Lennox EL195DF Installation Instructions PDF

1 of 52
1 of 52

Summary of Content for Lennox EL195DF Installation Instructions PDF

Page 1 02/11

50659401

2011 Lennox Industries Inc.

Dallas, Texas, USA

AIR FLOW

DOWNFLOW

INSTALLATION INSTRUCTIONS EL195DF ELITE SERIES GAS FURNACE DOWNFLOW AIR DISCHARGE

50659401 02/2011 Supersedes 01/2011

THIS MANUAL MUST BE LEFT WITH THE HOMEOWNER FOR FUTURE REFERENCE

This is a safety alert symbol and should never be ignored. When you see this symbol on labels or in manuals, be alert to the potential for personal injury or death.

CAUTION As with any mechanical equipment, personal injury can result from contact with sharp sheet metal edges. Be careful when you handle this equipment.

WARNING Improper installation, adjustment, alteration, service or maintenance can cause property damage, person- al injury or loss of life. Installation and service must be performed by a licensed professional installer (or equivalent), service agency or the gas supplier.

Table of Contents Unit Dimensions 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EL195DF Parts Arrangement 3. . . . . . . . . . . . . . . . . . . . .

EL195DF Gas Furnace 4. . . . . . . . . . . . . . . . . . . . . . . . . .

Shipping and Packing List 4. . . . . . . . . . . . . . . . . . . . . . . .

Safety Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Use of Furnace as a Construction Heater 5. . . . . . . . . . .

General 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Combustion, Dilution and Ventilation Air 6. . . . . . . . . . . .

Setting Equipment 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filters 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Duct System 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pipe and Fittings Specifications 12. . . . . . . . . . . . . . . . . . . Joint Cementing Procedure 14. . . . . . . . . . . . . . . . . . . . . . . Venting Practices 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vent Piping Guidelines 15. . . . . . . . . . . . . . . . . . . . . . . . . . . Gas Piping 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unit Start Up 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gas Pressure Measurement 38. . . . . . . . . . . . . . . . . . . . . . Proper Combustion 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Altitude 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing Non Direct Appliances for Proper Air 39. . . . . . . . Other Unit Adjustments 40. . . . . . . . . . . . . . . . . . . . . . . . . . Blower Motor Performance 41. . . . . . . . . . . . . . . . . . . . . . . Service 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Planned Service 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Integrated Control Diagnostic Codes 44. . . . . . . . . . . . . . . Troubleshooting 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair Parts List 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start Up Checklist 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Litho U.S.A.

Page 2

EL195DF Unit Dimensions inches (mm)

AIR

EXHAUST AIR OUTLET

COMBUSTION AIR INTAKE

FLOW

21/16 (52)

GAS PIPING INLET (Either Side)

ELECTRICAL INLET (Either Side)

RETURN AIR OPENING

FRONT VIEW SIDE VIEW

TOP VIEW

A

B

C 3/4 (19)

273/4 (705)

191/4 (489)

91/8 (232) Right 69/16 (167) Left

2 (51) Either Side33

(838)

3/4 (19)

B

Supply Air

Supply Air

9/16 (14)

9/16 (14)

9/16 (14)

9/16 (14)

197/16 (494)

3/4 (19)

CONDENSATE TRAP CONNECTION

5 (127)

67/16 (163) Either Side

9 (229) Either Side

21/4 (57)

(Either Side)

11/2 (38) Front Panel

Model No. A B C

in. mm in. mm in. mm

EL195DF045P36B EL195DF070P48B

171/2 446 163/8 416 16 406

EL195DF090P60C EL195DF110P60C

21 533 197/8 505 191/2 495

Page 3

EL195DF Parts Arrangement

FIGURE 1

CONTROL BOX (Includes integrated control, transformer and door switch)

BAG ASSEMBLY (shipping location)

BLOWER MOTOR (hidden)

OUTER ACCESS PANEL

COMBUSTION AIR INDUCER

BURNER BOX ASSEMBLY (includes sensor, rollout switches and ignitor) GAS VALVE

BLOWER DECK

COLD END HEADER BOX

PRIMARY LIMIT

DuralokPlusTM

HEAT EXCHANGER ASSEMBLY

COMBUSTION AIR INDUCER PRESSURE SWITCH

Page 4

EL195DF Gas Furnace

The EL195DF Category IV gas furnace is shipped ready

for installation in the downflow position.

The furnace is equipped for installation in natural gas ap-

plications. A conversion kit (ordered separately) is re-

quired for use in propane/LP gas applications.

The EL195DF can be installed as a Direct Vent or Non

Direct Vent gas central furnace.

NOTE In Direct Vent installations, combustion air is taken

from outdoors and flue gases are discharged outdoors. In

NonDirect Vent installations, combustion air is taken from

indoors and flue gases are discharged outdoors. See figure

2 for applications involving roof termination.

FIGURE 2

DIRECT VENT INSTALLATION NONDIRECT VENT INSTALLATION

EXHAUST OUTLET

EL195DF

COMBUSTION AIR INTAKE INSIDE

OF HOUSE

EXHAUST OUTLETCOMBUSTION

AIR INTAKE OUTSIDE OF HOUSE

EL195DF

Shipping and Packing List

Package 1 of 1 contains

1 Assembled EL195DF unit

1 Bag assembly containing the following:

3 Wire nuts

1 Snap bushing

1 Snap plug

1 Wire tie

1 Condensate trap

1 Condensate trap cap

1 Condensate trap clamp

1 2" diameter Air intake screen

DANGER Danger of explosion.

There are circumstances in which odorant used with LP/propane gas can lose its scent. In case of a leak, LP/propane gas will settle close to the floor and may be difficult to smell. An LP/propane leak detector should be installed in all LP applications.

Check equipment for shipping damage. If you find any

damage, immediately contact the last carrier.

The following items may also be ordered separately:

1 Thermostat

1 LP/Propane changeover kit

1 High altitude pressure switch

Safety Information

WARNING Improper installation, adjustment, alteration, service or maintenance can cause property damage, person- al injury or loss of life. Installation and service must be performed by a licensed professional installer (or equivalent), service agency or the gas supplier.

CAUTION As with any mechanical equipment, personal injury can result from contact with sharp sheet metal edges. Be careful when you handle this equipment.

Use only the type of gas approved for use with this furnace.

Refer to unit nameplate.

EL195DF units are CSA International certified to ANSI

Z21.47 and CSA 2.3 standards.

Building Codes

In the USA, installation of gas furnaces must conform with lo-

cal building codes. In the absence of local codes, units must

be installed according to the current National Fuel Gas Code

(ANSI-Z223.1/NFPA 54). The National Fuel Gas Code is

available from the following address:

American National Standards Institute, Inc.

11 West 42nd Street

New York, NY 10036

In Canada, installation must conform with current National

Standard of Canada CSA-B149 Natural Gas and Propane

Installation Codes, local plumbing or waste water codes

and other applicable local codes.

In order to ensure proper unit operation in nondirect vent

applications, combustion and ventilation air supply must be

provided according to the current National Fuel Gas Code

or CSA-B149 standard.

Locations and Clearances

This furnace is CSA International certified for installation

clearances to combustible material as listed on the unit

nameplate and in the table in figure 10. Accessibility and ser-

vice clearances must take precedence over fire protection

clearances.

For installation in a residential garage, the furnace must

be installed so that the burner(s) and the ignition source

are located no less than 18 inches (457 mm) above the

floor. The furnace must be located or protected to avoid

physical damage by vehicles. When a furnace is installed

Page 5

in a public garage, hangar, or other building that has a haz-

ardous atmosphere, the furnace must be installed accord-

ing to recommended good practice requirements and cur-

rent National Fuel Gas Code or CSA B149 standards.

NOTE Furnace must be adjusted to obtain a temperature

rise within the range specified on the unit nameplate. Failure

to do so may cause erratic limit operation and premature heat

exchanger failure.

This EL195DF furnace must be installed so that its electri-

cal components are protected from water.

Installation in Combination with a Cooling Coil

When this furnace is used with cooling units (figure 3), it

shall be installed in parallel with, or on the upstream side of,

cooling units to avoid condensation in the heating compart-

ment. With a parallel flow arrangement, a damper (or other

means to control the flow of air) must adequately prevent

chilled air from entering the furnace. If the damper is manu-

ally operated, it must be equipped to prevent operation of ei-

ther the heating or the cooling unit, unless it is in the full

HEAT or COOL setting.

When installed, this furnace must be electrically grounded

according to local codes. In addition, in the United States,

installation must conform with the current National Electric

Code, ANSI/NFPA No. 70. The National Electric Code

(ANSI/NFPA No. 70) is available from the following ad-

dress:

National Fire Protection Association

1 Battery March Park

Quincy, MA 02269

In Canada, all electrical wiring and grounding for the unit

must be installed according to the current regulations of the

Canadian Electrical Code Part I (CSA Standard C22.1)

and/or local codes.

FIGURE 3

Heating Unit Installed Parallell to Air Handler Unit

AIR HANDLERGAS UNIT

Dampers (open during cooling

operation only)

Dampers (open during heating

operation only)

NOTE This furnace is designed for a minimum continu-

ous return air temperature of 60F (16C) or an intermit-

tent operation down to 55F (13C) dry bulb for cases

where a night setback thermostat is used. Return air tem-

perature must not exceed 85F (29C) dry bulb.

The EL195DF furnace may be installed in alcoves, closets,

attics, basements, garages, utility rooms and crawl

spaces.

This furnace design has not been CSA certified for installa-

tion in mobile homes, recreational vehicles, or outdoors.

Never use an open flame to test for gas leaks. Check all

connections using a commercially available soap solution

made specifically for leak detection.

Use of Furnace as Construction Heater

Lennox does not recommend the use of EL195DF units as

a construction heater during any phase of construction.

Very low return air temperatures, harmful vapors and op-

eration of the unit with clogged or misplaced filters will dam-

age the unit.

EL195DF units may be used for heating of buildings or

structures under construction, if the following conditions

are met:

The vent system must be permanently installed per

these installation instructions.

A room thermostat must control the furnace. The use of

fixed jumpers that will provide continuous heating is not

allowed.

The return air duct must be provided and sealed to the

furnace.

Return air temperature range between 60F (16C) and

80F (27C) must be maintained.

Air filters must be installed in the system and must be

maintained during construction.

Air filters must be replaced upon construction comple-

tion.

The input rate and temperature rise must be set per the

furnace rating plate.

One hundred percent (100%) outdoor air must be pro-

vided for combustion air requirements during construc-

tion. Temporary ducting may supply outdoor air to the

furnace. Do not connect duct directly to the furnace.

Size the temporary duct following these instructions in

section for Combustion, Dilution and Ventilation Air in a

confined space with air from outside.

The furnace heat exchanger, components, duct system,

air filters and evaporator coils must be thoroughly

cleaned following final construction cleanup.

All furnace operating conditions (including ignition, in-

put rate, temperature rise and venting) must be verified

according to these installation instructions.

Page 6

General

These instructions are intended as a general guide and do

not supersede local codes in any way. Consult authorities

having jurisdiction before installation.

In addition to the requirements outlined previously, the fol-

lowing general recommendations must be considered

when installing a EL195DF furnace:

Place the furnace as close to the center of the air dis-

tribution system as possible. The furnace should also be

located close to the chimney or vent termination point.

When the furnace is installed in nondirect vent applica-

tions, do not install the furnace where drafts might blow

directly into it. This could cause improper combustion

and unsafe operation.

When the furnace is installed in nondirect vent applica-

tions, do not block the furnace combustion air opening

with clothing, boxes, doors, etc. Air is needed for proper

combustion and safe unit operation.

When the furnace is installed in an attic or other insu-

lated space, keep insulation away from the furnace.

When the furnace is installed in an unconditioned

space, consider provisions required to prevent freezing

of condensate drain system.

CAUTION EL195DF unit should not be installed in areas nor- mally subject to freezing temperatures.

WARNING Product contains fiberglass wool.

Disturbing the insulation in this product during installation, maintenance, or repair will expose you to fiberglass wool. Breathing this may cause lung cancer. (Fiberglass wool is known to the State of Cal- ifornia to cause cancer.)

Fiberglass wool may also cause respiratory, skin, and eye irritation.

To reduce exposure to this substance or for further information, consult material safety data sheets available from address shown below, or contact your supervisor.

Lennox Industries Inc. P.O. Box 799900 Dallas, TX 753799900

Combustion, Dilution & Ventilation Air

If the EL195DF is installed as a NonDirect Vent Fur-

nace, follow the guidelines in this section.

NOTE In NonDirect Vent installations, combustion air

is taken from indoors and flue gases are discharged out

doors.

WARNING Insufficient combustion air can cause headaches, nausea, dizziness or asphyxiation. It will also cause excess water in the heat exchanger resulting in rust- ing and premature heat exchanger failure. Excessive exposure to contaminated combustion air will result in safety and performance related problems. Avoid exposure to the following substances in the com- bustion air supply:

Permanent wave solutions Chlorinated waxes and cleaners Chlorine base swimming pool chemicals Water softening chemicals Deicing salts or chemicals Carbon tetrachloride Halogen type refrigerants Cleaning solvents (such as perchloroethylene) Printing inks, paint removers, varnishes, etc. Hydrochloric acid Cements and glues Antistatic fabric softeners for clothes dryers Masonry acid washing materials

In the past, there was no problem in bringing in sufficient

outdoor air for combustion. Infiltration provided all the air

that was needed. In todays 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

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.

Page 7

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

fuelburning 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 ensure 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 m3) 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 equipment 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 mm2) per 1,000 Btu (.29 kW) per hour of

total input rating of all gasfired equipment in the confined

space. Each opening must be at least 100 square inches

(64516 mm2). 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 4.

