Lennox International Inc. Elite Series Gas Furnace manual

Page 1 02/13 *2P0213* 507067-01 *P507067-01* E 2013 Lennox Industries Inc. Dallas, T exas, USA AIR FLOW UPFLOW AIR FLOW AIR FLOW HORIZONT AL RIGHT HORIZONT AL LEFT INST ALLA TION INSTRUCTIONS EL296UHE ELITE ® SERIES GAS FURNACE UPFLOW / HORIZONT AL AIR DISCHARGE 507067-01 02/2013 Supersedes 01/2012 THIS MANUAL MUST BE LEFT WITH THE HOMEOWNER FOR F[...]

Page 2 EL296UHE Unit Dimensions - inches (mm) 1−1/ 2 (38) 9/16 (14 ) AIR FLOW mm in. 6−9/16 (167) Left 9 (229) Right 23 (584) (19) 3/4 (19) 1 Bottom Return Air Opening GAS PIPING INLET (Either Side) Side Return Air Opening (Either Side) 1 Bottom Return Air Opening EXHAUST AIR OUTLET ELECTRICAL INLET (Either Side) SUPPL Y AIR OPENING FRONT VIEW [...]

P age 3 EL296UHE Gas Furnace The E L296UHE Category IV gas furnace is s hipped ready for installation in the upflow o r h orizontal position. T he f ur nace is shipped with the bottom panel in place. The bot tom panel must b e removed i f the unit is to b e installed in horizontal or upflow applications with bottom return air . The EL296UHE c[...]

Page 4 In order to ensure proper unit operation in non-direct vent applications, combustion and ventilation air supply must be provided according to the current National Fuel Gas Code or CSA‐B149 standard. Installation Locations This furnace is CSA International certified for installation clearances to combustible material as listed on the unit n[...]

P age 5 D The input rate and temperature rise must be set per the furnace rating plate. D One hundred percent (100%) outdoor air must be pro vided for combustion air requirements during construc tion. T emporary ducting may supply outdoor air to the furnace. Do not connect duct directly to the furnace. Size the temporary duct following these [...]

Page 6 piping. A portion of this information has been reprinted with permission from the National F uel Gas Code ( ANSI- Z223.1/NFP A 54). This reprinted material is not the com  plete and official position of the ANSI on the referenced subject, w hich is represented only by the standard in its entirety . In Canada, refer to the CSA B149 install[...]

P age 7 Air from Outside If a ir f r om o utside i s b rought i n for combustion and v entila tion, t he confined space shall be provided with two perma  nent o penings. One opening s hall be within 1 2” (305mm) of t he t op o f the enclosure and one within 12” ( 305mm) o f the bottom. These openings must communicate directly or b y ducts[...]

Page 8 FIGURE 9 EQUIPMENT IN CONFINED SP ACE - ALL AIR FROM OUTSIDE OUTLET AIR INLET AIR NOTE -Each air duct opening shall have a free area of at least one square inch per 2,000 Btu (645mm 2 p er .59kW) per hour of the total input rating of all equipment in the enclosure. If the equipment room is located against an outside wall and the air openings[...]

P age 9 FIGURE 1 1 SETTING EQUIPMENT UPFLOW APPLICA TION HORIZONT AL APPLICA TION FRONT VIEW SIDE VIEW FRONT VIEW END VIEW UNIT FRONT AIR FLOW UNIT FRONT 1/2” max. 1/2” max. AIR FLOW AIR FLOW SIDE VIEW UNIT FRONT Unit must be level side-to-side. Unit may be positioned from level to 1/2” toward the front to aid in draining.[...]

Page 10 W ARNING Improper installation of the furnace can result in per sonal injury or death. Combustion and flue products mus t never be allowed to enter the return air system or air in th e living space. Use sheet metal screws and joint tape to seal return air system to furnace. In platform installations with f urnace return, the fur nace [...]

P age 11 FIGURE 14 Optional Return Air Base (Upflow Applications Only) NOTE- Optional side return air filter kits are not for use with return air base. 1 Both the unit return air opening and the base return air opening must be covered by a single plenum or IAQ cabinet. Minimum unit side return air opening dimensions for units requiring 1800 cfm of [...]

Page 12 The EL296UHE furnace can be installed in horizontal ap plications with either right- or left-hand air discharge. Refer to fig ure 17 for clearances in horizontal applications. Horizontal Application Installation Clearances Left End Right End Right-Hand Discharge Left-Hand Discharge To p Bottom (Floor)** Bottom (Floor)** Left End Right En[...]

