pressure switch
closes and a 15-second pre-purge begins.
Page 7
®
After the 15-second pre-purge period, the SureLight
igni
tor warms up for 20 seconds after which the gas valve
opens for a 4-second trial for ignition. The ignitor remains
energized during the trial until flame is sensed. If ignition is
not proved during the 4-second period, the control will try
four more times with an inter purge and warm-up time be
tween trials of 35 seconds. After a total of five trials for igni
tion (including the initial trial), the control goes into Watch
guard-Flame Failure mode. After a 60-minute reset period,
the control will begin the ignition sequence again.
NOTE - During abnormal conditions such as low supply
voltage or low outdoor temperatures and the low fire pres
sure switch does not close, the combustion air inducer will
switch to high speed. After the low & high pressure switch
close, the unit will proceed with a 15 sec pre-purge, fol
lowed by a 20 sec ignitor warm up, then ignition on highfire. After 10 to 20 seconds of high fire operation the unit will
switch to low fire.
Two Stage Operation / Thermostat Selection DIP
Switch
The control can be utilized in two modes: SINGLE-STAGE
thermostat or TWO-STAGE thermostat. The thermostat
selection is made using a DIP switch and must be posi
tioned for the particular application. DIP switch 1, labeled
T”STAT HEAT STAGE is factory-set in the OFF position for
use with a two-stage thermostat. Move the DIP switch to
ON for use with a single stage thermostat.
While in the single-stage thermostat mode, the burners will
always fire on first-stage heat. The combustion air inducer
will operate on low speed and indoor blower will operate on
low heat speed. The unit will switch to second stage heat
after a “recognition period”. DIP switch 2, labeled SECOND
STAGE DELAY, is factory set in the OFF position for a 7
minute recognition period. The switch can be moved to the
ON position for a 12 minute recognition period, after which
time the unit will switch to second-stage heat. While in the
two-stage thermostat mode, the burners will fire on firststage heat. The combustion air inducer will operate on low
speed and indoor blower will operate on low heat speed.
The unit will switch to second-stage heat on call from the
indoor thermostat. If there is a simultaneous call for first
and second stage heat, the unit will fire on first stage heat
and switch to second stage heat after 30 seconds of opera
tion. See Sequence of Operation flow charts in the back of
this manual for more detail.
TABLE 1
SureLight
®
Control 5 Pin Terminal Designation
PIN #Function
1Ignitor
2Combustion Air Inducer High Speed
3Combustion Air Inducer Low Speed
4Combustion Air Inducer Neutral
5Ignitor Neutral
TABLE 2
®
SureLight
Control 12 Pin Terminal Designation
PIN #Function
1Gas Valve Second Stage
2Second Stage pressure Switch