FIGURE 4

EQUIPMENT IN CONFINED SPACE ALL AIR FROM INSIDE

OPENINGS (To Adjacent Unconfined

Space)

NOTE Each opening shall have a free area of at least one square inch per 1,000 Btu (645mm2 per .29kW) per hour of the total input rating of all equipment in the enclosure, but not less than 100 square inches (64516mm.2).

ROOF TERMINATED EXHAUST PIPE

SIDE WALL TERMINATED

EXHAUST PIPE (ALTERNATE LOCATION)

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 (645mm2

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 (645mm2

per .59kW) per total input rating of all equipment in the en- closure (See figure 5).

Page 8

FIGURE 5

EQUIPMENT IN CONFINED SPACE ALL AIR FROM OUTSIDE (Inlet Air from Crawl Space and Outlet Air to Ventilated Attic)

NOTEThe inlet and outlet air openings shall each have a free area of at least one square inch per 4,000 Btu (645mm2 per 1.17kW) per hour of the total input rating of all equipment in the enclosure.

OUTLET AIR

INLET AIR

VENTILATION LOUVERS

(For unheated crawl space)

ROOF TERMINATED EXHAUST PIPE

VENTILATION LOUVERS (Each end of attic)

SIDE WALL TERMINATED

EXHAUST PIPE (ALTERNATE LOCATION)

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 5 and 6. When communicat- ing with the outdoors through horizontal ducts, each open- ing shall have a minimum free area of 1 square inch (645 mm2) per 2,000 Btu (.56 kW) per total input rating of all equipment in the enclosure. See figure 7.

When ducts are used, they shall be of the same crosssec- 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 assumed 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.

FIGURE 6

EQUIPMENT IN CONFINED SPACE ALL AIR FROM OUTSIDE (All Air Through Ventilated Attic)

NOTEThe inlet and outlet air openings shall each have a free area of at least one square inch per 4,000 Btu (645mm2 per 1.17kW) per hour of the total input rating of all equipment in the enclosure.

OUTLET AIR

VENTILATION LOUVERS (Each end of attic)

INLET AIR (Ends 12" above

bottom)

ROOF TERMINATED EXHAUST PIPE

SIDE WALL TERMINATED

EXHAUST PIPE (ALTERNATE LOCATION)

FIGURE 7

EQUIPMENT IN CONFINED SPACE ALL AIR FROM OUTSIDE

OUTLET AIR

INLET AIR

NOTEEach air duct opening shall have a free area of at least one square inch per 2,000 Btu (645mm2 per .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 (645mm2 per 1.17kW) per hour of the total input rating of all other equipment in the enclosure.

ROOF TERMINATED EXHAUST PIPE

SIDE WALL TERMINATED

EXHAUST PIPE (ALTERNATE LOCATION)

Page 9

Installation Setting Equipment

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. Doing so will adversely affect the operation of the safety con- trol devices, which could result in personal injury or death.

Select a location that allows for the required clearances

that are listed on the unit nameplate. Also consider gas

supply connections, electrical supply, vent connection,

condensate trap and drain connections, and installation

and service clearances [24 inches (610 mm) at unit

front]. The unit must be level from side to side. Unit may

be positioned from level to 1/2" toward the front to aid in

draining. See figure 8.

Allow for clearances to combustible materials as indicated

on the unit nameplate. Minimum clearances for closet or al-

cove installations are shown in figure 10.

WARNING Blower access panel must be securely in place when blower and burners are operating. Gas fumes, which could contain carbon monoxide, can be drawn into living space resulting in personal injury or death. FIGURE 8

SETTING EQUIPMENT

FRONT VIEW

SIDE VIEW

AIR FLOW

AIR FLOW

UNIT FRONT

1/2" max.

AIR FLOW

UNIT FRONT

Unit must be level sidetoside. Unit may be positioned from level to 1/2" toward the front to aid in draining.

SIDE VIEW

FIGURE 9

Front Back

Horizontal

NOTE Do not install the furnace on its front, back or in the horizontal position

Page 10

WARNING Improper installation of the furnace can result in per- sonal injury or death. Combustion and flue products must never be allowed to enter the return air system or air in the living space. Use sheet metal screws and joint tape to seal return air system to furnace. In platform installations with furnace return, the fur- nace should be sealed airtight to the return air ple- num. A door must never be used as a portion of the return air duct system. The base must provide a stable support and an airtight seal to the furnace. Al- low absolutely no sagging, cracks, gaps, etc. For no reason should return and supply air duct sys- tems ever be connected to or from other heating de- vices such as a fireplace or stove, etc. Fire, explo- sion, carbon monoxide poisoning, personal injury and/or property damage could result.

The unit may be installed three ways in downflow applica-

tions: on noncombustible flooring, on combustible flooring

using an additive base, or on a reverseflow cooling coil

cabinet. Do not drag the unit across the floor in the

downflow position. Floor and furnace flange damage

will result.

Refer to figure 10 for clearances in downflow applica-

tions.

Downflow Application Installation Clearances

Top

Bottom

Left Side Right Side

Top 0

*Front 0

Back 0

Sides 0

Vent 0

Floor NC

*Front clearance in alcove installation must be 24 in. (610 mm). Maintain a minimum of 24 in. (610 mm) for front service access. Allow proper clearances to accommodate condensate trap and vent pipe installation. The furnace may be installed on a combustible wood floor if an op- tional additive base is installed between the furnace and the com- bustible floor.

FIGURE 10

Installation on NonCombustible Flooring Figure 11

1 Cut floor opening keeping in mind clearances listed on

unit rating plate. Also keep in mind gas supply connec-

tions, electrical supply, flue and air intake connections

and sufficient installation and servicing clearances.

See table 1 for correct floor opening size.

2 Flange warm air plenum and lower the plenum into the

opening.

3 Set the unit over the plenum and seal the plenum to

the unit.

4 Ensure that the seal is adequate.

TABLE 1 NONCOMBUSTIBLE FLOOR OPENING SIZE

Cabinet Width Front to Rear Side to Side

in. mm in. mm

B Cabinet (17.5") 19 3/4 502 16 5/8 422

C Cabinet (21") 19 3/4 502 201/8 511

NOTE Floor opening dimensions listed are 1/4 inch (6 mm) larger than the unit opening. See dimension drawing on page 2.

FIGURE 11

SUPPLY AIR PLENUM

PROPERLY SIZED FLOOR

OPENING

FURNACE

Installation on Combustible Flooring Figure 12

1 When unit is installed on a combustible floor, a down-

flow combustible flooring base must be installed be-

tween the furnace and the floor. The base must be or-

dered separately. See table 2 for opening size to cut in

floor.

CAUTION The furnace and combustible flooring base shall not be installed directly on carpeting, tile, or other com- bustible material other than wood flooring.

Page 11

TABLE 2 COMBUSTIBLE FLOORING BASE OPENING SIZE

Cabinet Width

Catalog Number

Front to Rear Side to Side

in. mm in. mm

B Cabinet (17.5")

11M60 22 559 18 3/4 476

C Cabinet (21")

11M61 22 559 22 3/4 578

FIGURE 12

FURNACE

SUPPLY AIR PLENUM

COMBUSTIBLE FLOORING BASE

PROPERLY SIZED FLOOR

OPENING

2 After opening is cut, set the combustible flooring base

into opening.

3 Check fiberglass strips on the combustible flooring

base to make sure they are properly glued and posi-

tioned.

4 Lower supply air plenum into the combustible flooring

base until plenum flanges seal against fiberglass

strips.

NOTE Be careful not to damage fiberglass strips.

Check for a tight seal.

5 Set the furnace over the plenum.

6 Ensure that the seal between the furnace and plenum

is adequate.

Installation on Cooling Coil Cabinet Figure 13

NOTE Downflow combustible flooring kit is not used.

1 Refer to reverseflow coil installation instructions for

correctly sized opening in floor and installation of cabi-

net.

2 When cooling cabinet is in place, set and secure the

furnace according to the instructions that are provided

with the cooling coil. Secure the furnace to the cabinet.

3 Seal the cabinet and check for air leaks.

FIGURE 13

COOLING COIL

PLENUM

PROPERLY SIZED FLOOR

OPENING

FURNACE

Return Air Opening Downflow Units

Return air may be brought in only through the top opening

of a furnace installed in the downflow position. The follow-

ing steps should be taken when installing plenum:

1 Bottom edge of plenum should be flanged with a

hemmed edge (See figure 14 or 15).

2 Sealing strips should be used to ensure an airtight seal

between the cabinet and the plenum.

3 In all cases, plenum should be secured to top of fur-

nace using sheet metal screws.

4 Make certain that an adequate seal is made.

FIGURE 14

SECURE FROM

OUTSIDE CABINET

PLENUM

(Field Provided)

SEALING STRIP

(Field Provided)

Side View

CABINET

SIDE PANEL

SECURE FROM

INSIDE CABINET

PLENUM

(Field Provided) SEALING STRIP

(Field Provided)

Side View

CABINET

SIDE PANEL

FIGURE 15

Page 12

Filters

This unit is not equipped with a filter or rack. A fieldpro-

vided filter is required for the unit to operate properly. Table

3 lists recommended minimum filter size.

A filter must be in place whenever the unit is operating.

TABLE 3

Furnace Cabinet Width

Minimum Filter Size

16 x 25 x 1 (1)171/2"

21"

Duct System

Use industry-approved standards to size and install the

supply and return air duct system. Refer to ACCA Manual

D. This will result in a quiet and low-static system that has

uniform air distribution.

NOTE This furnace is not certified for operation in heating

mode (indoor blower operating at selected heating speed)

with an external static pressure which exceeds 0.5 inches

w.c. Operation at these conditions may result in improper

limit operation.

Supply Air Plenum

If the furnace is installed without a cooling coil, a removable

access panel should be installed in the supply air duct. The

access panel should be large enough to permit inspection

of the heat exchanger. The furnace access panel must al-

ways be in place when the furnace is operating and it must

not allow leaks into the supply air duct system.

Return Air Plenum

NOTE Return air must not be drawn from a room

where this furnace, or any other gasfueled appliance

(i.e., water heater), or carbon monoxideproducing de-

vice (i.e., wood fireplace) is installed.

When return air is drawn from a room, a negative pres-

sure is created in the room. If a gas appliance is operating

in a room with negative pressure, the flue products can

be pulled back down the vent pipe and into the room. This

reverse flow of the flue gas may result in incomplete com-

bustion and the formation of carbon monoxide gas. This

raw gas or toxic fumes might then be distributed through-

out the house by the furnace duct system.

Use fiberglass sealing strips, caulking, or equivalent seal-

ing method between the plenum and the furnace cabinet to

ensure a tight seal. If a filter is installed, size the return air

duct to fit the filter frame.

Pipe & Fittings Specifications

All pipe, fittings, 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 4 below for approved piping and fitting ma-

terials.

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 be maintained to reduce fire hazard and to minimize breathing of solvent vapors. Avoid contact of cement with skin and eyes.

TABLE 4 PIPING AND FITTINGS SPECIFICATIONS

Schedule 40 PVC (Pipe) D1785

Schedule 40 PVC (Cellular Core Pipe) F891

Schedule 40 PVC (Fittings) D2466

Schedule 40 CPVC (Pipe) F441

Schedule 40 CPVC (Fittings) F438

SDR21 PVC or SDR26 PVC (Pipe) D2241

SDR21 CPVC or SDR26 CPVC (Pipe) F442

Schedule 40 ABS Cellular Core DWV (Pipe) F628

Schedule 40 ABS (Pipe) D1527

Schedule 40 ABS (Fittings) D2468

ABSDWV (Drain Waste & Vent) (Pipe & Fittings)

D2661

PVCDWV (Drain Waste & Vent) Pipe & Fittings)

D2665

PRIMER & SOLVENT CEMENT ASTM

SPECIFICATION

PVC & CPVC Primer F656

PVC Solvent Cement D2564

CPVC Solvent Cement F493

ABS Solvent Cement D2235

PVC/CPVC/ABS All Purpose Cement For Fittings & Pipe of the same material D2564, D2235, F493

ABS to PVC or CPVC Transition Solvent Cement D3138

CANADA PIPE & FITTING & SOLVENT CEMENT

MARKING

PVC & CPVC Pipe and Fittings

ULCS636PVC & CPVC Solvent Cement

ABS to PVC or CPVC Transition Cement

Page 13

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 4. 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.

TABLE 5 OUTDOOR TERMINATION KITS USAGE

EL195 UNIT

VENT PIPE DIA. (in.)

STANDARD CONCENTRIC

Outdoor Exhaust

Accelerator (Dia. X Length)

Outdoor Exhaust

Accelerator (Dia. X Length)

2" Wall Plate Kit

3" Wall Plate Kit

2" Wall Ring Kit

Flush- Mount

Kit

11/2" Concentric

Kit

2" Concentric

Kit

3" Concentric

Kit

11/2" X 12" 2" X 12" 22G44

or 30G28 44J40

or 81J20 15F74 51W11**

71M80 or

44W92

69M29 or

44W92

60L46 or 44W93

045

2 YES YES YES* YES YES YES

21/2 YES YES YES* YES YES YES

3 YES YES YES* YES YES YES

070

2 YES YES YES* YES YES YES

21/2 YES YES YES* YES YES YES

3 YES YES YES* YES YES YES

090

2 YES YES YES YES YES YES

21/2 YES YES YES YES YES YES

3 YES YES YES YES YES YES

110 3 YES YES YES YES YES YES

*Requires fieldprovided and installed 11/2" exhaust accelerator. ** Kit 51W11 is provided with a 11/2" accelerator which must be used for all EL195DF045, 070 and 090 installations.

