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S e r v i c e L i t e r a t u r e
EL195UHEK series units are high-efficiency gas furnaces
available in heating input capacities of 40,000 to 100,000
Btuh and cooling applications from 2 through 5 tons.
Refer to Engineering Handbook for proper sizing.
Units are factory equipped for use with natural gas. All
EL195UHNEK units are equipped with a hot surface igni-
tion 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 out-
lined in this manual are presented as a recommendation
only and do not supersede or replace local or state codes.
WARNING
This furnace is equipped with an ignition control
factory enabled for use with Lennox A2L refrigerant
systems.
Disabling
functionality on A2L system is prohibited by safety
codes. Refer to furnace installation instructions for
refrigerant system setup.
WARNING
Electric shock hazard. Can cause injury
or death. Before attempting to perform
any service or maintenance, turn the
electrical power to unit OFF at disconnect
switch(es). Unit may have multiple power
supplies.
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . . . 3
Blower Performance Data . . . . . . . . . . . . . . . . . . . . . . 4
Twinning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
I-Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
II Placement and Installation . . . . . . . . . . . . . . . . . . . . 22
III-Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
IV-Heating System Service Checks . . . . . . . . . . . . . . 44
V-Typical Operating Characteristics . . . . . . . . . . . . . . 50
VI-Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
VII- Low GWP Application . . . . . . . . . . . . . . . . . . . . . . . . . 54
VIII-Sequence of Operation and Flow Charts . . . . . . . . . 57
XI-Troubleshooting. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .58
UNIT INFORMATION
UNIT INFORMATION
EL195UHNEK SERIES UNITS With R454B
the
refrigerant
detection
100158
Improper
installation,
service or maintenance can cause property damage,
personal injury or loss of life. Installation and service
must
be performed by a licensed professional
HVAC installer or equivalent, service agency, or the
gas supplier.
As with any mechanical equipment, contact with
sharp sheet metal edges can result in personal
injury. Take care while handling this equipment and
wear gloves and protective clothing.
Page 1
EL195UHNEK
WARNING
adjustment,
CAUTION
alteration,
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Related Manuals for Lennox EL195UHNEK Series
Summary of Contents for Lennox EL195UHNEK Series
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Page 1: Table Of Contents
WARNING This furnace is equipped with an ignition control factory enabled for use with Lennox A2L refrigerant systems. Disabling refrigerant... -
Page 2: Specifications
SP ECIF ICATIONS Model EL195UH040NE36BK EL195UH060NE36BK Heating AFUE Performance Input - Btuh 40,000 60,000 Output - Btuh 39,000 58,000 Temperature rise range - °F 30 - 60 35 - 65 Gas Manifold Pressure (in. w.g.) 3.5 / N/A 3.5 / 4.0 Nat. -
Page 3: Optional Accessories
OPT IONAL AC C ESSORIES - ORD ER SEPARAT ELY “B” Width “C” Width Models Models CABINET ACCESSORIES Horizontal Suspension Kit - Horizontal only 51W10 51W10 Return Air Base - Upflow only 50W98 50W99 High Performance Economizer (Commercial Only) 10U53 10U53 CONDENSATE DRAIN KITS Condensate Drain Heat Cable... -
Page 4: Blower Performance Data
BLOWER DATA EL195UH040NE36BK PERFORMANCE (Less Filter) Air Volume / Watts at Various Blower Speeds External Static High Medium-High Medium Medium-Low (Black) (Brown) (Blue) (Yellow) (Red) Pressure in. w.g. Watts Watts Watts Watts Watts 0.10 1413 1257 1155 0.20 1385 1231 1124 0.30 1354... - Page 5 EL195UH080NE48CK PERFORMANCE (Less Filter) Air Volume / Watts at Various Blower Speeds External Static High Medium-High Medium Medium-Low Pressure (Black) (Brown) (Blue) (Yellow) (Red) in. w.g. Watts Watts Watts Watts Watts 0.10 1651 1441 1314 1236 1114 0.20 1622 1419 1286 1201 1077...