3Rollout Switch In
4Ground
524V Hot
6Primary Limit In
7Gas Valve First Stage
8Gas Valve Common
924V Neutral
10Ground
11Primary Limit Out
12First Stage pressure Switch
Page 8
INTEGRATED CONTROL
24VAC Indoor
Blower Terminals
Flame Sense
LED
S4 DIP Switches
Diagnostic Push
Button
HUM
ACC
Ignitor and Combustion
Air Inducer
Neutrals
On Board Links
3/16” QUICK CONNECT TERMINALS
FLAME SENSE SIGNAL
HI COOL 24VAC
HI HEAT 24VAC
LO COOL 24VAC
LO HEAT 24VAC
PAR
PAR
K
COMMON 24VAC
K
1/4” QUICK CONNECT TERMINALS
NEUTRALS = 120 VAC NEUTRAL
HUM = UNPOWERED NORMALLY OPEN (DRY) CONTACTS
LI = 120 VAC INPUT TO CONTROL
ACC = 120 VAC OUTPUT TO OPTIONAL ACCESSORY
FIGURE 4
THERMOSTAT CONNECTIONS (TB1)
DS = DEHUMIDIFICATION SIGNAL
W2 = HEAT DEMAND FROM 2ND STAGE T/STAT
W1 = HEAT DEMAND FROM 1ST STAGE T/STAT
R = CLASS 2 VOLTAGE TO THERMO
G = MANUAL FAN FROM
C = THERMOSTAT SIGNAL GROUND CONNECTED TO
TRANSFORMER GRD (TR) & CHASIS GROUND (GRD)
Y1 = THERMOSTAT 1ST STAGE COOL SIGNAL
Y2 = THERMOSTAT 2ND STAGE COOL SIGNAL
O = THERMOSTAT SIGNAL TO HEAT PUMP
DH = NOT USED
L = NOT USED
STAT
T'STAT
REVERSING VALVE
Page 9
THERMOSTAT SELECTION
1
2
*
TWO STAGE
THERMOSTAT
1−STAGE
THERMOSTAT
(TIMED STAGING)
−SEE SW #2
HEATING BLOWER−OFF DELAY
*
90 SECOND
HTG BLOWER
OFF DELAY
60 SECOND
HTG BLOWER
OFF DELAY
120 SECOND
HTG BLOWER
OFF DELAY
180 SECOND
HTG BLOWER
OFF DELAY
−BLOWER ON DELAY − 30 SEC. FIXED
3
ON
1
2
3
ON
1
2
3
ON
1
2
3
ON
1
2
3
ON
1
2
3
ON
INTEGRATED CONTROL CONFIGURATION GUIDE
2ND STAGE HEAT ON DELAY
1
2
3
4
5
6
7
COOLING BLOWER-OFF
5
N
P79
6
12
NEUTRALS
J2
DELAY
*45 SECOND
COOL BLOWER
OFF DELAY
2 SECOND
COOL BLOWER
OFF DELAY
LOW HEAT SPEED
LOW COOL SPEED
HIGH HEAT SPEED
HIGH COOL SPEED
1
2
3
4
5
ON
1
ON
6
7
2
3
4
5
6
7
CONTINUOUS FAN SETTINGS
1
2
3
4
5
ON
1
ON
1
ON
1
ON
6
2
3
4
5
6
7
2
3
4
5
6
7
2
3
4
5
6
7
7
2
3
4
5
6
7
HSI/CAI
L1
LED
1
J3
IGN
CAI2
®
110
4 7
3
SELECTION
N
CAI1
14
3
CUT FOR
OPTION
W915
2 STAGE
COMPR
W951
HEAT
PUMP
W914
DEHUM
ACC
HUM
DIAGNOSTIC
S1
7
SureLight
7 MIN
UPSTAGE
DELAY
12 MIN
UPSTAGE
DELAY
FLAME
SENSE
123456
ON
S4S3
ON
1
ON
DIAGNOSTIC
PUSH BUTTON
*
4
5
6
7
4
5
6
7
4
5
6
7
4
5
6
7
4
5
6
7
4
5
6
7
1−STG COMPRESSOR
W915
2 STAGE
COMPR
DO NOT CUT
2−STG COMPRESSOR
W915
2 STAGE
COMPR
CUT LINK
1
2−STAGE
COMPRESSOR LINK
(JUMPERS Y1 to Y2)
W915
W1W2 G Y2 Y1 C CDHL O DSR
W1
W2GY2
ON−BOARD LINK
OPTION SELECTION
A/C UNIT
W951
HEAT
PUMP
Y1
C
DO NOT CUT
HEAT PUMP UNIT
W951
HEAT
PUMP
CUT LINK
1
HEAT PUMP LINK
(JUMPERS R to O)
W951
FIGURE 5
C
L
R
DH
NO SIGNATURESTAT
W/ DS CONNECTION
DO NOT CUT
W914
DEHUM
SIGNATURESTAT W/
DS CONNECTION
CUT LINK
1
W914
DEHUM
DEHUMIFICATION LINK
(JUMPERS R to DS)
W914
−CUT ON−BOARD LINK (SOLDER TRACE) COMPLETELY THROUGH
1
BOTH LAYERS ON THE CONTROL BOARD
−LINKS CUT IN ERROR −INSTALL A JUMPER ON THE APPROPRIATE
TERMINALS ON THE TERMINAL STRIP
−PROTECTIVE PLASTIC FILM ON DIP SWITCHES MAY BE
REMOVED FOR EASE IN SETTING OF DIP SW.
