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Service Manual 02/2012

1. justed by changing the jumper position across the five pins BOG on the integrated control The unit is shipped with a factory e fan off setting of 90 seconds The fan off delay affects com fort and is adjustable to satisfy individual applications Ad just the fan off delay to achieve a supply air temperature be E ale tween 90 110 F at the moment that the blower is o 19 HAMA O de energized Longer off delay settings provide lower re Red LED Recall E ORA turn air temperatures shorter settings provide higher re BE uem off delay turn air temperatures See figure 3 jumper Cooling Fan On Delay TERMINAL DESIGNATIONS The cool fan on delay is 2 seconds and not adjustable Humidifier 120VAC Cooling Fan Off Delay Ca Hv The cool fan off delay amount of time that the blower oper Indoor Air Quality Accessories 120VAC ates after the cool demand has been satisfied is 45 sec Blower Cooling Speed 120VAC onds and not adjustable Blower Heating Speed 120VAC Dead terminals to park alternate speed taps Flame sensor Continuous blower Humidifier 24VAC FIGURE 4 Page 7 TABLE 3 RED LED Flash Code Diagnostic Codes Status of Furnace 0f No power to control or board fault
2. H High Altitude NOTE In Canada certification for installations at eleva tions over 4500 feet 1372 m is the jurisdiction of local au thorities EL195DF units require no manifold pressure adjustments for operation at altitudes up to 10 000 feet 3048 m above sea level Units installed at altitude of 4501 10 000 feet 1373 to 3048m require a pressure switch change which can be ordered separately Table 16 lists conversion kit and pressure switch requirements at varying altitudes The combustion air pressure switch is factory set and re quires no adjustment NOTE A natural to LP propane gas changeover kit is nec essary to convert this unit Refer to the changeover kit installation instruction for the conversion procedure TABLE 16 Conversion Kit and Pressure Switch Requirements at Varying Altitudes High Altitude Natural Burner LP Propane Orifice Kit Burner Orifice Kit 0 7500 ft 7501 10 000 ft 7501 10 000 ft 4501 7500 ft 7501 10 000 ft 0 2286m 2286 3038m 2286 3038m 1373 2286m 2286 3048m Natural to High Altitude LP Propane High Altitude Pressure Switch EL195 Unit 045 ___ 80060 Se LE 69W73 73W37 68W68 80W59 80W59 Conversion requires installation of a gas valve manifold spring which is provided with the gas conversion kit Pressure switch is factory set No adjustment necessary All models use the factory installed pre
3. E 127mm 18 MAX 457mm EXHAUST VENT y 12 305mm Min above grade or average snow ac cumulation Front View A EL Inches mm 2777 INTAKE optional intake elbow Side View OPTIONAL VENT TERMINATION FOR MULTIPLE UNIT INSTALLATION OF DIRECT VENT WALL TERMINATION KIT 22044 44J40 30G28 81J20 FIGURE 32 EXHAUST VENT SIZE Q TERMINATION PIPE PER INTAKE nis TABLE 11 Front View AIR Top View 1 2 13mm Foam Insulation in Unconditioned Space REDUCER MAY BE REQUIRED TO ADAPT LARGER VENT PIPE SIZE TO TERMINATION OUTSIDE WALL DIRECT VENT WALL TERMINATION KIT 30G28 or 81J20 FIGURE 33 EXHAUST VENT SIZE TERMINATION PIPE PER INTAKE TABLE 11 AIR Front View Top View 1 2 13mm Foam Insulation in Unconditioned Space FIELD PROVIDED 2777777777 ZZA BE REQUIRED TO Z ZZ Z LL 177 27711 ADAPT LARGER VENT PIPE SIZE TO TERMINATION 8 206mm MIN OUTSIDE WALL DIRECT VENT WALL TERMINATION KIT 22G44 or 44J40 FIGURE 34 Page 30 WALL TERMINATION KITS CLOSE COUPLE EXTENDED VENT FOR GRADE CLEARANCE 2 inch 51 mm 22G44 US 3 inch 76 mm 44J40 US If intake and exhaust pipe is less than 12 in 305 mm above snow accumulation or other obstructions field FIELD PROVIDED REDUCER MAY BE REQUIRED TO ADAPT fabricated piping must be installed LARGER VENT PIPE SIZE TO TERMINATION 203 mm M
4. LENNOX Service Literature UNIT INFORMATION Corp 1102 L1 Revised 02 2012 EL195DF EL195DF SERIES UNITS EL195DF series units are high efficiency gas furnaces manufactured with Lennox DuralokPlus aluminized steel clamshell type heat exchangers with a stainless steel condensing coil EL195DF units are available in heating input capacities of 44 000 to 110 000 Btuh 13 to 32 2 kW and cooling applications from 2 through 5 tons 7 0 through 17 6 kW Refer to Engineering Handbook for proper sizing Units are factory equipped for use with natural gas A kit is available for conversion to LP Propane operation All EL195DF units are equipped with a hot surface ignition system The gas valve is redundant to assure safety shut off as required by C S A The heat exchanger burners and manifold assembly can be removed for inspection and service The maintenance section gives a detailed description on how this is done All specifications are subject to change Procedures outlined in this manual are presented as a recommendation only and do not supersede or replace local or state codes AWARNING Electric shock hazard Can cause injury or death Before attempting to perform any service or maintenance turn the electrical power to unit OFF at discon nect switch es Unit may have multiple power supplies Table of Contents Specifications 2 Optional Accessories
5. 3 Blower Performance Data 4 l Unit Components 6 II Placement and Installation 16 Ill Start Up 36 System Service Checks 37 V Typical Operating Conditions 40 VI Maintenance 41 VII Wiring and Sequence of Operation 43 Vill Troubleshooting 44 Technical Publications Page 1 AWARNING 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 installer or equivalent service agency or the gas supplier A WARNING Sharp edges Be careful when servicing unit to avoid sharp edges which may result in personal injury 2012 Lennox Industries Inc Litho U S A SPECIFICATIONS Gas Model EL195DF045P36B EL195DF070P48B EL195DF090P60C EL195DF110P60C a M 1 AFUE 95 95 95 95 Input Btuh 44 000 66 000 88 000 110 000 Output Btuh 42 000 64 000 85 000 106 000 Temperature rise range F 25 55 25 55 30 60 40 70 Gas Manifold Pressure in w g 3 5 10 3 5 10 3 5 10 3 5 10 Nat Gas LPG Propane High static in w g 0 5 0 5 0 5 0 5 Connections Intake Exhaust Pipe PVC 212 2 2 2 2 2 2
6. imun Connection In Uni Condensate Drain m Connection In Unit 90 Street Elbow 1 2 inch PVC Furnished 90 Elbow 1 2 inch PV a Not Furnished To 1 2 inch PVC Pipe 1 2 inch PVC Pipe Optional Drain Piping From Trap Not Furnished Not Furnished i i in Pi Coupling 1 2 inch slip X slip Drain Assembly for 1 2 inch Drain Pipe Not Furnished 1 2 inch PVC Pipe Not Furnished Drain Trap 90 Elbow Assembly 1 2 inch PVC Furnished To Not Furnished Drain Drain Assembly for 3 4 inch Drain Pipe Drain Trap Clean Out 90 Elbow 90 Elbow Y 3 4 inch PVC 3 4 inch PVC Not Furnished Not Furnished Drain Trap Assembly with 3 4 inch Piping c Vs Coupling 3 4 inch slip X slip Dra Not Furnished Drain Trap A bly with 3 4 inch Pipi Drain Trap Assembly with 1 2 inch Piping Fen 1 25 mm Min 2 50 mm Max Above 1 25 mm Min 2 50 mm Max Above Top Of Condensate Drain Connection In Unit Of Condensate Drain Connection In Unit Drain Trap Assembly Vent Vent Furnished CE 1 2 inch C ndensate Drain Condensate Drain Connection In Unit Connection In Unit Ill START UP A Preliminary and Seasonal Checks 1 Inspect electrical wiring both field and factory installed for loose connections Tighten as required 2 Check voltage at disconnect switch Voltage must be with in range listed on the nameplate If not consult the power company and have voltage condition c
7. 1 2 m below or to side of opening Btuh 3kw 12 inches 305mm for 1 foot 30cm above opening appliances 10 000 Btuh 3kw and 100 000 Btuh 30kw 36 inches 9m for appliances gt 100 000 Btuh 30kw Clearance to permanently 42 42 closed window Vertical clearance to ventilated soffit located above the terminal within a Equal to or greater than soffit depth Equal to or greater than soffit depth horizontal distance of 2 feet 610 mm from the center line of the terminal Clearance to unventilated soffit Equal to or greater than soffit depth Equal to or greater than soffit depth Clearance to outside corner No minimum to outside corner No minimum to outside corner Clearance to inside corner Clearance to each side of center line ex feet 9m within a height 15 feet 4 5m feet 9m within a height 15 feet 4 5m tended above meter regulator assembly above the meter regulator assembly above the meter regulator assembly Clearance to service regulator 3 feet 9m 3 feet 9m vent outlet Clearance to non mechanical air 6 inches 152mm for appliances 10 000 supply inlet to building or the com 4 feet 1 2 m below or to side of opening Btuh 3kw 12 inches 305mm for bustion air inlet to any other ap 1 foot 30 cm above opening appliances gt 10 000 Btuh 3kw and pliance 100 000 Btuh 30kw 36 inches 9m for appliances gt 100 000 Btuh 30kw Clearance to mechanical
8. 10 Turn on all electrical power to to the unit 11 Set the thermostat to desired setting NOTE When unit is initially started steps 1 through 11 may need to be repeated to purge air from gas line 12 If the appliance will not operate follow the instructions Turning Off Gas to Unit and call your service techni cian or gas supplier Turning Off Gas to Unit 1 Setthe thermostat to the lowest setting 2 Turn off all electrical power to the unit if service is to be performed 3 Remove the upper access panel 4 Move gas valve switch to OFF 5 Replace the upper access panel Failure To 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 Dirty or plugged filters will cause the limit control to shut the unit off 6 Is gas turned on at the meter 7 15 the manual main shut off valve open 8 15 the internal manual shut off valve open 9 Is the unit ignition system in lockout If the unit locks out again inspect the unit for blockages Page 36 IV HEATING SYSTEM SERVICE CHECKS A C S A Certification All units are C S A design certified without modifications Refer to the EL195DF Operation and Installation Instruc tion Manual Information B Gas Piping A CAUTION If flexible gas connector is
9. 95 3 9 19 s j S ig 407 8 55 s s 235 t rz 8 9 o 6 7 s s s l E 3 2 wa ma 7 7 3485 183 9 Concentric Termination at Elevation 0 4500 ft 2 Pipe 2 1 2 Pipe 3 Pipe Number Of 90 Model Model Model Elbows Used 045 070 090 110 045 070 090 110 045 070 090 110 1 73 58 42 22 105 105 89 54 121 121 114 114 2 68 53 37 17 100 100 84 49 116 116 109 109 3 63 48 32 12 95 95 79 44 11 104 104 4 5 85 85 69 34 101 101 94 94 6 7 80 8 64 2 9 9 8 8 7 2 8 70 70 54 19 86 86 79 79 9 65 65 49 81 81 74 74 10 60 60 76 69 69 Concentric Termination Elevation 4501 10 000 ft FPip 212 Pipe Pip Eee soq cac ee _________ Elb Used oo oo p mo os 070 090 110 645 070 5 2 e 5 amp 5 m n 55 3 m m M 4 He 9 3 5 s 7 4 m mn 3 s 72 m me 9 9 5 s 6 3 m 9 9 a 2 9 s 8 WS DOE 080 TYPICAL EXHAUST PIPE CONNECTIONS Pipe size determined in table 10 o 3 TRANSITION xo INTAKE EXHAUST DO NOT transition from smaller to larger pipe size in horizontal TOP VIEW runs of
10. Set the thermostat to initiate a heating demand and again al low the burners to fire for approximately 3 minutes 6 Adjust the thermostat to deactivate the heating de mand and again wait for the combustion air inducer to stop At this point the trap should be primed with suffi cient water to ensure proper condensate drain opera tion 1 AWARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or death Gas Valve Operation Figure 48 1 STOP Read the safety information at the beginning of this section 2 Set the thermostat to the lowest setting 3 Turn off all electrical power to the unit 4 This furnace is equipped with an ignition device which automatically lights the burners Do not try to light the burners by hand 5 Remove the upper access panel 6 Move gas valve switch to OFF See figure 48 7 Wait five minutes to clear out any gas If you then smell gas STOP Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instruc tions If you do not smell gas go to next step 8 Move gas valve switch to ON See figure 48 MANIFOLD PRESSURE ADJUSTMENT SCREW under barbed MANIFOLD PRESSURE fitting m INLET PRESSURE PORT GAS VALVE SHOWN IN ON POSITION FIGURE 48 9 Replace the upper access panel
11. 60L46 US 430G28 CA 51W11 444W93 CA w 3YES Low p TEST m ow pes p se se E wa 110 YES 135 YES NOTE Standard Terminations do not include any vent pipe or elbows external to the structure Any vent pipe or elbows external to the structure must be included in total vent length calculations See vent length tables Requires field provided outdoor 1 1 2 exhaust accelerator 2Concentric kits 71M80 and 44W92 include 1 1 2 outdoor accelerator when used with 045 and 070 input models 3 Flush mount kit 51W11 includes 1 1 2 in outdoor exhaust accelerator required when used with 045 070 and 090 input models 4 Termination kits 30G28 44W92 4493 and 81J20 are certified to ULC S636 for use in Canada only 5 See table 11 for vent accelerator requirements Page 19 Joint Cementing Procedure All cementing of joints should be done according to the specifications outlined in ASTM D 2855 NOTE A sheet metal screw may be used to secure the intake pipe to the connector if desired Use a drill or self tapping screw to make a pilot hole A DANGER DANGER OF EXPLOSION Fumes from PVC glue may ignite during system check Allow fumes to dissipate for at least 5 minutes before placing unit into operation 1 Measure and cut vent pipe to desired length 2 Debur and chamfer end of pipe removing any ridges or rough edges If end is not chamfered edge of pipe may remove cement f