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Page 6: Twinning
The 24 VAC secondary of the two systems must be in Twinning phase. All thermostat connections are made to one control The control board in this furnace is equipped with a provi- only. See diagram below. sion to ”twin” (interconnect) two(2) adjacent furnaces with The twinned furnace without thermostat connections is a common plenum such that they operate as one (1) large to have the call for heat supplied by an external 24VAC... -
Page 7: Parts Identification
PARTS IDENTIFICATION Exhaust Pipe Inlet Air Assembly Heat Exchanger Rollout Switch Burner Assembly Intake Air Pipe Gas Valve Combustion Gas Pipe Inlet Air Inducer (right side only) Ignition Control Ignition Control FIGURE 1 Page 7... -
Page 8: I-Unit Components
I-UNIT COMPONENTS 3-Circuit Breaker (CB8) A 24V circuit breaker is also located in the control box. The ELECTROSTATIC DISCHARGE (ESD) switch provides overcurrent protection to the transform- Precautions and Procedures er (T1). The breaker is rated at 3A at 32V. If the current CAUTION exceeds this limit the breaker will trip and all unit opera- tion will shutdown. - Page 9 Indoor Blower Operation DIP Switch Settings Electronic Ignition FIGURE 6 The heat fan-on time of 30 seconds is not adjustable The On a call for heat the integrated control monitors the com- heat fan-off delay (amount of time that the blower oper- bustion air inducer pressure switch.
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Page 10: Common Ground
Single Stage, Constant, Torque, Non-Communicating 107792-01 FIGURE 3 TABLE 2 TABLE 3 THERMOSTAT INPUT TERMINALS LOW GWP INTERFACE HEAT LGWP1 LOW GWP SENSOR #1 INTERFACE COMMON GROUND LGWP2 LOW GWP SENSOR # 2 INTERFACE 24V AC ALARM INTERFACE TO LOW GWP LEAK AUDIBLE ALARM (DRY CONTACT) ZONE INTERFACE TO ZONING CONTROL (DRY... -
Page 11: Electronic Ignition
On Board Links Must NOT Be Cut To Select Thermostat Wiring Connections AC ON System Options Heat / Cool FURNACE OUTDOOR T'STAT TERM. STRIP UNIT DO NOT CUT ANY ON-BOARD LINKS FIGURE 4 On Board Links Must Be Cut To Select Wiring Connections Thermostat Heat Pump Options... - Page 12 TABLE 4 Integrated Diagnostic Codes/Status of Equipment Code Diagnostic Codes/Status of Equipment Action Required to Clear and Recover Indoor Blower Opetration: Continuous Fan only mode Defrost mode Idle mode (Decimal blinks at 1 Hertz -- 0.5 second ON, 0.5 second OFF). Cooling stage (1 second ON, 0.5 second OFF) 1 or 2 displayed / Pause / Repeat codes.
- Page 13 The sensor #1 is of a type not suitable for use in the application. incorrect Replace the sensor with a Lennox approved replacement part. This fault clears when a sensor suitable for the application is detected by the furnace control board, but blower will latch for a minimum of 5 minutes.
- Page 14 TABLE 4 Continued Code Diagnostic Codes/Status of Equipment Action Required to Clear and Recover E164 Low GWP Test Low GWP Test mode activates by manually engaging Low GWP test button. Normal operations resumes and code clears automatically after 1-minute E200 Hard lockout - Rollout circuit open or previously Correct cause of rollout trip, or replace flame rollout switch.
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Page 15: Orifice Size
SureLight control will go into Watch guard for one hour. The switch is factory set and cannot be adjust- ed. The switch may have a different set point for each unit model number. See Lennox Repair Parts Handbook if limit switch must be replaced. HEATING COMPONENTS... -
Page 16: Gas Valve
4. Gas Valve (FIGURE 8) 5. Flame Sensor The EL195UHNEK uses an internally redundant valve to A flame sensor is located on the top of the air gas plenum. assure safety shut-off. If the gas valve must be replaced, The sensor can be removed for service without remov- the same type valve must be used. - Page 17 Ignitor Check Out (exploded view for clarity) Test 1 Remove 5-pin plug from control Check ohms reading across terminals 1and 5 Ohm value should be between 39 - 70. Meter (set to ohms) Integrated control detail Test 2 Seperate the 2-pin jack plug near the manifold and check resistance of the ignitor.
- Page 18 The pressure switch opens if the differential EL195UHNEK series units are equipped with a differential drops below the set point. See TABLE 7. pressure switch located on the cold end header box. The...
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Page 19: Blower Wheel Replacement
C- Blower Compartment ALIGN AND TIGHTEN SET SCREW WITH FLAT SIDE OF MOTOR SHAFT IMPORTANT Each blower is statically and dynamically balanced as an assembly before installation in the unit. Set Screw Housing Hub EL195UHEK units are equipped with a constant torque ECM motor. - Page 20 Multi−Meter (set to VAC) Multi-met (set to VAC) "9A” Test 3 (if necessary) NOTE- Ignition control illustration is typical "7A” Check for 120 volts across terminals “L1” and “Neutrals” on the Turn power on to unit. Check for 120 volts integrated control.
