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Service Literature
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
) Standards and California Seasonal
x
Efficiency requirements. All units use a redundant gas
valve to assure safety shut-off as required by C.S.A.
All specifications in this manual are subject to change. Pro­
cedures outlined in this manual are presented as a recom­
mendation only and do not supersede or replace local or
state codes. In the absence of local or state codes, the
guidelines and procedures outlined in this manual (except
where noted) are recommendations only and do not consti­
tute code.

TABLE OF CONTENTS

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II Installation
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. . . . . . . . . . . . . . . . . . . . . . . . . .
VIII Field Wiring and Jumper Settings
. . . . . . . . . . . . . . . . . . . . . . . .
Corp. 1246-L10
Revised 03/2014
EL296UHE SERIES UNITS
®
two-stage
Page 2
Page 7
Page 22
Page 44
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Page 45
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Page 49
Page 50
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Page 53
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Page 56
Page 60
Page 1
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.
EL296UHE
© 2014 Lennox Industries Inc.

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   Summary of Contents for Lennox EL296UH045XE36B

  • Page 1: Table Of Contents

    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.
  • Page 2: Specifications

    SPECIFICATIONS Model No. EL296UH045XE36B EL296UH070XE36B EL296UH090XE48C Heating AFUE 95.5% 95.7% Performance High Input - Btuh 44,000 66,000 88,000 Fire Output - Btuh 43,000 64,000 85,000 Temperature rise range - °F 35-65 50-80 45-75 Gas Manifold Pressure (in. w.g.) 3.5 / 10.0 3.5 / 10.0...
  • Page 3 OPTIONAL ACCESSORIES - ORDER SEPARATELY NOTE - FURNACES CANNOT BE TWINNED! “B” Width “C” Width “D” Width Models Models Models CABINET ACCESSORIES Horizontal Suspension Kit - Horizontal only 51W10 51W10 51W10 Return Air Base - Upflow only 50W98 50W99 51W00 CONDENSATE DRAIN KITS Condensate Drain Heat Cable 6 ft.
  • Page 4: Blower Data

    BLOWER DATA EL296UH045XE36B PERFORMANCE (Less Filter) External Air Volume / Watts at Various Blower Speeds Static High Medium-High Medium Medium-Low Pressure Watts Watts Watts Watts Watts in. w.g. 0.00 1345 1255 1150 0.10 1305 1225 1105 0.20 1290 1190 1080 0.30...
  • Page 5 BLOWER DATA EL296UH110XE60C PERFORMANCE (Less Filter) Air Volume / Watts at Different Blower Speeds Bottom Return Air, Side Return Air with Optional Return Single Side Return Air − Air volumes in bold require field External Air Base, Return Air from Both Sides or Return Air from fabricated transition to accommodate 20 x 25 x 1 in.
  • Page 6: El296uhe Parts Identification

    EL296UHE PARTS IDENTIFICATION Field Make Up Box Burner Box Assembly Heat Exchanger Gas Valve Combustion Pressure Air Inducer Switch Assembly Bag Assemblies (shipping location) Door Interlock Primary Limit Switch Constant Torque Indoor Blower Motor Outer Access Panel Inner Access Panel Two-Stage Integrated Control FIGURE 1 Page 6...
  • Page 7: I Unit Components

    I-UNIT COMPONENTS 3. Circuit Breaker (CB8) A 24V circuit breaker is also located in the control box. The switch provides overcurrent protection to the transformer EL296UHE unit components are shown in figure 1. The (T1). The breaker is rated 3A at 32V. If the current exceeds gas valve, combustion air inducer and burners can be ac­...
  • Page 8 ® After the 15-second pre-purge period, the SureLight igni­ TABLE 1 tor warms up for 20 seconds after which the gas valve ® SureLight Control 5 Pin Terminal Designation opens for a 4-second trial for ignition. The ignitor remains PIN # Function energized during the trial until flame is sensed.
  • Page 9 INTEGRATED CONTROL 24VAC Indoor Blower Terminals Ignitor and Combustion Air Inducer Neutrals Flame Sense S4 DIP Switches Diagnostic Push Button On Board Links THERMOSTAT CONNECTIONS (TB1) 3/16” QUICK CONNECT TERMINALS DS = DEHUMIDIFICATION SIGNAL FLAME SENSE SIGNAL W2 = HEAT DEMAND FROM 2ND STAGE T/STAT HI COOL 24VAC W1 = HEAT DEMAND FROM 1ST STAGE T/STAT HI HEAT 24VAC...
  • Page 10 INTEGRATED CONTROL CONFIGURATION GUIDE 2ND STAGE HEAT ON DELAY 7 MIN UPSTAGE THERMOSTAT SELECTION DELAY COOLING BLOWER-OFF TWO STAGE DELAY THERMOSTAT 12 MIN UPSTAGE *45 SECOND COOL BLOWER DELAY 1−STAGE OFF DELAY THERMOSTAT (TIMED STAGING) −SEE SW #2 HSI/CAI 2 SECOND COOL BLOWER HEATING BLOWER−OFF DELAY OFF DELAY...
  • Page 11: Integrated Diagnostic Codes/status Of Equipment