12. IG OG DOODO O 44440 NEUTRALS HUM24 FLAME OO FS PARK PARK O Red LED FIGURE 50 Page 39 V TYPICAL OPERATING CHARACTERISTICS A Blower Operation and Adjustment1 NOTE The following is a generalized procedure and does not apply to all thermostat controls 1 Blower operation is dependent on thermostat control system 2 Generally blower operation is set at thermostat sub base fan switch With fan switch in ON position blower operates continuously With fan switch in AUTO position blower cycles with demand or runs continuously while heating or cooling circuit cycles 3 Depending on the type of indoor thermostat blower and entire unit will be off when the system switch is in OFF position B Temperature Rise Figure 51 Temperature rise for EL195UH units depends on unit input
13. a call for heat W1 of the thermostat energizes W of the furnace control with 24VAC 510 primary limit switch and S47 rollout switch are closed Call for heat can continue The integrated contol A92 energizes combustion air inducer B6 Combustion air inducer runs until S18 combustion air prove switch closes switch must close within 2 1 2 minutes or control goes into 5 minute Watchguard Pressure Switch delay Once S18 closes a 15 second pre purge follows The integrated control A92 energizes ignitor A 20 second warm up period begins Page 43 BLOWER SPEED CHART FACTORY CONNECTED SPEED TAPS MOTOR UNIT COOL HEAT PARK AYNI 045P36B_ BROWN YELLOW BLACK 070P48B_ BLACK YELLOW BROWN 4 4 090P60C BLACK YELLOW RED BROWN 110P60C BLACK YELLOW RED BROWN BLOWER SPEED SELECTION HI _Omm nO 10 SPEED TAPS BLACK BROWN YELLOW RED THERMOSTAT HEAT ANTICIPATION SETTINGS 65 AMP HONEYWELL VALVE J P58 JACK PLUG BURNER CONTROL 5 156 JACKIPLUG NDUCERIIGNITER piso JACKIPLUGIGNITER WARNING ELECTRIC SHOCK HAZARD CAN CAUSE INJURY OR DEATH UNIT MUST BE GROUNDED IN ACCORDANCE WITH NATIONAL AND LOCAL CODES NOTE IF ANY WIRE IN THIS APPLIANCE IS REPLACED IT MUST BE REPLACED WITH WIRE OF LIKE SIZE RATING INSULATION THICKNESS AND TERMINATION Z IMPORTANT TO PREVENT MOTOR BURNOUT NEVER CONNECT MORE THAN ONE LEAD TO ANY ONE CONNECTION A PARK TE
14. appliances gt 10 000 Btuh 3kw and pliance Btuh 15 kw 12 inches 305mm for ap 100 000 Btuh 30kw 36 inches 9m pliances gt 50 000 Btuh 15kw for appliances gt 100 000 Btuh 30kw Clearance to mechanical air sup 3 feet 9m above if within 10 feet 6 feet 1 8m ply inlet 3m horizontally Clearance above paved sidewalk or 7 feet 2 1m 7 feet 2 1m T paved driveway located on public property M Clearance under veranda porch deck or balcony 12 inches 305mm t 12 inches 305mm t 1 n accordance with the current ANSI Z223 1 NFPA 54 Natural Fuel Gas Code 2 n accordance with the current CSA B149 1 Natural Gas and Propane Installation Code clearances not specified in ANSI Z223 1 NFPA 54 or B149 1 clearance will be in accordance with local installation T A vent shall not terminate directly above a sidewalk or paved driveway that is located codes and the requirements of the gas supplier and these between two single family dwellings and serves both dwellings installation instructions t 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 24 Page 26 Details of Intake and Exhaust Piping Terminations for Direct Vent Installations NOTE In Direct Vent installations combustion air is tak en from outdoors and flue gases are discharged to out doors NOTE Flue
15. blower speed blower horsepower and static pressure as marked on the unit rating plate The blower speed must be setfor unit operation within the range of TEMP RISE F listed on the unit rating plate TEMPERATURE RISE Supply Duct Temperature Return Duct Temperature Temperature Rise Temperatures lt RETURN AIR FIGURE 51 C External Static Pressure 1 Taplocations shown in figure 52 2 Punch a 1 4 diameter hole in supply and return air ple nums Insert manometer hose flush with inside edge of hole or insulation Seal around the hose with perma gum Connect the zero end of the manometer to the discharge supply side of the system On ducted sys tems connect the other end of manometer to the return duct as above 3 With only the blower motor running and the evaporator coil dry observe the manometer reading Adjust blow er motor speed to deliver the air desired according to the job requirements For heating speed external static pressure drop must not be more than 0 5 W C For cooling speed external static pressure drop must not be more than 0 8 W C 4 Seal the hole when the check is complete EXTERNAL STATIC PRESSURE Supply Duct Static Return Duct Static Total Duct Static dry coil Supply Air Duct S
16. cleaning the heat exchanger becomes necessary follow the below procedures and refer to figure 1 when disassem bling unit Use papers or protective covering in front of fur nace while removing heat exchanger assembly 1 Turn off electrical and gas supplies to the furnace 2 Remove the furnace access panels 3 Disconnect the wires from the gas valve 4 Remove gas supply line connected to gas valve Re move the burner box cover if equipped and remove gas valve manifold assembly 5 Remove sensor wire from sensor Disconnect 2 pin plug from the ignitor 6 Disconnect wires from flame roll out switches 7 Loosen clamps at vent elbow Disconnect condensate drain tubing from flue collar and remove the vent el bow 8 Loosen clamps and remove combustion air intake flexible connector if equipped 9 Remove four burner box screws at the vestibule panel and remove burner box Set burner box assembly aside NOTE If necessary clean burners at this time Follow procedures outlined in Burner Cleaning section 10 Mark and disconnect all combustion air pressure tub ing from cold end header collector box 11 Mark and remove wires from pressure switch assem bly Remove pressure switch assembly Keep tubing attached to pressure switch assembly Disconnect the plug from the combustion air inducer Remove two screws which secure combustion air in ducer to collector box Remove combustion air induc er assembly Remove grou
17. detected ON Board Fault Detected Heartbeat Control powered displayed during all modes of operation if no errors are detected Reverse Line Voltage Corrective Action Check the 120V line and neutral connections and reverse the connection if necessary Improper Earth Ground Corrective Action Check for proper unit ground and install if necessary Burner failed to light or lost flame during heat demand Corrective Action Check condition of flame sensor and clean if necessary using steel wool Check flame sensor signal and replace if necessary Check flame sensor wiring and replace if necessary Low Flame Signal Corrective Action Check flame sensor micro amp reading Normal reading is 1 5 Replace sensor if lower than 0 5 Watchguard burner failed to light exceeded maximum number of retries or recycles Ignitor Circuit Failure not available on this control Rollout Switch Open Corrective Action Check continuity across switch and replace switch if necessary Check for restriction in vent pipe combustion air inlet and heat exchanger Determine cause of restriction before placing furnace back inoperation Pressure Switch failed to close or opened during heat demand Corrective Action Check the differential in the pressure switch See figure 11 Check for restricted vent pipe and remove all blockage Check vent pipe sizing See table 10 Watchguard Pressure Switch opened 5 times during one heat demand Co
18. given in table 13 NOTE Shut unit off and remove manometer as soon as an accurate reading has been obtained Take care to remove barbed fitting and replace threaded plug TABLE 13 Manifold and Supply Pressure Outlet inches w c Supply Manifold Pressure Pressure in wg in wg Min Model Input Sizes BI 37 F Proper Gas Flow Approximate Gas Flow Approximate TABLE 14 GAS METER CLOCKING CHART Seconds for One Revolution ELt95 Natural P Unit 2 cu ft DIAL 045 80 160 200 400 090 21 82 2 204 70 33 e 6 G Natural 1000 btu cu ft LP 2500 btu cu ft NOTE To obtain accurate reading shut off all other gas appliances connected to meter Furnace should operate at least 5 minutes before check ing gas flow Determine time in seconds for two revolu tions of gas through the meter Two revolutions assures a more accurate time Divide by two and compare to time in table 14 If manifold pressure matches table 13 and rate is incorrect check gas orifices for proper size and restric tion Remove temporary gas meter if installed G Proper Combustion Furnace should operate at least 15 minutes with correct manifold pressure and gas flow rate before checking com bustions Take sample beyond the flue outlet and compare to table 15 TABLE 15 EL195 05 72 82 8 6 9 6 Mm eee The maximum carbon monoxide reading should not exceed 50 ppm
19. off for 3 sec then next error code is displayed etc To clear error codes depress and hold button longer than 5 seconds Page 8 EL195DF Burner Box Assembly IGNITOR SENSOR FRONT BURNER BOX PLATE GAS VALVE FIGURE 5 B Heating Components Combustion air inducer primary limit control 510 SureLight ignitor burners flame rollout switch S47 gas valve GV1 combustion air prove switch 818 and clam shell heat exchangers are located in the heating compart ment The heating compartment can be accessed by re moving the burner access panel 1 Flame Rollout Switches Figure 5 Flame rollout switches S47 are SPST N C high temperature limits located on the top left and bottom right of the front buner box plate S47 is wired to the burner ignition control A92 When either of the switches sense flame rollout indicat ing a blockage in the combustion passages the flame rollout switch trips and the ignition control immediately closes the gas valve Switch S47 in all EL195DF units is factory preset to open at 2109 12 F 99 6 7 ona temperature rise All flame rollout switches are manual reset 2 Heat Exchanger Figure 6 EL195DF units use an aluminized steel primary and stainless steel secondary heat exchanger assembly Heat is transferred to the air stream from all surfaces of the heat exchanger The shape of the heat exchanger en sures maximum efficiency The combustion air inducer
20. pulls fresh air through the burn er box This air is mixed with gas in the burners The gas air mixture is then burned at the entrance of each clam shell Combustion gases are then pulled through the primary and secondary heat exchangers and exhausted out the ex haust vent pipe 3 Primary Limit Control Figure 6 Primary limit S10 used on EL195DF units is located in the heating vestibule panel When excess heat is sensed in the heat exchanger the limit will open Once the limit opens the furnace control energizes the supply air blower and de en ergizes the gas valve The limit automatically resets when unit temperature returns to normal The switch is factory set and cannot be adjusted For limit replacement remove wires from limit terminals and rotate limit switch 90 de grees Slowly remove from the vestibule panel Install re placement limit with same care Page 9 Primary Limit Location and Heat Exchanger Install limit face down FIGURE 6 4 Gas Valve GV1 The EL195DF uses an internally redundant to valve to assure safety shut off If the gas valve must be replaced the same type valve must be used 24VAC terminals and gas control switch are located on top of the valve All terminals on the gas valve are con nected to wires from the ignition control 24V applied to the terminals opens the valve Inlet and outlet pressure taps are located on the valve A manifold adjustment screw is also located on the valve An LP Propa
21. required allowed by the authority that has jurisdiction black iron pipe shall be installed at the gas valve and extend outside the furnace cabinet The flexible connector can then be added between the black iron pipe and the gas supply line Gas supply piping should not allow more than 0 5 W C drop in pressure between gas meter and unit Supply gas pipe must not be smaller than unit gas connection Compounds used on gas piping threaded joints should be resistant to action of liquefied petroleum gases C Testing Gas Piping IMPORTANT In case emergency shutdown is required turn off the main shut off valve and disconnect the main power to unit These controls should be properly labeled by the installer When pressure testing gas lines the gas valve must be dis connected and isolated Gas valves can be damaged if subjected to more than 0 5psig 14 W C See figure 49 MANUAL MAIN SHUT OFF VALVE WILL NOT HOLD NORMAL TEST PRESSURE FURNACE ISOLATE GAS VALVE 1 8 N P T PLUGGED TAP FIGURE 49 When checking piping connections for gas leaks use pre ferred means Kitchen detergents can cause harmful corro sion on various metals used in gas piping Use of a specialty Gas Leak Detector is strongly recommended It is available through Lennox under part number 31B2001 See Corp 8411 L10 for further details WARNING Do not use matches candles flame or any other source of ignition to check for
22. run is mandatory for drainage NOTE Exhaust pipe MUST be glued to furnace exhaust fittings NOTE Exhaust piping should be checked carefully to make sure there are no sags or low spots Page 21 TABLE 10 Maximum Allowable Intake or Exhaust Vent Length 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 Standard Termination at Elevation 0 4500 ft Numerot _______ AFP TP 90 Elbows Modi Used ws wo we wo ws wo 090 wo ws 070 o 6 99 39 55 z 5 8 3 8 s 15 12 3 7 5 3 16 85 46 328 327 108 4 s 8 2 wa mo o 78 4 12 105 m s 4 22 we 9 9 75 3 Wr 9 5 wh s s nz 9 a 39 159 9 9 wa ma 5 235 65 Standard Termination Elevation 4500 10 000 ft Numberor Pipe 2 12 Pipe 90 Elbows Used f os o 9s wu o ws wv o9 us s s uo s s 35 85 4 28 39 2 4 Te