* FACTORY DEFAULT
Page 10
TABLE 3
Integrated Control Diagnostic Modes
DisplayAction (when button released)
No change (idle)*Remain in idle mode
Solid “E”Enter diagnostic recall mode
Solid “F”Enter flame signal mode
TABLE 4
Integrated Diagnostic Codes/Status of Equipment
CodeDiagnostic Codes/Status of EquipmentAction Required to Clear and Recover
.
Idle mode (Decimal blinks at 1 Hertz -- 0.5 second ON, 0.5 second OFF).
C
Cooling stage (1 second ON, 0.5 second OFF) 1 or 2 displayed / Pause
/ Repeat codes.
d
Dehumidification mode (1 second ON, 1 second OFF) / Pause / Repeat
Codes).
H
Gas Heat Stage (1 second ON, 0.5 second OFF) 1 or 2 displayed /
Pause / Repeat codes. Blinking during ignition.
h
Heat pump stage.
E 110
Low line voltage.Line Voltage Low (Voltage lower than nameplate
rating).Check power line voltage and correct. Alarm
clears 5 seconds after fault recovered.
E 111
Line voltage polarity reversed.Reverse line power voltage wiring. System resumes
normal operation 5 seconds after fault recovered.
E 112
Ground not detectedSystem shuts down. Provide proper earth ground.
System resumes normal operation 5 seconds after
fault recovered.
E 113
High line voltage.Line Voltage High (Voltage higher than nameplate
rating). Provide power voltage within proper range.
System resumes normal operation 5 seconds after
fault recovered.
E 114
Line voltage frequency out-of-range.No 60 Hertz Power.Check voltage and line power
frequency. Correct voltage and frequency problems.
System resumes normal operation 5 seconds after
fault recovered.
E 115
Low 24V - Control will restart if the error recovers.24-Volt Power Low (Range is 18 to 30 volts). Check
and correct voltage. Check for additional power-rob
bing equipment connected to system. May require
installation of larger VA transformer to be installed
in furnace / air handler. Clears after fault recovered.
E 117
Poor ground detected (Warning only)Provide proper grounding for unit. Check for proper
earth ground to the system. Warning only will clear
30 seconds after fault recovered.
* No change implies the display will continue to show whatever is currently being displayed for normal operation (blinking decimal, active error code, heat state, etc..)
Diagnostic LED (Figure 4)
The seven-segment diagnostic LED displays operating
status, error codes and other information. The table begin
ning on Page 11 lists diagnostic LED codes.
Diagnostic Push Button (Figure 4)
The diagnostic push button is located adjacent to the
seven-segment diagnostic LED. This button is used to en
able the Error Code Recall “E” mode and the Flame Signal
“F” mode. Press the button and hold it to cycle through a
menu of options. Every five seconds a new menu item will
be displayed. When the button is released, the displayed
item will be selected. Once all items in the menu have been
displayed, the menu resumes from the beginning until the
button is released.
Error Code Recall Mode
Select ”E” from the menu to access the most recent 10 error
codes. Select “c” from the Error Code Recall menu to clear
all error codes. Button must be pressed a second time
while “c” is flashing to confirm command to delete codes.
Press the button until a solid “≡” is displayed to exit the Error
Code Recall mode.
Flame Signal Mode
Select ”F” from the menu to access the flame signal mode.
The integrated control will display the flame current on
seven-segment LED in in micro amps (uA).
Flame signal mode is exited after any of the following:
D Power is reset
D Pressing and holding push button until 3 horizontal
lines “≡” are displayed
D 10 minutes after entering the flame sense mode.
