Lennox EL195DF SERIES User Manual
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Lennox EL195DF SERIES User Manual

Lennox EL195DF SERIES User Manual

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Service Literature
EL195DF series units are high−efficiency gas furnaces
manufactured with Lennox DuralokPlust 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.
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 discon-
nect switch(es). Unit may have multiple
power supplies.

Table of Contents

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Revised 02/2012
EL195DF SERIES UNITS
2
3
. . . . . . . . . . . . . . . . . . . . . .
4
6
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16
36
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37
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40
41
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43
44
Corp. 1102−L1
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.
Sharp edges.
Be careful when servicing unit to avoid sharp edges
which may result in personal injury.
Page 1
EL195DF
WARNING
WARNING
© 2012 Lennox Industries Inc.
Litho U.S.A.

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Summary of Contents for Lennox EL195DF SERIES

  • Page 1: Table Of Contents

    Corp. 1102−L1 Revised 02/2012 Service Literature EL195DF SERIES UNITS EL195DF series units are high−efficiency gas furnaces manufactured with Lennox DuralokPlust 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...

  • Page 2: Specifications

    SPECIFICATIONS Model No. EL195DF045P36B EL195DF070P48B EL195DF090P60C EL195DF110P60C Heating AFUE Performance 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.

  • Page 3: Optional Accessories

    OPTIONAL ACCESSORIES - MUST BE ORDERED EXTRA “B” Width Models “C” Width Models CABINET ACCESSORIES 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.

  • Page 4: Blower Performance Data

    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 5 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) GAS VALVE...

  • Page 6: I−Unit Components

    I−UNIT COMPONENTS 3. Integrated Ignition Control (A92) WARNING ELECTROSTATIC DISCHARGE (ESD) Precautions and Procedures Shock hazard. CAUTION Disconnect power before servicing. Control is not field repairable. If control is inoperable, simply re- place entire control. Electrostatic discharge can affect elec- Can cause injury or death.
  • Page 7 Electronic Ignition HEAT FAN-OFF TIME IN SECONDS On a call for heat the integrated control monitors the com- bustion air inducer prove switch. The integrated control will not begin the heating cycle if the pressure switch is closed (by−passed). Once the pressure switch is determined to be open, the combustion air inducer is energized.
  • Page 8 TABLE 3 RED LED Diagnostic Codes / Status of Furnace Flash Code No power to control or board fault detected. Board Fault Detected. Heartbeat Control powered − displayed during all modes of operation if no errors are detected. Reverse Line Voltage. Corrective Action −...
  • Page 9 EL195DF Burner Box Assembly IGNITOR BURNERS ROLLOUT SWITCHES FRONT BURNER BOX PLATE SENSOR GAS VALVE FIGURE 5 B−Heating Components 2. Heat Exchanger (Figure 6) EL195DF units use an aluminized steel primary and Combustion air inducer (B6), primary limit control (S10), stainless steel secondary heat exchanger assembly.
  • Page 10 5. Flame Sensor (Figure 5) Primary Limit Location and Heat Exchanger 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.
  • Page 11 Measuring Flame Signal Flame Signal In Microamps Normal Drop Out  1.5  0.4 0.5 − 1.4 Flame Sensor Terminal Remove Sensor Wire from Intergrated Control and Intergrated Connect Alligator Clip (−) Control to Frame Sensor Lead Remove Sensor Wire from Intergrated Control and Connect Alligator Clip (+) to Terminal on Control...
  • Page 12 Multi−Meter (set to ohms) Test 1 Check ignitor circuit for correct resistance. Remove 4−pin plug from control. Integrated Control Detail 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.
  • Page 13 (Figure 10) inducer or other components. EL195DF series units are equipped with a differential TABLE 5 pressure switch located on the cold end header box. The switches monitor across the CAI orifice to insure proper flow...
  • Page 14 Measuring Pressure Differential Black Tubing Red Tubing (positive +) (negative −) To Cold End Header Box To Cold End Header Box Field Provided Tubing To Pressure Switch +" High −" 1 − Remove thermostat demand and allow unit to 4 − Operate unit and observe manometer reading. cycle off.
  • Page 15 TABLE 6 Pressure Switch Troubleshooting Guide Problem Corrective Action Check that the pressure switch is open without the combustion air inducer operat- Pressure switch stuck closed ing. Replace if defective. Pressure switch does not close due to Check for restricted vent. Remove all blockage. obstruction in vent pipe.