    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).
  • Page 12 TABLE 4 Continued E 125 Control failed self-check, internal error, failed hardware. Will restart if Hardware problem on the control. Cycle power on error control. Replace if problem prevents service and is recovers. Integrated control not communicating. Covers hardware errors persistent.
  • Page 13 TABLE 4 Continued E 270 Soft lockout - Exceeded maximum number of retries. No flame current Check for proper gas flow. Ensure that ignitor is sensed. lighting burner. Check flame sensor current. Clears when heat call finishes successfully. Code Diagnostic Codes/Status of Equipment Action Required to Clear and Recover E 271 Soft lockout - Exceeded maximum number of retries.
  • Page 14 Integrated Control DIP Switches TABLE 5 Blower Off Heating Mode Delay Switch Settings EL296UHE units are equipped with a two-stage integrated Blower Off Delay control. This control manages ignition timing, heating Switch 3 Switch 4 (Seconds) mode fan off delays and indoor blower speeds based on selections made using the control dip switches and jump­...
  • Page 15 B- Indoor Blower Motor BLOWER WHEEL REPLACEMENT IMPORTANT Center Blower Wheel in Blower Housing 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.
  • Page 16 Multi−Meter (set to VAC) Multi−Meter (set to VAC) Test 1 Test 3 (if necessary) Turn on power to unit. Check for 120 volts across terminals “L” Check for 120 volts across terminals “L1” and “Neutrals” on the and “N” on input plug P48. If voltage is present continue to test integrated control.
  • Page 17 Replacing the Motor Module Motor Test 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 TWO HARNESS FIGURE 11 CONNECTIONS TABLE 8 MOTOR...
  • Page 18 Inlet and outlet pressure taps are located on the valve. A regulator adjustment screw is located on the valve. Mounting Hole LPG change over kits are available from Lennox. Kits in­ clude burner orifices and a gas valve. 4. Flame Rollout Switches (S47)
  • Page 19 EL296UHE HEATING COMPONENTS Burner Assembly Intake Air Top Cap Sensor Rollout Switch Rollout Switch Ignitor Manifold And Gas Orifices Burner Box Cover Two-Stage Gas Valve FIGURE 14 Page 19...
  • Page 20 EL296UHE Ignitor Check Test 1 Check ignitor circuit for correct resistance. 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.
  • Page 21 7. Combustion Air Inducer (B6) and On heat demand (first or second stage) the switch senses Cold End Header Box that the combustion air inducer is operating. It closes a cir­ All EL296UHE units use a two-speed combustion air induc­ cuit to the integrated control when pressure across the er to move air through the burners and heat exchanger dur­...
  • Page 22 II-PLACEMENT AND INSTALLATION IMPORTANT All pipe, fittings, primer and solvent cement must conform with American National Standard Institute and the Ameri­ EL296UHE exhaust and intake connections are can Society for Testing and Materials (ANSI/ASTM) stan­ made of PVC. Use PVC primer and solvent cement dards.
  • Page 23: Joint Cementing Procedure