Page 11
E 125
E 200
E 204
E 205
E 206
E 207
E 223
E 224
E 225
E 226
E 227
E 229
E 240
E 241
E 250
TABLE 4 Continued
Control failed self-check, internal error, failed hardware. Will restart if
error
recovers. Integrated control not communicating. Covers hardware errors
(flame sense circuit faults, pin shorts, etc.).
Hard lockout - Rollout circuit open or previously open.Correct cause of rollout trip, or replace flame rollout
Gas valve mis-wired.Check gas valve operation and wiring. Clears when
Gas valve control relay contact shorted.Check wiring on control and gas valve. If wiring is
Gas valve second-stage relay failureFurnace will operate on 1st stage for remainder of
Hot surface ignitor sensed openMeasure resistance of hot surface ignitor. Replace
Low pressure switch failed closed.Check operation of low pressure switch to see if it is
High pressure switch failed open.Check pressure (inches w.c.) of high pressure
High pressure switch failed closed.Check operation of high pressure switch closing on
Low pressure switch open during trial for ignition or run mode.Check pressure (inches w.c.) of low pressure switch
Ignition on High Fire - Information Only. Code is displayed if 1) low pressure switch fails to
Low flame current - Run mode.Check micro-amperes of flame sensor using control
Flame sensed out of sequence - Flame still present.Shut off gas. Check for gas valve leak. Replace, if
Limit switch circuit open.Check for proper firing rate on furnace. Ensure
Hardware problem on the control. Cycle power on
control. Replace if problem prevents service and is
persistent. Critical alert. Cleared 300 seconds after
fault recovered.
switch. Test furnace operation. Cleared after fault
recovered.
repaired.
correct, replace control.
the heating demand. Will clear after fault recovered.
If unable to operate 2nd stage, replace control.
if open or not within specified range found in IOM.
Resumes normal operation after fault is cleared.
closing on heat call. Measure operating pressure
(inches w.c.). Inspect vent and combustion air in
ducer for correct operation and restriction. Re
sumes normal operation after fault is cleared
stuck closed on heat call longer than 150 seconds.
Measure operating pressure (inches w.c.). Inspect
vent and combustion air inducer for correct opera
tion and restriction. Resumes normal operation after
fault is cleared.
switch closing on heat call. Measure operating pres
sure (inches w.c.). Inspect vent and combustion air
inducer for correct operation and restriction. Re
sumes normal operation after fault is cleared.
heat call. Measure operating pressure (inches w.c.).
Inspect vent and combustion air inducer for correct
operation and restriction. Resumes normal opera
tion after fault is cleared.
closing on heat call. Measure operating pressure
(inches w.c.). Inspect vent and combustion air in
ducer for correct operation and restriction. Re
sumes normal operation after fault is cleared.
close, then furnace will switch to high speed inducer
to close both low and high pressure switches, then
furnace lights on high fire, or 2) if continuous fan is
active, furnace lights on high fire for 60 seconds to
improve heat exchanger warm up time.
diagnostics or field-installed mode. Clean or replace
sensor. Measure voltage of neutral to ground to
ensure good unit ground. Alert clears after current
heat call has been completed.
necessary. Alert clears when fault is recovered.
there is no blockage in heater. Check for proper air
flow. If limit not closed within 3 minutes, unit will go
into 1-hour soft lockout. Resumes normal operation
after fault is cleared.
Page 12
TABLE 4 Continued
E 270
Soft lockout - Exceeded maximum number of retries. No flame current
sensed.
CodeDiagnostic Codes/Status of EquipmentAction Required to Clear and Recover
E 271
Soft lockout - Exceeded maximum number of retries. Last retry failed due
to the pressure switch opening.
E 272
Soft lockout - Exceeded maximum number of recycles. Last recycle due
to the pressure switch opening.