23. 0 0 80 1690 1050 1590 760 1485 630 1370 540 0 90 945 430 800 335 700 290 605 250 0 90 1580 1010 1485 735 1405 610 1270 510 EL195DF070P48B PERFORMANCE Less Filter EL195DF110P60C PERFORMANCE Less Filter Air Volume Watts at Various Blower Speeds Air Volume Watts at Various Blower Speeds External External Static High Medium Medium Lou Static High Medium Medium Low Pressure High Low Pressure High Low in W 9 cfm Watts cfm Watts cfm Watts cfm watts in W9 cfm Watts cfm Watts cfm cfm Watts 0 00 1885 935 11830 815 1810 720 1700 640 0 00 2375 1250 2205 915 1975 785 1630 640 0 10 1850 910 1805 795 1785 705 1680 630 0 10 2365 1235 2195 905 1960 775 1625 635 0 20 1775 890 1750 775 1710 690 1620 610 0 20 2275 1200 2125 890 1950 760 1635 625 0 30 1715 870 1685 755 1640 660 1575 595 0 30 2200 1180 2060 880 1900 735 1620 610 0 40 1645 855 1620 735 1595 650 1495 575 0 40 2115 1150 1995 850 1845 710 1620 600 0 50 1575 835 1525 715 1485 625 1440 555 0 50 2040 1115 1940 835 1795 695 1585 580 0 60 1505 815 1450 690 1425 610 1360 540 0 60 1955 1090 1855 810 1745 670 1540 565 0 70 1390 790 1360 675 1340 590 1270 525 0 70 1860 1070
24. 1730 765 1640 650 1515 550 0 80 1280 770 1270 650 1255 570 1210 505 0 80 1735 1030 1620 740 1590 620 1415 535 0 90 1200 740 1185 635 1160 550 1090 485 0 90 1640 1010 1535 715 1480 600 1330 510 4 W o 5 lt o lt BLOWER MOTOR hidden BAG ASSEMBLY CONTROL BOX Includes integrated control transformer and door switch us 55 Z COMBUSTION AIR INDUCER W W N ae BLOWER DECK SS y Ae j JP WO e DuralokPlus HEAT EXCHANGER ASSEMBLY COLD END HEADER BOX COMBUSTION AIR INDUCER PRESSURE SWITCH PRIMARY LIMIT BURNER BOX ASSEMBLY includes sensor rollout switches and ignitor GAS VALVE FIGURE 1 Page 5 I UNIT COMPONENTS ELECTROSTATIC DISCHARGE ESD Precautions and Procedures 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 EL195DF unit components are shown in figure 1 The com bustion air inducer gas valve and burners can be accessed by removing the burner access panel The blower and con trolbox can be accessed by removing the blower access door A Control Box Components Figure 2 Unit transformer T1 and integrated igni
25. 69W73 73W81 73W37 68W68 110 77W43 73W22 69W73 73W81 73W37 68W68 Page 3 BLOWER DATA EL195DF045P36B PERFORMANCE Less Filter EL195DF090P60C PERFORMANCE Less Filter Air Volume Watts at Various Blower Speeds Air Volume Watts at Various Blower Speeds External External Static High Medium Medium Lodi Static High Medium Medium Low Pressure High Low Pressure High Low in W 9 cfm Watts cfm Watts cfm Watts cfm Watts in W9 cfm Watts cfm Watts cfm cfm Watts 0 00 1615 650 1385 555 1205 465 1045 390 0 00 2305 1255 2145 950 1900 810 1515 670 0 10 1605 640 1380 545 1195 455 1035 380 0 10 2295 1240 2135 940 1885 795 1500 665 0 20 1500 620 1345 525 1165 445 1015 370 0 20 2200 1220 2085 915 1865 775 1525 655 0 30 1450 590 1290 490 1125 420 975 365 0 30 2160 1210 1990 875 1830 755 1545 640 0 40 1350 560 1235 480 1090 405 920 345 0 40 2055 1170 1935 865 1790 725 1530 620 0 50 1300 545 1170 450 1035 380 880 330 0 50 1970 1130 1855 835 1705 700 1500 600 0 60 1195 500 1095 425 990 365 840 320 0 60 1890 1105 1765 805 1635 675 11495 580 0 70 1140 480 1020 395 895 345 780 300 0 70 1775 1075 1680 785 1565 655 1430 560 0 80 1025 450 920 370 840 330 695 27
26. BUSTION AIR INDUCER PREPURGE INITIATED BY CLOSED PRESSURE SWITCH YES LED FLASHES CODE 13 NO LOW LINE VOLTAGE IGNITOR WARM UP 20 SECONDS IS VOLTAGE ABOVE 70 VOLTS ONCE VOLTAGE IS ABOVE 75 VOLTS HEATING YES SEQUENCE RESTARTS 4 SECOND TRIAL FOR IGNITION GAS VALVE OPENS IGNITOR ENERGIZED FOR FIRST 3 SECONDS OF THE TRIAL GAS VALVE OFF COMBUSTION AIR INDUCER INDOOR BLOWER OFF HAS CONTROL FAILED TO SENSE FLAME FOR FIVE CONSECUTIVE TRIES DURING A SINGLE YES FLAME STABILIZATION PERIOD HEAT DEMAND 4 SECONDS FLAME RECTIFICATION CURRENT LED SIGNAL WATCHGUARD FAILURE CODE CHECK CAN FLAME BE PROVEN WITHIN WATCHGUARD MODE GAS VALVE OFF 4 SECONDS AFTER GAS VALVE OPENS COMBUSTION AIR INDUCER OFF 0 5 microamps INDOOR BLOWER OFF WITH DELAY IS 60 MINUTE RESET PERIOD COMPLETE YES FLAME PRESENT HAS CONTROL RESET IGNITION SEQUENCE FOUR TIMES 7 PRIMARY LIMIT LED FLASHES CODE 4 LOW OPEN GAS VALVE FLAME SIGNAL 1 5 MICROAMPS OR GREATER FLAME SIGNAL COMB AIR INDUCER Does not affect operation of control AND INDOOR BLOW LIMIT SWITCH OPEN LED FLASHES CODE 7 PRIMARY LIMIT OPEN UNTIL MAIN GAS VALVE DE ENERGIZED POWER IS No COMBUSTION AIR INDUCER DE ENERGIZED INTERRUPTED OR INDOOR BLOWER ON UNTIL SWITCH CLOSES _TSTAT IS CYCLED LIMIT SWITCH CLOSED OFF ON FOR 1 SEC MINIMUM 60 MINUTE YES WATCHGUARD PE HAS PRIMARY LIMIT RESET YES ETFI SES TIME EXCEEDED 3 MINUTES SEIMIN PERIOD C
27. CATION See venting table 10 for maximum venting lengths with this arrangement Use wall support every 24 610 mm Use two wall supports if extension is greater than 24 610 mm but less than 48 1219 mm NOTE One wall support must be 6 152 mm from top of each pipe intake and exhaust 2 51mm 3 76mm Vent Pipe Vent Pipe A Minimum clearance above grade or average 12 305MM 12 305MM snow accumulation B Maximum horizontal 6 152MM 6 152MM separation between intake and exhaust 8 203MM 8 203MM 12 305MM 20 508MM 6 152MM C Minimum from end of exhaust to inlet of intake D Maximum exhaust pipe length E Maximum wall support distance from top of each 6 152 pipe intake exhaust FIGURE 28 FIELD FABRICATED WALL TERMINATION OR 15F74 WALL RING TERMINATION KIT With INTAKE ELBOW NOTE FIELD PROVIDED REDUCER MAY BE REQUIRED TO ADAPT LARGER VENT PIPE SIZE TO TERMINATION 1 2 13mm ARMAFLEX INSULATION IN UN CONDITIONED SPACE SIZE TERMINATION PER TABLE 11 STRAIGHT APPPLICATION 1 2 13mm ARMAFLEX INSULATION IN UNCONDITIONED SPACE WALL SUPPORT EXTENDED APPLICATION See venting table 10 for maximum venting lengths with this arrangement Use wall support every 24 610 mm Use two wall supports if extension is greater than 24 610 mm but less than 48 1219 mm NOTE One wall support must be 6 152 mm from top of each pipe
28. Category IV gas furnace In both Non Direct Vent and Direct Vent applications the vent termination is limited by local building codes In the absence of local codes refer to the current National Fuel Gas Code ANSI Z223 1 NFPA 54 in U S A and current CSA B149 Natural Gas and Propane Installation Codes in Canada for details Position termination according to location given in figure 23 or 24 In addition position termination so it is free from any obstructions and 12 above the average snow accumula tion At vent termination care must be taken to maintain protective coatings over building materials prolonged exposure to exhaust condensate can destroy protective coatings It is recommended that the exhaust outlet not be located within 6 feet 1 8m of a condensing unit because the condensate can damage the painted coating NOTE If winter design temperature is below 32 F 0 C exhaust piping should be insulated with 1 2 13mm Ar maflex or equivalent when run through unheated space Do not leave any surface area of exhaust pipe open to out side air exterior exhaust pipe should be insulated with 1 2 13mm Armaflex or equivalent In extreme cold cli mate areas 3 4 19mm Armaflex or equivalent may be necessary Insulation on outside runs of exhaust pipe must be painted or wrapped to protect insulation from de terioration Exhaust pipe insulation may not be necessary in some specific applications NOTE During extremely co
29. Condensate Piping This unit is designed for either right or left side exit of con densate piping Refer to figures 42 and 43 for condensate trap locations NOTE If necessary the condensate trap may be installed up to 5 away from the furnace Use PVC pipe to connect trap to furnace condensate outlet Piping from furnace must slope down a minimum of 1 4 per ft toward trap CONDENSATE TRAP AND PLUG LOCATIONS Trap same on right side Plug 1 1 2 in same on left FIGURE 42 1 Determine which side condensate piping will exit the unit location of trap field provided fittings and length of PVC pipe required to reach available drain 2 Use a 3 8 allen wrench and remove plug figure 42 from the cold end header box at the appropriate loca tion on the side of the unit Install field provided 1 2 NPT male fitting into cold end header box Use teflon tape or appropriate pipe dope 3 Install the cap over the clean out opening at the base of the trap Secure with clamp See figure 47 4 Install drain trap using appropriate PVC fittings glue all joints Glue the provided drain trap as shown in fig ure 47 Route the condensate line to an open drain 5 Figure 44 shows the furnace and evaporator coil using a separate drain If necessary the con
30. M FAN AT FAN SPEED EAC TERM ENERGIZED HUM TERMINALS OFF AFTER POST PURGE BY COMBUSTION AIR INDUCER SYTEM FAN SWITCHES TO FAN SPEED AFTER BLOWER OFF DELAY EAC CONTINUES WITHOUT INTERUPTION Page 47
31. MM Max NOTE See unit installation instructions for proper exhaust pipe termination size reduction 1 The exhaust termination tee should be connected to the 2 or 3 PVC flue pipe as shown in the illustration Do not use an accelerator in applications that include an exhaust termination tee The accelerator is not required 2 As required Flue gas may be acidic and may adversely affect some building materials If a side wall vent termination is used and flue gases will impinge on the building materials a corrosion resistant shield 24 inches square should be used to protect the wall surface If optional tee is used the protective shield is recommende d The shield should be constructed using wood sheet metal or other suitable material All seams joints cracks etc in affected area should be sealed using an appropriate sealant 3Exhaust pipe 45 elbow can be rotated to the side away from the combustion air inlet to direct exhaust away from adjacent property The exhaust must never be directed toward the combustion air inlet FIGURE 27 Page 28 FIELD FABRICATED WALL TERMINATION OR 15F74 WALL RING TERMINATION KIT NOTE FIELD PROVIDED REDUCER MAY BE REQUIRED TO ADAPT LARGER VENT PIPE SIZE TO TERMINATION 1 2 13mm ARMAFLEX INSULATION IN UN CONDITIONED SPACE SIZE TERMINATION PER TABLE 11 STRAIGHT APPPLICATION 1 2 13mm ARMAFLEX INSULATION IN UNCONDITIONED SPACE WALL SUPPORT EXTENDED APPLI
32. NG IN IHIS CONDITION IS VOLTAGE LED FLASHES CODE 13 LOW VOLTAGE CONTROL ABOVE 70 VOLTS WILL CONTINUE TO CALL FOR COOLING IN THIS CONDITION LED FLASHES CODE 8 ROLLOUT SWITCH OPEN GAS VALVE OFF COMBUSTION AIR INDUCER ON INDOOR ROLLOUT SWITCH MONITORED CONTINUOUSLY IS ROLLOUT SWITCH CLOSED BLOWER ON SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES AND MAIN POWER IS INTERRUPTED OR THERMOSTAT IS CYCLED OFF ON FOR 1 SEC MINIMUM LED SLOW FLASH RATE REMAINS UNCHANGED THROUGHOUT COOLING CYCLE THERMOSTAT CALLS FOR COOLING COMPRESSOR CONTACTOR AND SYSTEM FAN ENERGIZED WITH 2 SECOND DELAY COOLING SPEED THERMOSTAT OPENS COMPRESSOR OFF SYSTEM FAN AND EAC TERM OFF WITH 45 SECOND DELAY Page 46 Troubleshooting Continuous Fan Accessories Sequence of Operation CONTINUOUS FAN ACCESSORIES SEQUENCE OF OPERATION LED SLOW FLASH RATE REMAINS UNCHANGED THROUGHOUT SEQUENCE MANUAL FAN SELECTION MADE AT THERMOSTAT CONTROL G ENERGIZES SYSTEM FAN AT FAN SPEED EAC TERMINAL IS ENERGIZED THERMOSTAT CALLS FOR HEAT W THERMOSTAT CALLS FOR COOLING SYSTEM FAN CONTINUES FAN SPEED WITHOUT INTERRUPTION EAC TERMINAL REMAIN ON HUM TERMINALS ARE ENERGIZED WITH SYSTEM FAN SWITCHED TO COOL SPEED COMBUSTION AIR BLOWER EAC TERM REMAINS ON THERMOSTAT OPENS SYSTEM FAN SWITCHES TO HEAT SPEAD AFTER 30 SECOND DELAY EAC AND HUM TERMINALS REMAIN ON MANUAL FAN SELECTION MADE AT THERMOSTAT CONTROL G ENERGIZES SYSTE
33. OMPLETE NO NO LED FLASHES CODE 8 ROLLOUT SWITCH OPEN ROLLOUT SWITCH CLOSED GAS VALVE POWER OFF COMBUSTION AIR INDUCER POWER SEs ON INDOOR BLOWER ON SEQUENCE HOLDS UNTIL ROLLOUT SWITCH IS RESET AND MAIN POWER IS INTERRUPTED OR COMBUSTION AIR PRESSURE SWITCH CLOSED HAS PRESSURE SWITCH OPENED 5 LED FLASHES THERMOSTAT IS CYCLED OFF ON FOR 1 SEC MINIMUM CODE 10 THERMOSTAT DEMAND SATISFIED TIVES IN SAME HEAT DEMAND 1 HR PRESSURE YES NO SWITCH LED SLOW FLASH GAS VALVE DE ENERGIZED MOERS COMBUSTION AIR INDUCER ON INDOOR BLOWER OFF WITH DELAY COMB AIR INDUCER CONTINUES 5 SECOND HAS CAI SWITCH CLOSED IN 2 5 MINUTES POST PURGE AFTER T STAT DEMAND IS SATISFIED INDOOR AIR BLOWER COMPLETES SELECTED OFF NO DELAY BEFORE SHUTTING OFF 5 MINUTE PRESSURE SWITCH WATCHGUARD MODE LED FLASHES CODE Page 45 Troubleshooting Cooling Sequence of Operation COOLING SEQUENCE OF OPERATION NORMAL COOLING MODE ABNORMAL COOLING MODE POWER ON IGNITION CONTROL MAIN POWER ON LED FLASHES STEADY CIRCUIT BOARD FAILURE CONTROL SELF DIAGNOSTIC CHECK GAS VALVE OFF COMBUSTION AIR INDUCER OFF 15 CONTROL OPERATING NORMALLY INDOOR BLOWER OFF WITH NORMAL DELAY INTERRUPT MAIN POWER TO RESET CONTROL LED FLASHES CODE 2 IMPROPER GROUND IS THERE A PROPER GROUND lt CONTROL WILL CONTINUE TO CALL FOR COOLING IN THIS CONDITION LED FLASHES CODE 1 POLARITY REVERSED 15 POLARITY CORRECT CONTROL WILL CONTINUE TO CALL FOR COOLI
34. OW FILTER KITS Downflow Air Filter and Rack Kit 51W07 51W08 No and Size of filter in NIGHT SERVICE KITS 2 20 x 20x 1 2 20 x 20x 1 Night Service Kit 51W03 51W03 Safety Service Kit 89W20 89W20 TERMINATION KITS See Installation Instructions for specific venting information Termination Kits Concentric US 2 in 71M80 69M29 Direct Vent Applications 3 in TP 60146 097 Canada 2 in 44W92 44W92 3 in 44W93 Flush Mount 2 2 1 2 or 3 in 51W11 51W11 Wall Close US 2 in 22G44 Couple 3 in 44340 44340 Wall Close Canada 2 in 30G28 Couple WTK 3 in 81J20 81J20 Termination Kits Roof 2 in 15F75 15F75 Direct or Non Direct vent Wall Ring Kit 2 in 15F74 3 45F74 Roof Termination Flashing Kit Direct or Non Direct 2 in 44J41 44J41 Vent 2 flashings 1 Cleanable polyurethane frame type filter Kits contain enough parts for two non direct vent installations Non direct vent only NOTE Termination Kits 44W92 44W93 30G28 81J20 are certified to ULC S636 standard for use in Canada only GAS HEAT ACCESSORIES High Altitude Natural Gas to LPG Propane Natural Gas Input Pressure Switch Kit LPG Propane Kit to Natural Gas Kit sic jd 4501 7500 ft 7501 10 000 ft 0 7500 ft 0 7500 ft 7501 10 000 ft 7501 10 000 ft 045 No Change 74W90 69W73 73W81 73W37 68W68 070 77W43 73W22 69W73 73W81 73W37 68W68 090 77W43 73W22