Termination kits 44W92, 44W93, 30G28 and 81J20 approved for use in Canadian installations to meet CSAB149.

The 44W92 Concentric kit is provided with a 11/2" accelerator which must be installed on the exhaust outlet when this kit is used with the EL195DF045P36B and

EL195DF070P36B furnaces.

Page 14

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.

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 from 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.

6 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.

7 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 assembly due to insufficient sol-

vent.

9 Handle joints carefully until completely set.

Venting Practices

FIGURE 16

* See table 4 for allowable pipe.

Piping Suspension Guidelines

NOTE Isolate piping at the point where it exits the outside wall or roof in order to prevent transmission of vibration to the structure.

SCHEDULE 40 PVC 5

all other pipe* 3

Wallinside outside

24" maximum 3/4" minimum

Wall Thickness Guidelines

CHIMNEY OR GAS

VENT (Check sizing

for water heater only)

FURNACE (Replaced by EL193)

WATER HEATER

OPENINGS (To Adjacent

Room)

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 17

REPLACING FURNACE THAT WAS PART OF A COMMON

VENT SYSTEM

1 In 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 15

2 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 19 and 20)

Route piping to outside of structure. Continue with installa-

tion following instructions given in piping termination sec-

tion.

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 re- quired, insert PVC pipe inside the stack until the end is even with the top or outlet end of the metal stack.

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 NonDirect 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 6 and 7. Table 6 lists the minimum vent pipe lengths permitted. Table 7 lists the maximum pipe lengths per- mitted.

TABLE 6 MINIMUM VENT PIPE LENGTHS

EL195DF MODEL

MIN. VENT LENGTH*

045, 070, 090, 110

15 ft. or 5 ft plus 2 elbows or 10 ft plus 1 elbow

*Any approved termination may be added to the minimum length listed.

Regardless of the diameter of pipe used, the standard roof and wall terminations 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 8.

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 freezeups and may block the terminations.

Use the following steps to correctly size vent pipe diameter.

1

2

3

4

5

6

045, 070, 090 or 110

Which termination?

Standard or Concentric? See table 5

Intake or exhaust

Which needs most elbows?

How many?

2", 21/2" or 3"

Desired pipe size?

Use table 7 to find max intake or exhaust pipe length.

FIGURE 18

What is the altitude?

7

Furnace capacity?

NOTE It is acceptable to use any pipe size which fits within the guidelines allowed in table 7.

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 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 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

Number Of 90 Elbows

Used

2" Pipe 21/2" Pipe 3" Pipe

Model Model Model

045 070 090 110 045 070 090 110 045 070 090 110

1 81 66 44 24 115 115 93 58 138 137 118 118

2 76 61 39 19 110 110 88 53 133 132 113 113

3 71 56 34 14 105 105 83 48 128 127 108 108

4 66 51 29 n/a 100 100 78 43 123 122 103 103

5 61 46 24 n/a 95 95 73 38 118 117 98 98

6 56 41 19 n/a 90 90 68 33 113 112 93 93

7 51 36 14 n/a 85 85 63 28 108 107 88 88

8 46 31 n/a n/a 80 80 58 23 103 102 83 83

9 41 26 n/a n/a 75 75 53 18 98 97 78 78

10 36 21 n/a n/a 70 70 48 13 93 92 73 73

Standard Termination Elevation 4500 10,000 ft

Number Of 90 Elbows

Used

2" Pipe 21/2" Pipe 3" Pipe

Model Model Model

045 070 090 110 045 070 090 110 045 070 090 110

1 81 66 44 n/a 115 115 93 58 138 137 118 118

2 76 61 39 n/a 110 110 88 53 133 132 113 113

3 71 56 34 n/a 105 105 83 48 128 127 108 108

4 66 51 29 n/a 100 100 78 43 123 122 103 103

5 61 46 24 n/a 95 95 73 38 118 117 98 98

6 56 41 19 n/a 90 90 68 33 113 112 93 93

7 51 36 14 n/a 85 85 63 28 108 107 88 88

8 46 31 n/a n/a 80 80 58 23 103 102 83 83

9 41 26 n/a n/a 75 75 53 18 98 97 78 78

10 36 21 n/a n/a 70 70 48 13 93 92 73 73

Concentric Termination at Elevation 0 4500 ft

Number Of 90 Elbows Used

2" Pipe 21/2" Pipe 3" Pipe

Model Model Model

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 44 111 111 104 104

4 58 43 27

n/a

90 90 74 39 106 106 99 99

5 53 38 22 85 85 69 34 101 101 94 94

6 48 33 17 80 80 64 29 96 96 89 89

7 43 28 12 75 75 59 24 91 91 84 84

8 38 23

n/a

70 70 54 19 86 86 79 79

9 33 18 65 65 49 14 81 81 74 74

10 28 13 60 60 44 n/a 76 76 69 69

Concentric Termination Elevation 4501 10,000 ft

Number Of 90 Elbows Used

2" Pipe 21/2" Pipe 3" Pipe

Model Model Model

045 070 090 110 045 070 090 110 045 070 090 110

1 73 58 42

n/a

105 105 89 54 121 121 114 114

2 68 53 37 100 100 84 49 116 116 109 109

3 63 48 32 95 95 79 44 111 111 104 104

4 58 43 27 90 90 74 39 106 106 99 99

5 53 38 22 85 85 69 34 101 101 94 94

6 48 33 17 80 80 64 29 96 96 89 89

7 43 28 12 75 75 59 24 91 91 84 84

8 38 23

n/a

70 70 54 19 86 86 79 79

9 33 18 65 65 49 14 81 81 74 74

10 28 13 60 60 44 n/a 76 76 69 69

Page 17

FIGURE 19

TYPICAL EXHAUST PIPE CONNECTIONS

TRANSITION

2 2

2

3

Pipe size determined in table 7.

2 2

or

DO NOT transition from smaller to larger pipe size in horizontal

runs of exhaust pipe. TOP VIEW

EXHAUSTINTAKE

* 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.

*2

FIGURE 20

TYPICAL INTAKE PIPE CONNECTIONS

2 2

TRANSITION

2

3

TRANSITION

3

Pipe size determined in table 7.

2 2

or

TOP VIEW

EXHAUSTINTAKE

* 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.

*2

*2

*2

Page 18

Intake Piping

The EL195DF furnace may be installed in either direct

vent or nondirect vent applications. In nondirect 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 instructions given in general

guide lines for piping terminations and intake and ex-

haust piping terminations for direct vent sections. Re-

fer to table 7 for pipe sizes.

FIGURE 21

TYPICAL AIR INTAKE PIPE CONNECTIONS NONDIRECT 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.

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 fieldprovided materials and the factoryprovided

air intake screen to route the intake piping as shown in

figure 21. 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,

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 Z2231/NFPA 54 in U.S.A., and current

CSAB149 Natural Gas and Propane Installation Codes in

Canada for details.

Position termination according to location given in figure 22

or 23. 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 32F (0C), 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 cold temperatures, below approximately 20F (6.7C), 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 freezeups. 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 freezeups 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 19

FIGURE 22

VENT TERMINATION CLEARANCES FOR NONDIRECT VENT INSTALLATIONS IN THE USA AND CANADA

K

D

E

L

B

C

F

G

A

B

J A

M

I

H

INSIDE CORNER

DETAIL

VENT TERMINAL AIR SUPPLY INLET AREA WHERE TERMINAL IS NOT PERMITTED

Fixed ClosedOperable

B

Fixed Closed

Operable

B

B

A =

B =

C =

D =

E =

F =

G =

H =

I =

J =

K =

L =

M =

US Installations1 Canadian Installations2

12 inches (305mm) or 12 in. 305mm) above average snow accumulation.

12 inches (305mm) or 12 in. 305mm) above average snow accumulation.

Clearance above grade, veranda, porch, deck or balcony

Clearance to window or door that may be opened 4 feet (1.2 m) below or to side of opening;

1 foot (30 cm) above opening

6 inches (152mm) for appliances <10,000 Btuh (3kw), 12 inches (305mm) for appliances > 10,000 Btuh (3kw) and

<100,000 Btuh (30kw), 36 inches (.9m) for appliances > 100,000 Btuh (30kw)

Clearance to permanently closed window

Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet (mm) 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- tended above meter / regulator assembly

Clearance to service regulator vent outlet

Clearance to nonmechanical air supply inlet to building or the com-

bustion air inlet to any other ap- pliance

Clearance to mechanical air sup- ply inlet

Clearance above paved sidewalk or paved driveway located on public property

Clearance under veranda, porch, deck or balcony

* 12"

* Equal to or greater than soffit depth.

*

* 3 feet (.9m)

* 12"

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 Btuh (3kw), 12 inches (305mm) for appliances > 10,000 Btuh (3kw) and

<100,000 Btuh (30kw), 36 inches (.9m) for appliances > 100,000 Btuh (30kw)

3 feet (.9m) above if within 10 feet (3m) horizontally

6 feet (1.8m)

7 feet (2.1m)

12 inches (305mm)

1 In accordance with the current ANSI Z223.1/NFPA 54 Natural Fuel Gas Code

2 In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code

A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings.

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.

4 feet (1.2 m) below or to side of opening; 1 foot (30 cm) above opening

7 feet (2.1m)

* 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

*12 inches (305mm)

* *

*For clearances not specified in ANSI Z223.1/NFPA 54 or CSA B149.1, clearance will be in accordance with local installation codes and the re- quirements of the gas supplier and these installation instructions."

Page 20

FIGURE 23

VENT TERMINATION CLEARANCES FOR DIRECT VENT INSTALLATIONS IN THE USA AND CANADA

K

D

E

L

B

C

F

G

A

B

J A

M

I

H

INSIDE CORNER

DETAIL

VENT TERMINAL AIR SUPPLY INLET AREA WHERE TERMINAL IS NOT PERMITTED

Fixed ClosedOperable

B

Fixed Closed

Operable

B

B

A =

B =

C =

D =

E =

F =

G =

H =

I =

J =

K =

L =

M =

US Installations1 Canadian Installations2

12 inches (305mm) or 12 in. 305mm) above average snow accumulation.

12 inches (305mm) or 12 in. 305mm) above average snow accumulation.

Clearance above grade, veranda, porch, deck or balcony

Clearance to window or door that may be opened

6 inches (152mm) for appliances <10,000 Btuh (3kw), 9 inches (mm) for appliances > 10,000 Btuh (3kw) and <50,000 Btuh

(15 kw), 12 inches (305mm) for ap- pliances > 50,000 Btuh (15kw)

6 inches (152mm) for appliances <10,000 Btuh (3kw), 12 inches (305mm) for appliances > 10,000 Btuh (3kw) and

<100,000 Btuh (30kw), 36 inches (.9m) for appliances > 100,000 Btuh (30kw)

Clearance to permanently closed window

Vertical clearance to ventilated soffit located above the terminal within a horizontal distance of 2 feet (mm) 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- tended above meter / regulator assembly

Clearance to service regulator vent outlet

Clearance to nonmechanical air supply inlet to building or the com-

bustion air inlet to any other ap- pliance

Clearance to mechanical air sup- ply inlet

Clearance above paved sidewalk or paved driveway located on public property

Clearance under veranda, porch, deck or balcony

* 12"

*

*

* 7 feet (2.1m)

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 Btuh (3kw), 9 inches (mm) for appliances > 10,000 Btuh (3kw) and <50,000 Btuh

(15 kw), 12 inches (305mm) for ap- pliances > 50,000 Btuh (15kw)

6 inches (152mm) for appliances <10,000 Btuh (3kw), 12 inches (305mm) for appliances > 10,000 Btuh (3kw) and

<100,000 Btuh (30kw), 36 inches (.9m) for appliances > 100,000 Btuh (30kw)

3 feet (.9m) above if within 10 feet (3m) horizontally

6 feet (1.8m)

7 feet (2.1m)

12 inches (305mm)

1 In accordance with the current ANSI Z223.1/NFPA 54 Natural Fuel Gas Code

2 In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code *For clearances not specified in ANSI Z223.1/NFPA 54 or CSA B149.1, clear- ance will be in accordance with local installation codes and the requirements of the gas supplier and these installation instructions." A vent shall not terminate directly above a sidewalk or paved driveway that is located

between two single family dwellings and serves both dwellings.

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.

* 12"

* 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)

*

*12 inches (305mm)

Page 21

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 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 corrosionresistant 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 26.

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 24 through 36 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 On roof terminations, the intake piping should termi- nate straight down using two 90 elbows (See figure 24).

4 Exhaust piping must terminate straight out or up as shown. A reducer may be required on the exhaust pip- ing at the point where it exits the structure to improve the velocity of exhaust away from the intake piping. See table 8.

TABLE 8 EXHAUST PIPE TERMINATION SIZE REDUCTION

EL195 MODEL Exhaust Pipe Size

Termination Pipe Size

*045 and *070 2" (51mm), 21/2" (64mm), 3" (76mm)

11/2" (38mm)

*090 2" (51mm) 110 2" (51mm)

*EL195DF045, 070 and 090 units with the flushmount termination must use the 11/2"accelerator supplied with the kit.

5 On fieldsupplied 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 27 and 28.

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" and a

minimum distance of 6" with a termination elbow. See

figures 27 and 28.

FIGURE 24

UNCONDITIONED ATTIC SPACE

1/2" (13mm) FOAM INSULATION IN

UNCONDITIONED SPACE

SIZE TERMINATION PIPE PER TABLE 8.

3"(76mm) MAX.