E 273
Soft lockout - Exceeded maximum number of recycles. Last recycle due
to flame failure.
E 274
Soft lockout - Exceeded maximum number of recycles. Last recycle
failed due to the limit circuit opening or limit remained open longer than
3 minutes.
E 275
Soft lockout - Flame sensed out of sequence. Flame signal is gone.Shut off gas. Check for gas valve leak. 1-hour soft
E 290
Ignitor circuit fault - Failed ignitor or triggering circuitry.Measure resistance of hot surface ignitor. Replace
Check for proper gas flow. Ensure that ignitor is
lighting burner. Check flame sensor current. Clears
when heat call finishes successfully.
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 operation and restriction. Clears
when heat call finishes successfully.
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 (inches w.c.). Inspect
vent and combustion air inducer for correct opera
tion and restriction. Clears when heat call finishes
successfully.
Check micro-amperes of flame sensor using control
diagnostics or field-installed mode. Clean or replace
sensor. Measure voltage of neutral to ground to
ensure good unit ground. Clears when heat call
finishes successfully.
Shut down system. 1-hour soft lockout. Check firing
rate and air flow. Check for blockage. Clears when
heat call finishes successfully.
lockout. Clears when flame has been proven stable.
if open or not within specifications. 1-hour soft lock
out. Clears when flame has been proven stable.
Page 13
Integrated Control DIP Switches
EL296UHE units are equipped with a two-stage 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 jump
ers. The control includes an internal watchguard feature
which automatically resets the ignition control when it has
been locked out. After one hour of continuous thermostat
demand for heat, the watchguard will break and remake
thermostat demand to the furnace and automatically reset
the control to relight the furnace.
Heating Operation DIP Switch Settings
Switch 1 -- Thermostat Selection -- This unit may be
used with either a single-stage or two-stage thermostat.
The thermostat selection is made using a DIP switch which
must be properly positioned for the particular application.
The DIP switch is factory-positioned for use with a twostage thermostat. If a single-stage thermostat is to be used,
the DIP switch must be repositioned.
a-a -Select “OFF” for two-stage heating operation con
trolled by a two-stage heating thermostat (factory set
ting);
b - Select “ON” for two-stage heating operation con
trolled by a single-stage heating thermostat. This set
ting provides a timed delay before second-stage heat
is initiated.
Switch 2 a --- Second Stage Delay (Used with SingleStage Thermostat Only) -- This switch is used to deter
mine the second stage on delay when a single-stage ther
mostat is being used. The switch is factory-set in the OFF
position, which provides a 7-minute delay before secondstage heat is initiated. If the switch is toggled to the ON
position, it will provide a 12-minute delay before secondstage heat is initiated. This switch is only activated when
the thermostat selector jumper is positioned for SINGLEstage thermostat use.
Indoor Blower Operation DIP Switch Settings
Switches 3 and 4 -- Heating Mode Blower-Off Delay --
The blower-on delay of 30 seconds is not adjustable. The
blower-off delay (time that the blower operates after the
heating demand has been satisfied) can be adjusted by
moving switches 3 and 4 on the integrated control. The unit
is shipped from the factory with a blower-off delay of 90 se
conds. The blower off delay affects comfort and is adjust
able to satisfy individual applications. Adjust the blower off
delay to achieve a supply air temperature between 90° and
110°F at the exact moment that the blower is de-energized.
Longer off delay settings provide lower supply air tempera
tures; shorter settings provide higher supply air temperatu
res.Table 5 provides the blower off timings that will result
from different switch settings.
Blower Off Heating Mode Delay Switch Settings
Blower Off Delay
(Seconds)
60OnOff
90 (Factory)OffOff
120OffOn
180OnOn
Switch 5 -- Cooling Mode Blower-Off Delay-- The unit is
shipped from the factory with the dip switch positioned OFF
for a 45 second delay. Table 6 provides the cooling mode
off delay settings.