35. RAP LOCATION Field Provided Vent shown with right side exit of condensation 1 Min to 2 Max above condensate drain connection Condensate Drain Connection Trap can be installed a maximum of 5 ft from furnace PVC Only Field Provided Vent 1 Min 2 Max Above Condensate Drain nas Evaporator Drain 1 min Line Vent Required 2 max FIGURE 45 Condensate Trap With Optional Overflow Switch to drain From Evaporator Coil Piping from furnace must slope down a minimum of 1 4 per ft toward trap FIGURE 43 Field Provided Vent 1 Min to 2 Max above condensate drain connection EL195DF with Evaporator Coil Using a Separate Drain Furnace Condensate c Drain Connection Optional Field Provided Vent Overflow Switch 1 Min to 2 Max above condensate drain connection Condensate Drain Connection Evaporator Drain Line Vent Required FIGURE 46 A CAUTION Do not use copper tubing or existing copper condensate lines for drain line Page 34 TRAP DRAIN ASSEMBLY USING 1 2 PVC OR 3 4 PVC Optional Condensate Drain Connection Adapter 1 2 inch slip X 1 2 inch mpt Not Furnished 90 Street Elbow Adapter 1 2 inch slip X 1 2 inch Not Furnishe 1 2 inch mpt Not Furnished Condensate Drain 1 25 mm Min Vent Connection In Unit 2 50 mm Max Condensate Drai Above Top Of 5
36. RMINALS ARE UNPOWERED TERMINALS ALL UNUSED MOTOR LEADS MUST BE WIRED TO A PARK TERMINAL FIELD SUPPLIED ACC WIRE 1 ROOM THERMOSTAT A 145 IS USED WITH HONEYWELL GAS VALVE WHEN APPLIED IN LP GAS UNITS 78 DENOTES OPTIONAL COMPONENTS LINE VOLTAGE FIELD INSTALLED CLASS VOLTAGE FIELD WIRING PURPLE YELLOW YELLOW HEATING UNITS GAS EL195DF045P36B EL195DF070P48B EL195DFO90P60C EL195DF110P60C Supersedes 1110 New Form No 537383 01 Litho U S A LENNOX Gas valve opens for a 4 second trial for ignition Flame is sensed gas valve remains open for the heat call After 30 second delay the integrated control A92 energizes indoor blower B3 When heat demand is satisfied W1 of the indoor thermostat de en ergizes W of the integrated control which de energizes the gas valve Combustion air inducer B6 continues a 5 second post purge period and indoor blower B3 completes a selected OFF time delay Troubleshooting Heating Sequence of Operation HEATING SEQUENCE OF OPERATION NORMAL HEATING MODE ABNORMAL HEATING MODE GAS VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER DELAY OFF H CONTROL SELF CHECK OKAY LED SLOW FLASH RESET CONTROL BY TURNING MAIN POWER OFF IS POLARITY CORRECT F C LED FLASHES CODE 1 POLARITY REVERSED NO IS THERE A PROPER GROUND L P LED FLASHES CODE 2 IMPROPER GROUND YES NO LED FLASHES CODE 13 LOW LINE VOLTAGE IS VOLTAGE CONTROL
37. UE EXHAUST END FLUSH INTO TERMINATION FURNACE 1 1 2 ACCELERATOR all 045 070 and 090 units FIGURE 26 7 fintake and exhaust piping must be run up a side wall to position above snow accumulation or other ob structions piping must be supported every 24 610mm as shown in figures 28 and 29 In addition close coupled wall termination kits must be extended for use in this application See figures 35 and 36 When exhaust and intake piping must be run up an outside wall the exhaust piping must be terminated with pipe sized per table 11 The intake piping may be equipped with a 90 elbow turndown Using turndown will add 5 feet 1 5m to the equivalent length of the pipe 8 A multiple furnace installation may use a group of up to four terminations assembled together horizontally as shown in figure 32 Page 27 Front View of Intake and Exhaust Exhaust Vent Pipe A Clearance above 12 eos grade or average snow 12 305MM Min 12 305MM Min accumulation B Horizontal 6 152MM Min 6 152MM Min separation between 24 610 MM 24 610 MM C Minimum from end of exhaust to 9 227MM Min 9 227MM Min inlet of intake peetppelngh 12 sun 305MM Min 12 305MM Min D Exhaust pipe length 7 d cid 16 405 MM Max 20 508MM Max E Wall support distance from top of each pipe intake exhaust 6 152MM Max 6 152
38. WILL NOT RESPOND A CALL FOR ABOVE 70 VOLTS HEATING UNTIL VOLTAGE RISES ABOVE 75 VOLTS YES LED FLASHES CODE 8 ROLLOUT SWITCH OPEN NO GAS VALVE OFF COMBUSTION AIR INDUCER ON INDOOR BLOWER ON SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES YES AND POWER IS RESET OR T STAT IS INTERRUPTED FOR MINIMUM OF 1 SECOND LED FLASHES CODE 12 FLAME SENSED NO WITHOUT GAS VALVE ENERGIZED BURNER CEE GAS VALVE OFF COMBUSTION AIR INDUCER ON VES INDOOR BLOWER ON HEATING SPEED NORMAL OPERATION LED SLOW FLASH YES THERMOSTAT CALLS FOR HEAT LED FLASHES CODE 7 PRIMARY LED SLOW FLASH LMIT OPEN COMBUSTION AIR INDUCER OFF I NDOOR BLOWER YES PRIMARY LIMIT SWITCH CLOSED LED FLASHES CODE 11 PRESSURE SWITCH CLOSED GAS VALVE OFF COMBUSTION AIR IS COMBUSTION AIR INDUCER OFF INDOOR BLOWER PRESSURE SWITCH OPEN OFF WITH DELAY YES Sequence holds until pressure switch opens or thermostat resets control IS COMBUSTION AIR INDUCER ENERGIZED YES LED FLASHES CODE 9 PRESSURE SWITCH FAILED HAS COMBUSTION AIR PRESSURE TO CLOSE OR OPENED DURING HEAT DEMAND SWITCH CLOSED IN 2 5 MINUTES PRESSURE SWITCH IS IN WATCHGUARD MODE GAS ves VALVE OFF COMBUSTION AIR INDUCER OFF INDOOR BLOWER OFF WITH DELAY IS 5 MINUTE RESET PERIOD COMPLETE CONTINUED NEXT PAGE Page 44 Troubleshooting Heating Sequence of Operation Continued HEATING SEQUENCE CONTINUED NORMAL HEATING MODE ABNORMAL HEATING MODE 15 SECOND COM
39. a Gas pipe size IPS 1 2 1 2 1 2 1 2 Condensate Drain Trap PVC pipe i d 1 2 1 2 1 2 1 2 with furnished 90 street elbow 1 2 slip x 1 2 Mipt 1 2 slip x 1 2 Mipt 1 2 slip x 1 2 Mipt 1 2 slip x 1 2 Mipt with field supplied PVC coupling o d 1 2 slip x 1 2 Npt 1 2 slip x 1 2 Npt 1 2 slip x 1 2 Npt 1 2 slip x 1 2 Npt Indoor Wheel nom dia x width in 10x8 11 1 2 x 10 11 1 2 x 10 11 1 2 x 10 NET Motor output hp 1 3 3 4 1 1 Tons of add on cooling 2 3 3 4 4 5 4 5 Air Volume Range cfm 605 1615 1090 1885 1270 2305 1330 2375 Electrical Voltage 120 volts 60 hertz 1 phase nii Blower motor full load amps 6 1 10 0 11 5 11 5 Maximum overcurrent protection 12 12 15 15 Shipping Data Ibs 1 package 121 134 154 164 NOTE Filters and provisions for mounting are not furnished and must be field provided 1 Annual Fuel Utilization Efficiency based on DOE test procedures and according to FTC labeling regulations Isolated combustion system rating for non weatherized furnaces Page 2 OPTIONAL ACCESSORIES MUST BE ORDERED EXTRA CABINET ACCESSORIES B Width Models C Width Models Downflow Combustible Flooring Base 11M60 11M61 CONDENSATE DRAIN KITS Condensate Drain Heat Cable 6 ft 26K68 26K68 24 ft 26K69 26K69 50 ft 26K70 26K70 Heat Cable Tape Fiberglass 1 2 in x 66 ft 36G53 36G53 Aluminum foil 2 in x 60 ft 16P89 16P89 Crawl Space Vent Drain Kit 51W18 51W18 CONTROLS DOWNFL
40. aged condensate trap Check trap for any cracks or damage and replace if necessary Cold end header box does not drain Check that the furnace is set properly with a slight tilt O 1 2 towards the front properly if necessary See furnace installation instruction Air leakage around the combustion air inducer gasket Check gasket and replace if necessary Air leakage around the cold end header Check gasket and replace if necessary box gasket Damaged cold end header box tubing Check tubing and replace if necessary Check that the correct pressure switch is installed in the unit Replace pressure switch if necessary Page 15 II PLACEMENT AND INSTALLATION Combustion Dilution amp Ventilation Air If the EL195DF is installed as a Non Direct Vent Fur nace follow the guidelines in this section NOTE In Non Direct Vent installations combustion air is taken from indoors and flue gases are discharged out doors In the past there was no problem in bringing in sufficient outdoor air for combustion Infiltration provided all the air that was needed In today s homes tight construction practices make it necessary to bring in air from outside for combustion Take into account that exhaust fans ap pliance vents chimneys and fireplaces force additional air that could be used for combustion out of the house Unless outside air is brought into the house for combus tion negative pressure outside pressure is greater than
41. air sup 3 feet 9m above if within 10 feet 6 feet 1 8m ply inlet 3m horizontally Clearance above paved sidewalk or 7 feet 2 1 7 feet 2 1 paved driveway located on public property M Clearance under veranda porch deck or balcony 12 inches 305mm t 12 inches 305mm t 1In accordance with the current ANSI Z223 1 NFPA 54 Natural Fuel Gas Code 2 ERN 2 1 accordance with the current CSA B149 1 Natural Gas and Propane Installation Code El eska DM VUES Cm dE enis T vent shall not terminate directly above a sidewalk or paved driveway that is d located between two single family dwellings and serves both dwellings MEE UOTE ofthe gas supplier and these installa t 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 23 Page 25 VENT TERMINATION CLEARANCES FOR DIRECT VENT INSTALLATIONS IN THE USA AND CANADA INSIDE CORNER DETAIL x AREA WHERE TERMINAL N VENT TERMINAL AIR SUPPLY INLET IS NOT PERMITTED US Installations1 Canadian Installations2 12 inches 305mm or 12 in 305mm 12 inches 305mm or 12 in 305mm Clearance above grade veranda above average snow accumulation porch deck or balcony above average snow accumulation 6 inches 152mm for appliances 10 000 6 inches 152mm for appliances 10 000 Btuh 3kw 9 inches 228mm for ap Btuh 3kw 12
42. ation 3 ZPE OTT L L TITITI 7 Ws GRADE z 4 12 805 mm Max for 2 51 mm Dia Exhaust Use wall support every 24 610 Use two supports if extension is greater than 24 but less than 48 1 20 508 mm 3 76 mm Dia Exhaust FIGURE 36 Page 31 EL195DF DIRECT VENT APPLICATION USING EXISTING CHIMNEY STRAIGHT CUT OR ANGLE CUT IN DIRECTION OF ROOF SLOPE EXHAUST VENT 1 2 13mm WEATHERPROOF INSULATION 8 12 203mm 305mm 03mm INTAKE PIPE 3 INSULATION optional SHEET METAL TOP Minimum 12 305MM above chimney top plate or average snow accumulation SHOULDER OF FITTINGS PROVIDE SUPPORT OF PIPE ON TOP PLATE ALTERNATE INTAKE PIPE SIZE TERMINATION PIPE PER TABLE 11 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 insulated FIGURE 37 Details of Exhaust Piping Terminations for Non Direct Vent Applications Exhaust pipes may be routed either horizontally through an outside wall or vertically through the roof In attic or closet installations vertical termination through the roof is pre ferred Figures 38 through 41 show typical terminations 1 Exhaust piping must termina
43. densate line from the furnace and evaporator coil can drain togeth er See figures 45 and 46 The field provided vent must be a minimum 1 to a maximum 2 length above the condensate drain outlet connection NOTE If necessary the condensate trap may be installed up to 5 feet away from the furnace Piping from furnace must slope down a minimum of 1 4 per ft toward trap NOTE Vinyl tubing may be used for condensate drain Tubing must be 1 1 4 OD X 1 ID and should be attached to the drain on the trap using a hose clamp Page 33 6 If unit will be started immediately upon completion of installation prime trap per procedure outlined in Unit Start Up section A IM PO RTANT Condensate line must slope downward away from the When combining the furnace and evaporator trap to drain If drain level is above condensate trap coil drains together the A C condensate drain condensate pump must be used Condensate drain outlet must be vented to relieve pressure in or line should be routed within the conditioned space to der for the furnace pressure switch to operate avoid freezing of condensate and blockage of drain properly line If this is not possible a heat cable kit may be used on the condensate trap and line Heat cable kit is avail EL195DF with Evaporator Coil able from Lennox in various lengths 6 ft 1 8m kit Using a Common Drain no 26K68 24 ft 7 3m kit no 26K69 and 50 ft 15 2m kit no 26K70 CONDENSATE T
44. described in section Exhaust Piping Terminations should be used Exhaust vent termination pipe is sized to optimize the velocity of the exhaust gas as it exits the termination Refer to table 11 In some applications which permit the use of several differ ent sizes of vent pipe a combination vent pipe may be used Contact Lennox Application Department for assis tance in sizing vent pipe in these applications IMPORTANT Do not use screens or perforated metal in exhaust or intake terminations Doing so will cause freeze ups and may block the terminations Use the following steps to correctly size vent pipe diameter Piping Size Process What is the furnace capacity D 045 070 090 110 or 135 Which style termination being used Standard or concentric See table 8 Which needs 3 most elbows Intake or exhaust How many elbows Count all elbows inside and outside house Desired pipe size 2 2 1 2 3 What is the altitude of the furnace installation Use table 10 to find max intake or exhaust pipe length Includes all vent pipe and elbows inside and outside the house FIGURE 19 NOTE It is acceptable to use any pipe size which fits within the guidelines allowed in table 10 NOTE All horizontal runs of exhaust pipe must slope back toward unit A minimum of 1 4 6mm drop for each 12 305mm of horizontal