12" (305mm) ABOVE AVERAGE SNOW ACCUMULATION

3" (76mm) OR 2" (51mm) PVC

PROVIDE SUPPORT FOR INTAKE AND EXHAUST LINES

8" (203mm) MIN

Inches(mm)

DIRECT VENT ROOF TERMINATION KIT (15F75 or 44J41)

11/2" ACCELERATOR (all 070 and 090 units)

FURNACE EXHAUST

PIPE

FURNACE INTAKE

PIPE

4 GLUE EXHAUST

END FLUSH INTO TERMINATION

FLUSHMOUNT SIDE WALL TERMINATION KIT 51W11

FIGURE 25

2" EXTENSION FOR 2" PVC PIPE 1" EXTENSION FOR 3" PVC PIPE

7 If intake 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 27 and 28. In addition,

close coupled wall termination kits must be extended

for use in this application. See figures 34 and 35.

When exhaust and intake piping must be run up an

outside wall, the exhaust piping must be terminated

with pipe sized per table 8.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 31.

Page 22

C

A

E

D

B

A

B D

D

B

C

A

C

12"

1

1

2

2

2" (51mm) Vent Pipe

3" (76mm) Vent Pipe

A Clearance above grade or average snow

accumulation

BHorizontal separation between intake and exhaust

CMinimum from end of exhaust to

inlet of intake

DExhaust pipe length

EWall support distance from top of each pipe

(intake/exhaust)

12" (508MM) Min. 12" (508MM) Min.

6" (152MM) Min. 24" (610 MM) Max

9" (227MM) Min.

12" (305MM) Min. 16" (405 MM) Max.

6" (152MM) Max.

6" (152MM) Min. 24" (610 MM) Max

9" (227MM) Min.

12" (305MM) Min. 20" (508MM) Max.

6" (152MM) Max.

TABLE 9

FIGURE 26

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 corrosionresistant 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.

NOTE See unit installation instructions for proper exhaust pipe termination size reduction.

Front View of Intake and Exhaust

Intake Exhaust

3Intake

Exhaust

Page 23

FIGURE 27

FIELD SUPPLIED WALL TERMINATION OR (15F74) WALL RING TERMINATION KIT

See venting table 7 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) Vent Pipe

3" (76mm) Vent Pipe

AMinimum clearance above grade or average

snow accumulation

BMaximum horizontal separation between intake and exhaust

CMinimum from end of exhaust to

inlet of intake

DMaximum exhaust pipe length

EMaximum wall support distance from top of each

pipe (intake/exhaust)

12" (508MM) 12" (508MM)

6" (152MM) 6" (152MM)

8" (203MM) 8" (203MM)

12" (305MM) 20" (508MM)

6" (152MM) 6" (152MM)

NOTE FIELD PROVIDED REDUCER MAY BE

REQUIRED TO ADAPT LARGER VENT PIPE SIZE

TO TERMINATION

D

B

C

SIZE TERMINATION PER TABLE 8

1/2" (13mm) ARMAFLEX INSULATION IN UN-

CONDITIONED SPACE

STRAIGHT APPPLICATION

B

C A

D

* WALL SUPPORT

1/2" (13mm) ARMAFLEX INSULATION IN UNCONDITIONED SPACE

E

EXTENDED APPLICATION

A

FIGURE 28

FIELD SUPPLIED WALL TERMINATION OR (15F74) WALL RING TERMINATION KIT

With INTAKE ELBOW

See venting table 7 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) Vent Pipe

3" (76mm) Vent Pipe

12" (508MM) 12" (508MM)

6" (152MM) 6" (152MM)

6" (152MM)

12" (305MM) 20" (508MM)

6" (152MM) 6" (152MM)

6" (152MM)

AMinimum clearance above grade or average

snow accumulation

BMaximum horizontal separation between intake and exhaust

CMinimum from end of exhaust to

inlet of intake

DMaximum exhaust pipe length

EMaximum wall support distance from top of each

pipe (intake/exhaust)

NOTE FIELD PROVIDED REDUCER MAY BE

REQUIRED TO ADAPT LARGER VENT PIPE SIZE

TO TERMINATION

D

B

C

SIZE TERMINATION PER TABLE 8

1/2" (13mm) ARMAFLEX INSULATION IN UN-

CONDITIONED SPACE

STRAIGHT APPPLICATION

B

C

D

* WALL SUPPORT

1/2" (13mm) ARMAFLEX INSULATION IN UNCONDITIONED SPACE

E

EXTENDED APPLICATION

A

A

Page 24

FIGURE 29

DIRECT VENT CONCENTRIC ROOFTOP TERMINATION 71M80, 69M29 or 60L46 (US) 44W92 or 44W93 (Canada)

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.)

FLASHING (Not Furnished)

CLAMP FIELDPROVIDED

REDUCER MAY BE REQUIRED TO ADAPT LARGER VENT

PIPE SIZE TO TERMINATION

INTAKE

11/2" (38mm) accelerator provided on 71M80 & 44W92 kits for EL195DF045P36B &

070P36B

12 (305mm)

12" (305mm) Min. above grade or

average snow ac- cumulation.

FIGURE 30

DIRECT VENT CONCENTRIC WALL TERMINATION 71M80, 69M29 or 60L46 (US) 44W92 or 44W93 (Canada)

INTAKE AIR

EXHAUST AIR

INTAKE AIRINTAKE

AIR

EXHAUST AIR

OUTSIDE WALL

GRADE

CLAMP (Not Furnished)

FIELDPROVIDED REDUCER MAY BE

REQUIRED TO ADAPT LARGER VENT PIPE

SIZE TO TERMINATION

11/2" (38mm) accelerator provided on 71M80 &

44W92 kits for EL195DF045P36B &

070P36B

FIGURE 31

EXHAUST VENT

INTAKE AIR

51/2" (140mm)

Front View

12" (305mm)

5" (127mm)

18" MAX. (457mm)

EXHAUST VENT

INTAKE AIR

OPTIONAL VENT TERMINATION FOR MULTIPLE UNIT INSTALLATION OF DIRECT VENT WALL TERMINATION KIT

(22G44, 44J40, 30G28 or 81J20)

Inches (mm)

Side View

12" (305mm) Min. above grade or

average snow ac- cumulation.

optional intake elbow

FIGURE 32

1/2" (13mm) Foam Insulation in Unconditioned Space

EXHAUST VENT

INTAKE AIR

OUTSIDE WALL

EXHAUST VENT

INTAKE AIR

Front View

Top View

DIRECT VENT WALL TERMINATION KIT (30G28 or 81J20)

6 (152mm) MIN.

SIZE TERMINATION

PIPE PER TABLE 8.

FIELDPROVIDED REDUCER MAY

BE REQUIRED TO ADAPT LARGER VENT PIPE SIZE

TO TERMINATION

FIGURE 33

1/2" (13mm) Foam Insulation in Unconditioned Space

EXHAUST VENT

INTAKE AIR

OUTSIDE WALL

EXHAUST VENT

INTAKE AIR

Front View

Top View

DIRECT VENT WALL TERMINATION KIT (22G44 or 44J40)

8" (206mm) MIN.

SIZE TERMINATION

PIPE PER TABLE 8.

FIELDPROVIDED REDUCER MAY

BE REQUIRED TO ADAPT LARGER VENT PIPE SIZE

TO TERMINATION

Page 25

FIGURE 34

12 (305 mm) Minimum Above Grade or Average

Snow Accumulation

1/2 (13 mm) FOAM INSULATION

(Field Furnished)

5 (127 mm)

51/2 (140 mm)

EXHAUST AIR

INTAKE AIR

GRADE

12 (305 mm)

INTAKE AIR

EXHAUST AIR

GRADE

12 (305 mm) Max. for 2 (51 mm) Dia. Exhaust 20 (508 mm) Max. for 3 (76 mm) Dia. Exhaust

WALL SUPPORT*

12 (305 mm) Max. for 2 (51 mm) Dia. Exhaust 20 (508 mm) Max. for 3 (76 mm) Dia. Exhaust

12 (305 mm) Minimum Above Grade or Average

Snow Accumulation

WALL TERMINATION KITS (CLOSECOUPLE) EXTENDED VENT FOR GRADE CLEARANCE

2 inch (51 mm) 22G44 (US) 3 inch (76 mm) 44J40 (US)

6 (152 mm) Maximum

8 (203 mm) Min. for 2 (51 mm) & 3 (76 mm) DIA. pipe between the end of the exhaust pipe and intake pipe

8 (203 mm) Min.

*Use wall support every 24" (610). Use two supports if extension is greater than 24" but less than 48".

FIELDPROVIDED REDUCER MAY BE REQUIRED TO ADAPT

LARGER VENT PIPE SIZE TO TERMINATION

If intake and exhaust pipe is less than 12 in. (305 mm) above snow accumulation or other obstructions, field fabricated piping must be installed.

FIGURE 35

12 (305 mm) Minimum Above Grade or Average

Snow Accumulation

1/2 (13 mm) FOAM INSULATION

(Field Furnished)

5 (127 mm)

51/2 (140 mm)

EXHAUST AIR

INTAKE AIR

GRADE

12 (305 mm)

INTAKE AIR

EXHAUST AIR

GRADE

WALL SUPPORT*

12 (305 mm) Minimum Above Grade or Average

Snow Accumulation

WALL TERMINATION KITS (CLOSECOUPLE) 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.

6 (152 mm) Maximum

12 (305 mm) Max. for 2 (51 mm) Dia. Exhaust 20 (508 mm) Max. for 3 (76 mm) Dia. Exhaust

12 (305 mm) Max. for 2 (51 mm) Dia. Exhaust 20 (508 mm) Max. for 3 (76 mm) Dia. Exhaust

6 (152 mm) Minimum

6 (152 mm) Minimum

*Use wall support every 24" (610). Use two supports if extension is greater than 24" but less than 48".

FIELDPROVIDED REDUCER MAY BE REQUIRED TO ADAPT

LARGER VENT PIPE SIZE TO TERMINATION

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 USING EXISTING 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 36

3" 8" (76mm 203mm)

3" 8" (76mm 203mm)

STRAIGHTCUT OR ANGLECUT IN DIRECTION

OF ROOF SLOPE *

EXHAUST VENT 1/2" (13mm)

WEATHERPROOF INSULATION

SHOULDER OF FITTINGS PROVIDE SUPPORT

OF PIPE ON TOP PLATE

ALTERNATE INTAKE PIPE

INTAKE PIPE INSULATION (optional)

EXTERIOR PORTION OF

CHIMNEY

INSULATE TO FORM

SEAL

SHEET METAL TOP

PLATE

*SIZE TERMINATION PIPE PER TABLE 8.

Minimum 12" (305MM) above chimney top

plate or average snow accumulation

8" 12" (203mm 305mm)

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 37 through 40 show typical terminations.

1 Exhaust piping must terminate straight out or up as

shown. The termination pipe must be sized as listed in

table 8.The specified pipe size ensures proper veloc-

ity required to move the exhaust gases away from the

building.

2 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 38.

FIGURE 37

NONDIRECT VENT ROOF TERMINATION KIT (15F75 or 44J41)

UNCONDITIONED ATTIC SPACE

3" (76mm) OR 2" (51mm) PVC

PROVIDE SUPPORT FOR EXHAUST LINES

12" (305mm) ABOVE AVE.

SNOW ACCUMULATION

SIZE TERMINATION PIPE PER TABLE 8.

1/2" (13mm) FOAM INSULATION

FIGURE 38

1/2" (13mm) ARMAFLEX INSULATION IN

UNCONDITIONED SPACE

PVC REDUCER

1/2" (13mm) ARMAFLEX INSULATION

NONDIRECT VENT FIELD SUPPLIED WALL TERMINATION OR (15F74) WALL TERMINATION KIT

SIZE TERMINATION PIPE PER TABLE 8.

FIELDPROVIDED REDUCER MAY

BE REQUIRED TO ADAPT LARGER VENT PIPE SIZE

TO TERMINATION 12" MIN. (305mm)

Above Grade or average snow accumulation

12" (305mm) MAX. for 2" (51mm) 20" (508mm) MAX. for 3" (76mm)

3 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 39. When exhaust piping must be run

up an outside wall, any reduction in exhaust pipe size

must be done after the final elbow.

Page 27

FIGURE 39

12" (305mm) ABOVE GRADE OR AVERAGE SNOW ACCUMULATION

UNCONDITIONED SPACE

1/2" (13mm) FOAM INSULATION

1/2" (13mm) FOAM INSULATION IN

UNCONDITIONED SPACE

*WALL SUPPORT

OUTSIDE WALL

SIZE TER- MINATION PIPE PER TABLE 8.

FIELDPROVIDED REDUCER MAY BE

REQUIRED TO ADAPT LARGER

VENT PIPE SIZE TO TERMINATION

*Use wall support every 24" (610). Use two supports if extension is greater

than 24" but less than 48".

12" (305mm) MAX. for 2" (51mm) 20" (508mm) MAX. for 3" (76mm)

NONDIRECT VENT FIELD SUPPLIED WALL TERMINATION EX- TENDED OR (15F74) WALL TERMINATION VENT PIPE EXTENDED

6" (152mm) Max

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 40

3" 8" (76mm 203mm)

3" 8" (76mm 203mm)

STRAIGHTCUT OR ANGLECUT IN DIRECTION

OF ROOF SLOPE

EXHAUST VENT 1/2" (13mm)

WEATHERPROOF INSULATION

SHOULDER OF FITTINGS PROVIDE SUPPORT

OF PIPE ON TOP PLATE

EXTERIOR PORTION OF

CHIMNEY

INSULATE TO FORM

SEAL

SHEET METAL TOP

PLATE

SIZE TERMINATION PIPE PER TABLE 8.