    TABLE 15 OUTDOOR TERMINATION USAGE* STANDARD CONCENTRIC Flush­ Wall Kit Wall Ring Kit Mount 1-1/2 inch 2 inch 3 inch Vent 2 inch 3 inch 2 inch Pipe Input Size Field Dia. in. 51W11 71M80 69M29 Fabricated 44J40 (US) 22G44 (US) (US) (US) 60L46 (US)
  • Page 24 Conduct the following test while each appliance is operat­ Venting Practices ing and the other appliances (which are not operating) re­ main connected to the common venting system. If the vent­ ing system has been installed improperly, you must cor­ rect the system as indicated in the general venting re­...
  • Page 25 NOTE - Exhaust piping should be checked carefully to make sure there are no sags or low spots. ® NOTE - Lennox has approved the use of DuraVent manu­ FIGURE 19 factured vent pipe and terminations as an option to PVC.
  • Page 26 TABLE 16 Use the following steps to correctly size vent pipe diameter. MINIMUM VENT PIPE LENGTHS EL296UHE MIN. VENT LENGTH* MODEL Piping Size Process 15 ft. or 5 ft. plus 2 elbows or 045, 070, 090, 110, 135 10 ft. plus 1 elbow What is the *Any approved termination may be added to the minimum length listed.
  • Page 27 TABLE 17 Maximum Allowable Intake or Exhaust Vent Length in Feet NOTE - 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. NOTE - Additional vent pipe and elbows used to terminate the vent pipe outside the structure must be included in the total vent length calculation.
  • Page 28 TABLE 17 Continued Maximum Allowable Intake or Exhaust Vent 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 Termination at Elevation 0 - 4500 ft 2”...
  • Page 29 TABLE 18 Maximum Allowable Exhaust Vent Lengths With Furnace Installed in a Closet or Basement Using Ventilated Attic or Crawl Space For Intake Air in Feet NOTE - 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.
  • Page 30 TYPICAL EXHAUST AND INTAKE PIPE CONNECTIONS IN UPFLOW DIRECT OR NON-DIRECT VENT APPLICATIONS EXHAUST INTAKE EXHAUST INTAKE 2” 2” 2” 2” 3” 3” TRANSITION TRANSITION 2” 2” *2” *2” DO NOT transition from smaller to larger pipe in horizontal runs of exhaust pipe.
  • Page 31 Intake Piping TYPICAL AIR INTAKE PIPE CONNECTIONS The EL296UHE furnace may be installed in either direct HORIZONTAL NON−DIRECT VENT APPLICATIONS vent or non-direct vent applications. In non-direct vent (Horizontal Right−Hand Air Discharge Application Shown) applications, when intake air will be drawn into the furnace from the surrounding space, the indoor air quality must be considered and guidelines listed in Combustion, Dilution PVC pipe...
  • Page 32 General Guidelines for Vent Terminations CAUTION In Non‐Direct Vent applications, combustion air is taken If this unit is being installed in an application with from indoors or ventilated attic or crawlspace and the flue combustion air coming in from a space serviced by gases are discharged to the outdoors.
  • Page 33 TABLE 19 Maximum Allowable Exhaust Vent Pipe Length (in ft.) Without Insulation In Unconditioned Space For Winter Design Temperatures Unit Input Size Winter Design Vent Pipe Temperatures °F (°C) Diameter 2 in. 32 to 21 (0 to -6) 2-1/2 in. 3 in.
  • Page 34: Vent Termination Clearances

    ‡ Permitted only if veranda, porch, deck or balcony is fully open on a minimum of two sides beneath the floor. Lennox recommends avoiding this location if possible. FIGURE 28...
  • Page 35 ‡ Permitted only if veranda, porch, deck or balcony is fully open on a minimum of two sides beneath the floor. Lennox recommends avoiding this location if possible. FIGURE 29 Page 35...
  • Page 36 Details of Intake and Exhaust Piping Terminations for Exiting Exhaust and Intake Vent Direct Vent Installations (different pressure zones) NOTE - In Direct Vent installations, combustion air is taken from outdoors and flue gases are discharged to outdoors. NOTE - Flue gas may be slightly acidic and may adversely affect some building materials.
  • Page 37 REDUCER MAY BE REQUIRED provided on 71M80 & 44W92 TO ADAPT LARGER VENT kits for EL296UH045XE36B & structions, piping must be supported. At least one PIPE SIZE TO TERMINATION 070XE36B bracket must be used within 6” from the top of the el­...
  • Page 38 FIELD FABRICATED WALL TERMINATION NOTE − FIELD−PROVIDED REDUCER MAY BE 2” (51mm) 3” (76mm) REQUIRED TO ADAPT LARGER VENT PIPE SIZE Vent Pipe Vent Pipe TO TERMINATION A− Minimum clearance above grade or average 12” (305 mm) 12” (305 mm) snow accumulation B−...
  • Page 39 Details of Exhaust Piping Terminations for Non‐Direct EL296UHE NON-DIRECT VENT APPLICATION Vent Applications USING EXISTING CHIMNEY Exhaust pipes may be routed either horizontally through an SIZE TERMINATION STRAIGHT-CUT OR outside wall or vertically through the roof. In attic or closet ANGLE-CUT IN DIRECTION PIPE PER TABLE 20.
  • Page 40 Condensate Piping 5 - Figures 44 and 46 show the furnace and evaporator This unit is designed for either right‐ or left‐side exit of con­ coil using a separate drain. If necessary the conden­ densate piping in upflow applications. In horizontal applica­ sate line from the furnace and evaporator coil can drain together.
  • Page 41 Heating cable kit is available from Lennox in various lengths; 6 ft. (1.8m) - Condensate Trap With Optional Overflow Switch kit no. 26K68; 24 ft. (7.3m) - kit no. 26K69; and 50 ft. From Evaporator Coil (15.2m) - kit no.
  • Page 42 EL296UHE with Evaporator Coil Using a Separate Drain (Unit shown in horizontal left-hand discharge position) Field Provided Vent Evaporator (4” min. to 5” max. above Coil condensate connection) 4”min 5”max 5’ max. PVC Pipe Only Condensate Drain Connection Drain Pan Piping from furnace and evaporator coil must slope down a minimum 1/4”...
  • Page 43 TRAP / DRAIN ASSEMBLY USING 1/2” PVC OR 3/4” PVC Optional Condensate Drain Connection Adapter 3/4 inch slip X 3/4 inch mpt (not furnished) 90° Street Elbow 3/4 inch PVC (not furnished) Adapter 3/4 inch slip X 3/4 inch mpt (not furnished) Condensate Drain Connection In Unit 1 (25 mm) Min.
  • Page 44: Iii Start Up

