Page 1: Table Of Contents
INSTALLATION INSTRUCTIONS E 2011 Lennox Industries Inc. Dallas, Texas, USA EL195DF ® ELITE SERIES GAS FURNACE DOWNFLOW AIR DISCHARGE 506594−01 02/2011 Supersedes 01/2011 Litho U.S.A. THIS MANUAL MUST BE LEFT WITH THE HOMEOWNER FOR FUTURE REFERENCE This is a safety alert symbol and should never be ignored.
Page 2: Unit Dimensions
EL195DF Unit Dimensions − inches (mm) 9/16 (14) COMBUSTION AIR INTAKE RETURN AIR OPENING EXHAUST AIR OUTLET 2−1/16 (52) 2−1/4 9/16 (57) (14) (127) TOP VIEW 27−3/4 1−1/2 (38) (705) Front Panel 9/16 19−7/16 9/16 (14) (494) (14) FLOW ELECTRICAL INLET (Either Side) 2 (51) Either Side...
Page 3: El195Df Parts Arrangement
EL195DF Parts Arrangement BLOWER MOTOR (hidden) CONTROL BOX (Includes integrated control, BAG ASSEMBLY transformer and door switch) (shipping location) COMBUSTION AIR INDUCER BLOWER DECK DuralokPlus HEAT EXCHANGER ASSEMBLY OUTER ACCESS PANEL COLD END HEADER BOX COMBUSTION AIR INDUCER PRESSURE SWITCH PRIMARY LIMIT BURNER BOX ASSEMBLY (includes sensor, rollout switches and ignitor)
Page 4: El195Df Gas Furnace
Check equipment for shipping damage. If you find any EL195DF Gas Furnace damage, immediately contact the last carrier. The EL195DF Category IV gas furnace is shipped ready The following items may also be ordered separately: for installation in the downflow position. 1 −...
Page 5: Use Of Furnace As A Construction Heater
If the damper is manu- Lennox does not recommend the use of EL195DF units as ally operated, it must be equipped to prevent operation of ei- a construction heater during any phase of construction.
Page 6: General
National Fuel Gas Code (ANSI− supervisor. Z223.1/NFPA 54). This reprinted material is not the com- Lennox Industries Inc. plete and official position of the ANSI on the referenced P.O. Box 799900 subject, which is represented only by the standard in its Dallas, TX 75379−9900...
Page 7 All gas-fired appliances require air for the combustion pro- dangerous negative pressure condition. Air for combustion cess. If sufficient combustion air is not available, the fur- and ventilation can be brought into the confined space ei- nace or other appliance will operate inefficiently and un- ther from inside the building or from outside.
Page 8 EQUIPMENT IN CONFINED SPACE − ALL AIR FROM OUTSIDE EQUIPMENT IN CONFINED SPACE − ALL AIR FROM OUTSIDE (Inlet Air from Crawl Space and Outlet Air to Ventilated Attic) (All Air Through Ventilated Attic) VENTILATION LOUVERS (Each end of attic) ROOF TERMINATED VENTILATION LOUVERS ROOF TERMINATED...
Page 9: Setting Equipment
Installation − Setting Equipment SETTING EQUIPMENT Unit must be level side−to−side. Unit may be positioned from level to 1/2" toward the front to aid in draining. WARNING Do not install the furnace on its front, back or in the horizontal position. See figure 9. Do not connect the return air ducts to the back of the furnace.
Page 10 Installation on Non−Combustible Flooring Figure 11 WARNING 1 − Cut floor opening keeping in mind clearances listed on Improper installation of the furnace can result in per- unit rating plate. Also keep in mind gas supply connec- sonal injury or death. Combustion and flue products tions, electrical supply, flue and air intake connections must never be allowed to enter the return air system and sufficient installation and servicing clearances.
Page 11 TABLE 2 COMBUSTIBLE FLOORING BASE OPENING SIZE Front to Rear Side to Side Cabinet Catalog FURNACE Width Number B Cabinet 11M60 18 − 3/4 (17.5") C Cabinet COOLING COIL 11M61 22 − 3/4 (21") PROPERLY SIZED FLOOR OPENING PLENUM FURNACE SUPPLY AIR PLENUM PROPERLY...
Page 12: Filters
Filters Pipe & Fittings Specifications All pipe, fittings, primer and solvent cement must conform This unit is not equipped with a filter or rack. A field−pro- with American National Standard Institute and the Ameri- vided filter is required for the unit to operate properly. Table can Society for Testing and Materials (ANSI/ASTM) stan- 3 lists recommended minimum filter size.
