Lennox EL296UH070XE36B, EL296UH135XE60D, EL296UH090XE48C, EL296UH110XE60C, EL296DFE Series Unit Information

...
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.
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........................
) 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.
Page 1
© 2014 Lennox Industries Inc.
SPECIFICATIONS
Gas Heating Performance
High Fire
Temperature rise range - °F 35-65 50-80 45-75
Gas Manifold Pressure (in. w.g.)
Nat. Gas / LPG/Propane
Low Fire
Temperature rise range - °F 20 - 50 25 - 55 30 - 60
Gas Manifold Pressure (in. w.g.)
Nat. Gas / LPG/Propane
High static - in. w.g. Heating 0.5 0.5 0.5
Connections
Intake / Exhaust Pipe (PVC) 2 / 2 2 / 2 2 / 2
in.
Condensate Drain Trap (PVC pipe) - i.d. 3/4 3/4 3/4
with furnished 90° street elbow 3/4 slip x 3/4 Mipt 3/4 slip x 3/4 Mipt 3/4 slip x 3/4 Mipt
with eld supplied (PVC coupling) - o.d. 3/4 slip x 3/4 MPT 3/4 slip x 3/4 MPT 3/4 slip x 3/4 MPT
Indoor
Wheel nominal diameter x width - in. 10 x 8 10 x 8 10 x 10
Blower
Tons of add-on cooling 1.5 - 3 1.5 - 3 2.5 - 4
Air Volume Range - cfm 520 - 1345 550 - 1380 760 - 1740
Electrical Data Voltage 120 volts - 60 hertz - 1 phase
Blower motor full load amps 6.8 6.8 8.4
Maximum overcurrent protection 15 15 15
Shipping Data lbs. - 1 package 129 137 161
NOTE - Filters and provisions for mounting are not furnished and must be eld provided.
1
Annual Fuel Utilization Efciency based on DOE test procedures and according to FTC labeling regulations. Isolated combustion system rating for non-weatherized
furnaces.
Model No. EL296UH045XE36B EL296UH070XE36B EL296UH090XE48C
1
AFUE 96% 95.5% 95.7%
Input - Btuh 44,000 66,000 88,000
Output - Btuh 43,000 64,000 85,000
3.5 / 10.0 3.5 / 10.0 3.5 / 10.0
Input - Btuh 29,000 43,000 57,000
Output - Btuh 28,000 42,000 55,000
1.7 / 4.9 1.7 / 4.9 1.7 / 4.9
Cooling 0.5 0.5 0.5
Gas pipe size IPS 1/2 1/2 1/2
Motor output - hp 1/2 1/2 3/4
SPECIFICATIONS
Gas Heating Performance
High Fire
Temperature rise range - °F 45-75 55-85
Gas Manifold Pressure (in. w.g.)
Nat. Gas / LPG/Propane
Low Fire
Temperature rise range - °F 35 - 65 40 - 70
Gas Manifold Pressure (in. w.g.)
Nat. Gas / LPG/Propane
High static - in. w.g. Heating 0.5 0.5
Connections
Intake / Exhaust Pipe (PVC) 2 / 2 2 / 2
in.
Condensate Drain Trap (PVC pipe) - i.d. 3/4 3/4
with furnished 90° street elbow 3/4 slip x 3/4 Mipt 3/4 slip x 3/4 Mipt
with eld supplied (PVC coupling) - o.d. 3/4 slip x 3/4 MPT 3/4 slip x 3/4 MPT
Indoor
Wheel nominal diameter x width - in. 11-1/2 x 10 11-1/2 x 10
Blower
Tons of add-on cooling 3 - 5 3.5 - 5
Air Volume Range - cfm 1055 - 2220 1260 - 2405
Electrical Data Voltage 120 volts - 60 hertz - 1 phase
Blower motor full load amps 10.9 10.9
Maximum overcurrent protection 15 15
Shipping Data lbs. - 1 package 174 189
NOTE - Filters and provisions for mounting are not furnished and must be eld provided.
1
Annual Fuel Utilization Efciency based on DOE test procedures and according to FTC labeling regulations. Isolated combustion system rating for non-weatherized
furnaces.
Model No. EL296UH110XE60C EL296UH135XE60D
1
AFUE 96% 96%
Input - Btuh 110,000 132,000
Output - Btuh 106,000 127,000
3.5 / 10.0 3.5 / 10.0
Input - Btuh 72,000 86,000
Output - Btuh 70,000 84,000
1.7 / 4.9 1.7 / 4.9
Cooling 0.5 0.5
Gas pipe size IPS 1/2 1/2
Motor output - hp 1 1
Page 2
OPTIONAL ACCESSORIES - ORDER SEPARATELY
NOTE - FURNACES CANNOT BE TWINNED!