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Page 21: Motor Test
Replacing the Motor Module Motor Test NOTE - Not all motors have field replaceable control mod- ules. Only motors that utilize a 4 pin power connector and 5 pin signal connector as shown below may have replace- able controls. Motors that use a 3 pin power connector and 6 pin signal connector do not have field replaceable control modules. -
Page 22: Placement And Installation
II-PLACEMENT AND INSTALLATION TABLE 9 NOTE - For any Low GWP refrigerant systems with ex- PIPING AND FITTINGS SPECIFICATIONS posed line set joints installed in the same space, each Schedule 40 PVC (Pipe) D1785 non-direct vent furnace system must have a refrigerant detection sensor installed below the level of the burners Schedule 40 PVC (Cellular Core F891... -
Page 23: Danger Of Explosion
TABLE 10 OUTDOOR TERMINATION USAGE* STANDARD CONCENTRIC Wall Kit 1-1.2 inch 2 inch 3 inch Flush Mount Vent Pipe 2 inch 3 inch Input Size Field 71M80 (US) 69M29 (US) 60L46 (US) Dia. in. 51W11 (US) Fabricated 44W92 44W92 44W93 22G44 (US) 44J40 (US) 51W12... -
Page 24: Venting Practices
Exhaust Piping (FIGURE 22, FIGURE 25 and FIGURE Venting Practices The vent adapter must be attached to the exhaust cou- pling on the furnace top panel. Use provided bands. See HORIZONTAL PIPING SUPPORT GUIDELINES steps below. SCHEDULE 40 PVC - 5' 1 - Remove the caution tag from vent adapter. - Page 25 TABLE 11 Vent Piping Guidelines MINIMUM VENT PIPE LENGTHS NOTE - Lennox has approved the use of DuraVent ® Centrotherm manufactured vent pipe and terminations EL195UHNEK Model MIN. VENT LENGTH* as an option to PVC. When using the PolyPro by Du- ®...
- Page 26 TABLE 12 NOTE - Size intake and exhaust pipe length separately. Values in table are for Intake OR Exhaust, not combined total. Both Intake and Exhaust must be same pipe size. NOTE - Additional vent pipe and elbows used to terminate the vent pipe outside the structure must be included in the total vent length calculation.
- Page 27 TABLE 12 Continued NOTE - Size intake and exhaust pipe length separately. Values in table are for Intake OR Exhaust, not combined total. Both Intake and Exhaust must be same pipe size. NOTE - Additional vent pipe and elbows used to terminate the vent pipe outside the structure must be included in the total vent length calculation.
- Page 28 TABLE 13 Maximum Allowable Exhaust Vent Lengths With Furnace Installed in a Closet or Basement Using Ventilated Attic or Crawl Space For Intake Air in Feet NOTE - Additional vent pipe and elbows used to terminate the vent pipe outside the structure must be included in the total vent length calculation.
- Page 29 TYPICAL EXHAUST AND INTAKE PIPE CONNECTIONS IN UPFLOW DIRECT OR NON-DIRECT VENT APPLICATIONS EXHAUST EXHAUST INTAKE 2” 2” 2” 2” 3” Appliance TRANSITION Appliance Adaptor 2” Adaptor DO NOT transition *2” from smaller to larger 2” 3” pipe in horizontal runs *2”...
- Page 30 Intake Piping TYPICAL AIR INTAKE PIPE CONNECTIONS UPFLOW NON−DIRECT The EL195UHNEK furnace may be installed in either di- VENT APPLICATIONS rect 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 and guidelines listed in Combustion, Dilution and Ventilation Air section must be followed.
- Page 31 General Guidelines for Vent Terminations CAUTION In Non-Direct Vent applications, combustion air is taken If this unit is being installed in an application with from indoors and the flue gases are discharged to the out- combustion air coming in from a space serviced by an doors.
- Page 32 TABLE 14 Maximum Allowable Exhaust Vent Pipe Length (in ft.) Without Insulation In Unconditioned Space For Winter Design Temperatures Single - Stage High Efficiency Furnace Unit Input Size Winter Design Vent Temp °F (°C) Pipe Diam 32 to 21 2 in (0 to -6) 3 in 20 to 1...
- Page 33 ‡ Permitted only if veranda, porch, deck or balcony is fully open NOTE - This figure is intended to illustrate clearance on a minimum of two sides beneath the floor. Lennox recommends requirement and does not serve as a substitute for avoiding this location if possible.