P age 13 *Gas connector may be used for Canadian installation if accept able by local authority having jurisdiction. FIGURE 19 *GAS CONNECTION RAISED PLA TFORM SERVICE PLA TFORM INT AKE PIPE EXHAUST PIPE Return Air -- Horizontal Applications Return a ir m ay b e brought in only through the end of a fur nace installed in the horizontal positio[...]

Page 14 CAUTION Solvent cements for plastic pipe are flammable liq uids and should be kept away from all sources of ignition. Do not use excessive amounts of solvent ce me nt when making joints. Good ventilation should be maintained to reduce fire hazard and to minimize breathing of solvent vapors. A void contact of ce ment with skin and eyes[...]

P age 15 8 - After assembly , w ipe e xcess c ement f rom pipe a t e nd of fitting socket. A properly made joint will show a bead a round its entire perimeter . A ny gaps may i ndi cate an improper assembly due to insuf ficient sol vent. 9 - Handle joints carefully until completely set. V enting Practices FIGURE 20 * See table 2 for allowable[...]

Page 16 Resize the common venting system to the minimum vent pipe size determined by using the appropriate tables in Appendix G. (These are in the current stan dards of the National Fuel Gas Code ANSI Z223.1. CHIMNEY OR GAS VENT (Check sizing for water heater only) FURNACE (Replaced by EL296) WA TER HEA TER OPENINGS (T o Adjacent Room) If an EL2[...]

P age 17 Us e the following steps to correctly size vent pipe diameter . FIGURE 23 Piping Size Process 1 2 3 4 5 6 Which style termination being used? Standard or concentric? See table 4. Which needs most elbows? Intake or exhaust? How many elbows? Count all elbows inside and outside house. Desired pipe size? 2”, 2-1/2”, 3” Use table 5 or 6 t[...]

Page 18 T ABLE 4 OUTDOOR TERMINA TION USAGE Input Size V ent Pipe Dia. in. ST ANDARD CONCENTRIC FlushMount Kit W all Kit W all Ring Kit Field Fabricated 1-1/2 inch 2 inch 3 inch 2 inch 3 inch 2 inch 51W1 1 (US) 51W12 (CA) 22G44 (US) 4 30G28 (CA) 44J40 (US) 4 81J20 (CA) 15F74 71M80 (US) 4 44W92 (CA) 69M29 (US) 4 44W92 (CA) 60L46 (US) 4 44W93 (CA) 04[...]

P age 19 T ABLE 5 Maximum Allowable Intake or Exhaust V ent Length in Feet NOTE - Size i ntake and e xhaus t pipe l ength separately . V alues in t able are for I ntake OR E xhaust, not c ombined total. Both I n tak e and E xhaus t must b e same p ipe size. N OT E - Additional vent pipe and elbows used to terminate the vent pipe outside the structu[...]

Page 20 T ABLE 5 Continued Maximum Allowable Intake or Exhaust V ent Length in Feet Size intake and exhaust pipe length separately . Values in table are for Intake OR Exhaust, not combined total. Both Intake and Exhaust must be same pipe size. Concentric T ermination at Elevation 0 - 4500 ft Number Of 90° Elbows Used 2” Pipe 2-1/2” Pipe 3” P[...]

P age 21 T ABLE 6 Maximum Allowable Exhaust V ent Lengths With Furnace Installed in a Closet or Basement Using V entilated Attic or Crawl Space For Intake Air in Feet NOTE - Size i ntake and e xhaus t pipe l ength separately . V alues in t able are for I ntake OR E xhaust, not c ombined total. Both I n tak e and E xhaus t must b e same p ipe size. [...]

Page 22 FIGURE 24 TYPICAL EXHAUST AND INT AKE PIPE CONNECTIONS IN UPFLOW DIRECT OR NON-DIRECT VENT APPLICA TIONS TRANSITION 2” 2” 2” 3” 2” 2” or DO NOT transition from smaller to larger pipe in horizontal runs of exhaust pipe . EXHAUST *2” * When transitioning up in pipe size, use the shortest length of 2” PVC pipe possible. INT AKE[...]

P age 23 Intake Piping The EL296UHE furnace may be installed in either direct vent or non-direct vent applications. In non-direct vent applications, w hen i ntake a ir will be d rawn i n to t he f urnace from t he s urrounding space, t he i ndoor air quality m ust be considered and guidelines listed in Combustion, Dilution and V entilation Air sect[...]