45. dings will change as heat exchanger warms a Take one reading immediately after start up b Take a second reading after unit has reached steady state approximately 5 minutes This will be the pressure differential The pressure differential should be greater than those listed in table 5 Remove thermostat demand and allow to cycle off To Cold End Header Box NOTE Both sides of the cold end header box are nega tive However the port reads less negative pressure than the port Remove manometer and tee s Reinstall combustion air sensing hoses to the pressure switch FIGURE 11 C Blower Compartment 1 Blower Motor B3 and Capacitor C4 Blower motor B3 and capacitor C4 are located in the All EL195DF units use single phase direct drive blower mo blower compartment The blower compartment can be ac tors All motors are 120V permanent split capacitor motors cessed by removing the blower access panel to ensure maximum efficiency See SPECIFICATIONS table at the front of this manual for more detail See motor name Blower Motor Housing plate for capacitor ratings To Remove Blower From Unit Disconnect Power Remove Control Box Remove Bolts and Unplug Motor Wires From Integrated Control Then Slide Out Front of Unit FIGURE 12 Page 14 TABLE 6 Pressure Switch Troubleshooting Guide Check that the pressure switch is open without the combustion air inducer operat Pressure switch stuck closed ing Re
46. done after the final elbow 12 305mm MAX for 2 51mm 20 508mm for 3 76mm UNCONDITIONED SPACE 6 152mm SIZE TER MINATION PIPE PER TABLE 11 WALL SUPPORT FIELD PROVIDED REDUCER MAY BE REQUIRED TO ADAPT LARGER VENT PIPE SIZE TO TERMINATION 12 305mm ABOVE GRADE OR AVERAGE SNOW ACCUMULATION 4 2 13mm FOA INSULATION IN UNCONDITIONED MN yis SPACE 1 2 13mm FOAM INSULATION Use wall support every 24 610 Use two supports if extension is greater than 24 but less than 48 NON DIRECT VENT FIELD SUPPLIED WALL TERMINATION EX TENDED OR 15F74 WALL TERMINATION VENT PIPE EXTENDED FIGURE 40 EL195DF NON DIRECT VENT APPLICATION USING EXISTING CHIMNEY SIZE TERMINATION PIPE PER TABLE 11 STRAIGHT CUT OR ANGLE CUT IN DIRECTION OF ROOF SLOPE E EXHAUST VENT 1 2 13mm w WEATHERPROOF Minimum 12 305MM INSULATION above chimney top plate or average snow accumulation HOULDER OF FITTINGS PROVIDE SUPPORT OF PIPE ON TOP PLATE SHEET METAL TOP PLATE INSULATE TO FORM EXTERIOR SEAL PORTION OF 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 exterior portion of chimney the exhaust vent must be insulated FIGURE 41
47. enings shall each have a free area of at least one square inch per 4 000 Btu 645mm per 1 17kW per hour of the total input rating of all equipment in the enclosure FIGURE 14 If air from outside is brought in for combustion and ventila tion the confined space must have two permanent open ings One opening shall be within 12 inches 305 mm of the top of the enclosure and one opening within 12 inches 305 mm of the bottom These openings must communi cate directly or by ducts with the outdoors or spaces crawl or attic that freely communicate with the outdoors or indi rectly through vertical ducts Each opening shall have a minimum free area of 1 square inch 645 mm2 per 4 000 Btu 1 17 kW per hour of total input rating of all equipment in the enclosure See figures 14 and 15 When communicating with the outdoors through horizontal ducts each opening shall have a minimum free area of 1 square inch 645 mm per 2 000 Btu 56 kW per total in put rating of all equipment in the enclosure See figure 16 When ducts are used they shall be of the same cross sec tional area as the free area of the openings to which they connect The minimum dimension of rectangular air ducts shall be no less than 3 inches 75 mm In calculating free area the blocking effect of louvers grilles or screens must be considered If the design and free area of protec tive covering is not known for calculating the size opening required it may be as
48. enter of the burner ports 9 Reconnect the sensor wire and reconnect the 2 pin plug to the ignitor wiring harness Reinstall combustion air intake flexible connector if equipped secure using existing clamps Reinstall the gas valve manifold assembly Reconnect the gas supply line to the gas valve Reinstall the burn er box cover 12 Reconnect plug to gas valve 13 Replace the blower compartment access panel 14 Refer to instruction on verifying gas and electrical con nections when re establishing supplies Follow lighting instructions to light and operate fur nace for 5 minutes to ensure that heat exchanger is clean and dry and that furnace is operating properly 16 Replace access panel 1 10 11 15 Page 42 VII WIRING DIAGRAM AND SEQUENCE OF OPERATION INDOOR C4 BLOWER CAPACITOR MOTOR CB8 CIRCUIT BREAKER J IGNITION BLOWER CONTROL 1 ROOM THERMOSTAT n DOOR TRANSFORMER INTERLOCK 120V ACC OR K43 ECON IF USED 18 COMBUSTION AIR PROVING SWITCH COMBUSTION AIR INDUCER MOTOR 145 AN LOW GAS PRESSURE SWITCH L1 510 PRIMARY GAS LIMIT NOTE USE COPPER CONDUCTORS ONLY GAS VALVE S47 FLAME ROLLOUT SWITCH J159 FLAME P159 Sar SENSOR FLAME ROLLOUT SWITCH BURNERS LINE H XFMR H EQUIPMENT GROUND SEE BLOWER SPEED CHART FOR CONNECTIONS SENSOR WHITE PINK FLAME J156 J156 BLOWER MOTOR COMMON When there is
49. er opening 23 Re secure the supporting screws along the vestibule sides and top to the cabinet 24 Reinstall cabinet screws on front flange at blower deck 25 Reinstall the primary limit on the vestibule panel 26 Route heating component wiring through hole in blow er deck and reinsert strain relief bushing 27 Reinstall electrical junction box 28 Reinstall exhaust and air intake pipe seal plate Rein stall exhaust and air intake pipes and tighten clamps on pipe seal plate 29 Reinstall the cold end header box 30 Reinstall the combustion air inducer Reconnect the combustion air inducer to the wire harness 31 Reinstall pressure switch assembly and reconnect pressure switch wiring 32 Carefully connect combustion air pressure switch tubing from pressure switches to proper ports on cold end header collector box 33 Reinstall condensate trap 34 Secure burner box assembly to vestibule panel using four existing screws Make sure burners line up in center of burner ports 35 Reconnect exhaust piping and exhaust drain tubing 36 Reconnect flame roll out switch wires 37 Reconnect sensor wire and reconnect 2 pin plug from ignitor 38 Reinstall gas valve manifold assembly Reconnect gas supply line to gas valve 39 Reinstall burner box cover if equipped 40 Reconnect plug to gas valve 41 Replace the blower compartment access panel 42 Follow lighting instructions on unit nameplate to
50. exhaust pipe When transitioning up in pipe size use the shortest length of 2 PVC pipe possible NOTE Exhaust pipe and intake pipe must be the same diameter FIGURE 20 TYPICAL NTAKE PIPE CONNECTIONS C Pipe size determined in table 10 TRANSITION 3 TRANSITION 2 INTAKE EXHAUST TOP VIEW When transitioning up in pipe size use the shortest length of 2 PVC pipe possible NOTE Intake pipe and exhaust pipe must be the same diameter FIGURE 21 Page 23 Intake Piping The EL195DF furnace may be installed in either direct vent or non direct vent applications In non direct vent applications when intake air will be drawn into the furnace from the surrounding space the indoor air quality must be considered Guidelines listed in Combustion Dilution and Ventilation Air section must be followed Follow the next two steps when installing the unit in Direct Vent applications where combustion air is taken from outdoors and flue gases are discharged outdoors The provided air intake screen must not be used in direct vent applications outdoors 1 Use cement to secure the intake pipe to the inlet air connector 2 Route piping to outside of structure Continue with installation following instruct
51. gas leaks D Testing Gas Supply Pressure When testing supply gas pressure use the 1 8 N P T plugged tap or pressure post located on the gas valve to facilitate test gauge connection See figure 48 Check gas line pressure with unit firing at maximum rate Low pres sure may result in erratic operation or underfire High pres sure can result in permanent damage to gas valve or over fire On multiple unit installations each unit should be checked separately with and without units operating Supply pres sure must fall within range listed in table 13 E Check Manifold Pressure After line pressure has been checked and adjusted check manifold pressure Move pressure gauge to outlet pres sure tap located on unit gas valve GV1 Checks of manifold pressure are made as verification of proper regulator adjustment A IMPORTANT For safety connect a shut off valve between the manometer and the gas tap to permit shut off of gas pressure to the manometer 1 Remove the threaded plug from the outlet side of the gas valve and install a field provided barbed fitting Connect to a manometer to measure manifold pres sure 2 Start unit and allow 5 minutes for unit to reach steady state 3 While waiting for the unit to stabilize observe the flame Flame should be stable and should not lift from burner Natural gas should burn blue 4 After allowing unit to stabilize for 5 minutes record manifold pressure and compare to value
52. gas may be slightly acidic and may adversely affect some building materials If any vent termination is used and the flue gasses may impinge on the building ma terial a corrosion resistant shield minimum 24 inches square should be used to protect the wall surface If the optional tee is used the protective shield is recommended The shield should be constructed using wood plastic sheet metal or other suitable material All seams joints cracks etc in the affected area should be sealed using an appropriate sealant See figure 27 Intake and exhaust pipes may be routed either horizontally through an outside wall or vertically through the roof In attic or closet installations vertical termination through the roof is preferred Figures 25 through 37 show typical termina tions 1 Exhaust and intake exits must be in same pressure zone Do not exit one through the roof and one on the side Also do not exit the intake on one side and the exhaust on another side of the house or structure 2 Intake and exhaust pipes should be placed as close together as possible at termination end refer to il lustrations Maximum separation is 3 76mm on roof terminations and 6 152mm on side wall termina tions 3 Onroofterminations the intake piping should termi nate straight down using two 90 elbows See figure 25 4 Exhaust piping must terminate straight out or up as shown A reducer may be required on the exhaust pip ing at the p
53. in for 2 51 mm amp 3 76 mm DIA pipe between the end of the exhaust pipe and intake pipe WALL SUPPORT 305 mm Max for 2 51 mm Dia Exhaust emen mm Max for 3 76 mm Dia Exhaust Ll EXHAUST iE 1 2 13 mm T FOAM INSULATION Field Furnished INTAKE AIR EXHAUST INTAKE AIR 12 805 mm Minimum 2 305 mm Minimum 87203 imm Min pu Grade or Average Above Grade or Average Snow Accumulation Snow Accumulation 7 Of GRADE GRADE 12 305 mm Max for 2 51 mm Dia Exhaust Use wall support every 24 610 Use two supports if 20 508 mm Max for 3 76 mm Dia Exhaust extension is greater than 24 but less than 48 FIGURE 35 WALL TERMINATION KITS CLOSE COUPLE EXTENDED VENT FOR GRADE CLEARANCE 2 inch 51 mm 30G28 WTK Canada 3 inch 76 mm 81J20 WTK Canada See Installation Instructions for additional information If intake and exhaust pipe is less than 12 in 305 mm above snow accumulation or other obstructions field RESBCER MAY BE REQUIRED e fabricated piping must be installed piping LARGER VENT PIPE SIZE TO TERMINATION WALL SUPPORT 12 305 mm Max for 2 51 mm Dia Exhaust 20 508 mm Max for 3 76 mm Dia Exhaust EXHAUST 1 2 13 mm FOAM INSULATION 6 152 mm AIR Field Furnished Maximum 152 mm INTAKE EXHAUST SU 12 305 mm Minimum 152 mm 2 305 mm Minimum Mini above Grade or Average PE Snow Accumul
54. inches 305mm for pliances gt 10 000 Btuh 3kw and 50 000 appliances 10 000 Btuh 3kw and Btuh 15 kw 12 inches 305mm for ap 100 000 Btuh 30kw 36 inches 9m pliances gt 50 000 Btuh 15kw for appliances gt 100 000 Btuh 30kw 12 42 Clearance to window or door that may be opened Clearance to permanently closed window Vertical clearance to ventilated soffit located above the terminal within horizontal distance of 2 feet 610mm from the center line of the terminal Clearance to unventilated soffit Clearance to outside corner Clearance to inside corner Clearance to each side of center line ex 3 feet 9m within a height 15 feet 4 5m tended above meter regulator assembly above the meter regulator assembly Clearance to service regulator 3 feet 9m vent outlet Clearance to non mechanical air Equal to or greater than soffit depth Equal to or greater than soffit depth Equal to or greater than soffit depth Equal to or greater than soffit depth No minimum to outside corner No minimum to outside corner 3 feet 9m within a height 15 feet 4 5m above the meter regulator assembly 3 feet 9m 6 inches 152mm for appliances 10 000 6 inches 152mm for appliances 10 000 supply inlet to building or the com Btuh 3kw 9 inches 228mm for ap Btuh 3kw 12 inches 305mm for bustion air inlet to any other ap pliances gt 10 000 Btuh 3kw and 50 000