  • Page 16: Placement And Installation

    II−PLACEMENT AND INSTALLATION In addition to providing combustion air, fresh outdoor air di- lutes contaminants in the indoor air. These contaminants may include bleaches, adhesives, detergents, solvents Combustion, Dilution & Ventilation Air and other contaminants which can corrode furnace compo- If the EL195DF is installed as a Non−Direct Vent Fur- nents.
  • Page 17 If air from outside is brought in for combustion and ventila- EQUIPMENT IN CONFINED SPACE − ALL AIR FROM INSIDE 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.
  • Page 18 TABLE 7 EQUIPMENT IN CONFINED SPACE − PIPING AND FITTINGS SPECIFICATIONS ALL AIR FROM OUTSIDE Schedule 40 PVC (Pipe) D1785 Schedule 40 PVC (Cellular Core Pipe) F891 ROOF TERMINATED EXHAUST PIPE Schedule 40 PVC (Fittings) D2466 Schedule 40 CPVC (Pipe) F441 Schedule 40 CPVC (Fittings) F438...

  • Page 19: Outdoor Termination Usage

    TABLE 8 OUTDOOR TERMINATION USAGE STANDARD KITS CONCENTRIC KITS Flush- Wall Kit Wall Ring Kit Mount 1−1/2 inch 2 inch 3 inch Vent 2 inch 3 inch 2 inch Pipe Input Size Field Dia. in. 71M80 69M29 Fabricated 44J40 22G44 (US) (US) (US) 60L46 (US)

  • Page 20: Venting Practices

    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 21: 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 22 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 −...
  • Page 23 TYPICAL EXHAUST PIPE CONNECTIONS Pipe size determined in table 10. 2” 2” 2” 2” 2” 3” TRANSITION INTAKE *2” EXHAUST DO NOT transition from smaller to larger pipe size in horizontal TOP VIEW runs of exhaust pipe. * When transitioning up in pipe size, use the shortest length of 2” PVC pipe possible. NOTE −...
  • Page 24 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 25: Vent Termination Clearances

    ‡ Permitted only if veranda, porch, deck or balcony is fully open on a minimum of two sides beneath the floor. Lennox recommends avoiding this location if possible. FIGURE 23...
  • Page 26 ‡ 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...
  • Page 27 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 28 Intake Front View of Intake and Exhaust Exhaust Intake Exhaust TABLE 2" (51mm) 3" (76mm) Vent Pipe Vent Pipe A− Clearance above grade or average snow 12" (305MM) Min. 12" (305MM) Min. accumulation B−Horizontal 6" (152MM) Min. 6" (152MM) Min. separation between 24"...
  • Page 29 FIELD FABRICATED WALL TERMINATION OR FIELD FABRICATED 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 30: Front View