Page 24 CAUTION If this unit is being installed in an application with combustion air coming in from a space serviced by an exhaust fan, power exhaust fan, or other device which may create a negative pressure in the space, take care when sizing the inlet air opening. The in let air opening must be sized to accommodate the maximum volume of exhau[...]

P age 25 T ABLE 7 Maximum Allowable Exhaust V ent Pipe Length Without Insulation In Unconditioned Space For Winter Design T emperatures Winter Design T emperatures 1 °F (°C) V ent Pipe Diameter Unit Input Size 045 070 090 11 0 135 32 to 21 (0 to -6) 2 in. 20 30 40 24 N/A 2-1/2 in. 15 22 30 40 N/A 3 in. 12 18 25 32 32 20 to 1 (-7 to -17) 2 in 12 2[...]

Page 26 FIGURE 30 VENT TERMINA TION CLEARANCES FOR NON-DIRECT VENT INST ALLA TIONS IN THE US AND CANADA K D E L B C F G A B J A M I H INSIDE CORNER DET AIL VENT TERMINAL AIR SUPPL Y INLET AREA WHERE TERMINAL IS NOT PERMITTED Fixed Closed Operable B Fixed Closed Operable B B A = B = C = D = E = F = G = H = I = J = K = L = M = US Installations 1 Cana[...]

P age 27 FIGURE 31 VENT TERMINA TION CLEARANCES FOR DIRECT VENT INST ALLA TIONS IN THE US AND CANADA K D E L B C F G A B J A M I H INSIDE CORNER DET AIL VENT TERMINAL AIR SUPPL Y INLET AREA WHERE TERMINAL IS NOT PERMITTED Fixed Closed Operable B Fixed Closed Operable B B A = B = C = D = E = F = G = H = I = J = K = L = M = US Installations 1 Canadia[...]

Page 28 Details of Intake and Exhaust Piping T erminations for Direct V ent Installations NOTE - In Direct V ent i nstallations, c ombustion air is t ak en from outdoors and flue gases are discharged to out doors. NOTE - Flue gas may be slightly acidic and may adversely affect some building materials. If any vent termination is used and the f[...]

P age 29 7 - If i ntake and exhaust piping m ust b e r un u p a s ide w all to position above snow accumulation or other ob  structions, piping must be supported every 24” (610MM) as shown in figures 36 and 37 . In addition, close c oupled wall termination kits m ust be extended for use in this application. See figures 44 and 45. When exhaust [...]

Page 30 FIGURE 36 FIELD F ABRICA TED W ALL TERMINA TION OR (15F74) W ALL RING TERMINA TION KIT See venting table 5 for maximum venting lengths with this arrangement. * Use wall support every 24” (610MM). Use two wall supports if extension is greater than 24” (610MM) but less than 48” (1219 MM). NOTE - One wall support must be 6” (152MM) fro[...]

P age 31 FIGURE 38 2” EXTENSION FOR 2” PVC PIPE1” EXTENSION FOR 3” PVC PIPE 1-1/2” ACCELERA TOR ( all -45, -070 and -090 units) FURNACE EXHAUST PIPE FURNACE INT AKE PIPE 4'' GLUE EXHAUST END FLUSH INTO TERMINA TION FLA T SIDE FLUSH-MOUNT SIDE W ALL TERMINA TION 51W1 1 (US) or 51W12 (Canada) FIGURE 39 DIRECT VENT CONCENTRIC ROOFT[...]

Page 32 FIGURE 44 12” (305MM) Minimum Above Grade or Average Snow Accumulation 1/2” (13 mm) FOAM INSULA TION (Field−Furnished) 5” (127 mm) 5−1/2” (140 mm) EXHAUST AIR INT AKE AIR GRADE 12” (305 mm) INT AKE AIR EXHAUST AIR GRADE 12” (305MM) Max. for 2” (51MM) Dia. Exhaust 20” (508MM) Max. for 3” (76MM) Dia. Exhaust WALL SUPPORT[...]

P age 33 EL296UHE DIRECT VENT APPLICA TION USING EXISTING CHIMNEY NOTE - Do not discharge exhaust gases directly into any chimney or vent stack. If ver tical discharge through an existing unused chimney or stack is required, insert piping inside chimney until the pipe open end is above top of chimney and terminate as illus trated. In any exte[...]

Page 34 NOTE - Do not discharge exhaust gases directly into any chimney or vent stack. If ver tical discharge through an existing unused chimney or stack is required, insert piping inside chimney until the pipe open end is above top of chimney and terminate as illus trated. In any exterior portion of chimney , the exhaust vent must be insulat[...]