Blower Off Cooling Mode Delay Switch Settings
Blower Off Delay
(Seconds)
45 (Factory)Off
2On
Switches 6 and 7 -- Continuous Fan Mode -- Continuous
fan speed can be controlled by changing DIP switch posi
tions. Table 7 below provides DIP switch settings for con
tinuous fan mode.
Continuous Fan Mode Settings
Continuous Fan
Mode
Low Heat Speed
(factory)
Low Cool SpeedOffOn
High High SpeedOnOff
High Cool SpeedOnOn
TABLE 5
Switch 3Switch 4
TABLE 6
Switch 5
TABLE 7
Switch 6Switch 7
OffOff
Onboard Links
W914 Dehum
Onboard link W914, is a clippable connection between ter
minals R and DS on the integrated control. W914 must be
cut when the furnace is installed with a thermostat which
features humidity control. If the link is not cut, terminal “DS'
will remain energized not allowing the blower to reduce to
low cool speed upon a call for dehumidification.
W951 Heat Pump (R to O)
Onboard link W951 is a clippable connection between ter
minals R and O on the integrated control. W951 must be cut
when the furnace is installed in applications which include a
heat pump unit and a thermostat which features dual fuel
use. If the link is left intact, terminal “O” will remain ener
gized eliminating the HEAT MODE in the heat pump.
W915 2 Stage Compr (Y1 to Y2)
Onboard link W915 is a clippable connection between ter
minals Y1 and Y2 on the integrated control. W915 must be
cut if two-stage cooling will be used. If the Y1 to Y2 link is
not cut the outdoor unit will operate in second-stage cool
ing only.
IMPORTANT
If any onboard link is cut by mistake, install a jump
er across the corresponding terminals on the low
voltage terminal strip. Do not replace control.
Page 14
B- Indoor Blower Motor
BLOWER WHEEL REPLACEMENT
IMPORTANT
Each blower is statically and dynamically bal
anced as an assembly before installation in the
unit.
EL296UHE 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. The
motor is programmed to provide constant torque at each of
the five selectable speed taps. Each tap requires 24 volts to
energize.
Input Voltage Requirements
The circuit is designed to be operated with AC voltage. To
enable a tap requires 12 to 33VAC. Expected current draw
will be less than 20mA.
Troubleshooting the Motor
Troubleshooting the motor is an easy process. Follow
steps below.
1- Shut off power to unit.
Center Blower Wheel
in Blower Housing
FIGURE 6
ALIGN AND TIGHTEN SET SCREW WITH
FLAT SIDE OF MOTOR SHAFT
2- Remove input plugs P48 and P49 from motor. See fig
ure 8 for troubleshooting procedure.
If correct voltage is present in tests 1 and 2 and motor is not
operating properly, replace motor. The motor is not field re
pairable.
If replacing the indoor blower motor or blower wheel is nec
essary, placement is critical. The blower wheel must be
centered in the blower housing as shown in figure 6. When
replacing the indoor blower motor the set screw must be
aligned and tightened with the motor shaft as shown in fig
ure 7.
Housing Hub
Motor
Shaft
Set Screw
FIGURE 7
Page 15
Multi−Meter
r
)
r
)
P49
5
4
3
2
1
N
G
L
C
Test 1
Turn on power to unit. Check for 120 volts across terminals “L”
and “N” on input plug P48. If voltage is present continue to test
2. If voltage is not present problem may be may be upstream
of plug P48 and proceed to test 3.
P48
(set to VAC)
12012
0
Multi−Mete
(set to VAC
12012
Test 3 (if necessary)
Check for 120 volts across terminals “L1” and “Neutrals” on the
integrated control. If voltage is present, problem is with the har
ness. If voltage is not present problem may be may be with the
integrated control.
0
P49
5
4
3
2
1
N
G
L
C
P48
Test 2
Switch thermostat to CONTINUOUS FAN MODE. Check for 24
volts across terminal “C” on input plug P48and speed tap used for
continuous fan. (1, 2, 3, 4 or 5) on input plug P49. If 24 volts is not
present problem may be up stream of plug P49. Proceed to test
4.