55. ing shall have a free area of at least one square inch per 1 000 Btu 645 mm per 29 kW per hour of the total input rating of all equipment in the enclosure but not less than 100 square inches 64516 2 SIDE WALL TERMINATED EXHAUST PIPE ALTERNATE LOCATION FIGURE 13 Air from Outside If air from outside is brought in for combustion and ventila tion the confined space shall be provided with two perma nent openings One opening shall be within 12 305mm of the top of the enclosure and one within 12 305mm of the bottom These openings must communicate directly or by ducts with the outdoors or spaces crawl or attic that freely communicate with the outdoors or indirectly through vertical ducts Each opening shall have a mini mum free area of 1 square inch per 4 000 Btu 645mm per 1 17kW per hour of total input rating of all equipment in the enclosure When communicating with the outdoors through horizontal ducts each opening shall have a mini mum free area of 1 square inch per 2 000 Btu 645mm per 59kW per total input rating of all equipment in the en closure See figure 14 EQUIPMENT IN CONFINED SPACE ALL AIR FROM OUTSIDE Inlet Air from Crawl Space and Outlet Air to Ventilated Attic VENTILATION LOUVERS Each end of attic ROOF TERMINATED EXHAUST PIPE 22 SIDE WALL TERMINATED EXHAUST PIPE ALTERNATE LOCATION VENTILATION LOUVERS For unheated crawl space NOTE The inlet and outlet air op
56. ings primer and solvent cement must conform with American National Standard Institute and the Ameri can Society for Testing and Materials ANSI ASTM stan dards The solvent shall be free flowing and contain no lumps undissolved particles or any foreign matter that ad versely affects the joint strength or chemical resistance of the cement The cement shall show no gelation stratifica tion or separation that cannot be removed by stirring Re fer to the table 7 below for approved piping and fitting ma terials A 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 cement when making joints Good ventilation should maintained to reduce fire hazard and to minimize breathing of solvent vapors Avoid contact of cement with skin and eyes TABLE 7 PIPING AND FITTINGS SPECIFICATIONS ABS DWV Drain amp Vent Pipe amp Fittings D2661 PVC DWV Drain Waste amp Vent D2665 Pipe amp NOE ASTM PRIMER amp SOLVENT CEMENT SPECIFICATION PVC amp CPVC Primer F656 PVC Solvent Cement D2564 CPVC Solvent Cement F493 ABS Solvent Cement D2235 PVC CPVC ABS All Purpose Cement For Fittings amp Pipe of the same material D2564 D2235 F493 ABS to PVC or CPVC Transition Solvent CANADA PIPE amp FITTING amp SOLVENT CEMENT amp CPVC Pipe and Fittings amp CPVC amp CPVC PipeandFiting
57. inside pressure will build to the point that a downdraft can occur in the furnace vent pipe or chimney As a result combustion gases enter the living space creating a po tentially dangerous situation In the absence of local codes concerning air for combus tion and ventilation use the guidelines and procedures in this section to install EL195DF furnaces to ensure effi cient and safe operation You must consider combustion air needs and requirements for exhaust vents and gas piping A portion of this information has been reprinted with permission from the National Fuel Gas Code ANSI Z223 1 NFPA 54 This reprinted material is not the com plete and official position of the ANSI on the referenced subject which is represented only by the standard in its entirety In Canada refer to the CSA B149 installation codes CAUTION Do not install the furnace in a corrosive or contami nated atmosphere Meet all combustion and ventila tion air requirements as well as all local codes All gas fired appliances require air for the combustion pro cess If sufficient combustion air is not available the fur nace or other appliance will operate inefficiently and un safely Enough air must be provided to meet the needs of all fuel burning appliances and appliances such as exhaust fans which force air out of the house When fireplaces ex haust fans or clothes dryers are used at the same time as the furnace much more air is required to e
58. intake and exhaust 2 51mm 3 76mm Vent Pipe Vent Pipe 12 305MM 12 305MM 6 152MM 6 152MM 6 152MM 6 152MM D Maximum exhaust 7 A Minimum clearance above grade or average snow accumulation B Maximum horizontal separation between intake and exhaust C Minimum from end of exhaust to inlet of intake pipe length 12 305MM 20 508MM E Maximum wall support distance from top of each 6 152MM 6 152MM pipe intake exhaust FIGURE 29 Page 29 1 1 2 38mm accelerator provided on 71M80 amp 44W92 kits for EL195DF045P36B amp 070P36B FLASHING 12 305mm Not Furnished Minimum Above Average Snow Accumulation SHEET METAL STRAP Clamp and sheet metal strap must be field installed to support the weight of the termination kit FIELD PROVIDED REDUCER MAY BE REQUIRED bJ TO ADAPT LARGER VENT 4 V PIPE SIZE TO TERMINATION DIRECT VENT CONCENTRIC ROOFTOP TERMINATION 71M80 69M29 60146 US 44W92 or 44W93 Canada FIGURE 30 1 1 2 38mm accelerator provided on 71M80 amp FIELD PROVIDED 44W92 kits for REQUIRED ADAPT EL195DF045P36B amp LARGER VENT PIPE 070P36B OUTSIDE SIZE TO TERMINATION WAL INTAKE AIR 2 EXHAUST EXHAUST above grade or average snow ac cumulation GRADE DIRECT VENT CONCENTRIC WALL TERMINATION 71M80 69M29 or 60L46 US 44W92 or 44W93 Canada FIGURE 31 Not Furnished EXHAUST gt O O
59. ions given in general guide lines for piping terminations and intake and ex haust piping terminations for direct vent sections Re fer to table 10 for pipe sizes TYPICAL AIR INTAKE PIPE CONNECTIONS NON DIRECT VENT APPLICATIONS AIR INTAKE SCREEN Provided NOTE Air intake screen and elbow may be rotated so that screen may be positioned to face forward or to either side FIGURE 22 Follow the next two steps when installing the unit in Non Direct Vent applications where combustion air is taken from indoors and flue gases are discharged outdoors 1 Use field provided materials and the factory provided air intake screen to route the intake piping as shown in figure 22 Maintain a minimum clearance of 3 76mm around the air intake opening The air intake opening with the protective screen should always be directed forward or sideways 2 Use cement to secure the intake pipe to the connector if desired General Guidelines for Vent Terminations In Non Direct Vent applications combustion air is taken from indoors and the flue gases are discharged to the out doors The EL195DF is then classified as a non direct vent Category IV gas furnace In Direct Vent applications combustion air is taken from outdoors and the flue gases are discharged to the out doors The EL195DF is then classified as a direct vent
60. ld temperatures below approximately 20 F 6 7 C units with long runs of vent pipe through unconditioned space even when insulated may form ice in the exhaust termination that prevents the unit from operating properly Longer run times of at least 5 minutes will alleviate most icing problems Also a heating cable may be installed on exhaust piping and termination to prevent freeze ups Heating cable installation kit is available from Lennox See Condensate Piping section for part numbers IMPORTANT Do not use screens or perforated metal in exhaust terminations Doing so will cause freeze ups and may block the terminations IMPORTANT For Canadian Installations Only In accordance to CSA International B149 installation codes the minimum allowed distance between the combustion air intake inlet and the exhaust outlet of other appliances shall not be less than 12 inches 305mm Page 24 VENT TERMINATION CLEARANCES FOR NON DIRECT VENT INSTALLATIONS IN THE USA AND CANADA INSIDE CORNER DETAIL lt AREA WHERE TERMINAL N VENT TERMINAL G9 AIR SUPPLY INLET IS NOT PERMITTED US Installations Canadian Installations Clearance above grade veranda 12 inches 305mm or 12 in 305mm 12 inches 305mm or 12 in 305mm porch deck or balcony above average snow accumulation above average snow accumulation Clearance to window or 6 inches 152mm for appliances 10 000 door that may be opened 4 feet
61. light and operate furnace for 5 minutes to ensure the fur nace is operating properly 43 Check all piping connections factory and field for gas leaks Use a leak detecting solution or other preferred means A CAUTION Some soaps used leak detection corrosive to certain metals Carefully rinse piping thoroughly af ter leak test has been completed Do not use matches candles flame or other sources of ignition to check for gas leaks 44 Replace access panel Cleaning the Burner Assembly if needed 1 Turn off electrical and gas power supplies to furnace Remove upper and lower furnace access panels 2 Disconnect the 2 pin plug from the gas valve 3 Remove the burner box cover if equipped 4 Disconnect the gas supply line from the gas valve Re move gas valve manifold assembly 5 Loosen clamps and remove combustion air intake flexible connector if equipped 5 Mark and disconnect sensor wire from the sensor Dis connect plug from the ignitor at the burner box 6 Remove four screws which secure burner box assem bly to vest panel Remove burner box from the unit 7 Use the soft brush attachment on a vacuum cleaner to gently clean the face of the burners Visually inspect the inside of the burners and crossovers for any block age caused by foreign matter Remove any blockage Reinstall the burner box assembly using the existing four screws Make sure that the burners line up in the c
62. mbly due to insufficient sol vent 9 Handle joints carefully until completely set Venting Practices Piping Suspension Guidelines SCHEDULE 40 5 all other pipe 3 See table 7 for allowable pipe NOTE Isolate piping at the point where it exits the outside wall or roof in order to prevent transmission of vibration to the structure Wall Thickness Guidelines 24 maximum 3 4 minimum inside Wall outside m REPLACING FURNACE THAT WAS PART OF A COMMON CHIMNEY VENT SYSTEM OR GAS VENT Check sizing for water heater only FURNACE Replaced by EL193 OPENINGS To Adjacent If an EL195DF furnace replaces a furnace which was com monly vented with another gas appliance the size of the ex isting vent pipe for that gas appliance must be checked Without the heat of the original furnace flue products the existing vent pipe is probably oversized for the single water heater or other appliance The vent should be checked for proper draw with the remaining appliance FIGURE 18 2 n areas where piping penetrates joists or interior walls hole must be large enough to allow clearance on all sides of pipe through center of hole using a hanger Page 20 3 When furnace is installed in a residence where unit is shut down for an extended period of time such as a vacation home make provisions for draining conden sate collection trap and lines Exhaust Piping Figures 20 and 21 Ro
63. nd wire from vest panel 12 Page 41 13 Remove electrical junction box from the side of the fur nace 14 Disconnect condensate line from cold end header box Remove cold end header box 15 Loosen clamps on exhaust and air intake pipe seal plate Slide exhaust and intake pipes up and out to clear blower deck Remove exhaust and air intake pipe seal plate 16 Mark and disconnect any remaining wiring to heating compartment components Disengage strain relief bushing and pull wiring and bushing through the hole in the blower deck 17 Remove the primary limit from the vestibule panel 18 Remove two screws from the front cabinet flange at the blower deck Spread cabinet sides slightly to allow clearance for removal of heat exchanger 19 Remove screws along vestibule sides which secure vestibule panel and heat exchanger assembly to cabi net Remove two screws from blower rail which secure top heat exchanger flange Remove heat exchanger from furnace cabinet 20 Back wash heat exchanger with soapy water solution or steam If steam is used it must be below 275 F 135 C 21 Thoroughly rinse and drain the heat exchanger Soap solutions can be corrosive Take care to rinse entire assembly 22 Reinstall heat exchanger into cabinet making sure that the clamshells of the heat exchanger assembly are engaged properly into the support bracket on the blower deck Remove the indoor blower to view this area through the blow
64. ne changeover kit is available Gas Valve MANIFOLD PRESSURE ADJUSTMENT SCREW under OUTLET barbed Y K PORT MANIFOLD PRESSURE fitting INLET PRESSURE PORT FIGURE 7 5 Flame Sensor Figure 5 A flame sensor is located on the left side of the burner sup port The sensor is mounted on the bottom burner box plate and the tip protrudes into the flame envelope of the left most burner The sensor can be removed for service with out removing any part of the burners During operation flame is sensed by current passed through the flame and sensing electrode The ignition control allows the gas valve to remain open as long as flame signal is sensed NOTE The EL195DF is polarity sensitive Make sure that the furnace is wired correctly and is properly grounded A microamp DC meter is needed to check the flame signal on the integrated control Flame microamp signal is an electrical current which passes from the integrated control to the sensor during unit operation Current passes from the sensor through the flame to ground to complete a safety circuit To Measure Flame Signal Integrated Control Use a digital readout meter capable of reading DC micro amps See figure 8 for flame signal check 1 Setthe meter to the DC amps scale 2 Turn off supply voltage to control 3 Disconnect integrated control flame sensor wire from the flame se