P age 35 FIGURE 52 T ubing Hose Clamp Barbed Fitting Field Provided Drain Components Elbow CAUTION Do not use copper tubing or existing copper conden sate lines for drain line. 6 - If unit will be started immediately upon completion of installation, prime trap per procedure outlined in Unit Start-Up section. Condensate line must slope downward a[...]

Page 36 FIGURE 56 EL296UHE with Evaporator Coil Using a Separate Drain (Unit shown in horizontal left-hand discharge position) . 5’ max. PVC Pipe Only 4”min 5”max Evaporator Coil Drain Pan Condensate Drain Connection Field Provided V ent (4” min. to 5” max. above condensate connec tion) Piping from furnace and evaporator coil must slope d[...]

P age 37 FIGURE 59 Drain T rap Assembly (Furnished) V ent Drain T rap Clean Out 5 Feet Maximum Coupling 3/4 inch slip X slip (Not Furnished) 90 ° Elbow 3/4 inch PVC (Not Furnished) 3/4 inch PVC Pipe (Not Furnished) 1/2 inch PVC Pipe (Not Furnished) Condensate Drain Connection In Unit Drain Assembly for 1/2 inch Drain Pipe 90 ° Elbow 3/4 inch PVC [...]

Page 38 Gas Piping Gas s upply p iping s hould n ot a llow m ore t han 0 .5”W .C. d rop in pressure between gas meter and unit. Supply gas pipe must not be smaller than unit gas connection. CAUTION If a flexible gas connector is required or allowed by the authority that has jurisdiction, black iron pipe shall be installed at the gas valve and ext[...]

P age 39 GROUND JOINT UNION FIELD PROVIDED AND INST ALLED Left Side Piping (Standard) DRIP LEG MANUAL MAIN SHUT-OFF VA LV E Right Side Piping (Alternate) NOTE - BLACK IRON PIPE ONL Y TO BE ROUTED INSIDE OF CABINET GROUND JOINT UNION DRIP LEG MANUAL MAIN SHUT-OFF VA LV E Gas V alve Gas V alve FIGURE 61 Horizontal Applications Possible Gas Piping Con[...]

Page 40 T ABLE 10 GAS PIPE CAP ACITY - FT 3 /HR (kL/HR) Nominal Iron Pipe Size inches (mm) Internal Diameter inches (mm) Length of Pipe - feet (m) 10 (3.048) 20 (6.096) 30 (9.144) 40 (12.192) 50 (15.240) 60 (18.288) 70 (21.336) 80 (24.384) 90 (27.432) 100 (30.480) 1/2 (12.7) .622 (17.799) 172 (4.87) 11 8 (3.34) 95 (2.69) 81 (2.29) 72 (2.03) 65 (1.8[...]

P age 41 Accessory T erminals One line voltage “ACC” 1/4” spade terminal is provided on the furnace integrated control. See figure 6 5 for integrated control configuration. This terminal is energized when the indoor blower is operating. Any accessory rated up to one amp can be connected to this terminal with the neutral leg of the circuit bei[...]

Page 42 TYPICAL EL296UHE WIRING DIAGRAM FIGURE 64[...]

P age 43 Integrated Control FIGURE 65 THERMOST A T CONNECTIONS (TB1) 1/4” QUICK CONNECT TERMINALS DS = DEHUMIDIFICA TION SIGNAL W2 = HEA T DEMAND FROM 2ND ST AGE T/ST A T W1 = HEA T DEMAND FROM 1ST ST AGE T/ST A T R = CLASS 2 VOL T AGE TO THERMOST A T G = MANUAL F AN FROM T'ST A T C = THERMOST A T SIGNAL GROUND CONNECTED TO TRANSFORMER GRD ([...]

Page 44 Integrated Control DIP Switch Settings 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 re[...]

P age 45 T ABLE 14 EL296 Field Wiring Applications With Conventional Thermostat Thermostat DIP Switch Settings and On-Board Links (See figure 65) Wiring Connections DIP Switch 1 Thermostat Heating Stages On Board Links Must Be Cut T o Select System Options 1 Heat / 1 Cool NOT E - Use DIP switch 2 to set second-stage heat ON delay . OFF-7 minutes. O[...]