Multi−Meter
(set to VAC)
24
FIGURE 8
Page 16
Multi−Mete
(set to VAC
24
Test 4 (if necessary)
Check for 24 volts across terminals “24 COM” and the “active
speed tap” on the integrated control. If voltage is present, prob
lem is with the harness. If voltage is not present problem may
be may be with the integrated control
Replacing the Motor Module
1. Disconnect electrical power to unit.
2. Remove unit access panel.
3. Unplug the two harnesses from the motor control mod
ule. See figure 9.
Unplug the Two Harness Connection
Motor Test
TWO HARNESS
CONNECTIONS
MOTOR
MOTOR CONTROL MODULE
FIGURE 9
4. Remove the two hex head bolts securing the motor
control module to the motor (see figure 10).
Remove the Hex Head Bolts
REMOVE BOTH HEX
HEAD BOLTS
FIGURE 10
5. Slide the motor control module away from the motor to
access and disconnect the internal three wire connec
tor. It is not necessary to remove blower motor itself.
Set both hex head bolts aside.
Testing the Motor (Figure11)
FIGURE 11
TABLE 8
Scale
2 M
200 K
20 K
2 K
200two hundred ohms0 - 200
Measurement range in
words
two megohm-two million
ohms
two hundred kilo-ohm-two
hundred thousand ohms
twenty kilo-ohm-twenty
thousand ohms
two kilo-ohm two-thousand
ohms
ohms
0 - 2,000,000
0 - 200,000
0 - 20,000
0 - 2,000
Motor Module Installation
All replacement motor control modules look similar; how
ever, each module is designed for a specific motor size. It is
very important to make sure that you are using the correct
replacement motor control module. USE OF THE WRONG
MOTOR CONTROL MODULE MAY RESULT IN UNEX
PECTED UNIT OPERATION.
1. Verify electrical power to unit is disconnected.
2. Connect three-wire harness from motor to control
module.
3. Mount new motor control module
to motor using two hex head bolts
removed in figure 10. Torque bolts
to 22 inch pounds or 1/16
th
clock
turn as exampled to the right.
4. Reconnect the two harnesses to
9
10
8
11
7
12
6
1
5
1/16
TURN
2
3
4
the motor control module.
5. The electrical connectors of the motor should be facing
down to form a drip loop (figure12). This will directs
moisture away from the motor and its electric connec
tions on the motor.
Drip Loop
If any motor fails the below tests, do not install the new con
trol module. The motor is defective and it also must be re
placed. The new control can fail if placed on a defective mo
tor.
1. Using an ohmmeter check the resistance from any one
of the motor connector pins to the aluminum end plate
of the motor. This resistance should be greater than
100k ohms.
2. Check the resistances between each of the three mo
tor connector pins. These should all read approxim
ately the same resistance within an ohm.
3. Check to see if the blower wheel spins freely.
Page 17
BACK OF CONTROL
MODULE
FIGURE 12
CONNECTOR
ORIENTATION
BETWEEN 4 AND 8
O'CLOCK
DRIP LOOP
C- Heating Components
1. Ignitor
®
The SureLight
ignitor is made of durable silicon nitride.
The integrated control provides 120 volts to the ignitor for a
consistent ignition and long ignitor life. Ohm value should
be 39 to 70. See figure 14 for ignitor location and figure 15
for ignitor check out.
NOTE - The EL296UHE furnace contains electronic com
ponents that are polarity sensitive. Make sure that the fur
nace is wired correctly and is properly grounded.
2. Flame Sensor
A flame sensor is located on the left side of the burner sup
port. See figure 14. The sensor tip protrudes into the flame
envelope of the left-most burner. The sensor can be re
moved for service without removing any part of the burn
ers. During operation, flame is sensed by current passed
through the flame and sensing electrode. The SureLight
control allows the gas valve to remain open as long as
flame signal is sensed. To check flame sense signal use
the push-button found on the integrated control and go to
Field Test Mode. The menu will display the flame signal.