    1−1/2" (38mm) accelerator EXHAUST VENT Front View provided on 71M80 & 44W92 kits for EL195DF045P36B− & SIZE 070P36B TERMINATION PIPE PER INTAKE FLASHING TABLE 11. 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 31 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 32 EL195DF DIRECT VENT APPLICATION SIZE TERMINATION USING EXISTING CHIMNEY STRAIGHT−CUT OR ANGLE−CUT IN DIRECTION PIPE PER TABLE OF ROOF SLOPE * 12" (305mm) ABOVE AVE. SNOW 1/2" (13mm) FOAM 8" − 12" 3" − 8" EXHAUST VENT ACCUMULATION (76mm− INSULATION 1/2"...
  • Page 33 12" (305mm) MAX. for 2" (51mm) CONDENSATE TRAP AND PLUG LOCATIONS 20" (508mm) MAX. for 3" (76mm) UNCONDITIONED SPACE 6" (152mm) SIZE TER- MINATION *WALL SUPPORT PIPE PER TABLE 11. OUTSIDE WALL FIELD−PROVIDED 12" (305mm) REDUCER MAY BE ABOVE GRADE OR REQUIRED TO AVERAGE SNOW ADAPT LARGER...
  • Page 34 Heat cable kit is avail- Using a Common Drain able from Lennox in various lengths; 6 ft. (1.8m) − kit no. 26K68; 24 ft. (7.3m) − kit no. 26K69; and 50 ft. (15.2m) − kit no. 26K70.
  • Page 35 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 1/2 inch PVC (Not Furnished) Adapter 1/2 inch slip X 1/2 inch mpt (Not Furnished) Condensate Drain Connection In Unit 1 (25 mm) Min.

  • Page 36: Start-Up

    III−START-UP 2 − Set the thermostat to the lowest setting. 3 − Turn off all electrical power to the unit. A−Preliminary and Seasonal Checks 4 − This furnace is equipped with an ignition device which 1 − Inspect electrical wiring, both field and factory installed for loose connections.

  • Page 37: Heating System Service Checks

    Kitchen detergents can cause harmful corro- sion on various metals used in gas piping. Use of a specialty All sizes 10.0 Gas Leak Detector is strongly recommended. It is available through Lennox under part number 31B2001. See Corp. LP/Propane All sizes 11.0 13.0 10.0...
  • Page 38 F− Proper Gas Flow (Approximate) G− Proper Combustion Furnace should operate at least 15 minutes with correct Gas Flow (Approximate) manifold pressure and gas flow rate before checking com- TABLE 14 bustions. Take sample beyond the flue outlet and GAS METER CLOCKING CHART compare to table 15.
  • Page 39 I− Proper Ground and Voltage 2 − In addition, measure the AC voltage from Line Hot to Line Neutral (spade terminals) on the integrated con- A poorly grounded furnace can contribute to premature ig- trol. See figure 50. This voltage should be in the range nitor failure.

  • Page 40: Typical Operating Conditions

    V−TYPICAL OPERATING CHARACTERISTICS C−External Static Pressure 1 − Tap locations shown in figure 52. A−Blower Operation and Adjustment1 2 − Punch a 1/4" diameter hole in supply and return air ple- nums. Insert manometer hose flush with inside edge of NOTE−...

  • Page 41: Maintenance

    VI−MAINTENANCE Check Motor AMP Draw (Typical set−up with upflow furnace shown) WARNING 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.
  • Page 42 13 − Remove electrical junction box from the side of the fur- 37 − Reconnect sensor wire and reconnect 2−pin plug from nace. ignitor. 14 − Disconnect condensate line from cold end header 38 − Reinstall gas valve manifold assembly. Reconnect box.

  • Page 43: Wiring And Sequence Of Operation

    VII−WIRING DIAGRAM AND SEQUENCE OF OPERATION 1 − When there is a call for heat, W1 of the thermostat energizes W of 5 − Gas valve opens for a 4−second trial for ignition the furnace control with 24VAC. 6 − Flame is sensed, gas valve remains open for the heat call.

  • Page 44: 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 45 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 IGNITOR WARM-UP −− 20 SECONDS. IS VOLTAGE ABOVE 70 VOLTS? 75 VOLTS, HEATING SEQUENCE RESTARTS.
  • Page 46 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. IS CONTROL OPERATING NORMALLY? INDOOR BLOWER OFF WITH NORMAL DELAY.
  • Page 47 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).

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