Page 46 T ABLE 14 EL296 Field Wiring Applications With Conventional Thermostat (Continued) Thermostat DIP Switch Settings and On-Board Links (See figure 65) Wiring Connections DIP Switch 1 Thermostat Heating Stages On Board Links Must Be Cut T o Select System Options 2 Heat / 2 Cool OFF CUT ON-BOARD LINK W915 2 ST AGE COMPR DEHUM S1 T'STAT FUR[...]

P age 47 T ABLE 14 EL296 Field Wiring Applications With Conventional Thermostat (Continued) Thermostat DIP Switch Settings and On-Board Links (figure 65) Wiring Connections DIP Switch 1 Thermostat Heating Stages On Board Links Must Be Cut T o Select System Options Dual Fuel Single Stage Heat Pump ComfortSense 7000 L7724U thermostat w/ dual fuel cap[...]

Page 48 T ABLE 14 EL296 Field Wiring Applications With Conventional Thermostat (Continued) Thermostat DIP Switch Settings and On-Board Links (figure 65) Wiring Connections DIP Switch 1 Thermostat Heating Stages On Board Links Must Be Cut T o Select System Options Dual Fuel Single Stage Heat Pump ComfortSense 7000 L7742U thermostat w/ dual fuel capa[...]

P age 49 Unit Start-Up FOR YOUR SAFETY READ BEFORE OPERA TING W ARNING Do not use this furnace if any part has been under  water . A flood-damaged furnace is extremely dan gerous. Attempts to use the furnace can result in fire or explosion. Immediately call a qualified ser vice t echnician t o inspect the furnace a nd t o r eplace all g as[...]

Page 50 4 - Move gas valve switch to OFF . 5 - Replace the access panel. Failure T o Operate If the unit fails to operate, check the following: 1 - Is the thermostat calling for heat? 2 - Are access panels securely in place? 3 - Is the main disconnect switch closed? 4 - Is there a blown fuse or tripped breaker? 5 - Is the filter dirty or plugged? D[...]

P age 51 Proper Combustion Furnace should operate minimum 15 minutes with correct manifold pressure and gas flow rate before checking com bustion. T ake combustion sample beyond the flue outlet and compare to the tables below . T ABLE 16 EL296 Model CO 2 % For Nat CO 2 % For L.P Low Fire High Fire Low Fire High Fire 045 5.4 - 6 .4 7.5 - 8 .5 6.4[...]

Page 52 T esting for Proper V enting and Sufficient Combustion Air for Non-Direct V ent Applications W ARNING CARBON MONOXIDE POISONING HAZARD! Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monox ide poisoning or death. The following steps shall be[...]

P age 53 Other Unit Adjustments Primary Limit . The primary limit is located on the heating compartment vestibule panel. This limit is factory set and requires no ad justment. Flame Rollout Switches (T wo) These manually reset switches are located on the front of the burner box. Pressure Switch The pressure switch is located in the heating compa[...]

Page 54 Applications Using A Single-Stage Thermostat B - Heating Sequence -- Integrated Control Thermostat Selection DIP Switch 1 ON in “Single-Stage” Position NOTE - In these applications, two-stage heat will be initi ated by the integrated control if heating demand has not been sat isfi ed aft er th e field adjustable period (7 or 12 min?[...]

P age 55 Service W ARNING ELECTRICAL SHOCK, FIRE, OR EXPLOSION HAZARD. Failure to follow safety warnings exactly could result in dangerous operation, serious injury , death or property damage. Improper servicing could result in dangerous opera tion, serious injury , death, or property damage. Before servicing, disconnect all electrical power to [...]

Page 56 Start-Up & Performance Check List Gas Supply Pressure SUPPL Y AIR Line V oltage GAS SUPPL Y Natural Gas LP Propane Gas Piping Connections Tight Leak T ested Supply Line Pressure “W .C.________ 1 INT AKE / EXHAUST PIPE All Joints Primed and Glued T erminations Installed Properly Pipes Supported Condensate T rap Primed / Line Sloped Hea[...]

P age 57 Contractor's: Name_________________________T elephone_____________Checklist Completed____________________ Job Address_____-________________________________T echnician's Name___________________________________ 1 HEA TING MODE GAS MANIFOLD PRESSURE “W .C._____ COMBUSTION SAMPLE CO 2 % ______ CO PPM_______ 2 INDOOR BLOWER AMPS____[...]

Page 58 Requirements for Commonwealth of Massachusetts Modifications to NFP A-54, Chapter 10 Revise NF P A-54 section 10.8.3 to add the following re quirements: Fo r all side wall, horizontally vented, gas-fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned [...]