Page 13 Low temperature solvent cement is recommended during IMPORTANT cooler weather. Metal or plastic strapping may be used for vent pipe hangers. Uniformly apply a liberal coat of PVC EL195DF exhaust and intake connections are made primer for PVC or use a clean dry cloth for ABS to clean in- of PVC.
Page 14: Joint Cementing Procedure
Venting Practices Joint Cementing Procedure All cementing of joints should be done according to the Piping Suspension Guidelines specifications outlined in ASTM D 2855. SCHEDULE 40 NOTE − A sheet metal screw may be used to secure PVC − 5’ the intake pipe to the connector, if desired.
Page 15: Vent Piping Guidelines
NOTE − All horizontal runs of exhaust pipe must slope back used. Contact Lennox’ Application Department for assis- toward unit. A minimum of 1/4" (6mm) drop for each 12"...
Page 16 TABLE 7 Maximum Allowable Intake or Exhaust Vent Length *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. Standard Termination at Elevation 0 − 4500 ft 2"...
Page 17 TYPICAL EXHAUST PIPE CONNECTIONS Pipe size determined in table 7. 2” 2” 2” 2” 2” 3” TRANSITION INTAKE *2” EXHAUST DO NOT transition from smaller TOP VIEW to larger pipe size in horizontal runs of exhaust pipe. * When transitioning up in pipe size, use the shortest length of 2” PVC pipe possible. NOTE −...
Page 18 Heating cable installation kit is NOTE − Air intake screen and elbow may be rotated, so that available from Lennox. See Condensate Piping section screen may be positioned to face forward or to either side. for part numbers.
Page 19 ‡ 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 22 Page 19...
Page 20 ‡ 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 20...
Page 21 Details of Intake and Exhaust Piping Terminations for between the end of the exhaust pipe and the end of the intake pipe without a termination elbow is 8" and a Direct Vent Installations minimum distance of 6" with a termination elbow. See NOTE −...
Page 22 Intake Front View of Intake and Exhaust Exhaust Intake Exhaust TABLE 9 2" (51mm) 3" (76mm) Vent Pipe Vent Pipe A− Clearance above grade or average snow 12" (508MM) Min. 12" (508MM) Min. accumulation B−Horizontal 6" (152MM) Min. 6" (152MM) Min. separation between 24"...
Page 23 FIELD SUPPLIED WALL TERMINATION OR FIELD SUPPLIED WALL TERMINATION OR (15F74) WALL RING TERMINATION KIT (15F74) WALL RING TERMINATION KIT With INTAKE ELBOW NOTE − FIELD PROVIDED NOTE − FIELD PROVIDED REDUCER MAY BE REDUCER MAY BE 1/2" (13mm) ARMAFLEX 1/2"...
Page 24 1−1/2" (38mm) accelerator EXHAUST VENT Front View provided on 71M80 & 44W92 kits for EL195DF045P36B− & SIZE 070P36B TERMINATION PIPE PER INTAKE FLASHING TABLE 8. 12” (305mm) (Not Furnished) INTAKE Minimum Above Average Snow Accumulation Top View 1/2" (13mm) Foam Insulation in Unconditioned Space SHEET METAL STRAP (Clamp and sheet metal strap...
Page 25 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− fabricated piping must be installed.
Page 26 EL195DF DIRECT VENT APPLICATION SIZE TERMINATION STRAIGHT−CUT OR USING EXISTING CHIMNEY ANGLE−CUT IN DIRECTION PIPE PER TABLE 8. OF ROOF SLOPE * 12" (305mm) ABOVE AVE. SNOW 1/2" (13mm) FOAM 8" − 12" 3" − 8" EXHAUST VENT ACCUMULATION (76mm− INSULATION 1/2"...
Page 27 NOTE − If necessary the condensate trap may be installed 12" (305mm) MAX. for 2" (51mm) 20" (508mm) MAX. for 3" (76mm) up to 5´ away from the furnace. Use PVC pipe to connect UNCONDITIONED trap to furnace condensate outlet. Piping from furnace SPACE must slope down a minimum of 1/4"...
Page 28 If this is not possible, a heat cable kit may be used on the condensate trap and line. Heat cable kit is avail- able from Lennox in various lengths; 6 ft. (1.8m) − kit no. 26K68; 24 ft. (7.3m) − kit no. 26K69; and 50 ft.