“B” Width
Models
CABINET ACCESSORIES
Horizontal Suspension Kit - Horizontal only 51W10 51W10 51W10
Return Air Base - Upow only 50W98 50W99 51W00
CONDENSATE DRAIN KITS
Condensate Drain Heat Cable 6 ft. 26K68 26K68 26K68
24 ft. 26K69 26K69 26K69
50 ft. 26K70 26K70 26K70
Heat Cable Tape Fiberglass - 1/2 in. x 66 ft. 36G53 36G53 36G53
Aluminum foil - 2 in. x 60 ft. 16P89 16P89 16P89
Crawl Space Vent Drain Kit US 51W18 51W18 51W18
Canada 51W19 51W19 51W19
CONTROLS
Blower Relay Kit (for two-stage outdoor units) 85W66 85W66 85W66
FILTER KITS
1
Air Filter and
Rack Kit
Horizontal (end) Size of lter - in. 87L96 - 18 x 25 x 1 87L97 - 20 x 25 x 1 87L98 - 25 x 25 x 1
Side Return Single 44J22 44J22 44J22
Ten Pack 66K63 66K63 66K63
Size of lter - in. 16 x 25 x 1 16 x 25 x 1 16 x 25 x 1
SERVICE KITS
Night Service Kit 10B89 10B89 10B89
Universal Service Kit - Switches 89W20 89W20 89W20
TERMINATION KITS
See Installation Instructions for specic venting information.
Termination Kits ­Direct Vent Applications Only
Termination Kits ­Direct or Non­Direct vent
2
Roof Termination Flashing Kit - Direct or
Non-Direct Vent (2 ashings)
1
Cleanable polyurethane, frame-type lter.
5
Kits contain enough parts for two, non-direct vent installations.
3
Non-direct vent only.
NOTE - Termination Kits 44W92, 44W93, 30G28, 51W12, 51W19, 81J20 are certied to ULC S636 standard for use in Canada only.
Concentric US - 2 in. 71M80 69M29 - - -
3 in. - - - 60L46 60L46
Canada - 2 in. 44W92 44W92 - - -
3 in. - - - 44W93 44W93
Flush-Mount US - 2, 2-1/2 or 3 in. 51W11 51W11 51W11
Canada - 2, 2-1/2 or 3 in. 51W12 51W12 51W12
Wall - Close
Couple
Wall - Close
Couple WTK
US - 2 in. 22G44 - - - - - -
3 in. 44J40 44J40 44J40
Canada - 2 in. 30G28 - - - - - -
3 in. 81J20 81J20 81J20
Roof 2 in. 15F75 15F75 - - -
Wall Ring Kit 2 in. 15F74
2 in. 44J41 44J41 44J41
“C” Width
“D” Width
Models
3
15F74 - - -
Models
Page 3
BLOWER DATA
EL296UH045XE36B PERFORMANCE (Less Filter)
External
Static
Pressure
in. w.g.
0.00 1345 340 1255 245 1150 185 895 105 845 95
0.10 1305 345 1225 250 1105 200 855 110 810 95
0.20 1290 360 1190 260 1080 205 825 120 780 105
0.30 1275 370 1150 270 1045 215 785 125 720 110
0.40 1220 385 1120 280 1015 220 735 135 690 120
0.50 1215 390 1090 290 980 230 705 140 635 125
0.60 1190 395 1060 300 950 240 650 150 600 135
0.70 N/A N/A 1015 300 900 250 620 155 555 140
0.80 N/A N/A 1000 310 870 260 580 160 520 145
EL296UH070XE36B PERFORMANCE (Less Filter)
External
Static
Pressure
in. w.g.
0.00 1380 315 1305 250 1190 200 965 105 920 100
0.10 1360 325 1270 255 1180 205 915 115 865 100
0.20 1310 335 1250 265 1130 215 880 120 815 110
0.30 1275 340 1205 275 1100 225 835 125 775 115
0.40 1250 355 1175 280 1065 230 795 135 730 125
0.50 1215 370 1145 295 1045 240 745 145 670 130
0.60 1200 380 1100 310 995 245 705 150 640 140
0.70 1145 380 1070 310 960 255 670 160 585 145
0.80 N/A N/A 1035 320 925 265 610 165 550 155
High Medium-High Medium Medium-Low Low
cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts
High Medium-High Medium Medium-Low Low
cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts
Air Volume / Watts at Various Blower Speeds
Air Volume / Watts at Various Blower Speeds
EL296UH090XE48C PERFORMANCE (Less Filter)
External
Static
Pressure
in. w.g.