65. nitor is made from a non porous high strength pro prietary ceramic material that provides long life and trouble free maintenance The integrated control continu ously monitors line voltage and maintains the ignitor pow er ata consistent level to provide proper lighting and maxi mum ignitor life TABLE 1 4 Pin Terminal Designation FUNCTION Combustion Air Inducer Line Combustion Air Inducer Neutral Ignitor Neutral TABLE 2 12 Pin Terminal Designations FUNCTION 3 anbaston A ENDS m ea Wea x s jem 3 11 Rollout Switch In Gas Valve Out Page 6 Electronic Ignition On a call for heat the integrated control monitors the com HEAT FAN OFF TIME IN SECONDS bustion air inducer prove switch The integrated control will JUMPER POSITION PEAT rT not begin the heating cycle if the pressure switch is closed PINI 60 by passed Once the pressure switch is determined to be 5 open the combustion air inducer is energized When the PIN4 PINS 180 NO JUMPER 80 differential in the pressure switch is great enough the pres sure switch closes and a 15 second pre purge begins If the pressure switch is not proven within 2 1 2 minutes the 60 Second 90 Second 120 Second 180 Second integrated control goes into Watchguard Pressure Switch mode for a 5 minute re set period After the 15 second pre purge period the ignito
66. nsor 4 Connect lead to flame sensor 5 Connect lead to the ignition control sensor wire 6 Turn supply voltage on and close thermostat contacts to cycle system 7 When main burners are in operation for two minutes take reading 6 Ignitor Figure 5 EL195DF units use a mini nitride ignitor made from a pro prietary ceramic material To check ignitor measure its re sistance and voltage A value of 39 to 70 ohms indicates a good ignitor Voltage to the ignitor should be 102VAC 132VAC See figure 9 for resistance and voltage checks Page 10 Measuring Flame Signal Flame Signal In Microamps Normal Low Drop Out Connect Alligator Clip to Frame Sensor Lead Flame Sensor Terminal emove Sensor Wire from Intergrated Intergrated Control and 2 Remove Sensor Wire from Intergrated Control and Connect Alligator Clip to Terminal on Control Multi Meter Flame Sensor Wire Red Oollar P Indicates To Flame Terminal To Control Sensor Terminal FIGURE 8 Page 11 Multi Meter set to ohms Check ignitor circuit for correct resistance Remove 4 pin plug from control Check ohms reading across terminals 2 and 4 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 Multi Meter set to ohms Test 2 Check ignitor for correct resistance Seperate
67. nsure proper combustion and to prevent a downdraft Insufficient air causes incomplete combustion which can result in carbon monoxide In addition to providing combustion air fresh outdoor air di lutes contaminants in the indoor air These contaminants may include bleaches adhesives detergents solvents and other contaminants which can corrode furnace compo nents The requirements for providing air for combustion and ven tilation depend largely on whether the furnace is installed in an unconfined or a confined space Unconfined Space An unconfined space is an area such as a basement or large equipment room with a volume greater than 50 cubic feet 1 42 m3 per 1 000 Btu 29 kW per hour of the com bined input rating of all appliances installed in that space This space also includes adjacent rooms which are not separated by a door Though an area may appear to be un confined it might be necessary to bring in outdoor air for combustion if the structure does not provide enough air by infiltration If the furnace is located in a building of tight construction with weather stripping and caulking around the windows and doors follow the procedures in the Air from Outside section Confined Space A confined space is an area with a volume less than 50 cubic feet 1 42 m per 1 000 Btu 29 kW per hour of the com bined input rating of all appliances installed in that space This definition includes furnace closets or small equipmen
68. ntial and opens the circuit to the ignition control If the condensate line is blocked water will back up into the header box and reduce the pressure dif ferential across the switch The prove switch opens if the dif ferential drops below the set point See table 5 Checks of pressure differential can aid in troubleshooting When measuring the pressure differential readings should be taken at the pressure switch See figure 11 and table 6 Lack of differential usually indicates problems in the intake or ex haust piping but may indicate problems in the heat ex changer condensing coil header boxes combustion inducer or other components TABLE 5 Altitude ft ma 0 4500 4501 7500 Set Point 7501 10000 Set point is factory set and non adjustable Page 13 Measuring Pressure Differential Black Tubing Red Tubing negative To Cold End Header Box positive Field Provided Tubing To Pressure Switch Remove thermostat demand and allow unit to cycle off Install a tee in the negative line red tubing and a tee in the positive line black tubing running from the pressure switch to the cold end header box Install a manometer with hose from the negative side of the manometer to the tee installed in the negative line and with hose from the positive side of the manometer to the tee in the positive line 4 Operate unit and observe manometer reading Rea
69. oint where it exits the structure to improve the velocity of exhaust away from the intake piping See table 11 TABLE 11 EXHAUST PIPE TERMINATION SIZE REDUCTION EL195 7 Termination MODEL Exhaust Pipe Size 045 and 070_ 2 51mm 2 1 2 64mm 112 38mm 3 76mm EL195DF 045 070 and 090 units with the flush mount termination must use the 1 1 2 accelerator supplied with the kit 5 On field supplied terminations for side wall exit ex haust piping may extend a maximum of 12 inches 305mm for 2 PVC and 20 inches 508mm for 3 76mm PVC beyond the outside wall Intake piping should be as short as possible See figures 28 and 29 NOTE Care must be taken to avoid recirculation of exhaust back into intake pipe 6 On field supplied terminations a minimum distance between the end of the exhaust pipe and the end of the intake pipe without a termination elbow is 8 anda minimum distance of 6 with a termination elbow See figures 28 and 29 3 76mm MAX SIZE TERMINATION PIPE PER TABLE 11 Inches mm UNCONDITIONED 8 203mm MIN ATTIC SPACE 1 2 13mm FOAM 12 305mm ABOVE INSULATION IN AVERAGE SNOW UNCONDITIONED ACCUMULATION SPACE 3 76mm O 2 51mm PVC PROVIDE SUPPORT FOR INTAKE AND EXHAUST LINES DIRECT VENT ROOF TERMINATION KIT 15F75 or 44J41 FIGURE 25 2 EXTENSION FOR FURNACE 2 PVC PIPE EXHAUST 1 EXTENSION FOR PIPE 3 PVC PIPE GL
70. orrected be fore starting unit 3 Inspect condition of condensate traps and drain as sembly Disassemble and clean seasonally B Heating Start Up BEFORE LIGHTING the unit smell all around the fur nace area for gas Be sure to smell next to the floor be cause some gas is heavier than air and will settle on the floor The gas valve on the EL195DF is equipped with a gas control switch Use only your hand to move the switch Never use tools If the the switch will not move by hand replace the valve Do not try to repair it Force or at tempted repair may result in a fire or explosion Placing the furnace into operation EL195DF units are equipped with a SureLight ignition system Do not attempt to manually light burners on this furnace Each time the thermostat calls for heat the burners will automatically light The ignitor does not get hot when there is no call for heat on units with SureLight ignition system Priming Condensate Trap The condensate trap should be primed with water prior to start up to ensure proper condensate drainage Either pour 10 fl oz 300 ml of water into the trap or follow these steps to prime the trap 1 Follow the lighting instructions to place the unit into op eration 2 Setthe thermostat to initiate a heating demand 3 Allow the burners to fire for approximately 3 minutes 4 Adjust the thermostat to deactivate the heating de mand Wait for the combustion air inducer to stop
71. ower access panel must be securely in place when the blower and burners are operating Gas fumes which could contain carbon monoxide can be drawn into living space resulting in personal inju ry or death Filters All air filters are installed external to the unit Filters should be inspected monthly Clean or replace the filters when necessary to ensure proper furnace operation Table 18 lists recommended filter sizes TABLE 18 Furnace Exhaust and air intake pipes Check the exhaust and air intake pipes and all connections for tightness and to make sure there is no blockage NOTE After any heavy snow ice or frozen fog event the furnace vent pipes may become restricted Always check the vent system and remove any snow or ice that may be obstructing the plastic intake or exhaust pipes Electrical 1 Check all wiring for loose connections 2 Check for the correct voltage at the furnace furnace operating Correct voltage is 120VAC 10 3 Check amp draw on the blower motor with blower ac cess panel in place Motor Nameplate Actual Check Motor AMP Draw Typical set up with upflow furnace shown O AMP Meter FIGURE 54 Winterizing and Condensate Trap Care 1 Turn off power to the furnace 2 Have a shallow pan ready to empty condensate water 3 Remove the clean out cap from the condensate trap and empty water Inspect the trap then reinstall the clean out cap Cleaning Heat Exchanger If
72. place if defective Pressure switch does not close due to Check for restricted vent Remove all blockage obstruction in vent pipe Check for proper vent sizing See table 10 Pressure switch does not close due to check that the pressure switch tubing is correctly routed Correctly route pressure incorrect routing of the pressure switch line tubing I n Switch 006 Hot close due o Remove any obstructions from the the pressure switch line and or taps obstructions in the pressure switch line y Pressure switch tubing damaged Check pressure switch tubing for leaks Replace damaged tubing if necessary Condensate in pressure switch tubing Check pressure switch tubing for condensate Remove condensate from tubing Pressure switch does not close due to Check the differential pressure across the pressure switch a low differential pressure across the Check for restricted inlet vent Remove all blockage pressure switch Check for proper vent sizing and run length See table 10 Wrong pressure switch installed in the unit or pressure switch is out of calibra tion Miswiring of furnace or improper Check for correct wiring and loose connections Correct wiring and or replace any connections at pressure switch loose connections If all the above modes of failure have been checked the pressure switch may have Pressure switch failure SM failed Replace pressure switch and determine if unit will operate Dam
73. r warms up for 20 seconds during which the gas valve opens at 19 sec onds for a 4 second trial for ignition The ignitor remains energized for the first 3 seconds during the 4 second trial If ignition is not proved during the 4 second period the inte grated control will try four more times with an inter purge and warm up time between trials of 35 seconds After a to INTEGRATED CONTROL tal of five trials for ignition including the initial trial the inte Automatic Hot Surface Ignition System grated control goes into Watchguard Flame Failure mode o O After a 60 minute reset period the integrated control will begin the ignition sequence again The integrated control has an added feature of ignitor pow er regulation to maintain consistent lighting and longer igni tor life under all line voltage conditions To adjust fan off timing reposition jumper across pins to achieve desired setting z E NEUTRALS Fan Control 0 00 Heating Fan On Delay The heating fan on time of 30 seconds is not adjustable Heating Fan Off Delay The heat fan off delay amount of time that the blower oper ates after the heat demand has been satisfied may be ad OOO
74. rom fitting socket and result in a leaking joint NOTE Check the inside of vent pipe thoroughly for any obstruction that may alter furnace operation 3 Clean and dry surfaces to be joined 4 Test fit joint and mark depth of fitting on outside of pipe 5 Uniformly apply a liberal coat of PVC primer for PVC or use a clean dry cloth for ABS to clean inside socket surface of fitting and male end of pipe to depth of fitting socket 1 Promptly apply solvent cement to end of pipe and in side socket surface of fitting Cement should be ap plied lightly but uniformly to inside of socket Take care to keep excess cement out of socket Apply sec ond coat to end of pipe NOTE Time is critical at this stage Do not allow prim er to dry before applying cement 1 Immediately after applying last coat of cement to pipe and while both inside socket surface and end of pipe are wet with cement forcefully insert end of pipe into socket until it bottoms out Turn PVC pipe 1 4 turn dur ing assembly but not after pipe is fully inserted to dis tribute cement evenly DO NOT turn ABS or cellular core pipe NOTE Assembly should be completed within 20 sec onds after last application of cement Hammer blows should not be used when inserting pipe 8 After assembly wipe excess cement from pipe at end of fitting socket A properly made joint will show a bead around its entire perimeter Any gaps may indi cate an improper asse
75. rrective Action Check for restricted vent pipe and remove all blockage Check the condensate line for proper drainage and correct as necessary Check for proper vent termination and replace if necessary See table 8 Pressure Switch stuck closed prior to activation of combustion air inducer Corrective Action Check that the pressure switch is open without the combustion air inducer operating Replace switch if defective Flame Sensed without gas valve energized Corrective Action Check that the gas valve is stuck open Replace gas valve Low Line Voltage Corrective Action Check line voltage to unit Voltage should be 120V 10 Contact power company if necessary Off ON 1 2 3 4 5 7 10 11 12 13 Primary or Secondary Limit Open or Watchguard Mode Limit Switch Open longer than 3 minutes Corrective Action Check for restriction on blower inlet air and outlet air Remove restrictions Check unit rate rise and static Make adjustments if necessary and run unit until equilarium Check continuity across switch and replace if necessary A Heartbeat is indicated by a Slow Flash 1 sec on 1 sec off repeating N Error codes are indicated by a Rapid Flash the LED flashes X times at 1 2 sec on 1 2 sec ote off remains off for 3 sec then repeats Last 10 error codes are stored in memory including when power is shut off to the unit To recall Note press and release button most recent will be displayed first LED