EL195DF NONDIRECT VENT APPLICATION USING EXISTING CHIMNEY

Minimum 12" (305MM) above chimney top

plate or average snow accumulation

Condensate Piping

This unit is designed for either right- or left-side exit of con-

densate piping. Refer to figure 41 for condensate trap loca-

tions.

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.

FIGURE 41

CONDENSATE TRAP AND PLUG LOCATIONS

Trap (same on right side)

Plug (same on left

side)

11/2 in.

1 Determine which side condensate piping will exit the

unit, location of trap, fieldprovided fittings and length of

PVC pipe required to reach available drain.

2 Remove plug (figure 41) from the cold end header box

at the appropriate location on the side of the unit. Install

fieldprovided 1/2" NPT male fitting into cold end head-

er box. Use teflon tape or appropriate pipe dope.

3 Install the cap over the clean out opening at the base of

the trap. See figure 44.

4 Install drain trap using appropriate PVC fittings, glue

all joints. Glue the provided drain trap as shown in fig-

ure 44. Route the condensate line to an open drain.

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 11/4" OD X 1" ID and should be

attached to the drain on the trap using a hose clamp.

Page 28

5 If unit will be started immediately upon completion of

installation, prime trap per procedure outlined in Unit

StartUp section.

Condensate line must slope downward away from the

trap to drain. If drain level is above condensate trap,

condensate pump must be used. Condensate drain

line should be routed within the conditioned space to

avoid freezing of condensate and blockage of drain

line. 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.

(15.2m) kit no. 26K70.

FIGURE 42

CONDENSATE TRAP LOCATION (shown with right side exit of condensation)

5 max.

to drain

Field Provided Vent min. 1" Above

Condensate Drain

1" min.

Trap can be installed a maximum of 5 ft. from furnace.

(*PVC Only)

*Piping from furnace must slope down a minimum of 1/4" per ft. toward trap.

FIGURE 43

EL195DF with Evaporator Coil

Drain

Condensate trap and evaporator coil must drain

separately as shown.

FieldProvided Vent

CAUTION Do not use copper tubing or existing copper condensate lines for drain line.

CAUTION A separate drain line must be run to the drain from the condensate trap to ensure proper drainage and pressure switch operation. DO NOT connect the condensate trap drain into the drain line from the evaporator coil.

Page 29

FIGURE 44

Adapter 1/2 inch slip X 1/2 inch mpt (Not Furnished)

Drain Trap Assembly

(Furnished)

Vent

Drain Trap Clean Out

5 Feet Maximum

Coupling 1/2 inch slip X slip (Not Furnished)

90 Elbow 1/2 inch PVC (Not Furnished)

1/2 inch PVC Pipe (Not Furnished) 1/2 inch PVC Pipe

(Not Furnished)

1 (25) Minimum

Above Top of Condensate Drain Connection In Unit

Condensate Drain Connection In Unit

7 (178)

Drain Trap Assembly (Furnished)

Drain Assembly for 1/2 inch Drain Pipe

90 Elbow 3/4 inch PVC

(Not Furnished)

Coupling 3/4 inch slip X slip (Not Furnished)

To Drain

To Drain

90 Elbow 3/4 inch PVC

(Not Furnished)

To Drain

90 Elbow 1/2 inch PVC

(Not Furnished)

1/2 inch PVC Pipe (Not Furnished)

Drain Assembly for 3/4 inch Drain Pipe

OPTIONAL Drain Piping

OPTIONAL Condensate Drain Connection

90 Street Elbow 1/2 inch PVC

(Not Furnished)

Condensate Drain Connection In Unit

Adapter 1/2 inch slip X 1/2 inch mpt (Not Furnished)

1 inch (25mm) Minimum Above Top of Condensate Drain Connection In Unit

Condensate Drain Connection In Unit

Drain Trap Assembly with 1/2 inch Piping

Vent

To Drain

1 inch (25mm) Minimum Above Top of Condensate Drain Connection In Unit

Condensate Drain Connection In Unit

Drain Trap Assembly with 3/4 inch Piping

Vent

To Drain

TRAP / DRAIN ASSEMBLY USING 1/2" PVC OR 3/4" PVC

To Drain

90 Street Elbow 1/2 inch PVC (Furnished)

Page 30

Gas Piping

CAUTION If a flexible gas connector is required or 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.

WARNING Do not exceed 600 inlbs (50 ftlbs) torque when at- taching the gas piping to the gas valve.

1 Gas piping may be routed into the unit through either

the left- or right-hand side. Supply piping enters into

the gas valve from the side of the valve as shown in

figure 46.

2 When connecting gas supply, factors such as length of

run, number of fittings and furnace rating must be con-

sidered to avoid excessive pressure drop. Table 10

lists recommended pipe sizes for typical applications.

NOTE Use two wrenches when connecting gas pip-

ing to avoid transferring torque to the manifold.

3 Gas piping must not run in or through air ducts, clothes

chutes, chimneys or gas vents, dumb waiters or eleva-

tor shafts. Center gas line through piping hole. Gas

line should not touch side of unit. See figures 46.

4 Piping should be sloped 1/4 inch per 15 feet (6mm per

5.6m) upward toward the gas meter from the furnace.

The piping must be supported at proper intervals, ev-

ery 8 to 10 feet (2.44 to 3.05m), using suitable hangers

or straps. Install a drip leg in vertical pipe runs to serve as

a trap for sediment or condensate.

5 A 1/8" N.P.T. plugged tap or pressure post is located

on the gas valve to facilitate test gauge connection.

See figure 53.

6 In some localities, codes may require installation of a

manual main shut-off valve and union (furnished by in-

staller) external to the unit. Union must be of the

ground joint type.

IMPORTANT Compounds used on threaded joints of gas piping must be resistant to the actions of liquified petro- leum gases.

Leak Check

After gas piping is completed, carefully check all piping connections (factory and fieldinstalled) for gas leaks. Use a leak detecting solution or other preferred means.

The furnace must be isolated from the gas supply system by closing its individual manual shut-off valve during any pressure testing of the gas supply system at pressures less than or equal to 1/2 psig (3.48 kPa, 14 inches w.c.).

FIGURE 45

MANUAL MAIN SHUTOFF VALVE WILL NOT HOLD

NORMAL TEST PRESSURE

CAP

FURNACE

ISOLATE GAS VALVE1/8" N.P.T. PLUGGED TAP

IMPORTANT When testing pressure of gas lines, gas valve must be disconnected and isolated. See figure 45. Gas valves can be damaged if subjected to pressures greater than 1/2 psig (3.48 kPa).

WARNING FIRE OR EXPLOSION HAZARD

Failure to follow the safety warnings exactly could result in serious injury, death, or property damage. Never use an open flame to test for gas leaks. Check all connections using a commercially available soap solution made specifically for leak detection. Some soaps used for leak detection are corrosive to certain metals. Carefully rinse piping thoroughly after leak test has been completed.

Page 31

GROUND JOINT UNION

AUTOMATIC GAS VALVE

FIELD PROVIDED

AND INSTALLED

GROUND JOINT UNION

Left Side Piping (Standard)

Right Side Piping (Alternate)

AUTOMATIC GAS VALVE

DRIP LEG

DRIP LEG

MANUAL MAIN SHUTOFF

VALVE (With 1/8 in. NPT

Plugged Tap Shown)

MANUAL MAIN SHUTOFF

VALVE (With 1/8 in. NPT

Plugged Tap Shown)

NOTE BLACK IRON PIPE ONLY TO BE ROUTED INSIDE OF CABINET

FIGURE 46

Bellows Grommet Bellows Grommet

Plug

Plug

TABLE 10 GAS PIPE CAPACITY FT3/HR (kL/HR)

Nominal Iron Pipe Size Inches(mm)

Internal Diameter

Inches(mm)

Length of PipeFeet(m)

10 (3.048)

20 (6.096)

30 (9.144)

40 (12.192)

50 (15.240)

60 (18.288)

70 (21.336)

80 (24.384)

90 (27.432)

100 (30.480)

1/2 (12.7)

.622 (17.799)

175 (4.96)

120 (3.40)

97 (2.75)

82 (2.32)

73 (2.07)

66 (1.87)

61 (1.73)

57 (1.61)

53 (1.50)

50 (1.42)

3/4 (19.05)

.824 (20.930)

360 (10.19)

250 (7.08)

200 (5.66)

170 (4.81)

151 (4.28)

138 (3.91)

125 (3.54)

118 (3.34)

110 (3.11)

103 (2.92)

1 (25.4)

1.049 (26.645)

680 (19.25)

465 (13.17)

375 (10.62)

320 (9.06)

285 (8.07)

260 (7.36)

240 (6.80)

220 (6.23)

205 (5.80)

195 (5.52)

11/4 (31.75)

1.380 (35.052)

1400 (39.64)

950 (26.90)

770 (21.80)

660 (18.69)

580 (16.42)

530 (15.01)

490 (13.87)

460 (13.03)

430 (12.18)

400 (11.33)

11/2 (38.1)

1.610 (40.894)

2100 (59.46)

460 (41.34)

1180 (33.41)

990 (28.03)

900 (25.48)

810 (22.94)

750 (21.24)

690 (19.54)

650 (18.41)

620 (17.56)

2 (50.8)

2.067 (52.502)

3950 (111.85)

2750 (77.87)

2200 (62.30)

1900 (53.80)

1680 (47.57)

1520 (43.04)

1400 (39.64)

1300 (36.81)

1220 (34.55)

1150 (32.56)

21/2 (63.5)

2.469 (67.713)

6300 (178.39)

4350 (123.17)

3520 (99.67)

3000 (84.95)

2650 (75.04)

2400 (67.96)

2250 (63.71)

2050 (58.05)

1950 (55.22)

1850 (52.38)

3 (76.2)

3.068 (77.927)

11000 (311.48)

7700 (218.03)

6250 (176.98)

5300 (150.07)

4750 (134.50)

4300 (121.76)

3900 (110.43)

3700 (104.77)

3450 (97.69)

3250 (92.03)

4 (101.6)

4.026 (102.260)

23000 (651.27)

15800 (447.39)

12800 (362.44)

10900 (308.64)

9700 (274.67)

8800 (249.18)

8100 (229.36)

7500 (212.37)

7200 (203.88)

6700 (189.72)

NOTE Capacity given in cubic feet of gas per hour (kilo liters of gas per hour) and based on 0.60 specific gravity gas.

Page 32

Removal of the Furnace from Common Vent

In the event that an existing furnace is removed from a

venting system commonly run with separate gas ap-

pliances, the venting system is likely to be too large to

properly vent the remaining attached appliances.

Conduct the following test while each appliance is operat-

ing and the other appliances (which are not operating) re-

main connected to the common venting system. If the

venting system has been installed improperly, you must

correct the system as indicated in the general venting re-

quirements section.

WARNING CARBON MONOXIDE POISONING HAZARD

Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon mon- oxide poisoning or death. The following steps shall be followed for each ap- pliance connected to the venting system being placed into operation, while all other appliances connected to the venting system are not in operation:

1 Seal any unused openings in the common venting sys-

tem.

2 Inspect the venting system for proper size and horizontal

pitch. Determine that there is no blockage, restriction,

leakage, corrosion, or other deficiencies which could

cause an unsafe condition.

3 Close all building doors and windows and all doors be-

tween the space in which the appliances remaining

connected to the common venting system are located

and other spaces of the building. Turn on clothes dry-

ers and any appliances not connected to the common

venting system. Turn on any exhaust fans, such as

range hoods and bathroom exhausts, so they will oper-

ate at maximum speed. Do not operate a summer ex-

haust fan. Close fireplace dampers.

4 Follow the lighting instructions. Turn on the appliance

that is being inspected. Adjust the thermostat so that

the appliance operates continuously.

5 After the main burner has operated for 5 minutes, test

for leaks of flue gases at the draft hood relief opening.

Use the flame of a match or candle.

6 After determining that each appliance connected to the

common venting system is venting properly, (step 3)

return all doors, widows, exhaust fans, fireplace damp-

ers, and any other gasburning appliances to their pre-

vious mode of operation.

7 If a venting problem is found during any of the preced-

ing tests, the common venting system must be modi-

fied to correct the problem.

Resize the common venting system to the minimum

vent pipe size determined by using the appropriate

tables in Appendix G. (These are in the current stan-

dards of the National Fuel Gas Code ANSI Z223.1.

Electrical

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.

The unit is equipped with a field makeup box on the left

hand side of the cabinet. A fieldprovided makeup box can

be installed on the exterior of the right side of the furnace to

facilitate installation. If the makeup box is moved to the

right side, clip the wire ties that bundle the wires together

and install on the outside of the cabinet. See figure 48. The

excess wire must be pulled into the blower compartment.

Secure the excess wire to the existing harness to protect it

from damage.

Page 33

FIGURE 47

MAKEUP BOX INSIDE

CABINET Left side

INTERIOR MAKEUP BOX (FACTORY INSTALLED LEFT SIDE)

FIGURE 48

MAKEUP BOX

OUTSIDE CABINET

Right Side

EXTERIOR MAKEUP BOX (FIELD PROVIDED RIGHT SIDE)

Refer to figure 50 for field wiring and figure 51 for schematic

wiring diagram and troubleshooting.

The power supply wiring must meet Class I restrictions.

Protected by either a fuse or circuit breaker, select circuit

protection and wire size according to unit nameplate.

NOTE Unit nameplate states maximum current draw.

Maximum OverCurrent Protection allowed is 15 AMP.

Holes are on both sides of the furnace cabinet to facilitate

wiring.