- Page 34 ‡ Permitted only if veranda, porch, deck or balcony is fully open on a minimum of locally adopted installation codes. two sides beneath the floor. Lennox recommends avoiding this location if possible. FIGURE 33 Page 34...
- Page 35 Details of Intake and Exhaust Piping Terminations for Exiting Exhaust and Intake Vent Direct Vent Installations (different pressure zone) NOTE - In Direct Vent installations, combustion air is taken from outdoors and flue gases are discharged to outdoors. NOTE - Flue gas may be slightly acidic and may adverse- ly affect some building materials.
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Page 36: Exhaust Vent
7 - If intake and exhaust piping must be run up a side wall to position above snow accumulation or FIELD-PROVIDED other obstructions, piping must be supported. At Accelerator not required REDUCER MAY BE for 3” concentric least one bracket must be used within 6” from the REQUIRED TO ADAPT DIFFERENT VENT PIPE top of the elbow and then every 24”... - Page 37 FIELD FABRICATED WALL TERMINATION NOTE − FIELD−PROVIDED REDUCER MAY BE 2” (51mm) 3” (76mm) REQUIRED TO ADAPT Vent Pipe Vent Pipe LARGER VENT PIPE SIZE TO TERMINATION A− Minimum clearance above grade or average 12” (305 mm) 12” (305 mm) snow accumulation B−...
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Page 38: Condensate Piping
OF PIPE ON TOP PLATE SHEET METAL TOP PLATE Lennox provides kit 51W18 (USA) kit 15Z70 (Canada) to install 2” or 3” PVC exhaust piping through the floor joists and into the crawl space. See figure below. This kit can INSULATE... - Page 39 Heating cable kit sate trap, filter rack must be installed beyond is available from Lennox in various lengths; 6 ft. condensate trap or trap must be re-located to (1.8m) - kit no. 26K68 and 24 ft. (7.3m) - kit no.
- Page 40 Furnace With Evaporator Condensate Trap With Optional Overflow Switch Coil Using A Separate Drain From Evaporator Coil HorizontalFurnace4” Min. to 5” Max.above Evaporator drain condensatedrain connection) line required (Trap at coil is optional) Field Provided Vent FurnaceCondensate (1” min. 2” max. above DrainConnection condensate connection) Optional...
- Page 41 IMPORTANT Furnace with Evaporator Coil Using a Common Drain When combining the furnace and evaporator coil drains together, the A/C condensate drain outlet Evaporator drain must be vented to relieve pressure in order for the line required furnace pressure switch to operate properly. (Trap at coil is optional) (1”...
- Page 42 TRAP / DRAIN ASSEMBLY USING 1/2” PVC OR 3/4” PVC Optional Condensate Drain Connection Adapter 3/4 inch slip X 3/4 inch mpt (not furnished) 90° Street Elbow 3/4 inch PVC (not furnished) Adapter 3/4 inch slip X 3/4 inch mpt (not furnished) Condensate Drain Connection In Unit 1 (25 mm) Min.
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Page 43: Iii-Start-Up
III-START-UP 3 - Turn off all electrical power to the unit. 4 - This furnace is equipped with an ignition device A-Preliminary and Seasonal Checks which automatically lights the burners. Do not try to 1 - Inspect electrical wiring, both field and factory light the burners by hand. -
Page 44: Iv-Heating System Service Checks
Refer to the changeover kit installation instruction for the conversion proce- specialty Gas Leak Detector is strongly recommended. It dure and manifold pressure measure procedure. is available through Lennox under part number 31B2001. E- High Altitude See Corp. 8411-L10, for further details. - Page 45 Manifold and Signal Pressure Measurement Air Orifice Replacement To correctly measure manifold and signal pressure, follow Do not replace the air orifice until the problem has been the steps below: determined. If the unit has difficulty igniting the orifice is oversized and brings in too much air.
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Page 46: Remove Screws
REMOVE SCREWS Screws Screw FIGURE 56 Air Orifice Replacement Gray Coupling Air Orifice and Part Number Air Intake Coupling FIGURE 57 Page 46... - Page 47 Operating Signal Pressure Measurement FIGURE 58 TABLE 19 Production Resonance (more air) Difficulty Igniting (less air) Single-Stage Orifice Size (Part No) Orifice Size Cat No Orifice Size Cat No -040 0.800 (16) 0.812 (01) 21U23 0.787 (20) 21U01 -060 0.995 (14) 1.010 (21) 21U02 0.980 (13)
- Page 48 FIGURE 59 Page 48...