See table 9 for flame signal.
TABLE 9
Flame Signal in Microamps
Normal
LowDrop Out
2.6 or greater2.5 or less0.6
3. Gas Valve
The valve (figure 14) is internally redundant to assure safe
ty shut-off. If the gas valve must be replaced, the same type
valve must be used.
24VAC terminals and gas control knob are located on the
valve. A wire harness connects the terminals from the gas
valve to the electronic ignition control. 24V applied to the
terminals energizes the valve.
Inlet and outlet pressure taps are located on the valve. A
regulator adjustment screw is located on the valve.
LPG change over kits are available from Lennox. Kits in
clude burner orifices and a gas valve.
caused by a blocked heat exchanger, flue or lack of com
bustion air. The switch is factory set to trip (open) at 210°F
and cannot be adjusted. The switch can be manually reset.
To manually reset a tripped switch, push the reset button
located on the control.
5. Burners
All units use inshot burners. Burners are factory set and re
quire no adjustment. Always operate the unit with the burn
er box front panel in place. Each burner uses an orifice that
is precisely matched to the burner input. Burners can be re
moved as a one piece assembly for service. If burner as
sembly has been removed, it is critical to align center of
each burner to the center of the clamshell when re-instal
ling. See more detail in Section VI- MAINTENANCE.
6. Primary Limit Control (S10)
The primary limit (S10) is located in the heating vestibule
panel. When excess heat is sensed in the heat exchanger,
the limit will open. If the limit is open, the furnace control en
ergizes the supply air blower and closes the gas valve. The
limit automatically resets when unit temperature returns to
normal. The switch must reset within three minutes or the
SureLight control will go into Watch guard for one hour.
The switch is factory set and cannot be adjusted.
The switch may have a different set point for each unit mod
el number. See Lennox Repair Parts Handbook if limit
switch must be replaced. When removing switch make
note of orientation. When replacing switch make sure the
three mounting holes are lined up with the screw holes in
the vestibule for correct orientation.
Primary Limit Control (S10)
Mounting Hole
Mounting Hole
4. Flame Rollout Switches (S47)
Flame rollout switch is a high temperature limit located on
top of the burner box, one on each side.- See figure 14. The
limit is a N.C. SPST manual‐reset limit. When S47 senses
rollout, the circuit breaks and the ignition control immedi
ately stops ignition and closes the gas valve. Rollout can be
Mounting Hole
FIGURE 13
Page 18
Intake Air Top Cap
Rollout Switch
EL296UHE HEATING COMPONENTS
Burner Assembly
Sensor
Rollout Switch
Ignitor
Burner Box Cover
Manifold And Gas Orifices
Two-Stage Gas Valve
FIGURE 14
Page 19
Check ignitor circuit for correct resistance.
Test 1
Remove 5-pin plug from control.
Check ohms reading across terminals 1 and 5.
Reading should be between 39 and 70 ohms. 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.
Meter
(set to ohms)
EL296UHE Ignitor Check
Integrated Control Detail
Seperate the 2-pin jack-plug near the manifold and check
Check ignitor for correct resistance.
resistance of ignitor at the plug. Reading should be
between 39 and 70 ohms. If the reading is correct, then
the problem is with the wiring between the jack-plug and
the control. If reading is not correct, the issue is the ignitor.
Test 2
Meter
(set to ohms)
Insert meter probes into terminals 1 and 5 (use small
Check ignitor for correct voltage
diameter probes in order not to damage plug).
Check voltage during 20 second ignitor warm up period.
Voltage should read 120 volts +
these values, check for correct supply voltage to furnace.
Test 3
10%. If voltage reads below
Integrated Control Detail
Meter
(set to AC volts)
Integrated Control Detail
FIGURE 15
Page 20
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