Install a separate (properly sized) disconnect switch near

the furnace so that power can be turned off for servicing.

Before connecting the thermostat or the power wiring,

check to make sure the wires will be long enough for servic-

ing at a later date. Remove the blower access panel to

check the length of the wire.

Complete the wiring connections to the equipment. Use the

provided unit wiring diagram and the field wiring diagram

shown in figure 50. Use 18gauge 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. 70) for the USA and

current Canadian Electric Code part 1 (CSA standard

C22.1) for Canada. A green ground wire is provided in the

field makeup box.

NOTE The EL195DF furnace contains electronic compo-

nents that are polarity sensitive. Make sure that the furnace

is wired correctly and is properly grounded.

Generator Use Voltage Requirements

The following requirements must be kept in mind when

specifying a generator for use with this equipment:

The furnace requires 120 volts + 10% (Range: 108 volts to 132 volts)

The furnace operates at 60 Hz + 5% (Range: 57 Hz to 63 Hz)

The furnace integrated control requires both polarity and proper ground. Both polarity and proper grounding should be checked before attempting to operate the furnace on either permanent or temporary power

Generator should have a wave form distortion of less than 5% THD (total harmonic distortion)

Accessory Terminals

One line voltage EAC" 1/4" spade terminal is provided on

the furnace integrated control. See figure 52 for integrated

control configuration. This terminal is energized when the

indoor blower is operating. Any accessory rated up to one

amp can be connected to this terminal with the neutral leg

of the circuit being connected to one of the provided neutral

terminals. If an accessory rated at greater than one amp is

connected to this terminal, it is necessary to use an exter-

nal relay.

One line voltage HUM" 1/4" spade terminal is provided on

the furnace integrated control. See figure 52 for integrated

control configuration. This terminal is energized in the

heating mode when the combustion air inducer is operat-

ing. Any humidifier rated up to one amp can be connected

to this terminal with the neutral leg of the circuit being con-

nected to one of the provided neutral terminals. If a humidi-

fier rated at greater than one amp is connected to this termi-

nal, it is necessary to use an external relay.

One 24V "H" 1/4" spade terminal is provided on the furnace

integrated control. See figure 52 for integrated control con-

figuration. The terminal is energized in the heating mode

when the combustion air inducer is operating and the pres-

sure switch is closed. Any humidifier rated up to 0.5 amp

can be connected to this terminal with the ground leg of the

circuit connected to ground or the "C" terminal.

Page 34

Thermostat Furnace Condensing Unit

EL195DF and CONDENSING UNIT THERMOSTAT DESIGNATIONS

(Refer to specific thermostat and outdoor unit.)

COMMON

POWER

HEAT

INDOOR BLOWER

Y

C

R

G

W1

Y

C

R

G

W

COOLING

FIGURE 49

CONDENSING UNIT

CONDENSING UNIT COMMON

*CONDENSING UNIT

*NOTE R" REQUIRED ON SOME OUTDOOR UNITS

Install the room thermostat according to the instruc- tions provided with the thermostat. See figure 49 for thermostat designations. If the furnace is being matched with a heat pump, refer to the FM21 installa- tion instruction or appropriate dual fuel thermostat in- structions.

Indoor Blower Speeds

1 When the thermostat is set to FAN ON," the indoor blower will run continuously on the fan speed when there is no cooling or heating demand.

2 When the EL195DF is running in the heating mode, the indoor blower will run on the heating speed.

3 When there is a cooling demand, the indoor blower will run on the cooling speed.

TYPICAL EL195DF FIELD WIRING DIAGRAM

FIGURE 50

IGNITOR

*R

*NOTE R" REQUIRED ON SOME OUTDOOR UNITS

Page 35

TYPICAL EL195DF WIRING DIAGRAM

FIGURE 51

Page 36

FIGURE 52

INTEGRATED CONTROL (Automatic Hot Surface Ignition System)

TERMINAL DESIGNATIONS HUM

LINE

XFMR

EAC

COOL

HEAT

PARK

FLAME

FAN

Humidifier (120VAC)

Input (120VAC)

Transformer (120VAC)

Indoor Air Quality Accessories (120VAC)

Blower Cooling Speed (120VAC)

Blower Heating Speed (120VAC)

Dead terminals to park alternate speed taps

Flame sensor

Continuous blower

Blower off delay jumper

HUM Humidifier (24VAC)

Red LED Recall

Unit StartUp

FOR YOUR SAFETY READ BEFORE OPERATING

WARNING Do not use this furnace if any part has been under- water. A flooddamaged furnace is extremely dan- gerous. Attempts to use the furnace can result in fire or explosion. Immediately call a qualified ser- vice technician to inspect the furnace and to replace all gas controls, control system parts, and electrical parts that have been wet or to replace the furnace, if deemed necessary.

CAUTION Before attempting to perform any service or mainte- nance, turn the electrical power to unit OFF at dis- connect switch.

WARNING Danger of explosion. Can cause injury or product or property damage. Should the gas supply fail to shut off or if overheating occurs, shut off the gas valve to the furnace before shutting off the electrical supply.

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 switch. Never

use tools. If the switch will not move by hand, do not try to

repair it. Force or attempted repair may result in a fire or

explosion.

Page 37

Placing the furnace into operation:

EL195DF units are equipped with an automatic hot sur-

face 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 these

units.

Priming Condensate Trap

The condensate trap should be primed with water prior to

startup 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 Set the 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.

5 Wait for the combustion air inducer to stop. 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 wait for the combustion air inducer to stop.

At this point, the trap should be primed with sufficient

water to ensure proper condensate drain operation.

WARNING 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 53)

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 access panel.

6 Move gas valve switch to OFF. See figure 53.

7 Wait five minutes to clear out any gas. If you then smell

gas, STOP! Immediately call your gas supplier from a

neighbors phone. Follow the gas suppliers instruc-

tions. If you do not smell gas go to next step.

8 Move gas valve switch to ON. See figure 53.

9 Replace the access panel.

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.

FIGURE 53

GAS VALVE SHOWN IN ON POSITION

MANIFOLD PRESSURE

OUTLET PORT

INLET PRESSURE

PORT

MANIFOLD PRESSURE ADJUSTMENT SCREW (under barbed fitting)

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 Set the thermostat to the lowest setting.

2 Turn off all electrical power to the unit if service is to be

performed.

3 Remove the access panel.

4 Move gas valve switch to OFF.

5 Replace the 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 Is the manual main shut-off valve open?

8 Is 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.

Heating Sequence Of Operation

1 When thermostat calls for heat, combustion air inducer starts.

2 Combustion air pressure switch proves blower opera- tion. Switch is factoryset and requires no adjustment.

3 After a 15second prepurge, the hot surface ignitor en- ergizes.

4 After a 20second ignitor warmup period, the gas valve solenoid opens. A 4second Trial for Ignition peri- od begins."

5 Gas is ignited, flame sensor proves the flame, and the combustion process continues.

6 If flame is not detected after first ignition trial, the igni- tion control will repeat steps 3 and 4 four more times before locking out the gas valve (WATCHGUARD" flame failure mode). The ignition control will then auto- matically repeat steps 1 through 6 after 60 minutes. To interrupt the 60minute WATCHGUARD" period, move thermostat from Heat" to OFF" then back to Heat". Heating sequence then restarts at step 1.

Page 38

Gas Pressure Adjustment

Gas Flow (Approximate)

TABLE 11

GAS METER CLOCKING CHART

ML193 Unit

Seconds for One Revolution

Natural LP

1 cu ft Dial

2 cu ft Dial

1 cu ft Dial

2 cu ft DIAL

045 80 160 200 400

070 55 110 136 272

090 41 82 102 204

110 33 66 82 164

Natural1000 btu/cu ft LP2500 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 11. If manifold pressure matches table 12 and rate

is incorrect, check gas orifices for proper size and restric-

tion. Remove temporary gas meter if installed.

Supply Pressure Measurement

A threaded plug on the inlet side of the gas valve provides

access to the supply pressure tap. Remove the threaded

plug, install a fieldprovided barbed fitting and connect a

manometer to measure supply pressure. See table 12 for

proper supply line pressure. Replace the threaded plug af-

ter measurements have been taken.

TABLE 12 Manifold and Supply Pressure (Outlet) inches w.c.

Fuel Model

Input Sizes

Manifold Pressure

in.wg.

Supply

Pressure

in.wg.

Min. Max.

Nat All sizes 3.5 4.5 10.0

LP/Propane All sizes 10.0 11.0 13.0

Manifold Pressure Measurement

1 Remove the threaded plug from the outlet side of the

gas valve and install a fieldprovided 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, notice 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 given in table

12.

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.

Proper Combustion

Furnace should operate minimum 15 minutes with correct

manifold pressure and gas flow rate before checking com-

bustion. Take combustion sample beyond the flue outlet

and compare to the tables below. The maximum carbon

monoxide reading should not exceed 50 ppm.

TABLE 13 EL195 Unit

CO2% For Nat CO2% For LP

045

7.2 8.2 8.6 9.6 070

090

110 The maximum carbon monoxide reading should not exceed 50 ppm.

High Altitude Information

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) may require a pressure switch change

which can be ordered separately. Table 14 lists conversion

kit and pressure switch requirements at varying altitudes.

The combustion air pressure switch is factoryset and re-

quires no adjustment.

Page 39

TABLE 14 Conversion Kit and Pressure Switch Requirements at Varying Altitudes

EL195 Unit

Natural to LP/Propane

High Altitude Natural Burner

Orifice Kit

High Altitude LP/Propane

Burner Orifice Kit High Altitude Pressure Switch

0 7500 ft (0 2286m)

7501 10,000 ft (2286 3038m)

7501 10,000 ft (2286 3038m)

4501 7500 ft (1373 2286m)

7501 10,000 ft (2286 3048m)

045

*69W73 73W37 *68W68

No Change 74W90

070 77W43 73W22

090 77W42 73W22

110 77W43 73W22

* 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 factoryinstalled pressure switch from 04500 feet (01370 m).

Testing of NonDirect Vent Applications for Proper Venting and Sufficient Combustion Air

WARNING CARBON MONOXIDE POISONING HAZARD!

Failure to follow the steps outlined below for each appliance connected to the venting system being placed into operation could result in carbon monox- ide poisoning or death. The following steps shall be followed for each ap- pliance connected to the venting system being placed into operation, while all other appliances con- nected to the venting system are not in operation.

After the EL195DF gas furnace has been started, the fol-

lowing test should be conducted to ensure proper venting

and sufficient combustion air has been provided to the

EL195DF as well as to other gas-fired appliances which

are separately vented.

If a EL195DF furnace replaces a Category I furnace which

was commonly vented with another gas appliance, the size

of the existing vent pipe for that gas appliance must be

checked. Without the heat of the original furnace flue prod-

ucts, 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.

The test should be conducted while all appliances (both in

operation and those not in operation) are connected to the

venting system being tested. If the venting system has

been installed improperly, or if provisions have not been

made for sufficient amounts of combustion air, corrections

must be made as outlined in the previous section.

1 Seal any unused openings in the venting system.

2 Visually inspect the venting system for proper size and horizontal pitch. Determine there is no blockage or re- striction, leakage, corrosion, or other deficiencies which could cause an unsafe condition.

3 To the extent that it is practical, close all building doors and windows and all doors between the space in which the appliances connected to the venting system are lo- cated and other spaces of the building.

4 Close fireplace dampers.

5 Turn on clothes dryers and any appliances not con- nected to the venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan.

6 Follow the lighting instruction to place the appliance being inspected into operation. Adjust thermostat so appliance will operate continuously.

7 Use the flame of match or candle to test for spillage of flue gases at the draft hood relief opening after 5 min- utes of main burner operation.

8 If improper venting is observed during any of the above tests, the venting system must be corrected or sufficient combustion/make-up air must be provided. The venting system should be re-sized to approach the minimum size as determined by using the ap- propriate tables in appendix G in the current standards of the National Fuel Gas Code ANSIZ223.1/NPFA 54 in the U.S.A., and the appropriate Natural Gas and Propane appliances venting sizing tables in the cur- rent standard of the CSAB149 Natural Gas and Pro- pane Installation Codes in Canada.

9 After determining that each appliance remaining connected to the common venting system properly vents when tested as indicated in step 3, return doors, windows, exhaust fans, fireplace dampers and any other gas-burning appliance to their previous condition of use.

Other Unit Adjustments

NOTE See troubleshooting flow charts if any safety

switches are found to be open.

Primary Limit

The primary limit is located on the heating compartment

vestibule panel. This limit is factory set and requires no ad-

justment.

Page 40

Flame Rollout Switches (Two)

These manually reset switches are located on the front of

the burner box.

Pressure Switch

The pressure switch is located in the heating compartment

on the cold end header box. This switch checks for proper

combustion air inducer operation before allowing ignition

trial. The switch is factoryset and must not be adjusted.

Temperature Rise

After the furnace has been started and supply and return air

temperatures have been allowed to stabilize, check the

temperature rise. If necessary, adjust the blower speed to

maintain the temperature rise within the range shown on

the unit nameplate. Increase the blower speed to decrease

the temperature. Decrease the blower speed to increase

the temperature rise. Failure to adjust the temperature rise

may cause erratic limit operation.

Fan Control

Fan On Delay

The heat fan on time of 30 seconds is not adjustable. The

cool fan on delay is 2 seconds and not adjustable.

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- justed by changing the jumper position across the five pins on the integrated control. The unit is shipped with a factory 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- tween 90 and 110F at the moment that the blower is deenergized. Longer off delay settings provide lower re- turn air temperatures; shorter settings provide higher re- turn air temperatures. See figure 54. The cool fan off delay (amount of time that the blower oper- ates after the cool demand has been satisfied) is 45 sec- onds and not adjustable.