    III-START‐UP 2 - Set the thermostat to the lowest setting. 3 - Turn off all electrical power to the unit. A-Preliminary and Seasonal Checks 4 - This furnace is equipped with an ignition device which 1 - Inspect electrical wiring, both field and factory installed automatically lights the burners.
  • Page 45: Heating System Service Checks

    All units are CSA design certified without modifications. Refer to the EL296UHE Installation Instruction. cialty Gas Leak Detector is strongly recommended. It is available through Lennox under part number 31B2001. B-Gas Piping See Corp. 8411-L10, for further details. Do not use matches, candles, flame or any other CAUTION source of ignition to check for gas leaks.
  • Page 46 MANIFOLD PRESSURE CHECK SET UP Gas Valve Regulator Manifold Post Vent Hose (to burner box) 2” Long Clamp Square Tubing 5/16” Round Hose Reducer Fitting 10” Long Square Tubing Measuring Device FIGURE 52 F- Proper Gas Flow (Approximate) G- Proper Combustion Furnace should operate at least 5 minutes before checking Furnace should operate minimum 15 minutes with correct gas flow.
  • Page 47 TABLE 23 Manifold and Supply Line Pressure 0-10,000ft. For -1 Units Manifold Pressure in.wg. Supply Line Pressure in. w.g. EL296 Unit Low Fire High Fire Natural 13.0 All Sizes LP/propane 10.0 11.0 13.0 NOTE - A natural to L.P. propane gas changeover kit is necessary to convert this unit. Refer to the changeover kit installation instruction for the conversion procedure.
  • Page 48 I- Proper Ground and Voltage 2 - In addition, measure the AC voltage from Line Hot to Line Neutral (spade terminals) on the integrated con­ Furnace must be properly grounded for proper perform­ trol. See figure 53. This voltage should be in the range ance.
  • Page 49: Typical Operating Characteristics

    V-TYPICAL OPERATING CHARACTERISTICS C-External Static Pressure A-Blower Operation and Adjustment 1 - Tap locations shown in figure 55. 1 - Blower operation is dependent on thermostat control 2 - Punch a 1/4” diameter hole in supply and return air ple­ system.
  • Page 50: Maintenance

    2 - Remove the furnace access panels. specifications provided by the filter manufacturer 3 - Disconnect the wires from the gas valve. against the data given in the appropriate Lennox Product Specifications bulletin. Additional informa­ 4 - Remove gas supply line connected to gas valve. Re­...
  • Page 51 5 - Remove sensor wire from sensor. Disconnect 2‐pin 25 - Re‐secure the supporting screws along the vestibule plug from the ignitor. sides and bottom to the cabinet. 6 - Disconnect wires from flame roll-out switches. 26 - Reinstall cabinet screws on front flange at blower deck.
  • Page 52 Cleaning the Burner Assembly (if needed) 9 - Reinstall the burner box assembly using the existing four screws. Make sure that the burners line up in the 1 - Turn off electrical and gas power supplies to furnace. center of the burner ports. Remove upper and lower furnace access panels.
  • Page 53: Wiring And Sequence Of Operation

    VII- Wiring and Sequence of Operation Page 53...
  • Page 54: Electronic Ignition