Page 29 TRAP / DRAIN ASSEMBLY USING 1/2" PVC OR 3/4" PVC OPTIONAL Condensate Drain Connection Adapter 1/2 inch slip X Adapter 1/2 inch slip X 1/2 inch mpt (Not Furnished) Condensate Drain 1/2 inch mpt (Not Furnished) Connection In Unit Vent 90°...
Page 30: Gas Piping
Gas Piping IMPORTANT Compounds used on threaded joints of gas piping CAUTION must be resistant to the actions of liquified petro- leum gases. If a flexible gas connector is required or allowed by the authority that has jurisdiction, black iron pipe Leak Check shall be installed at the gas valve and extend outside After gas piping is completed, carefully check all piping...
Page 31 Left Side Piping MANUAL (Standard) MAIN SHUT−OFF AUTOMATIC MANUAL VALVE GAS VALVE MAIN SHUT−OFF Plug (With 1/8 in. NPT AUTOMATIC VALVE Plugged Tap Plug GAS VALVE (With 1/8 in. NPT Shown) Plugged Tap Shown) GROUND JOINT UNION GROUND JOINT UNION DRIP LEG Right Side Piping FIELD...
Page 32: Electrical
Removal of the Furnace from Common Vent 4 − Follow the lighting instructions. Turn on the appliance that is being inspected. Adjust the thermostat so that In the event that an existing furnace is removed from a the appliance operates continuously. venting system commonly run with separate gas ap- pliances, the venting system is likely to be too large to 5 −...
Page 33 Complete the wiring connections to the equipment. Use the INTERIOR MAKE−UP BOX provided unit wiring diagram and the field wiring diagram (FACTORY− INSTALLED LEFT SIDE) shown in figure 50. Use 18−gauge wire or larger that is suit- able for Class II rating for thermostat connections. Electrically ground the unit according to local codes or, in the absence of local codes, according to the current Na- tional Electric Code (ANSI/NFPA No.
Page 34 Install the room thermostat according to the instruc- EL195DF and CONDENSING UNIT tions provided with the thermostat. See figure 49 for THERMOSTAT DESIGNATIONS thermostat designations. If the furnace is being (Refer to specific thermostat and outdoor unit.) matched with a heat pump, refer to the FM21 installa- tion instruction or appropriate dual fuel thermostat in- Thermostat Furnace...
Page 35 TYPICAL EL195DF WIRING DIAGRAM FIGURE 51 Page 35...
Page 36: Unit Start Up
INTEGRATED CONTROL (Automatic Hot Surface Ignition System) TERMINAL DESIGNATIONS Humidifier (120VAC) Input (120VAC) LINE Transformer (120VAC) XFMR Indoor Air Quality Accessories (120VAC) Blower − Cooling Speed (120VAC) COOL Blower − Heating Speed (120VAC) HEAT Dead terminals to park alternate speed taps PARK Flame sensor FLAME...
Page 37 Placing the furnace into operation: MANIFOLD PRESSURE ADJUSTMENT SCREW EL195DF units are equipped with an automatic hot sur- (under barbed fitting) face ignition system. Do not attempt to manually light MANIFOLD PRESSURE burners on this furnace. Each time the thermostat calls OUTLET for heat, the burners will automatically light.
Page 38: Gas Pressure Measurement
Manifold Pressure Measurement Gas Pressure Adjustment 1 − Remove the threaded plug from the outlet side of the gas valve and install a field−provided barbed fitting. Gas Flow (Approximate) Connect to a manometer to measure manifold pres- sure. TABLE 11 2 −...
Page 39: Testing Non Direct Appliances For Proper Air
TABLE 14 Conversion Kit and Pressure Switch Requirements at Varying Altitudes High Altitude High Altitude Natural to Natural Burner LP/Propane High Altitude Pressure Switch LP/Propane EL195 Orifice Kit Burner Orifice Kit Unit 0 − 7500 ft 7501 − 10,000 ft 7501 −...
Page 40 Flame Rollout Switches (Two) 3 − Check amp-draw on the blower motor. Motor Nameplate__________Actual__________ These manually reset switches are located on the front of HEAT FAN-OFF TIME IN SECONDS the burner box. Pressure Switch The pressure switch is located in the heating compartment on the cold end header box.
Page 41: Blower Motor Performance
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 Medium- Medium- Static Medium- Medium- High High Pressure High Pressure High in.