Thermostat Heat Anticipation

Set the heat anticipator setting (if adjustable) according to

the amp draw listed on the wiring diagram that is attached

to the unit.

Electrical

1 Check all wiring for loose connections.

2 Check for the correct voltage at the furnace (furnace operating).

3 Check amp-draw on the blower motor. Motor Nameplate__________Actual__________

HEAT FAN-OFF TIME IN SECONDS

To adjust fanoff timing, reposition jumper across pins to achieve desired setting.

NO JUMPER

FIGURE 54

6 0

9 0

1 2 0

1 8 0 6 0

9 0

1 2 0

1 8 0 6

0 9 0

1 2 0

1 8 0 6

0 9 0

1 2 0

1 8 0

60 Second off Time

90 Second off Time

120 Second off Time

180 Second off Time

Blower Speeds

Follow the steps below to change the blower speeds.

1 Turn off electrical power to furnace.

2 Remove blower access panel.

3 Disconnect existing speed tap at integrated control

speed terminal.

NOTE Termination of any unused motor leads must be

insulated.

4 Place unused blower speed tap on integrated control

PARK" terminal or insulate.

5 Refer to blower speed selection chart on unit wiring dia-

gram for desired heating or cooling speed. See Blower

performance data beginning on the next page.

6 Connect selected speed tap at integrated control

speed terminal.

7 Resecure blower access panel.

8 Turn on electrical power to furnace.

9 Recheck temperature rise.

Exhaust and Air Intake Pipe

1 Check exhaust and air intake connections for tightness and to make sure there is no blockage.

2 Is pressure switch closed? Obstructed exhaust pipe will cause unit to shut off at pressure switch. Check ter- mination for blockages.

3 Obstructed pipe or termination may cause rollout switches to open. Reset manual flame rollout switches on burner box assembly if necessary.

Page 41

BLOWER DATA

EL195DF070P48B PERFORMANCE (Less Filter)

External Static

Pressure in. w.g.

Air Volume / Watts at Various Blower Speeds

High Medium- High

Medium- Low Low

cfm Watts cfm Watts cfm Watts cfm Watts 0.00 1885 935 1830 815 1810 720 1700 640 0.10 1850 910 1805 795 1785 705 1680 630 0.20 1775 890 1750 775 1710 690 1620 610 0.30 1715 870 1685 755 1640 660 1575 595 0.40 1645 855 1620 735 1595 650 1495 575 0.50 1575 835 1525 715 1485 625 1440 555 0.60 1505 815 1450 690 1425 610 1360 540 0.70 1390 790 1360 675 1340 590 1270 525 0.80 1280 770 1270 650 1255 570 1210 505 0.90 1200 740 1185 635 1160 550 1090 485

EL195DF110P60C PERFORMANCE (Less Filter)

External Static

Pressure in. w.g.

Air Volume / Watts at Various Blower Speeds

High Medium- High

Medium- Low Low

cfm Watts cfm Watts cfm Watts cfm Watts 0.00 2375 1250 2205 915 1975 785 1630 640 0.10 2365 1235 2195 905 1960 775 1625 635 0.20 2275 1200 2125 890 1950 760 1635 625 0.30 2200 1180 2060 880 1900 735 1620 610 0.40 2115 1150 1995 850 1845 710 1620 600 0.50 2040 1115 1940 835 1795 695 1585 580 0.60 1955 1090 1855 810 1745 670 1540 565 0.70 1860 1070 1730 765 1640 650 1515 550 0.80 1735 1030 1620 740 1590 620 1415 535 0.90 1640 1010 1535 715 1480 600 1330 510

EL195DF045P36B PERFORMANCE (Less Filter)

External Static

Pressure in. w.g.

Air Volume / Watts at Various Blower Speeds

High Medium- High

Medium- Low Low

cfm Watts cfm Watts cfm Watts cfm Watts 0.00 1615 650 1385 555 1205 465 1045 390 0.10 1605 640 1380 545 1195 455 1035 380 0.20 1500 620 1345 525 1165 445 1015 370 0.30 1450 590 1290 490 1125 420 975 365 0.40 1350 560 1235 480 1090 405 920 345 0.50 1300 545 1170 450 1035 380 880 330 0.60 1195 500 1095 425 990 365 840 320 0.70 1140 480 1020 395 895 345 780 300 0.80 1025 450 920 370 840 330 695 270 0.90 945 430 800 335 700 290 605 250

EL195DF090P60C PERFORMANCE (Less Filter)

External Static

Pressure in. w.g.

Air Volume / Watts at Various Blower Speeds

High Medium- High

Medium- Low Low

cfm Watts cfm Watts cfm Watts cfm Watts 0.00 2305 1255 2145 950 1900 810 1515 670 0.10 2295 1240 2135 940 1885 795 1500 665 0.20 2200 1220 2085 915 1865 775 1525 655 0.30 2160 1210 1990 875 1830 755 1545 640 0.40 2055 1170 1935 865 1790 725 1530 620 0.50 1970 1130 1855 835 1705 700 1500 600 0.60 1890 1105 1765 805 1635 675 1495 580 0.70 1775 1075 1680 785 1565 655 1430 560 0.80 1690 1050 1590 760 1485 630 1370 540 0.90 1580 1010 1485 735 1405 610 1270 510

Page 42

Service

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. 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.

WARNING The blower 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 3

lists recommended filter sizes.

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).

3 Check ampdraw on the blower motor. Motor Nameplate__________Actual__________

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

drain plug.

Cleaning Heat Exchanger If 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 rollout 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.

12 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 ground wire from vest panel.

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.

Page 43

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 275F

(135C) .

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 blower 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 rollout switch wires.

37 Reconnect sensor wire and reconnect 2pin 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 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.

CAUTION Some soaps used for leak detection are 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 2pin 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.

8 Reinstall the burner box assembly using the existing

four screws. Make sure that the burners line up in the

center of the burner ports.

9 Reconnect the sensor wire and reconnect the 2pin

plug to the ignitor wiring harness.

10 Reinstall combustion air intake flexible connector (if

equipped), secure using existing clamps.

11 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 reestablishing supplies.

15 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.

Page 44

Planned Service

A service technician should check the following items dur-

ing an annual inspection. Power to the unit must be shut off

for safety.

Fresh air grilles and louvers (on the unit and in the room

where the furnace is installed) Must be open and unob-

structed to provide combustion air.

Burners Must be inspected for rust, dirt, or signs of water.

Vent pipe Must be inspected for signs of water, cracked,

damaged or sagging pipe, or disconnected joints.

Unit appearance Must be inspected for rust, dirt, signs

of water, burnt or damaged wires, or components.

Blower access door Must be properly in place and pro-

vide a seal between the return air and the room where the

furnace is installed.

Return air duct Must be properly attached and provide

an air seal to the unit.

Operating performance Unit must be observed during

operation to monitor proper performance of the unit and the

vent system.

Combustion gases Flue products must be analyzed and

compared to the unit specifications.

Problems detected during the inspection may make it nec-

essary to temporarily shut down the furnace until the items

can be repaired or replaced.

Instruct the homeowners to pay attention to their

furnace. Situations can arise between annual furnace in-

spections that may result in unsafe operation. For instance,

items innocently stored next to the furnace may obstruct

the combustion air supply. This could cause incomplete

combustion and the production of carbon monoxide gas.

Ignition Control Board Diagnostic Codes

RED LED Flash Code

Diagnostic Codes / Status of Furnace

Off No power to control or board fault detected

Heartbeat1 Control powered displayed during all modes of operation if no errors are detected

1 Reverse Line Voltage Polarity

2 Improper Earth Ground

3 Burner failed to light, or lost flame during heat demand

4 Low Flame Signal check flame sensor

5 Watchguard burner failed to light, exceeded maximum number of retries or recycles.

6 Ignitor Circuit Failure not available on this control

7 Primary or Secondary Limit Open or Watchguard Mode Limit Switch Open longer than 3 min- utes

8 Rollout Switch Open

9 Pressure Switch failed to close or opened during heat demand

10 Watchguard Pressure Switch opened 5 times during one heat demand

11 Pressure Switch stuck closed prior to activation of combustion air inducer

12 Flame Sensed without gas valve energized

13 Low Line Voltage

Notes

Note1 A "Heartbeat" is indicated by a "Slow Flash" 1 sec on 1 sec off, repeating

Note Error codes are indicated by a "Rapid Flash" the LED flashes X times at 1/2 sec on 1/2 sec off, remains off for 3 sec, then repeats

Note Last 10 error codes are stored in memory To recall, press and release button, most recent will be displayed first, LED off for 3 sec, then next error code is displayed, etc. To clear error codes, depress and hold button longer than 5 seconds.

Page 45

Troubleshooting: Heating Sequence of Operation

HEATING SEQUENCE OF OPERATION

NORMAL HEATING MODE ABNORMAL HEATING MODE

CONTROL SELFCHECK OKAY?

BURNER OFF?

(Flame sensed without gas valve energized)

NORMAL OPERATION: LED SLOW FLASH

NO

YES

YES

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF. INDOOR BLOWER DELAY OFF.

LED SLOW FLASH (RESET CONTROL BY TURNING MAIN POWER OFF.)

LED FLASHES CODE 1 POLARITY REVERSED.

POWER ON

IS POLARITY CORRECT?

ROLLOUT SWITCH CLOSED?

THERMOSTAT CALLS FOR HEAT: LED SLOW FLASH

IS COMBUSTION AIR PRESSURE SWITCH OPEN?

LED FLASHES CODE 8 ROLLOUT SWITCH OPEN. GAS VALVE OFF. COMBUSTION AIR INDUCER ON.

INDOOR BLOWER ON. SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES

AND POWER IS RESET OR TSTAT IS INTERRUPTED FOR MINIMUM OF 1 SECOND.

LED FLASHES CODE 12 FLAME SENSED WITHOUT GAS VALVE ENERGIZED.

GAS VALVE OFF. COMBUSTION AIR INDUCER ON. INDOOR BLOWER ON HEATING SPEED.

LED FLASHES CODE 11 PRESSURE SWITCH CLOSED.

GAS VALVE OFF COMBUSTION AIR INDUCER OFF. INDOOR BLOWER

OFF WITH DELAY. (Sequence holds until pressure switch opens or thermostat resets control.)

NO

NO

YES

YES

IS VOLTAGE ABOVE 70 VOLTS?

LED FLASHES CODE 13 LOW LINE VOLTAGE. CONTROL WILL NOT RESPOND TO A CALL FOR

HEATING UNTIL VOLTAGE RISES ABOVE 75 VOLTS.

NO

NO

NO

IS COMBUSTION AIR INDUCER ENERGIZED?

HAS COMBUSTION AIR PRESSURE SWITCH CLOSED IN 2.5 MINUTES?

YES

YES LED FLASHES CODE 9 PRESSURE SWITCH FAILED

TO CLOSE OR OPENED DURING HEAT DEMAND. PRESSURE SWITCH IS IN WATCHGUARD MODE. GAS

VALVE OFF. COMBUSTION AIR INDUCER OFF. INDOOR BLOWER OFF WITH DELAY. IS 5-MINUTE

RESET PERIOD COMPLETE?

NO

PRIMARY LIMIT SWITCH. CLOSED?

YES

YES

CONTINUED NEXT PAGE

LED FLASHES CODE 7 PRIMARY LMIT OPEN. COMBUSTION AIR INDUCER

OFF.INDOOR BLOWER ON NO

YES

NO

YES

IS THERE A PROPER GROUND?

YES

NO LED FLASHES CODE 2 IMPROPER GROUND.

YES

YES

Page 46

Troubleshooting: Heating Sequence of Operation (Continued)

HEATING SEQUENCE CONTINUED

NORMAL HEATING MODE ABNORMAL HEATING MODE

FLAME RECTIFICATION CURRENT CHECK. CAN FLAME BE PROVEN WITHIN 4 SECONDS AFTER GAS VALVE OPENS?

(0.5 microamps)

FLAME PRESENT?

INDOOR BLOWER ON AFTER 30SECOND DELAY

PRIMARY LIMIT SWITCH CLOSED?

COMBUSTION AIR PRESSURE SWITCH CLOSED?

LED FLASHES CODE 4 LOW FLAME SIGNAL.

(Does not affect operation of control)

LED FLASHES CODE 7 PRIMARY LIMIT OPEN GAS VALVE DEENERGIZED.

COMBUSTION AIR INDUCER DEENERGIZED. INDOOR BLOWER ON UNTIL SWITCH CLOSES.

LIMIT SWITCH CLOSED?

GAS VALVE DEENERGIZED. COMBUSTION AIR INDUCER ON.

INDOOR BLOWER OFF WITH DELAY HAS CAB SWITCH CLOSED IN 2.5 MINUTES?

15-SECOND COMBUSTION AIR INDUCER PREPURGE INITIATED BY CLOSED PRESSURE SWITCH.

YES

IGNITOR WARM-UP 20 SECONDS.

YES

YES

FLAME STABILIZATION PERIOD.

GAS VALVE OFF. COMBUSTION AIR INDUCER ON. INDOOR BLOWER OFF.

HAS CONTROL FAILED TO SENSE FLAME FOR FIVE CONSECUTIVE TRIES DURING A SINGLE

HEAT DEMAND?

LED SIGNAL WATCHGUARD FAILURE CODE WATCHGUARD MODE. GAS VALVE OFF.

COMBUSTION AIR INDUCER OFF. INDOOR BLOWER OFF WITH DELAY

IS 60-MINUTE RESET PERIOD COMPLETE?