0.00 1740 370 1505 250 1370 195 1285 160 1135 125
0.10 1695 390 1470 265 1325 205 1240 170 1090 135
0.20 1660 405 1435 280 1290 220 1195 185 1045 145
0.30 1615 415 1390 295 1240 235 1140 200 995 160
0.40 1590 425 1350 305 1200 245 111 0 210 945 165
0.50 1560 440 1310 320 1155 260 1055 225 895 175
0.60 1525 455 1255 335 1105 270 1005 230 855 190
0.70 1475 470 1220 340 1065 285 960 245 805 200
0.80 N/A N/A 1170 355 1010 295 920 255 760 210
High Medium-High Medium Medium-Low Low
cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts
Air Volume / Watts at Various Blower Speeds
Page 4
BLOWER DATA
EL296UH110XE60C PERFORMANCE (Less Filter)
Air Volume / Watts at Different Blower Speeds
External
Static
Pressure
in. w.g.
0.00 2220 645 1940 435 1765 335 1635 280 1435 200 2185 655 1915 440 1745 340 1620 275 1430 195
0.10 2170 660 1920 460 1715 350 1595 290 1380 205 2160 660 1880 460 1705 345 1570 285 1380 205
0.20 2130 680 1865 475 1670 370 1560 305 1345 220 2115 680 1835 470 1670 365 1535 305 1325 220
0.30 2095 700 1835 490 1640 390 1525 325 1285 230 2060 705 1795 495 1630 380 1505 320 1285 230
0.40 2065
0.50 2030 740 1755 525 1560 415 1425 355 1215 260 2000 740 1720 530 1535 415 1410 345 1195 260
0.60 1995 760 1705 550 1525 435 1380 370 1150 270 1955 760 1685 550 1505 435 1380 365 1145 275
0.70 1955 770 1660 560 1475 450 1350 375 1100 290 1935 775 1650 555 1455 450 1325 375 1100 285
0.80 1930 790 1635 575 1445 460 1300 395 1050 305 1890 790 1610 575 1425 460 1285 390 1055 295
EL296UH135XE60D PERFORMANCE (Less Filter)
External
Static
Pressure
in. w.g.
0.00 2405 940 2235 735 2070 545 1830 390 1620 280 2395 925 2235 710 2020 550 1800 380 1610 275
0.10 2365 960 2210 745 2020 565 1770 400 1585 295 2360 935 2175 735 2005 555 1760 395 1550 295
0.20 2330 975 2180 770 1950 580 1745 420 1535 315 2350 955 2160 760 1955 565 1725 415 1510 300
0.30 2295 1000 2120 785 1925 595 1690 435 1480 325 2290 990 2095 775 1890 590 1700 435 1420 325
0.40 2275
0.50 2225 1025 2035 815 1845 630 1605 475 1395 360 2230 1010 2040 815 1845 625 1590 470 1375 360
0.60 2185 1010 2020 835 1815 645 1565 485 1330 365 2170 1025 2000 820 1795 640 1580 485 1335 370
0.70 N/A N/A 1940 850 1735 665 1520 500 1310 385 N/A N/A 1935 845 1725 660 1520 500 1295 385
0.80 N/A N/A 1890 860 1715 680 1465 510 1285 400 N/A N/A 1880 855 1705 680 1470 510 1260 405
Bottom Return Air, Side Return Air with Optional Return Air Base, Return Air from Both Sides or Return Air from Bottom and One Side.
High Med-High Medium Med-Low Low High Med-High Medium Med-Low Low
cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts
720 1785 510 1600 405 1465 335 1250 245 2050 720 1760 510 1570 400 1455 330 1235 245
Air Volume / 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.
High Med-High Medium Med-Low Low High Med-High Medium Med-Low Low
cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts cfm Watts
1015 2075 805 1885 615 1640 460 1445 340 2255 995 2060 795 1850 615 1635 445 1390 340
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
1 Ignitor
2 Combustion Air Inducer High Speed
3 Combustion Air Inducer Low Speed
4 Combustion Air Inducer Neutral
5 Ignitor Neutral
TABLE 2
®
SureLight
Control 12 Pin Terminal Designation
PIN # Function
1 Gas Valve Second Stage
2 Second Stage pressure Switch
3 Rollout Switch In
4 Ground
5 24V Hot
6 Primary Limit In
7 Gas Valve First Stage
8 Gas Valve Common
9 24V Neutral
10 Ground
11 Primary Limit Out
12 First 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 C DHL 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
Display Action (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
Code Diagnostic Codes/Status of Equipment Action 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 detected System 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 failure Furnace will operate on 1st stage for remainder of
Hot surface ignitor sensed open Measure resistance of hot surface ignitor. Replace
Low pressure switch failed open. Check pressure (inches w.c.) of low pressure switch
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.
Code Diagnostic Codes/Status of Equipment Action 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)
60 On Off
90 (Factory) Off Off
120 Off On 180 On On
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
2 On
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 Speed Off On
High High Speed On Off
High Cool Speed On On
TABLE 5
Switch 3 Switch 4
TABLE 6
Switch 5
TABLE 7
Switch 6 Switch 7
Off Off
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
200 two hundred ohms 0 - 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
Low Drop Out
2.6 or greater 2.5 or less 0.6
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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