76. s _______ and Fittings PVC amp CPVC Solvent Cement ULCS636 ABS to PVC or CPVC Transition Cement IMPORTANT EL195DF exhaust and intake connections are made of PVC Use PVC primer and solvent cement when using PVC vent pipe When using ABS vent pipe use transitional solvent cement to make connections to the PVC fittings in the unit Use PVC primer and solvent cement or ABS solvent cement meeting ASTM specifications refer to Table 7 As an alter nate use all purpose cement to bond ABS PVC or CPVC pipe when using fittings and pipe made of the same materi als Use transition solvent cement when bonding ABS to ei ther PVC or CPVC Low temperature solvent cement is recommended during cooler weather Metal or plastic strapping may be used for vent pipe hangers Uniformly apply a liberal coat of PVC primer for PVC or use a clean dry cloth for ABS to clean in side socket surface of fitting and male end of pipe to depth of fitting socket Canadian Applications Only Pipe fittings primer and solvent cement used to vent exhaust this ap pliance must be certified to ULC S636 and supplied by a single manufacturer as part of an approved vent ex haust system In addition the first three feet of vent pipe from the furnace flue collar must be accessible for inspection Page 18 TABLE 8 OUTDOOR TERMINATION USAGE STANDARD KITS CONCENTRIC KITS Input Size Pipe Field 44J40 Fabricated US 481J20 CA 22G44 US
77. ssure switch from 0 4500 feet 0 1370 m Page 38 I Proper Ground and Voltage A poorly grounded furnace can contribute to premature ig nitor failure Use the following procedure to check for ground and voltage to the integrated control 1 Measure the AC voltage between Line Neutral spade terminals and terminal low voltage terminal block on the integrated control See figure 50 A wide variation in the voltage between Line Neutral and C as a function of load indicates a poor or partial ground Compare the readings to the table below If the read ings exceed the maximum shown in table 1 make re pairs before operating the furnace CHECK VOLTAGE BETWEEN LINE NEUTRAL AND LOW VOLTAGE C TERMINAL 2 In addition measure the AC voltage from Line Hot to Line Neutral spade terminals on the integrated con trol See figure 50 This voltage should be in the range of 97 to 132 Vac TABLE 17 Measurement VAC Furnace Status Expected Maximum Power On Furnace Idle 0 3 2 CA onor Energize o 5 Indoor Blower Energized Less than 2 CHECK VOLTAGE BETWEEN LINE HOT AND LINE NEUTRAL oO sm 384 d d WOO NEUTRALS
78. sumed that wood louvers will have 20 to 25 percent free area and metal louvers and grilles will have 60 to 75 percent free area Louvers and grilles must be fixed in the open position or interlocked with the equipment so that they are opened automatically during equipment operation EQUIPMENT IN CONFINED SPACE ALL AIR FROM OUTSIDE All Air Through Ventilated Attic ROOF TERMINATED EXHAUST PIPE VENTILATION LOUVERS Each end of attic INLET AIR Ends 12 above TERMINATED bottom EXHAUST PIPE ALTERNATE LOCATION NOTE The inlet and outlet air openings shall each have a free area of at least one square inch per 4 000 Btu 645mm per 1 17kW per hour of the total input rating of all equipment in the enclosure FIGURE 15 Page 17 EQUIPMENT IN CONFINED SPACE ALL AIR FROM OUTSIDE ROOF TERMINATED EXHAUST PIPE 2 SIDE WALL TERMINATED EXHAUST PIPE ALTERNATE LOCATION A ZAA T a LL a NOTE Each air duct opening shall have a free area of at least one square inch per 2 000 Btu 645mm2per 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 communi cate directly with the outdoors each opening shall have a free area of at least 1 square inch per 4 000 Btu 645mm per 1 17kW per hour of the total input rating of all other equipment in the enclosure FIGURE 16 Pipe amp Fittings Specifications All pipe fitt
79. t rooms When the furnace is installed so that supply ducts carry air circulated by the furnace to areas outside the space con taining the furnace the return air must be handled by ducts which are sealed to the furnace casing and which terminate outside the space containing the furnace This is especially important when the furnace is mounted on a platform in a confined space such as a closet or small equipment room Even a small leak around the base of the unit at the platform or at the return air duct connection can cause a potentially dangerous negative pressure condition Air for combustion and ventilation can be brought into the confined space ei ther from inside the building or from outside Air from Inside If the confined space that houses the furnace adjoins a space categorized as unconfined air can be brought in by providing two permanent openings between the two spaces Each opening must have a minimum free area of 1 square inch 645 mm per 1 000 Btu 29 kW per hour of total input rating of all gas fired equipment in the confined space Each opening must be at least 100 square inches 64516 mm One opening shall be within 12 inches 305 mm of the top of the enclosure and one opening within 12 inches 305 mm of the bottom See figure 13 Page 16 EQUIPMENT IN CONFINED SPACE ALL AIR FROM INSIDE ROOF TERMINATED g 21 ne OPENINGS Adjacent Unconfined ML193UH Space NOTE Each open
80. tatic Return Air FIGURE 53 D Blower Speed Taps Blower speed tap changes are made on the integrated con trol See figure 4 The heating tap is connected to the HEAT terminal and the cooling tap is connected to the COOL terminal On all units the continuous blower tap is connected to the FAN terminal Unused taps must be se cured on two dummy terminals labeled PARK To change out existing speed tap turn off power and switch out speed tap with tap connected to PARK See blower speed tap table on unit diagram for motor tap colors for each speed Page 40 VI MAINTENANCE AWARNING 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 furnace When servicing controls label all wires prior to dis connecting Take care to reconnect wires correctly Verify proper operation after servicing At the beginning of each heating season system should be checked as follows by a qualified service technician Blower Check the blower wheel for debris and clean if necessary The blower motors are prelubricated for extended bearing life No further lubrication is needed AWARNING The bl
81. te straight out or up as shown The termination pipe must be sized as listed in table 11 The specified pipe size ensures proper ve locity required to move the exhaust gases away from the building On field supplied terminations for side wall exit ex haust piping may extend a maximum of 12 inches 305mm for 2 PVC and 20 inches 508mm for 3 76mm PVC beyond the outside wall See figure 39 FIELD PROVIDED REDUCER MAY ACCUMULATION SIZE TERMINATION PIPE PER TABLE 12 305mm 11 ABOVE AVE SNOW 1 2 13mm FOAM INSULATION 3 76mm OR UNCONDITIONED 2 51mm PVC ATTIC SPACE PROVIDE SUPPORT FOR EXHAUST LINES NON DIRECT VENT ROOF TERMINATION KIT 15F75 or 44J41 FIGURE 38 12 305mm MAX for 2 51mm 20 508mm MAX for 3 76mm 4 2 13mm ARMAFLEX INSULATION IN UNCONDITIONED SPACE 4 2 13mm ARMAFLEX INSULATION BE REQUIRED TO ADAPT LARGER VENT PIPE SIZE PVC REDUCER TO TERMINATION 12 MIN 305mm Above Grade or average snow accumulation SIZE TERMINATION PIPE PER TABLE 11 NON DIRECT VENT FIELD SUPPLIED WALL TERMINATION OR 15F74 WALL TERMINATION KIT 3 Page 32 FIGURE 39 If exhaust piping must be run up a side wall to position above snow accumulation or other obstructions pip ing must be supported every 24 inches 610mm as shown in figure 40 When exhaust piping must be run up an outside wall any reduction in exhaust pipe size must be
82. the 2 pin jack plug near the manifold and check 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 Multi Meter set to VAC Test 3 Check ignitor for correct voltage Insert meter probes into terminals 2 and 4 use small diameter probes in order not to damage plug Check voltage during 20 second ignitor warm up period Voltage should read 120 volts 1096 If voltage reads below these values check for correct supply voltage to furnace FIGURE 9 Page 12 Integrated Control Detail SX NX STVULIGN Integrated Control Detail Integrated Control Detail 7 Combustion Air Inducer B6 amp Cold End Header Box All EL195DF units use a combustion air inducer to move air through the burners and heat exchanger during heat ing operation The blower uses a shaded pole 120VAC motor The motor operates during all heating operation and is controlled by burner ignition control A3 Blower operates continuously while there is a call for heat The burner igni tion control will not proceed with the ignition sequence until combustion air inducer operation is sensed by the proving switches The CAI is installed on the cold end header box The cold end header box is a single piece made of hard plastic The box has an internal channel where the comb
83. tion control A92 are located in the control box In addition a door interlock switch S51 is located in the control box EL195DF Control Box DOOR INTERLOCK SWITCH S51 INTEGRATED IGNITION CONTROL FIGURE 2 1 Transformer T1 A transformer located in the control box provides power to the low voltage section of the unit The transformers on all models are rated at 40VA with a 120V primary and 24V secondary 2 Door Interlock Switch S51 A door interlock switch rated 14A at 120VAC is located on the control box The switch is wired in series with line volt age When the blower door is removed the unit will shut down 3 Integrated Ignition Control A92 A WARNING Shock hazard Disconnect power before servicing Control is not field repairable If control is inoperable simply re place entire control Can cause injury or death Unsafe operation will result if repair is attempted The ignition control system consists of an integrated con trol figure 4 ignitor figure 5 and flame sensor figure 5 The integrated control and ignitor work in combination to ensure furnace ignition and ignitor durability The inte grated control controls all major furnace operations The integrated control also features a RED LED light for trou bleshooting and two accessory terminals rated at 1 one amp Tables 1 and 2 show jack plug terminal designations See table 3 for troubleshooting diagnostic codes The ni tride ig
84. ustion air inducer creates negative pressure at unit start up The channel contains an orifice used to regulate flow created by the CAI The box has pressure taps for the CAI pres sure switch hoses The pressure switch measure the pressure across the CAI orifice or difference in the chan nel and the box If replacement is necessary the gas kets used to seal the box to the vestibule panel and the CAI to the box must also be replaced TABLE 4 EL195DF Unit Orifice Size 8 Combustion Air Pressure Switch Figure 10 EL195DF series units are equipped with a differential pressure switch located on the cold end header box The switches monitor across the CAI orifice to insure proper flow through the heat exchanger The switch is a SPST N O prove switch electrically con nected to the integrated control The purpose of the switch is to prevent burner operation if the combustion air inducer is not moving enough air for proper combustion Pressure Switch TERMINALS FIGURE 10 On start up the switch senses that the combustion air inducer is operating It closes a circuit to the ignition control when the difference in pressure across the CAI orifice exceeds non adjustable factory setting If the switch does not suc cessfully sense the required differential the switch can not close and the furnace cannot operate If the flue or air inlet become obstructed during operation the switch senses aloss of pressure differe
85. ute piping to outside of structure Continue with installa tion following instructions given in piping termination sec tion A CAUTION Do not discharge exhaust into an existing stack or stack that also serves another gas appliance If verti cal discharge through an existing unused stack is quired insert PVC pipe inside the stack until the end is even with the top or outlet end of the metal stack A CAUTION The exhaust vent pipe operates under positive pres sure and must be completely sealed to prevent leak age of combustion products into the living space Vent Piping Guidelines The EL195DF can be installed as either a Non Direct Vent or a Direct Vent gas central furnace NOTE In Non Direct Vent installations combustion air is taken from indoors and flue gases are discharged outdoors In Direct Vent installations combustion air is taken from out doors and flue gases are discharged outdoors Intake and exhaust pipe sizing Size pipe according to tables 9 and 10 Count all elbows inside and outside the home Table 9 lists the minimum vent pipe lengths per mitted Table 10 lists the maximum pipe lengths permitted TABLE 9 MINIMUM VENT PIPE LENGTHS EL195DF MIN VENT LENGTH MODEL 15 ft or 045 070 090 110 5 ft plus 2 elbows or 10 ft plus 1 elbow approved termination may be added to the minimum length listed Regardless of the diameter of pipe used the standard roof and wall terminations

Service Manual 02/2012

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