Page 42: Service
2 − Have a shallow pan ready to empty condensate water. Service 3 − Remove the clean out cap from the condensate trap and empty water. Inspect the trap then reinstall the WARNING drain plug. Cleaning Heat Exchanger ELECTRICAL SHOCK, FIRE, If cleaning the heat exchanger becomes necessary, follow OR EXPLOSION HAZARD.
Page 43 19 − Remove screws along vestibule sides which secure 42 − Follow lighting instructions on unit nameplate to light vestibule panel and heat exchanger assembly to cabi- and operate furnace for 5 minutes to ensure the fur- net. Remove two screws from blower rail which secure nace is operating properly.
Page 44: Planned Service
Return air duct − Must be properly attached and provide Planned Service an air seal to the unit. A service technician should check the following items dur- Operating performance − Unit must be observed during ing an annual inspection. Power to the unit must be shut off operation to monitor proper performance of the unit and the for safety.
Page 45: Troubleshooting
Troubleshooting: Heating Sequence of Operation HEATING SEQUENCE OF OPERATION ABNORMAL HEATING MODE NORMAL HEATING MODE POWER ON GAS VALVE OFF. COMBUSTION AIR INDUCER OFF. INDOOR BLOWER DELAY OFF. CONTROL SELF−CHECK OKAY? LED SLOW FLASH (RESET CONTROL BY TURNING MAIN POWER OFF.) LED FLASHES CODE 1 −...
Page 46 Troubleshooting: Heating Sequence of Operation (Continued) HEATING SEQUENCE CONTINUED NORMAL HEATING MODE ABNORMAL HEATING MODE 15-SECOND COMBUSTION AIR INDUCER PREPURGE INITIATED BY CLOSED PRESSURE SWITCH. LED FLASHES CODE 13 − LOW LINE VOLTAGE. ONCE VOLTAGE IS ABOVE IS VOLTAGE ABOVE 70 VOLTS? IGNITOR WARM-UP −−...
Page 47 Troubleshooting: Cooling Sequence of Operation COOLING SEQUENCE OF OPERATION NORMAL COOLING MODE ABNORMAL COOLING MODE POWER ON IGNITION CONTROL MAIN POWER ON. GAS VALVE OFF. COMBUSTION AIR INDUCER OFF. INDOOR BLOWER OFF WITH NORMAL DELAY. CONTROL SELF DIAGNOSTIC CHECK. SIGNAL CIRCUIT BOARD FAILURE AT LED. IS CONTROL OPERATING NORMALLY? INTERRUPT MAIN POWER TO RESET CONTROL.
Page 48 Troubleshooting: Continuous Fan Sequence of Operation CONTINUOUS FAN 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). SYSTEM FAN CONTINUES FAN SPEED WITHOUT THERMOSTAT CALLS FOR COOLING.
Page 49: Repair Parts List
Repair Parts List The following repair parts are available through Lennox dealers. When ordering parts, include the complete furnace model number listed on the CSA nameplate −− Example: EL195DF04536B. All service must be performed by a licensed profes- sional installer (or equivalent), service agency, or gas supplier.
Page 50: Start Up Checklist
Start−Up & Performance Check List UNIT SET UP Furnace: Model Number_______________ Serial Number_________________ SUPPLY Line Voltage GAS SUPPLY LP Propane Gas Natural Gas Piping Connections Tight Leak Tested Flter Supply Line Pressure W.C.________ RETURN AIR Gas Supply Pressure DUCT SYSTEM SUPPLY AIR DUCT Sealed Insulated (if necessary)
Page 51 UNIT OPERATION HEATING MODE COOLING MODE GAS MANIFOLD PRESSURE W.C._____ INDOOR BLOWER AMPS______ COMBUSTION SAMPLE CO CO PPM_______ TEMPERATURE DROP ______ Return Duct Temperature _________ INDOOR BLOWER AMPS______ Supply Duct Temperature _______ Temperature Drop = _________ TEMPERATURE RISE TOTAL EXTERNAL STATIC (dry coil) Supply Duct Temperature ________ Supply External Static _______ Return Duct Temperature...
Page 52 Requirements for Commonwealth of Massachusetts Modifications to NFPA−54, Chapter 10 4 − INSPECTION. The state or local gas inspector of the side wall, horizontally vented, gas−fueled equipment Revise NFPA−54 section 10.8.3 to add the following re- shall not approve the installation unless, upon inspec- quirements: tion, the inspector observes carbon monoxide detec- For all side wall, horizontally vented, gas−fueled equipment...

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Lennox Elite EL195DF045P36B Installation Instructions Manual

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