    Electronic Ignition ON-delay. When the delay ends, the indoor blower motor is energized on the low fire heating speed, the The two-stage, variable speed integrated control used in HUM contacts close energizing the humidifier and EL296UHE units has an added feature of an internal 120V ACC terminal is energized.
  • Page 55 Applications Using A Single-Stage Thermostat 4 - After the 20-second warm-up period has ended, the See figure 58 for ignition control sequence gas valve is energized on low fire (first stage) and igni­ tion occurs. At the same time, the control module B - Heating Sequence -- Integrated Control Thermostat sends a signal to begin an indoor blower 30-second Selection DIP Switch 1 ON in “Single-Stage”...
  • Page 56 VIII- EL296UHE Field Wiring Applications TABLE 28 EL296 Field Wiring Applications DIP Switch Settings and On-Board Links (See figure 4) DIP Switch 1 On Board Links Must Be Cut To Select Thermostat Thermostat Wiring Connections System Options Heating Stages 1 Heat / 1 Cool FURNACE OUTDOOR T'STAT...
  • Page 57 TABLE 28 EL296 Field Wiring Applications (Continued) DIP Switch Settings and On-Board Links (See figure 4) DIP Switch 1 On Board Links Must Be Cut To Select Thermostat Thermostat Wiring Connections System Options Heating Stages 2 Heat / 2 Cool FURNACE OUTDOOR T'STAT...
  • Page 58 TABLE 28 EL296 Field Wiring Applications (Continued) DIP Switch Settings and On-Board Links (figure 4) DIP Switch 1 Wiring Connections Thermostat On Board Links Must Be Cut To Select Thermostat Heating System Options Stages Dual Fuel FURNACE HEAT PUMP L7724U TERM.
  • Page 59 TABLE 28 EL296 Field Wiring Applications (Continued) DIP Switch Settings and On-Board Links (figure 4) DIP Switch 1 Wiring Connections Thermostat On Board Links Must Be Cut To Select Thermostat Heating System Options Stages Dual Fuel FURNACE HEAT PUMP L7742U TERM.
  • Page 60: X Troubleshooting

    IX- Troubleshooting Troubleshooting: Heating Sequence of Operation CALL FOR FIRST-STAGE HEAT CALL FOR 1ST STAGE HEAT (LOW FIRE) INDOOR BLOWER OFF AFTER HEAT FAN OFF DELAY (LOW HEAT SPEED) INDOOR LIMIT BLOWER OFF HIGH ERROR SWITCH INDOOR WATCHGUARD − AFTER HEAT FAN LIMIT SWITCH CODE CLOSED WITHIN 3...
  • Page 61 Troubleshooting: Heating Sequence of Operation (Continued) CALL FOR SECOND-STAGE HEAT CALL FOR 2ND STAGE HEAT (HIGH FIRE) SINGLE STAGE 2 STAGE THERMOSTAT THERMOSTAT 2ND STAGE RECOGNITION DELAY ON DELAY (30 SECONDS) EXPIRED? EXPIRED? ONLY FOR 1ST REQUEST FOR 2ND STAGE HEAT INDUCER SWITCHED TO HIGH SPEED HIGH...
  • Page 62 Troubleshooting: Heating Sequence of Operation (Continued) CALL FOR HEAT SATISFIED FIRST-STAGE HEAT SECOND-STAGE HEAT RUN MODE: 1ST OR 2ND STAGE CALL FOR HEAT. ALL INPUTS MONITORED (LIMIT, PRESSURE, CALL FOR HEAT/COOL, FLAME LEVEL) 2ND STAGE HEAT 2ND STAGE CALL FOR HEAT SATISFIED? DE−ENERGIZE 2ND STAGE GAS VALVE...
  • Page 63 Troubleshooting: Cooling Sequence of Operation (Continued) CALL FOR COOLING 1ST STAGE COOLING REQUEST RECEIVED WAIT FOR COMPRESSOR TIMED OFF DELAY TO EXPIRE ENERGIZE 1ST STAGE COOLING CONTACTOR (COMPRESSOR & FAN) INDOOR BLOWER SECOND ON DELAY ENERGIZE INDOOR BLOWER (LOW COOLING MODE) MAINTAIN INDOOR BLOWER (LOW COOLING MODE)
  • Page 64: Troubleshooting: Continuous Fan Sequence Of Operation

    Troubleshooting: Continuous Fan Sequence of Operation CALL FOR FAN CALL FOR FAN INDOOR BLOWER ON CONTINUOUS FAN SPEED CALL FOR FAN MAINTAIN INDOOR BLOWER AT REMOVED? CONTINUOUS FAN REQUEST MAINTAIN INDOOR FOR COOLING GO TO CALL FOR COOLING BLOWER AT RECEIVED? CONTINUOUS FAN MAINTAIN INDOOR...

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