- Page 49 E-Proper Combustion A poorly grounded furnace can contribute to premature ignitor failure. Use the following procedure to check for Furnace should operate minimum 15 minutes with correct ground and voltage to the integrated control. manifold pressure and gas flow rate before checking com- 1 - Measure the AC voltage between Line Neutral bustion.
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Page 50: V-Typical Operating Characteristics
V-TYPICAL OPERATING CHARACTERISTICS C-External Static Pressure 1 - Tap locations shown in FIGURE 62. A-Blower Operation and Adjustment1 2 - Punch a 1/4” diameter hole in supply and return NOTE- The following is a generalized procedure and does air plenums. Insert manometer hose flush with not apply to all thermostat controls. -
Page 51: Vi-Maintenance
13 - Verify operation of CO detectors and replace At the beginning of each heating season, and to comply batteries as required. with the Lennox Limited Warranty, your system should be 14 - Inspect the Low GWP sensor / sensors and rubber checked as follows: sleeve. - Page 52 Winterizing and Condensate Trap Care 5 - Disconnect gas supply piping. Remove the screw securing the air fuel plenum and remove along with 1 - Turn off power to the unit. the air inake assembly as one component. 2 - Have a shallow pan ready to empty condensate 6 - Remove screws from both sides, top and bottom of water.
- Page 53 BURNER, C.A.I ASSEMBLY & HEAT EXCHANGER REMOVAL Heat Exchanger Gaskets Burner Box Air Gas Plenum Burner High Temperature Switch (location) Ignitor Primary Limit Sensor O Ring Gas Valve Gas Orifice FIGURE 64 Page 53...
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Page 54: Vii- Low Gwp Application
VII- Low GWP Application WARNING For use with Lennox approved evaporator coil and LGWP sensors only. Use original manufacturer recommended LGWP sensors if using non Lennox approved evaporator coil. CONNECTING THE FURNACE CONTROL BOARD SENSOR. See FIGURE 67 and follow steps below: FIGURE 66 1 - Route sensor wire #1 through provided grommet. - Page 55 FURNACE CONTROL BOARD LOW GWP MODES OF 2. The furnace control board activates the blower (high OPERATION speed). The blower purges refrigerant from the cabinet, plenum, and ductwork. The modes of operation for the furnace control board are Initializing, Normal, Leak Detected, and Fault. 3.
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Page 56: Start-Up Procedure
LGWP TEST BUTTON FUNCTIONALITY External Alarm (For applications with external alarms wired directly to the The furnace control board is equipped with a Test/Reset furnace control board) push button. The Test button can be used to perform sev- The furnace control board triggers the external alarm sys- eral functions, depending on the mode of operation of the tem when it enters Leak Detected mode. -
Page 57: Viii-Sequence Of Operation And Flow Charts
VIII-WIRING DIAGRAM AND SEQUENCE OF OPERATION Line voltage is applied to L1 and N. the T1 low voltage transformer is energized, and line voltage is applied to B3 indoor blower. S47 rollout switch(es) must be closed in order for 24V from transformer to be output on integrated control ”R” to power thermostat. When there is a call for heat, W1 of the thermostat energizes W of the furnace control with 24VAC. -
Page 58: Heating Sequence Of Operation
IX-TROUBLESHOOTING 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? (RESET CONTROL BY TURNING MAIN POWER OFF.) SEVEN SEGEMENT LED FLASHES E111 IS POLARITY CORRECT? - POLARITY REVERSED. - Page 59 HEATING SEQUENCE CONTINUED 15 SECOND COMBUSTION AIR INDUCER PREPURGE INITIATED BY CLOSED PRESSURE SWITCH. SEVEN SEGEMENT LED E110 LOW LINE VOLTAGE. ONCE VOLTAGE IS ABOVE IS VOLTAGE ABOVE 70 VOLTS? IGNITOR WARM UP -- 20 SECONDS. 75 VOLTS, HEATING SEQUENCE RESTARTS. 4 SECOND TRIAL FOR IGNITION.
- Page 60 COOLING SEQUENCE OF OPERATION 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. SEVEN SEGEMENT LED FLASHES E117 IMPROPER GROUND IS THERE A PROPER GROUND? CONTROL WILL CONTINUE TO CALL FOR COOLING...
- Page 61 CONTINUOUS FAN SEQUENCE OF OPERATION 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. INTERRUPTION. EAC TERMINAL REMAIN ON. HUM TERMINAL IS ENERGIZED WITH COMBUSTION SYSTEM FAN SWITCHED TO COOL SPEED.
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