YES

4 SECONDS

YES

HAS CONTROL RESET IGNITION SEQUENCE FOUR TIMES?

FLAME SIGNAL 1.5 MICROAMPS OR GREATER?

YES

YES

YES

ROLLOUT SWITCH CLOSED? LED FLASHES CODE 8 ROLLOT SWITCH OPEN.

GAS VALVE POWER OFF. COMBUSTION AIR INDUCER POWER ON. INDOOR BLOWER ON SEQUENCE HOLDS UNTIL ROLLOUT

SWITCH IS RESET AND MAIN POWER IS INTERRUPTED OR THERMOSTAT IS CYCLED OFF/ON FOR 1 SEC. MINIMUM.

YES

THERMOSTAT DEMAND SATISFIED.

LED SLOW FLASH.

COMB. AIR INDUCER CONTINUES 5-SECOND POST PURGE AFTER TSTAT DEMAND IS SATISFIED. INDOOR AIR BLOWER COMPLETES SELECTED OFF"

DELAY BEFORE SHUTTING OFF.

YES

NO

5-MINUTE PRESSURE SWITCH WATCHGUARD MODE.

YES

IS VOLTAGE ABOVE 70 VOLTS?

LED FLASHES CODE 13 LOW LINE VOLTAGE.

ONCE VOLTAGE IS ABOVE 75 VOLTS, HEATING

SEQUENCE RESTARTS.

NO

YES

YES

YES

NO

NO

NO

NO

NO

NO

YES

YES

NO

NO

NO

YES

YESHAS PRIMARY LIMIT RESET TIME EXCEEDED 3 MINUTES?

LED FLASHES CODE 7 PRIMARY LIMIT OPEN. GAS VALVE,

COMB. AIR INDUCER AND INDOOR BLOW- ER OFF. LEDs SIG- NAL LIMIT SWITCH OPEN UNTIL MAIN

POWER IS INTERRUPTED OR TSTAT IS CYCLED

OFF/ON FOR 1 SEC. MINIMUM. 60MINUTE

WATCHGUARD PE- RIOD STARTS AT

TIME LIMIT CLOSES. IS 60MIN. PERIOD

COMPLETE? NO

YES

4-SECOND TRIAL FOR IGNITION. GAS VALVE OPENS. IGNITOR ENERGIZED FOR

FIRST 3 SECONDS OF THE TRIAL.

HAS PRESSURE

SWITCH OPENED 5 TIMES IN

SAME HEAT DEMAND?

NO

1 HR PRESSURE SWITCH WATCHGUARD MODE

LED FLASHES CODE 10

Page 47

Troubleshooting: Cooling Sequence of Operation

COOLING SEQUENCE OF OPERATION

NORMAL COOLING MODE ABNORMAL COOLING MODE

IGNITION CONTROL MAIN POWER ON.

CONTROL SELF DIAGNOSTIC CHECK. IS CONTROL OPERATING NORMALLY?

YES

LED FLASHES CODE 1 POLARITY REVERSED CONTROL WILL CONTINUE TO CALL FOR COOLING IN

THIS CONDITION.

POWER ON

GAS VALVE OFF. COMBUSTION AIR INDUCER OFF. INDOOR BLOWER OFF WITH NORMAL DELAY.

SIGNAL CIRCUIT BOARD FAILURE AT LED. INTERRUPT MAIN POWER TO RESET CONTROL.

YES

IS POLARITY CORRECT?

ROLLOUT SWITCH MONITORED CONTINUOUSLY. IS ROLLOUT SWITCH CLOSED?

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). EAC TERM. ENERGIZED.

COMPRESSOR OFF.

THERMOSTAT OPENS.

SYSTEM FAN AND EAC TERM. OFF WITH 45-SECOND DELAY.

NO

NO

LED FLASHES CODE 8 ROLLOUT SWITCH OPEN. GAS VALVE OFF. COMBUSTION AIR INDUCER ON. INDOOR

BLOWER ON. SEQUENCE HOLDS UNTIL ROLLOUT SWITCH CLOSES AND MAIN POWER IS INTERRUPTED OR

THERMOSTAT IS CYCLED OFF/ON FOR 1 SEC. MINIMUM.

IS VOLTAGE ABOVE 70 VOLTS?

LED FLASHES CODE 13 LOW VOLTAGE. CONTROL WILL CONTINUE TO CALL FOR COOLING

IN THIS CONDITION.

YES

YES

NO

NO

IS THERE A PROPER GROUND?

YES

NO LED FLASHES CODE 2 IMPROPER GROUND

CONTROL WILL CONTINUE TO CALL FOR COOLING IN THIS CONDITION.

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).

THERMOSTAT CALLS FOR COOLING.

THERMOSTAT OPENS.

SYSTEM FAN SWITCHED TO COOL SPEED. EAC TERM. REMAINS ON.

THERMOSTAT OPENS.

MANUAL FAN SELECTION MADE AT THERMOSTAT. CONTROL (G) ENERGIZES SYSTEM FAN AT FAN

SPEED. EAC TERM. ENERGIZED.

NO YES

YES NO

SYSTEM FAN SWITCHES TO HEAT SPEAD AFTER 30 SECOND DELAY. EAC AND HUM TERMINAL REMAIN ON.

SYSTEM FAN CONTINUES FAN SPEED WITHOUT INTERRUPTION. EAC TERMINAL REMAIN ON.

HUM TERMINAL IS ENERGIZED WITH COMBUSTION AIR BLOWER.

HUM. TERMINAL OFF AFTER POST PURGE BY COMBUSTION AIR BLOWER. SYTEM FAN SWITCHES TO FAN SPEED AFTER BLOWER

OFF DELAY. EAC CONTINUES WITHOUT INTERRUPTION.

Page 49

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.

Cabinet Parts

Outer access panel

Blower access panel

Top Cap

Control Panel Parts

Transformer

Integrated control board

Door interlock switch

Blower Parts

Blower wheel

Motor

Motor mounting frame

Motor capacitor

Blower housing cutoff plate

Heating Parts

Flame Sensor

Heat exchanger assembly

Gas manifold

Combustion air inducer

Gas valve

Main burner cluster

Main burner orifices

Pressure switch

Ignitor

Primary limit control

Flame rollout switches

Page 50

StartUp & Performance Check List

Gas Supply Pressure

SUPPLY AIR

Line Voltage

GAS SUPPLY

Natural Gas LP Propane Gas

Piping Connections Tight

Leak Tested

Supply Line Pressure W.C.________

1

INTAKE / EXHAUST PIPE

All Joints Primed and Glued

Terminations Installed Properly

Pipes Supported

Condensate Trap Primed / Line Sloped

Heat Cable Installed and Operable (if applicable)

2

2

2

1

Horizontal Pipes Sloped (if applicable)

UNIT SET UP

3

4

Flter

RETURN AIR

Furnace: Model Number_______________

Serial Number_________________

3 DUCT SYSTEM

SUPPLY AIR DUCT

Sealed

Insulated (if necessary)

RETURN DUCT

Sealed

Filter Installed and Clean

Grilles Unobstructed

4 VOLTAGE CHECK

Supply Voltage _____

Electrical Connections Tight

1

Page 51

Contractors: Name_________________________Telephone_____________Checklist Completed____________________

Job Address_____________________________________Technicians Name___________________________________

1

HEATING MODE

GAS MANIFOLD PRESSURE W.C._____

COMBUSTION SAMPLE CO2%______CO PPM_______2

INDOOR BLOWER AMPS______3

TEMPERATURE RISE4

Supply Duct Temperature ________

Return Duct Temperature _ _____

Temperature Rise = ________

TOTAL EXTERNAL STATIC5

Supply External Static _______

Return External Static + ______

Total External Static = _______

CONDENSATE LINE6

Leak Free

VENT PIPE7

Leak Free

COOLING MODE

INDOOR BLOWER AMPS______3

TEMPERATURE DROP

Return Duct Temperature _________

Supply Duct Temperature _ _______

Temperature Drop = _________

4

DRAIN LINE8

Leak Free

THERMOSTAT

Adjusted and Programmed

Explained Operation to Owner

9

SUPPLY AIR

Blower Motor Amps

Duct Static

Thermostat

Gas Manifold Pressure

1

2

3

4

5

6

7

8

9

Temperatures

RETURN AIR

Combustion CO2

UNIT OPERATION

TOTAL EXTERNAL STATIC (dry coil)

Supply External Static _______

Return External Static + ______

Total External Static = _______

5

Page 52

Requirements for Commonwealth of Massachusetts

Modifications to NFPA54, Chapter 10

Revise NFPA54 section 10.8.3 to add the following re-

quirements:

For all side wall, horizontally vented, gasfueled equipment

installed in every dwelling, building or structure used in

whole or in part for residential purposes, including those

owned or operated by the Commonwealth and where the

side wall exhaust vent termination is less than seven (7)

feet above the finished grade in the area of the venting, in-

cluding but not limited to decks and porches, the following

requirements shall be satisfied:

1 INSTALLATION OF CARBON MONOXIDE DETEC-

TORS. At the time of installation of the side wall, hori-

zontally vented, gasfueled equipment, the installing

plumber or gasfitter shall observe that a hardwired

carbon monoxide detector with an alarm and battery

backup is installed on the floor level where the gas

equipment is to be installed. In addition, the installing

plumber or gasfitter shall observe that a batteryoper-

ated or hardwired carbon monoxide detector with an

alarm is installed on each additional level of the dwell-

ing, building or structure served by the side wall, hori-

zontally vented, gasfueled equipment. It shall be the

responsibility of the property owner to secure the ser-

vices of qualified licensed professionals for the instal-

lation of hardwired carbon monoxide detectors.

a In the event that the side wall, horizontally vented, gasfueled equipment is installed in a crawl space or an attic, the hardwired carbon monoxide detec- tor with alarm and battery backup may be installed on the next adjacent floor level.

b In the event that the requirements of this subdivi- sion cannot be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a batteryoperated carbon monoxide detec- tor with an alarm shall be installed.

2 APPROVED CARBON MONOXIDE DETECTORS.

Each carbon monoxide detector as required in accor-

dance with the above provisions shall comply with

NFPA 720 and be ANSI/UL 2034 listed and IAS certi-

fied.

3 SIGNAGE. A metal or plastic identification plate shall

be permanently mounted to the exterior of the building

at a minimum height of eight (8) feet above grade di-

rectly in line with the exhaust vent terminal for the hori-

zontally vented, gasfueled heating appliance or

equipment. The sign shall read, in print size no less

than onehalf (1/2) inch in size, GAS VENT DIRECT-

LY BELOW. KEEP CLEAR OF ALL OBSTRUC-

TIONS."

4 INSPECTION. The state or local gas inspector of the

side wall, horizontally vented, gasfueled equipment

shall not approve the installation unless, upon inspec-

tion, the inspector observes carbon monoxide detec-

tors and signage installed in accordance with the pro-

visions of 248 CMR 5.08(2)(a) 1 through 4.

EXEMPTIONS: The following equipment is exempt

from 24 CMR 5.08(2)(a) 1 through 4:

1 The equipment listed in Chapter 10 entitled Equip-

ment Not Required to Be Vented" in the most current

edition of NFPA 54 as adopted by the Board; and

2 Product Approved side wall, horizontally vented, gas

fueled equipment installed in a room or structure sepa-

rate from the dwelling, building or structure used in

whole or in part for residential purposes.

MANUFACTURER REQUIREMENTS

GAS EQUIPMENT VENTING SYSTEM PROVIDED.

When the manufacturer of Product Approved side wall,

horizontally vented, gasfueled equipment provides a vent-

ing system design or venting system components with the

equipment, the instructions provided by the manufacturer

for installation of the equipment and the venting system

shall include:

1 Detailed instructions for the installation of the venting

system design or the venting system components:

and

2 A complete parts list for the venting system design or

venting system.

MANUFACTURER REQUIREMENTS

GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED.

When the manufacturer of Product Approved side wall,

horizontally vented, gasfueled equipment does not pro-

vide the parts for venting the flue gases, but identifies spe-

cial venting systems," the following requirements shall be

satisfied by the manufacturer:

1 The referenced special venting system" instructions

shall be included with the appliance or equipment

installation instructions; and

2 The special venting systems" shall be Product Ap-

proved by the Board, and the instructions for that sys-

tem shall include a parts list and detailed installation

instructions.

A cop

Manualsnet FAQs

If you want to find out how the EL195DF Lennox works, you can view and download the Lennox EL195DF Installation Instructions on the Manualsnet website.

Yes, we have the Installation Instructions for Lennox EL195DF as well as other Lennox manuals. All you need to do is to use our search bar and find the user manual that you are looking for.

The Installation Instructions should include all the details that are needed to use a Lennox EL195DF. Full manuals and user guide PDFs can be downloaded from Manualsnet.com.

The best way to navigate the Lennox EL195DF Installation Instructions is by checking the Table of Contents at the top of the page where available. This allows you to navigate a manual by jumping to the section you are looking for.

This Lennox EL195DF Installation Instructions consists of sections like Table of Contents, to name a few. For easier navigation, use the Table of Contents in the upper left corner.

You can download Lennox EL195DF Installation Instructions free of charge simply by clicking the “download” button in the upper right corner of any manuals page. This feature allows you to download any manual in a couple of seconds and is generally in PDF format. You can also save a manual for later by adding it to your saved documents in the user profile.

To be able to print Lennox EL195DF Installation Instructions, simply download the document to your computer. Once downloaded, open the PDF file and print the Lennox EL195DF Installation Instructions as you would any other document. This can usually be achieved by clicking on “File” and then “Print” from the menu bar.